Polaris Ranger 6X6 700 EFI 2006 Manuals

Manuals and User Guides for Polaris Ranger 6X6 700 EFI 2006. We have 5 Polaris Ranger 6X6 700 EFI 2006 manuals available for free PDF download: Service And Owner's Manual, Service Manual, Owner's Manual

Polaris Ranger 6X6 700 EFI 2006 Service And Owner's Manual (687 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 48.79 MB

English

116
- Installation Instructions
  49
- Limited Warranty
  54
- Before You Start
  61
- Rear Panel
  62
- Care and Maintenance
  65
- Tools Required
  68
- Ordering Replacement Parts
  111
- Table of Contents
  116
- General Description
  117
- Specifications
  118
- Safety Message to Installers
  119
- Installation
  120
- Safety Message to Operators
  124
- Operation
  125
- Service
  127
- Priority Sound Elimination
  128
  - Parts List
    141
  - Safety Guidelines
    143
- General Safety Precautions
  157
- Winch Basics
  159
- How the Winch Works
  160
- Stretching Wire Rope
  161
- Before You Pull
  162
- Pulling
  163
- Rigging Techniques
  165
- Maintenance
  165
- The Final Analysis
  165
Français

166
- Mesures Générales de Sécurité
  167
- Comment Fonctionne Le Treuil
  170
- Étirement Initial du Cable
  171
- Avant de Treuiller
  172
- Treuillage
  173
- En Dernière Analyse
  175
  - Safety First
    186
- Maintenance
  175
- Techniques de Câblage
  175
- Vehicle Identification Numbers
  195
- Safety
  196
- Equipment Modifications
  204
- Features and Controls
  213
  - Diagnostic Mode
    219
  - Mode Button
    225
- Gear Selector
  226
- Ignition Switch
  229
- Operation
  231
  - Starting the Engine
    233
  - Stopping the Engine
    234
- Driving on Slippery Surfaces
  236
- Driving Uphill
  237
- Driving Downhill
  238
- Driving through Water
  239
- Driving over Obstacles
  240
- Driving in Reverse
  241
- Dumping the Cargo Box
  245
- Emission Control Systems
  250
- Maintenance
  253
  - Air Filter
    276
- Filter Systems
  276
  - Brake Inspection
    281
- Headlight Lamp Replacement
  286
- Headlight Beam Adjustment
  287
- Specifications
  301
- Polaris Products
  305
- Troubleshooting
  306
- Warranty
  310
  - Maintenance Schedule
    317
- Maintenance Log
  319
- Index
  321
- Engine Designation Number
  332
- Engine Serial Number Location
  332
- General Information
  332
- Model Identification
  332
- Model Information
  332
- Vin Identification
  332
- Transmission I.D. Number Location
  333
- Vehicle Identification Number (Vin) Location
  333
- Ranger 4X4 Crew / 6X6 (Height and Width)
  334
- Vehicle Dimensions
  334
- Ranger 4X4 Crew (Length and Wheel Base)
  335
- Ranger 6X6 (Length and Wheel Base)
  335
- General Specifications
  336
- Paint Codes
  340
- Publication Numbers
  340
- Replacement Keys
  340
- Special Tools
  340
- Vehicle Information
  340
- Conversion Table
  341
- Misc. Specifications and Charts
  341
- Standard Torque Specifications
  342
- Metric Tap / Drill Sizes
  343
- Sae Tap / Drill Sizes
  343
- Glossary of Terms
  344
- Break-In Period
  347
- Maintenance Chart Key
  347
- Periodic Maintenance Chart
  347
- Periodic Maintenance Overview
  347
- Pre-Ride - 25 Hour Maintenance Interval
  348
- 50 - 100 Hour Maintenance Interval
  349
- Polaris Lubricants, Maintenance and Service Products
  351
- Service Products and Lubes
  351
- Maintenance References
  352
- Maintenance References, Continued
  353
- Frame, Nuts, Bolts, and Fasteners
  354
- General Vehicle Inspection and Maintenance
  354
- Pre-Ride / Daily Inspection
  354
- Shift Linkage Inspection / Adjustment
  354
- Fuel Filter
  355
- Fuel Lines
  355
- Fuel System
  355
- Fuel System and Air Intake
  355
- Throttle Pedal Inspection
  355
- Vent Lines
  355
- Air Filter Service
  356
- Throttle Freeplay Adjustment
  356
- Air Intake Inspection
  357
- Breather Hose Inspection
  358
- Compression and Leakdown Test
  358
- Engine
  358
- Engine Oil Level
  358
- Engine Oil and Filter Change
  359
- Exhaust Pipe
  360
- Transmission and Gearcases
  361
- Transmission Lubrication
  361
- Front Gearcase Lubrication
  362
- Middle Gearcase Lubrication (6X6)
  363
- Rear Gearcase Lubrication (4X4 Crew)
  364
- Rear Gearcase Lubrication (6X6)
  365
- Coolant Level Inspection
