Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL – PDF DOWNLOAD
Original price was: $39.95.$18.95Current price is: $18.95.
POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:330
DOWNLOADABLE:YES
FILE TYPE:PDF
POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL
- Complete Factory Service Repair Workshop Manual. No Extra fees, No Expiry dates.
- Service Repair Workshop Manual, available for instant download to your computer tablet or smart phone.
- This Professional Manual covers all repairs, servicing and troubleshooting procedures. It is very detailed and contains hundreds of pages with detailed photos & diagrams.
- This is the same type of manual used by professional Mechanics and Technicians containing step by step instructions & highly detailed exploded diagrams & pictures to show you how to complete every job correctly.Q. Can I print out a page?
A. Yes you can print out a single page or the entire manual, its your choice.
Q. Can I use this Manual on more than one computer?
A. Yes, this Manual can be used on as many computers as required.
Q. Is this a trial or a limited version?
A. No, this is the FULL Manual without any limitations or trial periods and can be used for life.
Q, Will this Manual expire in 12 months or will I have to pay a renewal fee?
A. NO, Absolutely not! You can continue to use this Manual for life without the need to renew or pay any extra.
TABLE OF CONTENTS:
POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL
Document1.pdf................................................................................................................................................................................................................. 1 Ranger700 1.pdf............................................................................................................................................................................................................... 2 RANGER XP 700 EFI 4X4 / 6X6 SERVICE MANUAL................................................................................................................................................................................ 0 GENERAL INFORMATION....................................................................................................................................................................................................... 4 MODEL INFORMATION..................................................................................................................................................................................................... 5 Model Identification.............................................................................................................................................................................................. 5 Engine Designation Number......................................................................................................................................................................................... 5 VIN Identification................................................................................................................................................................................................ 5 Engine Serial Number Location..................................................................................................................................................................................... 5 Unit Serial Number (VIN) Location................................................................................................................................................................................. 6 Transmission I.D. Number Location................................................................................................................................................................................. 6 VEHICLE DIMENSIONS.................................................................................................................................................................................................... 7 RANGER 4X4, 6X6................................................................................................................................................................................................... 7 Vehicle Dimensions RANGER 4X4, 6X6................................................................................................................................................................................ 8 GENERAL SPECIFICATIONS................................................................................................................................................................................................ 9 MODEL: 2007 RANGER XP 4X4......................................................................................................................................................................................... 9 MODEL: 2007 RANGER XP 6X6......................................................................................................................................................................................... 9 MODEL: 2007 RANGER XP 4X4......................................................................................................................................................................................... 10 MODEL: 2007 RANGER XP 6X6......................................................................................................................................................................................... 11 VEHICLE INFORMATION................................................................................................................................................................................................... 12 Publication Numbers............................................................................................................................................................................................... 12 Paint Codes....................................................................................................................................................................................................... 12 Replacement Keys.................................................................................................................................................................................................. 12 SPECIAL TOOLS......................................................................................................................................................................................................... 12 MISC. SPECIFICATIONS AND CHARTS....................................................................................................................................................................................... 13 Conversion Table.................................................................................................................................................................................................. 13 Standard Torque Specifications.................................................................................................................................................................................... 14 SAE Tap / Drill Sizes............................................................................................................................................................................................. 15 Metric Tap / Drill Sizes.......................................................................................................................................................................................... 15 Decimal Equivalents............................................................................................................................................................................................... 15 Glossary of Terms................................................................................................................................................................................................. 16 MAINTENANCE............................................................................................................................................................................................................... 17 PERIODIC MAINTENANCE CHART............................................................................................................................................................................................ 19 Periodic Maintenance Overview..................................................................................................................................................................................... 19 Maintenance Chart Key............................................................................................................................................................................................. 19 Pre-Ride - 25 Hour Maintenance Interval........................................................................................................................................................................... 20 50 - 100 Hour Maintenance Interval................................................................................................................................................................................ 21 100 - 300 Hour Maintenance Interval............................................................................................................................................................................... 22 GENERAL COMPONENT LOCATIONS........................................................................................................................................................................................... 23 RH Side (4X4) and Dash View....................................................................................................................................................................................... 23 LH Side and Rear View (4X4)....................................................................................................................................................................................... 24 LH Side and RH Side Views (6X6)................................................................................................................................................................................... 25 SERVICE PRODUCTS AND LUBES............................................................................................................................................................................................ 26 Polaris Lubricants, Maintenance and Service Products.............................................................................................................................................................. 26 MAINTENANCE REFERENCES................................................................................................................................................................................................ 27 Maintenance References, Continued................................................................................................................................................................................. 28 GENERAL VEHICLE INSPECTION AND MAINTENANCE............................................................................................................................................................................ 29 Pre-Ride / Daily Inspection....................................................................................................................................................................................... 29 Frame, Nuts, Bolts, and Fasteners................................................................................................................................................................................. 29 Shift Linkage Inspection / Adjustment............................................................................................................................................................................. 29 FUEL SYSTEM AND AIR INTAKE............................................................................................................................................................................................ 30 Fuel System....................................................................................................................................................................................................... 30 Fuel Lines........................................................................................................................................................................................................ 30 Fuel Filter....................................................................................................................................................................................................... 30 Vent Lines........................................................................................................................................................................................................ 30 Throttle Pedal Inspection......................................................................................................................................................................................... 30 Throttle Freeplay Adjustment...................................................................................................................................................................................... 31 Air Filter Service................................................................................................................................................................................................ 31 Air Intake Inspection............................................................................................................................................................................................. 32 ENGINE................................................................................................................................................................................................................ 33 Compression and Leakdown Test..................................................................................................................................................................................... 33 Breather Hose Inspection.......................................................................................................................................................................................... 33 Engine Oil Level.................................................................................................................................................................................................. 33 Engine Oil and Filter Change...................................................................................................................................................................................... 