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1

9926595 R01 - 2015-2016

RANGER

EV Service Manual

© Copyright Polaris Industries Inc.

1.1

GENERAL / BATTERY

CHAPTER 1

GENERAL / BATTERY

SPECIAL INFORMATION REGARDING THE RANGER EV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

OPERATING THE

RANGER

EV

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

WORKING ON THE

RANGER

EV

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE TOWING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

MODEL NUMBER DESIGNATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

VEHICLE AND MOTOR SERIAL NUMBER LOCATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

PUBLICATION NUMBERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

REPLACEMENT KEYS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

2015 - 2016 RANGER EV

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

CONSOLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

KEY SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

PARKING BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

BATTERY DISCHARGE INDICATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

CHARGE STATUS INDICATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

BATTERY CHARGING CORD / BATTERY CHARGER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

HEADLIGHT SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

HOUR METER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

12 VOLT AUXILIARY POWER OUTLET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

AUXILIARY 12 VOLT TERMINAL BOARD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

DIRECTION SELECTOR SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

ALL WHEEL DRIVE (AWD) SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

INDICATOR LIGHT PANEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16

WINDSHIELD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

INDEX TO BATTERY INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

TROUBLESHOOTING - VEHICLE OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

BATTERY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

PROPOSITION 65 WARNING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

BATTERY CHARGING WARNING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

BATTERY CAUTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

BATTERY COMPARTMENT WARNING LABEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

TO MAXIMIZE BATTERY SERVICE LIFE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

BATTERY ACCESS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

MAIN POWER CONNECTOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

BATTERY TERMINAL FASTENER TORQUE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

BATTERY CONTACTOR FASTENER TORQUE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

Содержание RANGER EV 2015

Страница 1: ...uthorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this ma...

Страница 2: ...or bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION...

Страница 3: ...Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FO...

Страница 4: ......

Страница 5: ...Manual Chapter Summary CHAPTER 1 GENERAL BATTERY CHAPTER 2 MAINTENANCE CHAPTER 3 DRIVE MOTOR CHAPTER 4 BODY STEERING SUSPENSION CHAPTER 5 FINAL DRIVE CHAPTER 6 TRANSAXLE DIFFERENTIAL CHAPTER 7 BRAKE...

Страница 6: ......

Страница 7: ...CONSOLE 1 11 KEY SWITCH 1 11 PARKING BRAKE 1 11 BATTERY DISCHARGE INDICATOR 1 12 CHARGE STATUS INDICATOR 1 13 BATTERY CHARGING CORD BATTERY CHARGER 1 13 HEADLIGHT SWITCH 1 13 HOUR METER 1 14 12 VOLT...

Страница 8: ...RY REMOVAL AND INSTALLATION 1 28 BATTERY TERMINAL ORIENTATION AND CABLE ROUTING 1 29 BATTERY CABLE REMOVAL 1 31 BATTERY CABLE INSTALLATION 1 32 BATTERY STORAGE 1 33 ACCESSORY INSTALLATION PRECAUTIONS...

Страница 9: ...s chapter Chapter 1 GENERAL SAFETY REMINDERS Wear the proper protective gear Shield your eyes when working on the RANGER EV Working on or around lead acid batteries can be dangerous if you do not take...

Страница 10: ...or featured versions of models not including the base First 3 digits and 9th digit are used in model number only They are not used with the 17 digit VIN Digits 1 through 8 determine Digital Wrench cal...

Страница 11: ...ehicle be sure to refer to the vehicle identification number VIN and the motor model and serial number The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle and on t...

Страница 12: ...L PN 2015 RANGER EV R15RMAE4EJ 9925678 9925783 R15RMAE4GC 9925678 9925783 R15RMAE4GJ 9925678 9925783 2016 RANGER EV R16RMAE4G8 9926456 9926474 R16RMAE4G9 9926456 9926474 NOTE When ordering service par...

Страница 13: ...re 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...

Страница 14: ...dius 150 in 381 cm Dry Weight 1750 lbs 793 8 kg Gross Vehicle Weight 2750 lbs 1247 kg Cargo System Lock Ride Cargo Box Dimensions Inside dimensions inches centimeters Length 32 0 81 3 Width 42 107 Hei...

Страница 15: ...being charged the chassis is at ground potential Do not work on the vehicle when the battery charger is connected to an electrical outlet DRIVE TRAIN Final Drive Direct drive motor to transaxle with...

Страница 16: ...rged batteries see table for freeze points BATTERY FREEZE POINT Percent Charged 100 50 0 Freeze Point Approximate 60 F 51 C 0 18 C 25 F 4 C Also keep in mind the following Battery vehicle range decrea...

Страница 17: ...be removed from the switch when it is in the OFF position Turn key OFF when vehicle is not in use PARKING BRAKE To help prevent the vehicle from rolling set the park brake when parking the vehicle Wh...

Страница 18: ...MODE CHARACTERISTICS MODE MAX SPEED TORQUE PER CENT OF MAXIMUM TORQUE DECEL BRAK ING RE GEN USE THIS MODE FOR High 25 mph 40 km h 85 Minimum Trail Riding Max Range 15 mph 24 km h 60 Minimum Maximize b...

Страница 19: ...ge is completed Green Slow Flash More than 80 of charge is completed Amber Flashing Charge rate is reduced low AC voltage or high internal charger temperature exists open hood to improve air flow Red...

Страница 20: ...used to power auxiliary lights and accessories The switched and constant terminals are fused separately at 10 amps The 10 amp switched terminal fuse includes loads connected to both terminal board and...

Страница 21: ...d after turning the AWD switch OFF If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase 1 Stop the ve...

Страница 22: ...gh Temperature Flashing Reduced performance due to elevated temperature Steady Power delivery terminated to prevent damage from overheating 3 Park Brake Steady Park brake engaged Move lever forward to...

Страница 23: ...echarge batteries Battery Connections Dirty Or Loose Clean and re torque connections Contactor Connections Dirty Or Loose Clean and re torque connections Electronic Controller Connections Dirty Or Loo...

Страница 24: ...artment including but not limited to Rings wrist watches chains bracelets etc BATTERY CHARGING WARNING Location Inside glove box door WARNING Explosive gases are released when batteries are charged Ke...

