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RANGER EV 2015
Polaris RANGER EV 2015 User Manual
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2.18
9926595
R01
-
2015-2016
RANGER
EV
Service
Manual
©
Copyright
Polaris
Industries
Inc.
P
ARKING
BRAKE
P
AD
INSPECTION
Measure
the
thickness
of
the
rear
caliper
parking
brake
pads
as
described
below
.
Refer
to
Brakes
Chapter
for
pad
replacement
procedure.
MAINTENANCE
63
65
Table of Contents
Chapter 1 1 General / Battery
7
Table of Contents
7
Operating the Ranger Ev
9
Special Information Regarding the Ranger Ev
9
Vehicle Towing
9
Working on the Ranger Ev
9
Vehicle Identification
10
Model Number Designation
10
Vehicle Identification Number (Vin) Designation
10
Vehicle and Motor Serial Number Locations
11
Vehicle Information
12
Publication Numbers
12
Replacement Keys
13
Special Tools
13
General Specifications
14
2015 - 2016 Ranger Ev
14
Features and Controls
17
Console
17
Key Switch
17
Parking Brake
17
Battery Discharge Indicator
18
Charge Status Indicator
19
Battery Charging Cord / Battery Charger
19
Headlight Switch
19
Hour Meter
20
12 Volt Auxiliary Power Outlet
20
Auxiliary 12 Volt Terminal Board
20
Direction Selector Switch
20
All Wheel Drive (Awd) Switch
20
Indicator Light Panel
22
Windshield
23
Index to Battery Information
23
Troubleshooting - Vehicle Operation
23
Battery Safety
24
Proposition 65 Warning
24
Battery Charging Warning
24
Battery Caution
24
Battery Compartment Warning Label
25
Battery Maintenance
26
To Maximize Battery Service Life
26
Battery Access
26
Main Power Connector
26
Battery Terminal Fastener Torque
26
Battery Contactor Fastener Torque
27
General / Battery
27
Battery Charging
27
Battery Cleaning (External Surfaces)
27
Battery Terminal Cleaning
27
Battery Water Level
28
Battery Testing - Overview
29
Basic Discharger Instructions
30
Battery Discharge and Testing Procedure
31
Battery Specific Gravity Test
33
Battery Removal and Installation
34
Battery Terminal Orientation and Cable Routing
35
Battery Cable Removal
37
Battery Cable Installation
38
Accessory Installation Precautions
39
Battery Charger
39
Battery Storage
39
Battery Charger Led Function
40
Battery Charger Troubleshooting
40
Specific Gravity / Charge Percentage Table
41
Conversion Table
42
Reference
42
Metric Bolt Torque Specification
43
Sae Tap / Drill Sizes
43
Standard Bolt Torque Specification
43
Chapter 2 Maintenance
47
Maintenance Chart Key
48
Periodic Maintenance Chart
48
Periodic Maintenance Overview
48
Service Products and Lubricants
50
Polaris Lubricants, Maintenance and Service Products
50
General Vehicle Inspection and Maintenance
51
Pre-Ride / Daily Inspection
51
Frame, Nuts, Bolts, and Fasteners
51
Fluid Maintenance References
52
Component Quick Reference
52
Final Drive / Wheel and Tire
53
Wheel and Hub Torque Table
53
Wheel Removal
53
Wheel Installation
53
Tire Pressure
53
Tire Inspection
53
CV Shaft Boot Inspection
54
Gearcase Maintenance
55
Front Gearcase Lubrication
55
Transaxle (Rear Gearcase) Lubricant
56
Steering
58
Tie Rod End / Steering Inspection
58
Wheel Toe Alignment Inspection
58
Toe Adjustment
59
Suspension
61
Suspension Inspection
61
Suspension Pivot Point Lubrication
61
Stabilizer Bar Pivot Lubrication
61
Rear Shock Spring Pre-Load Adjustment
61
Brake System
62
Brake Fluid Inspection
62
Brake Hose and Fitting Inspection
62
Brake Pad / Disc Inspection
62
Parking Brake Adjustment
63
Parking Brake Pad Inspection
64
Electrical System
65
Battery Maintenance
