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2008 ranger 700 xp
Polaris 2008 ranger 700 xp Service Manual
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5.6
BODY / STEERING / SUSPENSION
Dash Instrument
s and Controls
C
D
E
F
G
A. S
peedometer
B. Headlight Switch
C. 2WD/A
WD Switch
D. 12 V
olt A
ccessory Receptacle
E. S
peedometer “Mode” Button
F
. Key Switch
G
. S
peedometer Mount Plate
B
C
D
B
E
F
G
A
A
137
139
Table of Contents
Polaris
2
Table of Contents
2
Chapter 1
5
Engine Designation Number
5
Engine Serial Number Location
5
Model Identification
5
Model Information
5
Vin Identification
5
Transmission I.D. Number Location
6
Unit Serial Number (Vin) Location
6
Vehicle Dimensions
7
Vehicle Dimensions Ranger 4X4, 6X6
8
General Specifications
9
Model: Ranger Xp 4X4
9
Model: Ranger Xp 6X6
9
Model: Ranger Xp 4X4
10
Model: Ranger Xp 6X6
11
Paint Codes
12
Replacement Keys
12
Special Tools
12
Misc. Specifications and Charts
13
Conversion Table
13
Standard Torque Specifications
14
Sae Tap / Drill Sizes
15
Metric Tap / Drill Sizes
15
Glossary of Terms
16
General Information Chapter 2 General Information
17
Chapter 2
19
Maintenance Chart Key
19
Periodic Maintenance Chart
19
Periodic Maintenance Overview
19
Engine
20
Pre-Ride - 25 Hour Maintenance Interval
20
50 - 100 Hour Maintenance Interval
21
General Component Locations
23
Rh Side and Dash View (4X4)
23
Lh Side and Rear View (4X4)
24
Lh Side and Rh Side Views (6X6)
25
Transmission
25
Brakes
26
Maintenance References
27
Maintenance References, Continued
28
General Vehicle Inspection and Maintenance
29
Pre-Ride / Daily Inspection
29
Frame, Nuts, Bolts, and Fasteners
29
Shift Linkage Inspection / Adjustment
29
Fuel System and Air Intake
30
Fuel System
30
Fuel Lines
30
Fuel Filter
30
Vent Lines
30
Throttle Pedal Inspection
30
Throttle Freeplay Adjustment
31
Air Filter Service
31
Air Intake Inspection
32
Engine
33
Compression and Leakdown Test
33
Breather Hose Inspection
33
Engine Oil Level
33
Engine Oil and Filter Change
34
Exhaust Pipe
35
Transmission and Gearcases
36
Transmission Lubrication
36
Front Gearcase Lubrication (4X4)
37
Middle Gearcase Lubrication (6X6)
38
Rear Gearcase Lubrication (4X4)
39
Rear Gearcase Lubrication (6X6)
40
Cooling System
41
Liquid Cooling System Overview
41
Coolant Level Inspection
41
Radiator Coolant Level Inspection
42
Coolant Strength / Type
42
Cooling System Pressure Test
42
Cooling System Hoses
42
Radiator
43
Coolant Drain / Radiator Removal
43
Final Drive / Wheel and Tire
43
Wheel, Hub, and Spindle Torque Table
43
CV Shaft Boot Inspection
44
Wheel Removal
44
Wheel Installation
44
Tire Inspection
44
Tire Pressure
45
Electrical and Ignition System
45
Battery Maintenance
45
Battery Fluid Level (Conventional Battery)
45
Battery Removal
45
Battery Installation
46
Battery Storage
46
Battery Charging
46
Spark Plug Service
46
Engine to Frame Ground
47
Steering and Suspension
47
Steering
47
Tie Rod End / Steering Inspection
47
Camber and Caster
47
Wheel Toe Alignment Inspection
48
Toe Adjustment
48
Front Suspension
49
Rear Suspension
49
Rear Suspension Adjustment (4X4)
50
Rear Spring Adjustment
50
Brake System
50
Brake System Inspection
50
Brake Pad Inspection
50
Parking Brake Pad Inspection
51
Brake Hose and Fitting Inspection
51
Chapter 3 Engine
52
Service Products and Lubes
26
Polaris Lubricants, Maintenance and Service Products
26
Crankcase Exploded Views
53
Engine Specifications
53
Fuel Injection
59
Engine Fastener Torque Patterns
60
Torque Specifications
61
700 EFI Engine Service Specifications
62
Special Tools
64
General Engine Service
64
Accessible Components
64
Piston Identification
64