  366
- Cooling System
  366
- Liquid Cooling System Overview
  366
- Coolant Strength / Type
  367
- Cooling System Hoses
  367
- Cooling System Pressure Test
  367
- Radiator Coolant Level Inspection
  367
- Coolant Drain / Radiator Removal
  368
- Radiator
  368
- CV Shaft Boot Inspection
  369
- Final Drive / Wheel and Tire
  369
- Wheel and Hub Torque Table
  369
- Wheel Installation
  369
- Wheel Removal
  369
- Battery Maintenance
  370
- Electrical and Ignition System
  370
- Tire Inspection
  370
- Tire Pressure
  370
- Battery Charging
  371
- Battery Fluid Level (Conventional Battery)
  371
- Battery Installation
  371
- Battery Removal
  371
- Battery Storage
  371
- Engine to Frame Ground
  372
- Spark Plug Service
  372
- Steering
  373
- Steering and Suspension
  373
- Tie Rod End / Steering Inspection
  373
- Front Suspension
  374
- Toe Adjustment
  374
- Rear Spring Adjustment
  375
- Rear Suspension
  375
- Rear Suspension Adjustment (4X4 Crew)
  375
- Brake Fluid Inspection
  376
- Brake Hose and Fitting Inspection
  376
- Brake Pad / Disc Inspection
  376
- Brake System
  376
- Parking Brake Cable Adjustment
  376
- Parking Brake Pad Inspection
  377
- Crankcase Exploded Views
  380
- Engine Specifications
  380
- Engine Fastener Torque Patterns
  387
- Torque Specifications
  388
- 700 EFI Engine Service Specifications
  389
- Accessible Components
  391
- Cooling System Specifications
  391
- General Engine Service
  391
- Piston Identification
  391
- Special Tools
  391
- Cooling System Pressure Test
  392
- Cooling System Bleeding Procedure
  393
- Cooling System Exploded View
  393
- Valve Cover Removal - 6X6 Models (Engine Installed)
  395
- Engine Removal
  396
- Engine Installation Notes
  397
- Engine Lubrication Specifications
  398
- Oil Pressure Test
  398
- Oil Flow Chart
  399
- Cylinder Head Assembly Exploded View
  400
- Engine Disassembly and Inspection
  400
- Cylinder Head Removal
  401
- Rocker Arms / Push Rods
  401
- Cylinder Head Inspection / Warp
  402
- Valve Seal / Spring Service (on Engine)
  402
- Cylinder Head Disassembly
  403
- Valve Inspection
  404
- Combustion Chamber
  405
- Valve Seat Reconditioning
  405
- Cylinder Head Reassembly
  407
- Cylinder Removal
  408
- Valve Lifter Removal / Inspection
  408
- Valve Sealing Test
  408
- Piston Removal
  409
- Cylinder Inspection
  410
- Cleaning the Cylinder after Honing
  411
- Cylinder Hone Selection and Honing Procedure
  411
- Honing to Deglaze
  411
- Piston / Rod Inspection
  412
- Piston-To-Cylinder Clearance
  412
- Piston Ring Installed Gap
  413
- Starter Drive Bendix Removal / Inspection
  413
- Engine Crankcase Disassembly / Inspection
  414
- Flywheel / Stator Removal / Inspection
  414
- Camshaft Inspection
  422
- Crankcase Reassembly
  423
- Engine Reassembly
  423
- Flywheel / Stator Installation
  432
- Cylinder Head Reassembly
  433
- Engine Break-In
  435
- Oil Pump Priming
  435
- Engine
  436
- Troubleshooting
  436
- Cooling System
  437
- General Information
  440
- Special Tools
  440
- Efi Service Notes
  443
- Fuel Tank Exploded View
  444
- Efi System Exploded View
  445
- Efi System Component Locations
  446
- Electronic Fuel Injection
  447
- Fuel Lines - Quick Connect Removal / Installation
  447
- Initial Priming / Starting Procedure
  448
- Principal Components / Efi Operation Overview
  448
- Electronic Control Unit (Ecu)
  449
- Fuel Pump
  450
- Fuel Pump Test
  450
- Fuel Sender Test
  450
- Fuel Pump / Tank Assembly Replacement
  451
- Fuel Pressure Regulator
  452
- Fuel Injectors
  453
- Crankshaft Position Sensor (Cps)
  454
  - Operation Overview
    454
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  455
- Throttle Position Sensor (Tps)
  455
- Engine Coolant Temperature Sensor (Ect)
  458
- Tps Replacement
  458
- Ignition Coil
  459
- Ignition Coil / Ht Lead Replacement
  459
- Ignition Coil Tests
  459
- Diagnostic "Blink Codes
  460
- General Troubleshooting
  460
- Efi Troubleshooting
  461
- Efi System Break-Out Diagrams
  462
- Fuel Injector Circuit (Mag)
  462
- Fuel Injector Circuit (Pto)
  462
- Crankshaft Position Sensor (Cps) Circuit
  463
- Fuel Pump Circuit
  463
