Polaris RANGER EV 2015 Service Manual
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Polaris RANGER EV 2015 Service Manual

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2015-2016 RANGER EV
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed August 2015 (PN 9926595 R01)
© Copyright 2015 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RANGER EV 2015

  • Page 1 Publication Printed August 2015 (PN 9926595 R01) © Copyright 2015 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 5 2015-2016 RANGER EV Service Manual Chapter Summary CHAPTER 1: GENERAL / BATTERY CHAPTER 2: MAINTENANCE CHAPTER 3: DRIVE MOTOR CHAPTER 4: BODY / STEERING / SUSPENSION CHAPTER 5: FINAL DRIVE CHAPTER 6: TRANSAXLE / DIFFERENTIAL CHAPTER 7: BRAKE SYSTEM CHAPTER 8: ELECTRICAL...

  • Page 7: Table Of Contents

    ............1.21 BATTERY CONTACTOR FASTENER TORQUE 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 8 .................1.38 DECIMAL EQUIVALENTS 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 9: Special Information Regarding The Ranger Ev

    Remove all jewelry or metal objects that could come in contact with battery terminals as you work in or around the battery compartment; including (but not limited to): • Rings, chains, wrist watches, bracelets, etc. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 10: Vehicle Identification

    INDIVIDUAL SERIAL NO. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 11: Vehicle And Motor Serial Number Locations

    GENERAL / BATTERY VEHICLE AND MOTOR SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris utility vehicle, be sure to refer to the vehicle identification number (VIN) and the motor model and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle and on the dash in front of the steering wheel (see Figure 1-1).

  • Page 12: Vehicle Information

    9926474 NOTE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www. polarisindustries.com or purchased from www. purepolaris.com. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 13: Replacement Keys

    Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.

  • Page 14: General Specifications

    Hitch Towed Load Weight (15 degree 850 lbs. / 386 kg grade) Hitch Vertical 150 lbs. / 68 kg Weight Capacity Maximum Towing 10 mph. / 16 kph Speed 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 15 20 psi (138 kPa) (Front and Rear) 4 Wheel Hydraulic Disc With Dual Brake System Bore Front Calipers Brake Fluid DOT 4 Dash Mounted Lever- Activated Parking Brake Mechanical 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 16 80°F (26.6°C) or higher. This is the case for all lead-acid battery products. Cold ambient temperatures can negatively affect the range by up to 30%. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.10 © Copyright Polaris Industries Inc.

  • Page 17: Features And Controls

    Always apply the service brakes before engaging or releasing the park brake. Be sure the lever is completely forward when releasing the park brake. Drive Mode Switch 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.11 © Copyright Polaris Industries Inc.

  • Page 18: Battery Discharge Indicator

    If the two left-most bars begin to flash, battery service life loads, steep will be significantly reduced with continued operation. hills, Stop the vehicle and recharge the batteries. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.12 © Copyright Polaris Industries Inc.

  • Page 19: Charge Status Indicator

    Flashing Amber charger temperature exists; open hood to improve air flow. Charger error exists; reset Flashing charger power and refer to Battery section in this chapter. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 20: Hour Meter

    Auxiliary Power Outlet on the dash. AWD MODE - Once enabled, the AWD remains enabled until the switch is turned off. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 This mode of operation is well suited to turf driving or whenever aggressive traction is not required. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: Indicator Light Panel

    Controller or motor out of Sequence fault temperature range Power fault Communication error Contactor issue Software fault Motor speed or throttle input See Chapter 8 for diagnostic procedures. error 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 23: Windshield

    Disconnected For Service Main Power Connector, page 1.20) In NEUTRAL, cycle key Required Torque Exceeds switch OFF and ON, Motor Capability select LOW range, then select direction. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.17 © Copyright Polaris Industries Inc.

  • Page 24: Battery Safety

    GENERAL / BATTERY BATTERY SAFETY PROPOSITION 65 WARNING • Refer to your Owner’s manual or contact your local Polaris dealer with any questions. WARNING PROPOSITION 65 WARNINGbattery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of california to cause cancer and reproductive harm.

  • Page 25: Battery Compartment Warning Label

    • Refer to your Owner’s manual or contact your local Polaris dealer with any questions. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.19 © Copyright Polaris Industries Inc.

  • Page 26: Battery Maintenance

    • Make sure vent caps are installed properly during vehicle operation and battery charging. • Avoid charging at high temperatures. See Battery Charging, page 1.21. • Use only genuine Polaris accessories and follow instructions provided. BATTERY CONDITIONING Number of Charge Cycles...

  • Page 27: Battery Contactor Fastener Torque

    AC outlet. This increases the risk of accidental short circuits to battery terminals or other wires caused 2. Remove seat and storage trays. by tools or other objects. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 28: Battery Water Level

    9. Inspect and top off battery water when charge cycle is complete. BATTERY WATER LEVEL NEVER add acid (electrolyte) to batteries. Use clean distilled water. Tap water contains minerals that are harmful to a battery. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.22 © Copyright Polaris Industries Inc.

  • Page 29: Battery Testing - Overview

    Battery Discharger - Lester 36/48 is recommended. 5. Install caps and slide levers to the locked position. (Available through Bosch Automotive Service Solutions and Commercially Available). 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 30: Basic Discharger Instructions

    The following list of functions and what they represent is should be 48 volts, and the shut-off voltage will be 42 printed on the front panel of the discharger unit. volts. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.24 © Copyright Polaris Industries Inc.

  • Page 31: Battery Discharge And Testing Procedure

    6. Connect the RED (+) cable of the discharger unit to the positive terminal of the rear-most battery in the LEFT bank (driver side) with the cable that leads to the top terminal of Contactor). 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.25 © Copyright Polaris Industries Inc.
  • Page 32 The tempera- ture is required for calculation of Adjusted Discharge Time later. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.26 © Copyright Polaris Industries Inc.

  • Page 33: Battery Specific Gravity Test

    A temperature-compensated digital or a numerically graduated hydrometer is required for this test. Floating ball types cannot be used. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.27 © Copyright Polaris Industries Inc.

  • Page 34: Battery Removal And Installation

    2. Set parking brake. 3. Remove seat and storage trays. 4. DISCONNECT the battery charging cord from the AC outlet and then from the vehicle charge cord. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.28 © Copyright Polaris Industries Inc.