Страница 25: ...H VOLTAGE CABLES and terminals are contained within this compartment Improper contact between battery terminals can result in electrical shorts ELECTRICAL SHORTS can result in burns Do not use high pr...

Страница 26: ...itioning chart below Make sure vent caps are installed properly during vehicle operation and battery charging Avoid charging at high temperatures See Battery Charging page 1 21 Use only genuine Polari...

Страница 27: ...dry DO NOT use pressure washers or compressed air to clean or dry batteries or contaminants may be forced through the battery cap vent and contaminate battery cells Cell contamination will reduce batt...

Страница 28: ...Be sure all battery cable connections are tight Do not work on the vehicle with the charger connected 1 Position vehicle on a level surface in a well ventilated area 2 Turn key switch OFF 3 Open hood...

Страница 29: ...ies must make up for the deficiency and the discharge time to 42 volts will be less than that of a good battery set Ambient temperature is a factor in the amount of time it takes to discharge a set of...

Страница 30: ...n while a discharge cycle is running Changing The Maximum Timer The default discharge time is 240 minutes This value is the maximum amount of time the discharge unit allows to discharge a set of batte...

Страница 31: ...reen 5 Place the discharge unit on a foundation of concrete brick stone or grounded metal Be sure area around discharge unit is well ventilated for proper cooling air flow and the unit is at least 18...

Страница 32: ...by the resistive element could cause damage to the discharge unit if the fan is not running 11 The discharger will stop when one of the following conditions occurs START STOP button is pressed Shut o...

Страница 33: ...y and set to Volts DC 17 Press START STOP to re start the discharger and test battery voltages under load A 3 minute test cycle will begin allowing ample time to test all 8 batteries 18 Connect red me...

Страница 34: ...d to Specific Gravity Table 6 on Specific Gravity Charge Percentage Table page 1 35 BATTERY SPECIFIC GRAVITY LEFT SIDE BATTERIES DRIVER SIDE SPECIFIC GRAVITY MEASUREMENT CELL C1 C2 C3 C4 C5 C6 Outside...

Страница 35: ...ove battery retaining bracket bolts Place bolts at a safe distance from battery compartment so they cannot fall and make contact with battery terminals 15 Remove batteries 16 Clean battery tub w and l...

Страница 36: ...ry compartment or on any electrical component on the vehicle while charging batteries The chassis of the vehicle is at ground potential when the battery charging cord is connected to an AC outlet This...

Страница 37: ...9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 1 31 BATTERY CABLE REMOVAL GENERAL BATTERY 1...

Страница 38: ...26595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc BATTERY CABLE INSTALLATION TORQUE Battery Retainer Bracket Nut 8 ft lbs 11 Nm Battery Terminal Nut 8 ft lbs 11 Nm GENERAL...

Страница 39: ...arge the batteries Review all Battery Charging Warning page 1 18 The charger will maintain batteries at their peak condition automatically ACCESSORY INSTALLATION PRECAUTIONS Follow these guidelines wh...

Страница 40: ...926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc BATTERY CHARGER LED FUNCTION BATTERY CHARGER TROUBLESHOOTING If an error fault occurs reference the table below GENERAL B...

Страница 41: ...CORRECTED TO 80 DEGREES F 26 7 DEGREES C OPEN CIRCUIT VOLTAGE APPROX 100 1 277 12 73 90 1 258 12 62 80 1 238 12 50 70 1 217 12 37 60 1 195 12 24 50 1 172 12 10 40 1 148 11 96 30 1 124 11 81 20 1 098...

Страница 42: ...cm mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg ki...

Страница 43: ...ION BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LBS NM DRY THREADS M3 0 3 0 5 0 5 0 7 1 1 3 1 5 2 1 5 2 M4 0 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 1...

Страница 44: ...39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 11 64 5 x 90 20 0 161 5 32 6 x 1 00 9 0 196 13 64 7 x 1 00 16 64 0 234 15 64 8 x 1 00 J 0 277 9 32 8 x...

Страница 45: ...14 mm 0 5512 9 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 18 mm 0 7087 23 32 0 7...

Страница 46: ...1 40 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc NOTES GENERAL BATTERY...

Страница 47: ...RQUE TABLE 2 7 WHEEL REMOVAL 2 7 WHEEL INSTALLATION 2 7 TIRE PRESSURE 2 7 TIRE INSPECTION 2 7 CV SHAFT BOOT INSPECTION 2 8 GEARCASE MAINTENANCE 2 9 FRONT GEARCASE LUBRICATION 2 9 TRANSAXLE REAR GEARCA...

Страница 48: ...aware of during maintenance CAUTION Due to the nature of these adjustments it is recommended this service be performed by an authorized Polaris dealer SEVERE USE ITEM See information provided above E...

Страница 49: ...Inspect level change yearly General Lubrication 50 H 3 Months Lubricate fittings pivots cable ends Steering 50 H 6 Months Inspect Lubricate Front Suspension 50 H 6 Months Check fastener torque Check t...

Страница 50: ...Gallon Jug Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871515 Premium U Joint Lube 3 oz 24 Count...

Страница 51: ...switch OFF check for free operation and closing Headlight Taillight Brakelight check operation of all indicator lights and switches Wheels check for tightness of wheel nuts and axle nuts check to be...

Страница 52: ...Inc FLUID MAINTENANCE REFERENCES COMPONENT QUICK REFERENCE ITEM LUBE REC METHOD CAPACITY DRY Front Gearcase Demand Drive Add lubricant to bottom of fill hole threads 6 1 oz 180 ml Transaxle Angle Driv...

Страница 53: ...b Be sure valve stem is outward and rotation arrows on tire point in forward rotation 2 Install washers and wheel nuts or lug nuts with tapered end toward wheel and tighten lightly by hand until wheel...

Страница 54: ...hicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less CV SHAFT BOOT INSPECTION Inspect inner and oute...

Страница 55: ...5 Reinstall fill plug and torque to specification TORQUE Fill Plug 10 ft lb 14 Nm Front Gearcase Fluid Change 6 Remove fill plug C 7 Place a drain pan under front gearcase area 8 Remove drain plug D D...