- Engine Coolant Temperature Sensor (Ect)
  464
- Temperature Overheat Indicator Lamp Circuit
  464
- Air Temperature / Barometric Air Pressure Sensor (T-Bap) Circuit
  465
- Throttle Position Sensor (Tps) Circuit
  465
- Diagnostic Connector Circuit
  466
- Diagnostic Indicator Lamp Circuit
  466
- Body / Steering / Suspension
  468
- Special Tools
  468
- Torque Specifications
  468
- Body Component Removal
  469
- Removal Procedures
  469
- Lower Body, Floor and Fenders (4X4 Crew)
  470
- Lower Body, Floor and Fenders (6X6)
  471
- Hood / Dash Components
  472
- Dash Instruments and Controls
  473
- Assembly / Removal (6X6)
  474
- Cab Frame
  474
- Assembly / Removal (4X4 Crew)
  475
- Seat / Head Rest
  476
- Chassis / Main Frame (4X4 Crew)
  477
- Chassis / Main Frame (6X6)
  478
- Steering Assembly
  479
- Steering and Suspension
  480
- Front A-Arm
  481
- Front Strut
  482
- Ball Joint Replacement
  483
- Front Strut Cartridge Replacement
  483
- MID Axle A-Arm (6X6)
  484
- Rear A-Arm (4X4 Crew)
  485
- Rear Stabilizer Bar (4X4 Crew)
  487
- Swing Arm (6X6)
  488
- Rear Drive Axle and Swing Arm Exploded View (6X6)
  489
- Cargo Box - Panels
  490
- Rear Cargo Box
  490
- Cargo Box - Tailgate / Box Support
  491
- Decal Replacement
  493
- Storage Box (4X4 Crew)
  493
- Drive Clutch Operation
  496
- General Operation
  496
- Pvt System Fastener Torques
  496
- Pvt System Overview
  496
- Special Tools and Supplies
  496
- Torque Specifications
  496
- Driven Clutch Operation
  497
- Maintenance / Inspection
  497
- Pvt Break-In (Drive Belt / Clutches)
  497
- Overheating / Diagnosis
  498
- Disassembly
  499
- Pvt Sealing, Guard, and Ducting Components
  499
- Pvt System Service
  499
- Assembly
  500
- Belt Removal
  501
- Drive Belt
  501
- Clutch Alignment
  502
- Pvt Break-In (Drive Belt / Clutches)
  502
- Clutch Center Distance
  503
- Drive Clutch Service
  504
- Spring Specifications
  504
- Shift Weights
  505
- Clutch Disassembly
  506
- Exploded View
  506
- Spider Removal
  507
- Button to Tower Clearance Inspection
  508
- Roller, Pin, and Thrust Washer Inspection
  508
- Shift Weight Inspection
  508
- Bearing Inspection
  509
- Clutch Inspection
  509
- Moveable Sheave Bushing Inspection
  510
- Bushing Service
  511
- Clutch Assembly
  513
- Clutch Disassembly / Inspection
  514
- Driven Clutch Service
  514
- Exploded View
  514
- Clutch Assembly
  516
- Troubleshooting
  517
- Front Hub
  521
- Hub Removal / Inspection
  521
- Special Tools
  521
- Torque Specifications
  521
- Wheel, Hub, and Spindle Torque Table
  521
- Hubstrut Bearing Replacement
  522
- Hub Installation
  523
- Front Hub Exploded View
  524
- Front Drive Shaft
  525
- Removal
  525
- Drive Shaft / CV Joint Handling Tips
  526
- Outer CV Joint / Boot Replacement
  526
- Inner Plunging Joint / Boot Replacement
  528
- Exploded View
  529
- Installation
  529
- Front Propshaft
  530
- Front Propshaft Components
  530
- Propshaft U-Joint Service
  531
- Centralized Hilliard Exploded View
  533
- Awd Diagnosis
  535
- Gearcase Removal
  536
- Gearcase Disassembly / Inspection
  537
- Gearcase Reassembly / Inspection
  539
- Backlash Pad (Thrust Pad) Adjustment
  541
- Gearcase Installation
  542
- MID Drive Hub / Bearing Carrier (6X6)
  542
- Removal
  542
- Hub Installation
  544
- Disassembly / Assembly
  545
- MID Drive Exploded View
  545
- MID Drive Shaft (6X6)
  545
- Removal
  545
- Installation
  546
- MID Propshaft (6X6)
  546
- Removal
  546
- Gearcase Removal
  547
- MID Drive Gearcase (6X6)
  547
- Gearcase Disassembly
  548
- Gearcase Assembly
  550
- Gearcase Installation
  553
- MID Gearcase Exploded
  554
- Rear Hub / Bearing Carrier (4X4)
  555
- Hub Assembly
  556
- Hub Disassembly
  556
- Hub Installation
  557
- Exploded View
  558
- Outer CV Joint / Boot Replacement
  559
- Rear Drive Shaft (4X4 Crew)
  559
- Removal
  559
- Inner Plunging Joint / Boot Replacement
  562
- Drive Shaft Exploded View
  564
- Installation
  565
- Installation
  566
- Rear Propshaft (4X4 Crew)
  566
- Removal
  566
- General Operation
  567
- Rear Gearcase (4X4 Crew)
  567
- Operation Modes
  568
- Gearcase Disassembly
  569
- Gearcase Removal
  569
- Rear Gearcase Assembly
