Polaris Ranger 500 (2X4, 4X4, 4X4 EFI) - Repair, Service Manual, Wiring Diagrams and Owners Manual

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POLARIS RANGER 500 (2X4, 4X4, 4X4 EFI) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for UTV Polaris Ranger 500 (2X4, 4X4, 4X4 EFI).

 
CONTENTS:

SERVICE MANUAL

General Information
- Vehicle Identification
- Model Identification
- Engine Designation Number
- VIN Identification
- Engine Serial Number Location
- Unit Serial Number (VIN) Location
- Transmission I.D. Number Location
- Vehicle Dimensions
- vehicle DIMENSIONS
- General Specifications
- MODEL: 2007 RANGER 2X4
- MODEL: 2007 RANGER 4X4 CARB
- MODEL: 2007 RANGER 4X4 EFI
- MODEL: 2007 RANGER 2X4
- MODEL: 2007 RANGER 4X4 CARB
- MODEL: 2007 RANGER 4X4 EFI
- Vehicle Information
- Publication Numbers
- Paint Codes
- Replacement Keys
- Special Tools
- Misc. Specifications And Charts
- Conversion Table
- Standard Torque Specifications
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
- Glossary of Terms
Maintenance
- Periodic Maintenance Chart
- Periodic Maintenance Overview
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 50 - 100 Hour Maintenance Interval
- 100 - 300 Hour Maintenance Interval
- General Component Location
- RH Side and Dash View
- LH Side and Rear View
- Service Products And Lubes
- Polaris Lubricants, Maintenance and Service Products
- Maintenance References
- Polaris Lubricant Symbol Identification
- Engine Lubrication
- Component Fluid Type and Use
- Component Lubrication Points
- General Vehicle Inspection And Maintenance
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, and Fasteners
- Shift Linkage Inspection / Adjustment
- Fuel System And Air Intake
- Fuel System
- Fuel Lines
- Fuel Filter (Carb Models)
- Vent Lines
- Throttle Pedal Inspection
- Throttle Freeplay Adjustment
- Throttle Cable Adjustment (Carb Models)
- Choke Adjustment (Carb Models)
- Pilot Screw (Carb Models)
- Pilot Screw Adjustment (Carb Models)
- Idle Speed Adjustment (Carb Models)
- Carburetor Draining (Carb Models)
- Air Intake Inspection
- Air Filter Service
- Fuel System (Efi)
- Fuel Filter
- Engine
- Compression and Leakdown Test
- Breather Filter Inspection
- Breather Hose
- Flywheel Housing
- Engine Oil Level
- Engine Oil and Filter Change
- Oil Pump Priming Procedure
- Valve Clearance
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Exhaust Pipe
- Transmission And Gearcases
- Transmission Lubrication
- Front Gearcase Lubrication (4x4)
- Rear Gearcase Lubrication
- Cooling System
- Liquid Cooling System Overview
- Coolant Level Inspection
- Radiator Coolant Level Inspection
- Coolant Strength / Type
- Cooling System Pressure Test
- Cooling System Hoses
- Radiator
- Coolant Drain / Radiator Removal
- Final Drive / Wheel And Tire
- Wheel, Hub, and Spindle Torque Table
- CV Shaft Boot Inspection
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
- Electrical And Ignition System
- Battery Maintenance
- Battery Fluid Level (Conventional Battery)
- Battery Removal
- Battery Installation
- Battery Storage
- Battery Charging
- Spark Plug Service
- Engine To Frame Ground
- Steering And Suspension
- Steering
- Tie Rod End / Steering Inspection
- Camber and Caster
- Wheel Toe Alignment Inspection
- Toe Adjustment
- Front Suspension
- Rear Suspension
- Rear Suspension Adjustment
- Rear Spring Adjustment
- Brake System
- Brake System Inspection
- Brake Pad Inspection
- Parking Brake Pad Inspection
- Brake Hose and Fitting Inspection
Engine
- Special Tools
- Specifications
- Torque Specifications
- Engine Service Data
- Engine Service Data
- Engine Fastener Torque Patterns
- General Engine Service
- Piston Identification
- Accessible Components
- Engine Removal
- Engine Installation Notes
- Cylinder Hone Selection / Honing Procedure
- Honing to Oversize
- Cleaning the Cylinder After Honing
- Crankshaft Straightening
- Engine Lubrication - EH50PL
- Oil Pressure Test - EH50PL
- Oil Pump Priming Procedure
- Oil Flow - EH50PL
- EH50PL Oil Flow Diagram
