Polaris Ranger 500 2x4 4x4 6x6 500 EFi 2x4 Carbureted 1999-2012 Service Repair Workshop Manual Download PDF

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🏷️ Basic Information Identification Make: Polaris Model: Ranger Model Variant: 500 Sub Model Variants: 2x4, 4x4, 6x6, 500 EFi, 2x4 Carbureted Product Name: Polaris Ranger 500 2x4 4x4 6x6 500...

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Tipo: Atv

Proveedor:

SKU: 6807

Etiquetas: 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Atv Polaris Powersports Ranger 500 2x4 Ranger 500 4x4 Ranger 500 6x6 Ranger 500 Carbureted Ranger 500 EFi 2x4 Ranger Models UTV

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Ranger

Model Variant:

Sub Model Variants:

2x4, 4x4, 6x6, 500 EFi, 2x4 Carbureted

Product Name:

Polaris Ranger 500 2x4 4x4 6x6 500 EFi 2x4 Carbureted 1999-2012 Service Repair Workshop Manual Download PDF

👋 Introduction

Market Position

Target Audience:

Polaris Ranger 500 owners, independent repair shops, technicians

Competitive Analysis

Value Proposition:

Provides complete factory service information, saving significant costs compared to dealership service or less comprehensive manuals.

Key Features

Content Scope:

Covers all repairs, servicing, and troubleshooting for the specified model years and variants.

Delivery Method:

Instant download for immediate access

📋 Manual Details

Coverage Areas

Covered Model Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012

Covered Variants:

Ranger 500 2x4, Ranger 500 4x4, Ranger 500 6x6, Ranger 500 EFi, Ranger 500 2x4 Carbureted

Page Count

Estimated Pages:

Hundreds (detailed with photos & diagrams)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

Accessibility

Device Compatibility:

Computers (Windows & MAC), Tablets, Smartphones

Licensing

Usage Rights:

Lifetime use, unlimited installations

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (carbureted & EFI), transmission, drivetrain (2x4, 4x4, 6x6)

Chassis And Suspension:

Frame, suspension (front & rear), steering, wheels, tires

Braking System:

Hydraulic brake system, calipers, master cylinder, lines

Electrical System

Electrical Components:

Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starting system, fuel injection system (EFI models)

Body And Frame

Body Panels:

Bodywork, plastics, seats, cargo bed

Fuel System

Fuel Delivery:

Fuel tank, fuel pump, fuel lines, carburetor (for carbureted models), EFI components (for EFI models)

Cooling System

Cooling Components:

Radiator, coolant, fan, water pump, thermostat

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication, ignition system checks

Troubleshooting:

Diagnostic procedures, fault finding for all major systems

Repair And Rebuild:

Component-level repair, complete engine and transmission overhauls

Disassembly And Assembly:

Step-by-step instructions with exploded diagrams for all major assemblies

Wiring Diagrams:

Complete electrical system wiring schematics

Technical Depth

Depth:

Comprehensive factory-level detail for professional mechanics and DIY enthusiasts

Illustrations

Diagrams And Photos:

Hundreds of detailed photos and exploded diagrams

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Printable (single page or entire manual)

Searchability

Text Search:

Likely searchable text within PDF for efficient information retrieval

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, Twin-Cylinder (Commonly) - Specific configurations may vary slightly between Carbureted and EFI models.

Engine Displacement

Displacement:

499cc to 500cc (Exact displacement may vary by specific model year and variant)

Performance

Horsepower Range:

Approximately 30-35 HP (estimated, varies by model year and specific tuning)

Torque Range:

Approximately 28-32 lb-ft (estimated, varies by model year and specific tuning)

Fuel System

Carbureted Models:

Mikuni BSR34 or similar carburetor

Efi Models:

Electronic Fuel Injection (EFI) system, likely including throttle body, injectors, ECU

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Gear Selection:

High, Low, Neutral, Reverse, Park

Features

Drive Modes:

2WD, 4WD, AWD (viscous or electronic engagement depending on model year)

Fluid Specification

Cvt Fluid:

Polaris recommended CVT fluid (e.g., AGL Synthetic Gearcase Lubricant or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 106-118 inches (varies by model and specific year)

Width:

Approx. 50-60 inches (varies by model and specific year)

Height:

Approx. 70-75 inches (varies by model and specific year)

Weights

Curb Weight:

Approx. 900-1100 lbs (varies by model and specific year)

Cargo

Cargo Bed Capacity:

Approx. 400-800 lbs (varies by model and specific year)

Towing

Towing Capacity:

Approx. 500-1500 lbs (varies by model and specific year)

🛡️ Safety Features

Ratings

Rollover Protection:

ROPS (Roll-Over Protective Structure) certified

Active Features

Braking System Type:

Hydraulic disc brakes (front and rear)

Passive Features

Seatbelts:

3-point seat belts

Lighting:

Headlights, taillights, brake lights

💡 Technology Features

Infotainment

Audio System:

Basic; typically no integrated infotainment system, but provisions for aftermarket accessories.

Driver Assistance

Efi System:

Electronic Fuel Injection (on applicable models) for improved fuel efficiency and performance over carbureted systems.

Connectivity

Accessories:

May include 12V power outlets for charging accessories.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact specification)

Air Filter Cleaning:

Inspect/clean every 50 hours, replace as needed (refer to manual)

Spark Plug Replacement:

Typically every 100 hours or annually (refer to manual for specific type and gap)

Fluid Specifications

Engine Oil Type:

Polaris Synthetic 2W-50 or recommended equivalent (API SG or higher)

Engine Oil Capacity:

Approx. 2.0-2.5 quarts (refer to manual for exact capacity)

Coolant Type:

Polaris recommended Antifreeze/Coolant or a quality ethylene glycol-based coolant with corrosion inhibitors

Known Issues

Cvtpulley Belt:

Wear and tear on CVT belt is common; regular inspection and replacement are crucial for performance and preventing damage.

Fuel Pump:

EFI models may experience fuel pump degradation over time, affecting starting and running.

Suspension Bushings:

Bushings in the suspension and steering can wear, leading to play and noise.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc., known for powersports vehicles

Model Evolution

Ranger Lineup:

The Ranger 500 represents an earlier generation of Polaris's utility-focused side-by-side UTVs, evolving into more powerful and feature-rich models over time.

Production

Production Period:

1999-2012, indicating a long and successful production run

🏆 Awards & Recognition

Recognitions

Industry Standing:

Polaris Ranger models are generally well-regarded for their utility and off-road capability within the UTV market.