Polaris RANGER EV (2015) Service manual

2015-2016 RANGER EV

Service Manual

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized 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 manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

FOREWORD

technicians in a properly

Publication Printed August 2015 (PN 9926595 R01)

© Copyright 2015 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, 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 indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE

NOTE provides key information by clarifying instructions.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-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 FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

2015-2016 RANGER EV

Service 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 SYSTEM

CHAPTER 8: ELECTRICAL

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

BATTERYACCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20

MAIN POWER CONNECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

BATTERY TERMINAL FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

BATTERY CONTACTOR FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

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1.1

GENERAL / BATTERY

BATTERY CLEANING (EXTERNAL SURFACES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

BATTERY TERMINAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21

BATTERY WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

BATTERY TESTING - OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23

BASIC DISCHARGER INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24

BATTERY DISCHARGE AND TESTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25

BATTERY SPECIFIC GRAVITY TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27

BATTERY 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33

BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33

BATTERY CHARGER LED FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34

BATTERY CHARGER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34

SPECIFIC GRAVITY / CHARGE PERCENTAGE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36

CONVERSION TABLE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36

STANDARD BOLT TORQUE SPECIFICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37

METRIC BOLT TORQUE SPECIFICATION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38

DECIMAL EQUIVALENTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38

1.2

9926595 R01 - 2015-2016 RANGER EV Service Manual

SPECIAL INFORMATION REGARDING THE RANGER EV

OPERATING THE RANGER EV

If you are not familiar with the controls, features, or safe operation of RANGER EV vehicles, read the Owner’s Manual thoroughly before you operate the vehicle.

If you are an experienced RANGER EV technician and have read and become familiar with safe vehicle operation, a basic description of the switches and controls unique to the RANGER EV is included in this manual.

WORKING ON THE RANGER EV

Improper contact between battery terminals can result in electrical shorts. Electrical shorts can result in burns.

WARNING

Use insulated tools or insulate any tools used within the

battery area to prevent sparks or battery explosion

caused by shorting the battery terminals or wiring.

Remove the batteries or cover the exposed terminals

with an insulating material.

The RANGER EV is equipped with eight 12-volt lead/acid batteries arranged in two banks of four batteries each. Each bank of batteries delivers 48 volts to a high efficiency AC induction motor via the motor controller unit and a key switch-controlled main contactor. Batteries, controller, and contactor are located under the seat. Here are a few key differences to remember when working on the RANGER EV.

48 VOLT FUSES AND RELAYS

Be aware that some of the fuses and relays on the RANGER EV are 48 volt; they may look similar to their 12 volt counterparts, but they are not the same and must not be substituted with other types. The fuse voltage and current rating is clearly marked on the fuse box label. Refer to Chapter 8 of this manual (Electrical) for more information and diagnostics for electrical system components. Battery information is in this 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 precautions and follow proper handling, charging, and service procedures while you work. Read the entire BATTERY SAFETY section of this manual.

Remove all jewelry or metal objects that could come in contact with battery terminals as you work in or around the battery compartment; including (but not limited to):

• Rings, chains, wrist watches, bracelets, etc.

If battery access is not required for the task at hand, keep storage trays and the seat in place to reduce the chance of a dropped tool or other conductive object making contact with the battery cables or terminals.

MAIN POWER CONNECTOR / BATTERY CHARGER

Some service procedures require special precautionary steps to reduce the chance of electrical shorts and avoid damage to expensive components. Always read and understand the entire procedure and be sure you have the proper tools and equipment before you begin. DO NOT disconnect or work on any electrical component without first disconnecting the Main Power Connector. See Main Power Connector, page 1.20. DO NOT work on the vehicle with the battery charger connected.

“FLOATING” CHASSIS

The RANGER EV frame and other chassis components ARE NOT used as a conductor (ground path) for electrical components and therefore not at ground potential. NEVER connect accessories or other wiring to the frame or chassis. Accessory Installation Precautions, page 1.33. NEVER work on the vehicle with the battery charger connected.

TIRE PRESSURE

Tire pressure for all tires is 20 psi (138 kPa) due to the tire design used on the RANGER EV.

VEHICLE TOWING

When towing the vehicle, the key MUST be in the OFF

position or severe motor damage will occur.

1. Place direction selector in NEUTRAL

2. Turn key switch OFF.

3. Verify the parking brake is not engaged.

GENERAL / BATTERY

CAUTION

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1.3

GENERAL / BATTERY

VEHICLE IDENTIFICATION

MODEL NUMBER DESIGNATION

Example: A14KA09AD

GROUP

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th

A 1 4 K A 0 9 A D

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/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 calibration.

MODEL

YEAR

CHASSIS

DRIVE-

LINE

ENGINE /

MOTOR CODE

CATEGORY OPTION REGION

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

Example: 4XAKA09A0E3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

WORLD MFG. ID

ENGINE

MODIFIER

ENGINE SIZE

CATEGORY

CHECK DIGIT

MODEL YEAR *

MFG. LOCATION

1 2 3 4

CHASSIS

DRIVELINE

5 6 7 8 9 10 11 12 13 14 15 16 17

4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016

INDIVIDUAL SERIAL NO.

1.4

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GENERAL / BATTERY

VEHICLE AND MOTOR SERIAL NUMBER LOCATIONS

Whenever corresponding about a Polaris utility vehicle, 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 the dash in front of the steering wheel (see Figure 1-1).

The drive motor model and serial number can be found on a label (A) applied to the motor (see Figure 1-2).

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1.5

GENERAL / BATTERY

VEHICLE INFORMATION

PUBLICATION NUMBERS

MODEL MODEL NO.

R15RMAE4EJ 9925678 9925783

2015 RANGER EV

2016 RANGER EV

R15RMAE4GC 9925678 9925783

R15RMAE4GJ 9925678 9925783 R16RMAE4G8 9926456 9926474 R16RMAE4G9 9926456 9926474

NOTE

When ordering service parts be sure to use the correct

Polaris factory publications can be found at www.

polarisindustries.com or purchased from www.

parts manual.

purepolaris.com.

OWNER’S MANUAL

PARTS MANUAL PN

1.6

9926595 R01 - 2015-2016 RANGER EV Service Manual

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

SERIES# PART NUMBER

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

GENERAL / BATTERY

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are 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 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/. A link to Bosch Automotive Service Solutions is also provided under the Service & Warranty tab at www.polarisdealers.com.

WARNING

Use insulated tools or insulate any tools used within the

battery area to prevent sparks or battery explosion

caused by shorting the battery terminals or wiring.

Remove the batteries or cover the exposed terminals

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

with an insulating material.

1.7

GENERAL / BATTERY

GENERAL SPECIFICATIONS

2015 - 2016 RANGER EV

MODEL NUMBERS: 2015: R15RMAE4EJ / R15RMAE4GC / R15RMAE4GJ

2016: R16RMAE4G8 / R16RMAE4G9

CATEGORY DIMENSION / CAPACITY

Length

Width 56.5 in. / 143.5 cm Height

Wheel Base 72 in. / 182.9 cm Ground Clearance 10 in. / 25.4 cm Turning Radius

Dry Weight 1750 lbs. / 793.8 kg

Gross Vehicle Weight

Cargo System

Cargo Box Dimensions (Inside dimensions inches / centimeters)

Cargo Box Capacity 500 lbs. / 226.8 kg

Vehicle Payload

Towing With The RANGER EV

Hitch Towed Load Weight (Level ground)

Hitch Towed Load Weight (15 degree grade)

Hitch Vertical Weight Capacity

Maximum Towing Speed

108 in. / 274.3 cm

73 in. / 185.4 cm

150 in. / 381 cm

2750 lbs. / 1247 kg

Lock & Ride

Length: 32.0 / 81.3 Width: 42 / 107 Height: 11.5 / 29

1000 lbs. / 454 kg (Includes weight of operator, passenger, cargo and accessories)

1250 lbs. / 567 kg

850 lbs. / 386 kg

150 lbs. / 68 kg

10 mph. / 16 kph

1.8

9926595 R01 - 2015-2016 RANGER EV Service Manual

GENERAL / BATTERY

DRIVE MOTOR & ELECTRICAL

Motor Configuration

Motor Peak

Modes

Controller

Battery Pack

Maximum Speed 25 MPH (40 km/h)

Throttle

On-board Charger

Charge Time

Electrical

Charge Indicator

Hour Meter

Indicator Lights

Auxiliary Power 12 volt Accessory Outlet

Lights: Main Headlights

Tail Light / Brake Light

Chassis

Single 48 Volt High Efficiency AC Induction Motor

30 HP (22.4 kW)

3 Modes: High for performance Low for pulling / towing Max for maximum distance

650 Amp Sevcon Gen 4 controller with multi-mode driving and regenerative braking

11.7 kW battery pack at 48Vdc with (8) 12 volt, US12VXC batteries in series-parallel configuration.