- EH50PL Engine Exploded View
- Cooling System
- Cooling System Specifications (Non-EFI)
- Cooling System Layout and Testing
- Engine Disassembly
- Engine Removal
- Cam Chain Tensioner / Rocker Arm / Camshaft Removal
- Cam Chain Tensioner Inspection
- Rocker Arm / Shaft Inspection
- Camshaft Removal
- Automatic Compression Release Removal / Inspection
- Automatic Compression Release Installation
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Exploded View, EH50PL (EFI Shown)
- Cylinder Head Inspection
- Cylinder Head Warpage
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Valve Clearance Adjustment (Intake and Exhaust)
- Cylinder / Piston Removal and Inspection
- Piston Removal
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Ring Installed Gap
- Crankcase Disassembly
- Starter Drive Removal / Inspection
- Flywheel and Stator Removal / Inspection
- Cam Chain / Tensioner Blade
- One Way Valve
- Crankcase Separation
- Oil Pump Removal / Inspection
- Oil Pump Assembly
- Counter Balancer Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Bearing Inspection
- Oil Seal / Mechanical Seal Removal (Engine Disassembled)
- Crankcase Inspection
- Bearing Installation
- End Play Inspection / Adjustment
- Crankshaft End Play Adjustment
- Counter Balancer Shaft End Play Adjustment
- Oil Pump Shaft End Play Adjustment
- Engine Reassembly
- Pump Shaft Oil Seal Installation
- Crankshaft / Counter Balance / Oil Pump Installation
- Crankcase Assembly
- Water Pump Mechanical Seal Installation
- Water Pump Mechanical Seal Removal (Engine Installed)
- One Way Valve Installation
- Cam Chain Drive Sprocket Installation
- Tensioner Blade Installation
- Piston Ring Installation
- Piston Installation
- Cylinder Installation
- Cylinder Head Installation
- Cam Chain / Camshaft Installation
- Camshaft Timing
- Camshaft Timing Illustration
- Cam Chain Tensioner Installation
- Stator, Flywheel and Starter Drive Installation
- Rocker Shaft / Rocker Arm Assembly Installation
- Thermostat Installation
- Oil Pipes
- Troubleshooting
- Engine
- Spark Plug Fouling
- Cooling Troubleshooting
Carburetion System
- Special Tools
- Carburetor Jetting
- Jetting Guidelines
- Mikuni Jet Part Numbers
- Mikuni Cv Carburetor
- Exploded View
- System Function - Mikuni CV Carb
- Vent Systems - Mikuni CV Carb
- Operation - Mikuni CV Carb
- Pilot System (Idle and Slow Speed)
- Starter System (Choke or Enrichment)
- Float System
- Main System
- Pilot Screw
- Carburetor Service
- Carburetor Removal
- Carburetor Disassembly
- Carburetor Cleaning
- Carburetor Inspection
- Float Height Adjustment
- Needle and Seat Leakage Test
- Fuel Level
- Carburetor Assembly
- Air Box Assembly
- Exploded View
- Fuel Tank Assembly
- Fuel Tank / Fuel Pump Exploded View
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Pump
- Replacement
- Troubleshooting
- Fuel Starvation / Lean Mixture
- Rich Mixture
- Idle Too High
- Idle Too Low
- Erratic Idle
Electronic Fuel Injection
- Special Tools
- Part Numbers / Descriptions
- Efi Service Notes
- General Service Information
- Efi System
- Exploded View
- Efi Component Locations
- Identification / Location
- Fuel Tank
- Exploded View
- Electronic Fuel Injection
- General Information
- EFI Operation Overview
- Initial Priming / Starting Procedure
- Fuel Lines
- Quick Connect Removal / Installation
- Electronic Control Module (Ecm)
- Operation Overview
- ECM Replacement
- ECM Service
- Fuel Pump Assembly
- Operation / Testing
- Fuel Pump Test
- Fuel Pump / Tank Assembly Replacement
- Fuel Pressure Regulator
- General Information
- Fuel Injector
- General Information
- Crankshaft Position Sensor (Cps)
- General Information
- Manifold Air Pressure Sensor (Map)
- General Information
- Map Sensor Test
- Map Sensor Replacement
- Intake Air Temperature Sensor (Iat)
- General Information
- Intake Air Temperature Sensor Test
- Intake Air Temperature Sensor Replacement
- Idle Air Control (Iac)
- General Information
- Throttle Position Sensor (Tps)
- General Information
- Throttle Position Sensor Test