Cooling System Specifications
64
Cooling System Pressure Test
65
Cooling System Exploded View
66
Cooling System Bleeding Procedure
66
Valve Cover Removal - 6X6 Models (Engine Installed)
68
Engine Removal
69
Engine Installation Notes
70
Cylinder Hone Selection and Honing Procedure
71
Honing to Deglaze
71
Cleaning the Cylinder after Honing
72
Engine Lubrication Specifications
72
Oil Pressure Test
72
Oil Flow Chart
73
Engine Disassembly and Inspection
74
Cylinder Head Assembly Exploded View
74
Rocker Arms / Push Rods
75
Cylinder Head Removal
75
Cylinder Head Inspection
76
Cylinder Head Warp
76
Valve Seal / Spring Service (on Engine)
76
Cylinder Head Disassembly
77
Valve Inspection
78
Combustion Chamber
79
Valve Seat Reconditioning
79
Cylinder Head Reassembly
81
Valve Sealing Test
82
Cylinder Removal
82
Valve Lifter Removal / Inspection
82
Piston Removal
83
Cylinder Inspection
84
Piston-To-Cylinder Clearance
85
Piston / Rod Inspection
85
Piston Ring Installed Gap
86
Starter Drive Bendix Removal / Inspection
86
Flywheel / Stator Removal / Inspection
87
Engine Crankcase Disassembly / Inspection
87
Camshaft Inspection
95
Engine Reassembly
96
Crankcase Reassembly
96
Flywheel / Stator Installation
105
Cylinder Head Reassembly
105
Oil Pump Priming
108
Troubleshooting
109
Engine
109
Cooling System
110
Fuel Injection Chapter 4 Fuel Injection
111
Chapter 4
112
Special Tools
112
Service Notes
114
Efi System Exploded View
115
Efi System Component Locations
116
Throttle Body
116
Fuel Tank
118
Exploded View
118
Fuel Lines - Quick Connect
119
Electronic Fuel Injection
119
Principal Components
119
Efi Operation Overview
119
Initial Priming / Starting Procedure
120
Electronic Control Unit (Ecu)
120
Operation Overview
120
Ecu Service
121
Ecu Replacement
121
Fuel Pump
121
Operation Overview
121
Fuel Pump Test
122
Fuel Pump / Tank Assembly Replacement
122
Fuel Injectors
124
Fuel Injector Service
125
Fuel Injector Replacement
125
Fuel Pressure Regulator
124
Operation Overview
124
Fuel Pressure Regulator Test
124
Fuel Pressure Regulator Replacement
124
Crankshaft Position Sensor (Cps)
125
Operation Overview
125
Cps Test
126
Cps Replacement
126
Temperature / Barometric Air Pressure Sensor (T-Bap)
126
Operation Overview
126
T-Bap Test
126
T-Bap Replacement
126
Throttle Position Sensor (Tps)
127
Operation Overview
127
Tps Test
127
Tps Initialization
128
Tps Replacement
129
Engine Coolant Temperature Sensor (Ect)
129
Operation Overview
129
Ect Sensor Test
130
Ect Sensor Replacement
130
Diagnostic "Blink Codes
131
Efi Troubleshooting
132
General Troubleshooting
131
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
133
Body / Steering / Suspension
133
Torque Specifications
134
Special Tools
134
Body Component Removal
135
Chapter 5
135
Removal Procedures
135
Lower Body Components
136
Hood / Dash Components
137
Dash Instruments and Controls
138
Cab Frame
139
Assembly / Removal
139
Chassis / Main Frame (4X4)
140
Exploded View
140
Chassis / Main Frame (6X6)
141
Exploded View
141
Seat / Head Rest
142
Seat Base / Seat Back / Head Rest Assembly
142
Steering Assembly
143
Exploded View
143
Steering and Suspension
144
Exploded View
144
Front A-Arm
145
Replacement
145
Front Strut
146
Exploded View
146
Front Strut Cartridge Replacement
147
Ball Joint Replacement
147
MID Axle A-Arm (6X6)
148
Replacement
148
Rear A-Arm (4X4)
149
Replacement
149
Rear Stabilizer Bar (4X4)
151
Removal / Installation
151
Swing Arm (6X6)
152
Removal
152
Installation
152
Rear Drive Axle and Swingarm Exploded View (6X6)
153
Rear Cargo Box
154
Cargo Box - Panels
154
Cargo Box - Tailgate / Box Support
155
Box Removal
156
Box Installation
156
Decal Replacement
