Polaris Ranger 500 2x4 2007 Manuals

Manuals and User Guides for Polaris Ranger 500 2x4 2007. We have 1 Polaris Ranger 500 2x4 2007 manual available for free PDF download: Service Manual

Polaris Ranger 500 2x4 2007 Service Manual

Polaris Ranger 500 2x4 2007 Service Manual (345 pages)

Electronic Fuel Injection

Brand: Polaris | Category: Utility Vehicle | Size: 26.99 MB

Table of Contents

General Information Chapter 1 1

3
- Table of Contents
  3
- Chapter 1
  4
- Engine Designation Number
  4
- Engine Serial Number Location
  4
- Model Identification
  4
- Vehicle Identification
  4
- Vin Identification
  4
- Transmission I.D. Number Location
  5
- Unit Serial Number (Vin) Location
  5
- Vehicle Dimensions
  6
- General Specifications
  8
  - Model: Ranger 2X4
    8
  - Model: Ranger 4X4 Carb
    8
  - Model: Ranger 4X4 Efi
    9
  - Model: Ranger 2X4
    10
  - Model: Ranger 4X4 Carb
    11
  - Model: Ranger 4X4 Efi
    12
- Vehicle Information
  13
  - Publication Numbers
    13
  - Paint Codes
    13
  - Replacement Keys
    13
- Special Tools
  14
- Misc. Specifications and Charts
  18
  - Conversion Table
    18
  - Standard Torque Specifications
    19
  - Sae Tap / Drill Sizes
    20
  - Metric Tap / Drill Sizes
    20
  - Glossary of Terms
    21
Maintenance Chapter 2 Maintenance 2

22
- Chapter 2
  24
- Maintenance Chart Key
  24
- Periodic Maintenance Chart
  24
- Periodic Maintenance Overview
  24
- Pre-Ride - 25 Hour Maintenance Interval
  25
- 50 - 100 Hour Maintenance Interval
  26
- General Component Location
  28
  - Rh Side and Dash View
    28
  - Lh Side and Rear View
    29
- Service Products and Lubes
  30
  - Polaris Lubricants, Maintenance and Service Products
    30
- Maintenance References
  31
- General Vehicle Inspection and Maintenance
  34
- Fuel System and Air Intake
  35
  - Fuel System
    35
  - Fuel Lines
    35
  - Fuel Filter (Carb Models)
    35
  - Vent Lines
    35
  - Throttle Pedal Inspection
    35
  - Throttle Freeplay Adjustment
    36
  - Throttle Cable Adjustment (Carb Models)
    36
  - Choke Adjustment (Carb Models)
    36
  - Pilot Screw (Carb Models)
    37
  - Pilot Screw Adjustment (Carb Models)
    37
  - Idle Speed Adjustment (Carb Models)
    38
  - Carburetor Draining (Carb Models)
    38
  - Air Intake Inspection
    39
  - Air Filter Service
    39
- Engine
  40
  - Compression and Leakdown Test
    40
  - Breather Filter Inspection
    41
  - Breather Hose
    41
  - Flywheel Housing
    41
  - Engine Oil Level
    41
  - Engine Oil and Filter Change
    42
  - Oil Pump Priming Procedure
    43
  - Valve Clearance
    44
  - Intake Valve Clearance Adjustment
    45
  - Exhaust Valve Clearance Adjustment
    45
  - Exhaust Pipe
    45
- Fuel System (Efi)
  40
  - Fuel Filter
    40
- Transmission and Gearcases
  46
- Cooling System
  49
  - Liquid Cooling System Overview
    49
  - Coolant Level Inspection
    50
  - Radiator Coolant Level Inspection
    50
  - Coolant Strength / Type
    50
  - Cooling System Pressure Test
    51
  - Cooling System Hoses
    51
  - Radiator
    51
  - Coolant Drain / Radiator Removal
    51
- Final Drive / Wheel and Tire
  52
  - Wheel, Hub, and Spindle Torque Table
    52
  - CV Shaft Boot Inspection
    52
  - Wheel Removal
    52
  - Wheel Installation
    52
  - Tire Inspection
    53
  - Tire Pressure
    53
- Electrical and Ignition System
  53
  - Battery Maintenance
    53
  - Battery Fluid Level (Conventional Battery)
    54
  - Battery Removal
    54
  - Battery Installation
    54
  - Battery Storage
    54
  - Battery Charging
    54
  - Spark Plug Service
    55
  - Engine to Frame Ground
    55
- Steering and Suspension
  55
  - Steering
    55
  - Tie Rod End / Steering Inspection
    56
  - Camber and Caster
    56
  - Front Suspension
    57
  - Rear Suspension
    58
  - Rear Suspension Adjustment
    58
  - Rear Spring Adjustment
    58
- Brake System
  59
Chapter 3 Engine

