2011 – 2012 Polaris Ranger 400 500 EFO Crew 500 EFI UTV Service Manual

Description

This 2011 – 2012 Polaris Ranger 400 500 EFO Crew 500 EFI UTV Service manual provides service, repair and maintenance information for the following Polaris Ranger Side by Sides:

2012 Polaris Ranger Crew 500 EFI
2012 Polaris Ranger 500 EFI 4X4
2012 Polaris Ranger 400 HO
2011 Polaris Ranger Crew 500 EFI
2011 Polaris Ranger 500 EFI 4X4
2011 Polaris Ranger 400 HO

Table of Contents

General Information
Maintenance
Engine
Fuel System
Body, Steering, Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical

Index of Topics

A
ACS/Hub Module – Overview
Adjustment, Valve Clearance
Air Box, Exploded View (Carb Model)
Air Filter Service
Air Intake Inspection, Engine
Air Intake Inspection, PVT
All Wheel Drive (AWD) Coil
Authorization Key
Authorization, Reflash
AWD Diagnostics
AWD, Diagnosis
AWD, Operation
B
Ball Joint, Replacement
Battery Charging
Battery Fluid Level
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Battery Storage
Battery Terminal Block
Body Removal
Brake Burnishing
Brake Caliper Assembly, Front
Brake Caliper Inspection, Front
Brake Caliper Installation, Front
Brake Caliper Removal, Front
Brake Caliper, Front
Brake Disc, Front
Brake Disc, Rear
Brake Hose and Fitting Inspection
Brake Pad and Disc Inspection
Brake Pad Assembly, Front
Brake Pad Thickness, Front
Brake Pads, Front
Brake Pads, Rear
Brake Pads, Removal, Front
Brake Pedal, Installation
Brake Pedal, Removal
Brake System Inspection
Brake System, Bleeding
Brake System, Exploded View
Brake System, Exploded View (4×4 XP, 6×6)
Brake System, Operation
Brake System, Troubleshooting
Break-In Period
Breather Filter Inspection
Breather Hose
c
Cab Frame, Exploded View/ Assembly
Caliper, Front
Caliper, Rear
Cam Chain Sprocket, Installation
Cam Chain Tensioner, Installation
Cam Chain Tensioner, Removal / Inspection
Cam Chain, Installation
Camshaft Timing
Camshaft, Inspection
Camshaft, Removal
Carburetor, Air/Fuel Ratio
Carburetor, Assembly
Carburetor, Cleaning
Carburetor, Disassembly
Carburetor, Float Height Adjustment
Carburetor, Inspection
Carburetor, Jet Needle
Carburetor, Jetting
Carburetor, Mikuni CV
Carburetor, Needle and Seat Test
Carburetor, Needle Jet
Carburetor, Removal
Carburetor, Throttle Opening vs Fuel Flow
Cargo Box, Installation
Cargo Box, Removal
Charging System
Circuit Breaker
Clutch Alignment
Clutch Offset
Clutch, Maintenance
Combustion Chamber
Communication Problems, Digital Wrench
Compression Test
Conversion Table
Coolant Level Inspection
Coolant Sensor Test, 500 engine
Coolant Strength and Type
Cooling System
Cooling System Hoses
Counter Balance Shaft, Removal
Crankcase, Assembly
Crankcase, Disassembly
Crankcase, Inspection
Crankcase, Separation
Crankshaft Position Sensor (CPS)
Crankshaft Straightening
Crankshaft, Removal
CV Shaft Boot Inspection
Cylinder Head, Assembly
Cylinder Head, Disassembly
Cylinder Head, Inspection
Cylinder Head, Installation
Cylinder Head, Removal
Cylinder Honing
Cylinder, Inspection
Cylinder, Installation
Cylinder, Removal
D
Dash
Dash Instruments and Controls
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostics, AWD
Diagnostics, Gear Circuit
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software, Overview
Digital Wrench Versions
Digital Wrench, Engine Controller Reprogramming (Reflash)
Digital Wrench, Serial Number Location