Страница 56: ...should be inside the frame rail and point downward 3 Remove fill plug A and check lubricant level 4 If lubricant level is not even with the bottom of fill hole threads B add ATV Angle Drive Fluid as...

Страница 57: ...Plug Fill Plug 14 ft lb 19 Nm 5 Add approximately 17 18 fluid ounces 500 550ml of lubricant through fill plug hole Continue to add lubricant to bring level to bottom of fill plug hole threads Do not o...

Страница 58: ...y an authorized Polaris MSD certified technician when replacing worn or damaged steering parts Use only genuine Polaris replacement parts TIE ROD END STEERING INSPECTION To check for play in the tie r...

Страница 59: ...ment The recommended vehicle toe tolerance is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B MEASUR...

Страница 60: ...ith washers bolt and nut Tighten nut by hand so rod end is securely supported and parallel with the mounting surface on strut 8 Verify steering wheel is centered and re check alignment 9 Repeat above...

Страница 61: ...eering and Suspension for fastener torque values SUSPENSION PIVOT POINT LUBRICATION Both the front and rear suspension A arms are equipped with grease fittings at the pivot points See the maintenance...

Страница 62: ...r cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts Be sure lines are secured away from moving parts or sharp edges Refer to Chapter 7 Brakes for...

Страница 63: ...back on the park brake lever 2 After 2 to 3 clicks the BRAKE light should illuminate on the indicator panel and the wheels of the vehicle should not rotate when turning by hand After 8 full clicks of...

Страница 64: ...GER EV Service Manual Copyright Polaris Industries Inc PARKING BRAKE PAD INSPECTION Measure the thickness of the rear caliper parking brake pads as described below Refer to Brakes Chapter for pad repl...

Страница 65: ...Service Manual Copyright Polaris Industries Inc 2 19 ELECTRICAL SYSTEM BATTERY MAINTENANCE Refer to Chapter 1 GENERAL BATTERY for all battery information BATTERY INFORMATION Refer to Index to Battery...

Страница 66: ...2 20 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc NOTES MAINTENANCE...

Страница 67: ...3 3 BATTERY HANDLING WARNINGS 3 3 SERVICE PRECAUTIONS 3 3 SPECIFICATIONS 3 4 TORQUE SPECIFICATIONS 3 4 MOTOR SERVICE DATA 3 4 DRIVE MOTOR 3 5 DRIVE MOTOR ASSEMBLY VIEW 3 5 DRIVE MOTOR SERVICE 3 6 DRIV...

Страница 68: ...ble Insulated Extension 3 inch Commercially Available Insulated Extension 6 inch Commercially Available Insulated Socket 1 2 inch Commercially Available Insulated Wrench Set Bosch Automotive Service S...

Страница 69: ...d within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring Remove any jewelry rings bracelets etc SERVICE PRECAUTIONS WARNING The main power co...

Страница 70: ...lt M8 17 ft lb 23 Nm Motor Support Bracket to Motor 8 ft lb 11 Nm Motor Support Bracket to Frame 17 ft lb 23 Nm Speed Sensor Screw 62 in lb 7 Nm MOTOR SERVICE DATA DRIVE MOTOR COMPONENT SPECIFICATION...

Страница 71: ...w Rotor f Connector Speed Sensor e Stator g Speed Sensor r Terminal Base h Screw Speed Sensor 62 in lb 7 Nm t Group Terminal Board 11 ft lb 15 Nm j Circlip y Group Plug Temperature Sensor k Ball Bear...

Страница 72: ...Connector page CAUTION Failure to disconnect the main power connector can permanently damage electrical components 6 Be sure cable identification tags U V and W are in place on cables at the motor end...

Страница 73: ...AUTION The drive motor weighs over 80 pounds 36 3 kg Have an assistant help remove the motor or use a suitable lift DRIVE MOTOR INSTALLATION 1 Apply a light film of anti seize compound to transaxle sh...

Страница 74: ...wer M8 rear support bracket bolts evenly by hand until all are hand tight Torque bolts to specification TORQUE Rear Support Bracket Lower Bolts 17 ft lb 23 Nm 10 Connect rear most drive motor cable ma...

Страница 75: ...Remove speed sensor screw q and speed sensor 3 Remove the three nuts w securing terminal leads to the terminal block 4 Remove the cover plate screws e cover plate and gasket 5 Lift terminal leads and...

Страница 76: ...efully pull wires through cover and slide rotor and housing out of stator 9 For bench tests see Drive Motor Bench Tests page 3 13 ROTOR REMOVAL 1 Remove threaded cap q from housing 2 Remove circlip w...

Страница 77: ...and bore with a light film of grease 5 Set new bearing in freezer on wax paper or plastic wrap for 15 30 minutes When bearing is cool warm cover on a thermostatically controlled hot plate to 150 F 65...

Страница 78: ...l leads e through the access port in the motor end cap r 3 With the motor end cap seated slide the terminal lead guide t into position fit the terminal block y onto the motor 4 Install drive end housi...

Страница 79: ...tion from overheating These tests can also be performed with the motor installed on the vehicle see Chapter 8 Electrical Thermistor Test 1 Connect an Ohmmeter across the two wires leading from the sta...

Страница 80: ...each combination of two stator windings NOTE If reading is greater than 5 Ohms be sure to subtract meter lead resistance from the measured resistance connect leads together and record resistance displ...

Страница 81: ...SUPPORT 4 10 CAB FRAME EXPLODED VIEW 4 11 BODY COMPONENT REMOVAL 4 12 SEAT STORAGE TRAYS 4 12 FRONT BUMPER GRILL 4 12 FOOT PADS CORNER PANEL SIDE PANEL 4 12 CARGO BOX REMOVAL 4 12 CARGO BOX INSTALLAT...

Страница 82: ...ner Wrench 2870623 Shock Spring Compressor Tool 2876389 Multi Function Pliers 2870871 Strut and Ball Joint Tool Set 2871573 Strut Spring Compressor LH 2871574 Strut Spring Compressor RH Dealers may or...

Страница 83: ...4 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 4 3 COMPONENT LOCATIONS RIGHT SIDE VIEW FRONT VIEW REAR VIEW BODY STEERING SUSPENSION...

