Polaris Ranger 4x4 500 EFI Owner's Manual
WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a Factory Certified Master Service Dealer (MSD)
Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2009 RANGER 4X4 500 EFI Owner’s Manual
P/N 9921868
3
TABLE OF CONTENTS
Vehicle Identification Numbers . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emission Control Systems . . . . . . . . . . . . . . . 53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 106
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 108
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 109
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 117
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number ____________________________________________________________
Engine Serial Number
VIN
Key
Number
####
5
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions of the decals on the vehicle carefully. If
any of the decals depicted in this manual differ from the decals on your
vehicle, always read and follow the instructions of the decals on the
vehicle.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
Container/Passenger/Tire Pressure Warning
WARNING
Remove flammable material
containers from box before filling.
• Passengers can be thrown off. This
can cause serious injury or death.
• Never carry passengers in cargo
box.
Maximum 2X4 Box Load 850 lbs.
(386 kg)
Maximum 4X4 Box Load 1000 lbs.
(455 kg)
Maximum 6X6 Box Load 1200 lbs.
(545 kg)
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
RANGER - 2X4 and 4X4 FRONT 10 (69) REAR 10 (69)
RANGER - 6X6 FRONT 10 (69) CENTER 10 (69) REAR 10 (69)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO AND ACCESSORIES.
RANGER 2X4 and 4X4 is 1500 LBS. (682 KG)
RANGER 6X6 is 1750 LBS. (795 KG)
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.
Read Owner's Manual for more detailed loading information.
7174886
+
6
SAFETY
Safety Decals and Locations
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM which can result in serious injury or
death.
7172563
Age 16 Warning
Operating this vehicle if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this vehicle if you are under age 16 or without a valid driver’s
license.
7175566
Clutch Cover
Warning
Discretionary
Warning
Age 16
Warning
7
SAFETY
Safety Decals and Locations
Discretionary Warning
WARNING
Improper vehicle use can result in Severe Injury or Death.
NEVER Operate:
• At speeds too fast for your skills or the conditions.
• After or while using Alcohol or Drugs.
• On hills steeper than 15 degrees 15°.
• On public roads, a collision can occur with a another vehicle.
• With more than two passengers, or passengers under age five.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-Polaris approved accessories - they may seriously affect stability.
ALWAYS:
• Wear your seat belt, the cab frame is not designed or intended to provide rollover protection. Vehicle rollover could cause severe injury or death.
• Wear eye protection and keep hands and feet in vehicle at all times.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passenger reads and understands all safety labels.
• Watch for branches or other hazards that could enter vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS.
7175565
8
SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may ride
as a passenger in this vehicle.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.
The RANGER is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
WARNING
Failure to follow the warnings contained in this manual can result in severe
injury or death.
A Polaris RANGER is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as motorcycles and cars.
A collision or rollover can occur quickly, even during routine maneuvers like
turning, or driving on hills or over obstacles, if you fail to take proper
precautions.
Read and understand your owner's manual and all warnings before operating
the vehicle.
9
SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
10
SAFETY
Operator Safety
• Read this manual and all labels carefully. Follow the operating
procedures described.
• Never allow anyone without a valid driver's license to operate this
vehicle.
• Minimum age recommendation for passengers is five years old.
Passengers under five years of age require special restraints which are
not available with this vehicle. Driver and passenger should wear
their seat belts at all times.
• Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
• Helmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
• Never consume alcohol or drugs before or while operating this
vehicle.
• Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your
experience.
• Never attempt jumps or other stunts.
• Always inspect your vehicle each time you use it to make sure it's in
safe operating condition. Always follow the inspection and
maintenance procedures and schedules described in this manual.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Always travel slowly and use extra caution when operating on
unfamiliar terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
WARNING
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.
11
SAFETY
Operator Safety
• Always follow proper procedures for turning as described in this
manual. Practice turning at slow speeds before attempting to turn at
faster speeds. Never turn at excessive speeds.
• Always have this vehicle checked by an authorized Polaris dealer if it
has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your
abilities. Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for trav-
eling downhill and for braking on hills. Check the terrain carefully
before descending a hill. Never travel downhill at high speed. Avoid
going downhill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as
ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.
• Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it's safe to proceed in reverse, move
slowly. Avoid turning at sharp angles in reverse.
• Always use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on page 5 and in the
specifications section beginning on page 106.
12
SAFETY
Operator Safety
• Never modify this vehicle through improper installation or use of
accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
• Always wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.
• Always keep arms and legs inside the cab frame while the vehicle is
in motion.
• Always engage the park brake before getting out of the vehicle. See
page 28.
• Always apply the brakes before engaging or releasing the park brake.
• Always turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 21 for fuel safety warnings.
• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800342-3764.
13
SAFETY
Operator Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not install
on a Polaris RANGER any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle for
these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris RANGER is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling
characteristics of the vehicle. Use only Polaris-approved accessories,
and familiarize yourself with their function and effect on the vehicle.
WARNING
Make sure your RANGER is in excellent operating condition at all times. We
strongly recommend that the operator check all safety components before
each ride.
Polaris RANGERs are designed to provide safe operation when used as
directed. Failure of critical machine components may result from operation
with any modifications, especially those that increase speed or power. The
RANGER may become aerodynamically unstable at speeds higher than
those for which it is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily injury.
Do not make any modifications to your RANGER.
14
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards while
climbing a hill
WHAT CAN HAPPEN
Vehicle overturn
HOW TO AVOID THE HAZARD
Maintain a steady speed when
climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is fully stopped. Place the
transmission in reverse and slowly allow the vehicle to roll straight downhill
while applying light brake pressure to control speed.
Engage the park brake after fully stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brakes gradually.
When fully stopped, engage the park brake.
In the event of an accident, have a qualified service dealer check the
complete vehicle for possible damage, including (but not limited to) brakes,
throttle and steering.
WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces
WHAT CAN HAPPEN
Loss of control
HOW TO AVOID THE HAZARD
This vehicle's tires are designed for off-road use only, not for use on
pavement. Paved surfaces may seriously affect handling and control of the
vehicle, and may cause the vehicle to go out of control.
Avoid operating the vehicle on pavement. If you must operate on a paved
surface, travel slowly and do not make sudden turns or stops.
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the
operator does not know how to operate the
vehicle properly in different situations and on
different types of terrain.
All operators must read and understand the
Owner's Manual and all warning and instruction labels before operating the
vehicle.
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways
WHAT CAN HAPPEN
Collision with another vehicle
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway, including
dirt or gravel.
In many states it's illegal to operate vehicles of this type on public streets,
roads and highways.
16
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle after consuming alcohol
or drugs
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving a RANGER requires your full attention. DO NOT drink alcohol or use
drugs or medications before or while driving. They will reduce your alertness
and slow your reaction time. In most states and provinces, it's prohibited by
law to drive while intoxicated or under the influence of drugs.
WARNING
POTENTIAL HAZARD
Operating this vehicle at excessive speeds
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
Always travel at a speed proper for the terrain, visibility and operating
conditions, and your experience.
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator fall through
the ice.
HOW TO AVOID THE HAZARD
Never operate the RANGER on a frozen body of water.
18
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating
Failure to properly maintain the vehicle
WHAT CAN HAPPEN
Accident, equipment damage
HOW TO AVOID THE HAZARD
Always inspect your RANGER before each use to make sure it's in safe
operating condition.
Always follow the inspection and maintenance procedures and schedules
described in the Owner's Manual.
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
You may come upon hidden rocks, bumps, or holes suddenly, without
enough time to react.
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this vehicle
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver's license should operate a Polaris RANGER.
Even though a child may be within the age group for which some vehicles are
recommended, he or she may not have the skills, abilities, or judgment
needed to operate the vehicle safely and may be involved in a serious
accident.
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or uneven tire
pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified in the Owner's Manual for this
vehicle. Always maintain proper tire pressure as described on the decal and
in the Owner's Manual. See pages 5 and 106.
20
SAFETY
Operator Safety
WARNING
Leaving the keys in the ignition can lead to unauthorized use of the vehicle
resulting in serious injury or death. Always remove the ignition key when the
vehicle is not in use.
