Polaris RANGER 2x4 Manuals

Manuals and User Guides for Polaris RANGER 2x4. We have 1 Polaris RANGER 2x4 manual available for free PDF download: Manual

Polaris RANGER 2x4 Manual

Polaris RANGER 2x4 Manual (292 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 4.8 MB

Table of Contents

Chapter 1 General Information

1
- Table of Contents
  1
- General Information
  2
- Model Identification
  2
- Serial Number Location
  2
- Machine Dimensions
  4
- Publication Numbers
  12
- Paint Codes
  12
- Starting the RANGER
  12
General Information Chapter 2 Maintenance

13
- Periodic Maintenance Chart
  14
- Pre-Ride Inspection
  17
- Special Tools
  17
- Front Gearcase Lubrication
  21
- Middle Gearcase Lubrication
  21
- Rear Gearcase Lubrication
  22
- Transmission Lubrication
  23
- Shift Linkage Adjustment
  25
- Throttle Pedal Inspection
  26
- Fuel System
  28
- Battery Maintenance
  29
- Spark Plug / Electrical
  30
- Air Filter / Breather Filter
  34
- Flywheel Housing
  36
- Oil Level and Filter Change
  37
- Oil Pump Priming Procedure
  38
- Valve Adjustment
  39
- Exhaust Pipe
  42
- Suspension
  44
Chapter 3 Engine

47
- Special Tools
  48
- Torque Specifications
  48
- Service Data
  49
- Piston Identification
  51
- Torque Patterns
  51
- Cooling System Specifications
  53
- Engine Removal
  53
- Engine Installation Notes
  54
- Engine Lubrication
  56
- Oil Pump Priming Procedure
  56
- Engine Exploded View
  59
- Valve Seat Service
  69
- Cylinder Head Assembly
  72
- Crankshaft End Play Inspection
  84
- Oil Pump Shaft End Play Inspection
  86
- Spark Plug Fouling Checklist
  99
- Troubleshooting
  99
Chapter 4 Fuel System/Carburetion

101
- Fuel Flow Diagram
  103
- Carburetor Jetting
  104
- Assembly, CV Carburetor
  105
- CV Carburetor System Function (4 Cycle)
  105
- Needle & Seat Leakage Test
  111
- Fuel Level
  112
- Fuel Pump Service
  112
- Fuel Tank Removal/Installation
  112
- Troubleshooting
  113
Body/Steering/Suspension Chapter 5 Body and Steering

115
- Body/Panel Removal
  117
- Cab Frame & Seat Exploded View
  118
- Frame/Body Assembly Exploded View
  119
- Body Molding Exploded View
  120
- Hood Exploded View
  121
- Cargo Box Exploded View
  122
- Dash Instruments & Controls
  123
- Steering Assembly Exploded View
  124
- A-Arm Replacement
  126
- Rear Axle & Swingarm
  129
- Swing Arm Removal & Installation
  129
- Front Strut Cartridge Replacement
  131
- Box Removal / Installation
  133
- Decal Replacement
  134
Clutch Chapter 6 Pvt System

135
- PVT System Torques
  136
- Service Tools and Supplies
  136
- PVT Maintenance/Inspection
  137
- PVT Disassembly
  139
- PVT Assembly
  140
- Drive Clutch Exploded View
  141
- PVT Sealing and Ducting Components
  141
- Drive Clutch Spring Specifications
  142
- Shift Weights
  143
- Drive Clutch Disassembly/Inspection
  144
- Drive Clutch Inspection
  144
- Drive Clutch Assembly
  146
- Drive Belt Tension
  147
- Drive Belt Removal/Inspection
  148
- Drive Belt Installation
  149
- Drive Clutch Bushing Service
  150
- Driven Clutch Disassembly/Inspection
  152
- Driven Clutch Assembly
  154
- Driven Clutch Bushing Service
  154
- Troubleshooting
  157
Chapter 8 Transmission Service

221
- Transmission Removal
  223
- Transmission Installation
  226
- Transmission Disassembly
  227
- Transmission Assembly
  233
- Troubleshooting
  238
- 2X4 Transmission, Exploded
  239
- 4X4 & 6X6 Transmission, Exploded
  241
Chapter 9 Brakes

243
- Brake Noise Troubleshooting
  245
- Brake System Service Notes
  245
- Hydraulic Brake System Operation
  246
- Brake System Exploded View
  247
- Parking Brake Adjustment
  249
- Parking Brake and Brake Line Inspection
  249
- Parking Brake Lock Exploded View
  251
- Front Pad Removal
  252
- Front Pad Assembly
  253
- Front Disc Inspection
  254
- Front Caliper Disassembly
  255
- Front Caliper Removal
  255
- Front Caliper Assembly
  256
- Front Caliper Inspection
  256
- Front Caliper Exploded View
  257
- Front Caliper Installation
  258
- Rear Brake Pad Removal
  258
- Rear Brake Pad Installation
  259
- Rear Brake Caliper Exploded View
  265
- Rear Brake Disc Inspection
  265
- Troubleshooting
  266
- Electrical
  269
- Timing Check Procedure
  269
- Flywheel I.D
  271
- Ignition System Testing Flow Chart
  273
- Ignition System Troubleshooting
  274
- Charging System Testing
  276
- Brake Light Switch
  281
- Gear Indicator Light Circuit Operation
  281
- Indicator Lamp Replacement
  282
- Starter System Troubleshooting
  282
- Starter Drive
  285

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