2011-2014 Polaris Ranger Diesel Crew UTV Service Manual

Description

This 2011-2014 Polaris Ranger Diesel Crew UTV Service Manual provides service, step-by-step repair and maintenance information for 2011, 2012, 2013, and 2014 Polaris Ranger Diesel / Diesel Crew UTVs.

Table of Contents

Chapter 1: General Information Chapter 2: Maintenance Chapter 3: Engine Chapter 4: Fuel System – General Chapter 5: Body I Steering I Suspension Chapter 6: Clutching Chapter 7: Final Drive Chapter 8: Transmission Chapter 9: Brakes Chapter 10: Electrical

Polaris Ranger Diesel Crew UTV Service Manual Index of Topics

Chapter 1 General Information Vehicle Identification Model Number Designation Vehicle Identification Number (vin) Designation Engine Number Designation Vehicle And Engine Serial Number Locations Vehicle Information Publication Numbers Replacement Keys Special Tools General Specifications Model: 2011-2014 Ranger Diesel Model: 2011-2014 Ranger Diesel Clutch Chart General Specifications Model: 2012-2014 Ranger Diesel Crew Model: 2012-2014 Ranger Diesel Crew Clutch Chart General Specifications Vehicle Controls / Gauges Fuel Information, Usage And Recommendations Fuel Information / Recommendations Bio-diesel Fuels B5 Diesel Fuel Requirements Bio-fuel Precautions B6 To B20 Bio-diesel Fuel Blend Engine Warranty Cold Weather Operation Block Heater Usage Misc Specifications And Charts Conversion Table Standard Bolt Torque Specification Metric Bolt Torque Specification Sae Tap / Drill Sizes Metric Tap / Drill Sizes Decimal Equivalents Chapter 2 Maintenance Periodic Maintenance Chart Periodic Maintenance Overview Break-in Period Maintenance Chart Key Pre-ride – 25 Hour Maintenance Interval 50 – 100 Hour Maintenance Interval 100 – 300 Hour Maintenance Interval Grease Lubrication Points Service Products And Lubricants Polaris Lubricants, Maintenance And Service Products Special Tools Fluid Maintenance References Component Quick Reference Component Quick Reference (continued) General Vehicle Inspection And Maintenance Pre-ride / Daily Inspection Frame, Nuts, Bolts, And Fasteners Shift Cable Inspection Shift Cable Adjustment Fuel System And Air Intake Fuel System Fuel Lines Vent Lines Throttle Pedal Inspection Throttle Freeplay Adjustment Air Filter Service Engine Air Intake Inspection Pvt Air Intake Inspection Air Intake Exploded View Fuel Filter / Water Separator General Information Fuel Filter / Water Separator Draining Fuel Filter / Water Separator Replacement Engine Compression And Leakdown Test Special Tools Engine Oil Level Engine Oil And Filter Change Exhaust Pipe Transmission And Gearcases Transmission Lubrication Front Gearcase Lubrication Rear Gearcase Lubrication Cooling System Liquid Cooling System Overview Coolant Level Inspection Coolant Strength / Type Cooling System Hoses Radiator Inspection / Cleaning Radiator Removal (2011) Radiator Removal (2012-2014) Final Drive / Wheel And Tire Wheel And Hub Torque Table Cv Shaft Boot Inspection Wheel Removal Wheel Installation Tire Inspection Tire Pressure Electrical System Battery Removal Battery Installation Battery Storage Battery Charging Engine Ground Steering Steering Inspection Tie Rod End / Steering Inspection Wheel Toe Alignment Inspection Toe Adjustment Suspension Suspension Inspection Spring Pre-load Adjustment Shock Position Adjustment Brake System Brake Fluid Inspection Brake Hose And Fitting Inspection Brake Pad / Disc Inspection Parking Brake Cable Adjustment Parking Brake Pad Inspection Chapter 3 Engine Special Tools Special Tools General Engine Service Accessible Components Engine Lubrication Specifications Oil Pressure Test Engine/tf5ansmission Assembly Removal Engine Installation Engine / Transmission Mounting Exploded View / Torque Values Engine Exhaust System Exploded View – Engine Exhaust System Engine Cooling System Cooling System Specifications And Testing Cooling Fan On/off & Hot Light On/off Cooling System Bleeding Procedure Chapter 4 Fuel System – General General Information Special Tools Diesel Service Notes Fuel Tank Exploded