  • Page 35: Battery Terminal Orientation And Cable Routing

    BATTERY TERMINAL ORIENTATION AND CABLE ROUTING The following illustration depicts general cable orientation and routing. See following pages for cable removal and installation sequence. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.29 © Copyright Polaris Industries Inc.
  • Page 36 The chassis of the vehicle is at ground potential when the battery charging cord is connected to an AC outlet. This increases the risk of accidental short circuits to battery terminals or wires caused by tools or other objects. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.30 © Copyright Polaris Industries Inc.

  • Page 37: Battery Cable Removal

    GENERAL / BATTERY BATTERY CABLE REMOVAL 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 38: Battery Cable Installation

    GENERAL / BATTERY BATTERY CABLE INSTALLATION TORQUE Battery Retainer Bracket Nut: 8 ft-lbs (11 Nm)Battery Terminal Nut: 8 ft-lbs (11 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.32 © Copyright Polaris Industries Inc.

  • Page 39: Battery Storage

    • NEVER connect an auxiliary battery to the factory- installed DC-to-DC converter. If more than 10 amps are needed for accessories, always install the polaris approved auxiliary accessory battery kit. • NEVER connect a 12 volt accessory directly to the drive system batteries.

  • Page 40: Battery Charger Led Function

    GENERAL / BATTERY BATTERY CHARGER LED FUNCTION BATTERY CHARGER TROUBLESHOOTING If an error fault occurs, reference the table below. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.34 © Copyright Polaris Industries Inc.

  • Page 41: Specific Gravity / Charge Percentage Table

    **TEMPERATURE CORRECTION: ADD .004 to the reading for every 10 degrees ABOVE 80 F. SUBTRACT .004 to the reading for every 10 degrees BELOW 80 F. 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.35 © Copyright Polaris Industries Inc.

  • Page 42: Reference

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.36 © Copyright Polaris Industries Inc.

  • Page 43: Standard Bolt Torque Specification

    DRILL SIZE THREAD THREAD #1–72 9/16–12 31/64 SIZE DRILL SIZE SIZE DRILL SIZE #2–56 9/16–18 33/64 #0–80 3/64 1/2–13 27/64 #2–64 5/8–11 17/32 #1–64 1/2–20 29/64 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.37 © Copyright Polaris Industries Inc.
  • Page 44 0.1406″ 21/64 0.3281″ 5/32 0.1563″ 4 mm = 0.1575″ 11/32 0.3438″ 9 mm = 0.3543″ 11/64 0.1719″ 23/64 0.3594″ 0.1875″ 5 mm = 0.1969″ 0.375″ 3/16 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.38 © Copyright Polaris Industries Inc.
  • Page 45 0.8906″ 23 mm = 0.9055″ 29/32 0.9063″ 59/64 0.9219″ 15/16 0.9375″ 24 mm = 0.9449″ 61/64 0.9531″ 31/32 0.9688″ 25 mm = 0.9843″ 63/64 0.9844″ 1.000″ 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.39 © Copyright Polaris Industries Inc.
  • Page 46 GENERAL / BATTERY NOTES 9926595 R01 - 2015-2016 RANGER EV Service Manual 1.40 © Copyright Polaris Industries Inc.
  • Page 47 ....... . 2.4 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS GENERAL VEHICLE INSPECTION AND MAINTENANCE..........2.5 .

  • Page 48: Periodic Maintenance Chart

    E = Emission Control System Service (California). NOTE Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.
  • Page 49 ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 50: Service Products And Lubricants

    Crankcase Sealant, 3-Bond 1215 (5oz.) 2871557 NOTE The number count indicated by each part number in the table above indicates the number of units that are shipped with each order. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 51: General Vehicle Inspection And Maintenance

    Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 52: Fluid Maintenance References

    Add lubricant to bottom of fill 6.1 oz. (180 ml) Front Gearcase Demand Drive hole threads Add lubricant to bottom of fill Angle Drive Fluid 20.3 oz. (600 ml) Transaxle hole threads 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 53: Final Drive / Wheel And Tire

    2. Install washers and wheel nuts (or lug nuts with tapered end toward wheel) and tighten lightly by hand until wheel is centered and firmly supported. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 54: Cv Shaft Boot Inspection

    Inspect inner and outer CV joint boots on front and rear drive axles for damage, tears, wear, or leaking grease. Replace if worn, damaged, or leaking. See Chapter 7 for boot replacement. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 55: Gearcase Maintenance

    6.1 oz. (180 ml) 12. Install fill plug with a new O-ring and torque to 4. If fluid level is not even with the bottom threads, add specification. Polaris Demand Drive Plus as needed. Do not overfill. TORQUE Drain Plug: 10 ft-lb (14 Nm) 13.

  • Page 56: Transaxle (Rear Gearcase) Lubricant

    14 ft-lb (19 Nm) Transaxle Lubricant Change 1. Place a drain pan under transaxle drain plug area. 2. Place towels beneath fill plug and remove fill plug. 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.10 © Copyright Polaris Industries Inc.
  • Page 57 20.3 oz. (600 ml) 6. Reinstall fill plug with a new O-ring and torque to specification above. 7. Check for leaks. Dispose of used lubricant properly. 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.11 © Copyright Polaris Industries Inc.

  • Page 58: Steering

    Whenever steering components are replaced, check front end alignment. WARNING Due to the critical nature of the procedures outlined in this section, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD-certified technician when replacing worn or damaged steering parts.

  • Page 59: Toe Adjustment

    (A) - (B) = 1/8 - 1/4" (.3 to .6 cm) TOE ADJUSTMENT If toe alignment is incorrect, adjust as follows. 4. Remove cotter pin (E) from tie rod end bolt. 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.13 © Copyright Polaris Industries Inc.
  • Page 60 10. Torque nut to specification and install a NEW cotter pin. TORQUE Tie Rod End Nut Torque: 40 ft-lb (54 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.14 © Copyright Polaris Industries Inc.

  • Page 61: Suspension

    The rear shock absorber springs are pre-load adjustable. Use Spanner Wrench to rotate adjuster cam to increase or decrease spring pre-load. Always adjust both left and right sides equally. Shock Spanner Wrench: 2871095 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.15 © Copyright Polaris Industries Inc.

