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RANGER 2x4
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Polaris RANGER 2x4 - Page 232
292 pages
Manual
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TRANSMISSION
8.12
26.
Remov
e
bearing
and
t
he
helical
gear.
27.
Remov
e
the
pinion
s
haft
r
etainer
plate
and
t
he
pinion
shaf
t.
28.
Remov
e
the
f
ront
housing
cover
screws.
29.
Remov
e
t
he
front
housing
c
over
,
shim,
t
hrust
butt
on,
and
t
hrust
butt
on
shim.
231
233
Table of Contents
Main Page
Chapter 1 General Information
1
Table of Contents
1
General Information
2
Model Identification
2
Serial Number Location
2
Machine Dimensions
4
Publication Numbers
12
Paint Codes
12
Starting the RANGER
12
General Information Chapter 2 Maintenance
13
Periodic Maintenance Chart
14
Pre-Ride Inspection
17
Special Tools
17
Front Gearcase Lubrication
21
Middle Gearcase Lubrication
21
Rear Gearcase Lubrication
22
Transmission Lubrication
23
Shift Linkage Adjustment
25
Throttle Pedal Inspection
26
Fuel System
28
Battery Maintenance
29
Spark Plug / Electrical
30
Air Filter / Breather Filter
34
Flywheel Housing
36
Oil Level and Filter Change
37
Oil Pump Priming Procedure
38
Valve Adjustment
39
Exhaust Pipe
42
Suspension
44
Chapter 3 Engine
47
Special Tools
48
Torque Specifications
48
Service Data
49
Piston Identification
51
Torque Patterns
51
Cooling System Specifications
53
Engine Removal
53
Engine Installation Notes
54
Engine Lubrication
56
Oil Pump Priming Procedure
56
Engine Exploded View
59
Valve Seat Service
69
Cylinder Head Assembly
72
Crankshaft End Play Inspection
84
Oil Pump Shaft End Play Inspection
86
Spark Plug Fouling Checklist
99
Troubleshooting
99
Chapter 4 Fuel System/Carburetion
101
Fuel Flow Diagram
103
Carburetor Jetting
104
Assembly, CV Carburetor
105
CV Carburetor System Function (4 Cycle)
105
Needle & Seat Leakage Test
111
Fuel Level
112
Fuel Pump Service
112
Fuel Tank Removal/Installation
112
Troubleshooting
113
Body/Steering/Suspension Chapter 5 Body and Steering
115
Body/Panel Removal
117
Cab Frame & Seat Exploded View
118
Frame/Body Assembly Exploded View
119
Body Molding Exploded View
120
Hood Exploded View
121
Cargo Box Exploded View
122
Dash Instruments & Controls
123
Steering Assembly Exploded View
124
A-Arm Replacement
126
Rear Axle & Swingarm
129
Swing Arm Removal & Installation
129
Front Strut Cartridge Replacement
131
Box Removal / Installation
133
Decal Replacement
134
Clutch Chapter 6 Pvt System
135
PVT System Torques
136
Service Tools and Supplies
136
PVT Maintenance/Inspection
137
PVT Disassembly
139
PVT Assembly
140
Drive Clutch Exploded View
141
PVT Sealing and Ducting Components
141
Drive Clutch Spring Specifications
142
Shift Weights
143
Drive Clutch Disassembly/Inspection
144
Drive Clutch Inspection
144
Drive Clutch Assembly
146
Drive Belt Tension
147
Drive Belt Removal/Inspection
148
Drive Belt Installation
149
Drive Clutch Bushing Service
150
Driven Clutch Disassembly/Inspection
152
Driven Clutch Assembly
154
Driven Clutch Bushing Service
154
Troubleshooting
157
Chapter 8 Transmission Service
221
Transmission Removal
223
Transmission Installation
226
Transmission Disassembly
227
Transmission Assembly
233
Troubleshooting
238
2X4 Transmission, Exploded
239
4X4 & 6X6 Transmission, Exploded
241
Chapter 9 Brakes
243
Brake Noise Troubleshooting
245
Brake System Service Notes
245
Hydraulic Brake System Operation
246
Brake System Exploded View
247
Parking Brake Adjustment
249
Parking Brake and Brake Line Inspection
249
Parking Brake Lock Exploded View
251
Front Pad Removal
252
Front Pad Assembly
253
Front Disc Inspection
254
Front Caliper Disassembly
255
Front Caliper Removal
255
Front Caliper Assembly
256
Front Caliper Inspection
256
Front Caliper Exploded View
257
Front Caliper Installation
258
Rear Brake Pad Removal
258
Rear Brake Pad Installation
259
Rear Brake Caliper Exploded View
265
Rear Brake Disc Inspection
265
Troubleshooting
266
Electrical
269
Timing Check Procedure
269
Flywheel I.D
271
Ignition System Testing Flow Chart
273
Ignition System Troubleshooting
274
Charging System Testing
276
Brake Light Switch
281
Gear Indicator Light Circuit Operation
281
Indicator Lamp Replacement
282
Starter System Troubleshooting
282
Starter Drive
285
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