Table of Contents
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Polaris Ranger 500 4x4 2007
Summarization of Contents
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Details on identifying the model and serial numbers.
VEHICLE DIMENSIONS
Specifications for the vehicle's size and measurements.
GENERAL SPECIFICATIONS
Key performance and capacity data for different models.
SPECIAL TOOLS
List of specific tools required for service.
Glossary of Terms
Definitions of common terms used in the manual.
MAINTENANCE
PERIODIC MAINTENANCE CHART
Overview of periodic maintenance intervals and tasks.
GENERAL COMPONENT LOCATION
Diagrams showing component locations on the vehicle.
SERVICE PRODUCTS AND LUBES
List of recommended lubricants and service products.
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-ride daily inspection checklist.
Engine Oil and Filter Change
Step-by-step guide for changing engine oil and filter.
BRAKE SYSTEM
General checks for brake system components.
ENGINE
SPECIAL TOOLS
List of special tools for engine service.
SPECIFICATIONS
Torque specifications for engine fasteners.
ENGINE REMOVAL
Step-by-step guide for removing the engine.
Cylinder Hone Selection / Honing Procedure
Choosing and using a cylinder hone.
Crankshaft Straightening
Procedures for straightening a crankshaft.
TROUBLESHOOTING
Common engine problems and solutions.
CARBURETION SYSTEM
CARBURETOR JETTING
Guidelines for adjusting carburetor jetting.
MIKUNI CV CARBURETOR
Exploded view of the Mikuni CV carburetor.
CARBURETOR SERVICE
Procedures for carburetor removal and disassembly.
FUEL TANK ASSEMBLY
Exploded view of the fuel tank and fuel pump.
TROUBLESHOOTING
Troubleshooting lean, rich, and poor idle conditions.
ELECTRONIC FUEL INJECTION
EFI SERVICE NOTES
General service information for EFI systems.
EFI SYSTEM
Exploded view of EFI system components.
INITIAL PRIMING / STARTING PROCEDURE
Procedure for priming the EFI system before initial start.
Fuel Injector
General information about the fuel injector.
CRANKSHAFT POSITION SENSOR (CPS)
General information about the crankshaft position sensor.
DIAGNOSTICS USING ‘BLINK CODES’
Explanation of how to enable and interpret blink codes.
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
Torque specifications for body and chassis components.
BODY COMPONENT REMOVAL
Procedures for removing body components.
CAB FRAME
Procedures for cab frame assembly and removal.
CHASSIS / MAIN FRAME
Exploded view of the chassis and main frame.
STEERING AND SUSPENSION
Exploded view of steering and suspension parts.
FRONT A-ARM
Procedures for front A-arm replacement.
REAR STABILIZER BAR
Procedures for rear stabilizer bar removal and installation.
BOX REMOVAL
Step-by-step guide for removing the cargo box.
CLUTCHING
PVT SYSTEM OVERVIEW
General operation of the Polaris Variable Transmission (PVT).
MAINTENANCE / INSPECTION
Items to inspect and maintain for PVT system performance.
OVERHEATING / DIAGNOSIS
Troubleshooting PVT system overheating.
DRIVE BELT
Information on drive belt deflection and removal.
CLUTCH ALIGNMENT / OFFSET
Procedures for aligning and setting clutch offset.
DRIVE CLUTCH SERVICE
Service procedures for the drive clutch.
DRIVEN CLUTCH SERVICE
Service procedures for the driven clutch.
TROUBLESHOOTING
Troubleshooting common clutch issues.
FINAL DRIVE
TORQUE SPECIFICATIONS
Torque specifications for final drive components.
FRONT HUB (2X4)
Hub removal and inspection procedures for 2x4 models.
FRONT HUB (4X4)
Hub removal, inspection, and bearing replacement for 4x4 models.
DRIVE SHAFT / CV JOINT HANDLING TIPS
Tips for handling driveshaft and CV joints.
CV Joint / Boot Replacement
Procedures for replacing CV joints and boots.
FRONT GEARCASE CENTRALIZED HILLIARD
Information on AWD operation and the Hilliard system.
AWD Diagnosis
Troubleshooting AWD engagement issues.
Gearcase Disassembly / Inspection
Procedures for disassembling and inspecting the gearcase.
Differential Removal
Procedures for removing the rear differential.
TRANSMISSION
TORQUE SPECIFICATIONS
Torque specifications for transmission components.
SHIFT LINKAGE
Inspection and adjustment of the shift linkage.
TRANSMISSION SERVICE
Procedures for transmission service.
TRANSMISSION REMOVAL
Step-by-step guide for removing the transmission.
TRANSMISSION DISASSEMBLY
Procedures for disassembling the transmission.
TRANSMISSION ASSEMBLY
Procedures for assembling the transmission.
TROUBLESHOOTING
Troubleshooting transmission shifting issues.
BRAKES
GENERAL SPECIFICATIONS
General specifications for the brake system.
TORQUE SPECIFICATIONS
Torque specifications for brake system components.
BRAKE SYSTEM SERVICE NOTES
Important notes for servicing the brake system.
BRAKE NOISE TROUBLESHOOTING
Troubleshooting common brake noises.
HYDRAULIC BRAKE SYSTEM OPERATION
Explanation of how the hydraulic brake system operates.
MASTER CYLINDER
Procedures for master cylinder removal and installation.
BRAKE BLEEDING / FLUID CHANGE
Procedures for bleeding the brake system and changing fluid.
FRONT BRAKE PADS
Procedures for front brake pad removal and installation.
REAR BRAKE PAD
Procedures for rear brake pad removal and inspection.
TROUBLESHOOTING
Troubleshooting brake system issues.
ELECTRICAL
GENERAL INFORMATION
General information on electrical systems.
ELECTRICAL SERVICE NOTES
Notes for diagnosing electrical problems.
SWITCHES / CONTROLS
Information on various switches and controls.
HEADLIGHTS
High beam headlight adjustment procedure.
POWER DISTRIBUTION MODULE (NON-EFI MODELS)
Operation and block diagram of the PDM.
Battery Testing
Checking battery condition via OCV and Load tests.
Starter System
Troubleshooting starter motor issues.
ELECTRIC BOX LIFT ACTUATOR
Diagnosis procedure for the electric box lift actuator.
Starting Circuit
Wiring diagram for the starting circuit.
Charging System Circuit
Wiring diagram for the charging system.
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