65
Battery Information
65
Chapter 3 Drive Motor
67
Special Tools
68
Battery Handling Warnings
69
Safety Information
69
Service Precautions
69
Specifications
70
Torque Specifications
70
Motor Service Data
70
Drive Motor
71
Drive Motor Assembly View
71
Drive Motor Service
72
Drive Motor Removal
72
Drive Motor Installation
73
Drive Motor Disassembly
74
Rotor Removal
76
Bearing Replacement
77
Drive Motor Assembly
78
Drive Motor Bench Tests
79
Chapter 4 Body / Steering / Suspension
81
General Specifications
82
Special Tools
82
Torque Specifications
82
Component Locations
83
Right Side View
83
Front View
83
Rear View
83
Exploded Views
84
Chassis / Main Frame / Bumper
84
Dash Switches and Instruments
85
Dash Mounting
86
Hood / Front Fascia / Mirrors
87
Seat Mounting / Seat Belts
88
Floor / Rear Fender / Side Panel / Corner Panel
89
Cargo Box / Tailgate / Cargo Box Support
90
Cab Frame Exploded View
91
Body Component Removal
92
Seat / Storage Trays
92
Front Bumper / Grill
92
Foot Pads / Corner Panel / Side Panel
92
Cargo Box Removal
92
Cargo Box Installation
93
Hood / Dash
93
Floor
93
Steering
95
Steering Assembly Exploded View
95
Suspension
96
Front A-Arm Removal / Installation
96
Ball Joint Replacement
96
Front Strut Cartridge Replacement
98
Front Strut Exploded View
99
Rear A-Arm Removal / Replacement
100
Rear A-Arm Installation
101
Rear A-Arm Exploded View
102
Rear Stabilizer Bar Removal / Installation
102
Exploded View
103
Shock Removal / Installation
103
Shock Replacement
104
Shocks Exploded View
104
Decal Replacement
104
Decal Replacement
105
Chapter 5 Final Drive
107
Special Tools
108
Torque Specifications
108
Wheel and Hub Torque Table
108
Front & Rear Hub/Wheel Exploded View
109
Prop Shaft Service
110
Prop Shaft Removal
110
Prop Shaft Installation
112
Prop Shaft U-Joint Service
112
Prop Shaft U-Joint Installation
113
Front Hub / Bearing
115
Hub Removal / Inspection
115
Hubstrut Bearing Replacement
115
Front Drive Shaft
117
Front Drive Shaft Removal
117
Front Drive Shaft Installation
118
Front Hub Installation
119
Front Gearcase / Centralized Hilliard
121
Centralized Hilliard Theory of Operation
121
Centralized Hilliard Exploded View
122
Awd Diagnosis
122
Gearcase Removal
124
Gearcase Disassembly / Inspection
125
Gearcase Reassembly / Inspection
129
Backlash Pad (Thrust Pad) Adjustment
132
Gearcase Installation
133
Rear Bearing Carrier
134
Rear Bearing Carrier Inspection
134
Rear Bearing Carrier Removal
134
Disassembly
135
Assembly
136
Installation
136
Rear Drive Shaft
138
Rear Drive Shaft Removal
138
Rear Drive Shaft Installation
138
Drive Shaft Service
139
Drive Shaft / CV Joint Handling Tips
139
Outer CV Joint / Boot Replacement
139
Inner Plunging Joint / Boot Replacement
141
Front Drive Shaft Exploded View
144
Rear Drive Shaft Exploded View
145
Chapter 6 Transaxle / Differential
147
General Operation (Typical)
148
Lubrication
148
Special Tools
148
Specifications
148
Torque Specifications
148
Transaxle Service
150
Transaxle Removal
150
Transaxle Disassembly
151
Transaxle Assembly
153
Transaxle Installation
154
Transaxle and Differential Exploded View, Complete
156
Transaxle Exploded View, Shaft and Gear Assemblies
157
Transaxle Exploded View, Differential
158
Transaxle Differential Disassembly / Inspect
159
Planetary Differential Disassembly
161
Planetary Differential Bushing Replacement
162
Planetary Differential Assembly
164
Differential Case Assembly
164
Troubleshooting
166
Troubleshooting Checklist
