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RANGER 500 2021
Polaris RANGER 500 2021 User Manual
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1
1.10
9850043
R01
-
2017-2021
RANGER
500
/
570
Service
Manual
©
Copyright
Polaris
Inc.
SEA
T
MOUNTING
/
SEA
T
BEL
TS
REF
.
DESCRIPTION
NOTES
q
Seat
Back
w
Seat
Base
e
LH
Seat
Belt
Assm
r
RH
Seat
Belt
Assm
t
Seat
Base
Frame
y
Screw
24
in-lbs
(3
Nm)
u
Bolt
40
ft-lbs
(54
Nm)
BODY
/
FRAME
521
523
Table of Contents
Chapter 1 1 General Information
9
Table of Contents
9
Model Number Designation (2015 +)
12
Vehicle Identification Number (Vin) Designation (2015+)
12
Vehicle Information
12
Vin / Engine Number Location
12
Reference Information
13
Replacement Keys
13
Publication Part Numbers
14
Special Tools
16
Master Special Tools Table
17
Master Torque Table
25
Clutching Chart
27
General Specifications
28
2017-2018 Ranger
28
2017-2018 Ranger 570 4X4 (Intl.)
32
Misc. Specifications and Charts
60
Conversion Table
60
Sae Tap / Drill Sizes
61
Metric Tap / Drill Sizes
62
Decimal Equivalents
63
General Diagnostics
65
General Diagnostics Information Overview
65
Guided Symptom Diagnostic
65
Guided Symptom References
66
Engine and Drivability Diagnostic Procedures
67
Engine Cranks but Does Not Start
70
No Crank no Start or Slow Crank
72
Over Heating
73
Warning Lights
74
Engine Troubleshooting
75
Cooling Troubleshooting
77
Digital Wrench
78
Digital Wrench® Software Overview
78
Special Tools
78
Guided Diagnostics
78
Digital Wrench® Software Installation and Updates
79
Digital Wrench® Communication Errors
80
Digital Wrench® - Diagnostic Connector
80
Digital Wrench® Serial Number Location
80
Digital Wrench® Feature Map
81
Engine Controller Reprogramming (Reflash)
82
Polaris Mobile Digital Wrench® (Pmdw)
82
Engine Electrical Diagnostics
83
Diagnostic Trouble Codes Overview
83
Master Trouble Code List
84
Cylinder Misfire Detection
95
Fluid Inspection
96
Fluid Leaks
96
Fuel System Diagnostics
97
Fuel System Troubleshooting
97
Pvt System Diagnostics
99
Pvt System Troubleshooting
99
Pvt System Overheating / Diagnosis
101
Transmission Diagnostics
102
Hard Shifting
102
Transmission Isolation
102
Final Drive Diagnostics
103
All Wheel Drive (Awd) Concerns
103
Driveshaft (Half Shaft) Diagnostics
103
Brake System Diagnostics
104
Brake Noise Troubleshooting
104
Brake Vibration
104
Caliper Overheats (Brakes Drag)
105
Poor Brake Performance
105
Brakes Lock
105
Steering / Suspension Diagnostics
106
Eps Troubleshooting (Power Steering Non-Functional with Mil
106
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
107
Eps Troubleshooting (Using Digital Wrench®)
108
Shock Analysis
109
Electrical Diagnostics
110
Electrical Service Notes
110
Digital Multi-Meter (DMM) Notes
110
Static and Dynamic Testing
110
Testing for a Short to Ground
112
Testing for a Short to Voltage
113
Testing Current Flow (Amperage)
114
Testing for Intermittent Conditions
114
Current Draw - Key off
115
Testing Voltage Drop
115
Maintenance Chapter 2 Maintenance 2
117
Maintenance
119
Periodic Maintenance Chart
119
Pre-Ride / Daily Inspection
119
Cold Weather Operation
119
Break-In Period
120
Brake System Break-In
120
Chapter 2
120
Engine and Drivetrain Break-In Period
120
Pvt Break-In (Clutches / Belt)
120
Vehicle Break-In Period
120
Periodic Maintenance Chart
121
Periodic Maintenance Chart Key
121
Grease Lubrication Points
124
Component Quick Reference