WARNING
After any overturn or accident, have a qualified service dealer inspect the
entire vehicle for possible damage, including (but not limited to) brakes,
throttle and steering systems.
CAUTION
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
21
SAFETY
Fuel Safety
WARNING
Gasoline is highly flammable and is explosive under certain conditions.
Always exercise extreme caution whenever handling gasoline.
Always stop the engine when refueling.
Always refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the refueling area or
where gasoline is stored.
Do not over fill the tank. Do not fill the tank neck.
If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered
engine exhaust fumes are poisonous and can cause loss of consciousness
and death in a short time.
22
FEATURES AND CONTROLS
Component Locations
Some Polaris vehicles are equipped with special features such as the cab
frame. Not all models come with all features. Refer to the specifications
section beginning on page 106.
Cab Frame
(if Equipped)
Console
Hip Bar
Cargo Box
Seat Belt
Fuel Tank Cap
Headlights
Front Bumper/Brush Guard
Radiator
23
FEATURES AND CONTROLS
Component Locations
Trailer Hitch Bracket
This vehicle is equipped with a receiver hitch bracket for a trailer hitch.
Trailer towing equipment is not supplied with this vehicle.
To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 46-49.
Tailgate
Latch Release
Receiver
Hitch
CV Boot/Rear Caliper
Muffler
(Spark Arrestor)
Tailgate
24
FEATURES AND CONTROLS
Console
Auxiliary Outlets
The 12-volt receptacles have spade connections on the back that may be
used to power an auxiliary light or other optional accessories or lights.
The connections are behind the console, under the hood.
Fuel Gauge/Hour Meter
Lighted bars in the upper display indicate fuel level. Hours of engine
operation since manufacture are indicated in the lower display.
Indicator
Lights
Cup
Holder
Storage
Compartment
12V Auxiliary
Outlets
Storage
Tray
Gear Selector
(Shifter)
Park Brake
Lever
Fuel Gauge
25
FEATURES AND CONTROLS
Indicator Lights
The indicator light panel is located on the console.
Gear Selector
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
NOTE: Low gear is the primary
driving range for the
RANGER. High gear is
intended for use on hardpacked surfaces with light
loads.
To change gears, stop the vehicle, and with the engine idling, move the
lever to the desired gear. Do not attempt to shift gears with engine speed
above idle or while the vehicle is moving.
NOTE: Maintaining shift linkage adjustment is important to assure proper
transmission function. See your dealer if you experience any shifting
problems.
NOTICE
Do not attempt to shift the transmission while the vehicle is moving or
damage to the transmission could result. Always shift when the vehicle is
stationary and the engine is at idle.
High
Gear
Low Gear
(if equipped)
Neutral
Gear
Reverse
Gear
High
Temperature
Brakes
H
L
N
R
26
FEATURES AND CONTROLS
Switches
Ignition Switch
The ignition switch is a three-position, key-operated switch. The key
can be removed from the switch when it is in the OFF position.
OFF The engine is off. Electrical circuits are off, except Acc, 12V.
ON Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter.
The key returns to the ON position when released.
WARNING
Leaving the keys in the ignition can lead to unauthorized use of the vehicle
resulting in serious injury or death. Always remove the ignition key when the
vehicle is not in use
Ignition Switch
Light Switch
AWD/Differential Switch
27
FEATURES AND CONTROLS
Switches
Light Switch
The ignition switch key must be in the ON/
RUN position to operate the headlights. Use the
light switch to turn the headlights on or off.
AWD/Differential Lock Switch
The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential
Lock/Two Wheel Drive (2WD) and Off (1WD/
Turf Mode).
Press the top of the rocker switch to engage All
Wheel Drive (AWD). See page 52 for AWD
operating instructions.
Move the rocker switch to the center position to
lock the differential and operate in two wheel
drive (2WD). See page 51 for Differential Lock
operating instructions.
Press the bottom of the switch to unlock the differential and allow the rear drive wheels to
operate independently (1WD). This mode of
operation is well suited to turf driving or when
active traction is not needed.
ON
OFF
AWD
2WD
OFF
Loading...