Polaris RANGER EV 2016 Manuals

Manuals and User Guides for Polaris RANGER EV 2016. We have 1 Polaris RANGER EV 2016 manual available for free PDF download: Service Manual

Polaris RANGER EV 2016 Service Manual

Polaris RANGER EV 2016 Service Manual (247 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 25.76 MB

Table of Contents

Chapter 1 1 General / Battery

7
- Table of Contents
  7
- Operating the Ranger Ev
  9
- Special Information Regarding the Ranger Ev
  9
- Vehicle Towing
  9
- Working on the Ranger Ev
  9
- Vehicle Identification
  10
- Vehicle Information
  12
  - Publication Numbers
    12
  - Replacement Keys
    13
  - Special Tools
    13
- General Specifications
  14
  - 2015 - 2016 Ranger Ev
    14
- Features and Controls
  17
  - Console
    17
  - Key Switch
    17
  - Parking Brake
    17
  - Battery Discharge Indicator
    18
  - Charge Status Indicator
    19
  - Battery Charging Cord / Battery Charger
    19
  - Headlight Switch
    19
  - Hour Meter
    20
  - 12 Volt Auxiliary Power Outlet
    20
  - Auxiliary 12 Volt Terminal Board
    20
  - Direction Selector Switch
    20
  - All Wheel Drive (Awd) Switch
    20
  - Indicator Light Panel
    22
  - Windshield
    23
  - Index to Battery Information
    23
  - Troubleshooting - Vehicle Operation
    23
- Battery Safety
  24
  - Proposition 65 Warning
    24
  - Battery Charging Warning
    24
  - Battery Caution
    24
  - Battery Compartment Warning Label
    25
- Battery Maintenance
  26
  - To Maximize Battery Service Life
    26
  - Battery Access
    26
  - Main Power Connector
    26
  - Battery Terminal Fastener Torque
    26
  - Battery Contactor Fastener Torque
    27
  - General / Battery
    27
- Battery Charging
  27
- Battery Cleaning (External Surfaces)
  27
- Battery Terminal Cleaning
  27
- Battery Water Level
  28
- Battery Testing - Overview
  29
- Basic Discharger Instructions
  30
- Battery Discharge and Testing Procedure
  31
- Battery Specific Gravity Test
  33
- Battery Removal and Installation
  34
- Battery Terminal Orientation and Cable Routing
  35
- Battery Cable Removal
  37
- Battery Cable Installation
  38
- Accessory Installation Precautions
  39
- Battery Charger
  39
- Battery Storage
  39
- Battery Charger Led Function
  40
- Battery Charger Troubleshooting
  40
- Specific Gravity / Charge Percentage Table
  41
- Conversion Table
  42
- Reference
  42
- Metric Bolt Torque Specification
  43
- Sae Tap / Drill Sizes
  43
- Standard Bolt Torque Specification
  43
Chapter 2 Maintenance

47
- Maintenance Chart Key
  48
- Periodic Maintenance Chart
  48
- Periodic Maintenance Overview
  48
- Service Products and Lubricants
  50
  - Polaris Lubricants, Maintenance and Service Products
    50
- General Vehicle Inspection and Maintenance
  51
  - Pre-Ride / Daily Inspection
    51
  - Frame, Nuts, Bolts, and Fasteners
    51
- Fluid Maintenance References
  52
  - Component Quick Reference
    52
- Final Drive / Wheel and Tire
  53
  - Wheel and Hub Torque Table
    53
  - Wheel Removal
    53
  - Wheel Installation
    53
  - Tire Pressure
    53
  - Tire Inspection
    53
  - CV Shaft Boot Inspection
    54
- Gearcase Maintenance
  55
  - Front Gearcase Lubrication
    55
  - Transaxle (Rear Gearcase) Lubricant
    56
- Steering
  58
- Suspension
  61
- Brake System
  62
- Electrical System
  65
  - Battery Maintenance
    65
  - Battery Information
    65
Chapter 3 Drive Motor

