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Polaris Ranger 500 6x6 Complete Workshop Service Repair Manual 2002 2003
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Basic Information Identification Make: Polaris Model: Ranger 500 6x6 Model Variant: 6x6 Year: 2002, 2003 Codes Platform Code: Ranger (General) Introduction Market Position Positioning: The Polaris Ranger 500 6x6 was...
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Taper: Atv
Distributeur:
UGS: 6845
Mots clés:
2002
2003
Atv
Polaris
Powersports
Ranger 500 6x6
Ranger Models
UTV
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| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | Ranger 500 6x6 |
| Model Variant: | 6x6 |
| Year: | 2002, 2003 |
| Codes | |
| Platform Code: | Ranger (General) |
| Introduction | |
| Market Position | |
| Positioning: | The Polaris Ranger 500 6x6 was positioned as a versatile and capable utility vehicle for work and recreation, emphasizing its six-wheel drive system for enhanced traction and stability in challenging terrain. |
| Competitive Analysis | |
| Competitors: | Competed with other utility ATVs/side-by-sides from brands like John Deere, Kawasaki, Arctic Cat, and Yamaha, focusing on its unique 6x6 drivetrain for increased payload and towing capacity. |
| Key Features | |
| Features: | Key features of the Ranger 500 6x6 included its robust chassis, independent suspension, powerful Polaris engine, and the distinct 6x6 drive system for superior off-road capability and load carrying. |
| Manual Purpose | |
| Purpose: | To provide comprehensive, step-by-step instructions and technical data for servicing, repairing, and maintaining the 2002-2003 Polaris Ranger 500 6x6, enabling owners and technicians to perform tasks efficiently and accurately. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | All models, engines, trim, and transmission types for 2002-2003 Polaris Ranger 500 6x6 |
| Secondary Coverage: | Includes all service and repair procedures from A-Z |
| Page Count | |
| Estimated Page Count: | Refer to actual manual for definitive count; typically 500+ pages for a complete workshop manual of this era |
| Manual Type | |
| Type: | Complete Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Engine assembly, disassembly, inspection, maintenance, tuning, cooling system, lubrication system, fuel system, ignition system, exhaust system, emissions control |
| Drivetrain: | Transmission (PVT), differential systems (front and rear), drive shafts, final drive, clutch system (primary and secondary), 6x6 drive engagement system |
| Chassis: | Frame and body construction, suspension (front and rear independent), steering system, braking system (hydraulic disc), wheel bearings, axle assemblies |
| Electrical: | Wiring diagrams, battery system, starting system, charging system (alternator/stator), lighting system, ignition system components, instrumentation, switches, relays, fuses, accessory circuits |
| Bodywork: | Body panel removal and installation, seats, cargo bed, controls, guards, bumpers |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, fluid changes, filter replacements, lubrication, battery care, tire maintenance, brake inspection |
| Repair: | Engine overhaul, transmission repair, suspension component replacement, brake caliper and line service, steering linkage repair, electrical component diagnosis and replacement |
| Troubleshooting: | Diagnostic flowcharts for common problems, symptom-based troubleshooting guides, electrical system diagnostics |
| Specifications: | Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters |
| Special Tools: | Identification of necessary special tools and their application |
| Technical Depth | |
| Depth: | Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including in-depth diagnostics and electrical schematics. |
| Manual Specifications | |
| File Format | |
| Compatibility: | Compatible with all PC & MAC Computers, tablets, and mobile phones via Adobe Reader or similar PDF viewer. |
| Print Quality | |
| Quality: | High quality, designed for clear viewing and printing of text and images. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper: | N/A (Digital Download) |
| Accessibility | |
| Features: | Printable pages, searchable text (OCR dependent), downloadable for offline access. |
| Engine Specifications | |
| Primary Engine | |
| Type: | 4-stroke, 4-valve, SOHC |
| Displacement: | 499cc |
| Bore X Stroke: | Refer to manual for exact specifications (typically around 76mm x 55mm for this engine family) |
| Cooling System: | Liquid-cooled |
| Performance | |
| Horsepower: | Approx. 30 HP (Refer to manual for exact dyno-tested figures) |
| Torque: | Refer to manual for specific torque output figures |
| Fuel System | |
| Fuel Delivery: | Carbureted (likely Mikuni BST40 or similar) |
| Fuel Type: | Unleaded gasoline |
| Ignition System | |