125
Storage Tips
126
Lubricants / Service Products
127
Polaris Lubricants, Maintenance and Service Products
127
Engine
128
Compression and Leakdown Test
128
Engine Oil Level
128
Oil and Filter Change
128
Breather Hose
129
Breather Valve Inspection
129
500 Sohc
130
Valve Clearance - Sohc
130
570 Dohc
130
Valve Clearance - Dohc
130
Cooling System
132
Cooling System Overview
132
Coolant Level Inspection
132
50/50 Extended-Life Engine Antifreeze
134
Coolant Strength / Type
135
Cooling System Hoses
135
Radiator Inspection / Cleaning
136
Coolant Drain / Radiator Removal
136
Fuel System and Air Intake
138
Fuel System
138
Fuel Lines
138
Fuel Pump / Filter
138
Vent Lines
138
Throttle Pedal Inspection
138
Air Filter Service
138
Engine Air Intake Inspection
139
Maintenance
139
Pvt Air Intake Inspection
139
Transmission and Gearcase
140
Shift Cable Inspection
140
Shift Cable Adjustment
140
Transmission Lubrication
140
Front Gearcase Lubrication
141
Final Drive / Wheel / Tire
143
Wheel and Hub Torque Table
143
CV Shaft Boot Inspection
143
Wheel Removal
143
Wheel Installation
144
Tire Inspection
144
Tire Pressure
144
Steering
145
Steering Inspection Note
145
Tie Rod End / Steering Inspection
145
Wheel Toe Alignment Inspection
146
Toe Adjustment
146
Camber and Caster
147
Suspension
148
Suspension Inspection
148
Spring Pre-Load Adjustment
148
Stabilizer Bar Pivot Lubrication
148
Suspension Pivot Point Lubrication
149
Shock Analysis
150
Brake System
151
Brake Fluid Inspection
151
Brake Hose and Fitting Inspection
151
Brake Pad Inspection
151
Brake Disc Inspection
152
Electrical and Ignition System
153
Battery Maintenance
153
Battery Fluid Level (Conventional Battery)
153
Battery Removal
153
Battery Installation
154
Battery Storage
154
Battery Charging
154
500 Sohc
154
Spark Plug Service - 500
154
570 Dohc
155
Spark Plug Service - 570
155
Main Frame/Engine Ground
156
Chapter 3 Engine / Cooling System
157
Engine Lubrication Specifications
161
General Engine Information
161
Special Tools
161
Oil Pressure Test
162
Engine Oil Flow Chart
163
Engine Specifications
164
Engine Service
166
Accessible Engine Components
166
Top-End Service (Engine in Chassis)
166
Engine Removal
166
Engine Installation
169
Engine Break-In Period
172
Engine Lubrication Specifications
172
Engine Mounting and Torque Values
173
Setting Tdc (Top-Dead-Center)
174
Cooling System
176
Cooling System Assembly View and Coolant Flow Diagram
176
Cooling System Specifications
177
Cooling System Pressure Test
177
Pressure Cap Test
177
Radiator
178
Coolant Drain / Radiator Removal
178
Thermostat Replacement
179
Cooling System Bleeding Procedure
180
Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
181
Water Pump Mechanical Seal / Oil Seal Replacement
181
Troubleshooting
187
Engine
187
Cooling System
188
500Cc Sohc Engine
189
Engine Detail, Torques / Sequences
189
Engine Specifications
189
Engine Torque Sequences
191
Crankcase Sealant Path
193
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
194
Cylinder / Oil Filter / Oil Pump / Breather
195
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
197
Spark Plugs / Starter / Throttle Body / Valve Cover
199
Piston / Crankshaft / Balance Shaft
201
Engine Disassembly / Inspection - Top End
204
Valve Cover Removal
204
Camshaft / Carrier Removal
204
Camshaft Sprocket Inspection
205
Exhaust Camshaft Decompression Mechanism
206
Cam Chain and Guide Service
