This is the COMPLETE official full factory service repair manual from POLARIS for the RANGER AND RANGER TM. Production model years 2004 2005 2006 2007 2008 2009.
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Over 400 pages allow you to print it out in its entirety or just the pages you need!!
These manuals are your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep your equipment working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure.
* Detailed substeps expand on repair procedure information
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Numbered instructions guide you through every repair procedure step by step.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
* Numbered table of contents easy to use so that you can find the information you need fast.
* This manual also makes it easy to diagnose and repair problems with your machines electrical system. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Complete download comes in pdf format which can work under all PC based windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM. All pages are printable. No need to pay for shipping and wait for the overpriced paper textbook or CD-ROM to arrive via snail mail.
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RELATED ATV SERVICE MANUAL SEARCHES:
FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTING
Excessive exhaust noise
* Deformed exhaust system
* Exhaust gas leaks
Poor performance
* Clogged muffler
* Broken exhaust system
* Exhaust gas leaks
LUBRICATION SYSTEM TROUBLESHOOTING
Oil level too low - high oil consumption
* Oil consumption
* External oil leak
* Worn piston rings or incorrect piston ring installation
* Worn cylinder
* Worn valve guide or stem seals
* Oil pump worn or damaged
Oil contamination
* Oil or filter not changed often enough
* Worn piston rings or incorrect piston ring installation
* Worn valve guide or stem seals
FUEL SYSTEM TROUBLESHOOTING
Engine cranks but wont start
* No fuel in tank
* No fuel to carburetor
* Clogged fuel strainer
* Clogged fuel line
* Clogged fuel tank breather tube
* Misadjusted fuel level
* Too much fuel getting to the engine
* Clogged air cleaner
* Flooded carburetor
* Intake air leak
* Contaminated/deteriorated fuel
* Clogged jets
* Clogged starting enrichment valve circuit
* Improper starting enrichment valve operation
* Improper throttle operation
* No spark at plug (faulty ignition system)
Lean mixture
* Clogged fuel jets
* Faulty float valve
* Float level too low
* Restricted fuel line
* Clogged carburetor air vent tube
* Restricted fuel tank breather tube
* Intake air leak
* Faulty vacuum piston
* Faulty throttle valve
Rich mixture
* Starting enrichment valve open (ON)
* Clogged air jets
* Faulty float valve
* Float level too high
* Dirty air cleaner
* Worn jet needle or needle jet
* Faulty vacuum piston
Engine stalls, hard to start, rough idling
* Restricted fuel line
* Fuel mixture too lean/rich
* Contaminated/deteriorated fuel
* Clogged jets
* Intake air leak
* Misadjusted idle speed
* Misadjusted pilot screw
* Misadjusted float level
* Restricted fuel tank breather tube
* Clogged air cleaner
* Clogged slow circuit
* Clogged starting enrichment valve circuit
* Faulty ignition system
Afterburn when engine braking is used
* Leanmixture in slow circuit
* Faulty air cut-off valve
* Faulty ignition system
Backfiring or misfiring during acceleration
* Leanmixture
* Faulty ignition system
Poor performance (driveability) and poor fuel economy
* Clogged fuel system
* Faulty ignition system
CYLINDER HEAD/VALVE TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring
Compression too low, hard starting or poor performance at low speed
Valves
Incorrect valve adjustment
Burned or bent valves
Incorrect valve timing
Broken valve spring
Uneven valve seating
Valve stuck open
Cylinder head
Leaking or damaged cylinder head gasket
Warped or cracked cylinder head
Loose spark plug
Compression too high
Excessive carbon build-up on piston head or
combustion chamber
Worn or damaged decompressor system
Excessive smoke
Worn valve stem or valve guide
Damaged stemseal
Cylinder/piston problem
Excessive noise
Incorrect valve clearance
Sticking valve or broken valve spring
Excessive worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve stem end
Worn or damaged push rod and/or cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem
Rough idle
Low cylinder compression
CYLINDER/PISTON TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
* Leaking cylinder head gasket
* Worn, stuck or broken piston ring
* Worn or damaged cylinder and piston
* Bent connecting rod
Compression too high, overheating or knocking
* Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
* Worn cylinder, piston or piston rings
* Improper installation of piston rings
* Scored or scratched piston or cylinder wall
Abnormal noise
* Worn piston pin or piston pin hole
* Worn connecting rod small end
* Worn cylinder, piston or piston rings
CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING
