🏷️ Basic Information

Make:

Polaris

Model:

Ranger 500

Model Variants:

2x4, 4x4, 6x6

Vin Code Prefix:

No specific VIN code prefix provided, but typical Polaris ATV VINs start with '4X6'

Engine Code Identifier:

'500' indicates 500cc displacement

👋 Introduction

Target Audience:

Owners of Polaris Ranger 500 UTVs, DIY mechanics, and professional ATV/UTV repair shops.

Value Proposition:

Provides dealership-level repair information at a fraction of the cost of professional shop labor or proprietary service contracts. '4 manuals in package' suggests exceptional value and breadth of coverage.

Accessibility:

Instant download, eliminating shipping wait times. Available for PC or Mac.

Usability:

Printable sections offer convenience and cleanliness during maintenance and repair.

📋 Manual Details

Model Years Covered:

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

Engine Variants Covered:

500 EFI (Electronic Fuel Injection), 500 2x4 Carbureted

Total Pages:

Not specified, but described as '4 manuals in package' indicating comprehensive coverage across multiple documents.

Type:

Service Repair Workshop Manual

Language:

English (presumed based on product description)

Format:

Adobe Acrobat PDF

📖 Manual Coverage

Engine:

Comprehensive engine diagnostics, overhaul, component testing, tuning, and repair for both EFI and carbureted variants.

Transmission:

Service and repair procedures for the drivetrain, including gearboxes, differentials, and drive shafts for 2x4, 4x4, and 6x6 configurations.

Chassis:

Frame inspection, repair, welding procedures, and general chassis component service.

Steering:

Steering system diagnosis, repair, component replacement (tie rods, steering rack/box), and alignment.

Suspension:

Front and rear suspension components, including A-arms, shocks, bushings, and wheel bearings; service and replacement.

Brakes:

Hydraulic brake system service, including disc brake pad replacement, caliper overhaul, master cylinder service, brake line bleeding, and fluid specifications.

Electrical:

Complete electrical system troubleshooting, wiring diagrams, component testing (starter, alternator/stator, ignition system), battery maintenance, and lighting.

Fuel System:

EFI system diagnosis and repair (fuel pump, injectors, sensors, ECU), carburetor tuning and overhaul, fuel tank service, and fuel lines.

Lubrication:

Lubrication points, fluid type recommendations, capacities, and change intervals for engine oil, transmission fluid, and final drive oil.

Clutch:

Primary and secondary clutch service, maintenance, alignment, and replacement procedures.

Cooling System:

Radiator, fan, coolant, and thermostat service and inspection.

Bodywork:

Panel removal and installation, seat system service, lock mechanisms, and accessory mounting.

Maintenance:

Detailed scheduled maintenance tasks, including oil changes, filter replacements, spark plug service, and general inspections.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for common and uncommon issues across all systems.

Repair:

Step-by-step instructions for component disassembly, repair, reassembly, and calibration.

Rebuilds:

Comprehensive procedures for engine and transmission rebuilds, including detailed torque specifications and tolerances.

Diagnostics:

Diagnostic procedures for EFI systems, including sensor testing and fault code interpretation (where applicable).

Depth:

Covers everything from basic owner maintenance to complex engine and transmission overhauls, suitable for both novice and experienced technicians.

📊 Manual Specifications

Format:

PDF

Searchable:

Yes, PDF format allows for text searching of technical information and procedures.

Quality:

High-resolution digital scans suitable for clear printing of individual sections or entire manuals.

Binding Recommendation:

Users can print and place in 3-ring binders for easy access and organization.

Recommended Usage:

Printable; users can print only needed sections to avoid damaging original paper manuals with grease.

⚙️ Engine Specifications

Engine Type:

Four-stroke, liquid-cooled, SOHC V-twin (common for Polaris 500 series)

Displacement:

499cc (common for Polaris 500 engines in this era)

Horsepower:

Approximately 30-33 HP (varies slightly by year and specific tune)

Torque:

Approximately 28-30 ft-lbs (varies slightly by year and specific tune)

Efi Variant Fuel Delivery:

Electronic Fuel Injection (EFI)

Carbureted Variant Fuel Delivery:

Carburetor (specific model like Mikuni or Keihin may be detailed in the manual)

Ignition System:

CDI (Capacitor Discharge Ignition) or similar electronic ignition system

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT) with Engine Braking

Drive Modes:

2WD, 4WD, and 6WD (on 6x6 models) selectable via electronic actuator or lever.

Gear Reduction:

High and Low range gearbox for versatile power delivery.

Differentials:

Front differential (locking/unlocking on some 4x4 models), rear differential.

📐 Dimensions

Length:

Typically around 111-115 inches (282-292 cm) depending on configuration.

Width:

Typically around 58-60 inches (147-152 cm).

Height:

Typically around 74-76 inches (188-193 cm).

Curb Weight:

Approximately 1000-1150 lbs (454-522 kg) depending on configuration.

Towing Capacity:

Typically 1,000 lbs (454 kg).

Bed Load Capacity:

Typically 400-900 lbs (181-408 kg) depending on model and configuration.

🛡️ Safety Features

Rollover Protection:

ROPS (Roll-Over Protective Structure) is standard on all Ranger models.

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Parking Brake:

Mechanical parking brake, typically hand or foot operated.

Seatbelts:

Standard seatbelts are typically installed. Aftermarket shoulder harnesses may be recommended or required by some users.

Lighting:

Headlights, taillights, and brake lights for visibility and signaling.

💡 Technology Features

Audio System:

No integrated infotainment system typically found on models of this vintage; aftermarket options are common.

Traction Control:

Not typically equipped with advanced electronic traction control systems.

Charging Port:

A 12V DC power outlet (cigarette lighter style) is usually present for charging accessories.

🔧 Maintenance

Engine Oil Change:

Typically every 100 hours or annually, whichever comes first. Specific oil grade will be detailed in the manual.

Air Filter Cleaning:

Check every 50 hours or as needed, clean or replace accordingly.

Spark Plug Replacement:

Typically every 200-400 hours or annually.

Engine Oil:

Polaris recommends specific viscosity grades such as 0W-40 or 10W-40 synthetic oil. Consult manual for exact specifications and capacity.

Transmission Fluid:

Polaris Synthetic Heavy Duty CVT Fluid or equivalent. Consult manual for exact type and capacity.

Coolant:

Ethylene glycol-based antifreeze/coolant mixture, typically a 50/50 mix. Consult manual for type and capacity.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid. Consult manual for exact specification and capacity.

Common Wear Items:

CVT belts, ball joints, tie rod ends, wheel bearings, and bushings are common wear items due to off-road use.

Efi Diagnostics:

EFI systems can be sensitive to fuel quality and sensor issues, requiring proper diagnostic tools and knowledge which this manual provides.

📚 Vehicle History

Polaris Offroad:

Polaris has a long-standing reputation in the powersports industry, particularly with ATVs and UTVs, known for innovation and off-road capability.

Ranger Series:

The Ranger line is Polaris's flagship utility vehicle, evolving from early models to incorporate more powerful engines, improved suspension, and advanced features. The 500 model has been a workhorse in the lineup.

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States.

🏆 Awards & Recognition

Utility Vehicle Class:

Polaris Ranger models are consistently recognized for their utility and off-road performance in industry reviews and awards within the UTV segment.

Reliability:

While specific model ratings vary, Polaris UTVs are generally considered reliable with proper maintenance, a factor this manual directly supports.