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.

8
SAFETY
Operator Safety
SAlways follow proper procedures for turning as described in this
manual. Practice turning at slow speeds before attempting to turn at
faster speeds. Never turn at excessive speeds.
SAlways have this vehicle checked by an authorized Polaris dealer if
it has been involved in an accident.
SNever operate this vehicle on hills too steep for the vehicle or for
your abilities. Practice on smaller hills before attempting larger hills.
SAlways follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes.
Never go over the top of a hill at high speed.
SAlways follow the proper procedures outlined in this manual for
traveling downhill and for braking on hills. Check the terrain care-
fully before descending a hill. Never travel downhill at high speed.
Avoid going downhill at an angle, which would cause the vehicle to
lean sharply to one side. Travel straight down the hill where pos-
sible.
SAlways check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
SAlways be careful of skidding or sliding. On slippery surfaces such
as ice, travel slowly and exercise caution to reduce the chance of
skidding or sliding out of control.
SNever operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced
stopping ability. Test your brakes after leaving water. If necessary,
apply them lightly several times to let friction dry out the pads.
SAlways be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it’s safe to proceed in reverse,
move slowly. Avoid turning at sharp angles in reverse.
SAlways use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on page 103.

9
SAFETY
Operator Safety
SNever modify this vehicle through improper installation or use of
accessories.
SNever exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and
follow the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
SAlways wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.
SAlways keep arms and legs inside the cab frame while the vehicle is
in motion.
SAlways apply the parking brake before getting out of the vehicle.
Seepage31.
SAlways activate the foot pedal brake before releasing the park brake.
SAlways turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks.
Gasoline is extremely flammable. See page 22 for refueling instruc-
tions.
SAlways remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at
1-800-342-3764.

10
SAFETY
Operator Safety
WARNING
Make sure your RANGER is in excellent operating condition at all
times. We strongly recommend that the operator check all safety
components before each ride.
Polaris RANGERs are designed to provide safe operation when
used as directed. Failure of critical machine components may
result from operation with any modifications, especially those that
increase speed or power. The RANGER may become
aerodynamically unstable at speeds higher than those for which it
is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
Do not make any modifications to your RANGER.
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris RANGER any equipment that may increase the
speed or power of the vehicle, or make any other modifications to the
vehicle for these purposes. Any modifications to the original
equipment of the vehicle create a substantial safety hazard and increase
the risk of bodily injury.
The warranty on your Polaris RANGER is terminated if any equipment
has been added to the vehicle, or if any modifications have been made
to the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.

11
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards while
climbing a hill
WHAT CAN HAPPEN
Vehicle overturn
HOW TO AVOID THE HAZARD
Maintain a steady speed when
climbing a hill.
Ifyouloseallforwardspeed:
Apply the brakes.
Lock the parking brake after fully stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brake gradually.
When fully stopped, lock parking brake.
In the event of an accident, have a qualified service dealer check
the complete vehicle for possible damage, including (but not
limited to) brakes, throttle and steering.

12
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces
WHAT CAN HAPPEN
Loss of control
HOW TO AVOID THE HAZARD
This vehicle’s tires are designed for off-road use only, not for use
on pavement. Paved surfaces may seriously affect handling and
control of the vehicle, and may cause the vehicle to go out of
control.
Avoid operating the vehicle on pavement. If you must operate on
a paved surface, travel slowly and do not make sudden turns or
stops.
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the operator does
not know how to operate the vehicle properly in different
situations and on different types of terrain.
All operators must read and understand the Owner’s Manual and
all warning and instruction labels before operating the vehicle.

13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways
WHAT CAN HAPPEN
Collision with another vehicle
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway,
including dirt or gravel.
In many states it’s illegal to operate vehicles of this type on public
streets, roads and highways.
WARNING
POTENTIAL HAZARD
Operating this vehicle after consuming alcohol or drugs
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving a RANGER requires your full attention. DO NOT drink
alcohol or use drugs or medications before or while driving. They
will reduce your alertness and slow your reaction time. In most
states and provinces, it’s prohibited by law to drive while
intoxicated or under the influence of drugs.

14
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle at excessive speeds
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
Always travel at a speed proper for the terrain, visibility and
operating conditions, and your experience.
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator
fall through the ice.
HOW TO AVOID THE HAZARD
Never operate the RANGER on a frozen body of water.

15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating
Failure to properly maintain the vehicle
WHAT CAN HAPPEN
Accident, equipment damage
HOW TO AVOID THE HAZARD
Always inspect your RANGER before each use to make sure it’s
in safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on
unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain.
Always be alert to changing terrain conditions when operating the
vehicle. You may come upon hidden rocks, bumps, or holes
suddenly, without enough time to react.

16
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this
vehicle
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver’s license should operate a Polaris
RANGER.
Even though a child may be within the age group for which some
vehicles are recommended, he or she may not have the skills,
abilities, or judgment needed to operate the vehicle safely and
may be involved in a serious accident.
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or
uneven tire pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified in the Owner’s
Manual for this vehicle. See page 103.
Always maintain proper tire pressure as described on the decal
and in the Owner’s Manual. See page 103.

17
SAFETY
Operator Safety
WARNING
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
WARNING
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
CAUTION
Always keep combustible materials away from the exhaust
system. Exposure to the hot components could result in a fire.