34 Exhaust Pipe...................................................................................................................................................................................................... 35 TRANSMISSION AND GEARCASES............................................................................................................................................................................................ 36 Transmission Lubrication.......................................................................................................................................................................................... 36 Front Gearcase Lubrication........................................................................................................................................................................................ 37 Middle Gearcase Lubrication (6x6)................................................................................................................................................................................. 38 Rear Gearcase Lubrication (4x4)................................................................................................................................................................................... 39 Rear Gearcase Lubrication (6x6)................................................................................................................................................................................... 40 COOLING SYSTEM........................................................................................................................................................................................................ 41 Liquid Cooling System Overview.................................................................................................................................................................................... 41 Coolant Level Inspection.......................................................................................................................................................................................... 41 Radiator Coolant Level Inspection................................................................................................................................................................................. 42 Coolant Strength / Type........................................................................................................................................................................................... 42 Cooling System Pressure Test...................................................................................................................................................................................... 42 Cooling System Hoses.............................................................................................................................................................................................. 42 Radiator.......................................................................................................................................................................................................... 43 Coolant Drain / Radiator Removal.................................................................................................................................................................................. 43 FINAL DRIVE / WHEEL AND TIRE.......................................................................................................................................................................................... 43 Wheel, Hub, and Spindle Torque Table.............................................................................................................................................................................. 43 CV Shaft Boot Inspection.......................................................................................................................................................................................... 44 Wheel Removal..................................................................................................................................................................................................... 44 Wheel Installation................................................................................................................................................................................................ 44 Tire Inspection................................................................................................................................................................................................... 44 Tire Pressure..................................................................................................................................................................................................... 45 ELECTRICAL AND IGNITION SYSTEM........................................................................................................................................................................................ 45 Battery Maintenance............................................................................................................................................................................................... 45 Battery Fluid Level (Conventional Battery)........................................................................................................................................................................ 45 Battery Removal................................................................................................................................................................................................... 45 Battery Installation.............................................................................................................................................................................................. 46 Battery Storage................................................................................................................................................................................................... 46 Battery Charging.................................................................................................................................................................................................. 46 Spark Plug Service................................................................................................................................................................................................ 46 Engine To Frame Ground............................................................................................................................................................................................ 47 STEERING AND SUSPENSION............................................................................................................................................................................................... 47 Steering.......................................................................................................................................................................................................... 47 Tie Rod End / Steering Inspection................................................................................................................................................................................. 47 Camber and Caster................................................................................................................................................................................................. 47 Wheel Toe Alignment Inspection.................................................................................................................................................................................... 48 Toe Adjustment.................................................................................................................................................................................................... 48 Front Suspension.................................................................................................................................................................................................. 49 Rear Suspension................................................................................................................................................................................................... 49 Rear Suspension Adjustment (4x4).................................................................................................................................................................................. 50 Rear Spring Adjustment............................................................................................................................................................................................ 50 BRAKE SYSTEM.......................................................................................................................................................................................................... 50 Brake System Inspection........................................................................................................................................................................................... 50 Brake Pad Inspection.............................................................................................................................................................................................. 50 Parking Brake Pad Inspection...................................................................................................................................................................................... 51 Brake Hose and Fitting Inspection................................................................................................................................................................................. 51 ENGINE.................................................................................................................................................................................................................... 52 ENGINE SPECIFICATIONS................................................................................................................................................................................................. 53 Crankcase Exploded Views.......................................................................................................................................................................................... 53 Engine Fastener Torque Patterns................................................................................................................................................................................... 60 Torque Specifications............................................................................................................................................................................................. 61 700 EFI Engine Service Specifications............................................................................................................................................................................. 62 Special Tools..................................................................................................................................................................................................... 64 GENERAL ENGINE SERVICE................................................................................................................................................................................................ 64 Accessible Components............................................................................................................................................................................................. 64 Piston Identification............................................................................................................................................................................................. 64 Cooling System Specifications..................................................................................................................................................................................... 64 Cooling System Pressure Test...................................................................................................................................................................................... 65 Cooling System Exploded View...................................................................................................................................................................................... 66 Cooling System Bleeding Procedure................................................................................................................................................................................. 66 Valve Cover Removal - 6x6 Models (Engine Installed)............................................................................................................................................................... 68 Engine Removal.................................................................................................................................................................................................... 69 Engine Installation Notes......................................................................................................................................................................................... 70 Cylinder Hone Selection And Honing Procedure...................................................................................................................................................................... 71 Honing To Deglaze................................................................................................................................................................................................. 71 Cleaning the Cylinder After Honing................................................................................................................................................................................ 72 Engine Lubrication Specifications................................................................................................................................................................................. 72 Oil Pressure Test................................................................................................................................................................................................. 72 Oil Flow Chart.................................................................................................................................................................................................... 73 ENGINE DISASSEMBLY AND INSPECTION..................................................................................................................................................................................... 