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Ranger 500 2x4 2007
Polaris Ranger 500 2x4 2007 User Manual
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2
Table of Contents
General Information Chapter 1 1
3
Table of Contents
3
Chapter 1
4
Engine Designation Number
4
Engine Serial Number Location
4
Model Identification
4
Vehicle Identification
4
Vin Identification
4
Transmission I.D. Number Location
5
Unit Serial Number (Vin) Location
5
Vehicle Dimensions
6
General Specifications
8
Model: Ranger 2X4
8
Model: Ranger 4X4 Carb
8
Model: Ranger 4X4 Efi
9
Model: Ranger 2X4
10
Model: Ranger 4X4 Carb
11
Model: Ranger 4X4 Efi
12
Vehicle Information
13
Publication Numbers
13
Paint Codes
13
Replacement Keys
13
Special Tools
14
Misc. Specifications and Charts
18
Conversion Table
18
Standard Torque Specifications
19
Sae Tap / Drill Sizes
20
Metric Tap / Drill Sizes
20
Glossary of Terms
21
Maintenance Chapter 2 Maintenance 2
22
Chapter 2
24
Maintenance Chart Key
24
Periodic Maintenance Chart
24
Periodic Maintenance Overview
24
Pre-Ride - 25 Hour Maintenance Interval
25
50 - 100 Hour Maintenance Interval
26
General Component Location
28
Rh Side and Dash View
28
Lh Side and Rear View
29
Service Products and Lubes
30
Polaris Lubricants, Maintenance and Service Products
30
Maintenance References
31
Polaris Lubricant Symbol Identification
31
Engine Lubrication
31
Component Fluid Type and Use
32
Component Lubrication Points
33
General Vehicle Inspection and Maintenance
34
Pre-Ride / Daily Inspection
34
Frame, Nuts, Bolts, and Fasteners
34
Shift Linkage Inspection / Adjustment
34
Fuel System and Air Intake
35
Fuel System
35
Fuel Lines
35
Fuel Filter (Carb Models)
35
Vent Lines
35
Throttle Pedal Inspection
35
Throttle Freeplay Adjustment
36
Throttle Cable Adjustment (Carb Models)
36
Choke Adjustment (Carb Models)
36
Pilot Screw (Carb Models)
37
Pilot Screw Adjustment (Carb Models)
37
Idle Speed Adjustment (Carb Models)
38
Carburetor Draining (Carb Models)
38
Air Intake Inspection
39
Air Filter Service
39
Engine
40
Compression and Leakdown Test
40
Breather Filter Inspection
41
Breather Hose
41
Flywheel Housing
41
Engine Oil Level
41
Engine Oil and Filter Change
42
Oil Pump Priming Procedure
43
Valve Clearance
44
Intake Valve Clearance Adjustment
45
Exhaust Valve Clearance Adjustment
45
Exhaust Pipe
45
Fuel System (Efi)
40
Fuel Filter
40
Transmission and Gearcases
46
Transmission Lubrication
46
Front Gearcase Lubrication (4X4)
47
Rear Gearcase Lubrication
48
Cooling System
49
Liquid Cooling System Overview
49
Coolant Level Inspection
50
Radiator Coolant Level Inspection
50
Coolant Strength / Type
50
Cooling System Pressure Test
51
Cooling System Hoses
51
Radiator
51
Coolant Drain / Radiator Removal
51
Final Drive / Wheel and Tire
52
Wheel, Hub, and Spindle Torque Table
52
CV Shaft Boot Inspection
52
Wheel Removal
52
Wheel Installation
52
Tire Inspection
53
Tire Pressure
53
Electrical and Ignition System
53
Battery Maintenance
53
Battery Fluid Level (Conventional Battery)
54
Battery Removal
54
Battery Installation
54
Battery Storage
54
Battery Charging
54
Spark Plug Service
55
Engine to Frame Ground
55
Steering and Suspension
55
Steering
55
Tie Rod End / Steering Inspection
56
Camber and Caster
56
Front Suspension
57
Rear Suspension
58
Rear Suspension Adjustment
58
Rear Spring Adjustment
58
Brake System
59
Brake System Inspection
59
