Polaris Ranger XP 700 EFI 4X4 / 6X6 Repair Service Manual 2007

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This workshop repair service manual PDF download for the Polaris Ranger XP 700 EFI 4X4 / 6X6 has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

RANGER XP 700 EFI 4X4
RANGER XP 700 EFI 6X6

TABLE OF CONTENTS :

GENERAL INFORMATION
MAINTENANCE
ENGINE
FUEL INJECTION
BODY / STEERING / SUSPENSION
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
INDEX
WIRE DIAGRAMS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 329

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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COVER
TOC
RANGER XP 700 EFI 4X4 / 6X6 SERVICE MANUAL
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
Engine Designation Number
VIN Identification
Engine Serial Number Location
Unit Serial Number (VIN) Location
Transmission I.D. Number Location
VEHICLE DIMENSIONS
RANGER 4X4, 6X6
Vehicle Dimensions RANGER 4X4, 6X6
GENERAL SPECIFICATIONS
MODEL: 2007 RANGER XP 4X4
MODEL: 2007 RANGER XP 6X6
MODEL: 2007 RANGER XP 4X4
MODEL: 2007 RANGER XP 6X6
VEHICLE INFORMATION
Publication Numbers
Paint Codes
Replacement Keys
SPECIAL TOOLS
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Glossary of Terms

MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Maintenance Chart Key
Pre-Ride – 25 Hour Maintenance Interval
50 – 100 Hour Maintenance Interval
100 – 300 Hour Maintenance Interval
GENERAL COMPONENT LOCATIONS
RH Side (4X4) and Dash View
LH Side and Rear View (4X4)
LH Side and RH Side Views (6X6)
SERVICE PRODUCTS AND LUBES
Polaris Lubricants, Maintenance and Service Products
MAINTENANCE REFERENCES
Maintenance References, Continued…..
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Frame, Nuts, Bolts, and Fasteners
Shift Linkage Inspection / Adjustment
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Lines
Fuel Filter
Vent Lines
Throttle Pedal Inspection
Throttle Freeplay Adjustment
Air Filter Service
Air Intake Inspection
ENGINE
Compression and Leakdown Test
Breather Hose Inspection
Engine Oil Level
Engine Oil and Filter Change
Exhaust Pipe
TRANSMISSION AND GEARCASES
Transmission Lubrication
Front Gearcase Lubrication
Middle Gearcase Lubrication (6×6)
Rear Gearcase Lubrication (4×4)
Rear Gearcase Lubrication (6×6)
COOLING SYSTEM
Liquid Cooling System Overview
Coolant Level Inspection
Radiator Coolant Level Inspection
Coolant Strength / Type
Cooling System Pressure Test
Cooling System Hoses
Radiator
Coolant Drain / Radiator Removal
FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table
CV Shaft Boot Inspection
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Fluid Level (Conventional Battery)
Battery Removal
Battery Installation
Battery Storage
Battery Charging
Spark Plug Service
Engine To Frame Ground
STEERING AND SUSPENSION
Steering
Tie Rod End / Steering Inspection
Camber and Caster
Wheel Toe Alignment Inspection
Toe Adjustment
Front Suspension
Rear Suspension
Rear Suspension Adjustment (4×4)
Rear Spring Adjustment
BRAKE SYSTEM
Brake System Inspection
Brake Pad Inspection
Parking Brake Pad Inspection
Brake Hose and Fitting Inspection

ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded Views
Engine Fastener Torque Patterns
Torque Specifications
700 EFI Engine Service Specifications
Special Tools
GENERAL ENGINE SERVICE
Accessible Components
Piston Identification
Cooling System Specifications
Cooling System Pressure Test
Cooling System Exploded View
Cooling System Bleeding Procedure
Valve Cover Removal – 6×6 Models (Engine Installed)
Engine Removal
Engine Installation Notes
Cylinder Hone Selection And Honing Procedure
Honing To Deglaze
Cleaning the Cylinder After Honing
Engine Lubrication Specifications
Oil Pressure Test
Oil Flow Chart
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Rocker Arms
Push Rods
Cylinder Head Removal
Cylinder Head Inspection
Cylinder Head Warp
Valve Seal / Spring Service (On Engine)
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Reassembly
Valve Sealing Test
Cylinder Removal
Valve Lifter Removal / Inspection
Piston Removal
Cylinder Inspection
Piston-to-Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Starter Drive Bendix Removal / Inspection
Flywheel / Stator Removal / Inspection
Engine Crankcase Disassembly / Inspection
Camshaft Inspection
ENGINE REASSEMBLY
Crankcase Reassembly
Flywheel / Stator Installation
Cylinder Head Reassembly
Oil Pump Priming
TROUBLESHOOTING
Engine
Cooling System

