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Polaris Ranger XP 700 EFI 4x4 , 6x6 2007 Service Repair Manual
This original Polaris Ranger XP 700 EFI 4x4 , 6x6 2007 UTV manual is a detailed file and it is illustrated with clear step-by-step instructions.
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Polaris Ranger XP 700 EFI 4x4 , 6x6 2007 Service Repair Manual for sale
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Total Pages: 330 pages GENERAL INFORMATION 1 MODEL INFORMATION 1.2 MODEL IDENTIFICATION 1.2 ENGINE DESIGNATION NUMBER . 1.2 VIN IDENTIFICATION . 1.2 ENGINE SERIAL NUMBER LOCATION . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . 1.3 TRANSMISSION I.D. NUMBER LOCATION 1.3 VEHICLE DIMENSIONS 1.4 VEHICLE DIMENSIONS RANGER 4X4, 6X6 1.5 GENERAL SPECIFICS 1.6 MODEL: RANGER XP 4X4 . 1.6 MODEL: RANGER XP 6X6 . 1.6 MODEL: RANGER XP 4X4 . 1.7 MODEL: RANGER XP 6X6 . 1.8 VEHICLE INFORMATION . 1.9 PUBLICATION NUMBERS 1.9 PAINT CODES . 1.9 REPLACEMENT KEYS 1.9 SPECIAL TOOLS . 1.9 MISC. SPECIFICS AND CHARTS 1.10 CONVERSION TABLE 1.10 STANDARD TORQUE SPECIFICS . 1.11 SAE TAP / DRILL SIZES 1.12 METRIC TAP / DRILL SIZES . 1.12 DECIMAL EQUIVALENTS . 1.12 GLOSSARY OF TERMS . 1.13 MAINTENANCE PERIODIC MAINTENANCE CHART . 2.3 PERIODIC MAINTENANCE OVERVIEW . 2.3 MAINTENANCE CHART KEY . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL 2.4 50 - 100 HOUR MAINTENANCE INTERVAL 2.5 100 - 300 HOUR MAINTENANCE INTERVAL . 2.6 GENERAL COMPONENT LOCATIONS 2.7 RH SIDE AND DASH VIEW (4X4) 2.7 LH SIDE AND REAR VIEW (4X4) 2.8 LH SIDE AND RH SIDE VIEWS (6X6) . 2.9 SERVICE PRODUCTS AND LUBES 2.10 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . 2.10 MAINTENANCE REFERENCES . 2.11 MAINTENANCE REFERENCES, CONTINUED . 2.12 GENERAL VEHICLE INSPECTION AND MAINTENANCE . 2.13 PRE-RIDE / DAILY INSPECTION . 2.13 FRAME, NUTS, BOLTS, AND FASTENERS . 2.13 SHIFT LINKAGE INSPECTION / ADJUSTMENT 2.13 FUEL SYSTEM AND AIR INTAKE . 2.14 FUEL SYSTEM 2.14 FUEL LINES 2.14 FUEL FILTER . 2.14 VENT LINES 2.14 THROTTLE PEDAL INSPECTION . 2.14 THROTTLE FREEPLAY ADJUSTMENT 2.15 AIR FILTER SERVICE 2.15 AIR INTAKE INSPECTION . 2.16 ENGINE 2.17 COMPRESSION AND LEAKDOWN TEST . 2.17 BREATHER HOSE INSPECTION . 2.17 ENGINE OIL LEVEL 2.17 ENGINE OIL AND FILTER CHANGE . 2.18 EXHAUST PIPE . 2.19 TRANSMISSION AND GEARCASES . 2.20 TRANSMISSION LUBRICATION . 2.20 FRONT GEARCASE LUBRICATION (4X4) 2.21 MIDDLE GEARCASE LUBRICATION (6X6) . 2.22 REAR GEARCASE LUBRICATION (4X4) . 2.23 REAR GEARCASE LUBRICATION (6X6) . 2.24 COOLING SYSTEM . 2.25 LIQUID COOLING SYSTEM OVERVIEW . 2.25 COOLANT LEVEL INSPECTION 2.25 RADIATOR COOLANT LEVEL INSPECTION 2.26 COOLANT STRENGTH / TYPE . 2.26 COOLING SYSTEM PRESSURE TEST . 2.26 COOLING SYSTEM HOSES . 2.26 RADIATOR . 2.27 COOLANT DRAIN / RADIATOR REMOVAL . 2.27 2.2 GENERAL INFORMATION FINAL DRIVE / WHEEL AND TIRE . 2.27 WHEEL, HUB, AND SPINDLE TORQUE TABLE 2.27 CV SHAFT BOOT INSPECTION 2.28 WHEEL REMOVAL 2.28 WHEEL INSTALLATION 2.28 TIRE INSPECTION . 2.28 TIRE PRESSURE 2.29 ELECTRICAL AND IGNITION SYSTEM . 2.29 BATTERY MAINTENANCE 2.29 BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . 2.29 BATTERY REMOVAL . 2.29 BATTERY INSTALLATION . 2.30 BATTERY STORAGE . 2.30 BATTERY CHARGING 2.30 SPARK PLUG SERVICE 2.30 ENGINE TO FRAME GROUND . 2.31 STEERING AND SUSPENSION . 2.31 STEERING . 2.31 TIE ROD END / STEERING INSPECTION 2.31 CAMBER AND CASTER 2.31 WHEEL TOE ALIGNMENT INSPECTION . 2.32 TOE ADJUSTMENT 2.32 FRONT SUSPENSION 2.33 REAR SUSPENSION . 2.33 REAR SUSPENSION ADJUSTMENT (4X4) . 2.33 REAR SPRING ADJUSTMENT . 2.34 BRAKE SYSTEM . 2.34 BRAKE SYSTEM INSPECTION . 2.34 BRAKE PAD INSPECTION 2.34 PARKING BRAKE PAD INSPECTION 2.35 BRAKE HOSE AND FITTING INSPECTION . 2.35 CHAPTER 3 ENGINE 3 ENGINE ENGINE SPECIFICS . 3.2 CRANKCASE EXPLODED VIEWS . 3.2 ENGINE FASTENER TORQUE PATTERNS 3.9 TORQUE SPECIFICS . 3.10 700 EFI ENGINE SERVICE SPECIFICS . 3.11 SPECIAL TOOLS 3.13 GENERAL ENGINE SERVICE 3.13 ACCESSIBLE COMPONENTS 3.13 PISTON IDENTIFICATION . 