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Drive Belt, Deflection
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Disassembly
Drive Clutch, Exploded View
Drive Clutch, Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Spider Removal
Drive Clutch, Spring
Drive Shaft / CV Joint, Handling Tips
Driven Clutch, Assembly
Driven Clutch, Bushing Service
Driven Clutch, Disassembly / Inspection
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
E
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI, Component Locations
EFI, Diagnostic Codes
EFI, Exploded View
EFI, Service Notes
Electrical, Cooling System
Electronic Control Unit (ECU)
Electronic Fuel Injection, Special Tools
Engine Designation Number
Engine Disassembly
Engine Installation Notes
Engine Reassembly
Engine Removal
Engine Serial Number Location
Engine Service, General Information
Engine Speed Display
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Oil and Filter Change
Engine, Oil Level
Engine, Service Data
Engine, Service Data (400 HO)
Exhaust Pipe
Exploded View, Cylinder Head
Exploded View, Engine
F
Fan Control Circuit Operation
Fan Control Circuit, Bypass Test
Floor
Flywheel Housing
Flywheel, Installation
Flywheel, Removal
Front A-arm, Replacement
Front Bumper
Front Caliper, Piston Bore ID
Front Drive Shaft, Installation
Front Drive Shaft, Removal
Front Fascia
Front Fenders
Front Gearcase – Ring Gear Backlash Adjustment
Front Gearcase Lubrication
Front Gearcase, Assembly / Inspection
Front Gearcase, Centralized Hilliard
Front Gearcase, Coil Resistance
Front Gearcase, Disassembly / Inspection
Front Gearcase, Exploded View
Front Gearcase, Installation
Front Gearcase, Removal
Front Hub (4×4)
Front Propshaft, Removal
Front Propshaft, Removal (CREW)
Front Strut, Cartridge Replacement
Front Strut, Exploded View
Fuel Filter :
Fuel Injector
Fuel Lines
Fuel Pressure Regulator
Fuel Pump Assembly
Fuel Pump Replacement
Fuel Pump, (Carb Model)
Fuel Sender Test
Fuel System Troubleshooting
Fuel Tank
Fuel Tank Assembly, (Carb Model)
Fuel Tank Removal
Fuses
G
Gear Circuit Diagnostics n
Gear Indicator
General Specifications, Brakes
Guided Diagnostics
H
Head Lights
Hood
Hour Meter
I
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Indicator Lamp, Replacement
Indicator, Service Interval1
Inner Plunging Joint / Boot Replacement
Instrument Cluster1
Instrument Cluster, Installation I
Instrument Cluster, Removal I
Instrument Cluster, Troubleshooting Tests 1
Intake Air Temperature (IAT) Sensor
K
Key, Reprogramming Authorization
Keys, Replacement
Kilometers to Miles ToggleI
L
LeakdownTest
Lower Seat Base
Lubrication Grease Points
Lubrication, Stabilizer bar Pivot
M
Maintenance Quick Reference Chart
Maintenance Schedule
Maintenance, Brake System
Maintenance, Cooling System
Maintenance, Electrical and Ignition
Maintenance, Engine
Maintenance, Final Drive
Maintenance, Fluid References
Maintenance, Fuel System and Air Intake
Maintenance, General Vehicle Inspection
Maintenance, Service Products and Lubricants
Maintenance, Steering
Maintenance, Transmission and Gearcases
Manifold Absolute Pressure (MAP) Sensor
Master Cylinder, Installation
Master Cylinder, Removal
Mechanical Seal, Installation
Mechanical Seal, Removal (engine disassembled)
Mechanical Seal, Removal (engine installed)
Metric Bolt Torque Specification
Miles to Kilometers Toggle
Model Identification
o
Odometer
