Polaris RANGER 500 2017 Service Manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
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Publication Printed January 2021 (PN 9850043 R01)
© Copyright 2021 Polaris 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.
2017-2021 RANGER 500 / 570
Service Manual

Polaris RANGER 500 2017 Specifications

General

Brand	Polaris
Model	RANGER 500 2017
Category	Offroad Vehicle
Language	English

Summary

CHAPTER 1 GENERAL INFORMATION

SPECIAL TOOLS

Tools required for servicing the vehicle.

MASTER SPECIAL TOOLS TABLE

Comprehensive list of special tools with part numbers.

MASTER TORQUE TABLE

Table of torque specifications for various components.

CLUTCHING CHART

Chart providing clutch specifications based on altitude.

GENERAL DIAGNOSTICS

Procedures for diagnosing vehicle concerns and troubleshooting.

CHAPTER 2 MAINTENANCE

PERIODIC MAINTENANCE CHART

Schedule of recommended maintenance tasks and intervals.

ENGINE

Procedures for engine maintenance including oil, compression, and valve clearance.

TRANSMISSION AND GEARCASE

Inspection and adjustment of the shift cable and transmission lubrication.

STEERING

Inspection of steering components and alignment.

BRAKES

Procedures for brake fluid inspection, pad inspection, and disc inspection.

ELECTRICAL AND IGNITION SYSTEM

Maintenance and testing procedures for the battery and starter system.

CHAPTER 3 ENGINE / COOLING SYSTEM

ENGINE LUBRICATION SPECIFICATIONS

Specifications for engine oil capacity, filter wrench, type, and pressure.

OIL PRESSURE TEST

Procedure to test engine oil pressure using a gauge.

ENGINE SPECIFICATIONS

Detailed specifications for camshaft, cylinder head, and cylinder.

ENGINE SERVICE

Information on accessible engine components and service procedures.

ENGINE REMOVAL

Procedure for removing the engine assembly from the vehicle.

ENGINE INSTALLATION

Procedure for reinstalling the engine assembly into the vehicle.

CHAPTER 4 ENGINE ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

ELECTRONIC THROTTLE BODY (ETC)

TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP)

PEDAL POSITION SENSOR (PPS)

CRANKSHAFT POSITION SENSOR (CPS)

Overview, testing, and replacement of the crankshaft position sensor.

ENGINE COOLANT TEMPERATURE SENSOR (ETC)

Overview, testing, and replacement of the engine coolant temperature sensor.

CHAPTER 5 FUEL SYSTEM

FUEL TANK / PUMP / SENDING UNIT

FUEL PUMP TEST

Procedure to test the fuel pump for proper operation and pressure.

FUEL INJECTOR

EFI DIAGNOSIS

Service notes and procedures for diagnosing EFI system failures.

TROUBLE CODE DISPLAY (DTC)

Procedure to display diagnostic trouble codes from the instrument cluster.

FUEL SYSTEM TROUBLESHOOTING

Common fuel system issues like lean mixture, rich mixture, and poor idle.

CHAPTER 6 PVT SYSTEM

PVT SYSTEM OVERVIEW

DRIVE CLUTCH OPERATION

DRIVEN CLUTCH OPERATION

MAINTENANCE / INSPECTION

OVERHEATING / DIAGNOSIS

Troubleshooting steps for PVT system overheating issues.

PVT SYSTEM SERVICE

PVT DISASSEMBLY

PVT ASSEMBLY

DRIVE BELT

PVT SYSTEM TROUBLESHOOTING

Common PVT system issues and their probable causes and remedies.

CHAPTER 7 TRANSMISSION

TRANSMISSION MOUNTING AND TORQUE VALUES

SHIFT CABLE

TRANSMISSION SERVICE

TRANSMISSION INTERNALS SERVICE

Information on differential operation and internal transmission service.

CHAPTER 8 FINAL DRIVE

FRONT HUB / BEARING

FRONT DRIVE SHAFT

FRONT GEARCASE

FRONT GEARCASE (ADC)

Exploded view, operation, disassembly, and reassembly of the front gearcase (ADC).

REAR BEARING CARRIER

REAR DRIVE SHAFT

DRIVE SHAFT SERVICE

Handling tips for drive shafts and CV joints, and boot replacement.

CHAPTER 9 STEERING / SUSPENSION

SHOCK ANALYSIS

STEERING ASSEMBLY

STEERING SHAFT BEARING REPLACEMENT

STEERING SHAFT / STEERING RACK REMOVAL (NON-EPS MODELS)

STEERING WHEEL / UPPER STEERING SHAFT REMOVAL (EPS)

POWER STEERING UNIT REMOVAL

Procedure for removing the power steering unit.

POWER STEERING UNIT INSTALLATION

Procedure for installing the power steering unit.

STEERING RACK REMOVAL / INSTALLATION (EPS)

Procedures for removing and installing the steering rack on EPS models.

FRONT STRUT

BALL JOINT REPLACEMENT

REAR A-ARMS

SHOCKS / SPRINGS

CHAPTER 10 BRAKE SYSTEM

BRAKE SERVICE SPECIFICATIONS

BRAKE NOISE TROUBLESHOOTING

Common causes and remedies for brake noise.

HYDRAULIC BRAKE SYSTEM OPERATION

MASTER CYLINDER

BRAKE SERVICE PROCEDURES

Procedures for brake bleeding, fluid change, and burnishing.

FRONT BRAKE PADS

FRONT CALIPER

FRONT BRAKE DISC

REAR BRAKE PADS

REAR CALIPERS

REAR BRAKE DISC

TROUBLESHOOTING

Troubleshooting common brake system issues.

CHAPTER 11 BODY / FRAME

BOX REMOVAL

BOX INSTALLATION

BODY COMPONENT REMOVAL

CHAPTER 12 ELECTRICAL

BATTERY SERVICE

STARTER SYSTEM

Troubleshooting and testing procedures for the starter system.

CHARGING SYSTEM

Procedures for testing charging system current draw and output.

DIAGNOSTIC MODE

Procedure to access and display diagnostic trouble codes.

INSTRUMENT CLUSTER

HEADLIGHTS

COOLING SYSTEM

Operation and testing procedures for the fan control circuit.

IGNITION COIL