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Polaris RANGER EV 2015

Polaris RANGER EV 2015
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FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed August 2015 (PN 9926595 R01)
© Copyright 2015 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2015-2016 RANGER EV
Service Manual

Table of Contents

Questions and Answers:

Polaris RANGER EV 2015 Specifications

General IconGeneral
BrandPolaris
ModelRANGER EV 2015
CategoryOffroad Vehicle
LanguageEnglish

Summary

Chapter 1 General Battery

Special Information Regarding the RANGER EV

Provides important operational and safety details for the RANGER EV.

Vehicle Identification

Explains the model number and VIN designation for vehicle identification.

Battery Safety

Covers critical safety warnings and precautions for handling and working with batteries.

Battery Maintenance

Details key procedures for maximizing battery service life and proper care.

Chapter 2 Maintenance

Periodic Maintenance Chart

Outlines scheduled maintenance intervals for various vehicle systems.

General Vehicle Inspection and Maintenance

Covers essential pre-ride checks and general vehicle inspection procedures.

Steering

Details inspection of steering components for wear, damage, and proper operation.

Brake System

Outlines inspection and maintenance procedures for the entire brake system.

Chapter 3 Drive Motor

Safety Information

Highlights critical safety warnings related to battery handling and service precautions.

Drive Motor Removal

Provides step-by-step instructions for safely removing the drive motor assembly.

Drive Motor Assembly

Details the process for assembling the drive motor after service or replacement.

Chapter 4 Body Steering Suspension

Component Locations

Illustrates the location of major vehicle components for reference.

Steering Assembly Exploded View

Provides a detailed exploded view of the steering assembly for service.

Front A-Arm Removal Installation

Covers the procedure for removing and installing the front A-arm.

Rear A-Arm Removal Replacement

Details the process for removing and replacing the rear A-arm components.

Chapter 5 Final Drive

Prop Shaft Service

Outlines procedures for servicing the drive shaft, including removal and installation.

Front Drive Shaft Removal

Provides instructions for removing the front drive shaft assembly.

Centralized Hilliard Theory of Operation

Explains the operational principles of the centralized Hilliard AWD system.

Gearcase Disassembly Inspection

Details the steps for disassembling and inspecting the front gearcase.

Chapter 6 Transaxle Differential

Transaxle Removal

Step-by-step guide for removing the transaxle from the vehicle.

Transaxle Disassembly

Covers the process of disassembling the transaxle for inspection and service.

Planetary Differential Disassembly

Details the disassembly procedure for the planetary differential.

Troubleshooting

Provides a checklist for diagnosing transaxle issues and potential causes.

Chapter 7 Brake System

Brake System Service

General notes and procedures for servicing the hydraulic brake system.

Master Cylinder

Covers the removal and installation procedures for the master cylinder.

Parking Brake Adjustment

Explains how to adjust the parking brake for proper function.

Front Caliper Service

Details the disassembly, inspection, and assembly of the front brake caliper.

Chapter 8 Electrical

Electrical Service Notes

Provides essential notes and precautions for diagnosing electrical problems.

Switches Controls

Covers the operation and testing of various vehicle switches and controls.

Indicator Lights

Explains the function and meaning of various indicator lights on the panel.

System Wiring Diagrams

Contains critical wiring diagrams for diagnosing and troubleshooting electrical systems.

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