  572
- Rear Gearcase Installation
  574
- Rear Gearcase Exploded View (4X4 Crew)
  575
- Rear Axle / Gearcase Service (6X6)
  576
- Rear Axle Removal
  576
- Axle Tube Removal
  577
- Axle Tube Bearing Replacement
  578
- Gearcase Disassembly / Inspection
  578
- Gearcase Assembly
  579
- Gearcase / Axle Installation
  580
  - Rear Gearcase Exploded View (6X)
    583
- Inspection
  586
- Installation
  586
- Removal
  586
- Shift Lever
  586
- Shift Linkage
  586
- Torque Specifications
  586
- Adjustment
  587
- Transmission Removal
  587
- Transmission Service
  587
- Transmission Disassembly
  589
- Transmission Assembly
  594
- Transmission Installation
  598
- Troubleshooting
  599
- Troubleshooting Checklist
  599
- Exploded View
  600
- Transmission Exploded Views
  600
- General Specifications
  604
- Special Tools
  604
- Torque Specifications
  604
- Brake Noise Troubleshooting
  605
- Brake System Service Notes
  605
- Hydraulic Brake System Operation
  606
- Brake System Exploded View
  607
- Foot Brake Pedal
  608
- Master Cylinder
  608
- Brake Bleeding / Fluid Change
  609
- Exploded View (4X4 Crew)
  610
- Parking Brake
  610
- Exploded View (6X6)
  611
- Caliper Removal
  613
- Exploded View
  613
- Parking Brake Caliper Service
  613
- Caliper Disassembly / Inspection
  614
- Caliper Installation
  615
- New Brake Pad Installation
  615
- Parking Brake Disc Service
  615
- Front Brake Pads
  616
- Brake Burnishing Procedure
  617
- Pad Assembly / Installation
  617
- Caliper Removal
  618
- Front Caliper Service
  618
- Caliper Disassembly
  619
- Caliper Installation
  621
- Front Brake Disc
  622
- Rear Brake Pads (6X6)
  623
- Pad Installation
  624
- Pad Removal
  624
- Rear Brake Pads (4X4 Crew)
  624
- Brake Burnishing Procedure
  626
- Caliper Removal
  627
- Rear Caliper Service (6X6)
  627
- Caliper Removal
  630
- Rear Caliper Service (4X4 Crew)
  630
- Caliper Disassembly
  631
- Caliper Installation
  633
- Rear Brake Disc
  634
- Troubleshooting
  635
- Electrical Service Notes
  639
- General Information
  639
- Special Tools
  639
- Under-Hood Components
  639
- Awd / 2Wd / Turf Switch (4X4 Crew)
  640
- Differential Solenoid (4X4 Crew)
  640
- Headlight Switch
  640
- Switches / Controls
  640
- Brake Light Switch
  641
- Parking Brake Switch
  642
- Instrument Cluster
  643
- Rider Information Display
  643
- Diagnostic Display Mode
  644
- Standard Display Modes
  644
- Viewing Diagnostic Codes
  646
- Instrument Cluster Troubleshooting Tests
  648
- Test 1 - no All Wheel Drive
  648
- Test 2 - no Display
  649
- Test 3 - Wheel Speed Sensor
  649
- Test 4 - no Awd Hub Safety Limiter
  650
- Test 5 - Fuel Gauge Display Not Working
  651
- Test 6 - Shift Indicator Not Working (Transmission Switch)
  651
- All Wheel Drive (Awd) Coil
  652
- Gear Position Indicator Switch
  652
- Headlight Housing Removal
  653
  - Lamp Replacement
    654
- Headlights
  653
- Headlight Housing Installation
  654
- Tail Light / Brake Light
  654
- Cooling System
  655
- Cooling System Break-Out Diagram
  655
- Coolant Temperature Sensor
  656
- Efi Diagnostics
  656
- Fuel Sender
  656
- Relays
  657
- Fuses / Circuit Breaker
  658
- Charging System
  659
- Charging System "Break Even" Test
  659
- Current Draw - Key off
  659
- Charging System Alternator Tests
  660
- Charging System Testing Flow Chart
  661
- Battery Activation
  662
- Battery Service
  662
- Battery Inspection
  663
- Battery Testing
  663
- Starter Motor Removal / Disassembly
  665
- Starter System
  665
- Troubleshooting
  665
- Voltage Drop Test
  665
- Brush Inspection / Replacement
  666
- Armature Testing
  667
- Starter Reassembly / Installation
  667
- Starter Drive
  668
- Starter Solenoid Bench Test
  669
- Starter Solenoid Operation
  669
- Starter Exploded View
  670
- Starting System Testing Flow Chart
  671
- Diagnosis (if Equipped)
  672
- Electric Box Lift Actuator
  672
- Electrical Break-Out Diagrams
  673
- Key-On Power Circuit
  673
- Starting Circuit
  673
- Awd Circuit
  674
- Transmission Switch Circuit
  674
- Charging System Circuit
  675
- Speed Sensor Circuit
  675
- Cooling Fan Circuit
  676
- Fuel Display / Fuel Pump Circuit
  676

