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.

More Info : http://www.sitelux.com

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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 (6x6)
            Rear Gearcase Lubrication (4x4)
            Rear Gearcase Lubrication (6x6)
        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 (4x4)
            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 - 6x6 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 (4x4)
            Exploded View
        CHASSIS / MAIN FRAME (6x6)
            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 (6x6)
            Replacement
        REAR A-ARM (4x4)
            Replacement
        REAR STABILIZER BAR (4x4)
            Removal / Installation
        SWING ARM (6X6)
            Removal
            Installation
        REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6x6)
        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 (6x6)
            Removal
            Hub Disassembly
            Hub Assembly
            Hub Installation
            Mid Drive Exploded View
        MID DRIVE SHAFT (6x6)
            Removal
            Disassembly / Assembly
            Installation
        MID PROP SHAFT (6x6)
            Removal
        MID DRIVE GEARCASE (6x6)
            Gearcase Removal
            Gearcase Disassembly
            Gearcase Assembly
            Gearcase Installation
            Mid Gearcase Exploded
        REAR DRIVE (4x4)
            Exploded View
        REAR HUB / BEARING CARRIER (4x4)
            Hub Inspection
            Hub Removal
            Hub Disassembly
            Hub Assembly
            Hub Installation
        REAR DRIVE SHAFT (4X4)
            Removal
            CV Joint / Boot Replacement
            Installation
        REAR PROPSHAFT (4x4)
            Removal
            Installation
        REAR GEARCASE (4x4)
            General Operation
            Operation Modes
            Differential Removal
            Differential Disassembly
            Differential Assembly
            Differential Installation
            Differential Exploded View
        REAR AXLE / GEARCASE SERVICE (6x6)
            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 (4x4, 6x6)
            
    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 (4x4)
            Pad Removal
            Pad Inspection
            Pad Installation
        REAR BRAKE PAD (6x6)
            Pad Removal
            Pad Inspection
            Pad Installation
        REAR CALIPER
            Rear Caliper Exploded View
            Caliper Removal (4x4)
            Caliper Removal (6x6)
            Caliper Disassembly
            Caliper Inspection
            Caliper Assembly
            Caliper Installation (4x4, 6x6)
        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 (4x4)
            Differential Solenoid (4x4)
            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

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