Brake Pad Inspection
59
Parking Brake Pad Inspection
59
Brake Hose and Fitting Inspection
59
Chapter 3 Engine
60
Special Tools
62
Specifications
62
Torque Specifications
62
Engine Service Data
63
Engine Fastener Torque Patterns
65
General Engine Service
65
Piston Identification
65
Accessible Components
66
Engine Removal
66
Engine Installation Notes
69
Cylinder Hone Selection / Honing Procedure
69
Honing to Oversize
69
Cleaning the Cylinder after Honing
70
Crankshaft Straightening
70
Engine Lubrication - Eh50Pl
71
Oil Pressure Test - Eh50Pl
71
Oil Pump Priming Procedure
71
Oil Flow - Eh50Pl
72
Eh50Pl Oil Flow Diagram
73
Eh50Pl Engine Exploded View
74
Cooling System
75
Cooling System Specifications (Non-Efi)
75
Cooling System Layout and Testing
75
Engine Disassembly
77
Engine Removal
77
Cam Chain Tensioner / Rocker Arm /Camshaft Removal
77
Cam Chain Tensioner Inspection
77
Rocker Arm / Shaft Inspection
78
Camshaft Removal
79
Automatic Compression Release Removal / Inspection
80
Automatic Compression Release Installation
80
Camshaft Inspection
81
Cylinder Head Removal
81
Cylinder Head Exploded View, Eh50Pl (Efi Shown)
82
Cylinder Head Inspection
83
Cylinder Head Warpage
83
Cylinder Head Disassembly
83
Valve Inspection
84
Combustion Chamber
84
Valve Seat Reconditioning
85
Cylinder Head Assembly
87
Valve Sealing Test
88
Valve Clearance Adjustment (Intake and Exhaust)
88
Cylinder / Piston Removal and Inspection
88
Piston Removal
89
Cylinder Inspection
90
Piston-To-Cylinder Clearance
90
Piston / Rod Inspection
91
Piston Ring Installed Gap
91
Crankcase Disassembly
92
Starter Drive Removal / Inspection
92
Flywheel and Stator Removal / Inspection
92
Cam Chain / Tensioner Blade
93
One Way Valve
93
Crankcase Separation
94
Oil Pump Removal / Inspection
94
Oil Pump Assembly
95
Counter Balancer Shaft Removal / Inspection
95
Crankshaft Removal / Inspection
96
Crankcase Bearing Inspection
96
Oil Seal / Mechanical Seal Removal (Engine Disassembled)
97
Crankcase Inspection
97
Bearing Installation
97
End Play Inspection / Adjustment
97
Crankshaft End Play Adjustment
97
Counter Balancer Shaft End Play Adjustment
99
Oil Pump Shaft End Play Adjustment
99
Engine Reassembly
100
Pump Shaft Oil Seal Installation
100
Crankshaft / Counter Balance / Oil Pump Installation
100
Crankcase Assembly
100
Water Pump Mechanical Seal Installation
100
Water Pump Mechanical Seal Removal (Engine Installed)
101
One Way Valve Installation
102
Cam Chain Drive Sprocket Installation
102
Tensioner Blade Installation
102
Piston Ring Installation
102
Piston Installation
103
Cylinder Installation
103
Cylinder Head Installation
104
Cam Chain / Camshaft Installation
104
Camshaft Timing
105
Camshaft Timing Illustration
106
Cam Chain Tensioner Installation
107
Stator, Flywheel and Starter Drive Installation
107
Rocker Shaft / Rocker Arm Assembly Installation
108
Thermostat Installation
108
Oil Pipes
108
Troubleshooting
109
Engine
109
Spark Plug Fouling
110
Cooling Troubleshooting
110
Carburetion System Chapter 4 Carburetion System
111
Chapter 4
113
Exploded View
113
Mikuni CV Carburetor
113
Operation - Mikuni CV Carb
114
System Function - Mikuni CV Carb
114
Vent Systems - Mikuni CV Carb
114
Pilot System (Idle and Slow Speed)
115
Float System
116
Starter System (Choke or Enrichment)
116
Main System
117
Pilot Screw
117
Carburetor Service
118
Carburetor Removal
118
Carburetor Disassembly
118