ELECTRONIC FUEL INJECTION
GENERAL INFORMATION
Special Tools
Service Notes
EFI System Exploded View
EFI System Component Locations
FUEL TANK
Exploded View
Fuel Lines – Quick Connect
ELECTRONIC FUEL INJECTION
Principal Components
EFI Operation Overview
Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
ECU Service
ECU Replacement
FUEL PUMP
Operation Overview
Fuel Pump Test
Fuel Pump / Tank Assembly Replacement
FUEL PRESSURE REGULATOR
Operation Overview
Fuel Pressure Regulator Test
Fuel Pressure Regulator Replacement
FUEL INJECTORS
Operation Overview
Fuel Injector Service
Fuel Injector Replacement
CRANKSHAFT POSITION SENSOR (CPS)
Operation Overview
CPS Test
CPS Replacement
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
Operation Overview
T-BAP Test
T-BAP Replacement
THROTTLE POSITION SENSOR (TPS)
Operation Overview
TPS Test
TPS Initialization
TPS Replacement
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Operation Overview
ECT Sensor Test
ECT Sensor Replacement
GENERAL TROUBLESHOOTING
Diagnostic “Blink Codes”
EFI Troubleshooting

BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BODY COMPONENT REMOVAL
Removal Procedures
Lower Body Components
Hood / Dash Components
Dash Instruments and Controls
CAB FRAME
Assembly / Removal
CHASSIS / MAIN FRAME (4×4)
Exploded View
CHASSIS / MAIN FRAME (6×6)
Exploded View
SEAT / HEAD REST
Seat Base / Seat Back / Head Rest Assembly
STEERING ASSEMBLY
Exploded View
STEERING AND SUSPENSION
Exploded View
FRONT A-ARM
Replacement
FRONT STRUT
Exploded View
Front Strut Cartridge Replacement
Ball Joint Replacement
MID AXLE A-ARM (6×6)
Replacement
REAR A-ARM (4×4)
Replacement
REAR STABILIZER BAR (4×4)
Removal / Installation
SWING ARM (6X6)
Removal
Installation
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6×6)
REAR CARGO BOX
Cargo Box – Panels
Cargo Box – Tailgate / Box Support
Box Removal
Box Installation
STORAGE BOX
Removal
Installation
DECAL REPLACEMENT

CLUTCHING
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
Drive Clutch Operation
Driven Clutch Operation
Maintenance / Inspection
Overheating / Diagnosis
PVT SYSTEM SERVICE
PVT Sealing, Guard, and Ducting Components
Disassembly
Assembly
DRIVE BELT
Belt Deflection (Tension)
Belt Removal
Belt Inspection
Belt Installation
CLUTCH ALIGNMENT / OFFSET
Clutch Alignment
Clutch Offset
DRIVE CLUTCH SERVICE
Spring Specifications
Shift Weights
Exploded View
Clutch Inspection
Clutch Disassembly
Spider Removal
Roller, Pin, and Thrust Washer Inspection
Bushing Service
Moveable Sheave – Bushing Removal
Moveable Sheave – Bushing Installation
Clutch Cover – Bushing Removal
Clutch Cover – Bushing Installation
Clutch Assembly
DRIVEN CLUTCH SERVICE
Exploded View
Clutch Disassembly / Inspection
Clutch Assembly
TROUBLESHOOTING

FINAL DRIVE
SPECIAL TOOLS
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
FRONT HUB
Hub Removal / Inspection
Hubstrut Bearing Replacement
Hub Installation
Front Hub Exploded View
DRIVE SHAFT / PROPSHAFT
Exploded View
DRIVESHAFT / CV JOINT HANDLING TIPS
FRONT DRIVE SHAFT
Removal
CV Joint / Boot Replacement
Installation
FRONT PROPSHAFT REMOVAL
PROPSHAFT U-JOINT SERVICE
Disassembly
Assembly
FRONT GEARCASE CENTRALIZED HILLIARD
AWD Operation
Centralized Hilliard Exploded View
AWD Diagnosis
Gearcase Removal
Gearcase Disassembly / Inspection
Gearcase Reassembly / Inspection
Backlash Pad (Thrust Pad) Adjustment
Gearcase Installation
MID DRIVE HUB / BEARING CARRIER (6×6)
Removal
Hub Disassembly
Hub Assembly
Hub Installation
Mid Drive Exploded View
MID DRIVE SHAFT (6×6)
Removal
Disassembly / Assembly
Installation
MID PROP SHAFT (6×6)
Removal
MID DRIVE GEARCASE (6×6)
Gearcase Removal
Gearcase Disassembly
Gearcase Assembly
Gearcase Installation
Mid Gearcase Exploded
REAR DRIVE (4×4)
Exploded View
REAR HUB / BEARING CARRIER (4×4)
Hub Inspection
Hub Removal
Hub Disassembly
Hub Assembly
Hub Installation
REAR DRIVE SHAFT (4X4)
Removal
CV Joint / Boot Replacement
Installation
REAR PROPSHAFT (4×4)
Removal
Installation
REAR GEARCASE (4×4)
General Operation
Operation Modes
Differential Removal
Differential Disassembly
Differential Assembly
Differential Installation
Differential Exploded View
REAR AXLE / GEARCASE SERVICE (6×6)
Rear Axle Removal
Axle Tube Removal
Axle Tube Bearing Replacement
Gearcase Disassembly / Inspection
Gearcase Assembly
Gearcase / Axle Installation
Gearcase Exploded View