74 Cylinder Head Assembly Exploded View.............................................................................................................................................................................. 74 Rocker Arms....................................................................................................................................................................................................... 75 Push Rods......................................................................................................................................................................................................... 75 Cylinder Head Removal ............................................................................................................................................................................................ 75 Cylinder Head Inspection.......................................................................................................................................................................................... 76 Cylinder Head Warp................................................................................................................................................................................................ 76 Valve Seal / Spring Service (On Engine)........................................................................................................................................................................... 76 Cylinder Head Disassembly......................................................................................................................................................................................... 77 Valve Inspection.................................................................................................................................................................................................. 78 Combustion Chamber................................................................................................................................................................................................ 79 Valve Seat Reconditioning......................................................................................................................................................................................... 79 Cylinder Head Reassembly.......................................................................................................................................................................................... 81 Valve Sealing Test................................................................................................................................................................................................ 82 Cylinder Removal.................................................................................................................................................................................................. 82 Valve Lifter Removal / Inspection................................................................................................................................................................................. 82 Piston Removal.................................................................................................................................................................................................... 83 Cylinder Inspection............................................................................................................................................................................................... 84 Piston-to-Cylinder Clearance...................................................................................................................................................................................... 85 Piston / Rod Inspection........................................................................................................................................................................................... 85 Piston Ring Installed Gap......................................................................................................................................................................................... 86 Starter Drive Bendix Removal / Inspection ........................................................................................................................................................................ 86 Flywheel / Stator Removal / Inspection............................................................................................................................................................................ 87 Engine Crankcase Disassembly / Inspection......................................................................................................................................................................... 87 Camshaft Inspection............................................................................................................................................................................................... 95 ENGINE REASSEMBLY..................................................................................................................................................................................................... 96 Crankcase Reassembly.............................................................................................................................................................................................. 96 Flywheel / Stator Installation....................................................................................................................................................................................105 Cylinder Head Reassembly..........................................................................................................................................................................................105 Oil Pump Priming..................................................................................................................................................................................................108 TROUBLESHOOTING.......................................................................................................................................................................................................109 Engine............................................................................................................................................................................................................109 Cooling System....................................................................................................................................................................................................110 ELECTRONIC FUEL INJECTION.................................................................................................................................................................................................111 GENERAL INFORMATION...................................................................................................................................................................................................112 Special Tools.....................................................................................................................................................................................................112 Service Notes.....................................................................................................................................................................................................114 EFI System Exploded View..........................................................................................................................................................................................115 EFI System Component Locations....................................................................................................................................................................................116 FUEL TANK.............................................................................................................................................................................................................118 Exploded View.....................................................................................................................................................................................................118 Fuel Lines - Quick Connect........................................................................................................................................................................................119 ELECTRONIC FUEL INJECTION.............................................................................................................................................................................................119 Principal Components..............................................................................................................................................................................................119 EFI Operation Overview............................................................................................................................................................................................119 Initial Priming / Starting Procedure..............................................................................................................................................................................120 ELECTRONIC CONTROL UNIT (ECU).........................................................................................................................................................................................120 Operation Overview................................................................................................................................................................................................120 ECU Service.......................................................................................................................................................................................................121 ECU Replacement...................................................................................................................................................................................................121 FUEL PUMP.............................................................................................................................................................................................................121 Operation Overview................................................................................................................................................................................................121 Fuel Pump Test....................................................................................................................................................................................................122 Fuel Pump / Tank Assembly Replacement.............................................................................................................................................................................122 FUEL PRESSURE REGULATOR...............................................................................................................................................................................................124 Operation Overview................................................................................................................................................................................................124 Fuel Pressure Regulator Test......................................................................................................................................................................................124 Fuel Pressure Regulator Replacement...............................................................................................................................................................................124 FUEL INJECTORS........................................................................................................................................................................................................124 Operation Overview................................................................................................................................................................................................124 Fuel Injector Service.............................................................................................................................................................................................125 Fuel Injector Replacement.........................................................................................................................................................................................125 CRANKSHAFT POSITION SENSOR (CPS)......................................................................................................................................................................................125 Operation Overview................................................................................................................................................................................................125 CPS Test..........................................................................................................................................................................................................126 CPS Replacement...................................................................................................................................................................................................126 TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)..................................................................................................................................................................126 Operation Overview................................................................................................................................................................................................126 T-BAP Test........................................................................................................................................................................................................126 T-BAP Replacement.................................................................................................................................................................................................126 THROTTLE POSITION SENSOR (TPS)........................................................................................................................................................................................127 Operation Overview................................................................................................................................................................................................127 