Polaris 2011 RANGER 500 EFI 4X4, Owner'S Manual

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety 500 EFI 4X4 500 EFI CREW RANGER ...

Page 2: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...the 4X4 with more than THREE passengers on the CREW or with passengers under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection ...

Page 5: ...r pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle...

Page 6: ... between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in E...

Page 7: ...ation Numbers 4 Safety 7 Features and Controls 20 Operation 39 Emission Control Systems 58 Maintenance 59 Specifications 104 POLARIS Products 106 Troubleshooting 107 Declaration of Conformity 111 Warranty 112 Maintenance Log 119 Index 122 ...

Page 8: ...eading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safet...

Page 9: ... Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor ...

Page 10: ...your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ label on side of engine Key Number _____________________________...

Page 11: ...ause serious injury or death Never carry passengers in cargo box Maximum Box Load 500 lbs 227 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT TIRE INFLATE TO 10 psi 68 9 kPa REAR TIRE INFLATE TO 12 psi 82 7 kPa MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES 1000 LBS 455 kg Red...

Page 12: ...ATE TO 14 psi 96 5 kPa REAR TIRE INFLATE TO 16 psi 110 kPa MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR PASSENGERS CARGO AND ACCESSORIES 1250 LBS 567 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For ...

Page 13: ...75488 Age 16 Warning Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver s license 7175566 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle APPLY BRAKE TO START When this vehicle is not in oper...

Page 14: ...aces pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy th...

Page 15: ...rfaces pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy ...

Page 16: ...engers must wear helmet eye protection and seat belt at all times Always use the cab nets while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To red...

Page 17: ...dures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for trav eling downhill and for braking on hills Check t...

Page 18: ...hicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and fol low the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always place the transmission in PARK before getting out of the vehicle Always stop the engine ...

Page 19: ...substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS RANGER is terminated if any equip ment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics...

Page 20: ...ing this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases...

Page 21: ...ated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a shor...

Page 22: ...or overturn Always follow proper procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Operating in Unfamiliar Terr...

Page 23: ... for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the...

Page 24: ... and passengers at all times The vehicle illustrated below is shown without cab nets only to allow com ponent identification Always use the cab nets Not all models come with all features Refer to the specifications section beginning on page 104 ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Headlights Front Bumper Brush Guard Radiator Cab Net ...

Page 25: ...receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 52 55 Tailgate Latch Releases Receiver Hitch CV Boot Rear Caliper Muffler Spark Arrestor Tailgate ...

Page 26: ...e connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Cup Holder 12V Auxiliary Outlet Mode Button Storage Tray Instrument Cluster Gear Selector Shifter Storage Compartment ...

Page 27: ...attended always place the transmission in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmis sion function See your dealer if you experience any shifting problems NOTICE Do not atte...

Page 28: ... off Electrical circuits are off except Acc 12V LIGHTS ON Lights are on Electrical circuits are on Electrical equip ment can be used LIGHTS OFF Lights are off Electrical circuits are on Electrical equip ment can be used START Turn the key to the START position to engage the electric starter Turn the key to the LIGHTS ON position after start ing the engine Ignition Switch Light Switch AWD Different...

Page 29: ...Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of opera tion is well suited to turf driving or when active traction is not needed Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure retur...

Page 30: ...operly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted For lap style belts place the belt across your lap as low on your hips as possible Make sure that the belt is not twisted 2 Push the lat...

Page 31: ...h the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat belt...

Page 32: ...replace worn or damaged cab nets with new cab nets avail able from your authorized Polaris dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is prop erly secured in the slot at the base of the mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Openin...

Page 33: ...h down firmly on the front of the seat until the pins are fully seated into the grommets Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle near the passen ger seat When refueling always use either leaded or unleaded gasoline with a mini mum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel ...

Page 34: ...mes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Storage Compartments A storage compartment is located under the driver s seat on Cr...

Page 35: ...cluster measures distance traveled by the vehicle as well as time hours of operation and engine RPM Tip In addition to showing vehicle speed the speedometer needle flashes when a low fuel condition exists Rider Information Center Speedometer Speedometer Needle ...

Page 36: ...gnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The...

Page 37: ...ach trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button until the total changes to 0 Tip In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is d...

Page 38: ...rn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Place the transmission in PARK 3 Hold the mode button and turn the key switch on Release the switch as soon as the display is activated 4 Use the mode button to toggle through the diagnostic screens ...

Page 39: ... your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5...