Redundant, non-contact, inductivesensing pedal

Delta Q 120 volt AC input; 48 volt DC output

8 Hours (dependant on depth of discharge)

Digital - Indicates Battery State-of-Charge

Digital - Indicates Cumulative Hours Of Vehicle Movement

Directional selection, Park Brake, Motor or Controller Malfunction

Dual 50 Watt

Sealed LED

Floating - no ground connection. NOTE: When the vehicle batteries are 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

Shift Type

Drive System

Drive Ratio - Front 3.81:1 Drive Ratio - Rear 20.56:1

Front Gearcase Lubricant Requirement

Front Gearcase Fill Plug Torque

Front Gearcase Drain Plug Torque

Rear Gearcase Rear Gearcase

(Transaxle) Lubricant

Rear Gearcase (Transaxle) Fill Plug & Drain Plug Torque

Toe Out

Front Suspension

Front Travel

Rear Suspension Dual A-Arm Independent (IRS)

Rear Travel

Shock Preload Adjustment

Front Wheel Size / Type

Rear Wheel Size / Type

Front Tire 25 x 9-12 Carlisle All-Trail ll Rear Tire 25 x 9-12 Carlisle All-Trail ll Tire Air Pressure

(Front and Rear)

Brake System

Brake Fluid DOT 4

Parking Brake

Direct drive motor-to-transaxle with low noise gears

N/A

On-Demand True AWD / 2WD / Versa Trac Turf Mode

Front Gearcase

Demand Drive Plus

6.1 oz. (180 ml)

8-10 ft-lbs (11-13.6 Nm)

11 ft-lbs (15.0 Nm)

ATVAngle Drive Fluid

20.3 oz. (600 ml)

14 ft-lbs (19.4 Nm)

Steering / Suspension

1/8 - 1/4 in. (3.2 - 6.35 mm)

MacPherson Strut / A-arm

8 in. (20.3 cm)

9 in. (22.9 cm)

Cam Adjustment (Rear)

Wheels / Brakes

12 x 6 / Steel

20 psi (138 kPa)

4 Wheel Hydraulic Disc With Dual Bore Front Calipers

Dash Mounted Lever- Activated Mechanical

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.9

GENERAL / BATTERY

Cold Weather Operation

Cold weather operation requires special vigilance in regard to battery state of charge. Discharged batteries freeze at a higher temperature than fully charged batteries (see table for freeze points).

BATTERY FREEZE POINT

Percent Charged

Freeze Point (Approximate)

Also keep in mind the following:

• Battery (vehicle) range decreases as the ambient temperature decreases.

• Maximum range will be attained at an ambient temperature of 80°F (26.6°C) or higher. This is the case for all lead-acid battery products. Cold ambient temperatures can negatively affect the range by up to 30%.

100% 50% 0%

-60° F

(-51° C)0°(-18° C)

+25° F (-4° C)

1.10

9926595 R01 - 2015-2016 RANGER EV Service Manual

FEATURES AND CONTROLS

CONSOLE

Console switches and controls are described on the following pages.

NUMBER DESCRIPTION

Indicator Lights

Discharge Indicator / Hour Meter

Key Switch

Drive Direction Selector

AWD Switch

Drive Mode Switch

Charge Status Indicator

Headlight Switch

GENERAL / BATTERY

KEY SWITCH

Move the Direction Selector Switch to NEUTRAL then turn the key to the ON position to activate electrical circuits.

NOTE

The accelerator will not start the drive motor if the

Direction Selector Switch is in the Forward or Reverse

position when the key is turned ON. Switch to NEUTRAL, then choose Forward or Reverse.

The key can 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. When the park brake is set and the park brake indicator is illuminated, motor speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.

This feature will not operate properly if the park brake connector or switch (under the hood) malfunctions or becomes disconnected, or if the switch has moved. Check to be sure the switch is properly connected or test and repair as required. See Chapter 7 (Brakes) or Chapter 8 (Electrical) for diagnostic procedure.

Always apply the service brakes before engaging or releasing the park brake.

Be sure the lever is completely forward when releasing the park brake.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

Drive Mode Switch

1.11

GENERAL / BATTERY

CAUTION

Changing the drive mode switch position while driving

could result in an automatic increase or decrease in

speed without a change to accelerator pedal pressure.

See Table 1. Use high mode for most trail-riding conditions. The

vehicle will operate at speeds up to 25 MPH (40 km/h). Low mode is recommended for short-term operation in

extreme load conditions. Use low mode when towing, hauling loads or maneuvering over obstacles. Speed will be limited to a maximum of 12 MPH (19 km/h) and regenerative braking increases to improve control in aggressive terrain.

Use the Maximum Range mode to operate the vehicle a greater distance or for a longer time period. This mode limits both speed and torque to obtain the maximum driving range.

BATTERY DISCHARGE INDICATOR

The battery discharge indicator displays the amount of charge removed (used) from fully charged batteries. When the batteries are fully charged, the right-most bar illuminates, indicating 0% has been used.

1 - DRIVE MODE CHARACTERISTICS

DECEL

BRAK-

ING

(RE-

GEN.)

Maxi-

mum

MODE

High

Max

Range

Low

MAX

SPEED

25 mph (40 km/

15 mph (24 km/

12 mph (19 km/

TORQUE

(PER-

CENT OF

MAXIMUM

TORQUE)

85% Minimum

60% Minimum

100%

1.12

USE THIS

MODE FOR:

Trail Riding

Maximize

battery range

Towing, hauling

loads, steep

hills,

As the batteries discharge, the bar moves toward the left.

If batteries are not allowed to recharge fully (solid green light), the battery discharge indicator may be inaccurate.

When the second bar from the left flashes, battery discharge is at 70%. The batteries should be recharged as soon as possible. Avoid discharging the batteries

more than 80%.

If the two left-most bars begin to flash, battery service life will be significantly reduced with continued operation. Stop the vehicle and recharge the batteries.

9926595 R01 - 2015-2016 RANGER EV Service Manual

GENERAL / BATTERY

CHARGE STATUS INDICATOR

When charging the batteries, the charge status indicator light flashes and changes color to indicate the status of the charge. See Table 2.

2 - Charge Status Indicator

COLOR

Green Solid

Green

Amber

Red

INDICA-

TION CODE DEFINITION

Charge is complete, charger is in maintenance mode.

Fast

Flash

Slow

Flash

Flashing

Less than 80% of charge is completed.

More than 80% of charge is completed.

Charge rate is reduced, low AC voltage or high internal charger temperature exists; open hood to improve air flow.

Charger error exists; reset charger power and refer to Battery section in this chapter.

BATTERY CHARGING CORD / BATTERY CHARGER

The battery charging cord (1) is located at the front of the vehicle, inside the right front bumper. See Battery Charging, page 1.21 for battery charging procedure. See Battery Charger Troubleshooting, page 1.34 for battery charger diagnostics.

HEADLIGHT SWITCH

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.13

GENERAL / BATTERY

HOUR METER

The hour meter (2) records and displays the hours of actual vehicle movement since manufacture (see image below).

12 VOLT AUXILIARY POWER OUTLET

The 12-volt receptacle (3) can be used to power accessories, but is limited to 10 amps (the terminal board and 12-volt outlet are fused together at 10 amps).

DIRECTION SELECTOR SWITCH

When the direction selector is in the center position, the vehicle is in neutral. The vehicle will not move if the accelerator is depressed. Place the switch in neutral before turning the key on.

Always come to a complete stop before reversing direction.

ALL WHEEL DRIVE (AWD) SWITCH

The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode).

AUXILIARY 12 VOLT TERMINAL BOARD

The 12-volt terminal board (under hood) contains a switched 12-voltq, a ground terminalwand a constant 12-volt 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 Auxiliary Power Outlet on the dash.

that can be used to power auxiliary lights and

AWD MODE - Once enabled, the AWD remains enabled until the switch is turned off.

