Polaris Ranger 4X4 Manuals

Polaris Ranger 4X4 Manuals

Manuals and User Guides for Polaris Ranger 4X4. We have 2 Polaris Ranger 4X4 manuals available for free PDF download: Manual, Owner's Manual

Polaris Ranger 4X4 Manual

Polaris Ranger 4X4 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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Polaris Ranger 4X4 Owner's Manual

Polaris Ranger 4X4 Owner's Manual (124 pages)

Maintenance and Safety

Brand: Polaris | Category: Utility Vehicle | Size: 9.32 MB

Table of Contents

Table of Contents
7
Vehicle Identification Numbers
10
Safety
11
- Age 16 Warning
  12
- Clutch Cover Warning
  12
- Operator Safety
  14
- Equipment Modifications
  17
- Age Restrictions
  18
- Operating Without Instruction
  18
- Seat Belts
  18
- Using Alcohol or Drugs
  18
- Operating at Excessive Speeds
  19
- Exposure to Exhaust
  19
- Handling Gasoline
  19
- Operating a Damaged Vehicle
  19
- Operating on Pavement
  20
- Operating on Public Roads
  20
- Turning Improperly
  20
- Jumps and Stunts
  20
- Operating in Unfamiliar Terrain
  20
- Operating on Slippery Terrain
  20
- Hot Exhaust Systems
  21
- Improper Hill Climbing
  21
- Improper Tire Maintenance
  21
- Stalling While Climbing a Hill
  21
Features and Controls
22
- Component Locations
  23
- Trailer Hitch Bracket
  23
- Auxiliary Outlets
  24
- Gear Selector
  25
- Indicator Lights
  25
- Ignition Switch
  26
- Light Switch
  27
- Brake Pedal
  28
- Park Brake Lever
  29
- Fuel Cap
  31
  - Seat Belt Inspection
    31
  - Seat Removal
    31
Operation
33
- Pre-Ride Inspection
  35
- Starting Engine
  36
- Stopping the Engine
  37
- Driving Procedure
  38
- Driving on Slippery Surfaces
  39
- Driving Downhill
  41
- Driving through Water
  42
- Driving over Obstacles
  43
- Driving in Reverse
  44
- Parking on an Incline
  45
- Hauling Cargo
  46
- Dumping the Cargo Box
  48
- Belt Life
  49
  - Towing Loads
    49
  - Parking the Vehicle
    50
- Disengaging Awd
  52
- Crankcase Emission Control System
  53
- Exhaust Emission Control System
  53
- Noise Emission Control System
  53
Emission Control Systems
53
- Severe Use Definition
  54
- Periodic Maintenance Chart
  54
Maintenance
54
- Lubrication Recommendations
  59
- Engine Oil
  60
  - Oil Check
    61
  - Oil and Filter Change
    62
- Gearcase Specification Chart
  64
  - Oil Pump Priming
    64
  - Spark Plug Inspection
    68
  - Spark Plug Recommendations
    68
  - Spark Plugs
    68
- Cooling System
  70
  - Radiator and Cooling Fan
    71
  - Radiator Coolant Level
    72
  - Pvt Drying
    74
  - Pvt System
    74
  - Vehicle Immersion
    75
- Air Filter
  76
- Filter Systems
  76
- Spark Arrestor
  78
- Throttle Freeplay
  80
  - Throttle Freeplay Inspection
    80
  - Throttle System
    80
  - Throttle Freeplay Adjustment
    81
- Brake Fluid
  82
- Brake Inspection
  83
  - Park Brake Adjustment
    84
  - Steering Wheel Inspection
    84
  - Tire Tread Depth
    86
  - Wheel Installation
    87
  - Wheel Removal
    87
- Headlight Lamp Replacement
  88
- Headlight Beam Adjustment
  89
- Brake Lights
  90
  - Indicator Lamp Replacement
    90
  - Battery Removal
    92
  - Battery Installation
    93
  - Battery Storage
    94
- Cleaning and Storage
  98
  - Polishing the Vehicle
    99
  - Battery Maintenance
    101
- Fluid Levels
  102
Removal from Storage
103
Specifications
104
Polaris Products
106
Troubleshooting
107
Declaration of Conformity
111
Limited Warranty
112
Warranty
112
Maintenance Log
118
Index
121
Index
123

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