Страница 84: ...LICABLE 1 Battery Tray 2 Cab Support 3 Main Frame 4 Floor Support Left 5 Floor Support Right 6 Seat Base Cab Support 7 Skid Plate 8 Screw M8 x 1 25 x 55 QTY 4 22 ft lbs 29 8 Nm 9 Screw 1 4 20 x 5 8 QT...

Страница 85: ...H SWITCHES AND INSTRUMENTS NUMBER PART DESCRIPTION 1 Hour Meter Battery Discharge Indicator 2 Indicator Light Panel 3 Key Switch OFF ON 4 Headlight Switch 5 Drive Direction Selector 6 Charge Status In...

Страница 86: ...6595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc DASH MOUNTING NUMBER PART DESCRIPTION TORQUE 1 Screw M6 x 1 0 x 25 QTY 2 8 ft lbs 10 8 Nm 2 Rivet QTY 11 BODY STEERING SUSP...

Страница 87: ...Service Manual Copyright Polaris Industries Inc 4 7 HOOD FRONT FASCIA MIRRORS NUMBER PART DESCRIPTION q Hood w Front Fascia e Dash Panel r Glove Box Lid t Hood Strap y Hood Hinge Pins u Push Rivet i H...

Страница 88: ...ART DESCRIPTION TORQUE IF APPLICABLE q Shoulder Anchor Seat Belt w Buckle Seat Belt Driver e Buckle Seat Belt Passenger r Seat Back t Seat Base y Washer Seat Belt Rubber u Screw Seat Back QTY 8 24 in...

Страница 89: ...anual Copyright Polaris Industries Inc 4 9 FLOOR REAR FENDER SIDE PANEL CORNER PANEL NUMBER PART DESCRIPTION TORQUE IF APPLICABLE q Front Floor w Main Floor e Floor Cover r Cup Holder t Push Rivet y S...

Страница 90: ...BOX SUPPORT NUMBER PART DESCRIPTION TORQUE IF APPLICABLE q Cargo Box w Box Frame e Tailgate Inner Panel r Tailgate Outer Panel t Box Tilt Shock y Box Tilt Latch u Heat Shield i Tailgate Tube o Tailgat...

Страница 91: ...rt Rear t Windshield Mount Upper y Grab Handle u Bolt M8 x 1 25 x 20 QTY 8 18 ft lb 24 Nm i Bolt M10 x 1 5 x 20 QTY 6 36 ft lb 49 Nm o Bolt M8 x 1 25 x 20 QTY 2 18 ft lb 24 Nm a Screw M10 x 1 25 x 30...

Страница 92: ...per 3 Remove the two fasteners q from each side of the upper portion of the bumper 4 Carefully remove the bumper from the vehicle FOOT PADS CORNER PANEL SIDE PANEL 1 FRONT Remove the lower T27 Torx he...

Страница 93: ...cket on the frame 3 Install the box hinges on both sides 4 Secure the box hinges with the hinge screws on both sides 5 With the hinges installed attach the shock to the cargo box by inserting the pin...

Страница 94: ...tries Inc 5 Remove the Torx head screws retaining the main floor and remove the main floor from the vehicle 6 Continue with Hood Dash Removal procedure 7 Remove the accelerator and brake pedals for ad...

Страница 95: ...4 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 4 15 STEERING STEERING ASSEMBLY EXPLODED VIEW BODY STEERING SUSPENSION...

Страница 96: ...stall A arm assembly onto vehicle frame Torque new bolts to specification TORQUE A arm Bolts 30 ft lb 41 Nm WARNING The locking features on the existing bolts were destroyed during removal DO NOT reus...

Страница 97: ...int removal installation tool kit remove ball joint F from strut housing Ball Joint Tool 2870871 Install puller guide G with extension cap H Apply grease to extension cap and threads of puller bolt to...

Страница 98: ...EMENT Refer to Illustration in Chapter 5 1 Hold strut rod and remove top nut 2 Compress spring using strut spring compressor tools Strut Spring Compressor Tools 2871573 and 2871574 3 Remove upper stru...

Страница 99: ...4 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 4 19 FRONT STRUT EXPLODED VIEW BODY STEERING SUSPENSION...

Страница 100: ...e lower portion of the shock and stabilizer linkage to the upper A arm 3 Remove the fastener attaching the upper A arm to the bearing carrier 4 Remove the fasteners attaching the upper A arm to the fr...

Страница 101: ...new A arm bushings and pivot tubes into the new A arm REAR A ARM INSTALLATION 1 Install lower A arm assembly onto vehicle frame Torque new fasteners to specification TORQUE A Arm Fasteners 30 ft lb 4...

Страница 102: ...wheel nuts to specification see Chapter 2 WARNING Upon A arm installation completion test vehicle at low speeds before putting into service REAR A ARM EXPLODED VIEW REAR STABILIZER BAR REMOVAL INSTAL...

Страница 103: ...ng the stabilizer linkage remove the lower shock bolt from the upper A arm 7 Reverse this procedure for installation 8 Torque the stabilizer retaining bolts and upper rubber bushing nuts to specificat...

Страница 104: ...emove the spring retainer 2 Remove the spring and adjusting cam from the existing shock and install components onto the new shock 3 Compress the shock spring and install the spring retainer 4 Reinstal...

Страница 105: ...d prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender o...

Страница 106: ...4 26 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc NOTES BODY STEERING SUSPENSION...

Страница 107: ...NSTALLATION 5 13 FRONT GEARCASE CENTRALIZED HILLIARD 5 15 CENTRALIZED HILLIARD THEORY OF OPERATION 5 15 CENTRALIZED HILLIARD EXPLODED VIEW 5 16 AWD DIAGNOSIS 5 16 GEARCASE REMOVAL 5 18 GEARCASE DISASS...

Страница 108: ...Tool Dealers may order special tools through Polaris official tool supplier Bosch Automotive Service Solutions by phone at 1 800 345 2233 or on line at http polaris service solutions com TORQUE SPECI...

Страница 109: ...5 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 5 3 FRONT REAR HUB WHEEL EXPLODED VIEW FINAL DRIVE...

Страница 110: ...e vertical position 3 Elevate and safely support vehicle under the frame WARNING Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure We...