3.13 COOLING SYSTEM SPECIFICS . 3.13 COOLING SYSTEM PRESSURE TEST . 3.14 COOLING SYSTEM EXPLODED VIEW . 3.15 COOLING SYSTEM BLEEDING PROCEDURE 3.15 VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) 3.17 ENGINE REMOVAL 3.18 ENGINE INSTALLATION NOTES . 3.19 CYLINDER HONE SELECTION AND HONING PROCEDURE . 3.20 HONING TO DEGLAZE . 3.20 CLEANING THE CYLINDER AFTER HONING . 3.21 ENGINE LUBRICATION SPECIFICS . 3.21 OIL PRESSURE TEST 3.21 OIL FLOW CHART . 3.22 ENGINE DISASSEMBLY AND INSPECTION . 3.23 CYLINDER HEAD ASSEMBLY EXPLODED VIEW 3.23 ROCKER ARMS / PUSH RODS . 3.24 CYLINDER HEAD REMOVAL 3.24 CYLINDER HEAD INSPECTION 3.25 CYLINDER HEAD WARP 3.25 VALVE SEAL / SPRING SERVICE (ON ENGINE) . 3.25 CYLINDER HEAD DISASSEMBLY 3.26 VALVE INSPECTION . 3.27 COMBUSTION CHAMBER . 3.28 VALVE SEAT RECONDITIONING . 3.28 CYLINDER HEAD REASSEMBLY . 3.30 VALVE SEALING TEST . 3.31 CYLINDER REMOVAL 3.31 VALVE LIFTER REMOVAL / INSPECTION 3.31 PISTON REMOVAL 3.32 CYLINDER INSPECTION 3.33 PISTON-TO-CYLINDER CLEARANCE . 3.34 PISTON / ROD INSPECTION . 3.34 PISTON RING INSTALLED GAP 3.35 STARTER DRIVE BENDIX REMOVAL / INSPECTION . 3.35 FLYWHEEL / STATOR REMOVAL / INSPECTION 3.36 ENGINE CRANKCASE DISASSEMBLY / INSPECTION 3.36 CAMSHAFT INSPECTION . 3.44 ENGINE REASSEMBLY . 3.45 CRANKCASE REASSEMBLY 3.45 FLYWHEEL / STATOR INSTALLATION 3.54 CYLINDER HEAD REASSEMBLY . 3.54 OIL PUMP PRIMING . 3.57 TROUBLESHOOTING CHAPTER 4 FUEL INJECTION 4 GENERAL INFORMATION 4.2 SPECIAL TOOLS . 4.2 SERVICE NOTES . 4.4 EFI SYSTEM EXPLODED VIEW . 4.5 EFI SYSTEM COMPONENT LOCATIONS . 4.6 FUEL TANK 4.8 EXPLODED VIEW 4.8 FUEL LINES - QUICK CONNECT 4.9 ELECTRONIC FUEL INJECTION . 4.9 PRINCIPAL COMPONENTS 4.9 EFI OPERATION OVERVIEW . 4.9 INITIAL PRIMING / STARTING PROCEDURE . 4.10 ELECTRONIC CONTROL UNIT (ECU) 4.10 OPERATION OVERVIEW . 4.10 ECU SERVICE 4.11 ECU REPLACEMENT 4.11 FUEL PUMP 4.11 OPERATION OVERVIEW . 4.11 FUEL PUMP TEST . 4.12 FUEL PUMP / TANK ASSEMBLY REPLACEMENT . 4.12 FUEL PRESSURE REGULATOR 4.14 OPERATION OVERVIEW . 4.14 FUEL PRESSURE REGULATOR TEST 4.14 FUEL PRESSURE REGULATOR REPLACEMENT 4.14 FUEL INJECTORS . 4.14 OPERATION OVERVIEW . 4.14 FUEL INJECTOR SERVICE 4.15 FUEL INJECTOR REPLACEMENT 4.15 CRANKSHAFT POSITION SENSOR (CPS) 4.15 OPERATION OVERVIEW . 4.15 CPS TEST . 4.16 CPS REPLACEMENT . 4.16 TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP) . 4.16 OPERATION OVERVIEW . 4.16 T-BAP TEST 4.16 T-BAP REPLACEMENT . 4.16 THROTTLE POSITION SENSOR (TPS) . 4.17 OPERATION OVERVIEW . 4.17 TPS TEST 4.17 TPS INITIALIZATION . 4.18 TPS REPLACEMENT . 4.19 ENGINE COOLANT TEMPERATURE SENSOR (ECT) . 4.19 OPERATION OVERVIEW . 4.19 ECT SENSOR TEST . 4.20 ECT SENSOR REPLACEMENT . 4.20 GENERAL TROUBLESHOOTING 4.21 DIAGNOSTIC BLINK CODES . 4.21 EFI TROUBLESHOOTING . 4.22 BODY / STEERING / SUSPENSION 5 TORQUE SPECIFICS . 5.2 SPECIAL TOOLS . 5.2 BODY COMPONENT REMOVAL . 5.3 REMOVAL PROCEDURES . 5.3 LOWER BODY COMPONENTS 5.4 HOOD / DASH COMPONENTS 5.5 DASH INSTRUMENTS AND CONTROLS 5.6 CAB FRAME . 5.7 ASSEMBLY / REMOVAL . 5.7 CHASSIS / MAIN FRAME (4X4) 5.8 EXPLODED VIEW 5.8 CHASSIS / MAIN FRAME (6X6) 5.9 EXPLODED VIEW 5.9 SEAT / HEAD REST 5.10 SEAT BASE / SEAT BACK / HEAD REST ASSEMBLY . 5.10 STEERING ASSEMBLY . 5.11 EXPLODED VIEW . 5.11 STEERING AND SUSPENSION . 5.12 EXPLODED VIEW . 5.12 FRONT A-ARM 5.13 REPLACEMENT . 5.13 FRONT STRUT 5.14 EXPLODED VIEW . 5.14 FRONT STRUT CARTRIDGE REPLACEMENT 5.15 BALL JOINT REPLACEMENT 5.15 MID AXLE A-ARM (6X6) . 5.16 REPLACEMENT . 5.16 REAR A-ARM (4X4) . 5.17 REPLACEMENT . 5.17 REAR STABILIZER BAR (4X4) 5.19 REMOVAL / INSTALLATION . 5.19 SWING ARM (6X6) . 5.20 REMOVAL . 5.20 INSTALLATION . 5.20 REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6) . 5.21 REAR CARGO BOX 5.22 CARGO BOX - PANELS . 5.22 CARGO BOX - TAILGATE / BOX SUPPORT . 5.23 BOX REMOVAL . 5.24 BOX INSTALLATION . 5.24 STORAGE BOX 5.25 REMOVAL . 5.25 INSTALLATION . 5.25 DECAL REPLACEMENT . 5.25 CHAPTER 6 CLUTCHING 6 SPECIAL TOOLS AND SUPPLIES 6.2 TORQUE SPECIFICS . 