TPS Test..........................................................................................................................................................................................................127 TPS Initialization................................................................................................................................................................................................128 TPS Replacement...................................................................................................................................................................................................129 ENGINE COOLANT TEMPERATURE SENSOR (ECT)...............................................................................................................................................................................129 Operation Overview................................................................................................................................................................................................129 ECT Sensor Test...................................................................................................................................................................................................130 ECT Sensor Replacement............................................................................................................................................................................................130 GENERAL TROUBLESHOOTING...............................................................................................................................................................................................131 Diagnostic “Blink Codes”..........................................................................................................................................................................................131 EFI Troubleshooting...............................................................................................................................................................................................132 BODY / STEERING / SUSPENSION..............................................................................................................................................................................................133 TORQUE SPECIFICATIONS.................................................................................................................................................................................................134 SPECIAL TOOLS.........................................................................................................................................................................................................134 BODY COMPONENT REMOVAL................................................................................................................................................................................................135 Removal Procedures................................................................................................................................................................................................135 Lower Body Components.............................................................................................................................................................................................136 Hood / Dash Components............................................................................................................................................................................................137 Dash Instruments and Controls.....................................................................................................................................................................................138 CAB FRAME.............................................................................................................................................................................................................139 Assembly / Removal................................................................................................................................................................................................139 CHASSIS / MAIN FRAME (4x4)............................................................................................................................................................................................140 Exploded View.....................................................................................................................................................................................................140 CHASSIS / MAIN FRAME (6x6)............................................................................................................................................................................................141 Exploded View.....................................................................................................................................................................................................141 SEAT / HEAD REST......................................................................................................................................................................................................142 Seat Base / Seat Back / Head Rest Assembly........................................................................................................................................................................142 STEERING ASSEMBLY.....................................................................................................................................................................................................143 Exploded View.....................................................................................................................................................................................................143 STEERING AND SUSPENSION...............................................................................................................................................................................................144 Exploded View.....................................................................................................................................................................................................144 FRONT A-ARM...........................................................................................................................................................................................................145 Replacement.......................................................................................................................................................................................................145 FRONT STRUT...........................................................................................................................................................................................................146 Exploded View.....................................................................................................................................................................................................146 Front Strut Cartridge Replacement.................................................................................................................................................................................147 Ball Joint Replacement............................................................................................................................................................................................147 MID AXLE A-ARM (6x6)..................................................................................................................................................................................................148 Replacement.......................................................................................................................................................................................................148 REAR A-ARM (4x4)......................................................................................................................................................................................................149 Replacement.......................................................................................................................................................................................................149 REAR STABILIZER BAR (4x4).............................................................................................................................................................................................151 Removal / Installation............................................................................................................................................................................................151 SWING ARM (6X6).......................................................................................................................................................................................................152 Removal...........................................................................................................................................................................................................152 Installation......................................................................................................................................................................................................152 REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6x6).....................................................................................................................................................................153 REAR CARGO BOX........................................................................................................................................................................................................154 Cargo Box - Panels................................................................................................................................................................................................154 Cargo Box - Tailgate / Box Support................................................................................................................................................................................155 Box Removal.......................................................................................................................................................................................................156 Box Installation..................................................................................................................................................................................................156 STORAGE BOX...........................................................................................................................................................................................................157 Removal...........................................................................................................................................................................................................157 Installation......................................................................................................................................................................................................157 DECAL REPLACEMENT.....................................................................................................................................................................................................157 CLUTCHING.................................................................................................................................................................................................................158 SPECIAL TOOLS AND SUPPLIES............................................................................................................................................................................................159 TORQUE SPECIFICATIONS.................................................................................................................................................................................................159 PVT System Fastener Torques.......................................................................................................................................................................................159 PVT SYSTEM OVERVIEW...................................................................................................................................................................................................159 General Operation.................................................................................................................................................................................................159 Drive Clutch Operation............................................................................................................................................................................................159 Driven Clutch Operation...........................................................................................................................................................................................160 Maintenance / Inspection..........................................................................................................................................................................................160 Overheating / Diagnosis...........................................................................................................................................................................................161 PVT SYSTEM SERVICE....................................................................................................................................................................................................162 PVT Sealing, Guard, and Ducting Components........................................................................................................................................................................162 Disassembly.......................................................................................................................................................................................................162 Assembly..........................................................................................................................................................................................................163 DRIVE BELT............................................................................................................................................................................................................164 Belt Deflection (Tension).........................................................................................................................................................................................164 Belt Removal......................................................................................................................................................................................................164 Belt Inspection...................................................................................................................................................................................................165 Belt Installation.................................................................................................................................................................................................166 CLUTCH ALIGNMENT / OFFSET.............................................................................................................................................................................................166 Clutch Alignment..................................................................................................................................................................................................166 Clutch Offset.....................................................................................................................................................................................................167 DRIVE CLUTCH SERVICE..................................................................................................................................................................................................168 Spring Specifications.............................................................................................................................................................................................168 Shift Weights.....................................................................................................................................................................................................169 Exploded View.....................................................................................................................................................................................................170 Clutch Inspection.................................................................................................................................................................................................170 Clutch Disassembly................................................................................................................................................................................................171 Spider Removal....................................................................................................................................................................................................172 Roller, Pin, and Thrust Washer Inspection.........................................................................................................................................................................172 Bushing Service...................................................................................................................................................................................................173 Moveable Sheave - Bushing Removal.................................................................................................................................................................................173 Moveable Sheave - Bushing Installation............................................................................................................................................................................173 Clutch Cover - Bushing Removal....................................................................................................................................................................................174 Clutch Cover - Bushing Installation...............................................................................................................................................................................174 Clutch Assembly...................................................................................................................................................................................................175 DRIVEN CLUTCH SERVICE.................................................................................................................................................................................................176 Exploded View.....................................................................................................................................................................................................176 Clutch Disassembly / Inspection...................................................................................................................................................................................176 Clutch Assembly...................................................................................................................................................................................................178 TROUBLESHOOTING.......................................................................................................................................................................................................179 FINAL DRIVE...............................................................................................................................................................................................................181 SPECIAL TOOLS.........................................................................................................................................................................................................183 TORQUE SPECIFICATIONS.................................................................................................................................................................................................183 Wheel, Hub, and Spindle Torque Table..............................................................................................................................................................................183 FRONT HUB.............................................................................................................................................................................................................183 Hub Removal / Inspection..........................................................................................................................................................................................183 Hubstrut Bearing Replacement......................................................................................................................................................................................184 Hub Installation..................................................................................................................................................................................................185 Front Hub Exploded View...........................................................................................................................................................................................186 DRIVE SHAFT / PROPSHAFT...............................................................................................................................................................................................187 Exploded View.....................................................................................................................................................................................................187 DRIVESHAFT / CV JOINT HANDLING TIPS...................................................................................................................................................................................188 FRONT DRIVE SHAFT.....................................................................................................................................................................................................188 Removal...........................................................................................................................................................................................................188 CV Joint / Boot Replacement.......................................................................................................................................................................................189 Installation......................................................................................................................................................................................................191 FRONT PROPSHAFT REMOVAL...............................................................................................................................................................................................191 PROPSHAFT U-JOINT SERVICE.............................................................................................................................................................................................192 Disassembly.......................................................................................................................................................................................................192 Assembly..........................................................................................................................................................................................................193 FRONT GEARCASE CENTRALIZED HILLIARD...................................................................................................................................................................................194 AWD Operation.....................................................................................................................................................................................................194 Centralized Hilliard Exploded View................................................................................................................................................................................195 AWD Diagnosis.....................................................................................................................................................................................................196 Gearcase Removal..................................................................................................................................................................................................197 Gearcase Disassembly / Inspection.................................................................................................................................................................................198 Gearcase Reassembly / Inspection..................................................................................................................................................................................200 Backlash Pad (Thrust Pad) Adjustment..............................................................................................................................................................................202 Gearcase Installation.............................................................................................................................................................................................203 MID DRIVE HUB / BEARING CARRIER (6x6).................................................................................................................................................................................203 Removal...........................................................................................................................................................................................................203 Hub Disassembly...................................................................................................................................................................................................204 Hub Assembly......................................................................................................................................................................................................204 Hub Installation..................................................................................................................................................................................................205 Mid Drive Exploded View...........................................................................................................................................................................................206 MID DRIVE SHAFT (6x6).................................................................................................................................................................................................207 Removal...........................................................................................................................................................................................................207 Disassembly / Assembly............................................................................................................................................................................................207 Installation......................................................................................................................................................................................................207 MID PROP SHAFT (6x6)..................................................................................................................................................................................................208 Removal...........................................................................................................................................................................................................208 MID DRIVE GEARCASE (6x6)..............................................................................................................................................................................................208 Gearcase Removal..................................................................................................................................................................................................208 Gearcase Disassembly..............................................................................................................................................................................................209 Gearcase Assembly.................................................................................................................................................................................................212 Gearcase