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Chapters
Table of Contents
Troubleshooting
Related Manuals for Polaris Ranger 500 4x4 EFI 2007
Summarization of Contents
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Details model, VIN, and engine serial number identification and locations.
VEHICLE DIMENSIONS
Provides diagrams and measurements for vehicle dimensions, including length, height, and wheelbase.
GENERAL SPECIFICATIONS
Lists key specifications for RANGER 2X4, 4X4 CARB, and 4X4 EFI models.
SPECIAL TOOLS
Lists specialized tools required for servicing the machine.
MISC. SPECIFICATIONS AND CHARTS
Provides conversion tables and standard torque specifications.
MAINTENANCE
PERIODIC MAINTENANCE CHART
Details periodic maintenance intervals and tasks for the vehicle.
GENERAL COMPONENT LOCATION
Identifies key components on the RH side and dash of the vehicle.
SERVICE PRODUCTS AND LUBES
Lists recommended Polaris lubricants, maintenance, and service products with part numbers.
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Covers pre-ride daily inspections and frame, nuts, bolts, and fasteners checks.
ENGINE
Covers engine-related maintenance, including oil, valves, and compression tests.
TRANSMISSION AND GEARCASES
Details maintenance procedures for the transmission and gearcases, including lubrication.
ENGINE
SPECIAL TOOLS
Lists special tools for engine service.
ENGINE SPECIFICATIONS AND SERVICE DATA
Covers torque specs, service data, and general engine service procedures.
ENGINE REMOVAL AND INSTALLATION
Details the procedure for removing and installing the engine from the chassis.
ENGINE COMPONENTS
Covers cylinder, piston, crankshaft, and valve train components.
COOLING SYSTEM
Details cooling system specifications, layout, and testing procedures.
ENGINE DISASSEMBLY AND REASSEMBLY
Covers the step-by-step process for engine disassembly and reassembly.
CARBURETION / EFI
SPECIAL TOOLS
Lists special tools for carburetion and EFI system service.
CARBURETOR JETTING AND SERVICE
Provides guidelines for carburetor jetting and covers service procedures like removal and cleaning.
FUEL SYSTEM COMPONENTS
Details fuel tank and fuel pump assembly, including exploded views and fuel flow diagram.
ELECTRONIC FUEL INJECTION (EFI) SYSTEM
Provides general information, operation overview, and component locations for the EFI system.
BODY / STEERING / SUSPENSION
BODY COMPONENT REMOVAL AND INSTALLATION
Procedures for removing and installing body components like dash, hood, cargo box, and fuel tank.
CHASSIS AND FRAME
Details the chassis and main frame components, including exploded views and torque specs.
STEERING AND SUSPENSION SYSTEM
Covers steering assembly, suspension components, and adjustment procedures.
FRONT AND REAR SUSPENSION COMPONENTS
Details replacement of front A-arm, front strut, and rear A-arm components.
REAR CARGO BOX AND STABILIZER BAR
Covers rear cargo box panels, tailgate support, and stabilizer bar service.
CLUTCHING
PVT SYSTEM OVERVIEW AND SERVICE
Explains PVT system operation, maintenance, and inspection.
DRIVE BELT SERVICE
Covers drive belt removal, inspection, installation, and deflection.
CLUTCH ALIGNMENT / OFFSET
Details procedures for aligning drive and driven clutches and adjusting offset.
DRIVE CLUTCH SERVICE
Covers drive clutch spring specifications, shift weights, and inspection.
DRIVEN CLUTCH SERVICE
Details driven clutch disassembly, inspection, and bushing service.
TROUBLESHOOTING
Provides a troubleshooting guide for common clutch drive belt and cover related issues.
FINAL DRIVE
SPECIAL TOOLS AND TORQUE SPECIFICATIONS
Lists special tools and torque values for final drive components.
FRONT HUB SERVICE (2X4 & 4X4)
Covers removal, inspection, and installation of front hubs and bearings.
DRIVESHAFT / CV JOINT HANDLING TIPS
Provides guidelines for handling driveshaft and CV joint components to prevent damage.
FRONT DRIVE SHAFT (4X4)
Details the procedure for removing the front drive shaft on 4x4 models.
CV JOINT / BOOT REPLACEMENT
Explains how to replace CV joints and boots, including grease requirements.
FRONT GEARCASE CENTRALIZED HILLIARD
Covers AWD operation, diagnosis, and gearcase removal/installation.
REAR GEARCASE (DIFFERENTIAL)
Explains rear gearcase operation modes, differential removal, and disassembly.
TRANSMISSION
TORQUE SPECIFICATIONS
Lists torque values for transmission components like fill plug, drain plug, and mounting bolts.
SHIFT LINKAGE AND LEVER
Covers shift lever removal/installation and linkage inspection/adjustment.
TRANSMISSION SERVICE
Covers transmission removal, disassembly, assembly, and installation.
TROUBLESHOOTING
Provides a checklist for diagnosing shifting difficulties in the transmission.
BRAKES
GENERAL SPECIFICATIONS AND TORQUE SPECIFICATIONS
Lists standard/service limits for brake pads/discs and torque values for brake system components.
HYDRAULIC BRAKE SYSTEM OPERATION
Explains the operation of the hydraulic brake system, including master cylinder and caliper function.
FRONT BRAKE COMPONENTS
Covers front brake pad and caliper removal, inspection, and installation.
REAR BRAKE COMPONENTS
Details rear brake disc inspection and rear brake pad/caliper service.
ELECTRICAL
GENERAL INFORMATION AND SPECIAL TOOLS
Provides general info, special tools, and service notes for the electrical system.
SWITCHES / CONTROLS
Covers headlamp, AWD/differential, and brake light switches.
HEAD LIGHTS
Details headlight adjustment and bulb replacement procedures.
POWER DISTRIBUTION MODULE (PDM)
Explains PDM operation, block diagrams, and isolation tests for non-EFI models.
CHARGING SYSTEM TESTS
Covers resistance and AC voltage output tests for the charging system.
STARTER SYSTEM
Details starter motor disassembly, brush inspection, armature testing, and starter drive.
ELECTRICAL BREAKOUT DIAGRAMS (EFI MODELS)
Provides wiring diagrams for starting, key-on power, and transmission switch circuits.
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