Polaris Ranger 700 XP, HD, (4X4) - Workshop Manual / Repair Manual - Wiring Schematics - User Manual

POLARIS RANGER 700 XP, HD, (4X4) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS - OWNERS MANUAL

- English Workshop Manual / Repair Manual, Wiring Schematics and User Manual, for UTV Polaris Ranger 700 XP, HD, (4X4).

 
INDEX:


SERVICE MANUAL

General Information
Model Information
- Model Identification
- Engine Designation Number
- VIN Identification
- Vehicle and Engine Serial Number Locations
Vehicle Information
- Publication Numbers
- Replacement Keys
Special Tools
General Specifications
- MODEL: 2009 RANGER XP 700 4X4
- MODEL: 2009 RANGER XP 700 4X4
- MODEL: 2009 RANGER HD 700 4X4
- MODEL: 2009 RANGER HD 700 4X4
Misc. Specifications And Charts
- Conversion Table
- Standard Torque Specifications
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
- Glossary of Terms
Maintenance
Periodic Maintenance Chart
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 50 - 100 Hour Maintenance Interval
- 100 - 300 Hour Maintenance Interval
- Grease Lubrication Points
Service Products And Lubricants
- Polaris Lubricants, Maintenance and Service Products
Fluid Maintenance References
- Component Quick Reference
- Component Quick Reference, Continued.....
General Vehicle Inspection And Maintenance
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, and Fasteners
- Shift Linkage Inspection / Adjustment
Fuel System And Air Intake
- Fuel System
- Fuel Lines
- Fuel Filter
- Vent Lines
- Throttle Pedal Inspection
- Throttle Freeplay Adjustment
- Air Filter Service
- Engine Air Intake Inspection
- PVT Air Intake Inspection
- Air Intake Exploded View
Engine
- Compression and Leakdown Test
- Breather Hose Inspection
- Engine Oil Level
- Engine Oil and Filter Change
- Exhaust Pipe
Transmission And Gearcases
- Transmission Lubrication
- Front Gearcase Lubrication
- Rear Gearcase Lubrication
Cooling System
- Liquid Cooling System Overview
- Coolant Level Inspection
- Coolant Strength / Type
- Cooling System Hoses
- Radiator Inspection / Cleaning
- Coolant Drain / Radiator Removal
Final Drive / Wheel And Tire
- Wheel and Hub Torque Table
- CV Shaft Boot Inspection
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
Electrical And Ignition System
- Battery Maintenance
- Battery Fluid Level (Conventional Battery)
- Battery Removal
- Battery Installation
- Battery Storage
- Battery Charging
- Spark Plug Service
- Engine To Frame Ground
Steering
- Steering Inspection
- Tie Rod End / Steering Inspection
- Wheel Toe Alignment Inspection
- Toe Adjustment
Suspension
- Suspension Inspection
- Spring Pre-Load Adjustment
- Shock Position Adjustment
Brake System
- Brake Fluid Inspection
- Brake Hose and Fitting Inspection
- Brake Pad / Disc Inspection
- Parking Brake Cable Adjustment
- Parking Brake Pad Inspection
Maintenance Log
Engine
Engine Specifications
- Crankcase Exploded Views
- Engine Fastener Torque Patterns
- Torque Specifications
- 700 EFI Engine Service Specifications
- Special Tools
General Engine Service
- Accessible Components
- Piston Identification
- Cooling System Specifications
- Cooling System Layout and Testing
- Cooling System Bleeding Procedure
- Engine Removal
- Engine Installation Notes
- Engine Lubrication Specifications
- Oil Pressure Test
- Oil Flow Chart
Engine Disassembly And Inspection
- Cylinder Head Assembly Exploded View
- Rocker Arms
- Push Rods
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp
- Valve Seal / Spring Service (On Engine)
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Reassembly
- Valve Sealing Test
- Cylinder Removal
- Valve Lifter Removal / Inspection
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection And Honing Procedure
- Honing To Deglaze
- Cleaning the Cylinder After Honing
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Ring Installed Gap
- Starter Drive Bendix Removal / Inspection
- Flywheel / Stator Removal / Inspection
- Engine Crankcase Disassembly / Inspection
- Camshaft Inspection
Engine Reassembly
- Crankcase Reassembly
- Flywheel / Stator Installation
- Cylinder Head Reassembly
- Oil Pump Priming
- Engine Break-In
Troubleshooting
- Engine
- Cooling System
Electronic Fuel Injection
General Information
