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

This Polaris factory service manual, P/N 9920852, covers the 2007 Ranger XP 4x4 and 6x6 on the Ranger 700 EFI platform. It includes model, VIN, engine, and transmission identification plus scheduled-maintenance references.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram access: The main text is searchable, with embedded bookmarks for chapters and service topics. Some diagnostic graphics and wiring-diagram labels are not searchable. Small wiring labels require zooming for comfortable reading.

One printable English PDF contains 328 pages, including the opening chapter guide, four index pages, and four wiring-diagram sheets.

Engine, EFI, and Configuration-Specific Driveline Service

The following selected content highlights outline the repair coverage. Other topics include exhaust spark-arrestor cleaning and headlight adjustment.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head and valve service, cylinder honing, crankcase inspection, timing-gear setup, reassembly, and oil-system priming.

• Bosch EFI diagnosis: Fuel-pressure and injector checks, ECU and sensor diagnosis, TPS testing and initialization, and diagnostic blink-code references.

• PVT and transmission: Belt inspection, clutch alignment and offset, drive/driven clutch service, overheating diagnosis, shift-linkage adjustment, and transmission disassembly and assembly.

• Final drive: Centralized Hilliard front gearcase service and AWD diagnosis, with separate coverage for the 4x4 rear differential and 6x6 mid-drive and rear axle.

• Body and suspension: Cab and body-component removal, steering service, front strut and ball-joint replacement, and configuration-specific A-arm, stabilizer-bar, and swingarm work.

• Brake service: Hydraulic-system operation, bleeding and fluid changes, master-cylinder work, parking-brake adjustment, caliper repair, pad/disc inspection, and symptom-based troubleshooting.

• Electrical troubleshooting: Instrument-cluster tests, charging and starter flowcharts, fan-control checks, battery testing, optional box-lift actuator diagnosis, and chassis/dash wiring diagrams.

The teardown depth, precision measurements, and special-tool requirements make this manual suited to professional technicians and experienced owners with a properly equipped shop. Polaris expressly reserves PVT maintenance and repair for trained Master Service Dealer technicians.

Engine Repair and Cooling-System Scope

The EH068OLE engine material distinguishes components accessible with the engine installed from crankshaft, connecting-rod, counterbalance-shaft, main-bearing, and crankcase work requiring engine removal. A separate procedure addresses valve-cover access on the 6x6.

Factory data covers fastener patterns, component-specific torque specifications, fluid requirements, and piston, ring, cylinder, valve, camshaft, and oil-pump inspection criteria. Cooling coverage includes pressure testing and bleeding; the Engine Oil Flow Chart explains lubrication through the engine.

Cylinder honing is limited to deglazing the Nicasil lining; excessively worn or damaged cylinders require replacement. The rebuild cautions address dry-installed crankshaft seals and mandatory oil-system priming to prevent sealing problems or internal damage on initial startup.

Bosch EFI Tests and Diagnostic Equipment

Fuel-pressure checks, wiring tests, sensor checks, and blink-code references support fault isolation before components are replaced. The EFI System Exploded View identifies the relationships between the ECU, sensors, fuel rail, injectors, and in-tank pump assembly.

Service limits: The ECU is sealed and is not intended for disassembly. The fuel pump and pressure regulator are not serviced individually; the manual specifies pump/tank assembly replacement. TPS replacement or movement requires initialization.

Manual test procedures are provided for several EFI components. T-BAP testing requires dealer-only Digital Wrench and refers to the separate EFI Diagnostic Software Manual.

Named equipment includes Fuel Pressure Gauge Kit PU-43506-A, Digital Wrench software PU-47063, and SmartLink Kit PU-47471.

PVT and Internal Transmission Work

Clutch coverage extends to sealing and ducting, belt deflection, bushing replacement, spring and shift-weight inspection, and clutch assembly. Standard Clutch Alignment Tool PA-47346 is specified. Misplaced spider spacer washers or mismatched clutch components can disturb the assembly’s precision balance.

Transmission material covers gear clusters, shift forks, the shift drum, engagement dogs, wave springs, chains, bearings, seals, and shift timing. Its troubleshooting checklist distinguishes linkage and clutch-related shifting problems from internal transmission faults.

4x4 and 6x6 Final-Drive Differences

The manual follows the configurations separately where their hardware differs, which matters when selecting axle, gearcase, suspension, brake, and driveline procedures.

Both versions receive front hub, CV-joint, propshaft U-joint, and front-drive-shaft service. The 4x4 has rear hub, shaft, propshaft, and lockable differential coverage; the 6x6 adds mid-drive hub, shaft, propshaft, gearcase, and rear axle/gearcase assembly work.

4x4 differential limit: Pinion and ring-gear shimming information is not provided. The pinion assembly requires OEM tooling and is specified for assembly replacement if its gear, bearings, or case are damaged.

Chassis, Brakes, and Electrical References

Body material covers the hood, dash, cab, cargo box, and storage box. Suspension procedures distinguish the 4x4 rear A-arms and stabilizer bar from the 6x6 mid A-arms and rear swingarm.

Electrical tests address no-AWD, no-display, wheel-speed, fuel-gauge, and shift-indicator faults. The Centralized Hilliard Exploded View, Cooling System Break-Out Diagram, Charging System Testing Flow Chart, and Ranger 700 EFI chassis, dash, and breakout wiring sheets support component and circuit identification.

The manual flags pressurized EFI fuel, spring-loaded clutch parts, brake hydraulics, engine lifting, and raised-vehicle support as work requiring the specified protective equipment and shop precautions. Oil System Priming Tool PU-45778 is identified for engine rebuild preparation.

Oil-Pressure and EFI Sensor Test Preview

For the hot-engine oil-pressure test using Polaris 0W-40 synthetic oil, the manual specifies 39 psi standard and 35 psi minimum at 5,500 RPM.

The crankshaft-position sensor test specifies 560 Ω ± 10% at 68°F (20°C). At the same temperature, the coolant-temperature sensor table lists 2.5 kΩ ± 6%.