6.2 PVT SYSTEM FASTENER TORQUES 6.2 PVT SYSTEM OVERVIEW 6.2 GENERAL OPERATION 6.2 DRIVE CLUTCH OPERATION . 6.2 DRIVEN CLUTCH OPERATION 6.3 MAINTENANCE / INSPECTION 6.3 OVERHEATING / DIAGNOSIS . 6.4 PVT SYSTEM SERVICE 6.5 PVT SEALING, GUARD, AND DUCTING COMPONENTS . 6.5 DISASSEMBLY . 6.5 ASSEMBLY . 6.6 DRIVE BELT . 6.7 BELT DEFLECTION (TENSION) . 6.7 BELT REMOVAL . 6.7 BELT INSPECTION . 6.8 BELT INSTALLATION . 6.9 CLUTCH ALIGNMENT / OFFSET . 6.9 CLUTCH ALIGNMENT . 6.9 CLUTCH OFFSET . 6.10 DRIVE CLUTCH SERVICE . 6.11 SPRING SPECIFICS 6.11 SHIFT WEIGHTS 6.12 EXPLODED VIEW . 6.13 CLUTCH INSPECTION . 6.13 CLUTCH DISASSEMBLY 6.14 SPIDER REMOVAL 6.15 ROLLER, PIN, AND THRUST WASHER INSPECTION . 6.15 BUSHING SERVICE 6.16 MOVEABLE SHEAVE - BUSHING REMOVAL . 6.16 MOVEABLE SHEAVE - BUSHING INSTALLATION . 6.16 CLUTCH COVER - BUSHING REMOVAL . 6.17 CLUTCH COVER - BUSHING INSTALLATION . 6.17 CLUTCH ASSEMBLY . 6.18 DRIVEN CLUTCH SERVICE 6.19 EXPLODED VIEW . 6.19 CLUTCH DISASSEMBLY / INSPECTION . 6.19 CLUTCH ASSEMBLY . 6.21 TROUBLESHOOTING . 6.22 CHAPTER 7 FINAL DRIVE 7 SPECIAL TOOLS . 7.3 TORQUE SPECIFICS . 7.3 WHEEL, HUB, AND SPINDLE TORQUE TABLE . 7.3 FRONT HUB . 7.3 HUB REMOVAL / INSPECTION 7.3 HUBSTRUT BEARING REPLACEMENT . 7.4 HUB INSTALLATION 7.5 FRONT HUB EXPLODED VIEW . 7.6 DRIVE SHAFT / PROPSHAFT . 7.7 EXPLODED VIEW 7.7 DRIVESHAFT / CV JOINT HANDLING TIPS 7.8 FRONT DRIVE SHAFT . 7.8 REMOVAL 7.8 CV JOINT / BOOT REPLACEMENT 7.9 INSTALLATION . 7.11 FRONT PROPSHAFT REMOVAL 7.11 PROPSHAFT U-JOINT SERVICE 7.12 DISASSEMBLY 7.12 ASSEMBLY 7.13 FRONT GEARCASE CENTRALIZED HILLIARD 7.14 AWD OPERATION . 7.14 CENTRALIZED HILLIARD EXPLODED VIEW 7.15 AWD DIAGNOSIS 7.16 GEARCASE REMOVAL . 7.17 GEARCASE DISASSEMBLY / INSPECTION . 7.18 GEARCASE REASSEMBLY / INSPECTION . 7.20 BACKLASH PAD (THRUST PAD) ADJUSTMENT . 7.22 GEARCASE INSTALLATION . 7.23 MID DRIVE HUB / BEARING CARRIER (6X6) 7.23 REMOVAL . 7.23 HUB DISASSEMBLY . 7.24 HUB ASSEMBLY 7.24 HUB INSTALLATION . 7.25 MID DRIVE EXPLODED VIEW 7.26 MID DRIVE SHAFT (6X6) 7.27 REMOVAL . 7.27 DISASSEMBLY / ASSEMBLY 7.27 INSTALLATION . 7.27 MID PROP SHAFT (6X6) . 7.28 REMOVAL . 7.28 MID DRIVE GEARCASE (6X6) 7.28 GEARCASE REMOVAL . 7.28 GEARCASE DISASSEMBLY . 7.29 GEARCASE ASSEMBLY 7.32 GEARCASE INSTALLATION . 7.34 MID GEARCASE EXPLODED 7.35 REAR DRIVE (4X4) . 7.36 EXPLODED VIEW . 7.36 7.2 FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) 7.36 HUB INSPECTION . 7.36 HUB REMOVAL . 7.36 HUB DISASSEMBLY . 7.37 HUB ASSEMBLY 7.38 HUB INSTALLATION . 7.38 REAR DRIVE SHAFT (4X4) 7.39 REMOVAL . 7.39 CV JOINT / BOOT REPLACEMENT . 7.40 INSTALLATION . 7.42 REAR PROPSHAFT (4X4) . 7.43 REMOVAL . 7.43 INSTALLATION . 7.43 REAR GEARCASE (4X4) 7.44 GENERAL OPERATION 7.44 OPERATION MODES 7.45 DIFFERENTIAL REMOVAL 7.46 DIFFERENTIAL DISASSEMBLY 7.46 DIFFERENTIAL ASSEMBLY . 7.49 DIFFERENTIAL INSTALLATION 7.51 DIFFERENTIAL EXPLODED VIEW 7.52 REAR AXLE / GEARCASE SERVICE (6X6) 7.53 REAR AXLE REMOVAL . 7.53 AXLE TUBE REMOVAL . 7.54 AXLE TUBE BEARING REPLACEMENT 7.55 GEARCASE DISASSEMBLY / INSPECTION 7.55 GEARCASE ASSEMBLY 7.56 GEARCASE / AXLE INSTALLATION . 7.57 GEARCASE EXPLODED VIEW . 7.60 CHAPTER 8 TRANSMISSION 8 TORQUE SPECIFICS . 8.2 SHIFT LEVER 8.2 REMOVAL 8.2 INSTALLATION 8.2 SHIFT LINKAGE 8.2 INSPECTION 8.2 ADJUSTMENT . 8.3 TRANSMISSION SERVICE 8.3 TRANSMISSION REMOVAL 8.3 TRANSMISSION DISASSEMBLY 8.5 TRANSMISSION ASSEMBLY 8.10 TRANSMISSION INSTALLATION . 8.14 TROUBLESHOOTING . 8.15 TROUBLESHOOTING CHECKLIST 8.15 TRANSMISSION EXPLODED VIEW 8.16 EXPLODED VIEW (4X4, 6X6) 8.16 CHAPTER 9 BRAKES 9 GENERAL SPECIFICS / TORQUE SPECIFICS / SPECIAL TOOLS . 9.2 BRAKE SYSTEM SERVICE NOTES . 9.3 BRAKE NOISE TROUBLESHOOTING . 9.3 HYDRAULIC BRAKE SYSTEM OPERATION 9.4 BRAKE SYSTEM EXPLODED VIEW 9.5 MASTER CYLINDER . 9.6 REMOVAL / INSTALLATION 9.6 FOOT BRAKE PEDAL 9.6 PEDAL REMOVAL / INSTALLATION 9.6 BRAKE BLEEDING / FLUID CHANGE . 9.7 PARKING BRAKE . 9.8 EXPLODED VIEW 9.8 INSPECTION / ADJUSTMENT . 9.9 PARKING BRAKE CALIPER SERVICE . 9.10 EXPLODED VIEW . 