Page 40: ...se the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle T...

Page 41: ...se the follow ing procedure to access blink codes failure codes from the EFI mod ule 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Turn the key switch to the ON position 5 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and t...

Page 42: ...Circuit to Battery 53 Rear Differential Open Load RANGER 4X4 only 53 Rear Differential Short Circuit to Ground RANGER 4X4 only 53 Rear Differential Short Circuit to Battery RANGER 4X4 only 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Ba...

Page 43: ...nty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following pro cedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage cl...

Page 44: ... positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 41 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break i...

Page 45: ...ration 87 Tires Inspect condition and pressure 7 88 Wheels fasteners Inspect ensure fastener tightness 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 29 65 Coolant level Ensure proper level 75 76 Coolant hoses Inspect for leaks Throttle Ensure proper operation 84 Indicator lights switches Ensure operation 24 Air filter pre filter Inspect clean 80 Air box s...

Page 46: ...y with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Place the transmission in PARK WARNING A rolling vehicle c...

Page 47: ...ervice brakes and shift the transmission into gear 6 Check your surroundings and determine your path of travel 7 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 9 Do not carry a passenger until you have at least two hours of drivi...

Page 48: ... belt 5 Make sure all cab nets are properly secured 6 Do not carry more than the recommended number of passengers for your vehicle See pages 10 11 7 Allow a passenger to ride only in a passenger seat 8 Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a pas...

Page 49: ...g weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels...

Page 50: ...r 4 Always check the ter rain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 7 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 15 maximum ...

Page 51: ...able follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 15 maximum 2 Drive straight down hill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 3 Slow down 4 Apply the...

Page 52: ...entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RANG...

Page 53: ...Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible ...

Page 54: ...verse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly ...

Page 55: ...ny source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 4 Block the rear wheels on the d...

Page 56: ...loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hit...

Page 57: ...eight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely Model Maximum Capacities Level Ground Cargo Box 4X4 1000 lbs 455 kg 500 lbs 227 k...

Page 58: ...o the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 7 Stand clear and pull up on the cargo box release lever 8 Lift the front of the cargo box to dump the cargo 9 Lower the cargo box and push down securely to latch 10 Close the tailgate and secure both tailgate latches WARNING Operating the vehicle while the cargo...

Page 59: ...the towing capacity chart below and the specifications charts begin ning on page 104 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo Model Total Towed Load Weight Leve...

Page 60: ...te in two wheel drive 2WD Locking the differential in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Differential Unlocked Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD When the rear differ ential is unlocked the rear wheels can rot...

Page 61: ...isengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AW...

Page 62: ...uipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not ...

Page 63: ...rvice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style hi...

Page 64: ...subjected to severe use E Emission Related Service n Have an authorized POLARIS dealer perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km n Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 41 X Front suspension Pre Ride X Rear suspension Pre Ride Tires Pre Ride X Brake fluid level Pre Ride X Brake pedal travel Brake sy...

Page 65: ...vel change yearly X E Engine breather filter if equipped 25 H Monthly Inspect replace if necessary X Engine oil change break in 25 H 1 M Perform a break in oil change at one month X General lubrication 50 H 3 M Lubricate all fittings pivots cables etc Shift Linkage 50 H 6 M Inspect lubricate adjust n Steering 50H 6 M Lubricate X Front Suspension 50 H 6 M Lubricate X Rear Suspension 50 H 6 M Lubric...

Page 66: ...ect for leaks X Engine mounts 100 H 12 M Inspect Exhaust muffler pipe 100 H 12 M Inspect X E Spark plug 100 H 12 M Inspect replace as needed n Ignition timing 100 H 12 M Inspect X Wiring 100 H 12 M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc n Clutches drive and driven 100 H 12 M Inspect clean replace worn parts n Front wheel bearings 100 H 12...

Page 67: ... listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil POLARIS PS 4 PLUS Performance Synthetic 2W 50 4 cycle Oil See page 65 Brake Fluid DOT 4 See page 86 Main Gearcase Oil Transmission Premium AGL Synthetic Gearcase Lube See page 69 Front Gearcase Oil Demand Drive Plus Fluid See page 70 Front Prop Shaft Yoke POLARIS Premium U Joint Lube Locate fi...

Page 68: ...use accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 PLUS Performance Synthetic 2W 50 4 cycle oil or a similar oil See page 106 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cau...