Clutch slips when accelerating
* Incorrect clutch adjustment
* Worn clutch discs
* Weak clutch springs
* Faulty clutch lifter
* Improper oil viscosity or oil additive used
Clutch will not disengage
* Faulty clutch lifter
* Warped clutch plates
The vehicle creeps
* Faulty centrifugal clutch
Clutch operating feels rough
* Worn clutch outer and center grooves
* Warped clutch plates
* Loose clutch lock nut
* Faulty clutch lifter
* Improper oil viscosity or oil level
Hard to shift
* Incorrect clutch adjustment
* Worn or damaged gearshift cam and stopper arm
* Faulty clutch lifter
* Improper engine oil viscosity
* Bent fork shaft and gearshift spindle or damaged shift forks and shift drum
Transmission jumps out of gear
* Broken shift drum stopper arm
* Weak or broken shift linkage return springs
* Worn or damaged gearshift cam
* Bent fork shaft or worn shift forks and shift drum
* Worn gear dogs or slots
ALTERNATOR/STARTER CLUTCH TROUBLESHOOTING
Starter motor turns, but engine does not turn
* Faulty starter clutch
* Damaged starter reduction gear
CRANKCASE/TRANSMISSION/CRANKSHAFT TROUBLESHOOTING
Excessive engine noise
* Worn, seized or chipped transmission gears
* Worn transmission bearings
* Worn or damaged connecting rod bearing
* Worn crankshaftmain journal bearing
* Worn connecting rod small end
* Worn balancer bearing
* Improper balancer installation
Transmission jumps out of gear
* Worn gear dogs or dog holes
* Worn shift drum guide groove
* Worn shift fork guide pin
* Worn gear shifter groove
* Worn shift fork
* Bent shift fork shaft
Hard to shift
* Damaged shift fork
* Bent shift fork shaft
* Damaged shift fork guide pin
* Damaged shift drum guide groove
Abnormal vibration
* Improper balancer timing
FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING
Hard steering
* Steering shaft holder too tight
* Damaged steering shaft bearing/bushing
* Insufficient tire pressure
Steers one side or does not track straight
* Incorrect wheel alignment
* Unequal tire pressure
* Bent tie-rod, suspension arm or frame
* Worn or damaged knuckle bearing or brake drum bearing
* Weak shock absorber
Front wheel wobbling
* Bent rim
* Worn or damaged knuckle bearing or brake drum bearing
* Faulty tire
* Axle nut not tightened properly
Soft suspension
* Weak shock absorber spring
* Faulty shock absorber damper
Hard suspension
* Bent shock absorber damper rod
* Improperly installed suspension arms
* Faulty suspension arm bushings
Front suspension noise
* Loose front suspension fasteners
* Damaged suspension components
REAR WHEEL/SUSPENSION TROUBLESHOOTING
Rear wheel wobbling
* Bent rim
* Worn or damaged rear axle bearings
* Faulty rear tire
* Axle fastener not tightened properly
* Faulty swingarm pivot bearings
Rear wheel turns hard
* Faulty rear axle bearings
* Bent rear axle
* Rear brake drag
Soft suspension
* Weak shock absorber spring
* Oil leakage fromdamper unit
Hard suspension
* Damaged rear suspension pivot bearing or bushing
* Damaged swingarm pivot bearing
* Improperly tightened swingarm pivot
Rear suspension noise
* Faulty rear shock absorber
* Loose rear suspension fasteners
* Worn rear suspension pivot bearing or bushing
BRAKE SYSTEM TROUBLE SHOOTING
Front wheel wobbling and noise
* Worn brake shoes
Poor brake performance
* Brake not adjusted properly
* Worn brake shoes and drum
* Water in brake drum
* Contaminated brake shoes and drum
* Air in hydraulic system
* Leaking hydraulic system
* Clogged/restricted fluid passage
* Incorrectly installed rear brake arm
* Worn rear brake cam
FRONT DRIVING MECHANISM TROUBLE SHOOTING
Consistent noise during cruising
* Oil level too low
* Foreignmatter contaminating gear oil
* Worn or damaged bearing
* Worn or damaged ring gear and pinion gear
* Deformed ring gear or differential case
* Improper tooth contact between ring gear and pinion gear
Gear noises while running
* Oil level too low
* Foreignmatter contaminating gear oil
* Chipped or damaged gears
* Improper tooth contact between ring gear and pinion gear
Gear noises while coasting
* Damage or chipped gears
Abnormal noises when turning
* Worn or damaged ring gear bearing
* Worn or damaged face cam and cam follower
* Worn or damaged differential housing groove
* Worn cone spring or shim
Abnormal noises at start or during acceleration
* Excessive backlash between ring gear and pinion gear
* Worn differential splines
* Loose fasteners
* Worn cone spring or shim
Oil leak
* Oil level too high
* Clogged breather
* Damaged seals
* Loose case cover bolt
Over heating
* Oil level too low
* Insufficient backlash between ring gear and pinion gear
REAR DRIVING MECHANISM TROUBLE SHOOTING
Excessive noise
* Worn or scored ring gear shaft and axle
* Worn or scored pinion and splines
* Worn pinion and ring gears
* Excessive backlash between pinion and ring gears
* Oil level too low
Wobble or vibration in vehicle
* Axle not tightened properly
* Bent axle
Oil leak
* Oil level too high
* Clogged breather
* Damaged seals
* Loose case cover bolt
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