1.14

9926595 R01 - 2015-2016 RANGER EV Service Manual

The AWD switch may be turned on or off while the vehicle is moving. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

AWD will not engage initially until speed is less than 5 MPH (8 km/h).

Engage the AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the accelerator before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning

may cause severe drive train damage. Always switch to

AWD while the rear wheels have traction or are at rest.

Disengaging AWD - If the AWD switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction.

In some situations, the front gearcase may remain locked 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 vehicle.

2. Move the direction selector to REVERSE. Operate in reverse for at least 10 feet (3 meters).

3. Stop completely, then move the direction selector to FORWARD and drive forward.

4. If the front gearcase remains locked after performing the above steps, refer to Final Drive (Chapter 5).

2WD MODE - Locking the differential in slippery or low traction conditions helps improve traction. Move the rocker switch to the center position (2WD) to lock the differential and operate in rear wheel drive.

GENERAL / BATTERY

CAUTION

Damage to the differential can occur if it is engaged

while the vehicle is traveling at high speeds or while the

rear wheels are spinning. Slow the vehicle to nearly

stopped before engaging the differential.

1WD / TURF MODE - Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently. This mode of operation is well suited to turf driving or whenever aggressive traction is not required.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.15

GENERAL / BATTERY

INDICATOR LIGHT PANEL

The indicator lights can activate only when the key is in the ON position. See Table 3.

3 - Indicator Light Function

NU-

MBE-

INDICATOR STATUS INDICATES

Key turned ON with Direction Selector in FORWARD or REVERSE. Move direction selector switch to neutral, then back to forward or reverse. NOTE: If accelerator pedal is depressed when key is turned ON, MIL will illuminate until pedal is fully released.

Electrical Malfunction Light on Controller will blink a flash sequence. See Table 4 for description of Blink Codes.

Power delivery terminated to prevent damage from overheating.

Park brake engaged. Move lever forward to fully released position or inspect switch (See Chapter 8). Drive motor will not receive power until park brake light is OFF.

F, N, or R will illuminate depending on position of the Direction Selector Switch.

1 Malfunction

Motor / Controller High

Temperature

3 Park Brake

4 Gear Position - Reverse 5 Gear Position - Neutral 6 Gear Position - Forward

Steady

Flashing

Flashing Reduced performance due to elevated temperature.

Steady

4 - Controller Malfunction Blink Codes

NUMBER OF BLINKS CODE DEFINITION NUMBER OF BLINKS CODE DEFINITION

3 Power fault 12 Communication error 4 Contactor issue 13 Software fault

Data or configuration error

Sequence fault

Motor speed or throttle input error

1.16

See Chapter 8 for diagnostic procedures.

9926595 R01 - 2015-2016 RANGER EV Service Manual

Voltage protection

Controller or motor out of temperature range

GENERAL / BATTERY

WINDSHIELD

The windshield must be removed before transporting the vehicle. See chapter 4 or refer to Owner’s manual for cleaning instructions.

INDEX TO BATTERY INFORMATION

NOTICE

Read all BATTERY SAFETY information outlined in this

• Battery Access

• How to Maximize Battery Service life

• Battery Terminal Torque / Cleaning

• Battery Charging

• Battery Water Level

• Battery Testing

• Battery Removal / Installation

• Battery Storage

chapter first.

TROUBLESHOOTING - VEHICLE OPERATION

Vehicle Will Not Operate

POSSIBLE CAUSE POSSIBLE SOLUTION

Parking Brake Set

Low Battery Voltage Recharge batteries

Battery Connections Dirty Or Loose

Contactor Connections Dirty Or Loose

Electronic Controller Connections Dirty Or Loose

Main Power Connector Disconnected For Service

Required Torque Exceeds Motor Capability

Release parking brake lever

Clean and re-torque connections

Remove, inspect, clean if necessary, and reinstall

Remove seat and storage tray and re-connect main power connector (See Main Power Connector, page 1.20)

In NEUTRAL, cycle key switch OFF and ON, select LOW range, then select direction.

POSSIBLE CAUSE POSSIBLE SOLUTION

Malfunction Indicator Displayed On Indicator Light Panel

Motor / Controller High Temperature Light Illuminated On Indicator Light Panel

Turn key switch OFF. See Indicator Light Panel, page 1.16 for further information.

Turn key switch OFF. Allow motor or controller to cool. See Indicator Light Panel, page 1.16.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.17

GENERAL / BATTERY

BATTERY SAFETY

PROPOSITION 65 WARNING

WARNING

PROPOSITION 65 WARNINGbattery posts, terminals,

and related accessories contain lead and lead

compounds, chemicals known to the state of california

to cause cancer and reproductive harm. wash hands

after handling.battery electrolyte is poisonous. it

contains acid!

serious burns can result from contact with the skin,

eyes, or clothing.ANTIDOTE:EXTERNAL: flush with

water.

INTERNAL: drink large quantities of water or milk.

follow with milk of magnesia, beaten egg, or vegetable

oil. call physician immediately.

EYES: flush with water for 15 minutes and get prompt

medical attention.

batteries produce explosive gases. keep sparks, flame,

cigarettes, etc. away. ventilate when charging or using

in closed space. always shield eyes when working near

batteries.

KEEP OUT OF REACH OF CHILDREN.

BEFORE WORKING IN OR AROUND THE BATTERY COMPARTMENT

Improper contact between battery terminals can result in electrical shorts. Electrical shorts can result in burns. Always use insulated tools in and around the batteries or battery compartment.

Remove all jewelry or metal objects that could come in contact with battery terminals as you work in or around the battery compartment; 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. Keep sparks, flames and cigarettes away. Shield eyes when working near batteries.

• Do not charge batteries in a non-ventilated enclosed area or near flammable materials.

• Do not attempt to charge frozen, leaking, or damaged batteries.

• Connect battery charger to properly rated electrical receptacle with GFCI.

• Do not charge with storage or weather cover on vehicle or with the cab enclosure doors closed, as fire and explosion are possible.

• Refer to your Owner’s manual or contact your local Polaris dealer with any questions.

BATTERY CAUTION

Location: On dashboard above steering column.

• Do not drive through water above the floor of the vehicle. Battery damage will occur.

• Batteries require regular maintenance.

• Failure to maintain batteries in accordance with the owners manual can result in battery damage, vehicle malfunction, fire and/or severe injury or death.

• Do not charge with storage or weather cover on vehicle or with the cab enclosure doors closed, as fire and explosion are possible.

• Max towing speed 25 mph (40 km/h). Drivetrain damage will occur if towed faster than 25 mph (40 km/ h).

• Set parking brake before leaving vehicle.

• Turn key to OFF position and remove when not in use.

• When towing vehicle, place the selector switch in neutral and turn key to “Off” position.

1.18

9926595 R01 - 2015-2016 RANGER EV Service Manual

BATTERY COMPARTMENT WARNING LABEL

Location: Under seat on battery compartment divider.

WARNING:

• SULFURIC ACID in batteries will burn skin, eyes, and clothing. Do not tip batteries. Keep vent caps tight and level. In event of injury, flush with water and call physician immediately.

• HIGH 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 pressure water to wash the battery compartment. Damage to the vented batteries will result.

• Tampering with or unauthorized modification of this unit could result in serious personal injury, will void the warranty, and can result in permanent damage to the vehicle.

• Refer to your Owner’s manual or contact your local Polaris dealer with any questions.

GENERAL / BATTERY

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.19

GENERAL / BATTERY

BATTERY MAINTENANCE

TO MAXIMIZE BATTERY SERVICE LIFE

The following are key items to ensure maximum service life from the batteries.

• Always check and maintain water level monthly. Use only distilled water. Water level should be kept 1/4” (6 mm) below fill well. Do not overfill the battery.

• Always keep batteries fully charged. For maximum life, charge your vehicle at every opportunity. Use only the charger supplied with the vehicle. See freeze point table below.

• Inspect / tighten battery terminal connections monthly or whenever batteries are serviced.

• Tighten terminals to specified torque.

TORQUE

Battery Cable Terminals: 8.0 ft-lbs (11.0 Nm)Battery

Contactor Terminals: 8.0 ft-lbs (11.0 Nm)

• Always keep battery terminals clean and free of corrosion at all times.