9.10 CALIPER REMOVAL . 9.10 CALIPER DISASSEMBLY / INSPECTION . 9.11 NEW BRAKE PAD INSTALLATION 9.12 CALIPER INSTALLATION . 9.12 PARKING BRAKE DISC SERVICE . 9.12 DISC REMOVAL / INSPECTION 9.12 FRONT BRAKE PADS . 9.13 PAD REMOVAL / DISASSEMBLY / INSPECTION . 9.13 PAD ASSEMBLY / INSTALLATION / ADJUSTMENT 9.14 FRONT CALIPER 9.15 FRONT CALIPER EXPLODED VIEW 9.15 CALIPER REMOVAL / DISASSEMBLY . 9.15 CALIPER INSPECTION / ASSEMBLY 9.16 CALIPER INSTALLATION . 9.17 FRONT BRAKE DISC . 9.18 DISC INSPECTION / REMOVAL / REPLACEMENT . 9.18 REAR BRAKE PAD (4X4) 9.18 PAD REMOVAL . 9.18 PAD INSPECTION / INSTALLATION . 9.19 REAR BRAKE PAD (6X6) 9.20 PAD REMOVAL . 9.20 PAD INSPECTION / INSTALLATION . 9.21 REAR CALIPER 9.22 REAR CALIPER EXPLODED VIEW 9.22 CALIPER REMOVAL (4X4) 9.22 CALIPER REMOVAL (6X6) 9.23 CALIPER DISASSEMBLY . 9.23 CALIPER INSPECTION / ASSEMBLY 9.24 CALIPER INSTALLATION (4X4, 6X6) 9.25 REAR BRAKE DISC 9.25 TROUBLESHOOTING . 9.26 BRAKES SQUEAL / POOR BRAKE PERFORMANCE . 9.26 PEDAL VIBRATION 9.26 CALIPER OVERHEATS (BRAKES DRAG) 9.26 BRAKES LOCK 9.26 CHAPTER 10 ELECTRICAL 10 GENERAL INFORMATION . 10.3 SPECIAL TOOLS 10.3 ELECTRICAL SERVICE NOTES 10.3 UNDER-HOOD COMPONENTS 10.3 SWITCHES / CONTROLS . 10.4 HEADLAMP SWITCH . 10.4 AWD / REAR DIFFERENTIAL SWITCH (4X4) 10.4 DIFFERENTIAL SOLENOID (4X4) . 10.4 BRAKE LIGHT SWITCH . 10.5 PARKING BRAKE SWITCH 10.6 INSTRUMENT CLUSTER 10.7 OVERVIEW . 10.7 RIDER INFORMATION DISPLAY . 10.7 STANDARD DISPLAY MODES . 10.8 DIAGNOSTIC DISPLAY MODE . 10.8 VIEWING DIAGNOSTIC CODES . 10.10 INSTRUMENT CLUSTER REMOVAL . 10.11 INSTRUMENT CLUSTER INSTALLATION . 10.11 INSTRUMENT CLUSTER TROUBLESHOOTING TESTS 10.12 TEST 1 - NO ALL WHEEL DRIVE 10.12 TEST 2 - NO DISPLAY . 10.13 TEST 3 - WHEEL SPEED SENSOR 10.13 TEST 4 - NO AWD HUB SAFETY LIMITER . 10.14 TEST 5 - FUEL GAUGE DISPLAY NOT WORKING 10.15 TEST 6 - SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) . 10.15 ALL WHEEL DRIVE (AWD) COIL . 10.16 OPERATION OVERVIEW 10.16 DIAGNOSING SYSTEM FAILURES . 10.16 GEAR POSITION INDICATOR SWITCH 10.16 TEST DIAGRAM 10.16 HEAD LIGHTS 10.17 HIGH BEAM HEADLIGHT ADJUSTMENT 10.17 HEADLAMP BULB REPLACEMENT 10.17 HEADLAMP HOUSING REMOVAL . 10.17 HEADLAMP HOUSING INSTALLATION . 10.18 TAIL LIGHT / BRAKE LIGHT . 10.18 LAMP REPLACEMENT 10.18 COOLING SYSTEM 10.19 COOLING SYSTEM BREAK-OUT DIAGRAM . 10.19 FAN CONTROL CIRCUIT OPERATION / TESTING 10.20 FAN CONTROL CIRCUIT BYPASS TEST 10.20 COOLANT TEMPERATURE SENSOR 10.20 EFI DIAGNOSTICS 10.20 EFI COMPONENT TESTING 10.20 FUEL SENDER pecno1 . 10.20 TESTING . 10.20 RELAYS . 10.21 OPERATION . 10.21 FUSES / CIRCUIT BREAKER 10.22 OPERATION . 10.22 10.2 ELECTRICAL CHARGING SYSTEM 10.22 CURRENT DRAW - KEY OFF . 10.22 CHARGING SYSTEM BREAK EVEN TEST . 10.23 CHARGING SYSTEM ALTERNATOR TESTS . 10.23 CHARGING SYSTEM TESTING FLOW CHART . 10.25 BATTERY TERMINAL BLOCK . 10.26 BATTERY SERVICE . 10.26 BATTERY TERMINALS / BOLTS . 10.26 BATTERY IDENTIFICATION 10.26 CONVENTIONAL BATTERY . 10.27 BATTERY ACTIVATION 10.27 BATTERY INSPECTION . 10.27 BATTERY REMOVAL 10.28 BATTERY INSTALLATION 10.28 CONVENTIONAL BATTERY TESTING 10.28 OCV - OPEN CIRCUIT VOLTAGE TEST . 10.28 SPECIFIC GRAVITY TEST . 10.28 LOAD TEST . 10.29 OFF SEASON STORAGE 10.29 CHARGING PROCEDURE . 10.29 LOW MAINTENANCE BATTERY . 10.30 BATTERY CHECK 10.30 BATTERY INSPECTION . 10.30 BATTERY REMOVAL 10.30 BATTERY INSTALLATION 10.31 BATTERY TESTING . 10.31 OCV - OPEN CIRCUIT VOLTAGE TEST . 10.31 LOAD TEST . 10.31 OFF-SEASON STORAGE 10.32 BATTERY CHARGING . 10.32 STARTER SYSTEM . 10.33 TROUBLESHOOTING . 10.33 VOLTAGE DROP TEST 10.33 STARTER MOTOR REMOVAL / DISASSEMBLY 10.33 BRUSH INSPECTION / REPLACEMENT 10.34 ARMATURE TESTING . 10.35 STARTER REASSEMBLY / INSTALLATION 10.35 STARTER SOLENOID BENCH TEST . 10.36 STARTER DRIVE . 10.36 STARTER EXPLODED VIEW . 10.37 STARTER SYSTEM TESTING FLOW CHART . 10.38 ELECTRIC BOX LIFT ACTUATOR 10.39
Polaris Ranger XP 700 EFI 4x4 , 6x6 2007 UTV pdf (How to fix...) - This is a specific and detailed pdf manual.
