Model Variants Covered:
2x4, 4x4, 6x6
Engine Variants Covered:
500 EFI, 2x4 Carbureted
Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Manual Product Name:
Polaris Ranger 500 2x4 4x4 6x6 500 EFI & 2x4 Carbureted Complete Workshop Service Repair Manual 1999-2012 PDF Download
Target Audience:
Polaris Ranger 500 owners and independent repair shops seeking to perform maintenance and repairs
Value Proposition:
Empowerment to perform DIY repairs, saving significant costs compared to dealership service
Competitors:
Dealership service manuals, other aftermarket repair manuals (less comprehensive or specific)
Ease Of Use:
Easy-to-follow step-by-step instructions and visual aids
Longevity Of Access:
Yours to keep forever once downloaded
Customization:
Printable for physical reference
Customer Satisfaction:
Guaranteed
Coverage Scope:
Complete Workshop Service and Repair
Specific Areas Mentioned:
Every Service & Repair Procedure
Page Count:
Not Specified (Comprehensive A-Z Coverage Implied)
Type:
Workshop Service Repair Manual
Engine Systems:
Fuel system (EFI and Carbureted), Ignition system, Cooling system, Lubrication system, Starting system, Exhaust system
Drivetrain Systems:
Transmission (gearbox, differential), Drive shafts, Axles, Final drive, AWD/4WD engagement systems
Chassis Suspension Steering:
Suspension components (shocks, springs, control arms), Steering system, Frame and chassis components
Braking Systems:
Brake system diagnosis, repair, and component replacement (discs, calipers, lines)
Electrical Systems:
Wiring diagrams, Battery, Charging system, Lighting, Ignition switches, Controls, Sensors, EFI Control Module (ECU)
Body And Trim:
Body panels, Seats, Controls, Exterior trim, Interior trim
Maintenance Procedures:
Scheduled maintenance, Oil changes, Filter replacements, Fluid checks and top-offs, Spark plug replacement, Belt inspection and replacement, Brake pad inspection
Diagnostic Procedures:
Troubleshooting common problems, Diagnostic codes (if applicable for EFI models), Fault finding for electrical and mechanical systems
Repair Procedures:
Engine component repair and overhaul, Transmission repair, Suspension component replacement, Steering system repair, Brake system overhaul, Electrical component diagnosis and replacement
Assembly Disassembly:
Step-by-step instructions for component removal, installation, and reassembly
Depth Of Information:
Complete A-Z coverage, detailed step-by-step instructions with pictures, suitable for DIY repairs and professional service
Diagnostic Capabilities:
Advanced diagnostic procedures, troubleshooting guides, and component testing methods
Software Requirements:
Adobe Reader (free download)
Printability:
Printable (single page, chapter, or entire document)
Image Quality:
High quality, detailed pictures
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Delivery Method:
Instant Email Delivery upon Payment Confirmation
Device Compatibility:
All PC & MAC Computers, Tablets, Smartphones
Engine Type Efi:
Liquid-cooled, 4-stroke, SOHC, V-Twin (Electronic Fuel Injection)
Engine Type Carbureted:
Liquid-cooled, 4-stroke, SOHC, V-Twin (Carbureted)
Displacement:
Approximately 499cc (specific variations may exist)
Horsepower:
Typically in the range of 25-30 HP (exact figures vary by model year and configuration)
Torque:
Detailed torque specifications for various engine components will be found within the manual.
Efi System:
Polaris P.E.A.C.H. (Polaris Electronic Advanced Combustion Handling) EFI system or similar
Carburetor Type:
Single or dual Mikuni carburetors (specific model dependent)
Ignition Type:
Electronic Ignition (CDI)
Cooling Method:
Liquid Cooling
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive Modes:
2WD, AWD (on demand), 4WD (on demand), 6WD (on select 6x6 models)
Gearbox Features:
High and Low range, Neutral, Reverse
Clutch Type:
Primary and Secondary clutch system (CVT)
Fluid Type:
Specific CVT Fluid (e.g., Polaris AGL Premium Gearcase Lubricant or equivalent, check manual for exact specifications)
Length:
Varies by configuration, typically around 103-117 inches (261-297 cm)
Width:
Varies by configuration, typically around 50-60 inches (127-152 cm)
Height:
Varies by configuration, typically around 72-75 inches (183-190 cm)
Dry Weight:
Approximately 950-1150 lbs (431-522 kg)
Payload Capacity:
Typically around 1000 lbs (454 kg)
Towing Capacity:
Typically around 1500 lbs (680 kg)
Safety Certification:
Likely compliant with relevant ATV/UTV safety standards of the time. Manual will detail safety precautions.
Braking System:
Hydraulic Disc Brakes (front and rear)
Parking Brake:
Mechanical parking brake
Seatbelts:
Standard on most models of this era for UTVs
Rollover Protection:
ROPS (Roll-Over Protection Structure) frame
Infotainment System:
Basic systems for this era; typically includes analog gauges and possibly a basic hour meter. No advanced infotainment typically.
Driver Assistance Features:
Limited driver assistance features. Focus is on basic utility and functionality.
Connectivity Options:
No typical connectivity options like Bluetooth or USB ports on models of this vintage.
Oil Change Interval:
Typically every 100 hours or 6 months (check manual for precise intervals and oil type)
Air Filter Maintenance:
Inspect every 50 hours, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Typically every 100 hours or 12 months (check manual for specific plug type and gap)
Engine Oil Type:
Polaris Synthetic 0W-40 or equivalent (confirm with manual)
Engine Oil Capacity:
Approximately 2.3 US quarts (2.2 liters) (confirm with manual)
Coolant Type:
Antifreeze/coolant with corrosion inhibitors (typically a 50/50 mix of ethylene glycol and distilled water)
Gearcase Lubricant:
Polaris AGL Premium Gearcase Lubricant or equivalent (confirm with manual for front and rear differentials)
Common Wear Items:
CV joints and boots, suspension bushings, brake pads, and CVT belt due to regular use and operating conditions.
Efi Vs Carb Maintenance:
EFI models may require occasional fuel injector cleaning, while carbureted models may need carburetor adjustments or cleaning.
Manufacturer:
Polaris Industries Inc., a well-established manufacturer of powersports vehicles.
Ranger Lineup:
The Ranger line has a long history of utility and recreational vehicles, with the 500 model being a popular workhorse in the late 1990s and early 2000s.
Production Period:
The Ranger 500 was a significant model produced from the late 1990s through the mid-2000s, covering the years specified in the manual.
Industry Recognition:
The Polaris Ranger 500 was generally well-regarded for its utility and capability within the utility UTV segment of its time. Specific awards may not be readily documented for this model year range.
Consumer Ratings:
Owner reviews often highlight its reliability for farm and trail use, though maintenance is key.
Certification Standards:
Vehicle must meet safety and emissions standards relevant to its production year and market.
