Polaris RANGER 500 Owner's Manual
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Polaris RANGER 500 Owner's Manual

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2019
OWNER'S MANUAL
RANGER® 500
RANGER® 570
RANGER® 570 EPS
RANGER CREW® 570
RANGER CREW® 570 EPS

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Summary of Contents for Polaris RANGER 500

  • Page 1 2019 OWNER’S MANUAL RANGER® 500 RANGER® 570 RANGER® 570 EPS RANGER CREW® 570 RANGER CREW® 570 EPS...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 2019 Owner’s Manual RANGER® 500 RANGER® 570 RANGER® 570 EPS RANGER CREW® 570 RANGER CREW® 570 EPS...
  • Page 4 POLARIS® and RANGER® are trademarks of POLARIS Industries Inc. Copyright 2018 Polaris Industries 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.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 WELCOME...

  • Page 7: Table Of Contents

    Specifications ....125 POLARIS Products ....129 Troubleshooting ....131 Warranty .

  • Page 9: Introduction

    INTRODUCTION INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used.
  • Page 10 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 11 Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
  • Page 12 INTRODUCTION EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

  • Page 13: Safety

    SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course.
  • Page 14 SAFETY SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over- the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.
  • Page 15 HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Parents should verify that the young operator has a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.
  • Page 16 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Seat Belt / Driver Warning...
  • Page 17 SAFETY SHIFT CAUTION CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position. SEAT BELT/DRIVE RESPONSIBLY WARNING WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared...
  • Page 18 SAFETY PROPER USE WARNING WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license. • Do not let people drive after using alcohol or drugs. •...
  • Page 19 SAFETY PASSENGER/TIRE PRESSURE WARNING WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. •...
  • Page 20 • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
  • Page 21 • Never modify this vehicle through improper installation or use of non- POLARIS approved accessories. • Always re-install plastics and heat shields after vehicle is serviced. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached.
  • Page 22 SAFETY INTERNATIONAL VEHICLE SAFETY LABELS GENERAL ALERT (7183794) • Read the owner’s manual. • Never allow anyone under 16 years of age to operate this vehicle. • Never use alcohol or drugs before or while driving or riding. • Do not allow operation on public roads (unless designated for off- highway vehicle access).
  • Page 23 SAFETY PASSENGER / TIRE PRESSURE WARNING WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. • Read the Owner’s Manual. • Never carry fuel on this vehicle. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
  • Page 24 SAFETY CLUTCH COVER ALERT (7181427) Keep body parts away from belt. HITCH CAPACITY ALERT (7183975) Read the owner’s manual. TRAILER MAXIMUM WEIGHT: 1700 N ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT: 1100 N...
  • Page 25 SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.
  • Page 26 SAFETY FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 27 CARRYING A PASSENGER This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components.
  • Page 28 SAFETY IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
  • Page 29 SAFETY IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. DESCENDING HILLS IMPROPERLY Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner’s manual.
  • Page 30 SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
  • Page 31 SAFETY OPERATING A DAMAGED VEHICLE Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems.
  • Page 32 EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 33: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS ROPS Frame Cargo Box Hip Bars Fuel Cap Front Bumper/Brush Guard Muffler Headlights Cargo Box Release Lever Radiator Storage Compartment (if Equipped) Tailgate Electric Compartment (if equipped)
  • Page 34 FEATURES AND CONTROLS CONSOLE Cup Holder 12V Auxiliary Outlet Instrument Cluster Steering Wheel Adjustment Lever MODE Button Ignition/Light Switch Gear Selector (Shifter) Storage Tray AWD Switch Storage Compartment AUXILIARY OUTLET The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights.
  • Page 35 FEATURES AND CONTROLS SWITCHES IGNITION SWITCH/LIGHT SWITCH The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Lights On Lights are on.
  • Page 36 FEATURES AND CONTROLS STANDARD TURF SWITCH (IF EQUIPPED) The standard Turf switch has two positions: • Differential Unlock (1WD/Turf Mode) • Differential Lock/Two Wheel Drive (2WD) GEAR SELECTOR To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.
  • Page 37 PARK. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.
  • Page 38 FEATURES AND CONTROLS STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.
  • Page 39 EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist. FOOT PEDALS BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle.
  • Page 40 FEATURES AND CONTROLS THROTTLE PEDAL Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. This vehicle is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle.
  • Page 41 FEATURES AND CONTROLS SEAT SEAT REMOVAL Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
  • Page 42 Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Your POLARIS dealer can assist.
  • Page 43 FEATURES AND CONTROLS SECURING THE NET 1. After entering the vehicle, insert the lower net rod into the net mount on the floor. Make sure the ball at the end of the rod is properly secured in the slot at the base of the mount.
  • Page 44 If your factory-installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, you may need to purchase a 30 AH battery and a battery strap bracket. Your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.
  • Page 45 FEATURES AND CONTROLS INSTRUMENT CLUSTER Speedometer Indicator Lamps Mode Button Rider Information Center...
  • Page 46 FEATURES AND CONTROLS INDICATOR LAMPS LAMP INDICATES CONDITION Vehicle Speed When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. This lamp illuminates to indicate an overheated Over Temperature engine.
  • Page 47 FEATURES AND CONTROLS RIDER INFORMATION CENTER The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer.
  • Page 48 FEATURES AND CONTROLS MODE BUTTON The yellow button located near the instrument cluster is used to toggle through mode options available. DISPLAY UNITS The display can be changed to display either standard or metric units of measurement. To exit the set-up mode at any time, wait 10 seconds. The display automatically exits and returns to the odometer display.
  • Page 49 FEATURES AND CONTROLS 3. With the segment flashing, tap the MODE button to advance to the desired setting. 4. Press and hold the MODE button until the next segment flashes. Release the button. 5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.
  • Page 50 3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. Your authorized POLARIS dealer can provide code details and diagnosis.

