2011 Polaris Ranger 500 EFI Service & Repair Manual
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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
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Online & Offline Access
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Full Search Facility
Print one or all pages of your manual
$39.99
Get the essential 2011 Polaris Ranger 500 EFI Service & Repair Manual for comprehensive guidance on servicing and repairing your vehicle. This manual is an invaluable resource for both professional mechanics and DIY enthusiasts, providing detailed information on engine specifications, electrical systems, EFI system management, transmission details, troubleshooting guides, and more. It includes illustrations, wiring diagrams, torque specifications, assembly and disassembly instructions, and safety precautions to ensure accurate and safe servicing practices.
Whether you are performing basic maintenance or advanced repairs, this manual is designed to help you maintain the durability and optimal performance of your Polaris Ranger. It is available in a printable PDF format and is compatible with various electronic devices, including PC, Mac, Android, and Apple devices. Adobe Reader is the only requirement for accessing this comprehensive manual.