Page 69: ...tart the engine and allow it to idle for 20 30 sec onds Stop the engine 3 Remove the seat See page 29 4 Remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick Screw it in completely 6 Remove the dipstick Make sure that the oil level is in the safe range Add oil if necessary Do not overfill Tip A rising oil level between checks in cool weather driving can indicate mois ture col...

Page 70: ...to drain com pletely 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and oil tank should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 9 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting Tip The fitting threads must be sealed with LOCTITE PST 505 or PTFE s...

Page 71: ...gasket contacts the sealing surface then turn and additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case Tip The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 17 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 18 Remove the dipstick an...

Page 72: ...or 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Tip If you do not hear air the line has not bled Repeat the priming procedure Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase Transmission Premium AGL Syntheti...

Page 73: ...eck The fill plug is located on the side of the gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change The drain plug is located near the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the gearcase 3 Remove the drain plug Allow the oil to ...

Page 74: ... to the Gearcase Specifications Chart on page 68 for recommended lubricants capacities and torque specifications See page 106 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill p...

Page 75: ...r s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right hand side 5 Remove the drain plug Drain the oil 6 Clean the drain plug Reinstall the drain plug Torque to specifica tion 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly ...

Page 76: ...d after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 72 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the seat to access the engine compartment 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove th...

Page 77: ...e service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recom...

Page 78: ...ec ommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti ...

Page 79: ...high pressure system is not recommended Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 1 Position the vehicle on a level surface 2 Lift the hood View the coolant level in the overflow bottle 3 If th...

Page 80: ...UTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But i...

Page 81: ... have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation When To Use Low Range vs High Range Belt slip is re...

Page 82: ...n stall the drain plug 3 Place the transmission in PARK 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 7 Test for belt slippage If the belt slips repeat...

Page 83: ... the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Thoroughly dry the air pre cleaner located under the hood 4 Remove the spark plugs Turn the engine over several times using the electric start 5 Dry the spark plugs and reinstall or replace with new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure 7 Take the vehic...

Page 84: ...x to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around Tip Grasp the filter end to pre vent damage to the filter paper 3 Remove the air filter 4 Do not attempt to clean the main element Install a new air filter Tip Apply a small amount of general purpose grease to the sealing edges of the filter before installing ...

Page 85: ... for debris Blow gently through the filter in the direction of the arrow to check for clog ging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine Secure the clamps NOTICE Operation of the vehicle without a breather filter can cause engine damage Always reinstall the breather filter after rem...

Page 86: ...mperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never go under the veh...

Page 87: ...e several times 5 If carbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plug while revving the engine several more times 6 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Block the wheels 7 Repeat steps 4 and 5 until no more particles are expelled when the engine is revved 8 Stop the engi...

Page 88: ... throttle pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on ...

Page 89: ... inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page 84 Tip While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Cylinder Head Cylinder Base Fastener...

Page 90: ... drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown See page 63 for fluid recommendations 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservo...

Page 91: ...and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an autho rized POLARIS dealer Spr...

Page 92: ...ize and type when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Aluminum Wheels Front and Rear 30 ft lbs 41 Nm PLUS 1 4 ...

Page 93: ...position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS de...

Page 94: ...e fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Ti...

Page 95: ...ark placed on the wall Include the weight of a rider on the seat while performing this step 5 If a headlight needs adjustment locate the adjustment screw at the back of the headlight 6 Loosen the screw adjust the headlight and tighten the screw 7 Repeat steps 4 6 until the lamp is properly adjusted Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake ligh...

Page 96: ...d eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is ...

Page 97: ...ck cable last 1 Remove the front seat 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Disconnect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solut...

Page 98: ...nt tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Coat the termina...

Page 99: ...rops below a pre determined point See page 106 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery Battery Charging Conventional Battery 1 ...

Page 100: ...For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 2 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using ...

Page 101: ...t Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box If you suspect that a fuse or relay may not be working prop erly please see your POLARIS dealer Fuse Feature Supported 10A Accessories 12V Power Receptacle 10A Headlight 10A Taillight 20A Chassis ...

Page 102: ...ucts to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do ...

Page 103: ...POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS ...

Page 104: ... Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the produ...

Page 105: ...om mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 66 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air f...

Page 106: ...e bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 72 4 Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs 5 Turn the engin...

Page 107: ...1 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Secure the fuel cap oil cap and seat 5 Always tie the fra...