| Ignition Type: | Electronic Ignition (CDI) |
| Lubrication System | |
| Oil Type: | SAE 10W-40, API SG or higher (Verify with manual for exact specification) |
| Oil Capacity: | Refer to manual for exact capacity with filter change |
| Transmission | |
| Standard | |
| Type: | Automatic Polaris Variable Transmission (PVT) with Hi/Lo range and Reverse |
| Optional | |
| Optional Transmissions: | N/A (Standard PVT for this model) |
| Features | |
| Drive Modes: | 2WD/4WD/6WD selectable engagement system |
| Belt Maintenance: | Drive belt inspection, adjustment, and replacement procedures covered |
| Fluid Specifications | |
| Transmission Fluid: | Polaris AGL Synthetic Gearcase Lubricant or equivalent API GL-4 (Verify with manual) |
| Fluid Capacity | |
| Gearcase Capacity: | Refer to manual for specific gearcase fluid capacity |
| Dimensions | |
| Exterior | |
| Length: | Refer to manual for exact dimensions (typically around 105-115 inches) |
| Width: | Refer to manual for exact dimensions (typically around 50-55 inches) |
| Height: | Refer to manual for exact dimensions (typically around 72-75 inches) |
| Cargo | |
| Cargo Bed Capacity: | Refer to manual for specific cargo bed weight limit (typically around 800-1000 lbs) |
| Weights | |
| Dry Weight: | Refer to manual for exact dry weight (typically around 850-950 lbs) |
| Payload Capacity: | Refer to manual for exact payload capacity |
| Towing Capacity: | Refer to manual for exact towing capacity (often around 1500-2000 lbs) |
| Wheelbase | |
| Wheelbase: | Refer to manual for exact wheelbase measurement |
| Safety Features | |
| Ratings | |
| Atv Safety Standards: | Adherence to ANSI B71.1 standards for off-road utility vehicles (as applicable for the era) |
| Active Features | |
| Braking System: | Hydraulic disc brakes on all wheels with parking brake mechanism |
| Lighting: | Headlights, taillights, brake lights |
| Passive Features | |
| Roll Over Protection: | Standard safety cage/ROPS structure |
| Seat Belts: | Typically equipped with seat belts |
| Engine Braking: | PVT system provides inherent engine braking |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Basic; primarily focused on functional instrumentation (speedometer, odometer, fuel gauge, warning lights). No advanced infotainment features. |
| Driver Assistance | |
| Assistance Features: | Limited to the mechanical capabilities of the 6x6 drivetrain and braking system. No electronic driver aids. |
| Connectivity | |
| Connectivity Features: | N/A |
| Lighting Technology | |
| Headlight Type: | Incandescent halogen bulbs |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Every 100 hours or annually (refer to manual for precise interval) |
| Air Filter Inspection: | Every 50 hours or as needed based on operating conditions |
| Drive Belt Inspection: | Every 100 hours or annually |
| Spark Plug Replacement: | Refer to manual, typically every 100-200 hours or as recommended |
| Gearcase Oil Change: | Every 200 hours or annually |
| Fluid Specifications | |
| Coolant Type: | Ethylene glycol-based antifreeze (e.g., 50/50 mix with distilled water) |
| Brake Fluid: | DOT 3 or DOT 4 hydraulic brake fluid |
| Known Issues | |
| Common Wear Items: | Drive belts, suspension bushings, wheel bearings, brake pads, and clutch components can be common wear items depending on usage. |
| Electrical Connectors: | Corrosion or loose connections in electrical harnesses can sometimes cause intermittent issues. |
| Cooling System Maintenance: | Proper coolant level and system integrity are crucial to prevent overheating, especially under load. |
| Vehicle History | |
| Brand Heritage | |
| Heritage: | Polaris is a long-standing American manufacturer renowned for its innovation in recreational vehicles, particularly snowmobiles and ATVs, with a history dating back to the 1950s. |
| Model Evolution | |
| Evolution: | The Polaris Ranger line, introduced in the late 1990s, evolved to offer more utility and versatility. The 500 6x6 model represented a significant step in capability, building on the success of earlier 2WD and 4WD Ranger models by adding the 6x6 drivetrain for enhanced traction and payload. |
| Production | |
| Manufacturing Location: | Polaris vehicles are primarily manufactured in the United States. |
| Production Period: | 2002-2003 model years |
| Awards & Recognition | |
| Recognitions | |
| Industry Accolades: | While specific awards for this exact model year might not be readily documented, Polaris vehicles of this era were generally well-regarded for their utility and off-road performance within the UTV segment. |
| Ratings | |
| Consumer Reviews: | Customer satisfaction generally focused on the robust 6x6 capability for heavy-duty tasks and challenging terrain. |
| Certifications | |
| Manufacturing Certifications: | ISO 9001 certifications for manufacturing processes (typical for Polaris facilities). |