Vehicle Segment:
Midsize Utility Side-by-Side (SxS) / UTV (Utility Task Vehicle)
Target Audience:
Recreational users, hunters, farmers, trail riders, property owners requiring a versatile and capable off-road vehicle.
Competitors 2013:
Arctic Cat Prowler, Kawasaki Mule, John Deere Gator, Can-Am Commander.
Crew Cab:
Seats up to 4 occupants, enhancing utility for transporting people and gear.
Efi:
Electronic Fuel Injection ensures improved throttle response, fuel efficiency, and easier starting in varying conditions.
Midsize Platform:
Offers a balance of maneuverability and capacity, suitable for tighter trails and general work.
Vehicle Systems Covered:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Transmission (PVT), Drivetrain (AWD/2WD), Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Electrical System, Lighting, Charging System, Starting System, Bodywork, Chassis, Troubleshooting, Maintenance, Specifications.
Estimated Page Count:
Likely between 300-500 pages (typical for comprehensive service manuals of this era and type).
Manual Type:
Service Manual / Repair Manual
Engine:
Detailed diagnostics, repair procedures, component overhaul for the 400cc and 500cc EFI engines.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, fuel pressure regulator, sensors.
Ignition System:
Spark plugs, ignition coils, ECU, troubleshooting ignition faults.
Cooling System:
Radiator, fan, thermostat, coolant, water pump, bleeding procedures.
Transmission Drivetrain:
PVT (Polaris Variable Transmission) belt inspection and replacement, clutch service, AWD system diagnostics and repair, drive shafts, differentials.
Suspension Steering:
Front and rear suspension component inspection, adjustment, and replacement; steering linkage, tie rods, steering column.
Brakes:
Hydraulic disc brake system service, pad replacement, caliper service, bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter motor, alternator/stator, fuses, relays, lighting circuits, accessory circuits.
Routine Maintenance:
Oil change, filter replacement, air filter service, spark plug replacement, brake checks, fluid level checks, tire pressure checks, CV joint boot inspection.
Troubleshooting:
System-specific diagnostic flowcharts and symptom-based troubleshooting guides for common issues.
Repair Overhaul:
Step-by-step instructions for major component repair and overhaul, including engine, transmission, and drivetrain rebuilds.
Installation Replacement:
Procedures for replacing wear items and major components such as bearings, seals, and body panels.
Depth Level:
Comprehensive, covering basic to advanced repair and diagnostic procedures, suitable for professional technicians and experienced DIYers.
File Type:
Portable Document Format (PDF)
Searchability:
Typically text-searchable PDF for efficient information retrieval.
Print Resolution:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type:
Not applicable (Digital PDF Download).
Paper Type:
Not applicable (Digital PDF Download).
Engine Type 400:
4-Stroke Single Cylinder SOHC (400cc class engine, specific displacement may vary slightly)
Engine Type 500:
4-Stroke Single Cylinder SOHC (500cc class engine, specific displacement may vary slightly)
Cooling Method:
Liquid-Cooled
Horsepower Estimate:
Ranger 400: Approx. 28-30 HP; Ranger 500: Approx. 32-34 HP (exact figures vary)
Torque Estimate:
Ranger 400: Approx. 26-28 lb-ft; Ranger 500: Approx. 28-30 lb-ft (exact figures vary)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane Minimum)
ECU:
Engine Control Unit (ECU) managing fuel, ignition, and other parameters.
Transmission Type:
Polaris Variable Transmission (PVT) Automatic with Engine Braking
Drive Modes:
2WD / AWD (On-Demand)
Gear Selection:
High, Low, Neutral, Reverse, Park
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent spec)
Transmission Fluid Capacity:
Refer to manual for exact capacity, typically around 1-2 quarts.
Length:
Approx. 116.5 inches (2959 mm)
Width:
Approx. 60 inches (1524 mm)
Height:
Approx. 72.1 inches (1831 mm)
Wheelbase:
Approx. 77 inches (1956 mm)
Cargo Bed Capacity:
Approx. 200 lbs (91 kg)
Dry Weight:
Approx. 1,160 lbs (526 kg)
Towing Capacity:
1,500 lbs (680 kg)
Gvw Rating:
Approx. 1,700 lbs (771 kg)
Front Tire Size:
25x8-12 (Commonly)
Rear Tire Size:
25x10-12 (Commonly)
Crash Test Ratings:
Not applicable, as UTVs are not subjected to NHTSA crash testing like passenger vehicles.
Braking System:
Hydraulic disc brakes (front and rear).
AWD System:
On-demand AWD for enhanced traction.
Seatbelts:
3-point seat belts for all occupants.
Roll Over Protection:
Standard ROPS (Roll Over Protective Structure) certified cage.
Lighting:
Dual halogen headlights, LED taillights.
Gauge Cluster:
Digital LCD display showing speed, RPM, fuel level, gear indicator, odometer, trip meter, AWD mode.
Lighting Technology:
Halogen headlights for illumination, LED taillights for visibility.
Engine Braking:
PVT system provides inherent engine braking for downhill control.
Accessory Power:
12V DC outlet for charging accessories (e.g., GPS, phone).
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Transmission Fluid Change:
Every 200 hours or 24 months, whichever comes first.
Air Filter Inspection:
Every 50 hours or 6 months, clean as needed.
Spark Plug Replacement:
Refer to manual, typically around 100-200 hours or 12-24 months.
Drive Belt Inspection:
Inspect every 100 hours or 12 months, replace as needed based on wear.
Engine Oil Type:
Polaris PS-4 10W-50 Full Synthetic (or equivalent API SG, JASO MA certified)
Engine Oil Capacity:
Refer to manual for exact capacity, typically around 2 quarts (1.9 Liters) with filter.
Coolant Type:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water.
Common Wear Items:
Drive belts (especially under heavy use), tie rod ends, suspension bushings, CV boots.
Efi System Quirks:
Potential for sensor issues (e.g., TPS, MAP) or fuel pump wear impacting performance; manual provides diagnostic steps.
Polaris Offroad Legacy:
Polaris has been a pioneer in the powersports industry since its founding in 1954, with a strong focus on off-road vehicles, including snowmobiles, ATVs, and UTVs.
Ranger Lineup:
The Ranger line has evolved significantly, offering a range of models from compact utility vehicles to high-performance off-roaders. The midsize crew models are designed to balance maneuverability with passenger/cargo capacity.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States (e.g., Roseau, Minnesota; Spirit Lake, Iowa).
