Body Component Removal; Removal Procedures - Polaris Ranger 500 2x4 2007 Service Manual

BODY COMPONENT REMOVAL

Removal Procedures

TO REMOVE:
SEAT
DASH
HOOD
CAB
HOOD LINER
FRONT BUMPER
CARGO BOX
FUEL TANK
BODY / STEERING / SUSPENSION
PERFORM THESE STEPS:
Pull up on front of seat and then pull forward
1. Remove the gear selector handle
2. Then remove the 4 screws that attach the hood to the dash
3. Remove the remaining dash screws that attach the RANGER emblem
4. Disconnect the dash component wires
5. Remove the steering wheel (1 nut)
1. Disconnect headlights
2. Remove the 4 hinge screws
1. Remove seat back and seat base
2. Remove the bolts for the front mounts
3. Remove the bolts for the rear mounts
1. Remove liner darts and screws
2. Disconnect the wiring harnesses
3. Remove the air baffling boxes
1. Lift the hood
2. Remove the 3 front Torx screws from LH and RH wheel well panels
3. Remove the 2 top bumper mounting bolts
4. Remove the 3 lower bumper mounting bolts
1. Place box in the dump position
2. Remove the pin and clip from the shock at the cargo box
3. Disconnect light harnesses
4. Remove (2) screws holding hinge pins
5. Tap out hinge pins
6. Lift the box off the frame with assistance
1. Raise the cargo box
2. Disconnect the vent and fuel lines (note locations)
3. Disconnect electrical connection
4. Remove the RH rear fender and fuel cap
5. Remove the 2 inner bolts and 2 outer bolts that hold the tank to the frame
6. Carefully lift the tank out through the side
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