2005-2007 Polaris Ranger 500 service manual
Factory repair manual for the 2005-2007 Polaris Ranger 500.
Manual covers complete tear down and rebuild, pictures and parts diagrams, torque specs, maintenance, troubleshooting and more.
Models covered by this manual:
Polaris Ranger 500 2x4
Polaris Ranger 500 4x4 carb
Polaris Ranger 500 4x4 EFI
Manual chapters:
- GENERAL INFORMATION
- MAINTENANCE
- ENGINE
- CARBURETION SYSTEM
- ELECTRONIC FUEL INJECTION
- BODY / STEERING / SUSPENSION
- CLUTCHING
- FINAL DRIVE
- TRANSMISSION
- BRAKES
- ELECTRICAL
- INDEX
- WIRING DIAGRAMS
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Full list of manual chapters:
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Identification
Engine Designation Number
VIN Identification
Engine Serial Number Location
Unit Serial Number (VIN) Location
Transmission I.D. Number Location
VEHICLE DIMENSIONS
vehicle DIMENSIONS
GENERAL SPECIFICATIONS
MODEL: 2007 RANGER 2X4
MODEL: 2007 RANGER 4X4 CARB
MODEL: 2007 RANGER 4X4 EFI
MODEL: 2007 RANGER 2X4
MODEL: 2007 RANGER 4X4 CARB
MODEL: 2007 RANGER 4X4 EFI
VEHICLE INFORMATION
Publication Numbers
Paint Codes
Replacement Keys
SPECIAL TOOLS
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Glossary of Terms
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Maintenance Chart Key
Pre-Ride - 25 Hour Maintenance Interval
50 - 100 Hour Maintenance Interval
100 - 300 Hour Maintenance Interval
GENERAL COMPONENT LOCATION
RH Side and Dash View
LH Side and Rear View
SERVICE PRODUCTS AND LUBES
Polaris Lubricants, Maintenance and Service Products
MAINTENANCE REFERENCES
Polaris Lubricant Symbol Identification
Engine Lubrication
Component Fluid Type and Use
Component Lubrication Points
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Frame, Nuts, Bolts, and Fasteners
Shift Linkage Inspection / Adjustment
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Lines
Fuel Filter (Carb Models)
Vent Lines
Throttle Pedal Inspection
Throttle Freeplay Adjustment
Throttle Cable Adjustment (Carb Models)
Choke Adjustment (Carb Models)
Pilot Screw (Carb Models)
Pilot Screw Adjustment (Carb Models)
Idle Speed Adjustment (Carb Models)
Carburetor Draining (Carb Models)
Air Intake Inspection
Air Filter Service
FUEL SYSTEM (EFI)
Fuel Filter
ENGINE
Compression and Leakdown Test
Breather Filter Inspection
Breather Hose
Flywheel Housing
Engine Oil Level
Engine Oil and Filter Change
Oil Pump Priming Procedure
Valve Clearance
Intake Valve Clearance Adjustment
Exhaust Valve Clearance Adjustment
Exhaust Pipe
TRANSMISSION AND GEARCASES
Transmission Lubrication
Front Gearcase Lubrication (4x4)
Rear Gearcase Lubrication
COOLING SYSTEM
Liquid Cooling System Overview
Coolant Level Inspection
Radiator Coolant Level Inspection
Coolant Strength / Type
Cooling System Pressure Test
Cooling System Hoses
Radiator
Coolant Drain / Radiator Removal
FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table
CV Shaft Boot Inspection
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Fluid Level (Conventional Battery)
Battery Removal
Battery Installation
Battery Storage
Battery Charging
Spark Plug Service
Engine To Frame Ground
STEERING AND SUSPENSION
Steering
Tie Rod End / Steering Inspection
Camber and Caster
Wheel Toe Alignment Inspection
Toe Adjustment
Front Suspension
Rear Suspension
Rear Suspension Adjustment
Rear Spring Adjustment
BRAKE SYSTEM
Brake System Inspection
Brake Pad Inspection
Parking Brake Pad Inspection
Brake Hose and Fitting Inspection
ENGINE
SPECIAL TOOLS
SPECIFICATIONS
Torque Specifications
Engine Service Data
Engine Service Data
Engine Fastener Torque Patterns
GENERAL ENGINE SERVICE
Piston Identification
Accessible Components
Engine Removal
Engine Installation Notes
Cylinder Hone Selection / Honing Procedure
Honing to Oversize