Polaris Ranger 6X6 700 EFI 2006 Service Manual (362 pages)

4X4 CREW / 6X6

Brand: Polaris | Category: Utility Vehicle | Size: 21.4 MB

General Information Chapter 1 1

6
- Table of Contents
  6
- Chapter 1
  7
- Engine Designation Number
  7
- Engine Serial Number Location
  7
- Model Identification
  7
- Model Information
  7
- Vin Identification
  7
- Transmission I.D. Number Location
  8
- Vehicle Identification Number (Vin) Location
  8
- Vehicle Dimensions
  9
- General Specifications
  11
  - General: 2009 Ranger 4X4 Crew
    15
  - General: 2009 Ranger 6X6
    15
- Special Tools
  15
- Vehicle Information
  15
  - Publication Numbers
    15
  - Paint Codes
    15
  - Replacement Keys
    15
- Misc. Specifications and Charts
  16
  - Conversion Table
    16
  - Standard Torque Specifications
    17
  - Sae Tap / Drill Sizes
    18
  - Metric Tap / Drill Sizes
    18
  - Glossary of Terms
    19
  - General Information
    19
Maintenance Chapter 2 Maintenance

20
- Break-In Period
  22
- Chapter 2
  22
- Maintenance Chart Key
  22
- Periodic Maintenance Chart
  22
- Periodic Maintenance Overview
  22
- Pre-Ride - 25 Hour Maintenance Interval
  23
- 50 - 100 Hour Maintenance Interval
  24
- Service Products and Lubes
  26
  - Polaris Lubricants, Maintenance and Service Products
    26
    
    Brakes
    27
- Transmission
  26
- Maintenance References
  27
  - Maintenance References, Continued
    28
- General Vehicle Inspection and Maintenance
  29
- Fuel System and Air Intake
  30
  - Fuel System
    30
  - Fuel Lines
    30
  - Fuel Filter
    30
  - Vent Lines
    30
  - Throttle Pedal Inspection
    30
  - Throttle Freeplay Adjustment
    31
  - Air Filter Service
    31
  - Air Intake Inspection
    32
- Engine
  33
  - Compression and Leakdown Test
    33
  - Breather Hose Inspection
    33
  - Engine Oil Level
    33
  - Engine Oil and Filter Change
    34
  - Exhaust Pipe
    35
- Transmission and Gearcases
  36
- Cooling System
  41
  - Liquid Cooling System Overview
    41
  - Coolant Level Inspection
    41
  - Radiator Coolant Level Inspection
    42
  - Coolant Strength / Type
    42
  - Cooling System Pressure Test
    42
  - Cooling System Hoses
    42
  - Radiator
    43
  - Coolant Drain / Radiator Removal
    43
- Final Drive / Wheel and Tire
  44
  - Wheel and Hub Torque Table
    44
  - CV Shaft Boot Inspection
    44
  - Wheel Removal
    44
  - Wheel Installation
    44
  - Tire Inspection
    45
  - Tire Pressure
    45
- Electrical and Ignition System
  45
  - Battery Maintenance
    45
  - Battery Fluid Level (Conventional Battery)
    46
  - Battery Removal
    46
  - Battery Installation
    46
  - Battery Storage
    46
  - Battery Charging
    46
  - Spark Plug Service
    47
  - Engine to Frame Ground
    47
- Steering and Suspension
  48
  - Steering
    48
  - Tie Rod End / Steering Inspection
    48
  - Wheel Toe Alignment Inspection
    48
  - Front Suspension
    49
  - Toe Adjustment
    49
  - Rear Suspension
    50
  - Rear Suspension Adjustment (4X4 Crew)
    50
  - Rear Spring Adjustment
    50
- Brake System
  51
Chapter 3 Engine

54
- Crankcase Exploded Views
  55
- Engine Specifications
  55
- Engine Fastener Torque Patterns
  62
- Torque Specifications
  63
- 700 EFI Engine Service Specifications
  64
- General Engine Service
  66
  - Accessible Components
    66
  - Piston Identification
    66
  - Cooling System Specifications
    66
  - Cooling System Pressure Test
    67
  - Cooling System Exploded View
    68
  - Cooling System Bleeding Procedure
    68
  - Valve Cover Removal - 6X6 Models (Engine Installed)
    70
  - Engine Removal
    71
  - Engine Installation Notes
    72
  - Engine Lubrication Specifications
    73
  - Oil Pressure Test
    73
  - Oil Flow Chart
    74
- Special Tools
  66
- Engine Disassembly and Inspection
  75
  - Cylinder Head Assembly Exploded View
    75
  - Rocker Arms / Push Rods
    76
  - Cylinder Head Removal
    76
  - Cylinder Head Inspection / Warp
    77
  - Valve Seal / Spring Service (on Engine)
    77
  - Cylinder Head Disassembly
    78
  - Valve Inspection
    79
  - Combustion Chamber
    80
  - Valve Seat Reconditioning
    80
  - Cylinder Head Reassembly
    82
  - Valve Sealing Test
    83
  - Cylinder Removal
    83
  - Valve Lifter Removal / Inspection
    83
  - Piston Removal
    84
  - Cylinder Inspection
    85
  - Cylinder Hone Selection and Honing Procedure
    86
  - Honing to Deglaze
    86
  - Cleaning the Cylinder after Honing
    86
  - Piston-To-Cylinder Clearance
    87
  - Piston / Rod Inspection
    87
  - Piston Ring Installed Gap
    88
  - Starter Drive Bendix Removal / Inspection
    88
  - Flywheel / Stator Removal / Inspection
    89
  - Engine Crankcase Disassembly / Inspection
    89
  - Camshaft Inspection
    97
- Engine Reassembly
  98
  - Crankcase Reassembly
    98
  - Flywheel / Stator Installation
    107
  - Cylinder Head Reassembly
    108
  - Oil Pump Priming
    110
  - Engine Break-In
    110
- Troubleshooting
  111
  - Engine
    111
  - Cooling System
    112
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