  • Page 62: Brake System

    Refer to Chapter 7 (Brakes) for torque values and repair procedures. BRAKE PAD / DISC INSPECTION 1. Check brake pads for wear, damage, or looseness. 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.16 © Copyright Polaris Industries Inc.

  • Page 63: Parking Brake Adjustment

    7. Inspect park brake adjustment as described in Steps 1 and 2. 8. Repeat Step 4-6 until the proper adjustment is obtained for the parking brake. 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.17 © Copyright Polaris Industries Inc.

  • Page 64: Parking Brake Pad Inspection

    MAINTENANCE PARKING BRAKE PAD INSPECTION Measure the thickness of the rear caliper parking brake pads as described below. Refer to Brakes Chapter for pad replacement procedure. 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.18 © Copyright Polaris Industries Inc.

  • Page 65: Electrical System

    MAINTENANCE ELECTRICAL SYSTEM BATTERY MAINTENANCE Refer to Chapter 1 GENERAL / BATTERY for all battery information. BATTERY INFORMATION Refer to Index to Battery Information, page 1.17 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.19 © Copyright Polaris Industries Inc.
  • Page 66 MAINTENANCE NOTES 9926595 R01 - 2015-2016 RANGER EV Service Manual 2.20 © Copyright Polaris Industries Inc.
  • Page 67 ..............3.13 DRIVE MOTOR BENCH TESTS 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 68: Special Tools

    Insulated Socket 1/2 inch Commercially Available Insulated Wrench Set Bosch Automotive Service Solutions: Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800- 345-2233 or on-line at http://polaris. service-solutions. com/ 9926595 R01 - 2015-2016 RANGER EV Service Manual...

  • Page 69: Safety Information

    Make sure the vehicle is properly immobilized before beginning any maintenance or repair. Always block the chassis securely and set the parking brake before working under the vehicle. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 70: Specifications

    580 W (.580 K +/- 20% @ 68° F (20° C) (Thermistor) harness) TEMPERATURE Sensor Resistance SENSOR Infinite (O.L.) (Black Wire or White Wire to Motor Case (Thermistor) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 71: Drive Motor

    Ball Bearing Temperature Sensor Temperature Sensor O-Ring Harness Circlip Gear Wheel Sensor Bolt, Drive Motor Seal, Fitting 8 ft-lb (11 Nm) Threaded Plug Seal, Plate Cover Plate 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 72: Drive Motor Service

    If cables tags are missing, mark cables location before removal. 7. Remove three cables from drive motor terminal block. 10. Remove lower motor mount bolt 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 73: Drive Motor Installation

    2. With the aid of an assistant or a mechanical lift or hoist, lift the motor into position near the transaxle shaft. Align splines of transaxle shaft with motor shaft and slide motor toward transaxle housing until seated. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 74: Drive Motor Disassembly

    1. Mark casing and drive end housing for reference terminal block and install washer and nut. during reassembly. 11. Connect cable marked “V” and install washer and nut. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 75 3. Remove the three nuts securing terminal leads to the terminal block. 5. Lift terminal leads and remove guide block 6. Remove motor case bolts and remove terminal block 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 76: Rotor Removal

    Be prepared to catch rotor. housing out of stator. 9. For bench tests see Drive Motor Bench Tests, page 3.13. ROTOR REMOVAL 1. Remove threaded cap from housing. 9926595 R01 - 2015-2016 RANGER EV Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 77: Bearing Replacement

    The bearing should install with minimal press effort. 8. Install the internal snap-ring. Be sure it is fully seated in the groove. 9926595 R01 - 2015-2016 RANGER EV Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 78: Drive Motor Assembly

    6. Install motor end cap access cover and gasket. Torque to specification. TORQUE Access Cover Screws: 31 in-lb (4 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 79: Drive Motor Bench Tests

    (Infinite or O.L.). TEMPERATURE SENSOR RESISTANCE 580 Ω ± 10% @ 68° F (20° C) SENSOR WIRE(S) TO MOTOR CASE: Ω (OL) 9926595 R01 - 2015-2016 RANGER EV Service Manual 3.13 © Copyright Polaris Industries Inc.
  • Page 80 (connect leads together and Stator Phase 2 Stator Phase 3 0.1 - 0.2 Ω record resistance displayed on meter. Subtract this value from stator winding resistance measurement. 9926595 R01 - 2015-2016 RANGER EV Service Manual 3.14 © Copyright Polaris Industries Inc.
  • Page 81 ................4.25 DECAL REPLACEMENT 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 82: General Specifications

    Strut Spring Compressor (LH) 2871573 Strut Spring Compressor (RH) 2871574 Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris. service-solutions. com/ Included in the tool kit, the multi- function pliers are designed to remove the plastic push rivets used to fasten body components.

  • Page 83: Component Locations

    BODY / STEERING / SUSPENSION COMPONENT LOCATIONS RIGHT SIDE VIEW REAR VIEW FRONT VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 84: Exploded Views

    8 ft-lbs (10.8 Nm) Bolt - M8 x 1.25 x 20 (QTY.32) 8 ft-lbs (10.8 Nm) Nut - M8 x 1.25 (QTY.4) 22 ft-lbs (29.8 Nm) Washer, Skid Plate (QTY.13) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 85: Dash Switches And Instruments

    Hour Meter / Battery Discharge Indicator Indicator Light Panel Key Switch (OFF / ON) Headlight Switch Drive Direction Selector Charge Status Indicator AWD Switch Drive Mode Switch 12V Accessory Socket 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 86: Dash Mounting

    BODY / STEERING / SUSPENSION DASH MOUNTING NUMBER PART DESCRIPTION TORQUE Screw - M6 x 1.0 x 25 (QTY.2) 8 ft-lbs (10.8 Nm) Rivet (QTY.11) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 87: Hood / Front Fascia / Mirrors

    BODY / STEERING / SUSPENSION HOOD / FRONT FASCIA / MIRRORS NUMBER PART DESCRIPTION Hood Front Fascia Dash Panel Glove Box Lid Hood Strap Hood Hinge Pins Push Rivet Hood Latch 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 88: Seat Mounting / Seat Belts