60
- Special Tools
  62
- Specifications
  62
- Torque Specifications
  62
- Engine Service Data
  63
- Engine Fastener Torque Patterns
  65
- General Engine Service
  65
  - Piston Identification
    65
  - Accessible Components
    66
  - Engine Removal
    66
  - Engine Installation Notes
    69
  - Cylinder Hone Selection / Honing Procedure
    69
  - Honing to Oversize
    69
  - Cleaning the Cylinder after Honing
    70
  - Crankshaft Straightening
    70
  - Engine Lubrication - Eh50Pl
    71
  - Oil Pressure Test - Eh50Pl
    71
  - Oil Pump Priming Procedure
    71
  - Oil Flow - Eh50Pl
    72
  - Eh50Pl Oil Flow Diagram
    73
  - Eh50Pl Engine Exploded View
    74
- Cooling System
  75
  - Cooling System Specifications (Non-Efi)
    75
  - Cooling System Layout and Testing
    75
- Engine Disassembly
  77
- Engine Reassembly
  100
  - Pump Shaft Oil Seal Installation
    100
  - Crankshaft / Counter Balance / Oil Pump Installation
    100
  - Crankcase Assembly
    100
  - Water Pump Mechanical Seal Installation
    100
  - Water Pump Mechanical Seal Removal (Engine Installed)
    101
  - One Way Valve Installation
    102
  - Cam Chain Drive Sprocket Installation
    102
  - Tensioner Blade Installation
    102
  - Piston Ring Installation
    102
  - Piston Installation
    103
  - Cylinder Installation
    103
  - Cylinder Head Installation
    104
  - Cam Chain / Camshaft Installation
    104
  - Camshaft Timing
    105
  - Camshaft Timing Illustration
    106
  - Cam Chain Tensioner Installation
    107
  - Stator, Flywheel and Starter Drive Installation
    107
  - Rocker Shaft / Rocker Arm Assembly Installation
    108
  - Thermostat Installation
    108
  - Oil Pipes
    108
- Troubleshooting
  109
  - Engine
    109
  - Spark Plug Fouling
    110
  - Cooling Troubleshooting
    110
Carburetion System Chapter 4 Carburetion System

111
- Chapter 4
  113
- Exploded View
  113
- Mikuni CV Carburetor
  113
- Operation - Mikuni CV Carb
  114
- System Function - Mikuni CV Carb
  114
- Vent Systems - Mikuni CV Carb
  114
- Pilot System (Idle and Slow Speed)
  115
- Float System
  116
- Starter System (Choke or Enrichment)
  116
- Main System
  117
- Pilot Screw
  117
- Carburetor Service
  118
  - Carburetor Removal
    118
  - Carburetor Disassembly
    118
  - Carburetor Cleaning
    119
  - Carburetor Inspection
    120
  - Float Height Adjustment
    120
  - Needle and Seat Leakage Test
    120
  - Fuel Level
    121
  - Carburetor Assembly
    121
- Air Box Assembly
  122
  - Exploded View
    122
- Fuel Tank Assembly
  123
  - Fuel Tank / Fuel Pump Exploded View
    123
  - Fuel Tank Removal
    124
  - Fuel Tank Installation
    124
- Fuel Pump
  125
  - Replacement
    125
- Troubleshooting
  126
  - Fuel Starvation / Lean Mixture
    126
  - Rich Mixture
    126
  - Idle too High
    126
  - Idle too Low
    126
  - Erratic Idle
    126
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

