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Polaris RANGER EV 2015 User Manual

Polaris RANGER EV 2015
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Page #188 background image
7.22
9926595 R01 - 2015-2016 RANGER EV Service Manual
© Copyright Polaris Industries Inc.
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Caliper Piston O.D.:
1.370″ (34.80 mm)
Service Limit: 1.368″ (34.75 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
CALIPER ASSEMBLY
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore
smoothly, with light resistance.
3. Lubricate the mounting bracket pins with disc brake
caliper lube, and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the
dust seal boots are fully seated. Install the brake
pads. Clean the disc and pads with brake parts
cleaner or denatured alcohol to remove any dirt, oil
or grease.
CALIPER INSTALLATION
1. Install caliper and torque mounting bolts to
specification.
TORQUE
Front Caliper Mount Bolt:
28 ft-lb (38 Nm)
BRAKE SYSTEM

Table of Contents

Questions and Answers:

Polaris RANGER EV 2015 Specifications

General IconGeneral
BrandPolaris
ModelRANGER EV 2015
CategoryOffroad Vehicle
LanguageEnglish

Summary

Chapter 1 General / Battery

Special Information Regarding the RANGER EV

Provides important operational and safety details for the RANGER EV.

Vehicle Identification

Explains the model number and VIN designation for vehicle identification.

Battery Safety

Covers critical safety warnings and precautions for handling and working with batteries.

Battery Maintenance

Details key procedures for maximizing battery service life and proper care.

Chapter 2 Maintenance

Periodic Maintenance Chart

Outlines scheduled maintenance intervals for various vehicle systems.

General Vehicle Inspection and Maintenance

Covers essential pre-ride checks and general vehicle inspection procedures.

Steering

Details inspection of steering components for wear, damage, and proper operation.

Brake System

Outlines inspection and maintenance procedures for the entire brake system.

Chapter 3 Drive Motor

Safety Information

Highlights critical safety warnings related to battery handling and service precautions.

Drive Motor Removal

Provides step-by-step instructions for safely removing the drive motor assembly.

Drive Motor Assembly

Details the process for assembling the drive motor after service or replacement.

Chapter 4 Body / Steering / Suspension

Component Locations

Illustrates the location of major vehicle components for reference.

Steering Assembly Exploded View

Provides a detailed exploded view of the steering assembly for service.

Front A-Arm Removal / Installation

Covers the procedure for removing and installing the front A-arm.

Rear A-Arm Removal / Replacement

Details the process for removing and replacing the rear A-arm components.

Chapter 5 Final Drive

Prop Shaft Service

Outlines procedures for servicing the drive shaft, including removal and installation.

Front Drive Shaft Removal

Provides instructions for removing the front drive shaft assembly.

Centralized Hilliard Theory of Operation

Explains the operational principles of the centralized Hilliard AWD system.

Gearcase Disassembly / Inspection

Details the steps for disassembling and inspecting the front gearcase.

Chapter 6 Transaxle / Differential

Transaxle Removal

Step-by-step guide for removing the transaxle from the vehicle.

Transaxle Disassembly

Covers the process of disassembling the transaxle for inspection and service.

Planetary Differential Disassembly

Details the disassembly procedure for the planetary differential.

Troubleshooting

Provides a checklist for diagnosing transaxle issues and potential causes.

Chapter 7 Brake System

Brake System Service

General notes and procedures for servicing the hydraulic brake system.

Master Cylinder

Covers the removal and installation procedures for the master cylinder.

Parking Brake Adjustment

Explains how to adjust the parking brake for proper function.

Front Caliper Service

Details the disassembly, inspection, and assembly of the front brake caliper.

Chapter 8 Electrical

Electrical Service Notes

Provides essential notes and precautions for diagnosing electrical problems.

Switches / Controls

Covers the operation and testing of various vehicle switches and controls.

Indicator Lights

Explains the function and meaning of various indicator lights on the panel.

System Wiring Diagrams

Contains critical wiring diagrams for diagnosing and troubleshooting electrical systems.

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