206
Cylinder Head Removal
207
Cylinder Head Disassembly
207
Cylinder Head Inspection
208
Cylinder Head Warp Inspection
208
Valve Inspection
208
Combustion Chamber Cleaning
210
Valve Seat Reconditioning
210
Cylinder Removal
211
Cylinder Inspection
212
Piston Removal
212
Piston-To-Cylinder Clearance
213
Piston / Rod Inspection
213
Piston Ring Installed Gap
214
Engine Assembly - Top End
215
Piston Ring Installation
215
Piston / Connecting Rod Assembly
216
Cylinder Installation
216
Cylinder Head Installation
217
Valve Sealing Test
218
Valve Clearance Check / Adjustment
218
Valve Lash - Tappet Selection Matrix
220
Camshaft Installation / Timing
221
Camshaft Timing - Quick Reference
223
Valve Cover Installation
224
Engine Disassembly / Inspection - Lower End
225
Crankcase Disassembly
225
Stator Cover Removal
225
Starter One-Way Clutch Inspection
225
Stator Removal
227
Oil Pump Removal
228
Oil Pump Assembly
230
Crankcase Breather Service
231
Crankcase Separation
231
Balance Shaft Removal / Inspection
232
Crankshaft Removal
233
Crankshaft Inspection
233
Pto Side Crankcase Bearing Service
234
Mag Side Crankcase Bearing Service
235
Oil Pickup Assembly Inspection
236
Oil Pressure Regulator (Bypass) Valve Inspection
236
Crankcase Inspection
236
Engine Assembly - Lower End
237
Crankcase Assembly - Pto Side
237
Balance Shaft Installation / Timing
239
Final Crankcase Assembly
239
Starter One-Way Clutch Installation
241
Flywheel Installation
241
Stator / Stator Cover Installation
243
570Cc Dohc Engine
244
Engine Detail, Torques / Sequences
244
Engine Fastener Torque Specifications
244
Torque Sequence
246
Crankcase - Timing / Sealing Path
248
Engine Disassembly / Inspection - Top End
249
Valve Cover Removal
249
Camshaft / Carrier Removal
249
Camshaft Sprocket Inspection
250
Camshaft Inspection
251
Exhaust Camshaft Decompression Mechanism
251
Cam Chain and Guide Service
252
Cylinder Head Removal
252
Cylinder Head Disassembly
253
Cylinder Head Inspection
254
Cylinder Head Warp Inspection
254
Valve Inspection
254
Combustion Chamber Cleaning
255
Valve Seat Reconditioning
256
Cylinder Removal
258
Cylinder Inspection
258
Piston Removal
259
Piston-To-Cylinder Clearance
259
Piston / Rod Inspection
260
Piston Ring Installed Gap
261
Engine Assembly - Top End
262
Piston Ring Installation
262
Piston / Connecting Rod Assembly
263
Cylinder Installation
264
Cylinder Head Identification
264
Crankcase Identification
265
Cylinder Head Installation - Black Bolts
266
Cylinder Head Installation - Silver Bolts
267
Valve Sealing Test
268
Valve Clearance Check / Adjustment
268
Valve Lash - Tappet Selection
271
Camshaft Installation / Timing
272
Camshaft Timing - Quick Reference
275
Valve Cover Installation
276
Engine Disassembly / Inspection - Lower End
277
Crankcase Disassembly
277
Stator Cover Removal
277
Starter One-Way Clutch Inspection
277
Stator Removal
279
Oil Pump Removal
280
Oil Pump Assembly
282
Crankcase Breather Service
283
Crankcase Separation
283
Balance Shaft Removal / Inspection
284
Crankshaft Removal
285
Crankshaft Inspection
285
Pto Side Crankcase Bearing Service
286
Mag Side Crankcase Bearing Service
287
Oil Pickup Assembly Inspection
288
Oil Pressure Regulator (Bypass) Valve Inspection
288
Crankcase Inspection
288
Engine Assembly - Lower End
289
Crankcase Assembly - Pto Side
289
Balance Shaft Installation / Timing
291
Final Crankcase Assembly
291
Starter One-Way Clutch Installation