View Fuel Injection System Exploded View Fuel System Component Locations Fuel Line Removal / Installation Fuel Injection Principal Components Operation Overview Initial Priming / Starting Procedure Fueltransfer Pump Operation Overview Fuel Pump Test Fuel Pump Replacement / Installation Fuel Tank Assembly Removal Fuel Tank Installation Fuel Filter / Water Separator General Information Fuel Filter / Water Separator Draining Fuel Filter / Water Separator Replacement Fuel Sender Fuel Sender Test Fuel Sender Replacement / Installation General Troubleshooting Fuel System Troubleshooting Chapter 5 Body / Steering I Suspension Torque Specifications Torque Specifications Special Tools Special Tools Multi-function Pliers Decal Replacement Cab Frame / Seat Back / Pvt Air Intake Box (non Crew) Exploded View /assembly Cab Frame / Seat Back/ Pvt Air Intake Box (crew) Chassis / Main Frame (non Crew) Exploded View Chassis / Main Frame (crew) Exploded View Body Exploded Views Dash Instruments / Controls Hood / Dash / Front Fenders / Front Fascia Floor / Rear Fenders (2011 Non Crew) Floor / Rear Fenders (2012-2013 Non Crew) Floor / Rear Fenders (crew) Seat Mounting / Seat Belts (non Crew) Seat Mounting / Seat Belts (crew) Cargo Box – Panels Cargo Box – Tailgate / Box Support Body Component Removal Box Removal Box Installation Lower Seat Base Wheel Well Panels Front Bumper Front Fascia Front Fenders Hood/dash Glove Box/storage Panel Steering Assembly Exploded View Steering Wheel Removal Steering Shaft Removal Steering Shaft Bearing Replacement Front A-arms Removal / Replacement Exploded View Ball Joint Service Service Preparation Ball Joint Removal Ball Joint Installation Rear A-arms Removal / Replacement Installation Exploded View Rear Stabilizer Bar / Linkage Removal / Installation Exploded View Shocks/springs Exploded View Shock Removal / Installation Shock Replacement Chapter 6 Clutching Special Tools And Supplies Special Tools 2871358-a Fixture Modification Special Supplies Torque Specifications Pvt System Fastener Torques Pvt System Overview General Operation Drive Clutch Operation Shift Weights Driven Clutch Operation Pvt Break-in (drive Belt / Clutches) Maintenance / Inspection Overheating/diagnosis Pvt System Service Pvt Sealing And Ducting Components Pvt Disassembly Pvtassembly Drive Belt Belt Removal Belt Inspection Belt Installation Pvt Break-in (drive Belt / Clutches) 2011 Drive Clutch Service 2011 Drive Clutch Exploded View Clutch Disassembly And Inspection Button To Tower Clearance Inspection Shift Weight Inspection Spider Removal Stationary Sheave Inspection Moveable Sheave Inspection Clutch Assembly 2012-2014 Drive Clutch Service 2012-2014 Drive Clutch Exploded View Clutch Disassembly And Inspection Drive Clutch Spring Inspection Needle Bearing Inspection Button To Tower Clearance Inspection Spider Removal Shift Weight Inspection Clutch Inspection Moveable Sheave Inspection Drive Clutch Assembly Driven Clutch Service (2011 -2014) Exploded View Clutch Disassembly / Inspection Clutch Assembly Clutch Offset Procedure Clutch Offset Adjustment Troubleshooting Pvt Troubleshooting Chapter 7 Final Drive Special Tools Special Tools Torque Specifications Wheel And Hub Torque Table Front Bearing Carrier Bearing Carrier Inspection / Removal Bearing Replacement Bearing Carrier Installation Front Drive Shaft Drive Shaft Removal Drive Shaft Installation Front Propshaft Removal / Installation Support Bearing Replacement Propshaft U-joint Service Disassembly Assembly Front Gearcase – Centralized Hilliard Centralized Hilliard Exploded View Operation Awd Diagnosis Gearcase Removal Gearcase Disassembly / Inspection Gearcase Assembly Gearcase Installation Rear Bearing Carrier Inspection Removal Disassembly Assembly Installation Rear Drive Shaft Removal Installation Drive Shaft Service Drive Shaft/cv Joint Handling Tips Outer Cv Joint / Boot Replacement Inner Plunging Joint / Boot Replacement Drive Shaft Exploded View Rear Propshaft Removal Installation Rear Gearcase General Operation Gearcase Removal Gearcase Disassembly