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Sign in with Google. Sign in with Microsoft. Polaris Ranger Service Manual ranger. By Robert Stutesman Find their other files. Share More sharing options Followers 3. Released June 23, No changelog available for this version. I recently purchased the subject UTV for my kids. The Clymer online manual is excellent for viewing on tablets such as the iPad.
The perfect tool can now be used in a mobile environment. Your one year subscription purchase is added to your MyClymer Toolbox and can be accessed wherever you have internet service with your account information. Clymer manuals are copyright protected. Remove dipstick and fill sump with 2 quarts 1.
Clean Out Plug Place the transmission in Park and start the engine. Set the hand brake and block the Transmission Lubrication wheels.
Remove the drain plug and allow lubricant to drain completely. Remove gearcase drain plug B 11 mm located on the bottom of the gearcase and drain oil. The drain plug is Fill Plug accessible through the skid plate. Catch and discard used oil properly. Refer to the procedure below.
Remove the fill plug. To check the lubricant level: Remove the drain plug and allow the lubricant to drain completely. Page Cooling System Overheating of engine could occur if air is not fully purged from system. Do not dilute with water. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator PN should be inspected and coolant added if necessary.
Drain the coolant into a suitable container and Check radiator A air passages for restrictions or damage. Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator.
Refer to Chapter 7 for CV boot replacement, tighten them. Lower the vehicle to the ground. Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section. Keep battery terminals and connections free of corrosion.
Page Battery Fluid Level Conventional Battery NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the Remove both spark plug high tension leads A. Spark Plug Torque: 18 ft. Damping vehicle center and each wheel. This will tell you which tie rod should be smooth throughout the range of travel.
Remove the top shock mounting bolts from the inside mounting holes. Reposition the shocks to the outside mounting holes. Reinstall the shock mounting bolts. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear.
Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector.
Journal Bearings B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N.
Page 56 6. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug Asm. Screw K. Page 59 A. Head Bolts B. Rocker Arms C. Head Assembly D.
Pushrods F. Bushing G. Expansion Plug H. Cylinder I. Piston Assembly J. Circlip K. Gasket L. Rocker Cover 2. Breather D. Fuel Injector B. Fuel Rail C. Nm ft. Page Special Tools System Capacity 3. Page Cooling System Pressure Test The cooling system is under heat dissipation, resulting in possible engine damage.
Polaris pressure and serious burns may result. Disconnect the air intake hose D from the air box and remove the air intake hose. Failing to do so may lead to possible injury or death. Use an engine lift or other means if the engine cover. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter.
If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.
Carefully remove the cylinder components. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.
Mark the valves with a white pen. Check valve face for runout, pitting, and burnt spots. Rinse and dry with compressed air. NOTE: Assemble the valves one at a time to maintain proper order. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats. Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.
The top rail has Remove circlip A. Mark the piston with a white pen to a locating tab on the end which fits into a notch B in the upper ensure proper orientation if reused during assembly. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder B for warp using a straight edge A and feeler gauge C. Refer to Ill. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.
Page Cylinder Hone Selection And Honing Procedure Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone or arbor honing machine. Cylinders may be wet or dry Example of Cross Hatch Pattern honed depending upon the hone manufacturer's recommendations.
Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin. If ring gap is smaller than Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within exceeds service limits. Replace starter drive if gear teeth are cracked, worn, or broken.
Inspect the bendix bushing C in the mag cover for wear. Replace as needed. Remove part of the water pump seal behind and the woodruff key I from the crankshaft. The stator the impeller. Wear safety glasses at all times.
Use caution when working with the top gear. Inspect the gear teeth and the three tabs on the gears for To Assemble: wear. Once the gears are pressed together, firmly hold the gears To remove the balance shaft gear, the flat side of the together with one hand.
Carefully remove the Tapered Pins camshaft P must face the balance shaft gear. Inspect the crankshaft gear Q for broken or worn teeth.
If Remove the four bolts with a hex need to be removed. Remove the oil pressure relief. The oil pressure relief Carefully press the gear off the assembly while supporting consists of a bolt, washer, spring, and valve dowel. Inspect the valve dowel for signs of possible obstructions. Use compressed air to blow out any debris.
Press shaft into the new bearing.. Remove thrust plate U. Press On Bearing Do not use the shaft to press the assembly into the Remove PTO end engine mount.
Remove crankcase bolts. Remove balance shaft and crankshaft. Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear or damage. Measure height of each cam lobe using a micrometer.
Compare to specification. Remove and inspect crankshaft main journal bearings for abnormal wear. Rotate balance shaft to ensure halve. Assemble the crankcase halves. Orientate the piston rings on the piston before installation set. Piston Ring Orientation 1. Top Ring 2. Push in Piston Pins Align the bolt holes and install oil pump assembly into
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