292
Flywheel Installation
293
Stator / Stator Cover Installation
294
Chapter 4 Engine Electrical
297
Ecu Overview
298
Ecu Service
298
Electronic Control Unit (Ecu)
298
Rpm Limit
298
Ecu Replacement
299
Electronic Throttle Body (Etc)
300
Etc Overview
300
Etc Test
300
Etc Replacement
300
Etc Learn Procedure
300
Temperature / Manifold Absolute Pressure (T-Map)
301
T-Map Overview
301
T-Map Sensor Test
301
T-Map Sensor Replacement
301
Pedal Position Sensor (Pps)
302
Operation Overview
302
Pps Test
302
Pps Replacement
302
Crankshaft Position Sensor
303
Cps Overview
303
Cps Test
303
Cps Replacement
305
Engine Coolant Temperature Sensor (Etc)
306
Ect Overview
306
Ect Sensor Test
306
Ect Sensor Replacement
307
Chapter 5 Fuel System
309
Efi Operation Overview
311
Initial Priming / Starting Procedure
312
Principal Components
312
Special Tools
313
Digital Wrench® - Diagnostic Connector
314
Digital Wrench® - Download Website
315
Digital Wrench® Diagnostic Softwarepu-47063-B
315
Digital Wrench® Smartlink Module Kitpu-47471
315
Efi Component Locations
316
Efi Component Locations - Left View
316
Efi Component Locations - Right View
317
Line / Hose Routing
318
Fuel Line Routing
318
Vent Line Termination Fitting
319
Air Box / Intake System
320
Air Box / Air Filter Assembly View
320
Air Box Removal / Installation
322
Fuel Tank / Pump / Sending Unit
323
Fuel Tank Assembly View
323
Fuel Tank Removal
323
Fuel Tank Installation
324
Fuel Sender Test
324
Fuel Pump Test
325
Fuel Pump Replacement
326
Ignition Coil Overview
330
Ignition Coil / Wire Overview
330
Ignition Coil / Wire Test
330
Fuel Injector
331
Fuel Injector Overview
331
Fuel Injector Test
331
Fuel Injector Replacement
332
Fuel Injector Troubleshooting
333
Efi Diagnosis
334
Service Notes - Fuel System
334
Trouble Code Display (Dtc)
335
Fuel System Troubleshooting
342
Fuel Starvation / Lean Mixture
342
Rich Mixture
342
Chapter 6 Pvt System
343
Pvt System Fastener Torques
344
Special Tools
344
Pvt System Overview
345
Clutching Chart
345
General Operation
345
Drive Clutch Operation
346
Driven Clutch Operation
346
Pvt Break-In (Drive Belt / Clutches)
346
Maintenance / Inspection
346
Overheating / Diagnosis
347
Pvt System Service
348
Pvt Sealing, Guard, and Duct Components
348
Pvt Disassembly
349
Pvt Assembly
350
Drive Belt
351
Belt Removal
351
Belt Inspection
351
Belt Installation
352
Pvt Break-In (Drive Belt / Clutches)
352
Clutch Alignment / Offset / Center Distance
353
Inspection
353
Adjustment
354
Drive Clutch Service
355
Drive Clutch Assembly View
355
Clutch Disassembly
356
Shift Weight Inspection
357
Spider Removal
358
Roller, Pin, and Thrust Washer Inspection
358
Button to Tower Clearance Inspection
359
Bearing Inspection
359
Clutch Inspection
359
Bushing Service
361
Clutch Assembly
364
Driven Clutch Service
365
Assembly View
365
Clutch Disassembly / Inspection
366
Clutch Assembly
367
Secondary Clutch Adjustment
367
Pvt System Troubleshooting
368
Troubleshooting
368
Chapter 7 Transmission
371
Special Tools, Transmission
372
Special Tools
373
Lubrication
374
Transmission Gears
374
Transmission Mounting and Torque Values
375
Assembly View
376
Transmission Assembly View
376
Shift Lever
378
Removal
378
Installation
378
Shift Cable
379
Inspection
379
Shift Cable Removal / Install and Routing
379
Adjustment
380
Transmission Service
381
Transmission Removal
381
Transmission Installation
383
