Polaris Ranger 500 EFI 2x4 4x4 6x6 1999-2012 Service Repair Workshop Manual 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

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Basic Information Identification Make: Polaris Model: Ranger 500 EFI Model Variants: 2x4, 4x4, 6x6 Product Type: Service Repair Workshop Manual Product Format: PDF Download Codes Chassis Codes: Not specified in...

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

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Description

Basic Information
Identification
Make:	Polaris
Model:	Ranger 500 EFI
Model Variants:	2x4, 4x4, 6x6
Product Type:	Service Repair Workshop Manual
Product Format:	PDF Download
Codes
Chassis Codes:	Not specified in product information, but typically associated with Ranger chassis designations.
Engine Codes:	Not specified in product information, but likely to include specific designations for the 500 EFI engine.

Introduction
Market Position
Category:	Utility Task Vehicle (UTV)
Target Audience:	Owners and technicians of Polaris Ranger 500 EFI models, including DIY enthusiasts and professional mechanics.
Competitive Analysis
Competitors:	This manual caters to a specific model within the UTV market, competing with other manufacturers' service manuals for similar utility vehicles like John Deere Gator, Kawasaki Mule, and Can-Am Commander.
Key Features
Feature 1:	Comprehensive coverage for a wide range of model years (1999-2012).
Feature 2:	Detailed, illustrated, step-by-step instructions for repairs and maintenance.
Feature 3:	Troubleshooting guidance for immediate problem resolution.
Feature 4:	Digital, instant download format for convenience and quick access.
Feature 5:	Provides factory-level information comparable to what professional technicians use.

Manual Details
Coverage Areas
Model Years Covered:	1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Vehicle Types Covered:	UTV (Utility Task Vehicle)
Page Count
Estimated Page Count:	Not explicitly stated, but manuals of this scope can range from 500-1500+ pages. Large file size (up to 5GB) suggests extensive detail.
Manual Type
Type:	Service Repair Workshop Manual
Language
Language:	English
Format
Delivery Format:	Digital Download (PDF, potentially zipped)

Manual Coverage
Systems Covered
Engine Mechanical:	Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, crankshaft, camshaft, valves, etc.).
Fuel System:	EFI system diagnostics, fuel pump, injectors, throttle body, fuel lines, fuel filter replacement, and pressure testing.
Ignition System:	Ignition coils, spark plugs, wiring harness, ECU troubleshooting, and timing.
Cooling System:	Radiator, fan, thermostat, water pump, coolant flushing, and leak detection.
Exhaust System:	Exhaust manifold, muffler, catalytic converter inspection and replacement.
Drivetrain 2Wd:	Front and rear drive shafts, differentials, CV joints, axle boots, and associated components for 2x4 models.
Drivetrain 4Wd:	Complete 4WD system operation, engagement mechanisms, front and rear differentials, drive shafts, CV joints, and transfer case for 4x4 models.
Drivetrain 6Wd:	Specific details for the 6x6 drivetrain, including the additional drive axle, differentials, and engagement systems.
Transmission Automatic:	Automatic transmission (CVT) service, repair, fluid changes, belt inspection/replacement, clutch operation, and troubleshooting.
Brakes Hydraulic:	Brake system diagnostics, master cylinder, brake calipers, brake lines, brake pads and rotors replacement, bleeding procedure, and parking brake.
Steering System:	Steering column, tie rods, ball joints, steering rack/box, and power steering system (if equipped) maintenance and repair.
Suspension System:	Front and rear suspension components (shocks, springs, control arms, bushings), alignment specifications, and bearing maintenance.
Electrical System:	Wiring diagrams, battery, charging system (alternator/stator), starting system (starter motor), lighting, fuses, relays, and accessory circuits.
Body And Frame:	Frame inspection, body panel removal/installation, seat removal, cargo bed maintenance, and cosmetic repairs.
Cooling Fan System:	Radiator fan operation, testing, and replacement.
Lubrication System:	Oil pump, oil filter, oil passages, and lubrication points.
Instrumentation And Controls:	Dashboard layout, indicator lights, gauges, switches, and control levers.
Procedures Included
Routine Maintenance:	Oil changes, filter replacements, air filter service, spark plug replacement, battery maintenance, tire pressure checks.
Troubleshooting Guides:	Systematic diagnostic procedures for common and uncommon issues, fault codes, symptom-based troubleshooting.
Repair Procedures:	Step-by-step instructions for disassembling, repairing, and reassembling all major vehicle components and systems.
Rebuild Instructions:	Detailed guidance for rebuilding major components like the engine, transmission, and differentials.
Diagnostics:	Procedures for diagnosing engine performance, electrical faults, and drivetrain issues.
Tune Up:	Procedures for performing routine tune-ups to maintain optimal engine performance.
Wiring Diagrams:	Comprehensive electrical wiring schematics for all vehicle systems.
Specifications And Tolerances:	Detailed technical specifications, torque values, clearances, and tolerances for all parts.
Special Tools:	Identification and usage instructions for specialized tools required for specific repairs.
Technical Depth
Depth:	Comprehensive (factory-level) coverage for repair, servicing, restoration, and diagnostics. Suitable for professional technicians and experienced DIY users.