• Avoid discharging batteries more than 80%. See , page 1.12and Battery Charging, page 1.21 for more details.

• Make sure new batteries are fully charged before using. New deep cycle batteries need to be cycled several times before reaching full capacity as shown in the Battery Conditioning 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 Polaris accessories and follow instructions provided.

MAIN POWER CONNECTOR

WARNING

Use insulated tools or insulate any tools used within the

battery area to prevent sparks or battery explosion

caused by shorting the battery terminals or wiring.

Remove the batteries or cover the exposed terminals

with an insulating material.

Always disconnect the Main Power Connector (A) before servicing or unplugging any electrical components.

BATTERY CONDITIONING

Number of Charge Cycles

Percent of Full Capacity

BATTERY FREEZE POINTS

Percent Charged

Freeze Point (Approximate)

NEW 15 30 45

80% 90% 95% 100%

100% 50% 0%

-60° F

(-51° C)

0° F

(-18° C)

+25° F (-4° C)

BATTERY ACCESS

1. Lift front edge of seat upward to release pins.

2. Slide seat forward to release hinge bracket tabs.

3. Remove storage trays by pulling upward at the rear

edges.

1.20

BATTERY TERMINAL FASTENER TORQUE

Battery terminal fastener torque is one of the most important maintenance items on the RANGER EV. Always use a torque wrench when tightening battery terminal fasteners.

Loose terminals reduce battery performance and increase the amount of heat present at the battery

9926595 R01 - 2015-2016 RANGER EV Service Manual

GENERAL / BATTERY

terminal. Permanent battery damage can result from lack of terminal maintenance.

Over-tightening of terminal fasteners can cause permanent damage to the battery.

TORQUE

Battery Cable Terminals: 8.0 ft-lbs (11.0 Nm)Battery

Contactor Terminals: 8.0 ft-lbs (11.0 Nm)

BATTERY CONTACTOR FASTENER TORQUE

Torque contactor fasteners using insulated tools as described for the battery terminals above.

Loose or over-tightened contactor terminals can permanently damage the contactor.

3. Disconnect the main electrical connector.

4. Check to be sure battery caps are in place and securely latched in the closed position. SeeBattery Water Level, page 1.22 for vent cap operation.

5. Mix a solution of one tablespoon baking soda per one cup of clean water. Wash battery case with solution to remove acid residue, dirt, and debris.

CAUTION

Do not allow cleaning solution or tap water to enter the

batteries.

6. Rinse thoroughly with a low pressure stream of water until batteries are clean. Allow to 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 battery performance and service life.

BATTERY TERMINAL CLEANING

1. Disconnect the Main Power Connector, page 1.20.

2. Using insulated tools, remove the battery cables for cleaning (SeeBattery Cable Removal, page 1.31).

3. Clean cables and terminals with a stiff wire brush. Wash with soda/water solution (proportions described below).

4. Rinse well with tap water and dry off with clean shop towels.

5. Reinstall the battery cables (SeeBattery Cable Installation, page 1.32) in order shown and torque terminal nuts to 8.0 ft-lbs (10.8 Nm).

6. Coat battery terminals with dielectric grease or petroleum jelly.

BATTERY CLEANING SOLUTIONS

PARTS BAKING SODA PARTS WATER

1 Teaspoon (15cc) 1 Cup (.25 Liter)

4 Tablespoons (60cc) 1 Quart (1 Liter)

1 Cup (250cc) 1 Gallon (4 Liters)

BATTERY CLEANING (EXTERNAL SURFACES)

1. Turn key OFF.

2. Remove seat and storage trays.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

BATTERY CHARGING

WARNING

Do not work in or around the battery compartment or on

any electrical component on the vehicle while charging

the batteries. The chassis of the vehicle is at ground

potential when the battery charging cord is connected

to an AC outlet. This increases the risk of accidental

short circuits to battery terminals or other wires caused

by tools or other objects.

1.21

GENERAL / BATTERY

WARNING

Failure to provide adequate ventilation while charging batteries can result in an explosion. Volatile hydrogen

gas is emitted during charging and may accumulate in

pockets at the ceiling.

• Always ensure a minimum of 5 air changes per hour in the charging area.

• Always remove any storage covers from the vehicle and open cab doors (if equipped) before charging.

• The charging unit produces heat in the charging process. Open the hood to allow better cooling air flow over the charger unit.

The battery charging cord (1) is located at the front of the vehicle through the bumper at the right hand frame rail. Supply voltage from the wall outlet can be 110-120 or 230-240 AC volts. The charger will recognize a power source and adjust automatically.

The charge cord is connected to the charger at a flying lead (2) under the hood.

Battery water level must be above the plates before charging. Inspect battery water level. If the plates are exposed in any cell, add distilled water to bring the level to approximately 1/8² (3mm) above the plates. Cells should be topped off after charging is complete, not before, due to a (normal) increase in water level during the charging cycle. Battery Water Level, page 1.22

DISTILLED WATER ONLY

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 and any door enclosures or zippers.

4. Use an extension cord with a minimum rating of 20 amps.

5. Inspect charging cord and extension cord for cracks, loose connections and frayed wiring. Replace any damaged components promptly.

6. Always connect vehicle charging cord to the extension cord first, then plug in to a 20A GFCI receptacle.

7. Make sure charger uses a dedicated circuit to prevent overloading. If charging multiple vehicles, each vehicle should use a dedicated circuit.

NOTE

When batteries are fully charged, the battery charger

will automatically cycle in and out of trickle charge

mode to maintain the charge. The charge cord can

remain connected indefinitely provided guidelines above are followed and battery water level is inspected monthly. Note that if the battery charger does not reach

the end of its cycle (solid green light on Charge Status

Indicator) the Battery Discharge Indicator may be

inaccurate. Always fully charge the batteries if possible.

1.22

8. Disconnect extension cord from the receptacle first, then disconnect the cord from the vehicle’s charging cord.

9. Inspect and top off battery water when charge cycle is complete.

BATTERY WATER LEVEL

NEVER add acid (electrolyte) to batteries. Use clean distilled water. Tap water contains minerals that are harmful to a battery.

9926595 R01 - 2015-2016 RANGER EV Service Manual

GENERAL / BATTERY

WARNING

Wear eye protection.

1. Turn key OFF, and remove seat and storage trays.

2. Push lever tabs in direction shown to unlock cell covers.

3. Remove cell covers and check each cell. Add distilled water as required to bring level to 1/4 (6mm) below bottom of fill well (A) in each cell.

BATTERY TESTING - OVERVIEW

The use of a battery discharger is important to accurately determine overall battery capacity and to identify weak or faulty cells or batteries in a battery set. Weak or faulty batteries can be replaced individually; it is not necessary to replace all batteries at the same time.

After fully charging the batteries, the discharger unit is connected and a discharge cycle begun. The discharger applies a resistive load to the batteries (56.25 amps for a 48 volt battery set) and automatically keeps track of the time elapsed between start and end of the discharge cycle. A discharge cycle ends when the batteries reach 42 volts, and the discharger shuts off automatically.

When the discharger shuts off, the elapsed time to discharge (42 volts) is then noted from the discharge unit display.

A good battery set will take longer to discharge to the 42 volt level than a battery set with a faulty battery or batteries. If one battery in a set is weak, the other batteries 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 batteries. Therefore, an adjustment table is provided in the test procedure to make it easy to calculate an accurate temperatureadjusted discharge time. Note that temperatures above 80° F require no adjustment, and actual discharge time is taken directly from the display of the discharger.

If the adjusted discharge time is 175 minutes or more, no further testing is required, as all batteries are in good to excellent condition.

If discharge time took less than 175 minutes, the discharger is re-started and the voltage of each battery tested under load and recorded. A weak or faulty battery or batteries will be identified by a noticeably lower voltage reading than other “healthy” batteries in the set.

NOTE: When the discharger is re-started for battery testing, it will load the batteries for a 3-minute period, allowing ample time to test the voltage of each of the eight batteries in the set.

Batteries that fall below the service limit under load must be replaced.

See Battery Testing Procedure to perform the discharge cycle and test each battery.

Read discharger unit instructions for complete information on features, operation, and program settings prior to connecting the unit. Only basic instructions for technicians familiar with the Lester Discharge Unit are provided in this manual.

4. Inspect O-rings on cell caps and replace if damaged.

5. Install caps and slide levers to the locked position.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

Equipment required:

Battery Discharger - Lester 36/48 is recommended. (Available through Bosch Automotive Service Solutions

and Commercially Available).