  • Page 51: Operation

    OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
  • Page 52 Ensure proper level page 96 Coolant hoses Inspect for leaks Throttle Ensure proper operation page 38 Indicator lights/switches Ensure proper operation page 33 page 44 Intake pre-filters Inspect, clean Headlamps Check operation, apply POLARIS dielectric page 112 grease when lamp is replaced...
  • Page 53 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).
  • Page 54 Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
  • Page 55 OPERATION 6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 5 and 6 until the engine starts. 7. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.
  • Page 56 OPERATION 5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 6. Remove the ignition key to prevent unauthorized use.
  • Page 57 OPERATION DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA.
  • Page 58 OPERATION • Never turn while applying heavy throttle. • Never make abrupt steering maneuvers. • Operate at speeds appropriate for your skills, the conditions and the terrain. • DO NOT do power slides, “donuts”, jumps or other driving stunts. DRIVING WITH A PASSENGER 1.
  • Page 59 OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 60 OPERATION 5. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly. 6. Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover. DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1.
  • Page 61 OPERATION 3. Avoid crossing the side of a steep hill. 4. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill. DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards.
  • Page 62 OPERATION 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. PARKING THE VEHICLE To park the vehicle, do the following: 1. Apply the brakes. Stop the vehicle on a level surface. 2.
  • Page 63 OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 64 OPERATION Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual.
  • Page 65 OPERATION TOWING LOADS WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2.
  • Page 66 OPERATION 7. Release the tailgate latches. WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.
  • Page 67 OPERATION ALL WHEEL DRIVE (AWD) SYSTEM The standard All Wheel Drive system is controlled by the AWD switch. When the switch is in the 2X4 position , the vehicle is in two-wheel drive at all times. When the switch is in the AWD position , the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.
  • Page 68 OPERATION ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential. ENGAGING AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD.
  • Page 69 OPERATION 2. Operate in reverse for at least 10 feet (3 m). 3. Stop completely. 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these instructions, see your dealer or other qualified service person for service. LOCKING THE DIFFERENTIAL Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD).
  • Page 70 OPERATION ALL WHEEL DRIVE/ACTIVE DESCENT CONTROL SYSTEM ADC models are equipped with a drive mode switch that controls the AWD system. The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge. DRIVE MODE OPERATION Use the drive mode switch to engage AWD (4X4), ADC 4X4, TURF mode or 2X4.
  • Page 71 OPERATION DRIVE MODE INDICATOR The Drive Mode Indicator displays the active drive mode. The Drive Mode Indicator will match the information displayed in the Rider Information Center. An amber light flashes when drive mode selection is pending. Once in the selected drive mode, a solid amber light will show next to the active drive mode.

  • Page 73: Winch Guide

    WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 74 WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.
  • Page 75 WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 76 Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 77 WINCH GUIDE • If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly®...
  • Page 78 WINCH GUIDE 10. Never use straps, chains or other rigging items that are damaged or worn. 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock”...
  • Page 79 Doing this reduces the chances of the winch cable “wedging” itself between lower layers of winch cable. WINCH CABLE CARE For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 80 WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 81 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 83: Emission Control Systems

    EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.