127
- Special Tools
  129
  - Part Numbers / Descriptions
    129
- Efi Service Notes
  131
  - General Service Information
    131
- Efi System
  132
  - Exploded View
    132
- Efi Component Locations
  133
  - Identification / Location
    133
- Electronic Fuel Injection
  135
  - General Information
    136
  - Efi Operation Overview
    136
  - Initial Priming / Starting Procedure
    136
- Fuel Tank
  135
  - Exploded View
    135
- Electronic Control Module (Ecm)
  137
  - Operation Overview
    137
  - Ecm Service
    138
- Fuel Lines
  137
  - Quick Connect Removal / Installation
    137
- Fuel Pump Assembly
  139
  - Operation / Testing
    139
  - Fuel Pump Test
    139
  - Fuel Pump / Tank Assembly Replacement
    140
- Fuel Injector
  142
- Fuel Pressure Regulator
  142
  - General Information
    142
- Crankshaft Position Sensor (Cps)
  143
  - General Information
    143
- Manifold Air Pressure Sensor (Map)
  144
  - General Information
    144
  - Map Sensor Test
    144
  - Map Sensor Replacement
    144
- Idle Air Control (Iac)
  145
- Intake Air Temperature Sensor (Iat)
  145
- Throttle Position Sensor (Tps)
  146
  - General Information
    146
  - Throttle Position Sensor Test
    146
  - Throttle Position Sensor Replacement
    147
  - Throttle Position Sensor Initialization
    147
- Engine Temperature Sensor
  148
  - General Information
    148
  - Engine Temperature Sensor Test
    148
  - Engine Temperature Sensor Replacement
    148
- Diagnostics Using 'Blink Codes
  149
  - Blink Codes - Operation
    149
- Fuel System Troubleshooting
  151
  - Fuel Starvation / Lean Mixture
    151
  - Rich Mixture
    151
  - Poor Idle
    151
- Efi System Break-Out Diagrams
  152
  - Fuel Injector Circuit
    152
  - Crankshaft Position Sensor (Cps) Circuit
    152
  - Fuel Pump Circuit
    153
  - Ignition Coil Circuit
    153
  - Idle Air Control (Iac) Circuit
    154
  - Throttle Position Sensor (Tps) Circuit
    154
  - Manifold Air Pressure Sensor (Map) Circuit
    155
  - Engine Coolant Temperature Sensor Circuit
    155
  - Intake Air Temperature Sensor (Iat) Circuit
    156
  - Malfunction Indicator Light (Mil) Circuit
    156
  - Diagnostic Connector Circuit
    157
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

158
- Special Tools
  159
- Torque Specifications
  159
- Body Component Removal
  160
- Chapter 5
  160
- Removal Procedures
  160
- Lower Body Components
  161
- Hood / Dash Components
  162
- Dash Instruments and Controls
  163
- Cab Frame
  164
  - Assembly / Removal
    164
- Chassis / Main Frame
  165
  - Exploded View
    165
- Seat / Head Rest
  166
  - Seat Base / Seat Back / Head Rest Assembly
    166
- Steering Assembly
  167
  - Exploded View
    167
- Steering and Suspension
  168
  - Exploded View
    168
- Front A-Arm
  169
  - Replacement
    169
- Front Strut
  170
  - Exploded View
    170
  - Front Strut Cartridge Replacement
    171
  - Ball Joint Replacement
    171
- Rear A-Arm
  172
  - Replacement
    172
- Rear Stabilizer Bar
  174
  - Removal / Installation
    174
- Rear Cargo Box
  175
  - Cargo Box - Panels
    175
  - Cargo Box - Tailgate / Box Support
    176
  - Box Removal
    177
  - Box Installation
    177
- Decal Replacement
  178
Clutching Chapter 6 Clutching

