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

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

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

 
CONTENTS:

SERVICE MANUAL

General Information
- Vehicle Identification
- Model Identification
- Engine Designation Number
- VIN Identification
- Vehicle and Engine Serial Number Locations
- Vehicle Information
- Publication Numbers
- Replacement Keys
- Special Tools
- General Specifications
- MODEL: 2009 RANGER 500 4X4 EFI
- MODEL: 2009 RANGER 500 4X4 EFI
- 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
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 50 - 100 Hour Maintenance Interval
- 100 - 300 Hour Maintenance Interval
- Grease Lubrication Points
- Service Products And Lubricants
- Polaris Lubricants, Maintenance and Service Products
- Fluid Maintenance References
- Component Quick Reference
- Component Quick Reference, Continued.....
- 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
- Vent Lines
- Throttle Pedal Inspection
- Throttle Freeplay Adjustment
- Air Filter Service
- Engine Air Intake Inspection
- PVT Air Intake Inspection
- Air Intake Exploded View
- Engine
- Compression and Leakdown Test
- Breather Filter Inspection
- Breather Hose
- Flywheel Housing Drain Plug
- 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
- Rear Gearcase Lubrication
- Cooling System
- Liquid Cooling System Overview
- Coolant Level Inspection
- Coolant Strength / Type
- Cooling System Hoses
- Radiator Inspection / Cleaning
- Coolant Drain / Radiator Removal
- Final Drive / Wheel And Tire
- Wheel and Hub 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
- Steering
- Tie Rod End / Steering Inspection
- Wheel Toe Alignment Inspection
- Toe Adjustment
- Suspension
- Suspension Inspection
- Spring Pre-Load Adjustment
- Shock Position Adjustment
- Brake System
- Brake Fluid Inspection
- Brake Hose and Fitting Inspection
- Brake Pad / Disc Inspection
- Parking Brake Cable Adjustment
- Parking Brake Pad Inspection
- Maintenance Log
Engine
- Special Tools
- Specifications
- Torque Specifications
- Engine Fastener Torque Patterns
- Engine Service Data
- Engine Service Data
- General Engine Service
- Accessible Components
- Engine Removal
- Engine Installation Notes
- Crankshaft Straightening
- Engine Lubrication - EH50PL
- Oil Pressure Test - EH50PL
- Oil Flow - EH50PL
- EH50PL Oil Flow Diagram
- EH50PL Engine Exploded View
- Cooling System
- 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
- 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
- Cylinder / Piston Removal and Inspection
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection / Honing Procedure
- Honing to Oversize
- Cleaning the Cylinder After Honing
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Identification
- 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
- Oil Pump Priming Procedure
- Troubleshooting
- Engine
- Spark Plug Fouling
- Cooling Troubleshooting
Electronic Fuel Injection
- Special Tools
- Part Numbers / Descriptions
- Efi Service Notes
- General Service Information
- Efi System
- Exploded View
- Efi Components
- 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 Unit (Ecu)
- Operation Overview
- ECU Replacement
- ECU Service
- Fuel Pump Assembly
- Operation
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump / Tank Assembly Replacement
- Fuel Pressure Regulator
- General Information
- Fuel Injector
- General Information
- Fuel Injector Service
- Fuel Injector Test
- Fuel Injector Replacement
- Crank Position Sensor (Cps)
- General Information
- CPS Test
- CPS Replacement
- Manifold Absolute 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
- IAC Test
- IAC Replacement
- Throttle Position Sensor (Tps)
- General Information
- TPS Resistance Tests
- TPS Tester Kit
- Checking TPS Reading
- TPS Adjustment
- TPS Replacement
- Engine Temperature Sensor
- General Information
- Engine Temperature Sensor Test
- Engine Temperature Sensor Replacement
- Ignition Coil
- Operation Overview
- Ignition Coil Tests
- Ignition Coil and HT Lead Replacement
- Diagnostics Using “Blink Codes”
- Blink Codes - Operation
- Fuel System Troubleshooting
- Fuel Starvation / Lean Mixture
- Rich Mixture
- Poor Idle
Body / Steering / Suspension
- Torque Specifications
- Special Tools
- Multi-Function Pliers
- Chassis / Main Frame
- Exploded View
- Cab Frame
- Exploded View / Assembly
- Seat Back / Headrest / Pvt Air Intake Baffle Box
- Exploded View / Assembly
- Body Exploded Views
- Dash Instruments / Controls
- Hood / Dash / Front Fenders / Front Fascia
- Floor / Rear Fenders
- Seat Mounting / Seat Belts
- Rear Cargo Box
- Cargo Box - Panels
- Cargo Box - Tailgate / Box Support
- Box Removal
- Box Installation
- Body Component Removal
- Lower Seat Base
