Polaris 500 4X4 - User Manual

Polaris 500 4X4

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Table of Contents:

  • Page 3 – WARNING
  • Page 4 – WELCOME; RANGER
  • Page 6 – TABLE OF CONTENTS
  • Page 7 – VEHICLE IDENTIFICATION NUMBERS; spaces provided. Remove the spare key and store it in a safe place.
  • Page 8 – SAFETY; Operator Safety; Age Restrictions
  • Page 9 – The following signal words and symbols appear throughout this; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution
  • Page 10 – Serious injury or death can result if you do not follow these
  • Page 12 – FOR MORE INFORMATION ABOUT SAFETY, call Polaris at
  • Page 13 – Equipment Modifications
  • Page 14 – the complete vehicle for possible damage, including (but not
  • Page 15 – on pavement. Paved surfaces may seriously affect handling and; not know how to operate the vehicle properly in different
  • Page 17 – operating conditions, and your experience.
  • Page 21 – Safety Decals and Locations; Location 1; NO STEP
  • Page 22 – Fuel / Passenger Warning Decal Text
  • Page 23 – ATTENTION; Location 6; To avoid transmission
  • Page 24 – Discretionary Warning Decal; Location 8
  • Page 25 – Fuel Safety; Gasoline is highly flammable and is explosive under certain
  • Page 26 – FEATURES AND CONTROLS; Not all models come with all features.; Component Locations
  • Page 29 – Indicator Lights
  • Page 30 – Seat Removal
  • Page 31 – Console
  • Page 32 – TM; lever to the desired gear. Do not attempt to shift gears with engine
  • Page 35 – OPERATION; Vehicle Break-In Period; Excessive heat build-up during the first three hours of operation
  • Page 36 – If a proper inspection is not done before each use, severe injury
  • Page 37 – Starting the Engine; Starting a Cold Engine; Sit in the driver’s seat and fasten the; switch and wait five seconds. Repeat steps 5 and 6 until the engine
  • Page 38 – Starting a Warm Engine; Sit in the driver’s seat and fasten the seat belt.; If the engine does not start and all conditions are favorable,; Stopping the Engine; Put the gear shift lever into neutral.; A rolling vehicle can cause property damage and serious injury.
  • Page 39 – Braking; Release the throttle pedal completely.
  • Page 40 – Driving Safely; Driving Procedures; Low is the primary gear for operating the
  • Page 41 – Driving On Slippery Surfaces; Drive with AWD engaged (if equipped) to assist in controlling the
  • Page 42 – Driving Uphill; Proceed at a steady rate of speed and throttle opening.; Climbing hills improperly can cause loss of control or vehicle
  • Page 43 – Sidehilling; Driving Downhill; slightly
  • Page 44 – Driving Through Water; critical; Do not start the engine!
  • Page 45 – Driving Over Obstacles; Watch for hazards such as logs, rocks and low hanging branches.; Severe injury or death can result if your vehicle suddenly comes
  • Page 46 – Driving in Reverse; Apply the brakes lightly for stopping.; Failure to use caution when operating in reverse can result in
  • Page 47 – Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
  • Page 48 – Hauling Cargo; drive in the lowest gear available.; The; Maximum Capacities
  • Page 49 – Dumping the Cargo Box
  • Page 50 – Towing Loads; Towing improperly can alter vehicle handling and may cause loss; Belt Life; To extend belt life, use the lowest gear possible when hauling or
  • Page 51 – Parking the; Remove the ignition switch key to prevent unauthorized use.
  • Page 52 – Differential Operation Modes; Damage to the differential can occur if it is engaged while the; WD/Rear Differential Locked
  • Page 53 – When in AWD, the front gearcase will automatically engage anytime; Engaging Front Gearcase; The AWD switch may be turned on or off while the vehicle is moving.; Switching to AWD while the rear wheels are spinning may cause
  • Page 54 – EMISSION CONTROL SYSTEMS; Crankcase Emission Control System; The installation of devices that effectively increase exhaust
  • Page 55 – Noise Emission Control System; Do not modify the engine, intake or exhaust components, as doing so; Electromagnetic Interference
  • Page 56 – MAINTENANCE AND LUBRICATION; Periodic Maintenance Chart; Service and adjustments are important for proper vehicle; Severe Use Definition
  • Page 57 – Maintenance Chart Key; not void the emissions warranty but may affect emissions.); Improperly performing the procedures marked with a
  • Page 61 – Lubrication Recommendations; Lubrication Chart Key; More often under severe use, such as wet or dusty conditions
  • Page 63 – Engine Oil; Premium 4 Synthetic Oil
  • Page 66 – The sealing surfaces on the drain plug and crankcase should; Prime the oil pump using the procedure on page 64.
  • Page 68 – A rising oil level between checks
  • Page 69 – Hot oil can cause serious burns. Do not allow hot oil to come into
  • Page 70 – The sealing surfaces on the