114
- Chapter 4
  115
- General Information
  115
- Special Tools
  115
- Efi Service Notes
  118
- Fuel Tank Exploded View
  119
- Efi System Exploded View
  120
- Efi System Component Locations
  121
- Throttle Body
  121
- Electronic Fuel Injection
  122
  - Principal Components / Efi Operation Overview
    123
  - Initial Priming / Starting Procedure
    123
- Fuel Lines - Quick Connect Removal / Installation
  122
- Electronic Control Unit (Ecu)
  124
- Fuel Pump
  125
  - Fuel Sender Test
    125
  - Fuel Pump Test
    125
  - Fuel Pump / Tank Assembly Replacement
    126
- Fuel Pressure Regulator
  127
- Fuel Injectors
  128
- Crankshaft Position Sensor (Cps)
  129
  - Cps Test
    129
  - Cps Replacement
    129
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  130
- Throttle Position Sensor (Tps)
  130
  - Tps Adjustment
    132
  - Tps Replacement
    133
- Engine Coolant Temperature Sensor (Ect)
  133
- Ignition Coil
  134
  - Ignition Coil Tests
    134
  - Ignition Coil / Ht Lead Replacement
    134
- Diagnostic "Blink Codes
  135
  - Efi Troubleshooting
    136
- General Troubleshooting
  135
- Efi System Break-Out Diagrams
  137
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

142
- Body / Steering / Suspension
  142
- Special Tools
  143
- Torque Specifications
  143
- Body Component Removal
  144
- Chapter 5
  144
- Removal Procedures
  144
- Lower Body, Floor and Fenders (4X4 Crew)
  145
- Lower Body, Floor and Fenders (6X6)
  146
- Hood / Dash Components
  147
- Dash Instruments and Controls
  148
- Cab Frame
  149
  - Assembly / Removal (6X6)
    149
  - Assembly / Removal (4X4 Crew)
    150
- Seat / Head Rest
  151
- Chassis / Main Frame (4X4 Crew)
  152
- Chassis / Main Frame (6X6)
  153
- Steering Assembly
  154
- Steering and Suspension
  155
- Front A-Arm
  156
- Front Strut
  157
  - Front Strut Cartridge Replacement
    158
  - Ball Joint Replacement
    158
- MID Axle A-Arm (6X6)
  159
- Rear A-Arm (4X4 Crew)
  160
- Rear Stabilizer Bar (4X4 Crew)
  162
- Swing Arm (6X6)
  163
- Rear Drive Axle and Swing Arm Exploded View (6X6)
  164
- Rear Cargo Box
  165
  - Cargo Box - Panels
    165
  - Cargo Box - Tailgate / Box Support
    166
- Decal Replacement
  168
- Storage Box (4X4 Crew)
  168
Clutching Chapter 6 Clutching

170
- Chapter 6 Pvt System Fastener Torques
  171
- Pvt System Overview
  171
  - General Operation
    171
  - Drive Clutch Operation
    171
  - Driven Clutch Operation
    172
  - Pvt Break-In (Drive Belt / Clutches)
    172
  - Maintenance / Inspection
    172
  - Overheating / Diagnosis
    173
- Special Tools and Supplies
  171
- Torque Specifications
  171
- Pvt System Service
  174
  - Pvt Sealing, Guard, and Ducting Components
    174
  - Disassembly
    174
  - Assembly
    175
- Drive Belt
  176
  - Belt Removal
    176
  - Pvt Break-In (Drive Belt / Clutches)
    177
- Clutch Alignment
  177
- Clutch Center Distance
  178
- Drive Clutch Service
  179
  - Spring Specifications
    179
  - Shift Weights
    181
  - Exploded View
    181
  - Spider Removal
    182
  - Roller, Pin, and Thrust Washer Inspection
    183
  - Button to Tower Clearance Inspection
    183
  - Shift Weight Inspection
    183
  - Bearing Inspection
    184
  - Clutch Inspection
    184
  - Moveable Sheave Bushing Inspection
    185
  - Bushing Service
    186
  - Clutch Assembly
    188
- Driven Clutch Service
  189
  - Exploded View
    189
  - Clutch Disassembly / Inspection
    189
  - Clutch Assembly
    191
- Troubleshooting
  192
Chapter 7 Final Drive