179
- Chapter 6 Pvt System Fastener Torques
  180
- Pvt System Overview
  180
  - General Operation
    180
  - Drive Clutch Operation
    180
  - Driven Clutch Operation
    181
  - Maintenance / Inspection
    181
  - Overheating / Diagnosis
    182
- Special Tools and Supplies
  180
- Torque Specifications
  180
- Pvt System Service
  183
  - Pvt Sealing, Guard, and Ducting Components
    183
  - Disassembly
    183
  - Assembly
    184
- Drive Belt
  185
  - Belt Deflection (Tension)
    185
  - Belt Removal
    185
  - Belt Inspection
    186
  - Belt Installation
    187
- Clutch Alignment / Offset
  187
  - Clutch Alignment
    187
  - Clutch Offset
    188
- Drive Clutch Service
  189
  - Spring Specifications
    189
  - Shift Weights
    190
  - Exploded View
    191
  - Clutch Inspection
    191
  - Clutch Disassembly
    192
  - Spider Removal
    193
  - Roller, Pin, and Thrust Washer Inspection
    193
  - Bushing Service
    194
  - Moveable Sheave - Bushing Removal
    194
  - Moveable Sheave - Bushing Installation
    194
  - Clutch Cover - Bushing Removal
    195
  - Clutch Cover - Bushing Installation
    195
  - Clutch Assembly
    196
- Driven Clutch Service
  197
  - Exploded View
    197
  - Clutch Disassembly / Inspection
    197
  - Bushing Service
    198
  - Moveable Sheave - Bushing Installation
    199
  - Clutch Assembly
    200
- Troubleshooting
  202
Final Drive Chapter 7 Final Drive

204
- Chapter 7 Wheel, Hub, and Spindle Torque Table
  205
- Front Hub (2X4)
  205
  - Hub Removal / Inspection
    205
  - Hub Installation
    206
  - Exploded View (2X4)
    207
- Special Tools
  205
- Torque Specifications
  205
- Front Hub (4X4)
  208
  - Hub Installation
    209
  - Exploded View (4X4)
    210
- Drive Shaft / Propshaft
  211
  - Exploded View
    211
- Driveshaft / CV Joint Handling Tips
  212
- Front Drive Shaft (4X4)
  212
  - Removal
    212
  - CV Joint / Boot Replacement
    213
  - Installation
    215
- Front Propshaft Removal
  215
- Propshaft U-Joint Service
  216
  - Disassembly
    216
  - Assembly
    217
- Front Gearcase Centralized Hilliard
  218
  - Awd Operation
    218
  - Centralized Hilliard Exploded View
    219
  - Awd Diagnosis
    220
  - Gearcase Removal
    221
  - Gearcase Disassembly / Inspection
    222
  - Gearcase Reassembly / Inspection
    224
  - Backlash Pad (Thrust Pad) Adjustment
    226
  - Gearcase Installation
    227
- Rear Drive
  228
  - Exploded View
    228
- Rear Hub / Bearing Carrier
  228
  - Hub Inspection / Removal
    228
  - Hub Disassembly
    229
  - Hub Assembly / Installation
    230
- Rear Drive Shaft
  231
  - Removal
    231
  - CV Joint / Boot Replacement
    232
  - Installation
    234
- Rear Propshaft
  235
- Rear Gearcase (Differential)
  236
  - General Operation
    236
  - Operation Modes
    237
  - Differential Removal / Disassembly
    238
  - Differential Assembly
    241
  - Differential Installation
    243
  - Differential Exploded View
    244
Transmission Chapter 8 Transmission

245
- Chapter 8
  246
- Installation
  246
- Removal
  246
- Shift Lever
  246
- Shift Linkage
  246
  - Inspection
    246
  - Adjustment
    247
- Torque Specifications
  246
- Transmission Service
  247
  - Transmission Removal
    247
  - Transmission Disassembly
    249
  - Transmission Assembly
    254
  - Transmission Installation
    258
- Troubleshooting
  259
  - Troubleshooting Checklist
    259
- Transmission Exploded View
  260
Brakes Chapter 9 Brakes

264
- Exploded View (2X4)
  271
- Exploded View (4X4)
  273
- Chapter 9 Parking Brake
  274
- Caliper Installation
  275
- New Brake Pad Installation
  275
- Parking Brake Disc Service
  275
  - Disc Removal / Inspection
    275
- Front Brake Pads
  276
  - Pad Removal / Disassembly / Inspection
    276
  - Pad Assembly / Installation / Adjustment
    277
- Front Caliper
  278
  - Front Caliper Exploded View
    278
  - Caliper Removal / Disassembly
    278
  - Caliper Inspection / Assembly
    279
  - Caliper Installation
    280
- Front Brake Disc
  281
  - Disc Inspection / Removal / Replacement
    281
- Rear Brake Pad
  281
  - Pad Removal
    281
  - Pad Inspection / Installation
    282
- Rear Caliper
  283
  - Rear Caliper Exploded View
    283
  - Caliper Removal / Disassembly
    284
  - Caliper Inspection
    284
  - Caliper Assembly
    285
  - Caliper Installation
    285
- Rear Brake Disc
  286
  - Disc Inspection
    286
- Troubleshooting
  286
  - Brakes Squeal / Poor Brake Performance
    286
  - Pedal Vibration
    286
  - Caliper Overheats (Brakes Drag)
    286
  - Brakes Lock
    286
Chapter 10 Electrical