Installation.............................................................................................................................................................................................214 Mid Gearcase Exploded.............................................................................................................................................................................................215 REAR DRIVE (4x4)......................................................................................................................................................................................................216 Exploded View.....................................................................................................................................................................................................216 REAR HUB / BEARING CARRIER (4x4)......................................................................................................................................................................................216 Hub Inspection....................................................................................................................................................................................................216 Hub Removal.......................................................................................................................................................................................................216 Hub Disassembly...................................................................................................................................................................................................217 Hub Assembly......................................................................................................................................................................................................218 Hub Installation..................................................................................................................................................................................................218 REAR DRIVE SHAFT (4X4)................................................................................................................................................................................................219 Removal...........................................................................................................................................................................................................219 CV Joint / Boot Replacement.......................................................................................................................................................................................220 Installation......................................................................................................................................................................................................222 REAR PROPSHAFT (4x4)..................................................................................................................................................................................................223 Removal...........................................................................................................................................................................................................223 Installation......................................................................................................................................................................................................223 REAR GEARCASE (4x4)...................................................................................................................................................................................................224 General Operation.................................................................................................................................................................................................224 Operation Modes...................................................................................................................................................................................................225 Differential Removal..............................................................................................................................................................................................226 Differential Disassembly..........................................................................................................................................................................................226 Differential Assembly.............................................................................................................................................................................................229 Differential Installation.........................................................................................................................................................................................231 Differential Exploded View........................................................................................................................................................................................232 REAR AXLE / GEARCASE SERVICE (6x6)....................................................................................................................................................................................233 Rear Axle Removal.................................................................................................................................................................................................233 Axle Tube Removal.................................................................................................................................................................................................234 Axle Tube Bearing Replacement.....................................................................................................................................................................................235 Gearcase Disassembly / Inspection.................................................................................................................................................................................235 Gearcase Assembly.................................................................................................................................................................................................236 Gearcase / Axle Installation......................................................................................................................................................................................237 Gearcase Exploded View............................................................................................................................................................................................240 TRANSMISSION..............................................................................................................................................................................................................241 TORQUE SPECIFICATIONS.................................................................................................................................................................................................242 SHIFT LEVER...........................................................................................................................................................................................................242 Removal...........................................................................................................................................................................................................242 Installation......................................................................................................................................................................................................242 SHIFT LINKAGE.........................................................................................................................................................................................................242 Inspection........................................................................................................................................................................................................242 Adjustment........................................................................................................................................................................................................243 TRANSMISSION SERVICE..................................................................................................................................................................................................243 Transmission Removal..............................................................................................................................................................................................243 Transmission Disassembly..........................................................................................................................................................................................245 Transmission Assembly.............................................................................................................................................................................................250 Transmission Installation.........................................................................................................................................................................................254 TROUBLESHOOTING.......................................................................................................................................................................................................255 Troubleshooting Checklist.........................................................................................................................................................................................255 TRANSMISSION EXPLODED VIEW............................................................................................................................................................................................256 Exploded View (4x4, 6x6)..........................................................................................................................................................................................256 BRAKES....................................................................................................................................................................................................................258 GENERAL SPECIFICATIONS................................................................................................................................................................................................259 TORQUE SPECIFICATIONS.................................................................................................................................................................................................259 SPECIAL TOOLS.........................................................................................................................................................................................................259 BRAKE SYSTEM SERVICE NOTES............................................................................................................................................................................................260 BRAKE NOISE TROUBLESHOOTING...........................................................................................................................................................................................260 HYDRAULIC BRAKE SYSTEM OPERATION......................................................................................................................................................................................261 BRAKE SYSTEM EXPLODED VIEW............................................................................................................................................................................................262 MASTER CYLINDER.......................................................................................................................................................................................................263 Removal...........................................................................................................................................................................................................263 Installation......................................................................................................................................................................................................263 FOOT BRAKE PEDAL......................................................................................................................................................................................................263 Pedal Removal.....................................................................................................................................................................................................263 Pedal Installation................................................................................................................................................................................................263 BRAKE BLEEDING / FLUID CHANGE.........................................................................................................................................................................................264 PARKING BRAKE.........................................................................................................................................................................................................265 Exploded View.....................................................................................................................................................................................................265 Inspection........................................................................................................................................................................................................266 Adjustment........................................................................................................................................................................................................266 PARKING BRAKE CALIPER SERVICE.........................................................................................................................................................................................267 Exploded View.....................................................................................................................................................................................................267 Caliper