194
- Front Hub
  196
  - Hub Removal / Inspection
    196
  - Hubstrut Bearing Replacement
    197
  - Hub Installation
    198
  - Front Hub Exploded View
    199
- Special Tools
  196
- Torque Specifications
  196
  - Final Drive
    196
- Front Drive Shaft
  200
  - Removal
    200
  - Drive Shaft / CV Joint Handling Tips
    201
  - Outer CV Joint / Boot Replacement
    201
  - Inner Plunging Joint / Boot Replacement
    203
  - Exploded View
    204
  - Installation
    204
- Front Propshaft
  205
  - Front Propshaft Components
    205
- Propshaft U-Joint Service
  206
  - Centralized Hilliard Exploded View
    208
  - All Wheel Drive Operation
    209
  - Awd Diagnosis
    210
  - Gearcase Removal
    211
  - Gearcase Disassembly / Inspection
    212
  - Gearcase Reassembly / Inspection
    214
  - Backlash Pad (Thrust Pad) Adjustment
    216
  - Gearcase Installation
    217
- MID Drive Hub / Bearing Carrier (6X6)
  217
  - Removal
    217
  - Hub Installation
    219
  - MID Drive Exploded View
    220
- MID Drive Shaft (6X6)
  220
  - Removal
    220
  - Disassembly / Assembly
    220
  - Installation
    221
- MID Propshaft (6X6)
  221
  - Removal
    221
- MID Drive Gearcase (6X6)
  222
  - Gearcase Removal
    222
  - Gearcase Disassembly
    223
  - Gearcase Assembly
    225
  - Gearcase Installation
    228
  - MID Gearcase Exploded
    229
- Rear Drive Shaft (4X4 Crew)
  234
  - Removal
    234
  - Outer CV Joint / Boot Replacement
    234
  - Inner Plunging Joint / Boot Replacement
    237
  - Drive Shaft Exploded View
    239
  - Installation
    240
- Rear Propshaft (4X4 Crew)
  241
  - Removal
    241
  - Installation
    241
- Rear Gearcase (4X4 Crew)
  242
  - General Operation
    242
  - Operation Modes
    243
  - Gearcase Removal
    244
  - Gearcase Disassembly
    244
  - Rear Gearcase Assembly
    247
  - Rear Gearcase Installation
    249
  - Rear Gearcase Exploded View (4X4 Crew)
    250
- Rear Axle / Gearcase Service (6X6)
  251
  - Rear Axle Removal
    251
  - Axle Tube Removal
    252
  - Axle Tube Bearing Replacement
    253
  - Gearcase Disassembly / Inspection
    253
  - Gearcase Assembly
    254
  - Gearcase / Axle Installation
    255
  - Rear Gearcase Exploded View (6X)
    258

Polaris Ranger 6X6 700 EFI 2006 Owner's Manual (122 pages)

Polaris Industries Automobile User Manual

Brand: Polaris | Category: Utility Vehicle | Size: 4.33 MB

Table of Contents
6
Vehicle Identification Numbers
7
Age Restrictions
8
Safety
8
- Operator Safety
  9
- Equipment Modifications
  13
- Fuel Safety
  25
Features and Controls
26
- Component Locations
  27
- Indicator Lights
  29
- Trailer Hitch Bracket
  29
- Auxiliary Outlet
  29
- Seat Removal
  30
- Seat Belts
  31
- Gear Selector
  33
- Ignition Switch
  34
- Brake Pedal
  35
- Vehicle Break-In Period
  36
Operation
36
- Starting the Engine
  38
- Stopping the Engine
  39
- Driving Safely
  40
- Driving Procedures
  40
- Driving on Slippery Surfaces
  41
- Driving Uphill
  42
- Driving Downhill
  43
- Driving through Water
  44
- Driving over Obstacles
  45
- Driving in Reverse
  46
- Parking on an Incline
  47
- Hauling Cargo
  48
- Dumping the Cargo Box
  50
- Towing Loads
  51
- Parking the Ranger
  52
- All Wheel Drive (Awd)
  54
- Disengaging Awd
  54
- Exhaust Emission Control System
  55
- Electromagnetic Interference
  55
- Noise Emission Control System
  55
- Crankcase Emission Control System
  55
Emission Control Systems
55
Maintenance and Lubrication
56
- Periodic Maintenance Chart
  57
- Maintenance Interval
  59
- Lubrication Recommendations
  61
- Engine Oil
  63
- Premium 4 Synthetic Oil
  63
- Oil Check
  64
- Engine Oil Check
  64
- Gearcase Specification Chart
  66
- Front Gearcase
  69
- Oil Change
  69
- Spark Plugs
  73
- Cooling System
  75
- Coolant Level
  76
- Radiator and Cooling Fan
  76
- Radiator Coolant Level
  77
- Low Range
  78
- High Range
  78
- Pvt System
  79
- Pvt Drying
  80
- Filter Systems
  81
- Fuel Filter
  81
- Air Filter
  81
- Spark Arrestor
  82
- Throttle System
  83
- Throttle Freeplay
  83
- Brake Fluid
  85
- Brake Inspection
  86
- Park Brake Inspection
  86
- Park Brake Adjustment
  86
- Steering Wheel Inspection
  87
- Rear Spring Adjustment
  87
- Tire Tread Depth
  89
- Wheel Installation
  90
- Wheel Removal
  90
- Headlight Lamp Replacement
  91
- Headlight Beam Adjustment
  92
- Brake Lights
  92
- Tool Kit
  93
- Indicator Lamp Replacement
  93
- Vehicle Immersion
  94
- Battery Removal
  96
- Battery Installation
  97
- Battery Storage
  97
- Battery Maintenance
  100
- Removal from Storage
  101
- Transporting the Ranger
  101

Polaris Ranger 6X6 700 EFI 2006 Owner's Manual (121 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 6.47 MB