Страница 111: ...ut shaft 9 Remove 48 Volt fuse block E 10 Disconnect large battery cable from battery terminal F and immediately re install the smaller cable and secure with the terminal nut Insulate the free end of...

Страница 112: ...or the front joint 4 Re connect battery cable s Place the larger cable against battery terminal and the smaller against the terminal nut and torque to specification TORQUE Battery Terminal Nut 8 ft lb...

Страница 113: ...l new bearing caps in yoke by hand 2 Carefully install U joint cross Take care not to dislodge needle bearings upon installation of cross joint Tighten vise to force bearing caps inward while keeping...

Страница 114: ...3 to install bearing caps on outer yoke 7 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 8 When installation is complete yokes must pivot freely...

Страница 115: ...3 and 4 are only required for hub bearing service Proceed to Step 5 for hub disc removal if bearing service is not required 3 Remove cotter pin and ball joint nut q and remove A arm from ball joint st...

Страница 116: ...or rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bea...

Страница 117: ...emoving bearings and seals 2 Remove wheel nuts and washers or lug nuts and wheel 3 Remove cotter pin and ball joint nut q and remove A arm from ball joint stud 4 Use a tie rod fork to remove A arm fro...

Страница 118: ...ward to remove Repeat if necessary until drive shaft is released from front gearcase See Drive Shaft CV Joint Handling Tips page for further Drive Shaft information FRONT DRIVE SHAFT INSTALLATION 1 In...

Страница 119: ...y install hub castle nut q 6 Install brake caliper using new bolts w Tighten bolts to specified torque TORQUE Brake Caliper Bolt 18 ft lb 25 Nm 7 Tighten spindle castle nut to specification TORQUE Fro...

Страница 120: ...5 14 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc TORQUE Ball Joint Nut 30 ft lb 41 Nm 11 Install wheel tire assembly Wheel and Hub Torque Table page 2 7 FINAL DRIVE...

Страница 121: ...irement goes away i e rear wheels regain traction AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts...

Страница 122: ...in Plug 1 9 Clutch Housing Ring Gear 1 28 Oil Seal 1 10 Thrust Plate 1 29 Pinion Gear 1 11 Roll Cage Asm Includes H Springs 1 30 Fill Plug Assembly 1 12 Bolt 1 31 Bearing Roller 14 13 Output Hub Femal...

Страница 123: ...t A minimum of 11 0 12 0 Volts is required for AWD operation 8 If voltage is present remove gearcase Gearcase Removal page 5 18 disassemble the gearcase Gearcase Disassembly Inspection page 5 19 and i...

Страница 124: ...ing surfaces 12 Inspect the torsion spring for damage and fatigue If the spring is misshapen or weak it should be replaced GEARCASE REMOVAL 1 Disconnect the Main Power Connector A under the seat 2 Dis...

Страница 125: ...e of frame GEARCASE DISASSEMBLY INSPECTION 1 Drain and properly dispose of used oil 2 Remove gearcase cover bolts 3 Remove gearcase cover output hub assembly NOTE Be careful not to misplace the thrust...

Страница 126: ...ect the shim for cracks 6 Remove the roll cage assembly rollers and H springs 7 Thoroughly clean all parts Inspect rollers A for nicks and scratches Rollers must slide up and down freely within roller...

Страница 127: ...ess it is being replaced Removal may result in spring deformation 10 Use a flat head screwdriver to remove retaining ring B from output cover 11 Remove spacer washer D armature plate E and rubber O ri...

Страница 128: ...NOTE AWD Diagnosis page 5 16 16 Inspect back lash pad J for excessive wear NOTE The backlash for the centralized hilliard is set at the factory Adjustment is required only when related parts are repl...

Страница 129: ...ls into the gearcase housing and use new O rings for the gearcase input and output covers GEARCASE REASSEMBLY INSPECTION 1 As mentioned in the disassembly section replace all O rings seals and worn co...

Страница 130: ...bs 23 Nm 5 Install the output hub A into the gearcase housing The output hub should spin freely 6 Install the other output hub B and thrust bearing C into the output cover Apply a small amount of grea...

Страница 131: ...g rollers into bearing cage Lower bearing assembly into ring gear 10 Install the ring gear shim into gearcase by fitting ears G into gearcase slots H 11 Holding the bearing assembly in place lower the...

Страница 132: ...H PAD THRUST PAD ADJUSTMENT Base Setting Perform after parts are replaced or adjustment screw was removed 1 Lay gearcase on the side with output cover facing UP 2 The backlash screw is installed with...

Страница 133: ...n in two wheel drive 2WD 7 Turn the backlash adjustment screw in clockwise 1 32 of a turn 8 Test drive vehicle to re evaluate noise performance 9 If noise is still present turn the screw in an additio...

Страница 134: ...gs for side play Grasp the top and bottom of the wheel or wheel hub and check for movement 3 If movement is detected inspect wheel hub hub castle nut torque and bearing condition The tire should rotat...

Страница 135: ...retaining ring from the bearing carrier 2 From the back side tap on the outer bearing race with a drift punch in the reliefs as shown NOTE Drive bearing out evenly by tapping on outer race only Once b...

Страница 136: ...ing carrier housing B Use an arbor press to install the bearing 3 Press the bearing into place until the outer bearing race bottoms in housing CAUTION Use an arbor and press only on the outer race as...

Страница 137: ...w the upper A arm to move freely 4 Torque the upper and lower bearing carrier fasteners to specification TORQUE Bearing Carrier Fasteners 30 ft lb 41 Nm 5 Install the wheel hub assembly onto the rear...

Страница 138: ...remove the shaft 4 Remove rear drive shaft using short sharp jerks to free the circlip from the transmission 5 Refer to Drive Shaft CV Joint Handling Tips page 5 33 for drive shaft service REAR DRIVE...

Страница 139: ...g to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension components...

Страница 140: ...Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise un...

Страница 141: ...is not dimpled or collapsed 18 Install and tighten the large clamp using the Axle Boot Clamp Tool PU 48951 or 8700226 Axle Boot Clamp Tool PU 48951 or 8700226 19 While pulling out on the CV shaft ful...