Transmission Internals Service
386
Differential Operation
386
Transmission Disassembly
387
Planetary Differential Disassembly
392
Planetary Differential Bushing Replacement
393
Planetary Differential Assembly
395
Gear / Shaft / Bearing Inspection
396
Snorkel Gear Backlash Procedure
397
Troubleshooting
405
Troubleshooting Checklist
405
Chapter 8 Final Drive
407
Front Hub / Bearing
410
Hub Removal / Inspection
410
Hubstrut Bearing Replacement
410
Hub Installation
411
Front Hub/Wheel Exploded View
413
Front Drive Shaft
414
Front Drive Shaft Removal
414
Front Drive Shaft Installation
415
Front Gearcase
416
Gearcase Removal
416
Gearcase Installation
416
Front Gearcase (Non-Adc)
418
Front Gearcase Assembly View
418
All Wheel Drive Operation
419
Awd Diagnosis
420
Front Gearcase Disassembly / Inspection
421
Front Gearcase Assembly
424
Front Gearcase (Adc)
427
Exploded View, Front Gearcase (4Wdc)
427
Operation, Front Gearcase (4Wdc)
429
Disassembly / Inspection, Front Gearcase (Adc)
430
Reassembly, Front Gearcase (Adc)
434
Troubleshooting, Front Gearcase (Adc)
437
Rear Bearing Carrier
441
Inspection
441
Removal
441
Disassembly
442
Assembly
442
Installation
443
Rear Drive Shaft
444
Rear Drive Shaft Removal
444
Rear Drive Shaft Installation
444
Drive Shaft Service
445
Drive Shaft / CV Joint Handling Tips
445
Outer CV Joint / Boot Replacement
445
Inner Plunging Joint / Boot Replacement
448
Drive Shaft Assembly View
450
Final Drive
451
Front Prop Shaft Components
451
Propshaft U-Joint Service
451
Removal / Installation
451
Removal / Installation (Crew)
451
Support Bearing Replacement (Crew)
452
Disassembly
453
Assembly
454
Chapter 9 Steering / Suspension
455
Special Tools
456
Shock Analysis
457
Steering Assembly
458
Steering Assembly View (Non-Eps)
458
Steering Assembly View (Eps)
460
Steering Wheel Removal (Non-Eps Models)
462
Steering Shaft Bearing Replacement
462
Steering Shaft / Steering Rack Removal (Non-Eps Models)
463
Steering Wheel / Upper Steering Shaft Removal (Eps)
464
Power Steering Unit Removal
465
Power Steering Unit Installation
465
Steering Rack Removal / Installation (Eps)
467
Front Strut
469
Assembly View
469
Front Strut Cartridge Replacement
470
Ball Joint Replacement
470
Rear A-Arms
472
Removal / Replacement
472
Installation
473
Assembly View
474
Rear Stabalizer Bar / Linkage
475
Removal / Installation
475
Assembly View
476
Shocks / Springs
476
Shock Removal / Installation
476
Shock Replacement
476
Chapter 10 Brake System
477
Brake Service Specifications
479
Special Tools
479
Brake System Notes
480
Brake System Service Notes
480
Brake Noise Troubleshooting
480
Hydraulic Brake System Operation
481
Brake System Assembly Views
482
Ranger
482
Ranger Crew
483
Master Cylinder
484
Removal
484
Installation
484
Brake Pressure Switch
484
Brake Pedal
485
Pedal Removal
485
Pedal Installation
485
Brake Service Procedures
486
Brake Bleeding / Fluid Change
486
Brake Burnishing Procedure
487
Front Brake Pads
488
Seat
488
Pad Removal / Disassembly
488
Brake Pad Inspection
488
Pad Assembly / Installation- Ranger
489
Pad Adjustment- Ranger
489
Crew
490
Pad Removal - Crew
490
Pad Inspection
491
Pad Assembly / Installation- Crew
491
Front Caliper
492
Seat
492
Front Caliper Assembly View
492
Front Caliper Removal- Ranger
493
Front Caliper Disassembly - Ranger
493
Front Caliper Inspection- Ranger
494
Front Caliper Assembly
494
Front Caliper Installation
495
Crew