287
- Electrical Service Notes
  289
- General Information
  289
- Special Tools
  289
- Under-Hood Components
  289
- Switches / Controls
  290
  - Headlamp Switch
    290
  - Awd / Rear Differential Switch
    290
  - Differential Solenoid
    290
  - Brake Light Switch
    291
  - Parking Brake Switch
    291
  - Gear Indicator Light Circuit Operation
    292
  - Indicator Lamp Replacement
    293
- Head Lights
  293
  - High Beam Headlight Adjustment
    293
  - Headlamp Bulb Replacement
    294
  - Headlamp Housing Removal
    294
  - Headlamp Housing Installation
    295
- Tail Light / Brake Light
  295
  - Lamp Replacement
    295
- Power Distribution Module (Non-Efi Models)
  296
  - Pdm Operation
    296
  - Pdm Block Diagram
    297
- Pdm Isolation Tests (Non-Efi Models)
  297
  - Battery Voltage Test
    297
  - Ground Test
    298
  - Static Stator Test
    298
  - Run Signal Test
    298
  - Dynamic Stator Test
    298
  - Battery + Test
    299
  - Protected Battery + Test
    299
  - Ignition Switch Test
    299
  - Accessory Power Test
    300
  - Pdm to Fan Output Test
    300
  - Fan Motor Test
    300
  - Static Thermistor Test
    301
  - Dynamic Thermistor Test
    301
  - Hot Lamp Test
    301
  - Differential Solenoid Test
    302
  - Awd out Test
    302
  - Awd / Turf Switch Test
    302
  - Differential out Test
    303
  - Differential Ground Test
    303
  - Acs out Test
    303
- Power Distribution Module (Efi Models)
  304
  - Pdm Operation
    304
  - Pdm Function Overview
    305
  - Pdm Block Diagram
    306
- Timing Check Procedure (Non-Efi Models)
  307
- Cooling System
  308
- DC / CDI Ignition System (Non-Efi Models)
  311
  - DC / CDI Ignition System Overview
    311
  - Ignition System Troubleshooting
    311
  - Resistance Tests
    312
  - Flywheel Identification
    312
  - Ignition System Testing Flow Chart
    313
  - Components of DC / CDI Ignition
    314
- Efi Diagnostics
  315
  - Efi Component Testing
    315
  - Current Draw - Key off
    315
  - Charging System "Break Even" Test
    315
  - Charging System Alternator Tests
    316
  - Charging System Testing Flow Chart
    317
- Battery Service
  318
  - Battery Terminals / Bolts
    318
  - Battery Identification
    318
- Battery Terminal Block
  318
- Conventional Battery
  319
  - Conventional Battery Testing
    320
  - Ocv - Open Circuit Voltage Test
    320
  - Specific Gravity Test
    320
  - Load Test
    321
  - Off Season Storage
    321
  - Charging Procedure
    321
- Low Maintenance Battery
  322
  - Battery Check
    322
  - Battery Inspection
    322
  - Battery Removal
    322
  - Battery Installation
    323
  - Battery Testing
    323
  - Ocv - Open Circuit Voltage Test
    323
  - Load Test
    323
  - Off-Season Storage
    324
  - Battery Charging
    324
- Starter System
  325
  - Troubleshooting
    325
  - Voltage Drop Test
    325
  - Starter Motor Disassembly
    325
  - Brush Inspection / Replacement
    326
  - Armature Testing
    326
  - Starter Reassembly
    327
  - Starter Drive
    327
  - Starter System Test Flow Chart
    328
- Electric Box Lift Actuator
  330
  - Diagnosis (if Equipped)
    330
- Electrical Breakout Diagrams (Efi Models)
  331
  - Starting Circuit
    331
  - Key-On Power Circuit
    331
  - Transmission Switch Circuit
    332
  - Differential Solenoid Circuit
    332
  - Charging System Circuit
    333
  - Cooling Fan Circuit
    333
  - Awd Circuit
    334

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