- Wheel Well Panels
- Front Bumper
- Front Fascia
- Front Fenders
- Hood / Dash
- Glove Box / Storage Panel
- Rear Fenders
- Floor
- Steering Assembly
- Exploded View
- Front A-Arms
- Removal / Replacement
- Exploded View
- Ball Joint Service
- Removal
- Installation
- Rear A-Arms
- Removal / Replacement
- Installation
- Exploded View
- Rear Stabilizer Bar
- Removal / Installation
- Exploded View
- Shocks / Springs
- Exploded View
- Shock Removal / Installation
- Shock Replacement
- Decal Replacement
Clutching
- Special Tools And Supplies
- Torque Specifications
- PVT System Fastener Torques
- Pvt System Overview
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In (Drive Belt / Clutches)
- 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
- PVT Break-In (Drive Belt / Clutches)
- Clutch Alignment / Offset / Center Distance
- Clutch Alignment
- Clutch Offset
- Clutch Center Distance
- 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 Bearing Carrier
- Bearing Carrier Inspection / Removal
- Bearing Replacement
- Bearing Carrier Installation
- Front Drive Shaft
- Removal
- Installation
- Front Propshaft
- Removal
- Installation
- Front Propshaft Components
- Propshaft U-Joint Service
- Disassembly
- Assembly
- Front Gearcase - Centralized Hilliard
- Exploded View
- Operation
- AWD Diagnosis
- Gearcase Removal
- Disassembly / Inspection
- Reassembly / Inspection
- Setting Ring Gear Backlash
- Gearcase Installation
- Rear Hub / Bearing Carrier
- Hub Inspection
- Hub Removal
- Hub Disassembly
- Hub Assembly
- Hub Installation
- Exploded View
- Rear Drive Shaft
- Removal
- Installation
- Drive Shaft Service
- Drive Shaft / CV Joint Handling Tips
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Exploded View
- Rear Propshaft
- Removal
- Installation
- Rear Gearcase
- General Operation
- Operation Modes
- Gearcase Removal
- Gearcase Disassembly
- Rear Gearcase Assembly
- Rear Gearcase Installation
- Rear Gearcase Exploded View
Transmission
- Torque Specifications
- Shift Lever
- Removal
- Installation
- Shift Cable
- Inspection
- Adjustment
- Transmission Service
- Transmission Removal
- Transmission Disassembly
- Transmission Assembly
- Transmission Installation
- Troubleshooting
- Troubleshooting Checklist
- Transmission Exploded View
- Exploded View
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
- Cable Tension Adjustment
- Parking Brake Caliper Service
- Exploded View
- Caliper Removal
- Caliper Disassembly / Inspection
- New Brake Pad Installation
- Caliper Installation
- Parking Brake Disc Service
- Disc Inspection / Removal
- Front Brake Pads
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure
- Front Caliper Service
- Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Front Brake Disc
- Disc Runout
- Disc Inspection
- Disc Removal / Replacement
- Rear Brake Pads
- Pad Removal
- Pad Inspection
- Pad Installation
- Brake Burnishing Procedure
- Rear Caliper Service
- Rear Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Rear Brake Disc
- Disc Runout
- Disc Inspection
- Disc Removal / Replacement
- Troubleshooting
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
Electrical
- General Information
- Special Tools
- Electrical Service Notes
- Components Under Hood
- Components Behind Dash Panel
- Switches / Controls
- Headlight Switch
- AWD / 2WD / TURF Switch
- Differential Solenoid
- Brake Light Switch
- Parking Brake Switch
- Gear Indicator Light Circuit Operation
- Indicator Lamp Replacement
- Fuel / Hour Gauge
- All Wheel Drive (Awd) Coil
- Operation Overview
- Diagnosing System Failures
- Headlights
- Headlight Adjustment
- Headlight Bulb Replacement
- Headlight Housing Removal
- Headlight Housing Installation
- Tail Light / Brake Light
- LED Lamp Replacement
- Cooling System
- Cooling System Break-Out Diagram
- Fan Control Circuit Operation
- Fan Control Circuit Bypass Test
- Efi Diagnostics
- EFI Component Testing
- Fuel Sender
- Testing
- Relays
- Operation
- Fuses / Circuit Breaker
- Operation
- Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Charging System Alternator Tests
- Regulator / Rectifier Test
- Charging System Testing Flow Chart
- Battery Service
- Battery Terminals / Bolts
- Battery Terminal Block
- Battery Activation
- Battery Inspection
- Battery Removal / Installation
- Conventional Battery Testing
- OCV - Open Circuit Voltage Test
- Specific Gravity Test
- Load Test
- Charging Procedure
- Off Season Storage
- Starter System
- Troubleshooting
- Voltage Drop Test
- Starter Motor Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter Drive
- Starter Solenoid Bench Test
- Starter Solenoid Operation
- Starting System Testing Flow Chart
- Condition: Starter fails to turn over the engine.
- Electric Box Lift Actuator
- DIAGNOSIS (if equipped)


OWNERS MANUAL