Polaris RANGER 500 2018 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,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2017 (PN 9928485 R01)
© 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. 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.
2017-2018 RANGER 500 / 570
Service Manual

Polaris RANGER 500 2018 Specifications

General

Brand	Polaris
Model	RANGER 500 2018
Category	Offroad Vehicle
Language	English

Summary

General Information

Master Torque Table

Table of torque specifications for various fasteners and components.

Maintenance

Periodic Maintenance Chart

Outlines recommended maintenance tasks and intervals for the vehicle.

Break-In Period

Details the procedures for breaking in the new vehicle's engine and drive components.

Engine

Cooling System

Brake System

Covers brake fluid inspection, hose inspection, and pad inspection.

Engine / Cooling System

Engine Service

Covers engine removal, installation, and top-end service procedures.

Engine Assembly - Top End

Step-by-step guide for disassembling and inspecting the engine's top end components.

Engine Assembly - Lower End

Procedures for assembling the engine's lower end components.

Engine Disassembly / Inspection - Lower End

Procedures for disassembling and inspecting the engine's lower end components.

Fuel System

Electronic Control Unit (ECU)

Explains ECU overview, service, replacement, and reprogramming procedures.

Electronic Throttle Body (ETC)

Information on ETC overview, testing, replacement, and learn procedure.

Pedal Position Sensor (PPS)

Fuel Tank / Pump / Sendor

Fuel Pump Replacement

Step-by-step guide for replacing the fuel pump assembly.

Temperature / Manifold Absolute Pressure (T-MAP)

Crankshaft Position Sensor

Covers CPS overview, testing, replacement, and related troubleshooting.

Fuel Injector

Engine Coolant Temperature Sensor (ECT)

EFI Diagnosis

Guidance on diagnosing EFI component issues, focusing on wiring and using Digital Wrench.

Trouble Code Display (DTC)

Procedure for displaying and interpreting diagnostic trouble codes.

PVT System

PVT System Service

Drive Belt

Instructions for drive belt removal, inspection, and installation.

Drive Clutch Service

Covers drive clutch assembly view, disassembly, inspection, and bushing service.

Clutch Disassembly / Inspection

Step-by-step guide for disassembling and inspecting the drive clutch.

PVT System Troubleshooting

Troubleshooting guide for common PVT system issues like overheating and belt slippage.

Transmission

Transmission Service

Details transmission removal and installation procedures.

Transmission Internals Service

Covers differential operation, disassembly, inspection, and assembly.

Final Drive

Front Hub / Bearing

Front Drive Shaft

Front Gearcase

Covers front gearcase removal, installation, and assembly views.

Front Gearcase (ADC)

Exploded view and operation details for the front gearcase with Active Descent Control.

All Wheel Drive Operation

AWD Diagnosis

Troubleshooting guide for AWD system engagement issues.

Rear Drive Shaft

Outer CV Joint / Boot Replacement

Step-by-step guide for replacing the outer CV joint boot.

Inner Plunging Joint / Boot Replacement

Procedures for replacing the inner plunging joint and boot.

Propshaft U-Joint Service

Brake System

Master Cylinder

Brake Service Procedures

Details brake bleeding, fluid change, and burnishing procedures.

Front Brake Pads

Covers front brake pad removal, inspection, and assembly/installation.

Front Caliper

Details front caliper assembly view, disassembly, inspection, and assembly.

Front Caliper Installation

Step-by-step instructions for installing the front caliper.

Front Brake Disc

Rear Brake Pads

Covers rear brake pad removal, inspection, and installation procedures.

Rear Calipers

Details rear caliper assembly view, removal, disassembly, inspection, and assembly.

Rear Caliper Installation

Instructions for installing the rear caliper.

Rear Brake Disc

Troubleshooting

Troubleshooting guide for common brake system issues like squeal, drag, and locking.

Electrical

Differential Solenoid

All Wheel Drive (AWD) Coil

Vehicle Speed Sensor

Instrument Cluster

Overview of the instrument cluster, rider information display, and diagnostic mode.

Ignition Coil

Charging System

Procedures for testing charging system components like current draw and alternator output.

Battery Service

Covers battery terminal maintenance, activation, inspection, and removal/installation.

Starter System

Troubleshooting common starter motor issues and bench testing procedures.