2012 Polaris Ranger 500 EFI OEM Service & Repair Manual

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEM 5 BODY / STEERING / SUSPENSION

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL: 2011 - 2012 RANGER 400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL: 2011 - 2012 RANGER 400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: 2011 - 2012 RANGER 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: 2011 - 2012 RANGER 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL: 2011 - 2012 RANGER 500 EFI CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL: 2011 - 2012 RANGER 500 EFI CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.2 GENERAL INFORMATION 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1). The engine model and serial number can be found on a decal applied to the engine’s magneto cover (see Figure 1-2). VEHICLE IDENTIFICATION Model Identification: RANGER 400 / RANGER 500 EFI / RANGER 500 EFI CREW The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH46PLE.................................................. 455cc High Output Single Cylinder, Liquid Cooled, 4-Stroke SOHC, Electric Start EH500PLE................................................................... 498cc Single Cylinder, Liquid Cooled, 4-Stroke SOHC, Electric Start VIN Identification } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 12 R H 45 A G } W H 50 4 X A R H 4 5 A * B P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier Check Digit Model Year Body Style Plant No. * This could be either a number or a letter Powertrain Emissions Individual Serial No. 5 0 Figure 1-1 400 / 500 EFI VIN 500 EFI CREW VIN Figure 1-2 Engine Serial Number

1.3 GENERAL INFORMATION 1 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Model Model No. Owner’s Manual PN Parts Manual PN 2011 RANGER 400 R11RH45AG, AH, AR 9923132 9923133 2011 RANGER 500 EFI R11RH50AG, AH, AR 9923135 9923136 2011 RANGER 500 EFI CREW R11WH50AG, AH, AR 9923135 9923143 2012 RANGER 400 R12RH45AG, AH, AR 9923509 9923510 2012 RANGER 500 EFI R12RH50AG, AH, AR, AZ 9923512 9923513 2012 RANGER 500 EFI CREW R12WH50AG, AH, AR, AK 9923512 9923511 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

1.4 GENERAL INFORMATION 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2011 - 2012 RANGER 400 MODEL NUMBER: R12RH45AG, AH, AR R11RH45AG, AH, AR ENGINE MODEL: EH46PLE Category Dimension / Capacity Length 108 in. / 274.3 cm Width 56.5 in. / 143.5 cm Height 73 in. / 185.4 cm Wheel Base 71 in. / 180.3 cm Ground Clearance 10 in. / 25.4 cm Turning Radius 150 in. / 381 cm Dry Weight 1050 lbs. / 476 kg Cargo Box Capacity 500 lbs. / 226.7 kg Cargo Box Dimensions (inside dimensions) L- 45.5” x W-32.1” x H-11.4” in. (115.5 x 81.5 x 28.9 cm) Vehicle Payload 1000 lbs. / 454 kg (Includes weight of operator, passenger, cargo and accessories) Hitch Towing Capacity 1250 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.5 GENERAL INFORMATION 1 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. MODEL: 2011 - 2012 RANGER 400 JETTING CHART CLUTCH CHART (2011 - 2012) Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH46PLE Engine Displacement 455 cc Number of Cylinders 1 Bore & Stroke 87.9 x 75 mm Compression Ratio 9.7:1 Compression Pressure 50-90 psi W/Compression Release Engine Idle Speed 1200 +/- 200 RPM Engine Max Speed 7000 RPM Valve Clearance Int./Exh. 0.006 in. (0.152 mm) Engine Hot Light Dash Light Lubrication Pressurized Dry Sump Oil Requirements PS4 PLUS 2W-50 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.7 qts. (3.5 L) Exhaust System Single Pipe Canister Style Carburetion Carburetor model Mikuni BST 34mm CV Main Jet 150 Pilot Jet 42.5 Jet Needle - clip position 4IB33-3 Needle Jet P-6 (829) Pilot Screw 2.75 Turns Out (Initial starting point, settings may vary) Float Height 13mm ± 1 (.51 ± 0.40") Fuel Delivery Electric Fuel Pump (External) Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 250 watts @ 3000 RPM Lights : Main Headlights 2 - Single Beam 50w / Halogen Tail LED (.28W) Brake LED (3.1W) Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System 12V DC/CDI Ignition Timing 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E / .036 in. (0.9 mm) Battery / Model / Amp Hr Yuasa Conventional 14 Amp Hr. / 12 Volt Instrument Panel Type Indicator Lights / Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift -P / H / L / N / R Transmission Gear Reduction: High Low Reverse 4.12:1 7.70:1 7.00:1 Drive Ratio - Front 3.818:1 Front Gearcase Lubricant Requirement Demand Drive Plus 8.97 oz. (265 ml) Transmission Lubricant Requirement Full Synthetic AGL Plus 33.8 oz. (1000 ml) Drive Belt 3211077 Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Strut Front Travel 8 in. (20.3 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment (Rear) Wheels / Brakes Front Wheel Size / Type 12 x 6 / Steel Rear Wheel Size / Type 12 x 8 / Steel Front Tire Make / Model / Size Titan / AT489 / 25 x 8 R12 Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 Tire Air Pressure 10 psi front / 12 psi rear Brake System 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Transmission - Park Lock Altitude Ambient Temperature Below 40° F Below 5° C Above +40° F Above +5° C Meters (Feet) 0-1829 (0-6000) 155 150 1829-3048 (6000-10,000) 150 145 #2 Jet Needle Clip Position Above 3048 (Above 10,000) 145 #2 Jet Needle Clip Position 140 #1 Jet Needle Clip Position Altitude Shift Weight Drive Spring Meters (Feet) 0-1500 (0-5000) 10 BHF (5632401) Blue / Grey (7042202) 1500-3700 (5000 - 12000) 10 RH (5630709) Blue / Red (7041157)