TRANSMISSION
TORQUE SPECIFICATIONS
SHIFT LEVER
Removal
Installation
SHIFT LINKAGE
Inspection
Adjustment
TRANSMISSION SERVICE
Transmission Removal
Transmission Disassembly
Transmission Assembly
Transmission Installation
TROUBLESHOOTING
Troubleshooting Checklist
TRANSMISSION EXPLODED VIEW
Exploded View (4×4, 6×6)

BRAKES
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
MASTER CYLINDER
Removal
Installation
FOOT BRAKE PEDAL
Pedal Removal
Pedal Installation
BRAKE BLEEDING / FLUID CHANGE
PARKING BRAKE
Exploded View
Inspection
Adjustment
PARKING BRAKE CALIPER SERVICE
Exploded View
Caliper Removal
Caliper Disassembly / Inspection
New Brake Pad Installation
Caliper Installation
PARKING BRAKE DISC SERVICE
Disc Removal / Inspection
FRONT BRAKE PADS
Pad Removal / Disassembly
Pad Inspection
Pad Assembly / Installation
Pad Adjustment
FRONT CALIPER
Front Caliper Exploded View
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
FRONT BRAKE DISC
Disc Inspection
Disc Removal / Replacement
REAR BRAKE PAD (4×4)
Pad Removal
Pad Inspection
Pad Installation
REAR BRAKE PAD (6×6)
Pad Removal
Pad Inspection
Pad Installation
REAR CALIPER
Rear Caliper Exploded View
Caliper Removal (4×4)
Caliper Removal (6×6)
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation (4×4, 6×6)
REAR BRAKE DISC
Disc Inspection
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
Pedal Vibration
Caliper Overheats (Brakes Drag)
Brakes Lock

ELECTRICAL
GENERAL INFORMATION
Special Tools
Electrical Service Notes
Under-Hood Components
SWITCHES / CONTROLS
Headlamp Switch
AWD / Rear Differential Switch (4×4)
Differential Solenoid (4×4)
Brake Light Switch
Parking Brake Switch
INSTRUMENT CLUSTER
Overview
Rider Information Display
Standard Display Modes
Diagnostic Display Mode
Viewing Diagnostic Codes
Instrument Cluster Removal
Instrument Cluster Installation
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
Test 1 – No All Wheel Drive
TEST 2 – No Display
TEST 3 – Wheel Speed Sensor
TEST 4 – No AWD Hub Safety Limiter
TEST 5 – Fuel Gauge Display Not Working
TEST 6 – Shift Indicator Not Working (Transmission Switch)
ALL WHEEL DRIVE (AWD) COIL
Operation Overview
Diagnosing System Failures
GEAR POSITION INDICATOR SWITCH
Test Diagram
HEAD LIGHTS
High Beam Headlight Adjustment
Headlamp Bulb Replacement
Headlamp Housing Removal
Headlamp Housing Installation
TAIL LIGHT / BRAKE LIGHT
Lamp Replacement
COOLING SYSTEM
Cooling System Break-Out Diagram
Fan Control Circuit Operation / Testing
Fan Control Circuit Bypass Test
Coolant Temperature Sensor
EFI DIAGNOSTICS
EFI Component Testing
FUEL SENDER
Testing
RELAYS
Operation
FUSES / CIRCUIT BREAKER
Operation
CHARGING SYSTEM
Current Draw – Key Off
Charging System “Break Even” Test
Charging System Alternator Tests
Charging System Testing Flow Chart
BATTERY TERMINAL BLOCK
BATTERY SERVICE
Battery Terminals / Bolts
Battery Identification
CONVENTIONAL BATTERY
Battery Activation
Battery Inspection
Battery Removal
Battery Installation
Conventional Battery Testing
OCV – Open Circuit Voltage Test
Specific Gravity Test
Load Test
Off Season Storage
Charging Procedure
LOW MAINTENANCE BATTERY
Battery Check
Battery Inspection
Battery Removal
Battery Installation
Battery Testing
OCV – Open Circuit Voltage Test
Load Test
Off-Season Storage
Battery Charging
STARTER SYSTEM
Troubleshooting
Voltage Drop Test
Starter Motor Removal / Disassembly
BRUSH INSPECTION / REPLACEMENT
Armature Testing
Starter Reassembly / Installation
Starter Solenoid Bench Test
Starter Drive
Starter Exploded View
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn over the engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test
ELECTRIC BOX LIFT ACTUATOR
DIAGNOSIS (if equipped)

INDEX

WIRE DIAGRAMS