Removal...................................................................................................................................................................................................267 Caliper Disassembly / Inspection..................................................................................................................................................................................268 New Brake Pad Installation........................................................................................................................................................................................269 Caliper Installation..............................................................................................................................................................................................269 PARKING BRAKE DISC SERVICE............................................................................................................................................................................................269 Disc Removal / Inspection.........................................................................................................................................................................................269 FRONT BRAKE PADS......................................................................................................................................................................................................270 Pad Removal / Disassembly.........................................................................................................................................................................................270 Pad Inspection....................................................................................................................................................................................................270 Pad Assembly / Installation.......................................................................................................................................................................................271 Pad Adjustment....................................................................................................................................................................................................271 FRONT CALIPER.........................................................................................................................................................................................................272 Front Caliper Exploded View.......................................................................................................................................................................................272 Caliper Removal...................................................................................................................................................................................................272 Caliper Disassembly...............................................................................................................................................................................................272 Caliper Inspection................................................................................................................................................................................................273 Caliper Assembly..................................................................................................................................................................................................273 Caliper Installation..............................................................................................................................................................................................274 FRONT BRAKE DISC......................................................................................................................................................................................................275 Disc Inspection...................................................................................................................................................................................................275 Disc Removal / Replacement........................................................................................................................................................................................275 REAR BRAKE PAD (4x4)..................................................................................................................................................................................................275 Pad Removal.......................................................................................................................................................................................................275 Pad Inspection....................................................................................................................................................................................................276 Pad Installation..................................................................................................................................................................................................276 REAR BRAKE PAD (6x6)..................................................................................................................................................................................................277 Pad Removal.......................................................................................................................................................................................................277 Pad Inspection....................................................................................................................................................................................................278 Pad Installation..................................................................................................................................................................................................278 REAR CALIPER..........................................................................................................................................................................................................279 Rear Caliper Exploded View........................................................................................................................................................................................279 Caliper Removal (4x4).............................................................................................................................................................................................279 Caliper Removal (6x6).............................................................................................................................................................................................280 Caliper Disassembly...............................................................................................................................................................................................280 Caliper Inspection................................................................................................................................................................................................281 Caliper Assembly..................................................................................................................................................................................................281 Caliper Installation (4x4, 6x6)...................................................................................................................................................................................282 REAR BRAKE DISC.......................................................................................................................................................................................................282 Disc Inspection...................................................................................................................................................................................................282 TROUBLESHOOTING.......................................................................................................................................................................................................283 Brakes Squeal / Poor Brake Performance............................................................................................................................................................................283 Pedal Vibration...................................................................................................................................................................................................283 Caliper Overheats (Brakes Drag)...................................................................................................................................................................................283 Brakes Lock.......................................................................................................................................................................................................283 ELECTRICAL................................................................................................................................................................................................................284 GENERAL INFORMATION...................................................................................................................................................................................................286 Special Tools.....................................................................................................................................................................................................286 Electrical Service Notes..........................................................................................................................................................................................286 Under-Hood Components.............................................................................................................................................................................................286 SWITCHES / CONTROLS...................................................................................................................................................................................................287 Headlamp Switch...................................................................................................................................................................................................287 AWD / Rear Differential Switch (4x4)..............................................................................................................................................................................287 Differential Solenoid (4x4).......................................................................................................................................................................................287 Brake Light Switch................................................................................................................................................................................................288 Parking Brake Switch..............................................................................................................................................................................................289 INSTRUMENT CLUSTER....................................................................................................................................................................................................290 Overview..........................................................................................................................................................................................................290 Rider Information Display.........................................................................................................................................................................................290 Standard Display Modes............................................................................................................................................................................................291 Diagnostic Display Mode...........................................................................................................................................................................................291 Viewing Diagnostic Codes..........................................................................................................................................................................................293 Instrument Cluster Removal........................................................................................................................................................................................294 Instrument Cluster Installation...................................................................................................................................................................................294 INSTRUMENT CLUSTER TROUBLESHOOTING TESTS..............................................................................................................................................................................295 Test 1 - No All Wheel Drive.......................................................................................................................................................................................295 TEST 2 - No Display...............................................................................................................................................................................................296 TEST 3 - Wheel Speed Sensor.......................................................................................................................................................................................296 TEST 4 - No AWD Hub Safety Limiter................................................................................................................................................................................297 TEST 5 - Fuel Gauge Display Not Working ..........................................................................................................................................................................298 TEST 6 - Shift Indicator Not Working (Transmission Switch)........................................................................................................................................................298 ALL WHEEL DRIVE (AWD) COIL............................................................................................................................................................................................299 