- Throttle Position Sensor Replacement
- Throttle Position Sensor Initialization
- Engine Temperature Sensor
- General Information
- Engine Temperature Sensor Test
- Engine Temperature Sensor Replacement
- Diagnostics Using ‘Blink Codes’
- Blink Codes - Operation
- Fuel System Troubleshooting
- Fuel Starvation / Lean Mixture
- Rich Mixture
- Poor Idle
- Efi System Break-Out Diagrams
- Fuel Injector Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Fuel Pump Circuit
- Ignition Coil Circuit
- Idle Air Control (IAC) Circuit
- Throttle Position Sensor (TPS) Circuit
- Manifold Air Pressure Sensor (MAP) Circuit
- Engine Coolant Temperature Sensor Circuit
- Intake Air Temperature Sensor (IAT) Circuit
- Malfunction Indicator Light (MIL) Circuit
- Diagnostic Connector Circuit
Body / Steering / Suspension
- Torque Specifications
- Special Tools
- Body Component Removal
- Removal Procedures
- Lower Body Components
- Hood / Dash Components
- Dash Instruments and Controls
- Cab Frame
- Assembly / Removal
- Chassis / Main Frame
- Exploded View
- Seat / Head Rest
- Seat Base / Seat Back / Head Rest Assembly
- Steering Assembly
- Exploded View
- Steering And Suspension
- Exploded View
- Front A-Arm
- Replacement
- Front Strut
- Exploded View
- Front Strut Cartridge Replacement
- Ball Joint Replacement
- Rear A-Arm
- Replacement
- Rear Stabilizer Bar
- Removal / Installation
- Rear Cargo Box
- Cargo Box - Panels
- Cargo Box - Tailgate / Box Support
- Box Removal
- Box Installation
- Decal Replacement
Clutching
- Special Tools And Supplies
- Torque Specifications
- PVT System Fastener Torques
- Pvt System Overview
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- Maintenance / Inspection
- Overheating / Diagnosis
- Pvt System Service
- PVT Sealing, Guard, and Ducting Components
- Disassembly
- Assembly
- Drive Belt
- Belt Deflection (Tension)
- Belt Removal
- Belt Inspection
- Belt Installation
- Clutch Alignment / Offset
- Clutch Alignment
- Clutch Offset
- Drive Clutch Service
- Spring Specifications
- Shift Weights
- Exploded View
- Clutch Inspection
- Clutch Disassembly
- Spider Removal
- Roller, Pin, and Thrust Washer Inspection
- Bushing Service
- Moveable Sheave - Bushing Removal
- Moveable Sheave - Bushing Installation
- Clutch Cover - Bushing Removal
- Clutch Cover - Bushing Installation
- Clutch Assembly
- Driven Clutch Service
- Exploded View
- Clutch Disassembly / Inspection
- Bushing Service
- Moveable Sheave - Bushing Installation
- Clutch Assembly
- Troubleshooting
Final Drive
- Special Tools
- Torque Specifications
- Wheel, Hub, and Spindle Torque Table
- Front Hub (2x4)
- Hub Removal / Inspection
- Hub Installation
- Exploded View (2X4)
- Front Hub (4x4)
- Hub Removal / Inspection
- Hubstrut Bearing Replacement
- Hub Installation
- Exploded View (4X4)
- Drive Shaft / Propshaft
- Exploded View
- Driveshaft / Cv Joint Handling Tips
- Front Drive Shaft (4x4)
- Removal
- CV Joint / Boot Replacement
- Installation
- Front Propshaft Removal
- Propshaft U-Joint Service
- Disassembly
- Assembly
- Front Gearcase Centralized Hilliard
- AWD Operation
- Centralized Hilliard Exploded View
- AWD Diagnosis
- Gearcase Removal
- Gearcase Disassembly / Inspection
- Gearcase Reassembly / Inspection
- Backlash Pad (Thrust Pad) Adjustment
- Gearcase Installation
- Rear Drive
- Exploded View
- Rear Hub / Bearing Carrier
- Hub Inspection
- Hub Removal
- Hub Disassembly
- Hub Assembly
- Hub Installation
- Rear Drive Shaft
- Removal
- CV Joint / Boot Replacement
- Installation
- Rear Propshaft
- Removal
- Installation
- Rear Gearcase (Differential)
- General Operation
- Operation Modes
- Differential Removal
- Differential Disassembly
- Differential Assembly
- Differential Installation
- Differential Exploded View
Transmission
- Torque Specifications
- Shift Lever
- Removal
- Installation
- Shift Linkage
- Inspection
- Adjustment
- Transmission Service
- Transmission Removal
- Transmission Disassembly
- Transmission Assembly
- Transmission Installation
- Troubleshooting