Carburetor Cleaning
119
Carburetor Inspection
120
Float Height Adjustment
120
Needle and Seat Leakage Test
120
Fuel Level
121
Carburetor Assembly
121
Air Box Assembly
122
Exploded View
122
Fuel Tank Assembly
123
Fuel Tank / Fuel Pump Exploded View
123
Fuel Tank Removal
124
Fuel Tank Installation
124
Fuel Pump
125
Replacement
125
Troubleshooting
126
Fuel Starvation / Lean Mixture
126
Rich Mixture
126
Idle too High
126
Idle too Low
126
Erratic Idle
126
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
127
Special Tools
129
Part Numbers / Descriptions
129
Efi Service Notes
131
General Service Information
131
Efi System
132
Exploded View
132
Efi Component Locations
133
Identification / Location
133
Electronic Fuel Injection
135
General Information
136
Efi Operation Overview
136
Initial Priming / Starting Procedure
136
Fuel Tank
135
Exploded View
135
Electronic Control Module (Ecm)
137
Operation Overview
137
Ecm Service
138
Fuel Lines
137
Quick Connect Removal / Installation
137
Fuel Pump Assembly
139
Operation / Testing
139
Fuel Pump Test
139
Fuel Pump / Tank Assembly Replacement
140
Fuel Injector
142
Fuel Pressure Regulator
142
General Information
142
Crankshaft Position Sensor (Cps)
143
General Information
143
Manifold Air Pressure Sensor (Map)
144
General Information
144
Map Sensor Test
144
Map Sensor Replacement
144
Idle Air Control (Iac)
145
Intake Air Temperature Sensor (Iat)
145
General Information
145
Intake Air Temperature Sensor Test
145
Intake Air Temperature Sensor Replacement
145
Throttle Position Sensor (Tps)
146
General Information
146
Throttle Position Sensor Test
146
Throttle Position Sensor Replacement
147
Throttle Position Sensor Initialization
147
Engine Temperature Sensor
148
General Information
148
Engine Temperature Sensor Test
148
Engine Temperature Sensor Replacement
148
Diagnostics Using 'Blink Codes
149
Blink Codes - Operation
149
Fuel System Troubleshooting
151
Fuel Starvation / Lean Mixture
151
Rich Mixture
151
Poor Idle
151
Efi System Break-Out Diagrams
152
Fuel Injector Circuit
152
Crankshaft Position Sensor (Cps) Circuit
152
Fuel Pump Circuit
153
Ignition Coil Circuit
153
Idle Air Control (Iac) Circuit
154
Throttle Position Sensor (Tps) Circuit
154
Manifold Air Pressure Sensor (Map) Circuit
155
Engine Coolant Temperature Sensor Circuit
155
Intake Air Temperature Sensor (Iat) Circuit
156
Malfunction Indicator Light (Mil) Circuit
156
Diagnostic Connector Circuit
157
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
158
Special Tools
159
Torque Specifications
159
Body Component Removal
160
Chapter 5
160
Removal Procedures
160
Lower Body Components
161
Hood / Dash Components
162
Dash Instruments and Controls
163
Cab Frame
164
Assembly / Removal
164
Chassis / Main Frame
165
Exploded View
165
Seat / Head Rest
166
Seat Base / Seat Back / Head Rest Assembly
166
Steering Assembly
167
Exploded View
167
Steering and Suspension
168
Exploded View
168
Front A-Arm
169
Replacement
169
Front Strut
170
Exploded View
170
Front Strut Cartridge Replacement
171
Ball Joint Replacement
171
Rear A-Arm
172
Replacement
172
Rear Stabilizer Bar
174
Removal / Installation
174
Rear Cargo Box
175
Cargo Box - Panels
175
Cargo Box - Tailgate / Box Support
176
Box Removal
177
Box Installation
177
Decal Replacement
178
Clutching Chapter 6 Clutching
179
Chapter 6 Pvt System Fastener Torques
180
Pvt System Overview
180