Page 108: ...d Clearance 10 in 25 4 cm 10 in 25 4 cm Min Turning Radius 150 in 381 cm 237 in 602 cm Towing Capacity 1250 lbs 567 kg 1250 lbs 567 kg Hitch Tongue Capacity 150 lbs 68 kg 150 lbs 68 kg Max Cargo Box Load 500 lbs 227 kg 500 lbs 227 kg Engine 4 valve 4 stroke single cylinder with counter balance Displacement 498 cc 498 cc Bore x Stroke mm 92 x 75 92 x 75 Alternator Output 350 W 350 W Compression Rat...

Page 109: ...1 4 12 1 Drive Ratio Front 3 818 1 3 818 1 Tire Size Front 25 x 8 12 25 x 10 12 Tire Size Rear 25 x 11 12 25 x 11 12 Tire Pressure Front 10 psi 68 9 kPa 14 psi 96 5 kPa Tire Pressure Rear 12 psi 82 7 kPa 16 psi 110 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Foot Activated 4 wheel hydraulic disc Hood Headlights 2 single beam 50W quartz halogen 2 single beam 50W quartz halogen Taill...

Page 110: ...mium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 287...

Page 111: ...smission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle o...

Page 112: ...ctive spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range...

Page 113: ... spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See yo...

Page 114: ... Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clea...

Page 115: ...RTSMAN 400 2008 2009 2010 2011 ___MH50__ SPORTSMAN 500 HO 2008 2009 2010 2011 ___DH50__ SPORTSMAN 500 HO TOURING 2010 2011 ___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009 2010 2011 ___TN55__ ___TX55__ SPORTSMAN 550 X2 2010 2011 ___DN55__ ___DX55__ SPORTSMAN 550 TOURING 2010 2011 ___MN76__ SPORTSMAN 800 2008 2009 2010 2011 ___CL76__ ___CF76__ SPORTSMAN 800 6X6 2009 2010 2011 ___ZN85__ ___ZX85__ SPORTSMA...

Page 116: ...n the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle ...

Page 117: ...f materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON F...

Page 118: ... that you use your original selling dealer however you may use any POLARIS Servicing Dealer to per form warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If...

Page 119: ...m any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence...

Page 120: ...e safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assignment out...

Page 121: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followi...

Page 122: ...d by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or...

Page 123: ...119 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 124: ...120 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 125: ...121 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 126: ...e Exhaust System 82 83 Cleaning the Spark Arrestor 82 83 Clutching 105 Component Locations 20 21 Console 22 23 Coolant Level Overflow Bottle 75 Coolant Level Radiator 76 Coolant Adding or Changing 74 Cooling Fan 75 Cooling System 74 76 Corrosion Removal Chrome 100 Crankcase Emission Control System 58 Cylinder Head 85 D Diagnostic Mode 34 36 Diagnostics AWD 35 Diagnostics EFI Blink Codes 38 Diagnos...

Page 127: ...smission 69 Fluid Levels During Storage 102 Fluid Recommendation Coolant 74 Engine Oil 64 Gearcases 68 Fluid Brake 86 Fogging the Engine 102 F Fouled Plugs 73 Freeplay Adjustment Throttle 85 Freeplay Throttle 84 Front Gearcase 70 71 Fuel Cap 29 Fuel Safety 17 Fuel Stabilizer 101 Fuel Tank Filler Cap 29 Fuses 97 G Gap Spark Plug 72 Gasoline Handling 17 Gear Circuit Diagnostics 35 Gear Selector 23 G...

Page 128: ...Safety 12 19 Outlets Auxiliary 22 P Parking on an Incline 51 Parking the Vehicle 51 Periodic Maintenance Chart 59 62 Plug Gap 72 Plug Torque 72 Plug Accessory 22 Plugs Fouled 73 Polaris Products 106 Polishing the Vehicle 99 Pre Ride Inspection 41 Programmable Service Interval 35 PVT Break In 40 PVT Drying 78 PVT System 78 PVT System Operation 77 PVT Warning 77 R Radiator 75 Radiator Coolant Level ...

Page 129: ...25 Ignition Switch 24 Light Switch 24 T Tachometer 33 35 Throttle Freeplay 84 Throttle Freeplay Adjustment 85 Throttle Freeplay Inspection 84 Throttle Pedal 25 Throttle System 84 85 Tires 88 89 Nut Torque 88 Tread Depth 88 Wheel Installation 89 Wheel Removal 89 Torque Spark Plug 72 Towing Loads 55 Towing Speed 55 Trailer Hitch Bracket 21 Transmission 69 Transmission Operation 77 Transmission Syste...