1.23

GENERAL / BATTERY

Fluke 73 Digital Multimeter (PV-43546) or Fluke 77 Digital Multimeter (PV-43568) or equivalent.

BASIC DISCHARGER INSTRUCTIONS

The following are brief instructions to program the Lester 36/48 Discharger Unit for use on RANGER EV 48 volt battery systems. These instructions are for basic set-up only. Refer to instructions provided with the discharger unit for a complete guide to other features and information. The following applies only to the Lester 36/ 48 model discharger unit which is the recommended discharger for the RANGER EV.

PROGRAMMING INSTRUCTIONS The following list of functions and what they represent is

printed on the front panel of the discharger unit.

Display Functions

Func1

Func2

Func3

Func4

Func5

The two functions that must be verified or reset are:

• Maximum Discharge Time

• Shut-off Voltage

NOTE: Values for the above variables can be changed at any time, even 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 batteries. Do not set the Maximum Timer below 200 minutes.

To INCREASE the maximum timer (if it has been decreased from the 240 minute default value to a value below 200 minutes):

1. Press and release the DISPLAY button until Func1 is

2. Continue to hold in the DISPLAY button while you

3. Press and release the DISPLAY button until you see

Present Battery Voltage

Discharge time in minutes and seconds. (Minutes are displayed on the left and seconds to the right of the decimal point).

Lowest battery voltage reached during discharge

Battery voltage sensed (36 or 48)

Discharge data printout interval. (Number of seconds)

displayed.

press and release the START/STOP button. Every time you press and release START/STOP the maximum timer will increase by 5 minutes. When the setting is at least 200 minutes, release the DISPLAY button.

Changing The Shut-off Voltage

When the discharge unit is powered up it will automatically decide whether to discharge at the 36 or the 48 volt rate. If the discharger senses a voltage above 42 volts, a 48 volt discharge will begin (56.25 amp rate) and the shut-off voltage will default to its lowest programmable value of 42 volts.

The time and voltage minimums specified in this manual are for a 42 volts shut-off. Do not change this setting to a different value.

To check which type of battery set the discharger has sensed:

the value of Func4 before you press the START/ STOP button. The voltage sensed by the discharger should be 48 volts, and the shut-off voltage will be 42 volts.

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GENERAL / BATTERY

BATTERY DISCHARGE AND TESTING PROCEDURE

1. Remove seat and storage trays and open the cargo box.

2. Torque all battery terminal nuts to specification

TORQUE

Battery Terminal Nuts: 8.0 ft-lbs (11.0 Nm)

3. Torque contactor nuts to specification.

TORQUE

Battery Contactor Nuts: 8.0 ft-lbs (11.0 Nm)

4. Fully charge the batteries. The dashboard indicator light should be solid green.

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 inches (46 cm) away from walls or equipment.

6. Connect the RED (+) cable of the discharger unit to the positive terminal of the rear-most battery in the LEFT bank (driver side) with the cable that leads to the top terminal of Contactor).

7. Connect the BLACK (-) cable of the discharger unit to the negative terminal of the rear-most battery in the RIGHT bank (passenger side) with the cable that leads to the negative (-) terminal of the Controller.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.25

GENERAL / BATTERY

TOP VIEW OF DISCHARGER CONNECTION

8. With cables securely connected, the discharger unit will display the voltage of the battery set.

NOTE

Depending on battery condition and state of charge, the

battery voltage may be considerably higher than 48

volts.

WARNING

Do not touch the back or sides of the case during or just

after operation of the discharge unit. A large amount of energy is being dissipated by the unit and the case will

become hot. To reduce the risk of fire, do not use the

discharger near flammable materials or vapors.

Never disconnect the discharge unit from the batteries

while the unit is operating. The large amount of energy

being dissipated 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-off voltage (42 volts) has been reached.

• Maximum time shut-off. This is programmable from 5

to 240 minutes, but should be set to a minimum of 200 minutes.

• Over temperature shut-off.

12. When a discharge cycle has been terminated (the discharger shuts off, and OFF is displayed on the screen) the cooling fan may continue to run for a certain amount of time to cool the internal coils.

13. Check to see which type of shut-off has occurred by pressing and releasing the DISPLAY button.

• If the value in Func2 is the value programmed for

maximum timer, then the terminating method was by maximum time shut-off.

• If the value in Function 3 is the value programmed for

the shut-off voltage, then the terminating method was by shut-off voltage.

• If NEITHER maximum time or shut-off voltage caused

the termination, then it was caused by overtemperature or by someone pressing the START/ STOP button.

• If overheat was the cause, make sure nothing is

obstructing the ventilation area around the discharge unit and that the unit is at least 18 inches from walls or equipment. Be sure cooling fan is operating (see discharger instructions).

14. Press the DISPLAY button to view Func2 (discharge time) and record the time in minutes from the display.

9. Press the START/STOP button to begin a discharge cycle. The cooling fan on the discharge unit should start running.

10. Note the time of day and the ambient (room) temperature for reference at end of discharge cycle.

NOTE: Although the discharger unit monitors total discharge time, it is advisable to note the time of day to compare with the logged data in the discharger unit at the end of the discharge cycle. The temperature is required for calculation of Adjusted Discharge Time later.

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GENERAL / BATTERY

15. Refer to Table 5. If ambient temperature recorded

earlier was below 80° F, multiply discharge time in minutes by the multiplier value in Table 5 that corresponds to that temperature. Record Adjusted Discharge Time. At peak capacity, the discharge cycle time will be about 220 minutes (3 hours and 40 minutes). If the Adjusted Discharge Time is greater than 175 minutes (2 hours and 55 minutes) the battery pack is in good to excellent condition, and no further testing is required. If the adjusted discharge time is LESS than 175 minutes, proceed to the next step - Battery Testing.

TABLE 5:

Time Adjustment For Temperature

TEMP, F

60 15.5 1.15 62 17 1.13 64 18 1.11 66 19 1.10 68 20 1.08 70 21 1.07 72 22 1.05 74 23 1.04 76 24.5 1.03 78 25.5 1.01

80-100

Adjusted Discharge Time = Multiplier x Discharge Minutes

BATTERY VOLTAGE TESTING (LOADED)

16. Have a digital voltmeter ready 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 meter lead to positive and black meter lead to negative terminal post of each individual battery. Record voltage reading in the table below.

19. Replace any battery with a voltage less than 9 volts.

TEMP, C

26.5-

38.0

MULTIPLIER

1.00

ADJUSTED DISCHARGE TIME

20. Press START/STOP to end test. DO NOT disconnect the discharger until cooling fan stops!

BATTERY VOLTAGE UNDER LOAD

LEFT (DRIVER’S SIDE) BATTERIES

Outside battery (Bat 1)

Front battery (Bat 2)

Center battery (Bat 3)

Rear battery (Bat 4)

VOLTAGE MEASUREMENT

BATTERY VOLTAGE UNDER LOAD

RIGHT (PASSENGER SIDE) BATTERIES

Outside battery (Bat 5)

Front battery (Bat 6)

Center battery (Bat 7)

Rear battery (Bat 8)

VOLTAGE MEASUREMENT

BATTERY SPECIFIC GRAVITY TEST

A Specific Gravity test measures the density of battery electrolyte in relation to water (water = 0). Specific gravity is the best indicator of battery condition and can identify a weak cell or cells in an individual battery.

A temperature-compensated digital or a numerically graduated hydrometer is required for this test. Floating ball types cannot be used.

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GENERAL / BATTERY

1. Fully charge the batteries. Be sure terminals and cables are clean and tight before charging.

2. Remove cell caps on the battery to be tested. Do not add distilled water at this time.

3. Insert hydrometer draw tube into the cell to be tested. Fill and drain the hydrometer 2-4 times to mix the fluid for a more accurate reading before pulling a sample and record the reading. Be sure enough fluid is drawn in the sample to fully support the float.

4. Repeat steps above for each cell in the battery (5).

5. Check the state of charge compared to Specific Gravity Table 6 on Specific Gravity / Charge Percentage Table, page 1.35.