496
Front Caliper Assembly View
496
Front Caliper Removal- Crew
497
Brake System
497
Front Caliper Disassembly - Crew
497
Front Caliper Inspection - Crew
498
Front Caliper Assembly - Crew
499
Front Caliper Installation - Crew
499
Front Brake Disc
501
Disc Inspection
501
Disc Removal / Replacement
502
Rear Brake Pads
502
Pad Removal
502
Brake Pad Inspection
503
Rear Pad Installation
504
Rear Calipers
505
Caliper Assembly View
505
Caliper Removal
506
Rear Caliper Disassembly
506
Rear Caliper Inspection
507
Rear Caliper Assembly
507
Rear Caliper Installation
508
Rear Brake Disc
509
Disc Runout
509
Brake Disc Inspection
509
Disc Removal / Replacement
510
Troubleshooting
511
Pedal Vibration
511
Caliper Overheats (Brakes Drag)
511
Brakes Lock
511
Brake Warning System Inspection (Intl Models)
512
Brake Pedal Switch Inspection
512
Chapter 11 Body / Frame
513
Special Tools
514
Torque Specifications
514
Chassis / Body Assembly Views
515
Frame Assembly View
515
Crew Frame Assembly View
516
Dash Instruments / Controls
519
Hood / Dash / Front Fascia
520
Floor / Rear Fenders
521
Seat Mounting / Seat Belts
522
Crew Floor / Rear Fenders
523
Crew Seat Mounting / Seat Belts
524
Rear Cargo Box
525
Cargo Box - Tailgate / Box Support
525
Box Removal
527
Box Installation
527
Body Component Removal
528
Lower Seat Base
528
Front Bumper
528
Fenders / Foot Pads
528
Hood / Dash
529
Floors
530
Decals
531
Decal Replacement
531
Chapter 12 Electrical
533
Battery Conductance Analyzer
535
Electrical Service Notes
535
Special Tools
535
Components under Hood
536
Switches / Controls
537
Ignition / Headlight Switch
537
Awd / 2Wd / Turf Switch
537
Differential Solenoid
538
Brake Pressure Switch
538
All Wheel Drive (Awd) Coil
539
Operation Overview
539
Diagnosing System Failures
539
Vehicle Speed Sensor
540
Speed Sensor Location
540
Speed Sensor Testing
540
Instrument Cluster
541
Overview
541
Rider Information Display
542
Information Display Area
543
Diagnostic Mode
545
Instrument Cluster Pinouts
546
Instrument Cluster Removal
546
Instrument Cluster Installation
546
Headlights
547
Headlight Adjustment
547
Headlight Bulb Replacement
548
Headlight Housing Removal
548
Headlight Housing Installation
548
Tail Light / Brake Light
549
Led Lamp Replacement
549
Cooling System
550
Fan Control Circuit Operation
550
Fan Control Circuit Bypass Test
550
Ignition Coil
551
Ignition Coil Tests
551
Ignition Coil and Ht Lead Replacement
552
Relays
553
Operation
553
Fuses / Circuit Breaker
555
Operation
555
Operation (Intl.)
556
Charging System
557
Current Draw - Key off
557
Charging System "Break Even" Test
557
Charging System Alternator Tests
558
Charging System Testing Flow Chart
560
Battery Service
561
Battery Terminals / Bolts
561
Battery Terminal Block
561
Battery Activation
561
Battery Inspection
562
Battery Removal / Installation
563
Conventional Battery Testing
563
Ocv - Open Circuit Voltage Test
563
Voltage Drop Test
563
Specific Gravity Test
563
Load Test
564
Charging Procedure
564
Off Season Storage
564
Starter System
565
Troubleshooting
565
Starter Drive
565
Starter Solenoid Bench Test
566
Starter Solenoid Operation
566
Starting System Testing Flow Chart
567
5
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Polaris RANGER 500 2021 Specifications
General
Brand
Polaris
Model
RANGER 500 2021
Category
Offroad Vehicle
Language
English
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