General Operation
180
Drive Clutch Operation
180
Driven Clutch Operation
181
Maintenance / Inspection
181
Overheating / Diagnosis
182
Special Tools and Supplies
180
Torque Specifications
180
Pvt System Service
183
Pvt Sealing, Guard, and Ducting Components
183
Disassembly
183
Assembly
184
Drive Belt
185
Belt Deflection (Tension)
185
Belt Removal
185
Belt Inspection
186
Belt Installation
187
Clutch Alignment / Offset
187
Clutch Alignment
187
Clutch Offset
188
Drive Clutch Service
189
Spring Specifications
189
Shift Weights
190
Exploded View
191
Clutch Inspection
191
Clutch Disassembly
192
Spider Removal
193
Roller, Pin, and Thrust Washer Inspection
193
Bushing Service
194
Moveable Sheave - Bushing Removal
194
Moveable Sheave - Bushing Installation
194
Clutch Cover - Bushing Removal
195
Clutch Cover - Bushing Installation
195
Clutch Assembly
196
Driven Clutch Service
197
Exploded View
197
Clutch Disassembly / Inspection
197
Bushing Service
198
Moveable Sheave - Bushing Installation
199
Clutch Assembly
200
Troubleshooting
202
Final Drive Chapter 7 Final Drive
204
Chapter 7 Wheel, Hub, and Spindle Torque Table
205
Front Hub (2X4)
205
Hub Removal / Inspection
205
Hub Installation
206
Exploded View (2X4)
207
Special Tools
205
Torque Specifications
205
Front Hub (4X4)
208
Hub Installation
209
Exploded View (4X4)
210
Drive Shaft / Propshaft
211
Exploded View
211
Driveshaft / CV Joint Handling Tips
212
Front Drive Shaft (4X4)
212
Removal
212
CV Joint / Boot Replacement
213
Installation
215
Front Propshaft Removal
215
Propshaft U-Joint Service
216
Disassembly
216
Assembly
217
Front Gearcase Centralized Hilliard
218
Awd Operation
218
Centralized Hilliard Exploded View
219
Awd Diagnosis
220
Gearcase Removal
221
Gearcase Disassembly / Inspection
222
Gearcase Reassembly / Inspection
224
Backlash Pad (Thrust Pad) Adjustment
226
Gearcase Installation
227
Rear Drive
228
Exploded View
228
Rear Hub / Bearing Carrier
228
Hub Inspection / Removal
228
Hub Disassembly
229
Hub Assembly / Installation
230
Rear Drive Shaft
231
Removal
231
CV Joint / Boot Replacement
232
Installation
234
Rear Propshaft
235
Rear Gearcase (Differential)
236
General Operation
236
Operation Modes
237
Differential Removal / Disassembly
238
Differential Assembly
241
Differential Installation
243
Differential Exploded View
244
Transmission Chapter 8 Transmission
245
Chapter 8
246
Installation
246
Removal
246
Shift Lever
246
Shift Linkage
246
Inspection
246
Adjustment
247
Torque Specifications
246
Transmission Service
247
Transmission Removal
247
Transmission Disassembly
249
Transmission Assembly
254
Transmission Installation
258
Troubleshooting
259
Troubleshooting Checklist
259
Transmission Exploded View
260
Brakes Chapter 9 Brakes
264
Exploded View (2X4)
271
Exploded View (4X4)
273
Chapter 9 Parking Brake
274
Caliper Installation
275
New Brake Pad Installation
275
Parking Brake Disc Service
275
Disc Removal / Inspection
275
Front Brake Pads
276
Pad Removal / Disassembly / Inspection
276
Pad Assembly / Installation / Adjustment
277
Front Caliper
278
Front Caliper Exploded View
278
Caliper Removal / Disassembly
278
Caliper Inspection / Assembly
279
Caliper Installation
280
Front Brake Disc
281
Disc Inspection / Removal / Replacement
281
Rear Brake Pad
281
Pad Removal
281
Pad Inspection / Installation
282
Rear Caliper
283
Rear Caliper Exploded View
283
Caliper Removal / Disassembly
284