Cleaning the Cylinder After Honing
Crankshaft Straightening
Engine Lubrication - EH50PL
Oil Pressure Test - EH50PL
Oil Pump Priming Procedure
Oil Flow - EH50PL
EH50PL Oil Flow Diagram
EH50PL Engine Exploded View
COOLING SYSTEM
Cooling System Specifications (Non-EFI)
Cooling System Layout and Testing
ENGINE DISASSEMBLY
Engine Removal
Cam Chain Tensioner / Rocker Arm / Camshaft Removal
Cam Chain Tensioner Inspection
Rocker Arm / Shaft Inspection
Camshaft Removal
Automatic Compression Release Removal / Inspection
Automatic Compression Release Installation
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Exploded View, EH50PL (EFI Shown)
Cylinder Head Inspection
Cylinder Head Warpage
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Valve Clearance Adjustment (Intake and Exhaust)
Cylinder / Piston Removal and Inspection
Piston Removal
Cylinder Inspection
Piston-to-Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Crankcase Disassembly
Starter Drive Removal / Inspection
Flywheel and Stator Removal / Inspection
Cam Chain / Tensioner Blade
One Way Valve
Crankcase Separation
Oil Pump Removal / Inspection
Oil Pump Assembly
Counter Balancer Shaft Removal / Inspection
Crankshaft Removal / Inspection
Crankcase Bearing Inspection
Oil Seal / Mechanical Seal Removal (Engine Disassembled)
Crankcase Inspection
Bearing Installation
End Play Inspection / Adjustment
Crankshaft End Play Adjustment
Counter Balancer Shaft End Play Adjustment
Oil Pump Shaft End Play Adjustment
ENGINE REASSEMBLY
Pump Shaft Oil Seal Installation
Crankshaft / Counter Balance / Oil Pump Installation
Crankcase Assembly
Water Pump Mechanical Seal Installation
Water Pump Mechanical Seal Removal (Engine Installed)
One Way Valve Installation
Cam Chain Drive Sprocket Installation
Tensioner Blade Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head Installation
Cam Chain / Camshaft Installation
Camshaft Timing
Camshaft Timing Illustration
Cam Chain Tensioner Installation
Stator, Flywheel and Starter Drive Installation
Rocker Shaft / Rocker Arm Assembly Installation
Thermostat Installation
Oil Pipes
TROUBLESHOOTING
Engine
Spark Plug Fouling
Cooling Troubleshooting
CARBURETION SYSTEM
SPECIAL TOOLS
CARBURETOR JETTING
Jetting Guidelines
Mikuni Jet Part Numbers
MIKUNI CV CARBURETOR
Exploded View
System Function - Mikuni CV Carb
Vent Systems - Mikuni CV Carb
Operation - Mikuni CV Carb
Pilot System (Idle and Slow Speed)
Starter System (Choke or Enrichment)
Float System
Main System
Pilot Screw
CARBURETOR SERVICE
Carburetor Removal
Carburetor Disassembly
Carburetor Cleaning
Carburetor Inspection
Float Height Adjustment
Needle and Seat Leakage Test
Fuel Level
Carburetor Assembly
AIR BOX ASSEMBLY
Exploded View
FUEL TANK ASSEMBLY
Fuel Tank / Fuel Pump Exploded View
Fuel Tank Removal
Fuel Tank Installation
FUEL PUMP
Replacement
TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Idle Too High
Idle Too Low
Erratic Idle
ELECTRONIC FUEL INJECTION
SPECIAL TOOLS
Part Numbers / Descriptions
EFI SERVICE NOTES
General Service Information
EFI SYSTEM
Exploded View
EFI COMPONENT LOCATIONS
Identification / Location
FUEL TANK
Exploded View
ELECTRONIC FUEL INJECTION
General Information
EFI Operation Overview
Initial Priming / Starting Procedure
FUEL LINES
Quick Connect Removal / Installation
ELECTRONIC CONTROL MODULE (ECM)
Operation Overview
ECM Replacement
ECM Service
FUEL PUMP ASSEMBLY
Operation / Testing
Fuel Pump Test
Fuel Pump / Tank Assembly Replacement
FUEL PRESSURE REGULATOR
General Information
FUEL INJECTOR
General Information
CRANKSHAFT POSITION SENSOR (CPS)
General Information
MANIFOLD AIR PRESSURE SENSOR (MAP)
General Information
Map Sensor Test
Map Sensor Replacement
INTAKE AIR TEMPERATURE SENSOR (IAT)
General Information
Intake Air Temperature Sensor Test
