2007 Polaris Ranger XP 4x4 / 6x6 UTV Service & Repair Manual (P/N 9920852)

• Exact vehicle coverage: 2007 Polaris Ranger XP 4x4 model codes R07RH68AD/AG/AH/AK/AL/AW and Ranger XP 6x6 R07RF68AF, all using the EH068OLE twin-cylinder Bosch EFI engine.
• Document identity: a 328-page PDF of the Polaris factory service manual, P/N 9920852, with model/VIN, engine, and transmission identification plus scheduled-maintenance references.
• Engine repair depth: engine removal and installation, cooling-system pressure testing and bleeding, oil-pressure testing, cylinder honing, cylinder-head and valve service, piston and crankcase inspection, timing-gear setup, reassembly, and oil-system priming.
• Bosch EFI diagnosis: ECU, fuel-pump/tank assembly, pressure regulator, injectors, CPS, T-BAP, TPS testing and initialization, ECT sensor checks, diagnostic blink codes, and both manual and Digital Wrench test coverage.
• PVT and transmission work: belt inspection, clutch alignment and offset, drive- and driven-clutch service, PVT overheating diagnosis, shift-linkage adjustment, and automatic-transmission removal, internal inspection, assembly, and installation.
• Configuration-specific chassis and driveline coverage: Centralized Hilliard front gearcase and AWD diagnosis, 4x4 rear differential, 6x6 mid-drive and rear-axle systems, CV joints, propshafts, suspension, brakes, electrical test charts, and four wiring-diagram sheets.

This is the factory service manual for the 2007 Ranger 700 EFI platform rather than an owner's manual. It follows the 4x4 and 6x6 hardware separately where the machines differ, which matters when selecting axle, gearcase, suspension, brake, and driveline procedures. Its teardown depth, precision measurements, and special-tool requirements make it best suited to professional technicians and experienced owners with a properly equipped shop. Internal PVT repair is expressly treated as trained Polaris Master Service Dealer work, and Digital Wrench is identified as dealer-only equipment.

Engine and Fuel-System Scope

The engine material is specific to the 683 cc EH068OLE family. It distinguishes components that can be serviced with the engine installed from crankshaft, connecting-rod, counterbalance-shaft, main-bearing, and crankcase work that requires engine removal. Factory data covers fastener patterns, component-specific torque specifications, oil and cooling-system tests, fluid requirements, wear limits, and piston, ring, cylinder, valve, camshaft, and oil-pump inspection criteria.

EFI coverage goes beyond a system overview. The manual explains circuit operation and fault isolation for the Bosch ECU and its sensors, along with fuel-pressure testing and injector checks. It also identifies sealed or assembly-only parts: the ECU is not intended for disassembly, while the pump, regulator, and gauge sender are shown as an in-tank assembly and the pump and regulator are not serviced separately. TPS replacement or movement is tied to a required initialization procedure.

PVT, Transmission, and Final Drive

The clutch chapter documents sealing and ducting, belt condition and deflection, alignment and offset, bushing service, spring and shift-weight inspection, and drive/driven clutch disassembly and assembly. Repair cautions explain how misplaced spider spacer washers or mixed clutch parts can upset the PVT's precision balance. The transmission section adds internal gear-cluster, shift-fork, shift-drum, engagement-dog, wave-spring, chain, bearing, seal, and shift-timing coverage.

Final-drive material is separated by configuration. Both versions receive front hub, CV-joint, propshaft U-joint, front-drive-shaft, and Centralized Hilliard gearcase service. The 4x4 section covers its rear hubs, shafts, propshaft, and lockable rear differential; the 6x6 section adds the mid-drive hub, shaft, propshaft, gearcase, and complete rear axle/gearcase assembly. One important limit is stated: 4x4 rear-differential pinion and ring-gear shimming is not supplied because that assembly requires OEM tooling.

Brakes, Electrical Diagnosis, and Reference Material

Body and suspension chapters cover cab, hood, dash, cargo-box and storage-box removal; steering components; front struts and ball joints; 4x4 rear A-arms and stabilizer bar; and 6x6 mid A-arms and swingarm. Brake content includes hydraulic-system operation, bleeding and fluid change, master-cylinder work, parking-brake adjustment, caliper repair, pad/disc inspection, and symptom-based troubleshooting.

Electrical support includes instrument-cluster diagnostic mode, no-AWD/no-display/wheel-speed/fuel-gauge/shift-indicator tests, charging and starter flowcharts, fan-control checks, battery tests, and box-lift actuator diagnosis where equipped. Representative visuals include the EFI System Exploded View, Engine Oil Flow Chart, Centralized Hilliard Exploded View, Cooling System Break-Out Diagram, Charging System Testing Flow Chart, and the Ranger 700 EFI chassis, dash, and breakout wiring diagrams.

Named service equipment includes Fuel Pressure Gauge Kit PU-43506-A, Digital Wrench software PU-47063 with SmartLink Kit PU-47471, Standard Clutch Alignment Tool PA-47346, and Oil System Priming Tool PU-45778. The manual also flags the pressurized EFI fuel system, spring-loaded clutch parts, brake hydraulics, engine lifting, and raised-vehicle support as work requiring the specified protective equipment and shop precautions. Its engine rebuild cautions cover dry-install crankshaft seals and mandatory oil-system priming, two details that can otherwise lead to seal failure or internal damage on the first start.