Страница 142: ...lip is still on the shaft and not left in the joint 7 Remove the boot from the shaft CAUTION Complete disassembly of the plunging joint is NOT recommended The internal components are a precision fit a...

Страница 143: ...20g PN 1350046 30g PN 1350047 50gInner Plunging Joint Capacity Front 60g Rear 100g 14 Fully compress the joint and push the drive shaft firmly into the inner race 15 Align the circlip with the lead i...

Страница 144: ...5 38 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc FRONT DRIVE SHAFT EXPLODED VIEW FINAL DRIVE...

Страница 145: ...5 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 5 39 REAR DRIVE SHAFT EXPLODED VIEW FINAL DRIVE...

Страница 146: ...5 40 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc NOTES FINAL DRIVE...

Страница 147: ...6 4 TRANSAXLE DISASSEMBLY 6 5 TRANSAXLE ASSEMBLY 6 7 TRANSAXLE INSTALLATION 6 8 TRANSAXLE AND DIFFERENTIAL EXPLODED VIEW COMPLETE 6 10 TRANSAXLE EXPLODED VIEW SHAFT AND GEAR ASSEMBLIES 6 11 TRANSAXLE...

Страница 148: ...special tools through Polaris official tool supplier Bosch Automotive Service Solutions by phone at 1 800 345 2233 or on line at http polaris service solutions com LUBRICATION FLUID CAPACITY Recommen...

Страница 149: ...gear that is part of the planetary differential assembly unlocking the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When Differential Lock i...

Страница 150: ...See Chapter 2 6 Remove drive motor See Chapter 3 7 Remove rear upper transaxle mounting bolt and remove bracket from frame 4 bolts 8 Elevate rear of vehicle and safely support machine under the rear...

Страница 151: ...the way and remove transaxle mounting bolts F 14 Lift transaxle out of the lower mount and pull rearward to dislocate the prop shaft G from the front transaxle shaft 15 With the help of an assistant...

Страница 152: ...emoval and all cover bolts B Tap cover evenly at projections on cover C to loosen sealant bond Remove cover straight outward CAUTION Do not pry on case sealing surfaces Tap only in reinforced areas on...

Страница 153: ...s of shaft and bearing or bearing outer race and case prior to bearing installation 1 Assemble idler shaft to case Install oil deflector plate and torque fasteners to specification TORQUE Oil Deflecto...

Страница 154: ...ication TORQUE Speed Sensor Retaining Screw 62 in lb 7 Nm TRANSAXLE INSTALLATION 1 If transaxle lubricant was drained fill with specified amount of Premium Angle Drive Lubricant prior to installation...

Страница 155: ...ransaxle vent line and route to upper left frame Be sure vent line is not kinked or pinched 10 Apply anti seize to the splines of each rear drive shaft 11 Lift bearing carrier and rotate drive shaft u...

Страница 156: ...6 10 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc TRANSAXLE AND DIFFERENTIAL EXPLODED VIEW COMPLETE TRANSAXLE DIFFERENTIAL...

Страница 157: ...6 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 6 11 TRANSAXLE EXPLODED VIEW SHAFT AND GEAR ASSEMBLIES TRANSAXLE DIFFERENTIAL...

Страница 158: ...6 12 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc TRANSAXLE EXPLODED VIEW DIFFERENTIAL TRANSAXLE DIFFERENTIAL...

Страница 159: ...lenoid service or inspection is not required 1 Drain and properly dispose of used lubricant 2 Remove differential solenoid 3 Remove spring A from differential cover and inspect for signs of wear or fa...

Страница 160: ...pped worn or broken teeth Rotate pinion shaft in transaxle housing Shaft should rotate smoothly Push and pull on pinion shaft to check for loose shaft support bearings 8 Inspect planetary gears G for...

Страница 161: ...sen screws H 13 Rotate shift fork retainer plates and carefully release pressure to remove fork 14 Inspect fork and return spring for wear or damage PLANETARY DIFFERENTIAL DISASSEMBLY 1 Use a scribe t...

Страница 162: ...necessary differential components If bushing replacement is required proceed to Planetary Differential Bushing Replacement PLANETARY DIFFERENTIAL BUSHING REPLACEMENT Ring Gear Bushing Replacement 1 S...

Страница 163: ...of planet gear 3 Press new bushing into planet gear until flush on each end 4 Repeat procedure for remaining planet gears Differential Cover Bushing Replacement 1 Press old bushing out of differentia...

Страница 164: ...w bushing into side gear until bottomed in bore PLANETARY DIFFERENTIAL ASSEMBLY 1 Thoroughly clean all components prior to reassembly 2 Assemble side gears and place them onto the ring gear along with...

Страница 165: ...er bearing Rotate differential assembly until properly seated in cover and engaged with dog gear NOTE Do not strike the differential assembly to seat it in the cover 5 Thoroughly clean gearcase mating...

Страница 166: ...following items if a transaxle problem is suspected Transaxle lubricant level type quality Transaxle mounting bolts and brackets Direction selector switch Chapter 8 AWD 2WD Turf mode switch Chapter 8...

Страница 167: ...SYSTEM VIEW 7 9 PARKING BRAKE CALIPER SERVICE 7 10 EXPLODED VIEW 7 10 PARKING BRAKE ADJUSTMENT 7 10 CALIPER REMOVAL 7 10 CALIPER DISASSEMBLY INSPECTION 7 11 NEW BRAKE PAD INSTALLATION 7 12 PARKING BR...

Страница 168: ...RVICE 7 28 REAR CALIPER EXPLODED VIEW 7 28 CALIPER REMOVAL 7 28 CALIPER INSPECTION 7 29 CALIPER ASSEMBLY 7 29 CALIPER INSTALLATION 7 30 REAR BRAKE DISC 7 31 DISC INSPECTION 7 31 DISC REPLACEMENT 7 31...

Страница 169: ...lb 47 Nm Brake Line Flare Fittings 15 ft lb 20 Nm Brake Line Banjo Bolts All 15 ft lb 20 Nm Front Brake Disc Bolts 18 ft lb 24 Nm Rear Brake Disc Bolts 28 ft lb 38 Nm Brake Switch 15 ft lb 20 Nm Maste...

Страница 170: ...it closes a small opening compensating port within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake cal...