Manual Specifications
File Format
Format:	PDF
Compatibility:	Windows, Linux, Mac operating systems.
Searchability:	Likely searchable text within the PDF due to its comprehensive nature, allowing for quick information retrieval.
Compression:	May be zipped (.zip, .rar), requiring unzipping software like WinZip or WinRAR.
Print Quality
Printability:	Printable on any computer and printer.
Illustration Quality:	Illustrated with clear, step-by-step instructions, zoomable illustrations, detailed component explosions, and exploded views.
Binding Type
Type:	Not applicable (digital download).
Paper Type
Type:	Not applicable (digital download).
Other
Download Availability:	Instant download after payment, with a three-day download window.
Storage Policy:	No lifetime storage space provided; user is responsible for saving the downloaded file.

Engine Specifications
Primary Engine
Engine Type:	4-stroke, Single-Cylinder, Liquid-Cooled (typical for this model range)
Displacement:	499cc (common for the Ranger 500 EFI)
Bore X Stroke:	Not explicitly stated, but typical for a 499cc single cylinder.
Fuel System:	Electronic Fuel Injection (EFI)
Performance
Horsepower:	Typically in the range of 25-30 HP, exact figures vary by year and specific tuning.
Torque:	Not explicitly stated, but adequate for utility tasks.
Fuel System
Fuel Type:	Unleaded gasoline
Fuel Delivery:	Electronic Fuel Injection (EFI) with multi-point or throttle body injection.

Transmission
Standard
Type:	Automatic (CVT - Continuously Variable Transmission)
Drive Modes:	High, Low, Neutral, Reverse, Park (with 2WD/4WD/6WD engagement controls)
Optional
Type:	Not applicable, CVT is standard for this model.
Features
Clutch Type:	Automatic CVT clutch system (primary and secondary clutches).
Gear Reduction:	Low gear ratio for increased pulling power and torque.
Fluid Specifications
Transmission Fluid Type:	Polaris AGL Synthetic Gearcase Lubricant (or equivalent meeting specifications).
Fluid Capacity
Transmission Fluid Capacity:	Refer to manual for specific capacity, typically around 1-2 quarts.

Dimensions
Exterior
Length:	Varies slightly by year and variant, but generally around 110-115 inches.
Width:	Varies slightly by year and variant, but generally around 55-60 inches.
Height:	Varies slightly by year and variant, but generally around 70-75 inches.
Weights
Dry Weight:	Typically around 900-1100 lbs, depending on 2WD/4WD/6WD configuration.
Payload Capacity:	Approximately 1000 lbs.
Towing Capacity:	Approximately 1500 lbs.
Cargo
Cargo Bed Capacity:	Approximately 400 lbs.

Safety Features
Ratings
Rollover Protection:	Features a protective cage and ROPS (Roll Over Protection Structure) compliant with industry standards for UTVs.
Active Features
Braking System:	Hydraulic disc brakes on all wheels.
Parking Brake:	Mechanical parking brake.
Passive Features
Seatbelts:	Standard safety belts.
Lighting:	Headlights, taillights, and brake lights for visibility and signaling.

Technology Features
Infotainment
Dashboard Features:	Includes essential gauges (speedometer, odometer, fuel gauge), indicator lights, and potentially a clock or hour meter.
Driver Assistance
Engine Management:	Electronic Fuel Injection (EFI) system for optimized fuel delivery and performance.
Connectivity
Accessories Power:	Provides 12V power outlets for charging accessories.

Maintenance
Service Intervals
Engine Oil Change:	Typically every 100 hours or 1 year, whichever comes first. Refer to manual for exact specification.
Air Filter Cleaning:	Recommended every 50 hours or as needed based on operating conditions.
Spark Plug Replacement:	Every 100 hours or 1 year.
Transmission Fluid Change:	Typically every 200 hours or 2 years.
Fluid Specifications
Engine Oil Type:	Polaris PS-4 5W-50 Full Synthetic (or equivalent meeting API SG or higher).
Engine Oil Capacity:	Refer to manual for specific capacity, typically around 2 quarts.
Coolant Type:	Polaris recommended coolant or a 50/50 mix of ethylene glycol and distilled water.
Brake Fluid Type:	DOT 3 or DOT 4 brake fluid.
Known Issues
Issue 1:	CV Joint boot wear and tear leading to contamination and premature failure, especially in harsh conditions.
Issue 2:	Radiator fan failure or obstruction can lead to overheating.
Issue 3:	EFI system sensitivity to fuel quality and maintenance; occasional sensor issues.
Issue 4:	Brake pad and rotor wear, requiring regular inspection and replacement.
Issue 5:	CVT belt wear and potential slippage if not maintained or if subjected to excessive strain.

Vehicle History
Brand Heritage
Manufacturer:	Polaris Industries is a long-standing manufacturer of powersports vehicles, known for ATVs and UTVs.
Model Evolution
Introduction Year:	The Ranger 500 model line began production around 1999, evolving through various iterations until 2012 and beyond with updated models.
Production
Production Period:	1999-2012 (as covered by this manual).

Awards & Recognition
Recognitions
Industry Standing:	Polaris Ranger series is widely recognized for its utility and off-road capabilities in the UTV market.
Ratings
Durability:	Generally considered a durable and reliable UTV for its intended purpose, with proper maintenance.