BATTERY SPECIFIC GRAVITY

LEFT SIDE BATTERIES (DRIVER SIDE)

CELL #: C1 C2 C3 C4 C5 C6

Outside battery (Bat 1)

Front battery (Bat

Center battery (Bat 3)

Rear battery (Bat

SPECIFIC GRAVITY MEASUREMENT

BATTERY SPECIFIC GRAVITY

RIGHT SIDE BATTERIES (PASSENGER SIDE)

CELL #: C1 C2 C3 C4 C5 C6

Outside battery (Bat 5)

Front battery (Bat

Center battery (Bat 7)

Rear battery (Bat

SPECIFIC GRAVITY MEASUREMENT

1.28

BATTERY REMOVAL AND INSTALLATION

Review all Battery Safety information. See Fig. 1 for proper orientation of battery terminals and

cable routing for reference.

1. Turn key switch OFF.

2. Set parking brake.

3. Remove seat and storage trays.

4. DISCONNECT the battery charging cord from the AC outlet and then from the vehicle charge cord.

9926595 R01 - 2015-2016 RANGER EV Service Manual

GENERAL / BATTERY

5. DISCONNECT the main power connector.

Always disconnect the Main Power Connector (A) before servicing or unplugging any electrical components.

6. FRONT - Remove the lower T27 Torx-head screws

retaining the foot pads.

10. Remove the three T27 Torx-head screws retaining the foot pads.

11. Remove the three T27 Torx-head screws retaining the rear panel.

12. Repeat this procedure to remove the other rear fender.

13. Remove battery cables in order shown on Battery Cable Removal, page 1.31 using an insulated ratchet, extension, and socket.

14. Remove 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 baking soda and water solution then rinse with clear water and dry with clean shop towels.

and lower battery trayewith a

17. Clean battery retainer bolt threads thoroughly and dry with compressed air. Apply anti-seize compound to threaded holes with a small brush.

18. Install battery tub with retainer bolt holes aligned.

19. Install batteries with terminals oriented as shown on Battery Terminal Orientation And Cable Routing, page 1.29.

20. Apply anti seize compound liberally to threads of

7. Remove the two push rivets retaining the front fender and remove the fender from the vehicle.

8. Repeat this procedure to remove the other front fender.

9. REAR - Remove the lowTorx-head screws retaining the foot pads.

retainer bolts.

21. Battery Cable Installation, page 1.32 in order shown.

22. Assemble parts removed for access and re-connect Main Power Connector.

BATTERY TERMINAL ORIENTATION AND CABLE ROUTING

The following illustration depicts general cable orientation and routing. See following pages for cable removal and installation sequence.

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GENERAL / BATTERY

WARNING

Do not work in or around the battery 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 increases the risk of accidental short circuits to battery terminals or wires caused by tools or other objects.

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BATTERY CABLE REMOVAL

GENERAL / BATTERY

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

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GENERAL / BATTERY

BATTERY CABLE INSTALLATION

Battery Retainer Bracket Nut: 8 ft-lbs (11 Nm)Battery Terminal Nut: 8 ft-lbs (11 Nm)

TORQUE

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GENERAL / BATTERY

BATTERY STORAGE

The battery charger can be connected during extended storage periods provided all battery charging precautions and guidelines are followed. Battery Charging, page

1.21.

The storage area must be well ventilated. Always remove any storage covers from the vehicle and open any cab doors (if equipped) and hood before charging.

Clean batteries, torque terminal nuts Battery Contactor Fastener Torque, page 1.21and inspect fluid level Battery Water Level, page 1.22 prior to storage.

If the storage area, conditions, or circumstances do not allow the charger to be plugged in continuously, fully charge the batteries initially, and then recharge once every 2-3 months following all charging guidelines. The main power connector should be disconnected if the unit is stored for longer than a month without the charger being plugged in. The main power connector must be reconnected to charge 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 when installing accessories on the RANGER EV:

• USE ONLY GENUINE RANGER EVAPPROVED ACCESSORIES and follow the instructions provided.

• ALWAYS make sure that all electrical accessories are grounded directly to the negative (-) battery post (of the auxiliary accessory battery) or to the accessory terminal block GROUND as indicated in the instructions.

• NEVER use the chassis or body as a ground connection.

• NEVER connect an auxiliary battery to the factoryinstalled DC-to-DC converter. If more than 10 amps are needed for accessories, always install the polaris approved auxiliary accessory battery kit.

• NEVER connect a 12 volt accessory directly to the drive system batteries. Battery damage will occur. ALWAYS connect any powered accessory to a 12 volt auxiliary power outlet or to the accessory terminal board.

BATTERY CHARGER

The battery charger unit is located under the hood. A display of 10 LEDs on the right side of the charger unit function as outlined below.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

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GENERAL / BATTERY

BATTERY CHARGER LED FUNCTION

BATTERY CHARGER TROUBLESHOOTING

If an error fault occurs, reference the table below.

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SPECIFIC GRAVITY / CHARGE PERCENTAGE TABLE

GENERAL / BATTERY

TABLE 6 - State of Charge

% OF CHARGE

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 11.66 10 1.073 11.51 **TEMPERATURE CORRECTION:

ADD .004 to the reading for every 10 degrees ABOVE 80 F. SUBTRACT .004 to the reading for every 10 degrees BELOW 80 F.

SPECIFIC GRAVITY (CORRECTED TO 80 DEGREES F / 26.7 DEGREES C)**

OPEN CIRCUIT VOLTAGE (APPROX)

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

1.35

GENERAL / BATTERY

REFERENCE

CONVERSION TABLE

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs x 12 = in-lbs

in-lbs x 0.0833

ft-lbs

in-lbs x 0.0115 = kg-m

Nm x 0.7376

kg-m x 7.233

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi)

km x 0.6214 = mile

ounces (oz)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

grams (g)

pounds (lb) x 0.454 = kg

kilogram (kg)

cubic inches (cu in)

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

liters (L) x 1.057 = US quarts

US gallons

liters (L)

PSI x 6.895 = kilopascals (kPa)

kilopascals (kPa)

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x 1.356 = Nm

x 0.03937 = inch

x 1.6 = km

x 28.35

x .03381

x 0.035

x 2.2046 = lbs

x 16.387

x 0.946

x 3.785

x 0.264

x 0.145

= ft-lbs

= mm

= cm

= grams (g)

= fluid ounces

= ounces

= cc

= liters (L)

= US gallons

PSI

= cylinder volume

1.36

9926595 R01 - 2015-2016 RANGER EV Service Manual

STANDARD BOLT TORQUE SPECIFICATION

BOLT SIZE

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

GRADE 2

FT. LBS. (NM)

5 (7) 8 (11) 12 (16)

6 (8) 10 (14) 14 (19)

11 (15) 17 (23) 25 (35)

12 (16) 19 (26) 29 (40)

20 (27) 30 (40) 45 (62)

23 (32) 35 (48) 50 (69)

30 (40) 50 (69) 70 (97)

35 (48) 55 (76) 80 (110)

50 (69) 75 (104) 110 (152)

55 (76) 90 (124) 120 (166)

METRIC BOLT TORQUE SPECIFICATION

GRADE 5

FT. LBS. (NM)

GENERAL / BATTERY

GRADE 8

FT. LBS. (NM)

BOLT

SIZE

M10

M12

M14

M16

M18

4.6 4.8 8.8 / 8.9 10.9 12.9

0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)

0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

26 (35) 33 (45) 63 (85) 97 (130) 111 (150)

