Essential Polaris Ranger XP Utility Vehicle Manual (2007) – 473 Pages | Workshop Ready

Polaris Ranger XP 2007 Service Manual

Maintaining Polaris Ranger XP utility vehicles requires a level of technical precision that only factory-verified data can provide. Ranger XP 4x4 and 6x6 platforms are engineered for extreme duty, and this documentation delivers the specific torque values, electrical logic, and fluid capacities essential for professional-grade overhauls. Navigating complex diagnostic "Blink Codes" or performing a full engine disassembly becomes a structured process with the specialized benchmarks included in this reference.

Technical Fleet & Series Inclusion:

This technical volume specifically treats the 2007 Polaris Ranger XP 4x4 and the Ranger XP 6x6. Coverage is focused on the Series RH68 chassis and the 683cc Polaris Twin Cylinder engine (EH068OLE044). Every schematic and specification provided is actively applied to these specific off-road configurations to ensure precision in the workshop.

Data Logistics & Format:

• Total Pages: 473
• Official Publication Number: LIT-9920770
• Release Date: 2007
• File Type: Searchable PDF

Mechanical Integrity & Investment Protection:

• Eliminates the "trial-and-error" approach by providing exact shim measurements and gear backlash adjustments.
• Protects the high-pressure Bosch Electronic Fuel Injection (EFI) system with strict priming and pressure-testing sequences.
• Prevents catastrophic component failure through the use of specific fastener torque patterns and sequence charts.
• Optimizes power delivery by including specialized altitude-based clutch charts for varying operational environments.

Powertrain & Chassis Benchmarks:

• Cylinder Compression: 150-170 psi (Standard range for engine health).
• EFI System Pressure: 39 psi +/- 3 (Critical for proper fuel atomization).
• Spark Plug Gap: 0.035 inches (Ensures consistent ignition timing).
• Valve Clearance (Cold): 0.006 inches (Prevents premature valve seat wear).
• Engine Idle Speed: 1150 RPM +/- 50 (Maintains oil pressure and charging logic).

System Schematics & Visual Paths:

Technical illustrations within the manual offer high-definition clarity for the Polaris Variable Transmission (PVT) assembly and engine crankcase internals. Specialized wiring maps detail the 500-Watt alternator circuit and the AWD/Differential solenoid logic. Every diagram supports high-ratio zooming to identify individual pin-outs and wire color-coding for faultless harness repair.

Professional Diagnostic Protocols:

Troubleshooting is handled via the Bosch ECU logic, which monitors the Engine Management System for anomalies. Technicians can interpret the instrument cluster "Blink Codes" to identify specific sensor failures, such as Throttle Position Sensor (TPS) range issues or T-BAP sensor shorts. The manual provides a systematic flow for testing fuel pumps, ignition coils, and cooling fan relays to minimize downtime.

Workshop Content Breakdown:

• Section 1: General Info: VIN Locations, Dimensions, and Technical Specs.
• Section 2: Periodic Maintenance: Severe Use Schedules and Fluid Intervals.
• Section 3: Engine Overhaul: Head Service, Valve Seats, and Crankcase Repair.
• Section 4: Fuel Injection: EFI Component Testing and Pressure Regulation.
• Section 5-8: Drive Systems: PVT Clutching, Final Drive, and Gearcase Service.
• Section 9-10: Support Systems: Hydraulic Disc Brakes and Electrical Schematics.

FAQ

How does this manual assist with 2007 Ranger XP ignition system troubleshooting? The documentation provides specific resistance values for the ignition coil and crank position sensor (CPS) to ensure peak firing efficiency. You are given the technical benchmark of 0.4 ohms (+/- 10%) for the primary coil resistance and 560 ohms for the CPS, allowing you to quickly isolate a weak spark condition and restore field uptime without guessing.

Which specific Ranger series and engine configurations are covered in this reference? This manual focuses on the 2007 Series RH68 chassis, encompassing both the Ranger XP 4x4 and the 6x6 variants. It treats the Polaris Twin Cylinder EH068OLE044 engine, providing exact specifications for the 683cc powerplant to ensure that any component replacement or overhaul meets factory air-fuel and timing requirements for this specific model year.

What are the critical fuel system pressures required for the Bosch EFI maintenance? Maintaining the high-pressure fuel circuit is vital for engine longevity; the manual specifies a technical benchmark of 39 psi (+/- 3) at the fuel rail. This value is critical when diagnosing the in-tank regulator or the fuel pump assembly, ensuring that the electronic fuel injection system provides the precise atomization required for high-load utility tasks.

Can the high-resolution schematics in this document be used for electrical harness repair? Yes, the manual includes detailed, high-contrast wiring maps that cover the entire 500-Watt charging system and the AWD solenoid logic. These schematics allow a technician to trace specific wire color-coding and pin-out locations, ensuring that complex electrical faults—such as a 12V DC drop in the lighting or ignition circuit—are resolved with OEM-level accuracy.

What is the correct valve clearance setting for the 683cc Twin engine? To prevent premature valve seat wear and maintain compression integrity, the manual identifies a cold valve clearance benchmark of 0.006 inches (0.15 mm). Setting these tolerances precisely ensures that the valvetrain operates within its engineered thermal expansion range, protecting the cylinder head from overheating during heavy-duty operation.