Polaris 500 2X4 User manual

The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!

2
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 RANGER 2X4/4X4/TM Owner’s Manual P/N 9920210

3
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS 4........
SAFETY 5...................................
FEATURES AND CONTROLS 23...............
OPERATION 32..............................
EMISSION CONTROL SYSTEMS 51............
MAINTENANCE AND LUBRICATION 53.........
POLARIS PRODUCTS 101.....................
SPECIFICATIONS 102........................
TROUBLESHOOTING 108.....................
WARRANTY 111..............................
MAINTENANCE LOG 120......................
INDEX 122...................................

4
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle’s identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.
Vehicle Model Number:
(behind left front wheel)
Frame VIN (1):
(under hood)
Engine Serial Number (2):
(right front side of engine crankcase)
Key Number (3):
1
31XX
3
2

5
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris RANGER is not a toy and can be hazardous to operate.
This vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating the vehicle.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may
ride as a passenger in this vehicle.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
The RANGER is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

6
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your RANGER. Your safety is involved when these
words and symbols are used. Become familiar with their meanings
before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

7
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
SRead this manual and all labels carefully. Follow the operating pro-
cedures described.
SNever allow anyone without a valid driver’s license to operate this
vehicle.
SMinimum age recommendation for passengers is five years old. Pas-
sengers under five years of age require special restraints which are
not available with this vehicle. Driver and passenger should wear
their seat belts at all times.
SNever permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
STo reduce tipover risk, be especially careful when encountering ob-
stacles and slopes and when braking on hills or during turns.
SThis vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
SHelmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
SNever consume alcohol or drugs before or while operating this ve-
hicle.
SNever operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your experi-
ence.
SNever attempt wheelies, jumps or other stunts.
SAlways inspect your vehicle each time you use it to make sure it’s in
safe operating condition. Always follow the inspection and mainte-
nance procedures and schedules described in this manual.
SAlways keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain.
SNever operate on excessively rough, slippery or loose terrain.