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Polaris RANGER 500 2019 Service Manual

Polaris RANGER 500 2019
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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 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

Table of Contents

Other manuals for Polaris RANGER 500 2019

Questions and Answers:

Polaris RANGER 500 2019 Specifications

General IconGeneral
BrandPolaris
ModelRANGER 500 2019
CategoryOffroad Vehicle
LanguageEnglish

Summary

CHAPTER 1 GENERAL INFORMATION

GENERAL DIAGNOSTICS

Overview of diagnostic procedures and guided symptom diagnostic flowcharts.

CHAPTER 2 MAINTENANCE

PERIODIC MAINTENANCE CHART

Outlines required maintenance tasks and their intervals (hours, calendar, miles).

FUEL SYSTEM AND AIR INTAKE

Covers inspection and service of fuel lines, pump, filter, vent lines, and air intake.

TRANSMISSION AND GEARCASE

Covers inspection, adjustment, and service of the transmission and shift cable.

BRAKE SYSTEM

Covers inspection and service of brake pads, calipers, and discs.

ELECTRICAL AND IGNITION SYSTEM

Maintenance and service procedures for the battery and related systems.

CHAPTER 3 ENGINE / COOLING SYSTEM

GENERAL ENGINE INFORMATION

Provides basic information, special tools, and lubrication specifications for the engine.

ENGINE SERVICE

Details accessible engine components and procedures for engine removal/installation.

TOP-END SERVICE (ENGINE IN CHASSIS)

Covers servicing of top-end engine components with the engine installed.

ENGINE REMOVAL

Step-by-step instructions for removing the engine assembly from the vehicle.

ENGINE DISASSEMBLY / INSPECTION - TOP END

Detailed instructions for disassembling and inspecting the engine's top end components.

CYLINDER HEAD REMOVAL

Instructions for removing the cylinder head.

PISTON / CONNECTING ROD ASSEMBLY

Procedure for assembling the piston to the connecting rod.

CYLINDER HEAD INSTALLATION - BLACK BOLTS

Instructions for installing the cylinder head using black bolts.

CYLINDER HEAD INSTALLATION - SILVER BOLTS

Instructions for installing the cylinder head using silver bolts.

VALVE CLEARANCE CHECK / ADJUSTMENT

Procedure for checking and adjusting valve clearance.

CAMSHAFT INSTALLATION / TIMING

Steps for installing camshafts and setting engine timing.

CHAPTER 4 ENGINE ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

Overview of the ECU's function, operation, and service requirements.

ECU SERVICE

Guidelines for servicing the ECU, including warranty and replacement procedures.

ECU REPLACEMENT

Step-by-step instructions for ECU replacement, emphasizing data transfer.

ELECTRONIC THROTTLE BODY (ETC)

Overview, testing, replacement, and learn procedure for the ETC.

TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP)

Overview and testing procedure for the T-MAP sensor.

PEDAL POSITION SENSOR (PPS)

Overview, testing, and replacement procedure for the PPS.

CRANKSHAFT POSITION SENSOR

Overview, resistance test, air gap test, and replacement for the CPS.

ENGINE COOLANT TEMPERATURE SENSOR (ETC)

Overview and resistance test for the engine coolant temperature sensor.

CHAPTER 5 FUEL SYSTEM

EFI OPERATION OVERVIEW

Explains how the EFI system manages engine performance and emissions.

INITIAL PRIMING / STARTING PROCEDURE

Procedure for purging air from the injection system before initial start-up.

FUEL PUMP TEST

Procedure for testing the fuel pump operation and system pressure.

FUEL PUMP REPLACEMENT

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

FUEL INJECTOR OVERVIEW

Explains the function and operation of the fuel injector.

FUEL INJECTOR REPLACEMENT

Step-by-step instructions for replacing a fuel injector.

FUEL INJECTOR TROUBLESHOOTING

Common problems and troubleshooting steps for fuel injectors.

EFI DIAGNOSIS

Service notes and general approach to diagnosing EFI system issues.

CHAPTER 6 PVT SYSTEM

PVT SYSTEM OVERVIEW

General information and overview of the PVT system components and operation.

OVERHEATING / DIAGNOSIS

Addresses overheating issues by checking air intake and outlet obstructions.

PVT SYSTEM SERVICE

Covers service procedures for PVT sealing, guards, and duct components.

DRIVE BELT

Information on drive belt removal, inspection, and installation.

DRIVE CLUTCH SERVICE

Detailed assembly view and service procedures for the drive clutch.

CLUTCH DISASSEMBLY / INSPECTION

Steps for disassembling and inspecting the drive clutch components.

PVT SYSTEM TROUBLESHOOTING

Troubleshooting chart for common PVT system issues and their remedies.

CHAPTER 7 TRANSMISSION

TRANSMISSION SERVICE

Covers transmission removal and installation procedures.

TRANSMISSION INSTALLATION

Step-by-step instructions for reinstalling the transmission assembly.

TRANSMISSION INTERNALS SERVICE

Overview of differential operation and internal transmission service.

PLANETARY DIFFERENTIAL DISASSEMBLY

Procedure for disassembling the planetary differential components.

CHAPTER 8 FINAL DRIVE

FRONT DRIVE SHAFT

Covers removal and installation of the front drive shaft.

CHAPTER 9 STEERING / SUSPENSION

POWER STEERING UNIT REMOVAL

Steps for removing the power steering unit.

POWER STEERING UNIT INSTALLATION

Instructions for installing the power steering unit.

STEERING RACK REMOVAL / INSTALLATION (EPS)

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

CHAPTER 10 BRAKE SYSTEM

BRAKE NOISE TROUBLESHOOTING

Identifies common causes of brake noise and their remedies.

MASTER CYLINDER

Covers removal, installation, and related components of the master cylinder.

BRAKE SERVICE PROCEDURES

Covers brake bleeding, fluid change, and burnishing procedures.

CHAPTER 11 BODY / FRAME

CHAPTER 12 ELECTRICAL

GENERAL INFORMATION

General information, special tools, and electrical service notes.

DIAGNOSING SYSTEM FAILURES

Steps to verify AWD switch and hub coil functionality.

TROUBLE CODE DISPLAY (DTC)

Procedure for displaying diagnostic trouble codes on the instrument cluster.

DIAGNOSTIC TROUBLE CODE TABLE

A table listing diagnostic trouble codes, SPN, FMI, and P-codes.

INSTRUMENT CLUSTER

Overview of the instrument cluster and its displayed information.

CHARGING SYSTEM

Procedures for testing current draw, charging system, and alternator.

BATTERY SERVICE

Covers battery terminal maintenance, activation, inspection, and charging.

STARTER SYSTEM

Troubleshooting for starter motor issues and testing procedures.

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