Rear Gearcase Assembly Rear Gearcase Installation Rear Gearcase Exploded View Chapter 8 Transmission Special Tools Special Tools Transmission Specifications Torque Specifications Lubrication Specifications Shift Lever Removal Installation Shift Cable Inspection Transmission Service Transmission Removal Transmission Disassembly Transmission Shaft Service Compensator Shaft Preload Check And Adjustment Procedure Transmission Assembly Transmission Installation Troubleshooting Checklist Transmission Exploded View Chapter 9 Brakes General Specifications Specifications And Service Limits Torque Specifications Torque Specifications Special Tools Special Tools Brake System General Information Brake System Service Notes Brake Noise Troubleshooting Hydraulic Brake System Operation Brake System Exploded View Master Cylinder Removal Installation Foot Brake Pedal Pedal Removal Pedal Installation Brake Bleeding / Fluid Change Brake Bleeding Procedure Front Brake Pads Pad Removal Pad Inspection Pad Assembly / Installation Brake Burnishing Procedure Front Caliper Service Caliper Exploded View Caliper Removal Caliper Disassembly Caliper Inspection Caliper Assembly Caliper Installation Rear Brake Pads (non Crew) Pad Removal Pad Inspection Pad Installation Brake Burnishing Procedure Rear Caliper Service (non Crew) Rear Caliper Exploded View Caliper Removal Caliper Disassembly Caliper Inspection Caliper Assembly Caliper Installation Rear Caliper Service (crew) Rear Caliper Exploded View Caliper Removal Caliper Disassembly Caliper Inspection Caliper Assembly Caliper Installation Front Brake Disc Disc Runout Disc Inspection Disc Removal / Replacement Rear Brake Disc Disc Runout Disc Inspection Disc Removal / Replacement Brake Burnishing Procedure Parking Brake Exploded View Inspection Cable Tension Adjustment Parking Brake Caliper Service Exploded View Caliper Removal Caliper Disassembly / Inspection New Brake Pad Installation Caliper Installation Parking Brake Disc Service Disc Inspection / Removal Troubleshooting Brakes Squeal / Poor Brake Performance Pedal Vibration Caliper Overheats (brakes Drag) Brakes Lock Chapter 10 Electrical General Information Special Tools Electrical Service Notes Battery Conductance Analyzer Components Under Seat Components Behind Dash Panel / Under Hood Switches / Controls Headlight Switch Awd / 2wd / Turf Switch Differential Solenoid Brake Light Switch Parking Brake Switch Instrument Cluster Overview Rider Information Display Standard Display Modes Diagnostic Display Mode Instrument Cluster Removal Instrument Cluster Installation Instrument Cluster Troubleshooting Tests Test 1 – No All Wheel Drive Test 2 – No Display Test 3 – Speed Sensors (mph & Rpm) Test 4 – No Awd Hub Safety Limiter Test 5 – Fuel Gauge Display Not Working Test 6 – Shift Indicator Not Working (transmission Switch) All Wheel Drive (awd) Coil Operation Overview Diagnosing System Failures Gear Position Indicator Switch Test Diagram Headlights Headlight Adjustment Headlight Bulb Replacement Headlight Housing Removal Headlight Housing Installation Ranger Diesel Lighting System Diagram (simplified) Tail Light / Brake Light Led Lamp Replacement Cooling System Cooling System Break-out Diagram Fan Control Circuit Operation Fan Control Circuit Bypass Test Coolant Temperature Sensor Cooling Fan On/off & Hot Light On/off Fuel Sender Testing Relays Fan Relay Chassis Relay Start Relay Park Relay Glow Plug Relay Fuel Pull-in Coil Relay Fuses / Circuit Breaker / Resistor Operation Vehicle Control Module Operation Fuel Solenoid Wiring Diagram Charging System Charging System Rating Current Draw – Key Off Charging System “break Even” Test Charging System Alternator Wiring Diagram Battery Service Battery Information Low Maintenance Battery Inspection Battery Terminal Blocks Battery Terminals / Bolts Battery Removal / Installation Conventional Battery Testing Battery Conductance Analyzer Ocv- Open Circuit Voltage Test Load Test Charging Procedure Off Season Storage Starter System And Wiring Diagram Troubleshooting Voltage Drop Test