- Special Tools
- EFI Service Notes
- Fuel Tank Exploded View
- EFI System Exploded View
- EFI System Component Locations
- Fuel Lines - Quick Connect Removal / Installation
Electronic Fuel Injection
- Principal Components
- EFI Operation Overview
- Initial Priming / Starting Procedure
Electronic Control Unit (Ecu)
- Operation Overview
- ECU Service
- ECU Replacement
Fuel Pump
- Operation Overview
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump / Tank Assembly Replacement
Fuel Pressure Regulator
- Operation Overview
- Fuel Pressure Regulator Test
- Fuel Pressure Regulator Replacement
Fuel Injectors
- Operation Overview
- Fuel Injector Service
- Fuel Injector Replacement
Crankshaft Position Sensor (Cps)
- Operation Overview
- CPS Test
- CPS Replacement
Temperature / Barometric Air Pressure Sensor (T-Bap)
- Operation Overview
- T-BAP Test
- T-BAP Replacement
Throttle Position Sensor (Tps)
- Operation Overview
- TPS Tester / Regulator
- Checking TPS Reading
- TPS Adjustment
- TPS Replacement
Engine Coolant Temperature Sensor (Ect)
- Operation Overview
- ECT Sensor Test
- ECT Sensor Replacement
Ignition Coil
- Operation Overview
- Ignition Coil Tests
- Ignition Coil / HT Lead Replacement
General Troubleshooting
- Diagnostic “Blink Codes”
- EFI Troubleshooting
Body / Steering / Suspension
Torque Specifications
Special Tools
- Multi-Function Pliers
Chassis / Main Frame
- Exploded View
Cab Frame
- Exploded View / Assembly
Seat Back / Headrest / Pvt Air Intake Baffle Box
- Exploded View / Assembly
Body Exploded Views
- Dash Instruments / Controls
- Hood / Dash / Front Fenders / Front Fascia
- Floor / Rear Fenders
- Seat Mounting / Seat Belts
Rear Cargo Box
- Cargo Box - Panels
- Cargo Box - Tailgate / Box Support
- Box Removal
- Box Installation
Body Component Removal
- Lower Seat Base
- Wheel Well Panels
- Front Bumper
- Front Fascia
- Front Fenders
- Hood / Dash
- Glove Box / Storage Panel
- Rear Fenders
- Floor
Steering Assembly
- Exploded View
Power Steering Assembly (Hd)
- Exploded View
- Power Steering Unit Removal
- Power Steering Unit Installation
Front A-Arms
- Removal / Replacement
- Exploded View
Ball Joint Service
- Removal
- Installation
Rear A-Arms
- Removal / Replacement
- Installation
- Exploded View
Rear Stabilizer Bar
- Removal / Installation
- Exploded View
Decal Replacement
Shocks / Springs
- Exploded View
- Shock Removal / Installation
- Shock Replacement
Self-Leveling Suspension (Hd)
- Nivomat® Shock Operation
- Nivomat® Shock Disposal / Replacement
Clutching
Special Tools And Supplies
Torque Specifications
- PVT System Fastener Torques
Pvt System Overview
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In (Drive Belt / Clutches)
- Maintenance / Inspection
- Overheating / Diagnosis
Pvt System Service
- PVT Sealing, Guard, and Ducting Components
- Disassembly
- Assembly
Drive Belt
- Belt Removal
- Belt Inspection
- Belt Installation
- PVT Break-In (Drive Belt / Clutches)
Clutch Alignment
- Clutch Alignment Tool Use
Clutch Center Distance
Drive Clutch Service
- Spring Specifications
- Shift Weights
- Exploded View
- Clutch Disassembly
- Spider Removal
- Roller, Pin, and Thrust Washer Inspection
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- Bearing Inspection
- Clutch Inspection
- Moveable Sheave Bushing Inspection
- Bushing Service
- Clutch Assembly
Driven Clutch Service
- Exploded View
- Clutch Disassembly / Inspection
- Clutch Assembly
Troubleshooting
Final Drive
Special Tools
Torque Specifications
- Wheel, Hub, and Spindle Torque Table
Front Bearing Carrier
- Bearing Carrier Inspection / Removal
- Bearing Replacement
- Bearing Carrier Installation
Front Drive Shaft
- Removal
- Installation
Front Propshaft
- Removal
- Installation
- Front Propshaft Components
Propshaft U-Joint Service
- Disassembly
- Assembly
Front Gearcase - Centralized Hilliard
- Exploded View
- Operation
- AWD Diagnosis
- Gearcase Removal
- Disassembly / Inspection
- Reassembly / Inspection
- Setting Ring Gear Backlash
- Gearcase Installation
Rear Hub / Bearing Carrier
- Hub Inspection
- Hub Removal
- Hub Disassembly
- Hub Assembly
- Hub Installation
- Exploded View
Rear Drive Shaft
- Removal
- Installation
Drive Shaft Service
- Drive Shaft / CV Joint Handling Tips