    Washer - Seat Belt, Rubber Screw, Seat Back (QTY.8) 24 in-lb (3 Nm) Bolt, Seat Belt Buckle - M12 x 1.75 (QTY.4) Nut, Seat Belt Buckle (QTY.4) 40 ft-lb (52 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 89: Floor / Rear Fender / Side Panel / Corner Panel

    FLOOR / REAR FENDER / SIDE PANEL / CORNER PANEL TORQUE (IF APPLICABLE) NUMBER PART DESCRIPTION Front Floor Main Floor Floor Cover Cup Holder Push Rivet 5 ft-lb (7 Nm) Screw: 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 90: Cargo Box / Tailgate / Cargo Box Support

    Box Tilt Shock Box Tilt Latch Heat Shield Tailgate Tube Tailgate Mount Bracket Bushing Tailgate Latch 8 ft-lb (11 Nm) Screw 5 ft-lb (7 Nm) Screw 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 91: Cab Frame Exploded View

    36 ft-lb (49 Nm) Screw - M10 x 1.5 x 30 (QTY.4) 36 ft-lb (49 Nm) Nut - M10 x 1.5 (QTY.6) Nut - M10 x 1.25 (QTY.4) 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 92: Body Component Removal

    3. Remove the two fasteners from each side of the upper portion of the bumper. 4. Carefully remove the bumper from the vehicle. 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 93: Cargo Box Installation

    3. Install the box hinges on both sides. 4. Remove the Torx-head screws retaining the front floor cover. 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.13 © Copyright Polaris Industries Inc.
  • Page 94 6. Continue with ‘Hood / Dash Removal’ procedure. 7. Remove the accelerator and brake pedals for adequate clearance to remove the front floor section. 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.14 © Copyright Polaris Industries Inc.

  • Page 95: Steering

    BODY / STEERING / SUSPENSION STEERING STEERING ASSEMBLY EXPLODED VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 96: Suspension

    Upon A-arm installation completion, test vehicle at low A-arm Bolts: speeds before putting into regular service. 30 ft-lb (41 Nm) BALL JOINT REPLACEMENT 1. Loosen front wheel nuts slightly. 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.16 © Copyright Polaris Industries Inc.
  • Page 97 • Insert new ball joint (L) into driver (M). • Slide ball joint / driver assembly into guide. • Apply heat to ease installation. • Drive new joint into strut housing until fully seated. 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.17 © Copyright Polaris Industries Inc.

  • Page 98: Front Strut Cartridge Replacement

    Refer to Illustration in Chapter 5. 1. Hold strut rod and remove top nut. 2. Compress spring using strut spring compressor tools. Strut Spring Compressor Tools: 2871573 and 2871574 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.18 © Copyright Polaris Industries Inc.

  • Page 99: Front Strut Exploded View

    BODY / STEERING / SUSPENSION FRONT STRUT EXPLODED VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.19 © Copyright Polaris Industries Inc.

  • Page 100: Rear A-Arm Removal / Replacement

    6. If not replacing the A-arm, thoroughly clean the a- arm and pivot tubes. 7. Insert new A-arm bushings and pivot tubes into the new A-arm. Lower A-arm Removal 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.20 © Copyright Polaris Industries Inc.

  • Page 101: Rear A-Arm Installation

    A-arm. Torque shock / linkage 12. Insert new A-arm bushings and pivot tubes into the new A-arm. fastener to specification. TORQUE Shock Fastener: 30 ft-lb (41 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.21 © Copyright Polaris Industries Inc.

  • Page 102: Rear A-Arm Exploded View

    Upon A-arm installation completion, test vehicle at low speeds before putting into service. REAR STABILIZER BAR REMOVAL / INSTALLATION 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.22 © Copyright Polaris Industries Inc.

  • Page 103: Exploded View

    8. Torque the stabilizer retaining bolts and upper rubber new fasteners to specification. bushing nuts to specification. TORQUE TORQUE Shock Fasteners: Stabilizer Bar Bolts: 30 ft-lb (41 Nm) 17 ft-lbs (23 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.23 © Copyright Polaris Industries Inc.

  • Page 104: Shock Replacement

    4. Reinstall the shock onto the vehicle and torque new fasteners to specification. TORQUE Shock Fasteners: 30 ft-lb (41 Nm) SHOCKS EXPLODED VIEW DECAL REPLACEMENT 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 105: Decal Replacement

    A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent, flexed, or damaged. 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.25 © Copyright Polaris Industries Inc.
  • Page 106 BODY / STEERING / SUSPENSION NOTES 9926595 R01 - 2015-2016 RANGER EV Service Manual 4.26 © Copyright Polaris Industries Inc.
  • Page 107 ............. .5.39 REAR DRIVE SHAFT EXPLODED VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 108: Special Tools

    TOOL DESCRIPTION 2872608 Roll Pin Removal Tool PU-48951 or 8700226 CV Boot Clamp Tool Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris. service-solutions.com/ TORQUE SPECIFICATIONS WHEEL AND HUB TORQUE TABLE...

  • Page 109: Front & Rear Hub/Wheel Exploded View

    FINAL DRIVE FRONT & REAR HUB/WHEEL EXPLODED VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 110: Prop Shaft Service

    Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 111 If additional cables must be removed, insulate the removed end thoroughly with electrical tape so they cannot come in contact with the contactor, controller, or any other battery terminal. Secure out of the way. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 112: Prop Shaft Installation

    4. Re-connect battery cable (s). Place the larger cable against battery terminal and the smaller against the terminal nut and torque to specification. TORQUE Battery Terminal Nut: 8 ft-lbs (10.8 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 113: Prop Shaft U-Joint Installation

    PROP SHAFT U-JOINT INSTALLATION 1. Install new bearing caps in yoke by hand. 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 114 6. Repeat Steps 1-3 to install bearing caps on outer yoke. 7. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 115: Front Hub / Bearing

    , front spindle castle nut, and washer. 4. Use a tie rod fork to remove A-arm from ball joint stud. 7. Pull hub straight outward to remove. HUBSTRUT BEARING REPLACEMENT Bearing Removal 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 116 The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 117: Front Drive Shaft

