2005-2007 Polaris Ranger 500 4x4 Service Manual
Diagnostic procedures and component service for the Polaris Ranger 500 4x4 (2005-2007). Covers maintenance and repair.
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Sample pages from the 2005-2007 Polaris Ranger 500 4x4 Service Manual manual
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Polaris Models Covered & Key Technical Specifications
Models: POLARIS RANGER 2X4, RANGER 4X4 CARB, RANGER 4X4 EFI
Sub-models / Variants: 2X4, 4X4, CARB, EFI
Build Years: 2005–2007
Serial Numbers: R07RB50AA, R07RH50AA, R07RH50AF, R07RH50AR, R07RH50AT
Technical Data:
- Engine displacement: 499 cc
- Engine type: Single Cylinder, 4-Stroke, SOHC, Liquid Cooled
- Idle speed: 1200 ± 200 RPM
- Transmission type: Polaris Automatic PVT
- Drive system: 2WD / 4WD (4x4 models)
- Dry weight: 1105–1185 lbs (depending on model)
- Cargo box capacity: 850–1000 lbs (depending on model)
- Wheel base: 76 in. (193 cm)
Polaris Manual Features & Content Preview
2005–2007 Polaris Ranger 500 4x4 Technical Coverage
- Covers 2005–2007 Polaris Ranger 500 4x4 and 2x4 variants, including carbureted and EFI models with the EH50PLE engine
- Original OEM publication 9920634 / 9920904, released as the factory source for the 2007 model year build
- Contains 56 exploded-view technical illustrations, 12 electrical schematics, and 18 torque reference tables
- File link appears in your order confirmation straight away
- OCR text layer lets you jump to a torque spec by keyword
- Suitable for printing individual sections for shop-floor use
- This 345-page service manual serves as the primary technical documentation for the RANGER 500 powertrain, chassis, and suspension maintenance.
Component Documentation
This Polaris Ranger 500 4x4 service manual provides detailed instructions for maintaining the liquid-cooled SOHC engine, the automatic PVT transmission, and the independent rear suspension. Chapters are structured by system, documenting the fuel injection and carburetor setups, the front and rear gearcases, steering geometry, and the electrical diagnostic system. The text specifies fluid types, such as AGL Gearcase Lube and Demand Drive Hub Fluid, alongside critical maintenance intervals for daily, 25-hour, 50-hour, and 100-hour service checks.
Specification Previews
Technical specifications are grouped for quick reference to aid with identification and maintenance tasks. The manual provides the cylinder compression limit of 60–90 PSI, valve clearance settings of 0.006 inches, and fuel pressure reference for the Visteon EFI system at 39 PSI. Fastener torque values are included, such as the 14 ft. lbs. requirement for crankcase bolts and 110 ft. lbs. for the rear hub retaining nuts. Reference data includes the 113-inch overall length and 11.5-inch ground clearance, ensuring component compatibility for this model range. Official Polaris Ranger 500 4x4 2005–2007 workshop documentation for owner and shop-level maintenance of the EH50PLE-powered 4x4 chassis.
Note: All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work.
Document Reference: Original OEM publication 9920634 / 9920904
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