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Polaris RANGER 500 2020 - Service Manual

Polaris RANGER 500 2020
574 pages
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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

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Polaris RANGER 500 2020 Specifications

General IconGeneral
BrandPolaris
ModelRANGER 500 2020
CategoryOffroad Vehicle
LanguageEnglish

Summary

CHAPTER 1 GENERAL INFORMATION

GENERAL DIAGNOSTICS

Information on diagnostic procedures, symptom troubleshooting, and common engine issues like no-start and overheating.

CHAPTER 2 MAINTENANCE

ENGINE

Details maintenance procedures for the engine, including compression tests, oil changes, valve clearance, and breather system checks.

CHAPTER 3 ENGINE; COOLING SYSTEM

ENGINE SERVICE

Details engine removal, installation, break-in period, and accessible engine components for service.

COOLING SYSTEM

Provides information on cooling system overview, specifications, pressure tests, radiator service, thermostat replacement, and bleeding.

ENGINE; COOLING SYSTEM TROUBLESHOOTING

Troubleshooting guides for engine issues like spark plug fouling, low power, excessive smoke, and cooling system overheating.

CHAPTER 4 ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

Overview of the ECU, RPM limit function, service procedures, and replacement guidelines.

ELECTRONIC THROTTLE BODY (ETC)

Details ETC overview, testing, replacement, and the necessary learn procedure after component changes.

CRANKSHAFT POSITION SENSOR

CPS TEST

Provides instructions for testing the CPS sensor's resistance, wiring, and air gap for proper functionality.

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

CHAPTER 5 FUEL SYSTEM

PRINCIPAL COMPONENTS

Lists and describes the main components of the EFI system, including fuel pump, rail, lines, filter, injectors, and sensors.

CHAPTER 6 PVT SYSTEM

PVT SYSTEM OVERVIEW

Explains the PVT system's function, components (drive clutch, driven clutch, belt), and general operation.

PVT SYSTEM SERVICE

Covers PVT sealing, guard, and duct components, along with disassembly and assembly procedures for the system.

PVT SYSTEM TROUBLESHOOTING

Guides for diagnosing and resolving common PVT system issues like overheating, belt slippage, and engagement problems.

CHAPTER 7 TRANSMISSION

CHAPTER 8 FINAL DRIVE

FRONT DRIVE SHAFT

Steps for removing and installing the front drive shaft, including handling tips for CV joints and boots.

FRONT GEARCASE

Details on front gearcase removal, installation, assembly views, and AWD operation for both ADC and non-ADC models.

CHAPTER 9 STEERING; SUSPENSION

STEERING ASSEMBLY

Details on steering assembly views (non-EPS and EPS), steering wheel removal, shaft bearing replacement, and rack removal/installation.

CHAPTER 10 BRAKE SYSTEM

BRAKE SERVICE SPECIFICATIONS

Provides standard and service limit specifications for front and rear brake pads, discs, and runout.

BRAKE NOISE TROUBLESHOOTING

Identifies common causes of brake noise and provides remedies for issues like dirt, dust, or improper pad adjustment.

CALIPER OVERHEATS (BRAKES DRAG)

Lists potential causes for caliper overheating and brake drag, such as plugged ports or incorrect adjustments.

CHAPTER 11 BODY; FRAME

CHASSIS; BODY ASSEMBLY VIEWS

Exploded views of the frame assembly for standard and crew models, detailing components and fasteners.

CHAPTER 12 ELECTRICAL

SWITCHES; CONTROLS

Details on ignition/headlight switch, AWD/2WD/TURF switch, differential solenoid, and brake pressure switch operation and testing.

INSTRUMENT CLUSTER

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

SPECIAL TOOLS

SWITCHES; CONTROLS

DIFFERENTIAL SOLENOID

DIFFERENTIAL SOLENOID

Overview of the differential solenoid's location and function in actuating the rear differential engagement dog.

ALL WHEEL DRIVE (AWD) COIL

DIAGNOSING SYSTEM FAILURES

Steps to verify AWD switch functionality, hub coil voltage, and coil resistance for diagnosing system failures.

VEHICLE SPEED SENSOR

SPEED SENSOR TESTING

Procedure for testing the speed sensor using a static timing light harness and hall sensor probe harness.

INSTRUMENT CLUSTER

DIAGNOSTIC MODE

DIAGNOSTIC MODE

Details how to access the diagnostic mode, display trouble codes, and interpret the FMI, SPN, and P-CODE.

COOLING SYSTEM

FAN CONTROL CIRCUIT OPERATION

Explains how the cooling fan operates via the relay, ECM, and temperature sensor, and the importance of proper coolant level.

FAN CONTROL CIRCUIT BYPASS TEST

Procedure to test the fan control circuit by disconnecting the ECT sensor and checking for fan operation.

IGNITION COIL

IGNITION COIL; WIRE TEST

Provides a table and illustrations for testing the ignition coil's primary and secondary resistance using a digital multimeter.

RELAYS

FUSES; CIRCUIT BREAKER

CHARGING SYSTEM

CURRENT DRAW - KEY OFF

Procedure for testing parasitic draw with the key off, identifying causes like accessory wiring and electronic component failures.

CHARGING SYSTEM “BREAK EVEN” TEST

Steps for performing a break-even test to determine the point at which the alternator overcomes system loads and charges the battery.

CHARGING SYSTEM ALTERNATOR TESTS

TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM

TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM

Procedure to measure AC voltage output of stator legs at specified RPMs using a multimeter.

CHARGING SYSTEM TESTING FLOW CHART

CHARGING SYSTEM TESTING FLOW CHART

A flowchart to guide the diagnosis of charging system problems, starting with system checks and progressing through meter tests.

BATTERY SERVICE

BATTERY ACTIVATION

Step-by-step guide for activating a new battery, including filling with electrolyte and allowing for absorption.

LOAD TEST

CHARGING PROCEDURE

STARTER SYSTEM

STARTER SOLENOID BENCH TEST

STARTING SYSTEM TESTING FLOW CHART

STARTING SYSTEM TESTING FLOW CHART

A flowchart to diagnose starting system issues, guiding through checks for battery, ECU communication, voltage drop, and solenoid tests.

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