67
- Special Tools
  68
- Battery Handling Warnings
  69
- Safety Information
  69
- Service Precautions
  69
- Specifications
  70
  - Torque Specifications
    70
  - Motor Service Data
    70
- Drive Motor
  71
  - Drive Motor Assembly View
    71
- Drive Motor Service
  72
  - Drive Motor Removal
    72
  - Drive Motor Installation
    73
  - Drive Motor Disassembly
    74
  - Rotor Removal
    76
  - Bearing Replacement
    77
  - Drive Motor Assembly
    78
  - Drive Motor Bench Tests
    79
Chapter 4 Body / Steering / Suspension

81
- General Specifications
  82
- Special Tools
  82
- Torque Specifications
  82
- Component Locations
  83
  - Right Side View
    83
  - Front View
    83
  - Rear View
    83
- Exploded Views
  84
- Body Component Removal
  92
  - Seat / Storage Trays
    92
  - Front Bumper / Grill
    92
  - Foot Pads / Corner Panel / Side Panel
    92
  - Cargo Box Removal
    92
  - Cargo Box Installation
    93
  - Hood / Dash
    93
  - Floor
    93
- Steering
  95
  - Steering Assembly Exploded View
    95
- Suspension
  96
  - Front A-Arm Removal / Installation
    96
  - Ball Joint Replacement
    96
  - Front Strut Cartridge Replacement
    98
  - Front Strut Exploded View
    99
  - Rear A-Arm Removal / Replacement
    100
  - Rear A-Arm Installation
    101
  - Rear A-Arm Exploded View
    102
  - Rear Stabilizer Bar Removal / Installation
    102
  - Exploded View
    103
  - Shock Removal / Installation
    103
  - Shock Replacement
    104
  - Shocks Exploded View
    104
- Decal Replacement
  104
  - Decal Replacement
    105
Chapter 5 Final Drive

107
- Special Tools
  108
- Torque Specifications
  108
- Wheel and Hub Torque Table
  108
- Front & Rear Hub/Wheel Exploded View
  109
- Prop Shaft Service
  110
  - Prop Shaft Removal
    110
  - Prop Shaft Installation
    112
  - Prop Shaft U-Joint Service
    112
  - Prop Shaft U-Joint Installation
    113
- Front Hub / Bearing
  115
  - Hub Removal / Inspection
    115
  - Hubstrut Bearing Replacement
    115
- Front Drive Shaft
  117
  - Front Drive Shaft Removal
    117
  - Front Drive Shaft Installation
    118
  - Front Hub Installation
    119
- Front Gearcase / Centralized Hilliard
  121
  - Centralized Hilliard Theory of Operation
    121
  - Centralized Hilliard Exploded View
    122
  - Awd Diagnosis
    122
  - Gearcase Removal
    124
  - Gearcase Disassembly / Inspection
    125
  - Gearcase Reassembly / Inspection
    129
  - Backlash Pad (Thrust Pad) Adjustment
    132
  - Gearcase Installation
    133
- Rear Bearing Carrier
  134
  - Rear Bearing Carrier Inspection
    134
  - Rear Bearing Carrier Removal
    134
  - Disassembly
    135
  - Assembly
    136
  - Installation
    136
- Rear Drive Shaft
  138
  - Rear Drive Shaft Removal
    138
  - Rear Drive Shaft Installation
    138
- Drive Shaft Service
  139
Chapter 6 Transaxle / Differential

147
- General Operation (Typical)
  148
- Lubrication
  148
- Special Tools
  148
- Specifications
  148
- Torque Specifications
  148
- Transaxle Service
  150
  - Transaxle Removal
    150
  - Transaxle Disassembly
    151
  - Transaxle Assembly
    153
  - Transaxle Installation
    154
  - Transaxle and Differential Exploded View, Complete
    156
  - Transaxle Exploded View, Shaft and Gear Assemblies
    157
  - Transaxle Exploded View, Differential
    158
  - Transaxle Differential Disassembly / Inspect
    159
  - Planetary Differential Disassembly
    161
  - Planetary Differential Bushing Replacement
    162
  - Planetary Differential Assembly
    164
  - Differential Case Assembly
    164
- Troubleshooting
  166
  - Troubleshooting Checklist
    166
Chapter 7 Brake System