166
Chapter 7 Brake System
167
General Specifications
169
Special Tools
169
Torque Specifications
169
Brake System Service
170
Brake System Service Notes
170
Hydraulic Brake System Operation
170
Brake System
171
System View and Torque Values
171
Brake Bleeding / Fluid Change
172
Master Cylinder
173
Removal
173
Installation
173
Foot Brake Pedal
174
Pedal Removal
174
Pedal Installation
174
Parking Brake
175
System View
175
Parking Brake Caliper Service
176
Exploded View
176
Parking Brake Adjustment
176
Caliper Removal
176
Caliper Disassembly / Inspection
177
New Brake Pad Installation
178
Parking Brake Caliper Installation
179
Parking Brake Disc Service
181
Disc Inspection / Removal
181
Front Brake Pads
182
Pad Removal
182
Pad Inspection
183
Pad Assembly / Installation
183
Brake Burnishing Procedure
184
Front Caliper Service
185
Caliper Exploded View
185
Caliper Removal
185
Caliper Disassembly
186
Caliper Inspection
187
Caliper Assembly
188
Caliper Installation
188
Front Brake Disc
190
Disc Inspection
190
Disc Replacement
190
Rear Brake Pads
192
Pad Removal
192
Pad Inspection
192
Pad Installation
193
Rear Caliper Service
194
Rear Caliper Exploded View
194
Caliper Removal
194
Caliper Inspection
195
Caliper Assembly
195
Caliper Installation
196
Rear Brake Disc
197
Disc Inspection
197
Disc Replacement
197
Troubleshooting
199
Brake Noise (Squeak)
199
Poor Brake Performance
199
Pedal Vibration
199
Caliper Overheats (Brakes Drag)
199
Brakes Lock
199
Chapter 8 Electrical
201
Battery Maintenance / Testing
203
Electrical Service Notes
203
General Information
203
General Wire Color Function
203
Overheat Control Circuit Operation
203
Special Tools
203
48 Volt Fuse and Relay Location
204
12 Volt Auxiliary Power Outlet
205
Switches / Controls
206
Headlight Switch
206
Awd / 2Wd / Turf Switch
206
Direction Selector Switch (F / N / R)
207
Drive Mode Switch (High, Max Range, Low)
208
Differential Solenoid / Solenoid Driver Module
209
Brake Light Switch (Hydraulic)
211
Parking Brake Switch
211
Indicator Light Circuits
212
Indicator Lamp Replacement
213
Indicator Lights
214
Battery Discharge Indicator
215
Charge Status Indicator
216
Digital Wrench Diagnostic Software
217
Accelerator Pedal Position Sensor
217
All Wheel Drive (Awd) Coil
218
Awd System
218
Diagnosing System Failures
218
Headlights
219
Headlight Adjustment
219
Headlight Bulb Replacement
219
Headlight Housing Removal
220
Tail Light / Brake Light
221
Led Lamp Replacement
221
48 VDC - 14 VDC Converter
222
Converter Information
222
System Wiring Diagrams
223
VDC - 14.0 VDC Converter Wiring Diagram
223
Battery System Wiring Diagram
224
Drive Motor Encoder System Wiring Diagram
225
Battery Charging System Wiring Diagram
226
Auxiliary (Accessory) Battery System Wiring Diagram
227
14.0 Volt System Wiring Diagram
228
Lighting System Wiring Diagram
229
Parking Brake System Wiring Diagram
230
Awd System Wiring Diagram
231
Awd / 2Wd / Turf Switch Contacts
232
Direction Selector - System Wiring Diagram
233
Direction Selector Switch Contacts
234
Drive Mode (High / Max Range / Low) - System Wiring Diagram
235
Accelerator Pedal Position Sensor - System Wiring Diagram
236
Main Fuse Box
237
Diagnostic Trouble Codes
238
Digital Wrench Trouble Code List
238
4
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Polaris RANGER EV 2015 Specifications
General
Brand
Polaris
Model
RANGER EV 2015
Category
Offroad Vehicle
Language
English
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