  • Page 85: Maintenance

    Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
  • Page 86 MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized dealer or other qualified person perform these services. Emission Control System Service (California) WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death.
  • Page 87 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES CLNDR (KM) Battery Monthly Check terminals; clean; test 20 H Inspect; Cycle the Key to pressurize the fuel pump; Fuel System Monthly 25 H check lines and fittings for leaks and abrasion. Perform a break-in oil level Monthly Front Gearcase oil...
  • Page 88 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES CLNDR (KM) Inspect; clean external Radiator 100 H 12 M surfaces Inspect for leaks; clean Cooling Hoses 100 H 12 M external surfaces Engine mounts Inspect 100 H 12 M Exhaust muffler Inspect 100 H 12 M...
  • Page 89 POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 90 MAINTENANCE OIL CHECK The oil dipstick and fill tube is located on the engine. Access the dipstick through the right rear wheel well. To check the oil, do the following: 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
  • Page 91 MAINTENANCE OIL AND FILTER CHANGE Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. The engine drain plug is located on the bottom of the crankcase. To change the oil and filter , do the following: 1.
  • Page 92 MAINTENANCE 7. Reinstall the drain plug. Torque to 12 ft. lbs. (16 Nm). 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed.
  • Page 93 MAINTENANCE GEARCASES TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. OIL CHECK The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.
  • Page 94 MAINTENANCE FRONT GEARCASE (DEMAND DRIVE) Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications.
  • Page 95 MAINTENANCE 9. Check for leaks. 10. Discard used oil properly. GEARCASE SPECIFICATION CHART DRAIN PLUG/ FILL PLUG LEVEL GEARCASE LUBRICANT CAPACITY TORQUE CHECK PLUG TORQUE AGL Gearcase Transmission 41 oz. 10-14 ft. lbs. 10-14 ft. lbs. Lubricant & (Main (1200 ml) (14-19 Nm) (14-19 Nm) Transmission...
  • Page 96 Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. SPARK PLUG GAP/TORQUE MODEL ELECTRODE GAP...
  • Page 97 MAINTENANCE NORMAL PLUG The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white.
  • Page 98 ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
  • Page 99 MAINTENANCE RADIATOR COOLANT LEVEL Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan.
  • Page 100 MAINTENANCE 5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part. OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart.
  • Page 101 • See your dealer or other qualified service person as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 102 MAINTENANCE BELT REPLACEMENT / DEBRIS REMOVAL If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt. WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
  • Page 103 15. Install all clutch cover screws. Torque to 4-5 ft. lbs. (5.5-6.5 Nm). POLARIS VARIABLE TRANSMISSION (PVT) SYSTEM PVT DRYING There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating: 1.
  • Page 104 6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist. VEHICLE IMMERSION...
  • Page 105 NOTICE Use of a non-POLARIS-approved air filter may cause engine damage. Always use a POLARIS-approved replacement filter. See page 92 for the part numbers of POLARIS products. 7. Make sure the filter is fully seated on the intake boot and that there is no gap between the filter and boot after installation.
  • Page 106 MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrestor. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
  • Page 107 MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING After opening a bottle of brake fluid, always discard any unused portion.
  • Page 108 MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.
  • Page 109 MAINTENANCE SUSPENSION ADJUSTMENT Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension. Always heed the following rules if you make adjustments to this suspension. • Always return the suspension to the lowest (softest) setting after the load is removed from the vehicle.
  • Page 110 MAINTENANCE POWER STEERING UNIT If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly.
  • Page 111 Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS approved size and type of tires for this vehicle when replacing tires.
  • Page 112 MAINTENANCE TIRE TREAD DEPTH Always replace tires when tread depth is worn to 1/8” (3 mm) or less. WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4.
  • Page 113 MAINTENANCE FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The fuse box is located in the electrical compartment under the left rearmost seat.
  • Page 114 MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.
  • Page 115 MAINTENANCE HEADLIGHT BEAM ADJUSTMENT To adjust the headlight beam, do the following: 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 116 MAINTENANCE BATTERY WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 117 MAINTENANCE BATTERY REMOVAL WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. To remove the battery, do the following: 1.
  • Page 118 See the Battery Charging (Sealed Battery) section for details. Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge.
  • Page 119 MAINTENANCE BATTERY CHARGING (SEALED BATTERY) The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 120 MAINTENANCE STATE OF VOLTAGE ACTION CHARGE TIME* CHARGE *(USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY) 50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify state of charge 0%-25% 11.5 volts or less Needs charge with...
  • Page 121 Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.
  • Page 122 POLARIS at no charge. POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 123 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 124 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.
  • Page 125 MAINTENANCE 4. Check all the points listed in the Daily Pre-Ride Inspection. Tightness of the bolts, nuts and other fasteners should be checked by an authorized dealer or other qualified service facility. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.