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Polaris Ranger XP 700 EFI 4x4 , 6x6 2007 Service Repair Manual
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This is the electronic download versions of the Polaris Ranger XP 700 EFI 4x4 , 6x6 2007 Service Repair Manual.
Total Pages: 330 pages GENERAL INFORMATION 1 MODEL INFORMATION 1.2 MODEL IDENTIFICATION 1.2 ENGINE DESIGNATION NUMBER . 1.2 VIN IDENTIFICATION . 1.2 ENGINE SERIAL NUMBER LOCATION . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . 1.3 TRANSMISSION I.D. NUMBER LOCATION 1.3 VEHICLE DIMENSIONS 1.4 VEHICLE DIMENSIONS RANGER 4X4, 6X6 1.5 GENERAL SPECIFICS 1.6 MODEL: RANGER XP 4X4 . 1.6 MODEL: RANGER XP 6X6 . 1.6 MODEL: RANGER XP 4X4 . 1.7 MODEL: RANGER XP 6X6 . 1.8 VEHICLE INFORMATION . 1.9 PUBLICATION NUMBERS 1.9 PAINT CODES . 1.9 REPLACEMENT KEYS 1.9 SPECIAL TOOLS . 1.9 MISC. SPECIFICS AND CHARTS 1.10 CONVERSION TABLE 1.10 STANDARD TORQUE SPECIFICS . 1.11 SAE TAP / DRILL SIZES 1.12 METRIC TAP / DRILL SIZES . 1.12 DECIMAL EQUIVALENTS . 1.12 GLOSSARY OF TERMS . 1.13 MAINTENANCE PERIODIC MAINTENANCE CHART . 2.3 PERIODIC MAINTENANCE OVERVIEW . 2.3 MAINTENANCE CHART KEY . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL 2.4 50 - 100 HOUR MAINTENANCE INTERVAL 2.5 100 - 300 HOUR MAINTENANCE INTERVAL . 2.6 GENERAL COMPONENT LOCATIONS 2.7 RH SIDE AND DASH VIEW (4X4) 2.7 LH SIDE AND REAR VIEW (4X4) 2.8 LH SIDE AND RH SIDE VIEWS (6X6) . 2.9 SERVICE PRODUCTS AND LUBES 2.10 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . 2.10 MAINTENANCE REFERENCES . 2.11 MAINTENANCE REFERENCES, CONTINUED . 2.12 GENERAL VEHICLE INSPECTION AND MAINTENANCE . 2.13 PRE-RIDE / DAILY INSPECTION . 2.13 FRAME, NUTS, BOLTS, AND FASTENERS . 2.13 SHIFT LINKAGE INSPECTION / ADJUSTMENT 2.13 FUEL SYSTEM AND AIR INTAKE . 2.14 FUEL SYSTEM 2.14 FUEL LINES 2.14 FUEL FILTER . 2.14 VENT LINES 2.14 THROTTLE PEDAL INSPECTION . 2.14 THROTTLE FREEPLAY ADJUSTMENT 2.15 AIR FILTER SERVICE 2.15 AIR INTAKE INSPECTION . 2.16 ENGINE 2.17 COMPRESSION AND LEAKDOWN TEST . 2.17 BREATHER HOSE INSPECTION . 2.17 ENGINE OIL LEVEL 2.17 ENGINE OIL AND FILTER CHANGE . 2.18 EXHAUST PIPE . 2.19 TRANSMISSION AND GEARCASES . 2.20 TRANSMISSION LUBRICATION . 2.20 FRONT GEARCASE LUBRICATION (4X4) 2.21 MIDDLE GEARCASE LUBRICATION (6X6) . 2.22 REAR GEARCASE LUBRICATION (4X4) . 2.23 REAR GEARCASE LUBRICATION (6X6) . 2.24 COOLING SYSTEM . 2.25 LIQUID COOLING SYSTEM OVERVIEW . 2.25 COOLANT LEVEL INSPECTION 2.25 RADIATOR COOLANT LEVEL INSPECTION 2.26 COOLANT STRENGTH / TYPE . 2.26 COOLING SYSTEM PRESSURE TEST . 2.26 COOLING SYSTEM HOSES . 2.26 RADIATOR . 2.27 COOLANT DRAIN / RADIATOR REMOVAL . 2.27 2.2 GENERAL INFORMATION FINAL DRIVE / WHEEL AND TIRE . 2.27 WHEEL, HUB, AND SPINDLE TORQUE TABLE 2.27 CV SHAFT BOOT INSPECTION 2.28 WHEEL REMOVAL 2.28 WHEEL INSTALLATION 2.28 TIRE INSPECTION . 2.28 TIRE PRESSURE 2.29 ELECTRICAL AND IGNITION SYSTEM . 2.29 BATTERY MAINTENANCE 2.29 BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . 2.29 BATTERY REMOVAL . 2.29 BATTERY INSTALLATION . 2.30 BATTERY STORAGE . 2.30 BATTERY CHARGING 2.30 SPARK PLUG SERVICE 2.30 ENGINE TO FRAME GROUND . 2.31 STEERING AND SUSPENSION . 2.31 STEERING . 2.31 TIE ROD END / STEERING INSPECTION 2.31 CAMBER AND CASTER 2.31 WHEEL TOE ALIGNMENT INSPECTION . 2.32 TOE ADJUSTMENT 2.32 FRONT SUSPENSION 2.33 REAR SUSPENSION . 2.33 REAR SUSPENSION ADJUSTMENT (4X4) . 2.33 REAR SPRING ADJUSTMENT . 2.34 BRAKE SYSTEM . 2.34 BRAKE SYSTEM INSPECTION . 2.34 BRAKE PAD INSPECTION 2.34 PARKING BRAKE PAD INSPECTION 2.35 BRAKE HOSE AND FITTING INSPECTION . 2.35 CHAPTER 3 ENGINE 3 ENGINE ENGINE SPECIFICS . 3.2 CRANKCASE EXPLODED VIEWS . 3.2 ENGINE FASTENER TORQUE PATTERNS 3.9 TORQUE SPECIFICS . 3.10 700 EFI ENGINE SERVICE SPECIFICS . 3.11 SPECIAL TOOLS 3.13 GENERAL ENGINE SERVICE 3.13 ACCESSIBLE COMPONENTS 3.13 PISTON IDENTIFICATION . 3.13 COOLING SYSTEM SPECIFICS . 3.13 COOLING SYSTEM PRESSURE TEST . 3.14 COOLING SYSTEM EXPLODED VIEW . 