Polaris Ranger 500 (2x4) - Workshop Manual / Repair Manual - Wiring Schematics - User Manual

POLARIS RANGER 500 (2x4) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS - OWNERS MANUAL

- English Workshop Manual / Repair Manual, Wiring Schematics and User Manual, for UTV Polaris Ranger 500  (2x4).

 
INDEX:

SERVICE MANUAL

General Information
- Vehicle Identification
- Model Identification
- Engine Designation Number
- Vin Identification
- Engine Serial Number Location
- Vehicle Identification Number (Vin) Location
- Transmission I.D. Number Location
- Vehicle Dimensions
- Vehicle Dimensions
- General Specifications
- Model: 2009 Ranger 2x4
- Model: 2009 Ranger 2x4
- 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
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 50 - 100 Hour Maintenance Interval
- 100 - 300 Hour Maintenance Interval
- Service Products And Lubricants
- Polaris Lubricants, Maintenance And Service Products
- General Component Location
- Rh Side And Dash View
- Lh Side And Rear View
- Maintenance References
- Maintenance Quick Reference
- 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
- Throttle Cable Adjustment
- Choke Adjustment
- Idle Speed Adjustment
- Pilot Screw
- Pilot Screw Adjustment
- Carburetor Draining
- Air Intake Inspection
- Air Filter Service
- 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 / Rear Gearcase
- Transmission Lubrication
- 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 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 And Suspension
- Steering
- Tie Rod End / Steering Inspection
- Wheel Toe Alignment Inspection
- Toe Adjustment
- Front Suspension
- Rear Suspension
- Rear Suspension Adjustment
- Rear Spring Adjustment
- Brake System
- Brake Fluid Inspection
- Brake Hose And Fitting Inspection
- Brake Pad / Disc Inspection
- Parking Brake Cable Adjustment
- Parking Brake Pad 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
- Crankshaft Straightening
- Engine Lubrication - Eh50pl
- Oil Pressure Test - Eh50pl
- Oil Flow - Eh50pl
- Eh50pl Oil Flow Diagram
- Eh50pl Engine Exploded View
- Cooling System
- Cooling System Specifications
- 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 (Intake And Exhaust)
- 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 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
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
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 Back / Head Rests
- 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
- 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 Hub
- Hub Removal / Inspection
- Hub Installation
- Exploded View
- Rear Hub / Bearing Carrier
- Hub Inspection
- Hub Removal
- Hub Disassembly
- Hub Assembly
- Hub Installation
- Exploded View
- Rear Drive Shaft
- Removal
- Outer Cv Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Exploded View
- Installation
- 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 Linkage
- 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 Inspection
- Disc Replacement
- Rear Brake Pads
- Pad Removal
- Pad Inspection
- Pad Installation
- Rear Caliper Service
- Rear Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Rear Brake Disc
- Disc Inspection
- Disc Replacement
- 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
- Headlight Switch
- Rear Differential Switch
- Differential Solenoid
- Parking Brake Switch
- Indicator Lamp Circuit Operation
- Indicator Lamp Replacement
- Headlights
- Headlight Adjustment
- Headlight Bulb Replacement
- Headlight Housing Removal
- Headlight Housing Installation
- Tail Light / Brake Light
- Lamp Replacement
- Power Distribution Module
- Functional Description
- Pdm Block Diagram
- Pdm Troubleshooting
- Solid State Circuit Breaker #1 (Sscb #1)
- Solid State Circuit Breaker #2 (Sscb #2)
- Pdm Fan Motor Troubleshooting
- Pdm Chassis Power Troubleshooting
- Timing Check Procedure
- Cooling System
- Cooling System Break-Out Diagram
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- Coolant Temperature Sensor Test
- Dc / Cdi Ignition System
- 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
- Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Charging System Alternator Tests
- Charging System Testing Flow Chart
- Battery Service
- Battery Terminals / Bolts
- Battery Terminal Block
- Battery Activation
- Battery Inspection
- Battery Removal / Installation
- Battery Testing
- Ocv - Open Circuit Voltage Test
- Specific Gravity Test
- Load Test
- Off Season Storage
- Charging Procedure
- Starter System
- Troubleshooting
- Voltage Drop Test
- Starter Motor Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Assembly
- 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