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

SAE TAP / DRILL SIZES

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

THREAD

SIZE DRILL SIZE

1/2–20 29/64

GRADE

FT.- LBS. (NM) DRY THREADS

THREAD

SIZE DRILL SIZE

#1–72

#2–56

#2–64

THREAD

SIZE DRILL SIZE

9/16–12 31/64

9/16–18 33/64

5/8–11 17/32

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GENERAL / BATTERY

THREAD

SIZE DRILL SIZE

#3–48 5/64 5/8–18 37/64

#3–56

#4–40 43 3/4–16 11/16

#4–48 42 7/8–9 49/64

#5–40

#5–44

#6–32

#6–40

#8–32

#8–36 29 1 1/4–7 1 7/64

#10–24 24 1 1/4–12 1 11/64

#10–32

#12–24

#12–28

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

7/16–20 25/64

37 1–8

36 1–12

4.6 mm

F 2–12 1 59/64

U 3–4

THREAD

SIZE DRILL SIZE

3/4–10 21/32

7/8–14 13/16

7/8

59/64

1 1/8–7 63/64

1 1/8–12 1 3/64

1 1/2–6 111/32

1 1/2–12 1 27/64

1 3/4–5 1 9/16

1 3/4–12 1 43/64

2–4 1/2 1 25/32

2 1/4–4 1/2 2 1/32

2 3/4

METRIC TAP / DRILL SIZES

TAP SIZE DRILL SIZE DECIMAL

3 x .50

3 x .60

4 x .70

4 x .75

5 x .80 #19 0.166 11/64

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277

8 x 1.25

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

11 x 1.50

12 x 1.50

12 x 1.75 13/32 0.406 13/32

#39

3/32

#30

1/8 0.125 1/8

#20

16/64

17/64

5/16

11/32

3/8

13/32

0.0995

0.0937

0.1285

0.161

0.196

0.234

0.265

0.3125

0.3437

0.375

0.406

NEAREST

FRACTION

3/32

1/8

5/32

13/64

15/64

9/32

17/64

5/16

11/32

3/8

13/32

DECIMAL EQUIVALENTS

FRACTION DECIMAL MM TO INCHES

1/64 0.0156″

1/32

3/64

1/16 0.0625″

5/64

3/32

7/64 0.1094″ 3 mm = 0.1181″

1/8

9/64

5/32 0.1563″ 4 mm = 0.1575″

11/64

3/16

0.0312″ 1 mm = 0.0394″

0.0469″

0.0781″ 2 mm = 0.0787″

0.0938″

0.1250″

0.1406″

0.1719″

0.1875″ 5 mm = 0.1969″

1.38

FRACTION DECIMAL MM TO INCHES

13/64 0.2031″

7/32

15/64

1/4 0.25″

17/64

9/32

19/64 0.2969″

5/16

21/64

11/32 0.3438″ 9 mm = 0.3543″

23/64

3/8

9926595 R01 - 2015-2016 RANGER EV Service Manual

0.2188″

0.2344″ 6 mm = 0.2362″

0.2656″ 7 mm = 0.2756″

0.2813″

0.3125″ 8 mm = 0.3150″

0.3281″

0.3594″

0.375″

GENERAL / BATTERY

FRACTION DECIMAL MM TO INCHES

25/64

13/32 0.4063″

27/64

7/16

29/64 0.4531″

15/32

31/64

1/2

0.3906″ 10 mm = 0.3937″

0.4219″ 11 mm = 0.4331″

0.4375″

0.4688″ 12 mm = 0.4724″

0.4844″

0.500″ 13 mm = 0.5118″

FRACTION DECIMAL MM TO INCHES

33/64

17/32 0.5313″

35/64 0.5469″ 14 mm = 0.5512″

9/16

37/64

19/32 0.5938″

39/64

5/8

41/64 0.6406″

21/32

43/64

11/16

45/64 0.7031″ 18 mm = 0.7087″

23/32

47/64

3/4 0.750″

49/64

25/32

51/64 0.7969″

13/16

53/64

27/32

55/64 0.8594″ 22 mm = 0.8661″

7/8

57/64

29/32 0.9063″

59/64

15/16

61/64 0.9531″

31/32

63/64

1 1.000″

0.5156″

0.5625″

0.5781″ 15 mm = 0.5906″

0.6094″

0.625″ 16 mm = 0.6299″

0.6563″ 17 mm = 0.6693″

0.6719″

0.6875″

0.7188″

0.7344″ 19 mm = 0.7480″

0.7656″

0.7813″ 20 mm = 0.7874″

0.8125″ 21 mm = 0.8268″

0.8281″

0.8438″

0.875″

0.8906″ 23 mm = 0.9055″

0.9219″

0.9375″ 24 mm = 0.9449″

0.9688″ 25 mm = 0.9843″

0.9844″

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GENERAL / BATTERY

NOTES

1.40

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MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

MAINTENANCE CHART KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

PERIODIC MAINTENANCE CHART .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

GENERAL VEHICLE INSPECTION AND MAINTENANCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

PRE-RIDE / DAILY INSPECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

FLUID MAINTENANCE REFERENCES... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

COMPONENT QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

FINAL DRIVE / WHEEL AND TIRE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

WHEEL AND HUB TORQUE 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 GEARCASE) LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

TIE ROD END / STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

TOE ADJUSTMENT ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

SUSPENSION PIVOT POINT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

STABILIZER BAR PIVOT LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

REAR SHOCK SPRING PRE-LOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

BRAKE SYSTEM ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

BRAKE PAD / DISC INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

PARKING BRAKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

2.1

MAINTENANCE

PERIODIC MAINTENANCE CHART

PERIODIC MAINTENANCE OVERVIEW

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts.

Record maintenance and service in the Maintenance Log of the Owner’s manual. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of

approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style use

• Prolonged low speed, heavy load operation

MAINTENANCE CHART KEY

The following symbols denote potential items to be 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 = Emission Control System Service (California).

NOTE

Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

PERIODIC MAINTENANCE CHART

MAINTENANCE INTERVAL

ITEM

HOURS CALENDAR PAGE

■ Steering -

Front Suspension -

▶

Rear Suspension -

▶

Tires

▶

Brake Fluid Level

▶

Brake Pedal Travel

(WHICHEVER COMES FIRST)

Pre-Ride

Steering, page

2.12

Suspension

Inspection,

page 2.15

Suspension

Inspection,

page 2.15

Tire Inspection,

page 2.7

Brake Fluid

Inspection,

page 2.16

Brake Hose

and Fitting

Inspection,

page 2.16

REMARKS

Inspect operation; Make adjustments as needed.

2.2

9926595 R01 - 2015-2016 RANGER EV Service Manual

MAINTENANCE INTERVAL

ITEM

Brake Systems Wheels / Fasteners

Frame Fasteners

Head Lamp / Tail Lamp -

▶

Brake Pad Wear 10 H

■ Parking Brake Cable

▶

Adjustment

■ Battery Terminals (Clean) Battery Terminals (Torque) Battery Fluid Level

▶

Front Gearcase Lubricant 25 H Transaxle (Rear Gearcase)

▶

Lubricant

▶

General Lubrication 50 H 3 Months

■ Steering

Front Suspension

▶

Rear Suspension

▶

Wiring

▶

■ Front Wheel Bearings

■

Brake Fluid 200 H 24 Months

■ Toe Adjustment -

Headlight Aim - Adjust as needed

▶ Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

■ Have an authorized Polaris dealer perform these services.

(WHICHEVER COMES FIRST)

HOURS CALENDAR PAGE

Pre-Ride

25 H

25 H 25 H 25 H

25 H

50 H 6 Months

100 H 12 Months

Pre-Ride Pre-Ride

Daily

Monthly

- - Inspect; adjust after first 25 hours

Monthly Monthly Monthly - Inspect and add distilled water as needed Monthly - Inspect level; change yearly

Monthly - Inspect level; change yearly

- Re-torque terminal nuts

- Lubricate fittings, pivots, cable ends

- Inspect; Lubricate

- Inspect; replace as needed

- Change every two years (DOT 4)

Check operation; apply dielectric grease to connector if replacing

Inspect periodically

Clean terminals and cable ends

Check fastener torque; Check that cotter pins are in place on castle nuts. Check and lubricate tie rod ends. Check fastener torque; Check that cotter pins are in place on castle nuts. Lubricate stabilizer bar pivots and A-arm joints.

Inspect for wear, routing, security; apply dielectric grease to non-sealed connectors subjected to water, mud, etc.

Inspect periodically; adjust when parts are replaced

MAINTENANCE

REMARKS

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

2.3

MAINTENANCE

SERVICE PRODUCTS AND LUBRICANTS

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS

PART NO. DESCRIPTION

Front Gearcase Lubricant

2877922

2877923

2876160

2872276

2870465

2871322

2871423

2871515

2871551 2871312 Grease Gun Kit 2871329

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2872189

2871557

Demand Drive(Quart)

Demand Drive (2.5 Gallon)

Transaxle (Rear Gearcase) Lubricant

Angle Drive Fluid (Quart) (12 count)

Angle Drive Fluid (2.5 Gallon) (2 count)

Oil Pump for 1 Gallon Jug

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Premium U-Joint Lube (3 oz.) (24 Count)

Premium U-Joint Lube (14 oz.) (10 Count)

Dielectric Grease (Nyogel)

Loctite® Threadlock 242 (6 ml.) (12 Count)

DOT 4 Brake Fluid (12 Count)

Crankcase Sealant, 3-Bond 1215 (5oz.)