    , front spindle castle nut, and washer. 4. Use a tie rod fork to remove A-arm from ball joint stud. 7. Pull hub straight outward to remove. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 118: Front Drive Shaft Installation

    1. Install new spring ring on drive shaft. Apply an anti- seize compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 119: Front Hub Installation

    10. Install the lower A-arm onto the lower ball joint, torque nut to specification and install new cotter pin. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.13 © Copyright Polaris Industries Inc.
  • Page 120 FINAL DRIVE 11. Install wheel / tire assembly (Wheel and Hub Torque TORQUE Table, page 2.7). Ball Joint Nut: 30 ft-lb (41 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 121: Front Gearcase / Centralized Hilliard

    AWD Engagement: When the AWD switch is activated, the AWD coil is powered by a 12 Vdc input which creates 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 122: Centralized Hilliard Exploded View

    Bearing AWD DIAGNOSIS Symptom: No AWD engagement or intermittent function. 1. Open the hood and locate the connector (A) for AWD engagement coil. Separate the connector. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.16 © Copyright Polaris Industries Inc.
  • Page 123 8. If voltage is present, remove gearcase (Gearcase Removal, page 5.18), disassemble the gearcase (Gearcase Disassembly / Inspection, page 5.19) and inspect components as described in Steps 9 - 12. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 124: Gearcase Removal

    3. Disconnect gearcase vent line (C). 4. Remove prop shaft from front gearcase (Prop Shaft Removal, page 5.4). 5. Remove both front drive shafts (Front Drive Shaft Removal, page 5.11). 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 125: Gearcase Disassembly / Inspection

    1. Drain and properly dispose of used oil. 2. Remove gearcase cover bolts. 4. Hold the roller bearing cage in place and carefully withdraw the ring gear assembly from the gearcase housing. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.19 © Copyright Polaris Industries Inc.
  • Page 126 8. Inspect the ring gear (A) for consistent wear 6. Remove the roll cage assembly, rollers, and H- patterns. The surfaces should be free of nicks and springs. scratches. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.20 © Copyright Polaris Industries Inc.
  • Page 127 Removal may result in spring deformation. AWD Diagnosis, page 5.16 10. Use a flat head screwdriver to remove retaining ring (B) from output cover. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.21 © Copyright Polaris Industries Inc.
  • Page 128 17. Inspect the output hub Garlock bushing (K) for scoring and wear. 15. Inspect the magnetic coil (I) in the output housing. NOTE AWD Diagnosis, page 5.16 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 129: Gearcase Reassembly / Inspection

    While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.23 © Copyright Polaris Industries Inc.
  • Page 130 The output hub should spin freely. NOTE Be sure backlash plate is in place. A small amount of grease can be used to help secure backlash plate. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.24 © Copyright Polaris Industries Inc.
  • Page 131 10. Install the ring gear shim into gearcase by fitting ears (G) into gearcase slots (H). This photo is for reference only, the armature plate is actually installed in the output cover. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.25 © Copyright Polaris Industries Inc.

  • Page 132: Backlash Pad (Thrust Pad) Adjustment

    1. Lay gearcase on the side with output cover facing 2. The backlash screw is installed with a locking agent. Use a heat gun to soften the Loctite on the adjuster screw (A). 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.26 © Copyright Polaris Industries Inc.

  • Page 133: Gearcase Installation

    10. Turn the backlash adjustment screw out (counter- clockwise) 1/32 of a turn. Demand Drive (PN 2877922) 11. Test drive vehicle to re-evaluate noise performance. Front Housing Capacity: 6.1 oz. (180 ml) 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.27 © Copyright Polaris Industries Inc.

  • Page 134: Rear Bearing Carrier

    1. Disconnect the Main Power Connector (A) under the seat. 2. Elevate rear of vehicle and safely support. 3. Remove rear wheels. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.28 © Copyright Polaris Industries Inc.

  • Page 135: Disassembly

    10. Remove the bearing carrier. Inspect the bearing 4. Inspect bearing housing for scratches, wear or again for smoothness and side to side movement, damage. Replace housing if damaged. replace as needed. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.29 © Copyright Polaris Industries Inc.

  • Page 136: Assembly

    2. Align the bottom of the bearing carrier with the lower A-arm. If previously removed, install new lower A- arm bushings. Install the lower bearing carrier fastener. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.30 © Copyright Polaris Industries Inc.
  • Page 137 TORQUE The lower shock bolt may need to be removed to allow Rear Hub Castle Nut: the upper A-arm to move freely. 110 ft-lb (150 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.31 © Copyright Polaris Industries Inc.

  • Page 138: Rear Drive Shaft

    3. Install the drive shaft into the rear bearing carrier. 4. Perform the “Rear Bearing Carrier Installation” procedure to properly reassemble the vehicle. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.32 © Copyright Polaris Industries Inc.

  • Page 139: Drive Shaft Service

    CV joints and CV joint boots. OUTER CV JOINT / BOOT REPLACEMENT 1. Using a side cutters, cut away and discard boot clamps. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.33 © Copyright Polaris Industries Inc.
  • Page 140 7. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.34 © Copyright Polaris Industries Inc.

  • Page 141: Inner Plunging Joint / Boot Replacement

    Boot Clamp Tool (PU-48951 or 8700226). INNER PLUNGING JOINT / BOOT REPLACEMENT 1. Using a side cutters, cut away and discard the boot clamps. Axle Boot Clamp Tool PU-48951 or 8700226 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.35 © Copyright Polaris Industries Inc.
  • Page 142 9. Visually inspect the joint for damage. Replace if needed. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.36 © Copyright Polaris Industries Inc.
  • Page 143 22. Position the boot lip in its groove. Install and tighten the large clamp using the Axle Boot Clamp Tool. 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.37 © Copyright Polaris Industries Inc.

  • Page 144: Front Drive Shaft Exploded View

    FINAL DRIVE FRONT DRIVE SHAFT EXPLODED VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.38 © Copyright Polaris Industries Inc.