3.15 COOLING SYSTEM BLEEDING PROCEDURE 3.15 VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) 3.17 ENGINE REMOVAL 3.18 ENGINE INSTALLATION NOTES . 3.19 CYLINDER HONE SELECTION AND HONING PROCEDURE . 3.20 HONING TO DEGLAZE . 3.20 CLEANING THE CYLINDER AFTER HONING . 3.21 ENGINE LUBRICATION SPECIFICS . 3.21 OIL PRESSURE TEST 3.21 OIL FLOW CHART . 3.22 ENGINE DISASSEMBLY AND INSPECTION . 3.23 CYLINDER HEAD ASSEMBLY EXPLODED VIEW 3.23 ROCKER ARMS / PUSH RODS . 3.24 CYLINDER HEAD REMOVAL 3.24 CYLINDER HEAD INSPECTION 3.25 CYLINDER HEAD WARP 3.25 VALVE SEAL / SPRING SERVICE (ON ENGINE) . 3.25 CYLINDER HEAD DISASSEMBLY 3.26 VALVE INSPECTION . 3.27 COMBUSTION CHAMBER . 3.28 VALVE SEAT RECONDITIONING . 3.28 CYLINDER HEAD REASSEMBLY . 3.30 VALVE SEALING TEST . 3.31 CYLINDER REMOVAL 3.31 VALVE LIFTER REMOVAL / INSPECTION 3.31 PISTON REMOVAL 3.32 CYLINDER INSPECTION 3.33 PISTON-TO-CYLINDER CLEARANCE . 3.34 PISTON / ROD INSPECTION . 3.34 PISTON RING INSTALLED GAP 3.35 STARTER DRIVE BENDIX REMOVAL / INSPECTION . 3.35 FLYWHEEL / STATOR REMOVAL / INSPECTION 3.36 ENGINE CRANKCASE DISASSEMBLY / INSPECTION 3.36 CAMSHAFT INSPECTION . 3.44 ENGINE REASSEMBLY . 3.45 CRANKCASE REASSEMBLY 3.45 FLYWHEEL / STATOR INSTALLATION 3.54 CYLINDER HEAD REASSEMBLY . 3.54 OIL PUMP PRIMING . 3.57 TROUBLESHOOTING CHAPTER 4 FUEL INJECTION 4 GENERAL INFORMATION 4.2 SPECIAL TOOLS . 4.2 SERVICE NOTES . 4.4 EFI SYSTEM EXPLODED VIEW . 4.5 EFI SYSTEM COMPONENT LOCATIONS . 4.6 FUEL TANK 4.8 EXPLODED VIEW 4.8 FUEL LINES - QUICK CONNECT 4.9 ELECTRONIC FUEL INJECTION . 4.9 PRINCIPAL COMPONENTS 4.9 EFI OPERATION OVERVIEW . 4.9 INITIAL PRIMING / STARTING PROCEDURE . 4.10 ELECTRONIC CONTROL UNIT (ECU) 4.10 OPERATION OVERVIEW . 4.10 ECU SERVICE 4.11 ECU REPLACEMENT 4.11 FUEL PUMP 4.11 OPERATION OVERVIEW . 4.11 FUEL PUMP TEST . 4.12 FUEL PUMP / TANK ASSEMBLY REPLACEMENT . 4.12 FUEL PRESSURE REGULATOR 4.14 OPERATION OVERVIEW . 4.14 FUEL PRESSURE REGULATOR TEST 4.14 FUEL PRESSURE REGULATOR REPLACEMENT 4.14 FUEL INJECTORS . 4.14 OPERATION OVERVIEW . 4.14 FUEL INJECTOR SERVICE 4.15 FUEL INJECTOR REPLACEMENT 4.15 CRANKSHAFT POSITION SENSOR (CPS) 4.15 OPERATION OVERVIEW . 4.15 CPS TEST . 4.16 CPS REPLACEMENT . 4.16 TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP) . 4.16 OPERATION OVERVIEW . 4.16 T-BAP TEST 4.16 T-BAP REPLACEMENT . 4.16 THROTTLE POSITION SENSOR (TPS) . 4.17 OPERATION OVERVIEW . 4.17 TPS TEST 4.17 TPS INITIALIZATION . 4.18 TPS REPLACEMENT . 4.19 ENGINE COOLANT TEMPERATURE SENSOR (ECT) . 4.19 OPERATION OVERVIEW . 4.19 ECT SENSOR TEST . 4.20 ECT SENSOR REPLACEMENT . 4.20 GENERAL TROUBLESHOOTING 4.21 DIAGNOSTIC BLINK CODES . 4.21 EFI TROUBLESHOOTING . 4.22 BODY / STEERING / SUSPENSION 5 TORQUE SPECIFICS . 5.2 SPECIAL TOOLS . 5.2 BODY COMPONENT REMOVAL . 5.3 REMOVAL PROCEDURES . 5.3 LOWER BODY COMPONENTS 5.4 HOOD / DASH COMPONENTS 5.5 DASH INSTRUMENTS AND CONTROLS 5.6 CAB FRAME . 5.7 ASSEMBLY / REMOVAL . 5.7 CHASSIS / MAIN FRAME (4X4) 5.8 EXPLODED VIEW 5.8 CHASSIS / MAIN FRAME (6X6) 5.9 EXPLODED VIEW 5.9 SEAT / HEAD REST 5.10 SEAT BASE / SEAT BACK / HEAD REST ASSEMBLY . 5.10 STEERING ASSEMBLY . 5.11 EXPLODED VIEW . 5.11 STEERING AND SUSPENSION . 5.12 EXPLODED VIEW . 5.12 FRONT A-ARM 5.13 REPLACEMENT . 5.13 FRONT STRUT 5.14 EXPLODED VIEW . 5.14 FRONT STRUT CARTRIDGE REPLACEMENT 5.15 BALL JOINT REPLACEMENT 5.15 MID AXLE A-ARM (6X6) . 5.16 REPLACEMENT . 5.16 REAR A-ARM (4X4) . 5.17 REPLACEMENT . 5.17 REAR STABILIZER BAR (4X4) 5.19 REMOVAL / INSTALLATION . 5.19 SWING ARM (6X6) . 5.20 REMOVAL . 5.20 INSTALLATION . 5.20 REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6) . 5.21 REAR CARGO BOX 5.22 CARGO BOX - PANELS . 5.22 CARGO BOX - TAILGATE / BOX SUPPORT . 5.23 BOX REMOVAL . 5.24 BOX INSTALLATION . 5.24 STORAGE BOX 5.25 REMOVAL . 5.25 INSTALLATION . 5.25 DECAL REPLACEMENT . 5.25 CHAPTER 6 CLUTCHING 6 SPECIAL TOOLS AND SUPPLIES 6.2 TORQUE SPECIFICS . 6.2 PVT SYSTEM FASTENER TORQUES 6.2 PVT SYSTEM OVERVIEW 6.2 GENERAL OPERATION 6.2 DRIVE CLUTCH OPERATION . 