Страница 171: ...7 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 7 5 BRAKE SYSTEM SYSTEM VIEW AND TORQUE VALUES BRAKE SYSTEM...

Страница 172: ...ly pump foot pedal until pressure builds and hold light pressure on the pedal 7 Open bleeder screw about 1 4 turn Close bleeder screw and release foot pedal pressure NOTE Do not release foot pedal bef...

Страница 173: ...use CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 4 Loosen banjo bolt and brake light switch C for brake lines and allow fluid t...

Страница 174: ...nd bolt from brake pedal 3 Remove retaining clip and clevis pin from master cylinder to remove pedal PEDAL INSTALLATION Reverse Steps 1 3 for foot brake installation Torque the clevis nut to specifica...

Страница 175: ...rking Brake h Bolt M10 x 1 25 x 20 QTY 8 28 ft lb 38 Nm r Lever Assembly Parking Brake j Bolt M8 x 1 25 x 20 QTY 4 17 ft lb 23 Nm t Brake System Assembly k Nut 5 16 18 QTY 2 y Shield Master Cylinder l...

Страница 176: ...PARKING BRAKE CALIPER SERVICE EXPLODED VIEW PARKING BRAKE ADJUSTMENT See Chapter 2 CALIPER REMOVAL 1 Place vehicle on level ground and block the wheels 2 Release the parking brake 3 Disconnect cable f...

Страница 177: ...PECTION NOTE The parking brake caliper is replaced as an assembly 1 Remove two caliper assembly nuts C 2 Remove bolts and pads with spacers and springs 3 Disassemble shims plate washer lever arm and b...

Страница 178: ...in the caliper on the vehicle is thicker than the rear pad NEW BRAKE PAD INSTALLATION 1 Assemble the stationary actuator with bolts upright as shown Grease the tracks and install 3 balls 2 Install lev...

Страница 179: ...n TORQUE Parking Brake Caliper Assembly Bolts 35 ft lb 47 Nm 9 Ensure the assembly functions properly by actuating the lever before reinstallation It should move freely and return to the upright posit...

Страница 180: ...7 14 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 4 Install retainer clip in pin 5 Test parking brake for proper function and adjust if necessary BRAKE SYSTEM...

Страница 181: ...ECTION REMOVAL 1 Measure parking brake disc thickness in multiple spots using a micrometer If the thickness of the disc is less than specified at any point of the pad contact surface replace the rear...

Страница 182: ...and lower caliper mounting bolts and remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper so to avoid kinking or bending brake line 4 Push...

Страница 183: ...nd make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new...

Страница 184: ...ion see Chapter 2 Maintenance BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Test drive...

Страница 185: ...ate and safely support the front of the vehicle 2 Remove the 4 wheel nuts and the front wheel WARNING Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean c...

Страница 186: ...ow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper assembly from the front strut CALIPER DISASSEMBLY 1 Push brake pad retainer pin inward...

Страница 187: ...stons out from the caliper NOTE Do not remove the caliper pistons with a pliers The piston sealing surfaces will become damaged if a pliers is used 7 Once the pistons are removed use a pick to careful...

Страница 188: ...kes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light re...

Страница 189: ...nstall the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Perform brake bleeding procedure as outlined earlier in this chapter 5 Install wheel and torque whe...

Страница 190: ...Thickness 158 4 01 mm Service Limit 140 3 56 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount dial indicator as shown to measure disc runout Slowly ro...

Страница 191: ...troyed upon removal 5 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Front Hub Nut 70 ft lb 95 Nm 6 Install front brake calipe...

Страница 192: ...r off of disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line PAD INSPECTION 1 Push caliper piston into caliper bore slowly with pad...

Страница 193: ...mm PAD INSTALLATION 1 Install new pads in caliper body with spring installed between pads at A 2 Install caliper and torque mounting bolts TORQUE Rear Brake Caliper Mounting Bolt 18 ft lb 25 Nm 3 Tur...

Страница 194: ...PER EXPLODED VIEW CALIPER REMOVAL 1 Safely support the rear of the machine WARNING Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 U...

Страница 195: ...I D 1 505 38 23 mm Service Limit 1 507 38 28 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit Rear Caliper Piston O D 1 500 3...

Страница 196: ...ated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease CALIPER INSTALLATION 1 Install the rear caliper with the mounting bol...

Страница 197: ...dial indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specification Brake Disc Runout Service Limit 010 254 mm DI...

Страница 198: ...alling the dust cap TORQUE Rear Hub Nut 110 ft lb 150 Nm 7 Install rear brake caliper see REAR CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter 8 Field test unit for prop...

Страница 199: ...ction pads Caliper dirty or damaged Incorrectly adjusted stationary pad Caliper disc misaligned Brake line damaged or lining ruptured Worn or damaged master cylinder or components PEDAL VIBRATION Disc...

Страница 200: ...7 34 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc NOTES BRAKE SYSTEM...

Страница 201: ...CIRCUITS 8 12 INDICATOR LAMP REPLACEMENT 8 13 INDICATOR LIGHTS 8 14 BATTERY DISCHARGE INDICATOR 8 15 CHARGE STATUS INDICATOR 8 16 DIGITAL WRENCH DIAGNOSTIC SOFTWARE 8 17 ACCELERATOR PEDAL POSITION SE...

Страница 202: ...GRAM 8 31 AWD 2WD TURF SWITCH CONTACTS 8 32 DIRECTION SELECTOR SYSTEM WIRING DIAGRAM 8 33 DIRECTION SELECTOR SWITCH CONTACTS 8 34 DRIVE MODE HIGH MAX RANGE LOW SYSTEM WIRING DIAGRAM 8 35 ACCELERATOR P...

Страница 203: ...to subtract meter lead resistance from the reading Connect the leads together and record the resistance The true resistance is equal to tested value minus lead resistance Be sure your meter leads are...

Страница 204: ...se Monitor Grounded in Reverse 48 VOLT FUSE AND RELAY LOCATION There are three 48 volt fuses located in fuse block A Two spare 48 volt fuses can be found in fuse block B located under the hood Open ca...

Страница 205: ...inal board The dash mounted receptacle and the 12 volt terminal board are on the same 10A ACCY fuse in the fuse box 10 amps total current capacity shared between switched accessory power locations and...