Intake Air Temperature Sensor Replacement
IDLE AIR CONTROL (IAC)
General Information
THROTTLE POSITION SENSOR (TPS)
General Information
Throttle Position Sensor Test
Throttle Position Sensor Replacement
Throttle Position Sensor Initialization
ENGINE TEMPERATURE SENSOR
General Information
Engine Temperature Sensor Test
Engine Temperature Sensor Replacement
DIAGNOSTICS USING 'BLINK CODES'
Blink Codes - Operation
FUEL SYSTEM TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Poor Idle
EFI SYSTEM BREAK-OUT DIAGRAMS
Fuel Injector Circuit
Crankshaft Position Sensor (CPS) Circuit
Fuel Pump Circuit
Ignition Coil Circuit
Idle Air Control (IAC) Circuit
Throttle Position Sensor (TPS) Circuit
Manifold Air Pressure Sensor (MAP) Circuit
Engine Coolant Temperature Sensor Circuit
Intake Air Temperature Sensor (IAT) Circuit
Malfunction Indicator Light (MIL) Circuit
Diagnostic Connector Circuit
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BODY COMPONENT REMOVAL
Removal Procedures
Lower Body Components
Hood / Dash Components
Dash Instruments and Controls
CAB FRAME
Assembly / Removal
CHASSIS / MAIN FRAME
Exploded View
SEAT / HEAD REST
Seat Base / Seat Back / Head Rest Assembly
STEERING ASSEMBLY
Exploded View
STEERING AND SUSPENSION
Exploded View
FRONT A-ARM
Replacement
FRONT STRUT
Exploded View
Front Strut Cartridge Replacement
Ball Joint Replacement
REAR A-ARM
Replacement
REAR STABILIZER BAR
Removal / Installation
REAR CARGO BOX
Cargo Box - Panels
Cargo Box - Tailgate / Box Support
Box Removal
Box Installation
DECAL REPLACEMENT
CLUTCHING
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
Drive Clutch Operation
Driven Clutch Operation
Maintenance / Inspection
Overheating / Diagnosis
PVT SYSTEM SERVICE
PVT Sealing, Guard, and Ducting Components
Disassembly
Assembly
DRIVE BELT
Belt Deflection (Tension)
Belt Removal
Belt Inspection
Belt Installation
CLUTCH ALIGNMENT / OFFSET
Clutch Alignment
Clutch Offset
DRIVE CLUTCH SERVICE
Spring Specifications
Shift Weights
Exploded View
Clutch Inspection
Clutch Disassembly
Spider Removal
Roller, Pin, and Thrust Washer Inspection
Bushing Service
Moveable Sheave - Bushing Removal
Moveable Sheave - Bushing Installation
Clutch Cover - Bushing Removal
Clutch Cover - Bushing Installation
Clutch Assembly
DRIVEN CLUTCH SERVICE
Exploded View
Clutch Disassembly / Inspection
Bushing Service
Moveable Sheave - Bushing Installation
Clutch Assembly
TROUBLESHOOTING
FINAL DRIVE
SPECIAL TOOLS
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
FRONT HUB (2X4)
Hub Removal / Inspection
Hub Installation
Exploded View (2X4)
FRONT HUB (4X4)
Hub Removal / Inspection
Hubstrut Bearing Replacement
Hub Installation
Exploded View (4X4)
DRIVE SHAFT / PROPSHAFT
Exploded View
DRIVESHAFT / CV JOINT HANDLING TIPS
FRONT DRIVE SHAFT (4X4)
Removal
CV Joint / Boot Replacement
Installation
FRONT PROPSHAFT REMOVAL
PROPSHAFT U-JOINT SERVICE
Disassembly
Assembly
FRONT GEARCASE CENTRALIZED HILLIARD
AWD Operation
Centralized Hilliard Exploded View
AWD Diagnosis
Gearcase Removal
Gearcase Disassembly / Inspection
Gearcase Reassembly / Inspection
Backlash Pad (Thrust Pad) Adjustment
Gearcase Installation
REAR DRIVE
Exploded View
REAR HUB / BEARING CARRIER
Hub Inspection
Hub Removal
Hub Disassembly
Hub Assembly
Hub Installation
REAR DRIVE SHAFT
Removal
CV Joint / Boot Replacement
Installation
REAR PROPSHAFT
Removal
Installation
REAR GEARCASE (DIFFERENTIAL)
General Operation
Operation Modes
Differential Removal
Differential Disassembly
Differential Assembly
Differential Installation
Differential Exploded View
TRANSMISSION
TORQUE SPECIFICATIONS
SHIFT LEVER
Removal
Installation
SHIFT LINKAGE
Inspection
Adjustment
TRANSMISSION SERVICE
Transmission Removal
Transmission Disassembly
Transmission Assembly
Transmission Installation