  • Page 71 – Gearcases; Gearcase Specification Chart
  • Page 72 – Oil Check; Refer to the Gearcase Specifications Chart on page 68.
  • Page 74 – Rear Gearcase
  • Page 75 – Operation; system. The recovery system components are the overflow bottle,; Some coolant level drop on new vehicles is normal as the; Adding or Changing Coolant; water. Polaris Premium 60/40 is already premixed and ready to use.; Always follow the manufacturer’s mixing recommendations; Any time the cooling system has been drained for maintenance or
  • Page 76 – Radiator and Cooling Fan; Coolant Level
  • Page 77 – Radiator Coolant Level; Periodic Maintenance Chart beginning on page 53.; Lift the hood and slowly
  • Page 78 – Spark Plugs; Spark Plug Gap/Torque; Spark Plug Removal and Replacement
  • Page 79 – Polaris Variable Transmission (PVT) System; PVT Drying; the PVT system. Use the following instructions to dry it out before
  • Page 80 – Vehicle Immersion; If your vehicle becomes immersed, major engine damage can; RANGER TM; If water has been ingested into the PVT follow the procedure
  • Page 81 – Air Filter; Remove the air box cover and
  • Page 82 – Breather Filter and Hoses; Fuel Filter
  • Page 83 – Do not attempt to clean the
  • Page 84 – Carburetor/Engine Idle RPM Adjustment
  • Page 85 – Spark Arrestor; Failure to heed the following warnings while servicing the spark
  • Page 87 – Throttle System; Failure to check or maintain proper operation of the throttle; Throttle Freeplay
  • Page 88 – Throttle Freeplay Inspection; While adjusting, flip the throttle lever back and forth.
  • Page 89 – Brakes; Brake Fluid
  • Page 90 – Brake Inspection
  • Page 91 – Steering Wheel Inspection; Rear Spring Adjustment
  • Page 92 – Seat Belts
  • Page 93 – Tires; Tire Tread Depth; Always replace tires when tread depth; Axle and Wheel Nut Torque Specifications; been loosened for maintenance service.; Location
  • Page 94 – Improperly installed wheels can adversely affect tire wear and; Wheel Removal
  • Page 95 – Lights; Headlight Lamp Replacement
  • Page 96 – Headlight Beam Adjustment; Include the weight of a rider on; Brake Lights
  • Page 97 – Indicator Lamp Replacement; Tool Kit; Additional tools will be necessary to perform routine
  • Page 98 – Cleaning Your; can also extend the life of various components. With a few; If warning labels are damaged, contact your Polaris dealer; If a high pressure type car wash system is used, extreme care must be; If a high pressure car wash is used, grease all zerk fittings
  • Page 99 – Storage; Premium 4 oil into the cylinder. Operate the starter for a few
  • Page 100 – Removal from Storage; Check the battery electrolyte level and charge the battery if; Tightness of the bolts, nuts and other fasteners should be; Chart beginning on page 53.; Engine exhaust contains poisonous carbon monoxide and can
  • Page 101 – Battery; Keep the battery terminals and connections free of corrosion. If
  • Page 102 – Replenishing Battery Fluid (Conventional Battery); in an explosion and cause serious injury or death. When; Battery Removal; tablespoon baking soda and one cup water to prevent damage to
  • Page 103 – Battery Installation; When installing a new battery, make sure it’s fully charged; Battery Storage
  • Page 104 – POLARIS PRODUCTS
  • Page 105 – SPECIFICATIONS
  • Page 111 – TROUBLESHOOTING; solutions using the following charts.; Engine Doesn’t Turn Over
  • Page 112 – Engine Backfires
  • Page 113 – Engine Stops or Loses Power; Possible Cause
  • Page 114 – WARRANTY; LIMITED WARRANTY; REGISTRATION; proper dealer set-up will void your warranty coverage.; WARRANTY COVERAGE AND EXCLUSIONS:
  • Page 115 – LIMITATIONS OF WARRANTIES AND REMEDIES; Lubricants; SPARK ARRESTOR
  • Page 116 – Exported Vehicles; How to Get Service
  • Page 117 – California Emission Control Warranty Statement; Your Warranty Rights and Obligations; Limited Warranty
  • Page 118 – Warranty Period
  • Page 119 – What is Not Covered Under This Warranty; Maintenance Schedule
  • Page 121 – Repair and Replacement of Emission-Related Parts; How to File a Warranty Claim/Where to Get Warranty Service
  • Page 123 – MAINTENANCE LOG; Periodic Maintenance Record; Use the following chart to record periodic maintenance.
  • Page 125 – INDEX
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Summary

Page 3 - WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. WARNING

Page 4 - WELCOME; RANGER

1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets ...

Page 6 - TABLE OF CONTENTS

3 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 4 . . . . . . . . SAFETY 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 23 . . . . . . . . . . . . . . . OPERATION 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMISSION CONTROL SYSTEMS...

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