167
- General Specifications
  169
- Special Tools
  169
- Torque Specifications
  169
- Brake System Service
  170
  - Brake System Service Notes
    170
  - Hydraulic Brake System Operation
    170
- Brake System
  171
  - System View and Torque Values
    171
  - Brake Bleeding / Fluid Change
    172
- Master Cylinder
  173
  - Removal
    173
  - Installation
    173
- Foot Brake Pedal
  174
  - Pedal Removal
    174
  - Pedal Installation
    174
- Parking Brake
  175
  - System View
    175
- Parking Brake Caliper Service
  176
  - Exploded View
    176
  - Parking Brake Adjustment
    176
  - Caliper Removal
    176
  - Caliper Disassembly / Inspection
    177
  - New Brake Pad Installation
    178
  - Parking Brake Caliper Installation
    179
- Parking Brake Disc Service
  181
  - Disc Inspection / Removal
    181
- Front Brake Pads
  182
  - Pad Removal
    182
  - Pad Inspection
    183
  - Pad Assembly / Installation
    183
  - Brake Burnishing Procedure
    184
- Front Caliper Service
  185
  - Caliper Exploded View
    185
  - Caliper Removal
    185
  - Caliper Disassembly
    186
  - Caliper Inspection
    187
  - Caliper Assembly
    188
  - Caliper Installation
    188
- Front Brake Disc
  190
  - Disc Inspection
    190
  - Disc Replacement
    190
- Rear Brake Pads
  192
  - Pad Removal
    192
  - Pad Inspection
    192
  - Pad Installation
    193
- Rear Caliper Service
  194
  - Rear Caliper Exploded View
    194
  - Caliper Removal
    194
  - Caliper Inspection
    195
  - Caliper Assembly
    195
  - Caliper Installation
    196
- Rear Brake Disc
  197
  - Disc Inspection
    197
  - Disc Replacement
    197
- Troubleshooting
  199
  - Brake Noise (Squeak)
    199
  - Poor Brake Performance
    199
  - Pedal Vibration
    199
  - Caliper Overheats (Brakes Drag)
    199
  - Brakes Lock
    199
Chapter 8 Electrical

201
- Battery Maintenance / Testing
  203
- Electrical Service Notes
  203
- General Information
  203
- General Wire Color Function
  203
- Overheat Control Circuit Operation
  203
- Special Tools
  203
- 48 Volt Fuse and Relay Location
  204
- 12 Volt Auxiliary Power Outlet
  205
- Switches / Controls
  206
  - Headlight Switch
    206
  - Awd / 2Wd / Turf Switch
    206
  - Direction Selector Switch (F / N / R)
    207
  - Drive Mode Switch (High, Max Range, Low)
    208
  - Differential Solenoid / Solenoid Driver Module
    209
  - Brake Light Switch (Hydraulic)
    211
  - Parking Brake Switch
    211
  - Indicator Light Circuits
    212
  - Indicator Lamp Replacement
    213
  - Indicator Lights
    214
  - Battery Discharge Indicator
    215
  - Charge Status Indicator
    216
  - Digital Wrench Diagnostic Software
    217
  - Accelerator Pedal Position Sensor
    217
- All Wheel Drive (Awd) Coil
  218
  - Awd System
    218
  - Diagnosing System Failures
    218
- Headlights
  219
  - Headlight Adjustment
    219
  - Headlight Bulb Replacement
    219
  - Headlight Housing Removal
    220
- Tail Light / Brake Light
  221
  - Led Lamp Replacement
    221
- 48 VDC - 14 VDC Converter
  222
  - Converter Information
    222
- System Wiring Diagrams
  223
- Parking Brake System Wiring Diagram
  230
- Awd System Wiring Diagram
  231
- Awd / 2Wd / Turf Switch Contacts
  232
- Direction Selector - System Wiring Diagram
  233
- Direction Selector Switch Contacts
  234
- Drive Mode (High / Max Range / Low) - System Wiring Diagram
  235
- Accelerator Pedal Position Sensor - System Wiring Diagram
  236
- Main Fuse Box
  237
- Diagnostic Trouble Codes
  238
- Digital Wrench Trouble Code List
  238

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