Polaris RANGER 500 2021

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
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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 2021 Specifications

General

Brand	Polaris
Model	RANGER 500 2021
Category	Offroad Vehicle
Language	English

Summary

CHAPTER 1 GENERAL INFORMATION

MASTER TORQUE TABLE

Comprehensive list of torque specifications for various fasteners.

GENERAL DIAGNOSTICS

Procedures for diagnosing common vehicle issues.

CHAPTER 2 MAINTENANCE

PERIODIC MAINTENANCE CHART

Schedule for routine vehicle maintenance tasks.

BREAK-IN PERIOD

Guidelines for initial vehicle operation and care.

ENGINE

Procedures for engine maintenance and checks.

FUEL SYSTEM AND AIR INTAKE

Maintenance for fuel delivery and air intake components.

TRANSMISSION AND GEARCASE

Maintenance procedures for the transmission and gearcase.

FINAL DRIVE WHEEL TIRE

Maintenance for final drive, wheels, and tires.

STEERING

Maintenance procedures for the steering system.

SUSPENSION

Maintenance procedures for the suspension system.

BRAKE SYSTEM

Maintenance procedures for the brake system.

ELECTRICAL AND IGNITION SYSTEM

Maintenance for electrical and ignition components.

CHAPTER 3 ENGINE COOLING SYSTEM

GENERAL ENGINE INFORMATION

General details and specifications for the engine.

ENGINE SERVICE

Procedures for servicing engine components.

TROUBLESHOOTING

Common engine and cooling system problems and solutions.

CHAPTER 4 ENGINE ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

Overview and service information for the ECU.

ELECTRONIC THROTTLE BODY (ETC)

Overview, testing, and replacement of the ETC.

TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (T-MAP)

Overview and service for the T-MAP sensor.

PEDAL POSITION SENSOR (PPS)

Overview, testing, and replacement of the PPS.

CRANKSHAFT POSITION SENSOR

Overview, testing, and replacement of the CPS.

ENGINE COOLANT TEMPERATURE SENSOR (ETC)

Overview, testing, and replacement of the ECT sensor.

CHAPTER 5 FUEL SYSTEM

EFI OPERATION OVERVIEW

How the EFI system operates.

PRINCIPAL COMPONENTS

Key parts of the EFI system.

EFI COMPONENT LOCATIONS

Visual guide to EFI component placement.

FUEL TANK PUMP SENDING UNIT

Service procedures for the fuel tank assembly.

FUEL INJECTOR

Overview and testing of fuel injectors.

EFI DIAGNOSIS

Notes and procedures for diagnosing EFI issues.

FUEL SYSTEM TROUBLESHOOTING

Common fuel system problems and their causes/solutions.

CHAPTER 6 PVT SYSTEM

PVT SYSTEM OVERVIEW

Explanation of PVT operation and components.

PVT SYSTEM SERVICE

Procedures for servicing PVT components.

DRIVE BELT

Inspection and service of the drive belt.

CLUTCH ALIGNMENT OFFSET CENTER DISTANCE

Procedures for aligning clutches.

DRIVE CLUTCH SERVICE

Disassembly and inspection of the drive clutch.

DRIVEN CLUTCH SERVICE

SECONDARY CLUTCH ADJUSTMENT

PVT SYSTEM TROUBLESHOOTING

Common PVT issues and their solutions.

CHAPTER 7 TRANSMISSION

SPECIAL TOOLS, TRANSMISSION

LUBRICATION

TRANSMISSION MOUNTING AND TORQUE VALUES

ASSEMBLY VIEW

SHIFT LEVER

SHIFT CABLE

TRANSMISSION SERVICE

TRANSMISSION INTERNALS SERVICE

PLANETARY DIFFERENTIAL DISASSEMBLY

GEAR SHAFT BEARING INSPECTION

CHAPTER 8 FINAL DRIVE

FRONT HUB BEARING

FRONT DRIVE SHAFT

FRONT GEARCASE

FRONT GEARCASE (NON-ADC)

ALL WHEEL DRIVE OPERATION

Explanation of how the AWD system works.

AWD DIAGNOSIS

Troubleshooting procedures for AWD system issues.

FRONT GEARCASE DISASSEMBLY INSPECTION

REAR BEARING CARRIER

REAR DRIVE SHAFT

DRIVE SHAFT SERVICE

OUTER CV JOINT BOOT REPLACEMENT

INNER PLUNGING JOINT BOOT REPLACEMENT

DRIVE SHAFT ASSEMBLY VIEW

CHAPTER 9 STEERING SUSPENSION

SHOCK ANALYSIS

STEERING ASSEMBLY

STEERING ASSEMBLY VIEW (NON-EPS)

STEERING ASSEMBLY VIEW (EPS)

STEERING WHEEL REMOVAL (NON-EPS MODELS)

STEERING SHAFT BEARING REPLACEMENT

STEERING SHAFT STEERING RACK REMOVAL (NON-EPS MODELS)

STEERING WHEEL UPPER STEERING SHAFT REMOVAL (EPS)

POWER STEERING UNIT REMOVAL

Removing the power steering unit.

POWER STEERING UNIT INSTALLATION

Installing the power steering unit.

STEERING RACK REMOVAL INSTALLATION (EPS)

Procedures for EPS steering rack.

FRONT STRUT

FRONT STRUT CARTRIDGE REPLACEMENT

BALL JOINT REPLACEMENT

REAR A-ARMS

SHOCKS SPRINGS

CHAPTER 10 BRAKE SYSTEM

BRAKE SERVICE SPECIFICATIONS

Critical specifications for brake service.

BRAKE SYSTEM NOTES

BRAKE NOISE TROUBLESHOOTING

HYDRAULIC BRAKE SYSTEM OPERATION

BRAKE SYSTEM ASSEMBLY VIEWS

MASTER CYLINDER

BRAKE SERVICE PROCEDURES

FRONT BRAKE PADS

FRONT CALIPER

FRONT CALIPER REMOVAL- RANGER

FRONT CALIPER DISASSEMBLY - RANGER

FRONT CALIPER INSPECTION- RANGER

FRONT CALIPER ASSEMBLY

FRONT CALIPER INSTALLATION - RANGER

CREW

FRONT CALIPER ASSEMBLY VIEW

FRONT CALIPER REMOVAL- CREW

FRONT BRAKE DISC

REAR BRAKE PADS

REAR CALIPERS

REAR CALIPER ASSEMBLY VIEW

REAR CALIPER REMOVAL

REAR CALIPER INSPECTION

REAR CALIPER ASSEMBLY

REAR CALIPER INSTALLATION

REAR BRAKE DISC

TROUBLESHOOTING

Common brake system problems.

CHAPTER 11 BODY FRAME

TORQUE SPECIFICATIONS

CHASSIS BODY ASSEMBLY VIEWS

FRAME ASSEMBLY VIEW

CREW FRAME ASSEMBLY VIEW

DASH INSTRUMENTS CONTROLS

HOOD DASH FRONT FASCIA

FLOOR REAR FENDERS

SEAT MOUNTING SEAT BELTS

CREW SEAT MOUNTING SEAT BELTS

REAR CARGO BOX

BOX REMOVAL

BOX INSTALLATION

BODY COMPONENT REMOVAL

CHAPTER 12 ELECTRICAL

GENERAL INFORMATION

Overview of the electrical system.

SPECIAL TOOLS

Tools for electrical system service.

ELECTRICAL SERVICE NOTES

COMPONENTS UNDER HOOD

SWITCHES CONTROLS

IGNITION HEADLIGHT SWITCH

AWD 2 WD TURF SWITCH

DIFFERENTIAL SOLENOID

ALL WHEEL DRIVE (AWD) COIL

DIAGNOSING SYSTEM FAILURES

VEHICLE SPEED SENSOR

INSTRUMENT CLUSTER

RIDER INFORMATION DISPLAY

HEADLIGHTS

TAIL LIGHT BRAKE LIGHT

COOLING SYSTEM

Fan control circuit operation and testing.

IGNITION COIL

RELAYS

FUSES CIRCUIT BREAKER

CHARGING SYSTEM

BATTERY SERVICE

STARTER SYSTEM