Caliper Inspection
284
Caliper Assembly
285
Caliper Installation
285
Rear Brake Disc
286
Disc Inspection
286
Troubleshooting
286
Brakes Squeal / Poor Brake Performance
286
Pedal Vibration
286
Caliper Overheats (Brakes Drag)
286
Brakes Lock
286
Chapter 10 Electrical
287
Electrical Service Notes
289
General Information
289
Special Tools
289
Under-Hood Components
289
Switches / Controls
290
Headlamp Switch
290
Awd / Rear Differential Switch
290
Differential Solenoid
290
Brake Light Switch
291
Parking Brake Switch
291
Gear Indicator Light Circuit Operation
292
Indicator Lamp Replacement
293
Head Lights
293
High Beam Headlight Adjustment
293
Headlamp Bulb Replacement
294
Headlamp Housing Removal
294
Headlamp Housing Installation
295
Tail Light / Brake Light
295
Lamp Replacement
295
Power Distribution Module (Non-Efi Models)
296
Pdm Operation
296
Pdm Block Diagram
297
Pdm Isolation Tests (Non-Efi Models)
297
Battery Voltage Test
297
Ground Test
298
Static Stator Test
298
Run Signal Test
298
Dynamic Stator Test
298
Battery + Test
299
Protected Battery + Test
299
Ignition Switch Test
299
Accessory Power Test
300
Pdm to Fan Output Test
300
Fan Motor Test
300
Static Thermistor Test
301
Dynamic Thermistor Test
301
Hot Lamp Test
301
Differential Solenoid Test
302
Awd out Test
302
Awd / Turf Switch Test
302
Differential out Test
303
Differential Ground Test
303
Acs out Test
303
Power Distribution Module (Efi Models)
304
Pdm Operation
304
Pdm Function Overview
305
Pdm Block Diagram
306
Timing Check Procedure (Non-Efi Models)
307
Cooling System
308
Non-Efi Cooling System Break-Out Diagram
308
Efi Cooling System Break-Out Diagram
309
Coolant Temperature Sensor Test (Non-Efi Models)
310
DC / CDI Ignition System (Non-Efi Models)
311
DC / CDI Ignition System Overview
311
Ignition System Troubleshooting
311
Resistance Tests
312
Flywheel Identification
312
Ignition System Testing Flow Chart
313
Components of DC / CDI Ignition
314
Efi Diagnostics
315
Efi Component Testing
315
Current Draw - Key off
315
Charging System "Break Even" Test
315
Charging System Alternator Tests
316
Charging System Testing Flow Chart
317
Battery Service
318
Battery Terminals / Bolts
318
Battery Identification
318
Battery Terminal Block
318
Conventional Battery
319
Conventional Battery Testing
320
Ocv - Open Circuit Voltage Test
320
Specific Gravity Test
320
Load Test
321
Off Season Storage
321
Charging Procedure
321
Low Maintenance Battery
322
Battery Check
322
Battery Inspection
322
Battery Removal
322
Battery Installation
323
Battery Testing
323
Ocv - Open Circuit Voltage Test
323
Load Test
323
Off-Season Storage
324
Battery Charging
324
Starter System
325
Troubleshooting
325
Voltage Drop Test
325
Starter Motor Disassembly
325
Brush Inspection / Replacement
326
Armature Testing
326
Starter Reassembly
327
Starter Drive
327
Starter System Test Flow Chart
328
Electric Box Lift Actuator
330
Diagnosis (if Equipped)
330
Electrical Breakout Diagrams (Efi Models)
331
Starting Circuit
331
Key-On Power Circuit
331
Transmission Switch Circuit
332
Differential Solenoid Circuit
332
Charging System Circuit
333
Cooling Fan Circuit
333
Awd Circuit
334
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Polaris Ranger 500 2x4 2007 Specifications
General
Brand
Polaris
Model
Ranger 500 2x4 2007
Category
Utility Vehicle
Language
English
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