Table of Contents
5
Know Your Vehicle
6
Vehicle Identification Numbers
6
Safety
7
- Operator Safety
  8
- Equipment Modifications
  12
Features and Controls
20
- Component Locations
  21
- Run-Flat Tires
  22
- Trailer Hitch Bracket
  22
- Fuel Cap
  23
- Fuel Requirements
  23
- Rear Box/Flatbed Conversion
  23
- Seat Belts
  24
- Seat Removal
  24
- Mode Button
  26
  - Slave Receptacles
    27
  - Steering Lock
    27
- Gear Selector
  28
- Headlight/Taillight Switch
  31
  - Winch Operation Switch
    31
  - Brake Pedal
    32
  - Throttle Pedal
    32
  - Park Brake Lever
    33
- Instrument Cluster
  34
- Rider Information Center
  35
- Programmable Service Interval
  39
Operation
42
- Pre-Ride Inspection
  43
  - Starting the Engine
    44
  - Stopping the Engine
    45
- Driving Procedure
  46
- Driving Safely
  46
- Driving on Slippery Surfaces
  47
- Driving Uphill
  48
- Driving Downhill
  49
- Driving through Water
  50
- Driving over Obstacles
  51
- Driving in Reverse
  52
- Parking on an Incline
  53
- Hauling Cargo
  54
- Dumping the Cargo Box
  56
- Towing Loads
  57
- Parking the Vehicle
  58
- Disengaging Awd
  59
- Locking the Differential
  60
- Severe Use Definition
  61
Maintenance
61
- Maintenance Chart Key
  62
- Lubrication Recommendations
  65
- Engine Oil
  67
- Oil Check
  68
- Oil and Filter Change
  69
- Gearcase Specification Chart
  70
- Rear Gearcase
  75
  - Spark Plug Inspection
    77
  - Spark Plugs
    77
  - Spark Plug Condition
    78
  - Cooling System
    79
- Radiator Coolant Level
  81
- Pvt System
  83
- Pvt Drying
  84
- Air Filter
  85
- Filter Systems
  85
- Fuel Filter
  85
- Spark Arrestor
  86
- Throttle Freeplay
  87
  - Throttle System
    87
  - Throttle Freeplay Adjustment
    88
  - Brake Inspection
    90
- Park Brake Cable Tension
  90
- Park Brake Inspection
  90
- Steering Wheel Inspection
  91
- Rear Spring Adjustment
  92
  - Suspension Adjustment
    92
  - Tire Tread Depth
    93
  - Wheel Installation
    94
  - Wheel Removal
    94
  - Vehicle Immersion
    95
- Headlight Lamp Replacement
  96
- Headlight Beam Adjustment
  97
  - Conventional Battery
    98
  - Battery Removal
    99
  - Battery Installation
    100
  - Battery Storage
    101
  - Cleaning and Storage
    104
- Polishing the Vehicle
  105
- Storage Tips
  106
- Battery Maintenance
  107
- Removal from Storage
  108
- Transporting the Vehicle
  109

Polaris Ranger 6X6 700 EFI 2006 Owner's Manual (126 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 4.75 MB

Table of Contents
6
Vehicle Identification Numbers
7
Safety
8
- Equipment Modifications
  16
Features and Controls
25
- Component Locations
  26
- Instrument Cluster
  28
- Programmable Service Interval
  33
- Seat Belts
  36
- Gear Selector
  38
  - Seat Removal
    38
  - Brake Pedal
    39
- Ignition Switch
  41
- Light Switch
  42
Awd Switch
42
Operation
43
- Pre-Ride Inspection
  44
  - Starting the Engine
    45
  - Stopping the Engine
    46
- Driving Procedure
  47
- Driving Safely
  47
- Driving on Slippery Surfaces
  48
- Driving Uphill
  49
- Driving Downhill
  50
- Driving through Water
  51
- Driving over Obstacles
  52
- Driving in Reverse
  53
- Parking on an Incline
  54
- Hauling Cargo
  55
- Dumping the Cargo Box
  57
  - Belt Life
    58
  - Towing Loads
    58
- Parking the Vehicle
  59
- Disengaging Awd
  60
Emission Control Systems
61
Maintenance
62
- Maintenance Chart Key
  63
- Lubrication Recommendations
  66
- Engine Oil
  67
- Gearcase Specification Chart
  70
- Middle Gearcase
  74
- Rear Gearcase
  75
  - Spark Plugs
    76
  - Spark Plug Condition
    77
  - Cooling System
    78
- Radiator Coolant Level
  80
- Pvt System
  82
- Pvt Drying
  83
- Air Filter
  84
- Fuel Filter
  84
- Spark Arrestor
  85
- Throttle Freeplay
  86
  - Throttle Freeplay Inspection
    86
  - Throttle System
    86
  - Throttle Freeplay Adjustment
    87
  - Brake Fluid
    88
  - Brake Inspection
    89
- Park Brake Inspection
  89
- Park Brake Adjustment
  90
- Rear Spring Adjustment
  90
  - Steering Wheel Inspection
    90
  - Tire Tread Depth
    92
  - Wheel Installation
    93
  - Wheel Removal
    93
- Headlight Lamp Replacement
  94
- Headlight Beam Adjustment
  95
  - Vehicle Immersion
    96
  - Battery Removal
    98
  - Battery Installation
    99
  - Battery Storage
    100
  - Cleaning and Storage
    103
- Polishing the Vehicle
  104
- Fluid Levels
  106
- Battery Maintenance
  107
- Removal from Storage
  108

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Polaris Ranger 6X6 700 EFI 2006 Service Manual (362 pages)

Table of Contents

General Information Chapter 1 1

Maintenance Chapter 2 Maintenance

Chapter 3 Engine

Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

Clutching Chapter 6 Clutching

Chapter 7 Final Drive

Polaris Ranger 6X6 700 EFI 2006 Owner's Manual (122 pages)

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Polaris Ranger 6X6 700 EFI 2006 Owner's Manual (121 pages)

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Polaris Ranger 6X6 700 EFI 2006 Owner's Manual (126 pages)

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