Страница 206: ...path on the BN wires in the harness Headlight Switch Power and Ground Testing NOTE If switch is illuminated this test is not required The ground is for switch lighting only 1 Open hood Reach under the...

Страница 207: ...of the TURF solenoid driver on the dark green DG wire to activate the differential solenoid and disengage the differential hub AWD Switch Testing 1 Open hood Reach under the dash and press tab on AWD...

Страница 208: ...to the drive motor The completed ground at the switch also turns on the appropriate indicator light on the indicator light panel See Direction Selector System Wiring Diagram page 8 33 Direction Selec...

Страница 209: ...very parameters MAX RANGE MAX The switch disconnects the Low range WH DB and the High range DG WH wires from ground This interrupts the circuit connection back to Pin 20 and Pin 9 at the controller an...

Страница 210: ...be tested separately by briefly applying a 12 volt DC power source to the solenoid wires for no more than 1 second Do not use the vehicle batteries for the test If the rear differential fails to swit...

Страница 211: ...cargo box wire harness is connected Disconnect wires from hydraulic brake switch 6 Connect an DC voltmeter to the OR and BN wires 12 14 volts should be present PARKING BRAKE SWITCH VOLTAGE LEVEL 14 0...

Страница 212: ...ystem Wiring Diagram page 8 33 Parking Brake Lamp See Parking Brake System Wiring Diagram page 8 30 Temperature See Drive Motor Encoder System Wiring Diagram page 8 25 MIL Connect Digital Wrench See D...

Страница 213: ...he following procedure to remove bulb s Turn lamp holder 1 4 turn with a small screwdriver Pull bulb assembly out with a needle nose pliers Replace with a new bulb 4 Reverse disassembly procedure to r...

Страница 214: ...ing NUMBER OF BLINKS CODE DEFINITION NUMBER OF BLINKS CODE DEFINITION 1 Data or configuration error 7 Voltage protection 2 Sequence fault 8 Controller or motor out of temperature range 3 Power fault 1...

Страница 215: ...g 0 has been used As batteries discharge the voltage on Pin B drops and the illuminated bar moves toward the left of the display NOTE If batteries are not allowed to fully recharge during charging the...

Страница 216: ...uge 4 Reverse removal procedures to reinstall the gauge CHARGE STATUS INDICATOR When charging the batteries the charge status indicator LED light D flashes and changes color to indicate the status of...

Страница 217: ...rded in the Logged Faults memory If a fault is currently active the code is also recorded in Current Faults memory and remains until the fault is no longer occurring If the problem is corrected the Cu...

Страница 218: ...hub coil must be grounded to function DIAGNOSING SYSTEM FAILURES Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil on the Gray wire Verify the AWD hub coil...

Страница 219: ...weight of a rider on the seat while performing this step 5 Locate the T25 Torx head adjustment screw A through the wheel well illustration or by opening the hood photo Adjust the beam to the desired p...

Страница 220: ...90 to lock it in place NOTE Disconnect the Main Power Connector see chapter 1 before disconnecting any electrical component The Main Power Connector is the first to disconnect and the last to connect...

Страница 221: ...h is present Lamps can be bench tested by applying 12 14 volts directly as the LED tail brake lamp units are internally regulated 3 If the LED lamp does not function with power and ground applied to t...

Страница 222: ...r 1 is located under the hood above the battery charger on the RH side of the vehicle The converter receives 48v from the DC DC Converter Relay 2 through a 30A fuse located in the 48v fuse center The...

Страница 223: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 23 SYSTEM WIRING DIAGRAMS 48 VDC 14 0 VDC CONVERTER WIRING DIAGRAM ELECTRICAL...

Страница 224: ...8 24 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc BATTERY SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 225: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 25 DRIVE MOTOR ENCODER SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 226: ...8 26 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc BATTERY CHARGING SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 227: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 27 AUXILIARY ACCESSORY BATTERY SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 228: ...8 28 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 14 0 VOLT SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 229: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 29 LIGHTING SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 230: ...8 30 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc PARKING BRAKE SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 231: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 31 AWD SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 232: ...8 32 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc AWD 2WD TURF SWITCH CONTACTS ELECTRICAL...

Страница 233: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 33 DIRECTION SELECTOR SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 234: ...8 34 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc DIRECTION SELECTOR SWITCH CONTACTS ELECTRICAL...

Страница 235: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 35 DRIVE MODE HIGH MAX RANGE LOW SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 236: ...8 36 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc ACCELERATOR PEDAL POSITION SENSOR SYSTEM WIRING DIAGRAM ELECTRICAL...

Страница 237: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 37 MAIN FUSE BOX ELECTRICAL...

Страница 238: ...8 38 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc DIAGNOSTIC TROUBLE CODES DIGITAL WRENCH TROUBLE CODE LIST ELECTRICAL...

Страница 239: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 39 ELECTRICAL...

Страница 240: ...8 40 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc Digital Wrench Trouble Code List Cont ELECTRICAL...

Страница 241: ...8 9926595 R01 2015 2016 RANGER EV Service Manual Copyright Polaris Industries Inc 8 41 ELECTRICAL...

Страница 242: ...ake Pad Assembly Front 7 17 Brake Pedal Installation 7 8 Brake Pedal Removal 7 8 Brake System Inspection 2 16 Brake System Bleeding 7 6 Brake System Exploded View 7 5 Brake System Operation 7 4 Brake...

Страница 243: ...stment 7 10 Periodic Maintenance Chart 2 2 Pre load Adjustment Rear Shock Spring 2 15 Pre Ride Daily Inspection 2 5 Propshaft U Joint Replacement 5 6 Propshaft Removal 5 4 Publication Numbers 1 6 R Re...

Страница 244: ...oded View Complete 6 10 Transaxle Exploded View Input Output 6 11 Transaxle Installation 6 8 Transaxle Special Tools 6 2 Transmission Transaxle Exploded View 6 10 Trouble Codes Digital Wrench 8 38 Tro...

Страница 245: ...2015 2016 RGR EV LSV CHASSIS...

Страница 246: ...2015 2016 RANGER EV CARGO BOX...

Страница 247: ...2015 2016 RGR EV LSV...

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