  • Page 127: Specifications

    SPECIFICATIONS SPECIFICATIONS RANGER® 500 Maximum Weight Capacity (includes 1000 lbs. (454 kg) weight of operator, passenger, cargo, accessories) Dry Weight 1080 lbs. (490 kg) Test GVW - Rollover Protection System 2750 lbs. (1247 kg) per OSHA 29 CFR (ROPS) 1928.53 Fuel Capacity 8.8 gal.
  • Page 128 SPECIFICATIONS RANGER® 500 Ignition Timing ECU Controlled Spark Plug Autolite 5924 / 0.030” - 0.037” (0.85 +/- 0.08 mm) Lubrication System Wet Sump Cooling Liquid Front Suspension McPherson Strut w/9 in. (22.7 cm) of travel Rear Suspension Dual A-arm, Anti-Sway Bar w/10 in. (25.4 cm) of travel Throttle Body Size 40 mm...
  • Page 129 SPECIFICATIONS RANGER 570/570 EPS RANGER CREW 570/570 Maximum Weight Capacity 1000 lbs. (454 kg) 1250 lbs. (567 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1075 lbs. (488 kg) (570) 1323 lbs. (600 kg) (570) 1100 lbs. (499 kg) (570 1352 lbs.
  • Page 130 SPECIFICATIONS RANGER 570/570 EPS RANGER CREW 570/570 Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled 32° +/- 2° @ 5000 RPM Spark Plug NGK MR7F / .031” (0.7-0.9 mm) Lubrication System Wet Sump Cooling Liquid Front Suspension McPherson Strut w/8 in.

  • Page 131: Polaris Products

    Dielectric Grease (Nyogel™) — 2871329 12 oz bottle (12) Carbon Clean 2871326 16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) 2872280 DOT 4 Brake Fluid — 2872189 Loctite™ 565 Thread Sealant — 2871956 POLARIS Battery Tender™ — 2859044 Charger...

  • Page 133: Troubleshooting

    Your dealer can assist. Check for fouled plug or foreign material in gas tank or fuel lines. Poor engine performance Your POLARIS dealer can assist. Slippage from failure to warm Always warm up the belt by operating below 30 mph for one mile up belt (5 miles or more when temperature is below freezing).
  • Page 134 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE...
  • Page 135 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Mechanical failure Your dealer can assist Loose ignition Check all connections and tighten connections Water present in fuel Replace with fresh recommended fuel ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or Set gap to specs or replace plug...
  • Page 136 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plug heat range Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC...

  • Page 137: Warranty

    This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 138 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 139 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 140 IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 141 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
  • Page 142 U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 143 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...
  • Page 144 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

  • Page 145: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 147 Clean the Exterior ....121 Clock Mode ......46 Active Descent Control ....69 Clothing........13 Adding or Changing Coolant ..96 Clutch Cover Alert (7181427) ..22 Age Restrictions ......23 Cold Weather Operation....52 Air Filter......... 103 Component Locations....31 Air Filter / Air Box.....
  • Page 148 European Vibration and Noise ..10 Exhaust Emission Control Ignition Switch ......33 System ........81 Improper Cargo Loading ..... 30 Exported Products ....139 Improper Tire Maintenance ..26 Exposure to Exhaust ....29 Indicator Lamps ......44 Extreme Use 30 AH Battery ..42 Inspect and Lubricate ....
  • Page 149 Spark Arrester ......104 Periodic Maintenance Chart ..83 Spark Plug Gap/Torque....94 Plugs, Spark......94 Spark Plug Inspection....94 Polaris Products ...... 129 Spark Plug Recommendations ..94 POLARIS Variable Specifications ....125, 127 Transmission (PVT) System Stabilize the Fuel ..... 121 PVT Drying ......
  • Page 150 Transporting the Vehicle.... 123 Trip Meter Mode ......47 Turning Improperly..... 26 Unauthorized Use of the Vehicle ... 30 Vehicle Identification Numbers ..9 Vehicle Immersion ....102 Warning Symbols ......7 Washing the Vehicle....119 Wet Fouled Plug......95 Wheel Installation .....110 Wheel Removal......110 Winch Cable Care .....
  • Page 152 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9928852 Rev 01 Printed in USA...

This manual is also suitable for:

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