Operation Overview................................................................................................................................................................................................299 Diagnosing System Failures........................................................................................................................................................................................299 GEAR POSITION INDICATOR SWITCH........................................................................................................................................................................................299 Test Diagram......................................................................................................................................................................................................299 HEAD LIGHTS...........................................................................................................................................................................................................300 High Beam Headlight Adjustment....................................................................................................................................................................................300 Headlamp Bulb Replacement.........................................................................................................................................................................................300 Headlamp Housing Removal..........................................................................................................................................................................................300 Headlamp Housing Installation.....................................................................................................................................................................................301 TAIL LIGHT / BRAKE LIGHT..............................................................................................................................................................................................301 Lamp Replacement..................................................................................................................................................................................................301 COOLING SYSTEM........................................................................................................................................................................................................302 Cooling System Break-Out Diagram..................................................................................................................................................................................302 Fan Control Circuit Operation / Testing...........................................................................................................................................................................303 Fan Control Circuit Bypass Test...................................................................................................................................................................................303 Coolant Temperature Sensor........................................................................................................................................................................................303 EFI DIAGNOSTICS.......................................................................................................................................................................................................303 EFI Component Testing.............................................................................................................................................................................................303 FUEL SENDER...........................................................................................................................................................................................................303 Testing...........................................................................................................................................................................................................303 RELAYS................................................................................................................................................................................................................304 Operation.........................................................................................................................................................................................................304 FUSES / CIRCUIT BREAKER...............................................................................................................................................................................................305 Operation.........................................................................................................................................................................................................305 CHARGING SYSTEM.......................................................................................................................................................................................................305 Current Draw - Key Off............................................................................................................................................................................................305 Charging System “Break Even” Test.................................................................................................................................................................................306 Charging System Alternator Tests..................................................................................................................................................................................306 Charging System Testing Flow Chart................................................................................................................................................................................308 BATTERY TERMINAL BLOCK................................................................................................................................................................................................309 BATTERY SERVICE.......................................................................................................................................................................................................309 Battery Terminals / Bolts.........................................................................................................................................................................................309 Battery Identification............................................................................................................................................................................................309 CONVENTIONAL BATTERY..................................................................................................................................................................................................310 Battery Activation................................................................................................................................................................................................310 Battery Inspection................................................................................................................................................................................................310 Battery Removal...................................................................................................................................................................................................311 Battery Installation..............................................................................................................................................................................................311 Conventional Battery Testing......................................................................................................................................................................................311 OCV - Open Circuit Voltage Test...................................................................................................................................................................................311 Specific Gravity Test.............................................................................................................................................................................................311 Load Test.........................................................................................................................................................................................................312 Off Season Storage................................................................................................................................................................................................312 Charging Procedure................................................................................................................................................................................................312 LOW MAINTENANCE BATTERY...............................................................................................................................................................................................313 Battery Check.....................................................................................................................................................................................................313 Battery Inspection ...............................................................................................................................................................................................313 Battery Removal...................................................................................................................................................................................................313 Battery Installation..............................................................................................................................................................................................314 Battery Testing...................................................................................................................................................................................................314 OCV - Open Circuit Voltage Test...................................................................................................................................................................................314 Load Test.........................................................................................................................................................................................................314 Off-Season Storage................................................................................................................................................................................................315 Battery Charging .................................................................................................................................................................................................315 STARTER SYSTEM........................................................................................................................................................................................................316 Troubleshooting...................................................................................................................................................................................................316 Voltage Drop Test.................................................................................................................................................................................................316 Starter Motor Removal / Disassembly ..............................................................................................................................................................................316 BRUSH INSPECTION / REPLACEMENT....................................................................................................................................................................................317 Armature Testing..................................................................................................................................................................................................318 Starter Reassembly / Installation.................................................................................................................................................................................318 Starter Solenoid Bench Test.......................................................................................................................................................................................319 Starter Drive.....................................................................................................................................................................................................319 Starter Exploded View.............................................................................................................................................................................................320 STARTER SYSTEM TESTING FLOW CHART.....................................................................................................................................................................................321 Condition: Starter fails to turn over the engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test....321 ELECTRIC BOX LIFT ACTUATOR............................................................................................................................................................................................322 DIAGNOSIS (if equipped)...........................................................................................................................................................................................322 INDEX.....................................................................................................................................................................................................................323 WIRE DIAGRAMS.............................................................................................................................................................................................................327
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
2 reviews for POLARIS RANGER XP 700 EFI 4X4 RANGER 6X6 SERVICE MANUAL 2005 2006 2007 DIY MAINTENANCE SHOP MANUAL – PDF DOWNLOAD
Add a review
Zaiden Bruno –
Zayn Jaxson –
Keeps getting better quality manuals every year.