157
Storage Box
157
Removal
157
Installation
157
Clutching Chapter 6 Clutching
158
Clutching
158
Special Tools and Supplies
159
Torque Specifications
159
Chapter 6 Pvt System Fastener Torques
159
Pvt System Overview
159
General Operation
159
Drive Clutch Operation
159
Driven Clutch Operation
160
Maintenance / Inspection
160
Overheating / Diagnosis
161
Pvt System Service
162
Pvt Sealing, Guard, and Ducting Components
162
Disassembly
162
Assembly
163
Drive Belt
164
Belt Deflection (Tension)
164
Belt Removal
164
Belt Inspection
165
Belt Installation
166
Clutch Alignment / Offset
166
Clutch Alignment
166
Clutch Offset
167
Drive Clutch Service
168
Spring Specifications
168
Shift Weights
169
Exploded View
170
Clutch Inspection
170
Clutch Disassembly
171
Spider Removal
172
Roller, Pin, and Thrust Washer Inspection
172
Bushing Service
173
Moveable Sheave - Bushing Removal
173
Moveable Sheave - Bushing Installation
173
Clutch Cover - Bushing Removal
174
Clutch Cover - Bushing Installation
174
Clutch Assembly
175
Driven Clutch Service
176
Exploded View
176
Clutch Disassembly / Inspection
176
Clutch Assembly
178
Troubleshooting
179
Chapter 7 Final Drive
181
Final Drive
181
Special Tools
183
Torque Specifications
183
Front Hub
183
Hub Removal / Inspection
183
Hubstrut Bearing Replacement
184
Hub Installation
185
Front Hub Exploded View
186
Drive Shaft / Propshaft
187
Exploded View
187
Driveshaft / CV Joint Handling Tips
188
Front Drive Shaft
188
Removal
188
CV Joint / Boot Replacement
189
Installation
191
Front Propshaft Removal
191
Propshaft U-Joint Service
192
Disassembly
192
Assembly
193
Front Gearcase Centralized Hilliard
194
Awd Operation
194
Centralized Hilliard Exploded View
195
Awd Diagnosis
196
Gearcase Removal
197
Gearcase Disassembly / Inspection
198
Gearcase Reassembly / Inspection
200
Backlash Pad (Thrust Pad) Adjustment
202
Gearcase Installation
203
MID Drive Hub / Bearing Carrier (6X6)
203
Removal
203
Hub Disassembly
204
Hub Assembly
204
Hub Installation
205
MID Drive Exploded View
206
MID Drive Shaft (6X6)
207
Removal
207
Installation
207
MID Drive Gearcase (6X6)
208
Gearcase Removal
208
Gearcase Disassembly
209
Gearcase Assembly
212
Gearcase Installation
214
MID Prop Shaft (6X6)
208
Removal
208
Rear Drive (4X4)
216
Exploded View
216
Rear Hub / Bearing Carrier (4X4)
216
Hub Inspection
216
Hub Removal
216
Hub Disassembly
217
Hub Assembly
218
Hub Installation
218
Rear Drive Shaft (4X4)
219
Removal
219
CV Joint / Boot Replacement
220
Installation
222
Rear Propshaft (4X4)
223
Removal
223
Installation
223
Rear Gearcase (4X4)
224
General Operation
224
Operation Modes
225
Differential Removal
226
Differential Disassembly
226
Differential Assembly
229
Differential Installation
231
Differential Exploded View
232
Rear Axle / Gearcase Service (6X6)
233
Rear Axle Removal
233
Axle Tube Removal
234
Axle Tube Bearing Replacement
235
Gearcase Disassembly / Inspection
235
Gearcase Assembly
236
Gearcase / Axle Installation
237
Gearcase Exploded View
240
Transmission Chapter 8 Transmission
241
Chapter 8
242
Installation
242
Removal
242
Shift Lever
242
Shift Linkage
242
Inspection
242
Adjustment
243
Torque Specifications
242
Transmission Service
243
Transmission Removal
243
Transmission Disassembly
245
Transmission Assembly
250
Transmission Installation
254
Troubleshooting
255
Troubleshooting Checklist
255
Transmission Exploded View
256
Exploded View (4X4, 6X6)
256
Brakes Chapter 9 Brakes
258
Chapter 9
259
General Specifications / Torque Specifications / Special Tools
259
Brake Noise Troubleshooting
260
Brake System Service Notes
260
Hydraulic Brake System Operation
261
Brake System Exploded View