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Exploded View
Rear Propshaft
- Removal
- Installation
Rear Gearcase
- General Operation
- Operation Modes
- Gearcase Removal
- Gearcase Disassembly
- Rear Gearcase Assembly
- Rear Gearcase Installation
- Rear Gearcase Exploded View
Transmission
Torque Specifications
Shift Lever
- Removal
- Installation
Shift Cable
- Inspection
- Adjustment
Transmission Service
- Transmission Removal
- Transmission Disassembly
- Transmission Assembly
- Transmission Installation
Troubleshooting
- Troubleshooting Checklist
Transmission Exploded View
- Exploded View
Brakes
General Specifications
Torque Specifications
Special Tools
Brake System Service Notes
Brake Noise Troubleshooting
Hydraulic Brake System Operation
Brake System Exploded View
Master Cylinder
- Removal
- Installation
Foot Brake Pedal
- Pedal Removal
- Pedal Installation
Brake Bleeding / Fluid Change
Parking Brake
- Exploded View
- Inspection
- Cable Tension Adjustment
Parking Brake Caliper Service
- Exploded View
- Caliper Removal
- Caliper Disassembly / Inspection
- New Brake Pad Installation
- Caliper Installation
Parking Brake Disc Service
- Disc Inspection / Removal
Front Brake Pads
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure
Front Caliper Service
- Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
Front Brake Disc
- Disc Runout
- Disc Inspection
- Disc Removal / Replacement
Rear Brake Pads
- Pad Removal
- Pad Inspection
- Pad Installation
- Brake Burnishing Procedure
Rear Caliper Service
- Rear Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
Rear Brake Disc
- Disc Runout
- Disc Inspection
- Disc Removal / Replacement
Troubleshooting
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
Electrical
General Information
- Special Tools
- Electrical Service Notes
- Components Under Hood
- Components Behind Dash Panel
Switches / Controls
- Headlight Switch
- AWD / 2WD / TURF Switch
- Differential Solenoid
- Brake Light Switch
- Parking Brake Switch
Instrument Cluster
- Overview
- Rider Information Display
- Standard Display Modes
- Diagnostic Display Mode
- Viewing Diagnostic Codes
- Instrument Cluster Removal
- Instrument Cluster Installation
Instrument Cluster Troubleshooting Tests
- Test 1 - No All Wheel Drive
- TEST 2 - No Display
- TEST 3 - Wheel Speed Sensor
- TEST 4 - No AWD Hub Safety Limiter
- TEST 5 - Fuel Gauge Display Not Working
- TEST 6 - Shift Indicator Not Working (Transmission Switch)
All Wheel Drive (Awd) Coil
- Operation Overview
- Diagnosing System Failures
Gear Position Indicator Switch
- Test Diagram
Headlights
- Headlight Adjustment
- Headlight Bulb Replacement
- Headlight Housing Removal
- Headlight Housing Installation
Tail Light / Brake Light
- LED Lamp Replacement
Cooling System
- Cooling System Break-Out Diagram
- Fan Control Circuit Operation
- Fan Control Circuit Bypass Test
- Coolant Temperature Sensor
Efi Diagnostics
- EFI Component Testing
Fuel Sender
- Testing
Relays
- Operation
Fuses / Circuit Breaker / Resistor
- Operation
Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Charging System Alternator Tests
- Regulator / Rectifier Test
- Charging System Testing Flow Chart
Battery Service
- Battery Terminals / Bolts
- Battery Terminal Block
- Battery Activation
- Battery Inspection
- Battery Removal / Installation
- Conventional Battery Testing
- OCV - Open Circuit Voltage Test
- Specific Gravity Test
- Load Test
- Charging Procedure
- Off Season Storage
Starter System
- Troubleshooting
- Voltage Drop Test
- Starter Motor Removal / Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly / Installation
- Starter Drive
- Starter Solenoid Bench Test
- Starter Solenoid Operation
- Starter Exploded View
Starting System Testing Flow Chart
- Condition: Starter fails to turn over the engine.
Electronic Power Steering (Eps)
- EPS System Breakout (HD Model)
- EPS Operation
- EPS 8-Way Wire Harness Connector
- EPS Malfunction Indicator Light (MIL)
- EPS Troubleshooting (Power Steering Non-Functional with EPS MIL ON)
- EPS Troubleshooting (Power Steering Non-Functional with EPS MIL OFF)
- EPS Troubleshooting (Power Steering Functional with EPS MIL ON)
Electric Box Lift Actuator
- DIAGNOSIS (if equipped)

OWNERS MANUAL