Oil Flow
Oil Pressure Test
Oil Pump Priming
Oil Pump, Assembly
Oil Pump, Removal
One-Way Valve
One-Way Valve, Installation
Outer CV Joint / Boot Replacement
P
Periodic Maintenance Chart
Piston Identification
Piston Ring, Installation
Piston, Inspection
Piston, Installation
Piston, Removal
Piston, Ring Installed Gap
Piston-to-Cylinder Clearance
Pre-Ride / Daily Inspection
Programmable Service Interval
Propshaft, U-Joint Service
Publication Numbers
PVT Break-In
PVT System, Assembly
PVT System, Disassembly
PVT System, Overview
PVT System, Service
PVT Troubleshooting
R
Radiator
Rear A-arm, Replacement
Rear Bearing Carrier
Rear Cargo Box
Rear Drive Shaft, Installation
Rear Drive Shaft, Removal
Rear Fenders
Rear Stabilizer Bar
Rectifier Test
Reflash Authorization
Regulator / Rectifier Test
Relays
Relays / Solenoid Driver – Overview
Reprogramming Authorization
Rocker Arm, Assembly
Rocker Arm, Inspection
s
Seat Assembly
Seat Belts
Service Interval Indicator
Shift Cable, Adjustment
Shift Cable, Inspection
Shift Lever, Installation
Shift Lever, Removal
Shocks and Springs
Software Version
Solenoid, Rear Differential
Spark Plug Service
Special Tools
Special Tools, Body/Steering/Suspension
Special Tools, Brakes
Special Tools, Carburetion
Special Tools, Clutching
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Special Tools, Transmission
Specification, Cylinder Compression
Specification, Fuel Pump Pressure
Specification, Transmission Silent Chain Length
Specification, Wheel Toe-Out
Specifications, General
Speedometer
Stabilizer bar Pivot Lubrication
Standard Bolt Torque Specification
Starter Drive
Starter Drive, Removal
Starter Motor, Assembly
Starter Motor, Disassembly
Starter Solenoid, Operation
Starter Solenoid, Test
Starter System, Troubleshooting
Starting System Flow Chart
Steering
Steering, Exploded View
Suspension Inspection
Suspension Spring Preload Adjustment
Switch, AWD / 2WD / TURF
Switch, Headlight
T
Tachometer
Tail Lights
Tap/Drill Sizes
Thermostat, Installation
Throttle Freeplay Adjustment
Throttle Pedal, Inspection
Throttle Position Sensor (TPS)
Tie Rod End and Steering Inspection
Tire Inspection
Tire Pressure
Toe Adjustment
Torque Patterns, Engine Fasteners
Torque Specification, Wheel and Hub
Torque Specifications, Body/Steering/Suspension
Torque Specifications, Brakes
Torque Specifications, Clutching
Torque Specifications, Engine
Torque Specifications, Final Drive
Torque Specifications, Transmission
TPS Adjustment
TPS Replacement
Transmission Lubrication
Transmission, Assembly
Transmission, Disassembly
Transmission, Exploded View
Transmission, Installation
Transmission, Operation
Transmission, Output Shaft Backlash Procedure
Transmission, Removal
Trip Meter
Troubleshooting, Brake Noise
Troubleshooting, Carburetion
Troubleshooting, Clutching
Troubleshooting, Cooling System
Troubleshooting, Engine
Troubleshooting, No AWD
Troubleshooting, No AWD Hub Safety Limiter
Troubleshooting, No Fuel Gauge Display
Troubleshooting, No Instrument Display
Troubleshooting, Spark Plug Fouling
Troubleshooting, Starter System
Troubleshooting, Transmission
Troubleshooting, Wheel Speed Sensor
V
Valve Clearance Adjustment
Valve Clearance, Adjustment
Valve Sealing Test
Valve Seat Reconditioning
Valve, Inspection
Vent Lines
Version, Software
VIN Identification
VIN Location
w
Wheel Alignment
Wheel Well Panels
Wheel, Installation
Wheel, Removal