TROUBLESHOOTING
Troubleshooting Checklist
TRANSMISSION EXPLODED VIEW
Exploded View (2X4)
Exploded View (4X4)
BRAKES
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
MASTER CYLINDER
Removal
Installation
FOOT BRAKE PEDAL
Pedal Removal
Pedal Installation
BRAKE BLEEDING / FLUID CHANGE
PARKING BRAKE
Exploded View
Inspection
Adjustment
PARKING BRAKE CALIPER SERVICE
Exploded View
Caliper Removal
Caliper Disassembly / Inspection
New Brake Pad Installation
Caliper Installation
PARKING BRAKE DISC SERVICE
Disc Removal / Inspection
FRONT BRAKE PADS
Pad Removal / Disassembly
Pad Inspection
Pad Assembly / Installation
Pad Adjustment
FRONT CALIPER
Front Caliper Exploded View
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
FRONT BRAKE DISC
Disc Inspection
Disc Removal / Replacement
REAR BRAKE PAD
Pad Removal
Pad Inspection
Pad Installation
REAR CALIPER
Rear Caliper Exploded View
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
REAR BRAKE DISC
Disc Inspection
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
Pedal Vibration
Caliper Overheats (Brakes Drag)
Brakes Lock
ELECTRICAL
GENERAL INFORMATION
Special Tools
Electrical Service Notes
Under-Hood Components
SWITCHES / CONTROLS
Headlamp Switch
AWD / Rear Differential Switch
Differential Solenoid
Brake Light Switch
Parking Brake Switch
Gear Indicator Light Circuit Operation
Indicator Lamp Replacement
HEAD LIGHTS
High Beam Headlight Adjustment
Headlamp Bulb Replacement
Headlamp Housing Removal
Headlamp Housing Installation
TAIL LIGHT / BRAKE LIGHT
Lamp Replacement
POWER DISTRIBUTION MODULE (NON-EFI MODELS)
PDM Operation
PDM Block Diagram
PDM ISOLATION TESTS (NON-EFI MODELS)
Battery Voltage Test
Ground Test
Static Stator Test
Run Signal Test
Dynamic Stator Test
Battery + Test
Protected Battery + Test
Ignition Switch Test
Accessory Power Test
PDM to Fan Output Test
Fan Motor Test
Static Thermistor Test
Dynamic Thermistor Test
Hot Lamp Test
Differential Solenoid Test
AWD Out Test
AWD / Turf Switch Test
Differential Out Test
Differential Ground Test
ACS Out Test
POWER DISTRIBUTION MODULE (EFI MODELS)
PDM Operation
PDM Function Overview
PDM Block Diagram
TIMING CHECK PROCEDURE (NON-EFI MODELS)
COOLING SYSTEM
Non-EFI Cooling System Break-Out Diagram
EFI Cooling System Break-Out Diagram
Fan Control Circuit Operation / Testing
Fan Control Circuit Bypass Test
Coolant Temperature Sensor Test (Non-EFI Models)
DC / CDI IGNITION SYSTEM (NON-EFI MODELS)
DC / CDI Ignition System Overview
Ignition System Troubleshooting
Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter
Resistance Tests
Flywheel Identification
Ignition System Testing Flow Chart
Components of DC / CDI Ignition
EFI DIAGNOSTICS
EFI Component Testing
CHARGING SYSTEM
Current Draw - Key Off
Charging System "Break Even" Test
Charging System Alternator Tests
Charging System Testing Flow Chart
BATTERY TERMINAL BLOCK
BATTERY SERVICE
Battery Terminals / Bolts
Battery Identification
CONVENTIONAL BATTERY
Battery Activation
Battery Inspection
Battery Removal
Battery Installation
Conventional Battery Testing
OCV - Open Circuit Voltage Test
Specific Gravity Test
Load Test
Off Season Storage
Charging Procedure
LOW MAINTENANCE BATTERY
Battery Check
Battery Inspection
Battery Removal
Battery Installation
Battery Testing
OCV - Open Circuit Voltage Test
Load Test
Off-Season Storage
Battery Charging
STARTER SYSTEM
Troubleshooting
Voltage Drop Test
Starter Motor Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly
Starter Drive
Starter System Test Flow Chart
ELECTRIC BOX LIFT ACTUATOR
DIAGNOSIS (if equipped)
ELECTRICAL BREAKOUT DIAGRAMS (EFI MODELS)
Starting Circuit
Key-On Power Circuit
Transmission Switch Circuit
Differential Solenoid Circuit
Charging System Circuit
Cooling Fan Circuit
AWD Circuit
INDEX
WIRE DIAGRAMS