  • Page 145: Rear Drive Shaft Exploded View

    FINAL DRIVE REAR DRIVE SHAFT EXPLODED VIEW 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.39 © Copyright Polaris Industries Inc.
  • Page 146 FINAL DRIVE NOTES 9926595 R01 - 2015-2016 RANGER EV Service Manual 5.40 © Copyright Polaris Industries Inc.
  • Page 147 ..............6.20 TROUBLESHOOTING CHECKLIST 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 148: Specifications

    2871699 (Part of 2871702 Driveshaft Seal Guide Kit) Bearing Seal Driver 2871282 (50 mm) Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris. service-solutions.com/ LUBRICATION FLUID CAPACITY...
  • Page 149 The shift fork slides a dog gear away from the side gear that is part of the planetary differential assembly, unlocking the rear differential. The rear drive shafts are now dependent on the differential, allowing for tighter turns. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 150: Transaxle Service

    WARNING Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Always wear eye protection. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 151: Transaxle Disassembly

    Exploded View, Complete, page 6.10 - Transaxle Exploded View, Shaft and Gear Assemblies, page 6.11). 1. Drain and properly dispose of transaxle lubricant (see Transaxle (Rear Gearcase) Lubricant, page 2.10). 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 152 CAUTION Do not pry on case sealing surfaces. Tap only in reinforced areas on the cover. 4. Remove motor shaft assembly. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 153: Transaxle Assembly

    10 ft-lb (14 Nm) 2. Clean bearing plate screw threads in case to remove all oil or grease residue. TORQUE Bearing Retainer Plate Screws: 20 ft-lb (27 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 154: Transaxle Installation

    20 ft-lb (27 Nm) 9. Install speed sensor with a new O-ring. Torque speed sensor retaining screw to specification. TORQUE Speed Sensor Retaining Screw: 62 in-lb (7 Nm) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 155 14. Install wheels (See Chapter 5). 15. Install drive motor (See Chapter 3). 16. Verify all fasteners are installed and properly tightened. 17. Connect Main Power Connector and install seat. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 156: Transaxle And Differential Exploded View, Complete

    TRANSAXLE / DIFFERENTIAL TRANSAXLE AND DIFFERENTIAL EXPLODED VIEW, COMPLETE 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 157: Transaxle Exploded View, Shaft And Gear Assemblies

    TRANSAXLE / DIFFERENTIAL TRANSAXLE EXPLODED VIEW, SHAFT AND GEAR ASSEMBLIES 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 158: Transaxle Exploded View, Differential

    TRANSAXLE / DIFFERENTIAL TRANSAXLE EXPLODED VIEW, DIFFERENTIAL 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.12 © Copyright Polaris Industries Inc.

  • Page 159: Transaxle Differential Disassembly / Inspect

    Inspect clip on solenoid plunger and be sure it fits tightly in the groove. Replace O-ring (C) upon assembly. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.13 © Copyright Polaris Industries Inc.
  • Page 160 10. If not previously removed, remove and record number of shims located against the cover bearing. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 161: Planetary Differential Disassembly

    14. Inspect fork and return spring for wear or damage. 3. Remove (6) planet gears and each side gear assembly from the ring gear. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 162: Planetary Differential Bushing Replacement

    2. Thoroughly clean and inspect bushing bore of ring gear. 3. Press the new bushing into the ring gear housing. 4. Install bushing to specified depth. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 163 4. Repeat procedure for remaining planet gears. Differential Cover Bushing Replacement Female Side Gear Bushing Replacement 1. Press old bushing out of differential cover. 2. Thoroughly clean and inspect bushing bore. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.17 © Copyright Polaris Industries Inc.

  • Page 164: Planetary Differential Assembly

    1. Thoroughly clean components prior 22 ft-lb (30 Nm) reassembly. DIFFERENTIAL CASE ASSEMBLY 1. Grease all seals with Polaris All Season Grease (PN 2871322) upon assembly. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.18 © Copyright Polaris Industries Inc.
  • Page 165 Do not strike the differential assembly to seat it in the cover. 5. Thoroughly clean gearcase mating surfaces and be sure alignment pins are in place. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.19 © Copyright Polaris Industries Inc.

  • Page 166: Troubleshooting

    • AWD / 2WD / Turf mode switch (Chapter 8) • Worn, broken or damaged internal transaxle components including gears, bearings, retaining rings, and drive splines. 9926595 R01 - 2015-2016 RANGER EV Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 167 REAR BRAKE PADS ..................7.26 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 168 ................... .7.33 BRAKES LOCK 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 169: General Specifications

    PART NUMBER TOOL DESCRIPTION MityVac® Pressure Test Tool 2870975 Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris. service-solutions.com/ 9926595 R01 - 2015-2016 RANGER EV Service Manual...

  • Page 170: Brake System Service

    HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.

  • Page 171: Brake System

    BRAKE SYSTEM BRAKE SYSTEM SYSTEM VIEW AND TORQUE VALUES 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 172: Brake Bleeding / Fluid Change

    Steps 4-9 for left rear and both front calipers. 11. Add brake fluid to MAX level inside reservoir 4. Add brake fluid to MAX level of reservoir. Polaris DOT 4 Brake Fluid 2872189 5. Install a box end wrench on caliper bleeder screw of right rear caliper.

  • Page 173: Master Cylinder

    4. Loosen banjo bolt and brake light switch (C) for brake lines and allow fluid to drain. NOTE Note how lines attach to master cylinder. 5. Remove master cylinder mounting bolts (D). 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 174: Foot Brake Pedal

    After installing the foot brake check pedal freeplay. TORQUE Clevis Nut: 13 ft-lb (18 Nm) MEASUREMENT Brake Pedal Free-play: Less than .090″ (2.3 mm) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 175: Parking Brake

    Cable Clamp Clevis Pin - 1/4 x 3/4 (QTY.1) Routing Clip Push Rivet (QTY.4) Cable, Parking Brake Clip, Silencer Screw - M8 x 1.25 x 55 (QTY.2) 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 176: Parking Brake Caliper Service

    1. Place vehicle on level ground and block the wheels. 2. Release the parking brake. 3. Disconnect cable from caliper lever arm by removing pin retaining clip (A) and clevis pin (B). 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 177: Caliper Disassembly / Inspection

    4. Inspect (3) steel balls for any signs of pitting, cracking, or flat spots. 5. Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 178: New Brake Pad Installation

    NEW BRAKE PAD INSTALLATION 1. Assemble the stationary actuator with bolts upright as shown. Grease the tracks and install (3) balls. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.12 © Copyright Polaris Industries Inc.