262
Foot Brake Pedal
263
Master Cylinder
263
Brake Bleeding / Fluid Change
264
Parking Brake
265
Exploded View
265
Parking Brake Caliper Service
267
Exploded View
267
Caliper Removal
267
Caliper Disassembly / Inspection
268
New Brake Pad Installation
269
Caliper Installation
269
Parking Brake Disc Service
269
Disc Removal / Inspection
269
Front Brake Pads
270
Front Caliper
272
Front Caliper Exploded View
272
Caliper Inspection
273
Caliper Assembly
273
Caliper Installation
274
Front Brake Disc
275
Rear Brake Pad (4X4)
275
Pad Removal
275
Rear Brake Pad (6X6)
277
Pad Removal
277
Rear Caliper
279
Rear Caliper Exploded View
279
Caliper Removal (4X4)
279
Caliper Removal (6X6)
280
Caliper Disassembly
280
Caliper Installation (4X4, 6X6)
282
Rear Brake Disc
282
Troubleshooting
283
Brakes Squeal / Poor Brake Performance
283
Pedal Vibration
283
Caliper Overheats (Brakes Drag)
283
Brakes Lock
283
Electrical Chapter 10 Electrical
284
Chapter 10
286
Electrical Service Notes
286
Special Tools
286
Under-Hood Components
286
Switches / Controls
287
Headlamp Switch
287
Awd / Rear Differential Switch (4X4)
287
Differential Solenoid (4X4)
287
Brake Light Switch
288
Parking Brake Switch
289
Instrument Cluster
290
Overview
290
Rider Information Display
290
Standard Display Modes
291
Diagnostic Display Mode
291
Viewing Diagnostic Codes
293
Instrument Cluster Removal
294
Instrument Cluster Installation
294
Instrument Cluster Troubleshooting Tests
295
Test 1 - no All Wheel Drive
295
Test 2 - no Display
296
Test 3 - Wheel Speed Sensor
296
Test 4 - no Awd Hub Safety Limiter
297
Test 5 - Fuel Gauge Display Not Working
298
Test 6 - Shift Indicator Not Working (Transmission Switch)
298
All Wheel Drive (Awd) Coil
299
Operation Overview
299
Diagnosing System Failures
299
Gear Position Indicator Switch
299
Test Diagram
299
Head Lights
300
High Beam Headlight Adjustment
300
Headlamp Bulb Replacement
300
Headlamp Housing Removal
300
Headlamp Housing Installation
301
Tail Light / Brake Light
301
Lamp Replacement
301
Cooling System
302
Cooling System Break-Out Diagram
302
Fan Control Circuit Operation / Testing
303
Fan Control Circuit Bypass Test
303
Coolant Temperature Sensor
303
Efi Diagnostics
303
Efi Component Testing
303
Fuel Sender
303
Testing
303
Relays
304
Operation
304
Charging System
305
Current Draw - Key off
305
Charging System "Break Even" Test
306
Charging System Alternator Tests
306
Charging System Testing Flow Chart
308
Fuses / Circuit Breaker
305
Operation
305
Battery Service
309
Battery Terminals / Bolts
309
Battery Identification
309
Battery Terminal Block
309
Conventional Battery
310
Battery Activation
310
Battery Inspection
310
Battery Removal
311
Battery Installation
311
Conventional Battery Testing
311
Ocv - Open Circuit Voltage Test
311
Specific Gravity Test
311
Charging Procedure
312
Low Maintenance Battery
313
Battery Check
313
Battery Inspection
313
Battery Removal
313
Battery Installation
314
Battery Testing
314
Ocv - Open Circuit Voltage Test
314
Load Test
314
Off-Season Storage
315
Battery Charging
315
Starter System
316
Troubleshooting
316
Voltage Drop Test
316
Starter Motor Removal / Disassembly
316
Brush Inspection / Replacement
317
Armature Testing
318
Starter Reassembly / Installation
318
Starter Solenoid Bench Test
319
Starter Drive
319
Starter Exploded View
320
Starter System Testing Flow Chart
321
Electric Box Lift Actuator
322
Diagnosis (if Equipped)
322
5
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Polaris 2008 ranger 700 xp Specifications
General
Brand
Polaris
Model
2008 ranger 700 xp
Category
Automobile
Language
English
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