2005-2007 Polaris Ranger 500 Service & Repair Manual

POLARIS RANGER 500 4X4 SERVICE MANUAL

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 CARBURETION / EFI 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 VEHICLE DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 1.6 MODEL: RANGER 4X4 CARB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER 4X4 EFI . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL: RANGER 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL: RANGER 4X4 CARB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MODEL: RANGER 4X4 EFI . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH50PLE .......................................................................................... Single, L/C, SOHC 4 Stroke, Electric Start VIN Identification Engine Serial Number Location Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the flywheel housing on the right side of engine. } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 7 R B 5 0 A A } 4 X A R B 5 0 A * 7 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. Individual Serial No. * This could be either a number or a letter Powertrain Emissions A Engine Serial Number

1.3 GENERAL INFORMATION 1 Unit Serial Number (VIN) Location The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower LH frame rail close to the front drive wheel. The model and serial number are also located on a sticker under the hood (B). Transmission I.D. Number Location A A A B The transmission I.D. number is located on the right side when installed in the machine.

1.4 GENERAL INFORMATION VEHICLE DIMENSIONS 75 in. 190.50 cm 10 in. 25.4 cm 58 in. 147 cm RANGER 2X4, 4X4 RANGER 2X4, 4X4

1.5 GENERAL INFORMATION 1 VEHICLE DIMENSIONS 113 in. 287 cm 58 in. 147 cm 76 in. 193 cm RANGER 2X4, 4X4

1.6 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: RANGER 2X4 MODEL NUMBER: R07RB50AA ENGINE MODEL: EH50PLE MODEL: RANGER 4X4 CARB MODEL NUMBER: R07RH50AA ENGINE MODEL: EH50PLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1105 lbs. / 502 kg Gross Vehicle Weight 2500 lbs. / 1135 kg Cargo Box Capacity 850 lbs. / 386 kg Cargo Box Dimensions 58 x 42 x 10 in. (147 x 106.7 x 25.4 cm) Vehicle Payload 1350 lbs. / 613 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1185 lbs. / 537 kg Gross Vehicle Weight 2700 lbs. / 1226 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions 58 x 42 x 10 in. (147 x 106.7 x 25.4 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.7 GENERAL INFORMATION 1 MODEL: RANGER 4X4 EFI MODEL NUMBER: R07RH50AF,AR,AT ENGINE MODEL: EH50PLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1185 lbs. / 537 kg Gross Vehicle Weight 2700 lbs. / 1226 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions 58 x 42 x 10 in. (147 x 106.7 x 25.4 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.8 GENERAL INFORMATION MODEL: RANGER 2X4 MODEL NUMBER: R07RB50AA ENGINE MODEL: EH50PLE JETTING CHART CLUTCH CHART Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH500PLE168 Engine Displacement 499 cc Number of Cylinders 1 Bore & Stroke 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi Engine Idle Speed 1200 ± 200 RPM Valve Clearance Int./Exh. 0.152 mm (.006 in.) Engine Hot Light Dash Light Lubrication Pressurized Dry Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity 2.25 qts. / 2.13 L Exhaust System Single Canister Style Carburetion Carburetor model Mikuni BST 34mm CV Main Jet 135 Pilot Jet 42.5 Jet Needle 4MB32-3 Needle Jet P-6 (829) Pilot Screw 2.5 Turns Out (Initial starting point, settings may vary) Pilot Air Jet 160 Float Height 13 ± 1 mm (0.51 ± 0.40“) Fuel Delivery Electric Fuel Pump (External) Fuel Capacity / Requirement 9 gal. (34 l) 87 Octane (minimum) Electrical Alternator Max Output 250 watts @ 5000 RPM Lights : Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System 12V DC/CDI RPM Limit 6600 RPM Ignition Timing 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR5E / .036 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrument Panel Type Indicator Lights / Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio : High Low Rev. 3.83:1 8.71:1 5.9:1 Final Drive Ratio 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211077 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.5” / 12.7 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Rear Suspension Independent Rear Suspension Rear Travel 9 in. / 23 cm Ground Clearance 11.5 in. (29 cm) Shock Preload Adjustment Front / Rear Cam Adjustment 2-2” Twin Tubes Turning Radius 132 in. / 335.3 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Rear Wheel Size 12 x 8 / 10 gauge Front Tire Make / Model / Size Titan / AT489 / 25x10-12 Rear Tire Make / Model / Size Titan / AT489 / 25x11-12 F/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4 Altitude Ambient Temperature Below 40° F Below 5° C +40° F TO +80° F +5° C TO +28° C Meters (Feet) 0-1500 (0-5000) 140 (3130527) 135 (3130563) above 1500 (above 5000) 132.5 (3130562) 127.5 (3130560) Altitude Shift Weight Drive Spring Driven Spring Driven Helix Meters (Feet) 0-1500 (0-5000) 10 MH (5630513) Blu/Grn (7041157) Black (7041782) 45° (5131446) 1500-3700 (5000 - 12000) 10 WH (5630710) Blu/Grn (7041157) Black (7041782) 45° (5131446)

2005-2007 Polaris Ranger 500 Service & Repair Manual

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