6.2 DRIVEN CLUTCH OPERATION 6.3 MAINTENANCE / INSPECTION 6.3 OVERHEATING / DIAGNOSIS . 6.4 PVT SYSTEM SERVICE 6.5 PVT SEALING, GUARD, AND DUCTING COMPONENTS . 6.5 DISASSEMBLY . 6.5 ASSEMBLY . 6.6 DRIVE BELT . 6.7 BELT DEFLECTION (TENSION) . 6.7 BELT REMOVAL . 6.7 BELT INSPECTION . 6.8 BELT INSTALLATION . 6.9 CLUTCH ALIGNMENT / OFFSET . 6.9 CLUTCH ALIGNMENT . 6.9 CLUTCH OFFSET . 6.10 DRIVE CLUTCH SERVICE . 6.11 SPRING SPECIFICS 6.11 SHIFT WEIGHTS 6.12 EXPLODED VIEW . 6.13 CLUTCH INSPECTION . 6.13 CLUTCH DISASSEMBLY 6.14 SPIDER REMOVAL 6.15 ROLLER, PIN, AND THRUST WASHER INSPECTION . 6.15 BUSHING SERVICE 6.16 MOVEABLE SHEAVE - BUSHING REMOVAL . 6.16 MOVEABLE SHEAVE - BUSHING INSTALLATION . 6.16 CLUTCH COVER - BUSHING REMOVAL . 6.17 CLUTCH COVER - BUSHING INSTALLATION . 6.17 CLUTCH ASSEMBLY . 6.18 DRIVEN CLUTCH SERVICE 6.19 EXPLODED VIEW . 6.19 CLUTCH DISASSEMBLY / INSPECTION . 6.19 CLUTCH ASSEMBLY . 6.21 TROUBLESHOOTING . 6.22 CHAPTER 7 FINAL DRIVE 7 SPECIAL TOOLS . 7.3 TORQUE SPECIFICS . 7.3 WHEEL, HUB, AND SPINDLE TORQUE TABLE . 7.3 FRONT HUB . 7.3 HUB REMOVAL / INSPECTION 7.3 HUBSTRUT BEARING REPLACEMENT . 7.4 HUB INSTALLATION 7.5 FRONT HUB EXPLODED VIEW . 7.6 DRIVE SHAFT / PROPSHAFT . 7.7 EXPLODED VIEW 7.7 DRIVESHAFT / CV JOINT HANDLING TIPS 7.8 FRONT DRIVE SHAFT . 7.8 REMOVAL 7.8 CV JOINT / BOOT REPLACEMENT 7.9 INSTALLATION . 7.11 FRONT PROPSHAFT REMOVAL 7.11 PROPSHAFT U-JOINT SERVICE 7.12 DISASSEMBLY 7.12 ASSEMBLY 7.13 FRONT GEARCASE CENTRALIZED HILLIARD 7.14 AWD OPERATION . 7.14 CENTRALIZED HILLIARD EXPLODED VIEW 7.15 AWD DIAGNOSIS 7.16 GEARCASE REMOVAL . 7.17 GEARCASE DISASSEMBLY / INSPECTION . 7.18 GEARCASE REASSEMBLY / INSPECTION . 7.20 BACKLASH PAD (THRUST PAD) ADJUSTMENT . 7.22 GEARCASE INSTALLATION . 7.23 MID DRIVE HUB / BEARING CARRIER (6X6) 7.23 REMOVAL . 7.23 HUB DISASSEMBLY . 7.24 HUB ASSEMBLY 7.24 HUB INSTALLATION . 7.25 MID DRIVE EXPLODED VIEW 7.26 MID DRIVE SHAFT (6X6) 7.27 REMOVAL . 7.27 DISASSEMBLY / ASSEMBLY 7.27 INSTALLATION . 7.27 MID PROP SHAFT (6X6) . 7.28 REMOVAL . 7.28 MID DRIVE GEARCASE (6X6) 7.28 GEARCASE REMOVAL . 7.28 GEARCASE DISASSEMBLY . 7.29 GEARCASE ASSEMBLY 7.32 GEARCASE INSTALLATION . 7.34 MID GEARCASE EXPLODED 7.35 REAR DRIVE (4X4) . 7.36 EXPLODED VIEW . 7.36 7.2 FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) 7.36 HUB INSPECTION . 7.36 HUB REMOVAL . 7.36 HUB DISASSEMBLY . 7.37 HUB ASSEMBLY 7.38 HUB INSTALLATION . 7.38 REAR DRIVE SHAFT (4X4) 7.39 REMOVAL . 7.39 CV JOINT / BOOT REPLACEMENT . 7.40 INSTALLATION . 7.42 REAR PROPSHAFT (4X4) . 7.43 REMOVAL . 7.43 INSTALLATION . 7.43 REAR GEARCASE (4X4) 7.44 GENERAL OPERATION 7.44 OPERATION MODES 7.45 DIFFERENTIAL REMOVAL 7.46 DIFFERENTIAL DISASSEMBLY 7.46 DIFFERENTIAL ASSEMBLY . 7.49 DIFFERENTIAL INSTALLATION 7.51 DIFFERENTIAL EXPLODED VIEW 7.52 REAR AXLE / GEARCASE SERVICE (6X6) 7.53 REAR AXLE REMOVAL . 7.53 AXLE TUBE REMOVAL . 7.54 AXLE TUBE BEARING REPLACEMENT 7.55 GEARCASE DISASSEMBLY / INSPECTION 7.55 GEARCASE ASSEMBLY 7.56 GEARCASE / AXLE INSTALLATION . 7.57 GEARCASE EXPLODED VIEW . 7.60 CHAPTER 8 TRANSMISSION 8 TORQUE SPECIFICS . 8.2 SHIFT LEVER 8.2 REMOVAL 8.2 INSTALLATION 8.2 SHIFT LINKAGE 8.2 INSPECTION 8.2 ADJUSTMENT . 8.3 TRANSMISSION SERVICE 8.3 TRANSMISSION REMOVAL 8.3 TRANSMISSION DISASSEMBLY 8.5 TRANSMISSION ASSEMBLY 8.10 TRANSMISSION INSTALLATION . 8.14 TROUBLESHOOTING . 8.15 TROUBLESHOOTING CHECKLIST 8.15 TRANSMISSION EXPLODED VIEW 8.16 EXPLODED VIEW (4X4, 6X6) 8.16 CHAPTER 9 BRAKES 9 GENERAL SPECIFICS / TORQUE SPECIFICS / SPECIAL TOOLS . 9.2 BRAKE SYSTEM SERVICE NOTES . 9.3 BRAKE NOISE TROUBLESHOOTING . 9.3 HYDRAULIC BRAKE SYSTEM OPERATION 9.4 BRAKE SYSTEM EXPLODED VIEW 9.5 MASTER CYLINDER . 9.6 REMOVAL / INSTALLATION 9.6 FOOT BRAKE PEDAL 9.6 PEDAL REMOVAL / INSTALLATION 9.6 BRAKE BLEEDING / FLUID CHANGE . 9.7 PARKING BRAKE . 9.8 EXPLODED VIEW 9.8 INSPECTION / ADJUSTMENT . 9.9 PARKING BRAKE CALIPER SERVICE . 9.10 EXPLODED VIEW . 