- Troubleshooting Checklist
- Transmission Exploded View
- Exploded View (2X4)
- Exploded View (4X4)
Brakes
- General Specifications
- Torque Specifications
- Special Tools
- Brake System Service Notes
- Brake Noise Troubleshooting
- Hydraulic Brake System Operation
- Brake System Exploded View
- Master Cylinder
- Removal
- Installation
- Foot Brake Pedal
- Pedal Removal
- Pedal Installation
- Brake Bleeding / Fluid Change
- Parking Brake
- Exploded View
- Inspection
- Adjustment
- Parking Brake Caliper Service
- Exploded View
- Caliper Removal
- Caliper Disassembly / Inspection
- New Brake Pad Installation
- Caliper Installation
- Parking Brake Disc Service
- Disc Removal / Inspection
- Front Brake Pads
- Pad Removal / Disassembly
- Pad Inspection
- Pad Assembly / Installation
- Pad Adjustment
- Front Caliper
- Front Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Front Brake Disc
- Disc Inspection
- Disc Removal / Replacement
- Rear Brake Pad
- Pad Removal
- Pad Inspection
- Pad Installation
- Rear Caliper
- Rear Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Rear Brake Disc
- Disc Inspection
- Troubleshooting
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
Electrical
- General Information
- Special Tools
- Electrical Service Notes
- Under-Hood Components
- Switches / Controls
- Headlamp Switch
- AWD / Rear Differential Switch
- Differential Solenoid
- Brake Light Switch
- Parking Brake Switch
- Gear Indicator Light Circuit Operation
- Indicator Lamp Replacement
- Head Lights
- High Beam Headlight Adjustment
- Headlamp Bulb Replacement
- Headlamp Housing Removal
- Headlamp Housing Installation
- Tail Light / Brake Light
- Lamp Replacement
- Power Distribution Module (Non-Efi Models)
- PDM Operation
- PDM Block Diagram
- Pdm Isolation Tests (Non-Efi Models)
- Battery Voltage Test
- Ground Test
- Static Stator Test
- Run Signal Test
- Dynamic Stator Test
- Battery + Test
- Protected Battery + Test
- Ignition Switch Test
- Accessory Power Test
- PDM to Fan Output Test
- Fan Motor Test
- Static Thermistor Test
- Dynamic Thermistor Test
- Hot Lamp Test
- Differential Solenoid Test
- AWD Out Test
- AWD / Turf Switch Test
- Differential Out Test
- Differential Ground Test
- ACS Out Test
- Power Distribution Module (Efi Models)
- PDM Operation
- PDM Function Overview
- PDM Block Diagram
- Timing Check Procedure (Non-Efi Models)
- Cooling System
- Non-EFI Cooling System Break-Out Diagram
- EFI Cooling System Break-Out Diagram
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- Coolant Temperature Sensor Test (Non-EFI Models)
- Dc / Cdi Ignition System (Non-Efi Models)
- DC / CDI Ignition System Overview
- Ignition System Troubleshooting
- Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter
- Resistance Tests
- Flywheel Identification
- Ignition System Testing Flow Chart
- Components of DC / CDI Ignition
- Efi Diagnostics
- EFI Component Testing
- Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Charging System Alternator Tests
- Charging System Testing Flow Chart
- Battery Terminal Block
- Battery Service
- Battery Terminals / Bolts
- Battery Identification
- Conventional Battery
- Battery Activation
- Battery Inspection
- Battery Removal
- Battery Installation
- Conventional Battery Testing
- OCV - Open Circuit Voltage Test
- Specific Gravity Test
- Load Test
- Off Season Storage
- Charging Procedure
- Low Maintenance Battery
- Battery Check
- Battery Inspection
- Battery Removal
- Battery Installation
- Battery Testing
- OCV - Open Circuit Voltage Test
- Load Test
- Off-Season Storage
- Battery Charging
- Starter System
- Troubleshooting
- Voltage Drop Test
- Starter Motor Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter Drive
- Starter System Test Flow Chart
- Electric Box Lift Actuator
- DIAGNOSIS (if equipped)
- Electrical Breakout Diagrams (Efi Models)
- Starting Circuit
- Key-On Power Circuit
- Transmission Switch Circuit
- Differential Solenoid Circuit
- Charging System Circuit
- Cooling Fan Circuit
- AWD Circuit
Index
Wire Diagrams


OWNERS MANUAL