1.6 GENERAL INFORMATION 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2011 - 2012 RANGER 500 EFI MODEL NUMBER: R12RH50AG, AH, AR, AZ R11RH50AG, AH, AR ENGINE MODEL: EH500PLE Category Dimension / Capacity Length 108 in. / 274.3 cm Width 56.5 in. / 143.5 cm Height 73 in. / 185.4 cm Wheel Base 71 in. / 180.3 cm Ground Clearance 10 in. / 25.4 cm Turning Radius 150 in. / 381 cm Dry Weight 1055 lbs. / 479 kg Cargo Box Capacity 500 lbs. / 226.7 kg Cargo Box Dimensions (inside dimensions) L- 45.5” x W-32.1” x H-11.4” in. (115.5 x 81.5 x 28.9 cm) Vehicle Payload 1000 lbs. / 454 kg (Includes weight of operator, passenger, cargo and accessories) Hitch Towing Capacity 1250 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.7 GENERAL INFORMATION 1 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. MODEL: 2011 - 2012 RANGER 500 EFI CLUTCH CHART (2011 - 2012) Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH500PLE270 Engine Displacement 498 cc Number of Cylinders 1 Bore & Stroke 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi W/Compression Release Engine Idle Speed 1100 +/- 200 RPM Engine Max Speed 7000 RPM Valve Clearance Int./Exh. 0.006 in. (0.152 mm) Engine Hot Light Dash Light Lubrication Pressurized Dry Sump Oil Requirements PS4 PLUS 2W-50 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.7 qts. (3.5 L) Exhaust System Single Pipe / Canister Style Carburetion Fuel System Type EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 350 watts @ 3000 RPM Lights : Main Headlights 2 - Single Beam 50w / Halogen Tail LED (.28W) Brake LED (3.1W) Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System EFI (ECU Controlled) Ignition Timing 10° ± 1° BTDC @ 1150 RPM Spark plug / Gap NGK BKR6E / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa Conventional 14 Amp Hr. / 12 Volt Instrument Panel Type Indicator Lights / Hour Meter DC Outlet Standard Instrumentation Multifunction Speedometer Relays EFI / FAN / Ign & Fuel pump / Chassis / Rear Diff Circuit Breaker Fan Motor 15A Fuses Headlight 10A Taillight 10A Fuel - IGN 10A ACC 10A Brake Light 10A Chassis 20A EFI 15A ACC Terminal Block 20A Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - P/ H / L / N / R Transmission Gear Reduction: High Low Reverse 4.12:1 7.70:1 7.00:1 Drive Ratio - Front 3.818:1 Front Gearcase Lubricant Requirement Demand Drive Plus 8.97 oz. (265 ml) Transmission Lubricant Requirement Full Synthetic AGL Plus 33.8 oz. (1000 ml) Drive Belt 3211113 Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Strut Front Travel 8 in. (20.3 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment (Rear) Wheels / Brakes Front Wheel Size / Type 12 x 6 / Steel 12 x 6 / Cast Aluminum (AZ) Rear Wheel Size / Type 12 x 8 / Steel 12 x 8 / Cast Aluminum (AZ) Front Tire Make / Model / Size Titan / AT489 / 25 x 8 R12 Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 Tire Air Pressure 10 psi front / 12 psi rear Brake System 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Transmission - Park Lock Altitude Shift Weight Drive Spring Meters (Feet) 0-1500 (0-5000) 25-52 (5632409) Blue / Red (7043199) 1500-3700 (5000 - 12000) 25-48 (5632408) Blue / Red (7043199)

1.8 GENERAL INFORMATION 9923511 - 2011 - 2012 RANGER 400 / 500 EFI / 500 EFI Crew Service Manual © Copyright 2011 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2011 - 2012 RANGER 500 EFI CREW MODEL NUMBER: R12WH50AG, AH, AR, AK R11WH50AG, AH, AR ENGINE MODEL: EH500PLE Category Dimension / Capacity Length 140 in. / 355.6 cm Width 58 in. / 147.3 cm Height 73 in. / 185.4 cm Wheel Base 104 in. / 180.3 cm Ground Clearance 10 in. / 25.4 cm Turning Radius 237 in. / 602 cm Dry Weight 1300 lbs. / 589.7 kg Cargo Box Capacity 500 lbs. / 226.7 kg Cargo Box Dimensions (inside dimensions) L- 45.5” x W-32.1” x H-11.4” in. (115.5 x 81.5 x 28.9 cm) Vehicle Payload 1250 lbs. / 576 kg (Includes weight of operator, passenger, cargo and accessories) Hitch Towing Capacity 1250 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg