Polaris Ranger 500 700 RZR 170 XP HD Diesel 4x4 6x6 Crew 2007-2014 Workshop Repair Manual PDF - MPLRRANGER.zip
This complete service and repair guide covers the Polaris Ranger ATV, featuring Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, fix, and rebuild the machine just like an expert technician would.
Inside the Polaris Ranger ATV workshop service and repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,910 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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TABLE OF CONTENTS
Polaris '07 Ranger 700 4X4, 6X6, Ranger XP 700 4X4, 6X6 Service Repair Manual....1
RANGER XP 700 EFI 4X4 / 6X6 SERVICE MANUAL....2
GENERAL INFORMATION....3
MODEL INFORMATION....4
Model Identification....4
Engine Designation Number....4
VIN Identification....4
Engine Serial Number Location....4
Unit Serial Number (VIN) Location....5
Transmission I.D. Number Location....5
VEHICLE DIMENSIONS....6
RANGER 4X4, 6X6....6
Vehicle Dimensions RANGER 4X4, 6X6....7
GENERAL SPECIFICATIONS....8
MODEL: 2007 RANGER XP 4X4....8
MODEL: 2007 RANGER XP 6X6....8
MODEL: 2007 RANGER XP 4X4....9
MODEL: 2007 RANGER XP 6X6....10
VEHICLE INFORMATION....11
Publication Numbers....11
Paint Codes....11
Replacement Keys....11
SPECIAL TOOLS....11
MISC. SPECIFICATIONS AND CHARTS....12
Conversion Table....12
Standard Torque Specifications....13
SAE Tap / Drill Sizes....14
Metric Tap / Drill Sizes....14
Decimal Equivalents....14
Glossary of Terms....15
MAINTENANCE....16
PERIODIC MAINTENANCE CHART....18
Periodic Maintenance Overview....18
Maintenance Chart Key....18
Pre-Ride - 25 Hour Maintenance Interval....19
50 - 100 Hour Maintenance Interval....20
100 - 300 Hour Maintenance Interval....21
GENERAL COMPONENT LOCATIONS....22
RH Side (4X4) and Dash View....22
LH Side and Rear View (4X4)....23
LH Side and RH Side Views (6X6)....24
SERVICE PRODUCTS AND LUBES....25
Polaris Lubricants, Maintenance and Service Products....25
MAINTENANCE REFERENCES....26
Maintenance References, Continued.......27
GENERAL VEHICLE INSPECTION AND MAINTENANCE....28
Pre-Ride / Daily Inspection....28
Frame, Nuts, Bolts, and Fasteners....28
Shift Linkage Inspection / Adjustment....28
FUEL SYSTEM AND AIR INTAKE....29
Fuel System....29
Fuel Lines....29
Fuel Filter....29
Vent Lines....29
Throttle Pedal Inspection....29
Throttle Freeplay Adjustment....30
Air Filter Service....30
Air Intake Inspection....31
ENGINE....32
Compression and Leakdown Test....32
Breather Hose Inspection....32
Engine Oil Level....32
Engine Oil and Filter Change....33
Exhaust Pipe....34
TRANSMISSION AND GEARCASES....35
Transmission Lubrication....35
Front Gearcase Lubrication....36
Middle Gearcase Lubrication (6x6)....37
Rear Gearcase Lubrication (4x4)....38
Rear Gearcase Lubrication (6x6)....39
COOLING SYSTEM....40
Liquid Cooling System Overview....40
Coolant Level Inspection....40
Radiator Coolant Level Inspection....41
Coolant Strength / Type....41
Cooling System Pressure Test....41
Cooling System Hoses....41
Radiator....42
Coolant Drain / Radiator Removal....42
FINAL DRIVE / WHEEL AND TIRE....42
Wheel, Hub, and Spindle Torque Table....42
CV Shaft Boot Inspection....43
Wheel Removal....43
Wheel Installation....43
Tire Inspection....43
Tire Pressure....44
ELECTRICAL AND IGNITION SYSTEM....44
Battery Maintenance....44
Battery Fluid Level (Conventional Battery)....44
Battery Removal....44
Battery Installation....45
Battery Storage....45
Battery Charging....45
Spark Plug Service....45
Engine To Frame Ground....46
STEERING AND SUSPENSION....46
Steering....46
Tie Rod End / Steering Inspection....46
Camber and Caster....46
Wheel Toe Alignment Inspection....47
Toe Adjustment....47
Front Suspension....48
Rear Suspension....48
Rear Suspension Adjustment (4x4)....49
Rear Spring Adjustment....49
BRAKE SYSTEM....49
Brake System Inspection....49
Brake Pad Inspection....49
Parking Brake Pad Inspection....50
Brake Hose and Fitting Inspection....50
ENGINE....51
ENGINE SPECIFICATIONS....52
Crankcase Exploded Views....52
Engine Fastener Torque Patterns....59
Torque Specifications....60
700 EFI Engine Service Specifications....61
Special Tools....63
GENERAL ENGINE SERVICE....63
Accessible Components....63
Piston Identification....63
Cooling System Specifications....63
Cooling System Pressure Test....64
Cooling System Exploded View....65
Cooling System Bleeding Procedure....65
