2005-2007 POLARIS RANGER XP 700 EFI 4X4 and 6X6 UTV Service Repair Manual (Highly Detailed FSM, Preview)

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL INJECTION 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10 - projex@inbox.lv -

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 VEHICLE DIMENSIONS RANGER 4X4, 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 - projex@inbox.lv -

1.2 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH068OLE043PLE ............................................................ Twin, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification Engine Serial Number Location Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the cylinder head on the side of engine. } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 7 R H 6 8 A G } 4 X A R H 6 8 A * 7 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier } Check Digit Model Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions A Engine Serial Number - projex@inbox.lv -

1.3 GENERAL INFORMATION 1 Unit Serial Number (VIN) Location The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower LH frame rail close to the front drive wheel. The model and serial number are also located on a sticker under the hood (B). Transmission I.D. Number Location A A A B The transmission I.D. number is located on the right side when installed in the machine. - projex@inbox.lv -

1.4 GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4X4, 6X6 75 in. 190.50 cm 10 in. 25.4 cm 58 in. 147 cm RANGER 4x4 - projex@inbox.lv -

1.5 GENERAL INFORMATION 1 Vehicle Dimensions RANGER 4X4, 6X6 120 in. 305 cm 58 in. 147 cm 27 in. 69 cm 90 in. 229 cm 113 in. 287 cm 58 in. 147 cm 76 in. 193 cm - projex@inbox.lv -

1.6 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE MODEL: RANGER XP 6X6 MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1185 lbs. / 537 kg Gross Vehicle Weight 2750 lbs. / 1247 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions 58 x 42 x 10 in. (147 x 106.7 x 25.4 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg Category Dimension / Capacity Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in. / (18.25 cm) Turning Radius 180 in. / 457 cm Dry Weight 1410 lbs. / 640 kg Gross Vehicle Weight 2900 lbs. / 1315 kg Cargo Box Capacity 1250 lbs. / 567 kg Cargo Box Dimensions 58 x 48 x 10 in. (147 x 122 x 25.4 cm) Vehicle Payload 1750 lbs. / 794 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1750 lbs. / 794 kg Hitch Tongue Capacity 150 lbs. / 68 kg - projex@inbox.lv -

1.7 GENERAL INFORMATION 1 MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE CLUTCH CHART Engine Platform Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH068OLE044 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity 3.25 qts. / 3.1 L Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 Fuel Capacity / Requirement 9 gal. (34 l) 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrument Type Multifunction Speedometer DC Outlet Standard Circuit Breakers Fan: 20 Amp Dash Harness: 20 Amp Accessory Terminal: 20 Amp Power Relay: 15 Amp ECU Battery Supply: 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High Low Rev 3.34:1 / 2.89:1 8.67:1 / 7.49:1 5.92:1 / 5.11:1 Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.365” / 9.27 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Rear Suspension Independent Rear Suspension Rear Travel 9 in. / 23 cm Ground Clearance 11.5 in. / 29 cm Shock Preload Adjustment Front / Rear Cam Adjustment 2-2” Twin Tubes Turning Radius 132 in. / 335 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge L.E. Model AW - 14 x 7 Rear Wheel Size 12 x 8 / 10 gauge L.E. Model AW - 14 x 8 Front Tire Make / Model / Size Carlisle / PXT / 26 x 8 R12 L.E. Model AW - Kenda / Radial Bounty Hunter / 26 x 10 R14 Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12 L.E. Model AW - Kenda / Radial Bounty Hunter / 26 x 12 R14 F/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 20-60 (5631698) Blu/Gray (7042202) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 20-56 (5631215) Blu/Gray (7042202) Blk/Almd (7043167) - projex@inbox.lv -

1.8 GENERAL INFORMATION MODEL: RANGER XP 6X6 MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE CLUTCH CHART Engine Platform Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH068OLE044 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity 3.25 qts. / 3.1 L Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 Fuel Capacity / Requirement 9 gal. (34 l) 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrument Panel Type Multifunction Speedometer DC Outlet Standard Circuit Breakers Fan: 20 Amp Dash Harness: 20 Amp Accessory Terminal: 20 Amp Power Relay: 15 Amp ECU Battery Supply: 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High Low Rev 3.89:1 / 3.36:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1 Drive Ratio - Front 3.818:1 Drive Ratio - Mid 3.70:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.365” / 9.27 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Center Suspension Progressive Rate / Independent Center Travel 5.25 in. / 13 cm Rear Suspension Swing Arm w/Dual Shocks Rear Travel 6.25 in. / 16 cm Ground Clearance 7.2 in. / 18.25 cm Shock Preload Adjustment Front / Rear Cam Adjustment 2-2” Twin Tubes Turning Radius 180 in. / 457 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Middle / Rear Wheel Size 12 x 8 / 10 gauge Front Tire Make / Model / Size Titan / AT489 / 25 x 10 R12 Middle / Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 F/M/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 20-60 (5631698) Blu/Gray (7042202) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 20-56 (5631215) Blu/Gray (7042202) Blk/Almd (7043167) - projex@inbox.lv -

1.9 GENERAL INFORMATION 1 V P NOTE: NOTE: www.purepolaris.com. Paint Codes Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, 1-800-328-6657. M 20 20 Painted Part Color Description Polaris Number Frame / Cab Medium Gloss Black P-067 RANGER XP 4x4 - Plastic - Hood / Dash Black Metallic P-177 RANGER XP 6x6 - Plastic - Hood / Dash Dark Green P-195 RANGER XP 4x4 - Plastic - Hood / Dash Turbo Silver P-402 RANGER XP 4x4 - Plastic - Hood / Dash Mossy Oak ™ P-455 RANGER XP 4x4 - Plastic - Hood / Dash Delta Green P-492 RANGER XP 4x4 - Plastic - Hood / Dash Sunset Red Metallic P-520 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534 - projex@inbox.lv -

2005-2007 POLARIS RANGER XP 700 EFI 4X4 and 6X6 UTV Service Repair Manual (Highly Detailed FSM, Preview)

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