  • Page 179: Parking Brake Caliper Installation

    35 ft-lb (47 Nm) Caliper Bracket-to-Transaxle Case Bolts: 19 ft-lb (26 Nm) 3. Install the cable to lever arm with pin (pin is installed from front to rear). 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.13 © Copyright Polaris Industries Inc.
  • Page 180 BRAKE SYSTEM 4. Install retainer clip in pin. 5. Test parking brake for proper function and adjust if necessary. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.14 © Copyright Polaris Industries Inc.

  • Page 181: Parking Brake Disc Service

    / disc assembly. 2. Follow prop shaft removal procedure (See Chapter 5) to remove prop shaft / disc assembly. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 182: Front Brake Pads

    Then remove inner pad. NOTE When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 183: Pad Inspection

    5. Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.17 © Copyright Polaris Industries Inc.

  • Page 184: Brake Burnishing Procedure

    Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times to maximize pad service life. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.18 © Copyright Polaris Industries Inc.

  • Page 185: Front Caliper Service

    2. Remove the (4) wheel nuts and the front wheel. WARNING Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 3. Clean caliper area before removal. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 186: Caliper Disassembly

    6. Remove the two caliper mounting bolts and remove the caliper assembly from the front strut. 2. Remove both brake pads from the caliper. 3. Remove mounting bracket, pin assembly and dust boot. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.20 © Copyright Polaris Industries Inc.

  • Page 187: Caliper Inspection

    Measure bore size compare specifications. Replace if damaged or worn beyond service limit. MEASUREMENT Caliper Piston Bore I.D.: 1.373″ (34.87 mm) Service Limit: 1.375″ (34.93 mm) 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.21 © Copyright Polaris Industries Inc.

  • Page 188: Caliper Assembly

    TORQUE Front Caliper Mount Bolt: 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. 28 ft-lb (38 Nm) Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
  • Page 189 5. Install wheel and torque wheel nuts to specification (see Chapter 2). NOTE If new brake pads are installed, brake burnishing is recommended (see procedure Brake Burnishing Procedure, page 7.18). 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 190: Front Brake Disc

    Service Limit: .002″ (.051 mm) 3. Remove the wheel hub assembly from the vehicle difference between measurements and remove the (4) bolts retaining the disc to the hub. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.24 © Copyright Polaris Industries Inc.
  • Page 191 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 192: Rear Brake Pads

    .496 in. (12.60 mm). NOTE When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 193: Pad Installation

    PAD INSTALLATION master cylinder. 1. Install new pads in caliper body with spring installed between pads at (A). 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 194: Rear Caliper Service

    1. Safely support the rear of the machine. lines. WARNING Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.28 © Copyright Polaris Industries Inc.

  • Page 195: Caliper Inspection

    3. Coat the piston with clean DOT 4 Brake Fluid (PN 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.29 © Copyright Polaris Industries Inc.

  • Page 196: Caliper Installation

    TORQUE Banjo Bolt: 15 ft-lb (20 Nm) 3. Install rear wheel and wheel nuts. Carefully lower vehicle. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.30 © Copyright Polaris Industries Inc.

  • Page 197: Rear Brake Disc

    2. Remove dust cap, cotter pin, castle nut and washers. WARNING Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 198 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.32 © Copyright Polaris Industries Inc.

  • Page 199: Troubleshooting

    • Residue build up under caliper seals • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 200 BRAKE SYSTEM NOTES 9926595 R01 - 2015-2016 RANGER EV Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 201 ............. .8.29 LIGHTING SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 202 ..............8.38 DIGITAL WRENCH TROUBLE CODE LIST 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 203: General Information

    Digital Wrench SmartLink Module Kit PU-47471 power supply. • Verify battery voltage and general battery condition. Dealers may order special tools through Polaris’ official • Inspect battery and contactor terminal cleanliness, tool supplier, Bosch Automotive Service Solutions, by condition, and fastener torque.

  • Page 204: 48 Volt Fuse And Relay Location

    Two 48 volt relays and a 48 volt fuse (fuse is for accessory battery charge circuit) are located in the main fuse box (B) under the hood. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 205: 12 Volt Auxiliary Power Outlet

    OR/WH ACCY switched power wires leading to the terminal board and receptacle. SYSTEM WIRING DIAGRAM REFERENCE: See14.0 Volt System Wiring Diagram, page 8.28 . 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 206: Switches / Controls

    (RD/BK) is connected through Pin 9 of the Chassis to Dash harness connector to terminal 2 of the AWD switch. Power entering terminal 2 is switched as follows: 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 207: Direction Selector Switch (F / N / R)

    Main Power Connector is the first to disconnect and the last to connect when servicing the electrical system. DIRECTION SELECTOR SWITCH (F / N / R) VOLTAGE LEVEL: 14.0 VDC LOCATION: On Dashboard. 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 208: Drive Mode Switch (High, Max Range, Low)

    Direction Selector Switch Contacts, page 8.34. DRIVE MODE SWITCH (HIGH, MAX RANGE, LOW) VOLTAGE LEVEL: 14.0 VDC 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

  • Page 209: Differential Solenoid / Solenoid Driver Module

    Direction Selector Switch Contacts, page 8.34. DIFFERENTIAL SOLENOID / SOLENOID DRIVER MODULE VOLTAGE LEVEL: 14.0 VDC LOCATION: 9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.
  • Page 210 Disconnect the Main Power Connector (see chapter 1) before disconnecting any electrical component. The Main Power Connector is the first to disconnect and the last to connect when servicing the electrical system. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 211: Brake Light Switch (Hydraulic)

    Disconnect wire harness from parking is connected. Disconnect wires from hydraulic brake switch. brake switch. 2. Connect an Ohmmeter to the switch terminals. Reading should be infinite (OL). 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 212: Indicator Light Circuits

    Disconnect panel harness and verify power (14.0 Vdc) is present on the RD/DG wire terminal (Pin A) with key switch ON. If power is present, inspect the appropriate ground-controlling switch and/or circuit. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 213: Indicator Lamp Replacement