Valve Cover Removal - 6x6 Models (Engine Installed)....67
Engine Removal....68
Engine Installation Notes....69
Cylinder Hone Selection And Honing Procedure....70
Honing To Deglaze....70
Cleaning the Cylinder After Honing....71
Engine Lubrication Specifications....71
Oil Pressure Test....71
Oil Flow Chart....72
ENGINE DISASSEMBLY AND INSPECTION....73
Cylinder Head Assembly Exploded View....73
Rocker Arms....74
Push Rods....74
Cylinder Head Removal ....74
Cylinder Head Inspection....75
Cylinder Head Warp....75
Valve Seal / Spring Service (On Engine)....75
Cylinder Head Disassembly....76
Valve Inspection....77
Combustion Chamber....78
Valve Seat Reconditioning....78
Cylinder Head Reassembly....80
Valve Sealing Test....81
Cylinder Removal....81
Valve Lifter Removal / Inspection....81
Piston Removal....82
Cylinder Inspection....83
Piston-to-Cylinder Clearance....84
Piston / Rod Inspection....84
Piston Ring Installed Gap....85
Starter Drive Bendix Removal / Inspection ....85
Flywheel / Stator Removal / Inspection....86
Engine Crankcase Disassembly / Inspection....86
Camshaft Inspection....94
ENGINE REASSEMBLY....95
Crankcase Reassembly....95
Flywheel / Stator Installation....104
Cylinder Head Reassembly....104
Oil Pump Priming....107
TROUBLESHOOTING....108
Engine....108
Cooling System....109
ELECTRONIC FUEL INJECTION....110
GENERAL INFORMATION....111
Special Tools....111
Service Notes....113
EFI System Exploded View....114
EFI System Component Locations....115
FUEL TANK....117
Exploded View....117
Fuel Lines - Quick Connect....118
ELECTRONIC FUEL INJECTION....118
Principal Components....118
EFI Operation Overview....118
Initial Priming / Starting Procedure....119
ELECTRONIC CONTROL UNIT (ECU)....119
Operation Overview....119
ECU Service....120
ECU Replacement....120
FUEL PUMP....120
Operation Overview....120
Fuel Pump Test....121
Fuel Pump / Tank Assembly Replacement....121
FUEL PRESSURE REGULATOR....123
Operation Overview....123
Fuel Pressure Regulator Test....123
Fuel Pressure Regulator Replacement....123
FUEL INJECTORS....123
Operation Overview....123
Fuel Injector Service....124
Fuel Injector Replacement....124
CRANKSHAFT POSITION SENSOR (CPS)....124
Operation Overview....124
CPS Test....125
CPS Replacement....125
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....125
Operation Overview....125
T-BAP Test....125
T-BAP Replacement....125
THROTTLE POSITION SENSOR (TPS)....126
Operation Overview....126
TPS Test....126
TPS Initialization....127
TPS Replacement....128
ENGINE COOLANT TEMPERATURE SENSOR (ECT)....128
Operation Overview....128
ECT Sensor Test....129
ECT Sensor Replacement....129
GENERAL TROUBLESHOOTING....130
Diagnostic “Blink Codes”....130
EFI Troubleshooting....131
BODY / STEERING / SUSPENSION....132
TORQUE SPECIFICATIONS....133
SPECIAL TOOLS....133
BODY COMPONENT REMOVAL....134
Removal Procedures....134
Lower Body Components....135
Hood / Dash Components....136
Dash Instruments and Controls....137
CAB FRAME....138
Assembly / Removal....138
CHASSIS / MAIN FRAME (4x4)....139
Exploded View....139
CHASSIS / MAIN FRAME (6x6)....140
Exploded View....140
SEAT / HEAD REST....141
Seat Base / Seat Back / Head Rest Assembly....141
STEERING ASSEMBLY....142
Exploded View....142
STEERING AND SUSPENSION....143
Exploded View....143
FRONT A-ARM....144
Replacement....144
FRONT STRUT....145
Exploded View....145
Front Strut Cartridge Replacement....146
Ball Joint Replacement....146
MID AXLE A-ARM (6x6)....147
Replacement....147
REAR A-ARM (4x4)....148
Replacement....148
REAR STABILIZER BAR (4x4)....150
Removal / Installation....150
SWING ARM (6X6)....151
Removal....151
Installation....151
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6x6)....152
REAR CARGO BOX....153
Cargo Box - Panels....153
Cargo Box - Tailgate / Box Support....154
Box Removal....155
Box Installation....155
STORAGE BOX....156
Removal....156
Installation....156
DECAL REPLACEMENT....156
CLUTCHING....157
SPECIAL TOOLS AND SUPPLIES....158
TORQUE SPECIFICATIONS....158
PVT System Fastener Torques....158
PVT SYSTEM OVERVIEW....158
General Operation....158
Drive Clutch Operation....158
Driven Clutch Operation....159
Maintenance / Inspection....159
Overheating / Diagnosis....160
PVT SYSTEM SERVICE....161
PVT Sealing, Guard, and Ducting Components....161
Disassembly....161
Assembly....162
DRIVE BELT....163
Belt Deflection (Tension)....163