9.10 CALIPER REMOVAL . 9.10 CALIPER DISASSEMBLY / INSPECTION . 9.11 NEW BRAKE PAD INSTALLATION 9.12 CALIPER INSTALLATION . 9.12 PARKING BRAKE DISC SERVICE . 9.12 DISC REMOVAL / INSPECTION 9.12 FRONT BRAKE PADS . 9.13 PAD REMOVAL / DISASSEMBLY / INSPECTION . 9.13 PAD ASSEMBLY / INSTALLATION / ADJUSTMENT 9.14 FRONT CALIPER 9.15 FRONT CALIPER EXPLODED VIEW 9.15 CALIPER REMOVAL / DISASSEMBLY . 9.15 CALIPER INSPECTION / ASSEMBLY 9.16 CALIPER INSTALLATION . 9.17 FRONT BRAKE DISC . 9.18 DISC INSPECTION / REMOVAL / REPLACEMENT . 9.18 REAR BRAKE PAD (4X4) 9.18 PAD REMOVAL . 9.18 PAD INSPECTION / INSTALLATION . 9.19 REAR BRAKE PAD (6X6) 9.20 PAD REMOVAL . 9.20 PAD INSPECTION / INSTALLATION . 9.21 REAR CALIPER 9.22 REAR CALIPER EXPLODED VIEW 9.22 CALIPER REMOVAL (4X4) 9.22 CALIPER REMOVAL (6X6) 9.23 CALIPER DISASSEMBLY . 9.23 CALIPER INSPECTION / ASSEMBLY 9.24 CALIPER INSTALLATION (4X4, 6X6) 9.25 REAR BRAKE DISC 9.25 TROUBLESHOOTING . 9.26 BRAKES SQUEAL / POOR BRAKE PERFORMANCE . 9.26 PEDAL VIBRATION 9.26 CALIPER OVERHEATS (BRAKES DRAG) 9.26 BRAKES LOCK 9.26 CHAPTER 10 ELECTRICAL 10 GENERAL INFORMATION . 10.3 SPECIAL TOOLS 10.3 ELECTRICAL SERVICE NOTES 10.3 UNDER-HOOD COMPONENTS 10.3 SWITCHES / CONTROLS . 10.4 HEADLAMP SWITCH . 10.4 AWD / REAR DIFFERENTIAL SWITCH (4X4) 10.4 DIFFERENTIAL SOLENOID (4X4) . 10.4 BRAKE LIGHT SWITCH . 10.5 PARKING BRAKE SWITCH 10.6 INSTRUMENT CLUSTER 10.7 OVERVIEW . 10.7 RIDER INFORMATION DISPLAY . 10.7 STANDARD DISPLAY MODES . 10.8 DIAGNOSTIC DISPLAY MODE . 10.8 VIEWING DIAGNOSTIC CODES . 10.10 INSTRUMENT CLUSTER REMOVAL . 10.11 INSTRUMENT CLUSTER INSTALLATION . 10.11 INSTRUMENT CLUSTER TROUBLESHOOTING TESTS 10.12 TEST 1 - NO ALL WHEEL DRIVE 10.12 TEST 2 - NO DISPLAY . 10.13 TEST 3 - WHEEL SPEED SENSOR 10.13 TEST 4 - NO AWD HUB SAFETY LIMITER . 10.14 TEST 5 - FUEL GAUGE DISPLAY NOT WORKING 10.15 TEST 6 - SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) . 10.15 ALL WHEEL DRIVE (AWD) COIL . 10.16 OPERATION OVERVIEW 10.16 DIAGNOSING SYSTEM FAILURES . 10.16 GEAR POSITION INDICATOR SWITCH 10.16 TEST DIAGRAM 10.16 HEAD LIGHTS 10.17 HIGH BEAM HEADLIGHT ADJUSTMENT 10.17 HEADLAMP BULB REPLACEMENT 10.17 HEADLAMP HOUSING REMOVAL . 10.17 HEADLAMP HOUSING INSTALLATION . 10.18 TAIL LIGHT / BRAKE LIGHT . 10.18 LAMP REPLACEMENT 10.18 COOLING SYSTEM 10.19 COOLING SYSTEM BREAK-OUT DIAGRAM . 10.19 FAN CONTROL CIRCUIT OPERATION / TESTING 10.20 FAN CONTROL CIRCUIT BYPASS TEST 10.20 COOLANT TEMPERATURE SENSOR 10.20 EFI DIAGNOSTICS 10.20 EFI COMPONENT TESTING 10.20 FUEL SENDER pecno1 . 10.20 TESTING . 10.20 RELAYS . 10.21 OPERATION . 10.21 FUSES / CIRCUIT BREAKER 10.22 OPERATION . 10.22 10.2 ELECTRICAL CHARGING SYSTEM 10.22 CURRENT DRAW - KEY OFF . 10.22 CHARGING SYSTEM BREAK EVEN TEST . 10.23 CHARGING SYSTEM ALTERNATOR TESTS . 10.23 CHARGING SYSTEM TESTING FLOW CHART . 10.25 BATTERY TERMINAL BLOCK . 10.26 BATTERY SERVICE . 10.26 BATTERY TERMINALS / BOLTS . 10.26 BATTERY IDENTIFICATION 10.26 CONVENTIONAL BATTERY . 10.27 BATTERY ACTIVATION 10.27 BATTERY INSPECTION . 10.27 BATTERY REMOVAL 10.28 BATTERY INSTALLATION 10.28 CONVENTIONAL BATTERY TESTING 10.28 OCV - OPEN CIRCUIT VOLTAGE TEST . 10.28 SPECIFIC GRAVITY TEST . 10.28 LOAD TEST . 10.29 OFF SEASON STORAGE 10.29 CHARGING PROCEDURE . 10.29 LOW MAINTENANCE BATTERY . 10.30 BATTERY CHECK 10.30 BATTERY INSPECTION . 10.30 BATTERY REMOVAL 10.30 BATTERY INSTALLATION 10.31 BATTERY TESTING . 10.31 OCV - OPEN CIRCUIT VOLTAGE TEST . 10.31 LOAD TEST . 10.31 OFF-SEASON STORAGE 10.32 BATTERY CHARGING . 10.32 STARTER SYSTEM . 10.33 TROUBLESHOOTING . 10.33 VOLTAGE DROP TEST 10.33 STARTER MOTOR REMOVAL / DISASSEMBLY 10.33 BRUSH INSPECTION / REPLACEMENT 10.34 ARMATURE TESTING . 10.35 STARTER REASSEMBLY / INSTALLATION 10.35 STARTER SOLENOID BENCH TEST . 10.36 STARTER DRIVE . 10.36 STARTER EXPLODED VIEW . 10.37 STARTER SYSTEM TESTING FLOW CHART . 10.38 ELECTRIC BOX LIFT ACTUATOR 10.39
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