    Disconnect the Main Power Connector (see chapter 1) before disconnecting any electrical component. The Main Power Connector is the first to disconnect and the last to connect when servicing the electrical system. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 214: Indicator Lights

    Cycle key OFF-ON. P1B62 STC Hand Brake Parking brake switch active (parking brake applied or brake switch contacts are Fault closed). Release brake / test switch. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 215: Battery Discharge Indicator

    If the warning (3) begin to flash, battery service life will be significantly reduced with continued operation. Stop the vehicle and recharge the batteries. The Battery Discharge indicator also displays Battery usage numerically (4). 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 216: Charge Status Indicator

    Flashing Amber temperature exists; open hood to improve air flow. Charger error exists; reset Flashing charger power and refer to Battery section in this chapter. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 217: Digital Wrench Diagnostic Software

    “Logged Faults” and can be ignored. It does not represent an actual problem with the system. ACCELERATOR PEDAL POSITION SENSOR VOLTAGE LEVEL: 5.0 VDC LOCATION: On accelerator pedal bracket 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 218: All Wheel Drive (Awd) Coil

    Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before suspecting a component failure. Most electrical problems are caused by poor connections and grounds. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 219: Headlights

    1. Open the hood and locate the headlight bulb. by loosening the adjustment screw and moving the 2. Turn bulb 1/4 turn counterclockwise to remove it. lamp to the appropriate height. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 220: Headlight Housing Removal

    2. Remove the bulb from the headlight housing (see “Headlight Bulb Replacement”). 3. Remove the O-rings from each side of the headlight housing. Remove the adjustment screw and pull the headlight from the brackets. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 221: Tail Light / Brake Light

    Disconnect the Main Power Connector (see chapter 1) before disconnecting any electrical component. The Main Power Connector is the first to disconnect and the last to connect when servicing the electrical system. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 222: 48 Vdc - 14 Vdc Converter

    The converter’s ground is located on the controller #2 ground post. The converter distributes 14.0v to terminal A2 (Chassis fuse, 20A) in the fuse/ relay box. 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 223: System Wiring Diagrams

    ELECTRICAL SYSTEM WIRING DIAGRAMS 48 VDC - 14.0 VDC CONVERTER WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 224: Battery System Wiring Diagram

    ELECTRICAL BATTERY SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 225: Drive Motor Encoder System Wiring Diagram

    ELECTRICAL DRIVE MOTOR ENCODER SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 226: Battery Charging System Wiring Diagram

    ELECTRICAL BATTERY CHARGING SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.26 © Copyright Polaris Industries Inc.

  • Page 227: Auxiliary (Accessory) Battery System Wiring Diagram

    ELECTRICAL AUXILIARY (ACCESSORY) BATTERY SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 228: 14.0 Volt System Wiring Diagram

    ELECTRICAL 14.0 VOLT SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.28 © Copyright Polaris Industries Inc.

  • Page 229: Lighting System Wiring Diagram

    ELECTRICAL LIGHTING SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.29 © Copyright Polaris Industries Inc.

  • Page 230: Parking Brake System Wiring Diagram

    ELECTRICAL PARKING BRAKE SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.30 © Copyright Polaris Industries Inc.

  • Page 231: Awd System Wiring Diagram

    ELECTRICAL AWD SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.31 © Copyright Polaris Industries Inc.

  • Page 232: Awd / 2Wd / Turf Switch Contacts

    ELECTRICAL AWD / 2WD / TURF SWITCH CONTACTS 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.32 © Copyright Polaris Industries Inc.

  • Page 233: Direction Selector - System Wiring Diagram

    ELECTRICAL DIRECTION SELECTOR - SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.33 © Copyright Polaris Industries Inc.

  • Page 234: Direction Selector Switch Contacts

    ELECTRICAL DIRECTION SELECTOR SWITCH CONTACTS 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 235: Drive Mode (High / Max Range / Low) - System Wiring Diagram

    ELECTRICAL DRIVE MODE (HIGH / MAX RANGE / LOW) - SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.35 © Copyright Polaris Industries Inc.

  • Page 236: Accelerator Pedal Position Sensor - System Wiring Diagram

    ELECTRICAL ACCELERATOR PEDAL POSITION SENSOR - SYSTEM WIRING DIAGRAM 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.36 © Copyright Polaris Industries Inc.

  • Page 237: Main Fuse Box

    ELECTRICAL MAIN FUSE BOX 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.37 © Copyright Polaris Industries Inc.

  • Page 238: Diagnostic Trouble Codes

    ELECTRICAL DIAGNOSTIC TROUBLE CODES DIGITAL WRENCH TROUBLE CODE LIST 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 239 ELECTRICAL 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.39 © Copyright Polaris Industries Inc.
  • Page 240 ELECTRICAL Digital Wrench Trouble Code List (Cont.) 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.40 © Copyright Polaris Industries Inc.
  • Page 241 ELECTRICAL 9926595 R01 - 2015-2016 RANGER EV Service Manual 8.41 © Copyright Polaris Industries Inc.
  • Page 242 Brake, Parking, Adjustment .........2.17 Front Gearcase, Assembly ..........5.23 Front Gearcase, Backlash Pad Adjustment .....5.26 Front Gearcase, Disassembly / Inspection ......5.19 Front Gearcase, Installation.........5.27 Front Gearcase, Removal ...........5.18 9926595 R01 - 2015-2016 RANGER EV Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 243 Parking Brake Pad Inspection ........2.18 Theory of Operation ...........5.15 Parking Brake Switch ..........8.11 Tie Rod End and Steering Inspection ......2.12 Parking Brake, Adjustment ..........7.10 Tire Inspection ............2.7 9926595 R01 - 2015-2016 RANGER EV Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 244 VIN ................. 1.4 VIN Location ............. 1.5 VIN Number .............. 1.4 Warranty ..............1.27 Water Level..............1.22 Wheel Alignment ............2.12 Wheel, Installation ............2.7 Wheel, Removal............2.7 Windshield...............1.17 9926595 R01 - 2015-2016 RANGER EV Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 245 2015-2016 RGR EV/LSV (CHASSIS)
  • Page 246 2015-2016 RANGER EV (CARGO BOX)
  • Page 247 2015-2016 RGR EV/LSV...

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