NOTE

The number count indicated by each part number in the

table above indicates the number of units that are

shipped with each order.

2.4

9926595 R01 - 2015-2016 RANGER EV Service Manual

GENERAL VEHICLE INSPECTION AND MAINTENANCE

PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check condition and pressure

• Battery charge level - note charge level and plan accordingly

• All brakes - check operation and adjustment (includes parking brake)

• Key switch - check for proper function

• Accelerator pedal - with key 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 sure axle nuts are secured by cotter pins

• Steering - check for free operation noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Check all suspension components for wear or damage.

FRAME, NUTS, BOLTS, AND FASTENERS

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

MAINTENANCE

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

2.5

MAINTENANCE

FLUID MAINTENANCE REFERENCES

COMPONENT QUICK REFERENCE

ITEM

Front Gearcase Demand Drive

Transaxle

LUBE REC. METHOD

Angle Drive Fluid

Add lubricant to bottom of fill

hole threads

Add lubricant to bottom of fill

hole threads

CAPACITY (DRY)

6.1 oz. (180 ml)

20.3 oz. (600 ml)

2.6

9926595 R01 - 2015-2016 RANGER EV Service Manual

FINAL DRIVE / WHEEL AND TIRE

MAINTENANCE

WHEEL AND HUB TORQUE TABLE

ITEM SPECIFICATION

Steel Wheels Lug Nuts

Front Hub Nut

Rear Hub Nut

35 ft-lb (47 Nm)

70 ft-lb (95 Nm)

110 ft-lb (150 Nm)

WHEEL REMOVAL

1. Place vehicle on a level surface.

2. Turn key off and set parking brake.

3. Block front and rear edge of tires on the side opposite the wheels to be removed.

4. Loosen wheel nuts slightly.

5. Elevate side of vehicle by placing a jack or lift under the frame. Place blocks under frame for additional safety.

3. Remove safety supports and lower the jack.

4. Tighten wheel nuts (or lug nuts) to proper torque listed in the Wheel and Hub torque table on Wheel and Hub Torque Table, page 2.7.

CAUTION

If wheels are improperly installed it could affect vehicle

handling and tire wear. On vehicles with tapered lug

nuts, be sure tapered end of nut faces the wheel.

TIRE PRESSURE

WARNING

Maintain proper tire pressure. Refer to the warning tire

pressure decal applied to the vehicle.

TIRE PRESSURE INSPECTION (COLD)

Front Rear

20 psi (138 kPa) 20 psi (138 kPa)

TIRE INSPECTION

• Improper tire inflation may affect vehicle

maneuverability.

• When replacing a tire always use original equipment

size and type.

• The use of non-standard size or type tires may affect

vehicle handling.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

WARNING

Care should be taken to be sure the vehicle is securely

supported and blocked to prevent movement when

elevated. Failure to follow the safety precautions could

6. Remove wheel nuts and washers (or lug nuts) and remove wheel.

result in serious injury or death.

WHEEL INSTALLATION

1. Place wheel on hub. 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 is centered and firmly supported.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

2.7

MAINTENANCE

WARNING

Operating a RANGER EV with worn tires will increase

the possibility of the vehicle skidding easily with

Always replace tires when the tread depth measures 1/

possible loss of control.

Worn tires can cause an accident.

8" (.3 cm) or less.

CV SHAFT BOOT INSPECTION

Inspect inner and outer CV joint boots on front and rear drive axles for damage, tears, wear, or leaking grease. Replace if worn, damaged, or leaking. See Chapter 7 for boot replacement.

2.8

9926595 R01 - 2015-2016 RANGER EV Service Manual

GEARCASE MAINTENANCE

MAINTENANCE

FRONT GEARCASE LUBRICATION

Level Inspection

1. Position vehicle on a level surface.

2. Inspect vent hose routing and check it for kinks or obstructions. The end of the hose should be under the frame rail and point downward.

3. Remove fill plug (A). Fluid level should be even with bottom of threads.

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). Drain fluid completely.

4. If fluid level is not even with the bottom threads, add Polaris Demand Drive Plus as needed. Do not overfill.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

9. Clean drain plug magnetic surface.

10. Install drain plug with a new O-ring and torque to specification.

11. Add recommended amount of fluid through fill hole until level is even with bottom of fill hole threads (see Level Inspection).

FLUID CAPACITY

Recommended Front Gearcase Fluid:

Demand Drive

(PN 2877922) (Quart)

6.1 oz. (180 ml)

12. Install fill plug with a new O-ring and torque to specification.

TORQUE

Drain Plug:

10 ft-lb (14 Nm)

13. Check for leaks. Dispose of used fluid properly.

2.9

MAINTENANCE

TRANSAXLE (REAR GEARCASE) LUBRICANT

Level Inspection

1. Position vehicle on a level surface.

2. Inspect vent hose routing and check it for kinks or obstructions. The end of the hose 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 needed. Do not overfill.

2.10

5. Reinstall fill plug and torque to specification.

TORQUE

Fill Plug / Drain Plug:

14 ft-lb (19 Nm)

Transaxle Lubricant Change

1. Place a drain pan under transaxle drain plug area.

2. Place towels beneath fill plug and remove fill plug.

9926595 R01 - 2015-2016 RANGER EV Service Manual

3. Remove drain plug (C). Drain lubricant completely.

4. Clean drain plug magnetic surface. Reinstall drain plug with a new O-ring and torque to specification.

TORQUE

Drain Plug & Fill Plug:

14 ft-lb (19 Nm)

MAINTENANCE

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 overfill.

FLUID CAPACITY

Recommended Transaxle Lubricant:

Angle Drive Fluid

(PN 2876160 - Quart)

Capacity:

20.3 oz. (600 ml)

6. Reinstall fill plug with a new O-ring and torque to specification above.

7. Check for leaks. Dispose of used lubricant properly.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

2.11

MAINTENANCE

STEERING

Check steering components for loose fasteners, worn tie rod ends, and damage. Check to be sure cotter pins are in place on lower ball joints and steering tie rod ends.

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE

Whenever steering components are replaced, check

front end alignment.

WARNING

Due to the critical nature of the procedures outlined in

this section, Polaris recommends steering component

repair and adjustment be performed by 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 rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• If abnormal movement is detected, inspect hub and wheel assembly to determine cause (loose wheel nuts or loose front hub nut).

• Replace worn steering parts. Steering should move freely through entire range of travel without binding.

• Elevate front end so front wheels are off the ground. Check for any movement in front hub/wheel assembly by grasping tire firmly at top and bottom first, and then at front and rear. Try to move wheel and hub by pushing inward and pulling outward.

2.12

WHEEL TOE ALIGNMENT INSPECTION

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure steering wheel in this position.

9926595 R01 - 2015-2016 RANGER EV Service Manual

MAINTENANCE

2. Place a chalk mark on center line of front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

NOTE

It is important the height of both marks be equally

positioned to get an accurate measurement.

3. Measure the distance between the marks and record the measurement. Call this measurement “A”.

4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. 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).

WARNING

Do not attempt to compensate for worn or damaged steering parts by adjusting the tie rod ends. The threads of the tie rod must engage the tie rod end by a minimum

of 3/4 inch (19 mm). If either tie rod is bent or damaged,

replace the steering gear box.

1. Turn steering wheel to straight ahead position.

2. Measure distance from centerline of vehicle to centerline of each tire. Adjust tie rod end on side with greatest amount of toe-out or toe-in.

3. Hold tie rod end (C) securely and loosen jam nut (D). DO NOT allow rod end to rotate to full stop or damage could occur to the rod end.

MEASUREMENT

Wheel Toe-Out:

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

TOE ADJUSTMENT

If toe alignment is incorrect, adjust as follows.

9926595 R01 - 2015-2016 RANGER EV Service Manual © Copyright Polaris Industries Inc.

4. Remove cotter pin (E) from tie rod end bolt.

2.13

MAINTENANCE

5. Remove tie rod end nut and bolt with washers (F).

6. Hold tie rod at (G) and rotate rod end 1/2 turn at a time to shorten or lengthen the overall tie rod length. Shorten the tie rod to increase the amount of toe-out. Lengthen the rod to decrease the amount of toe-out).

7. Temporarily install the tie rod on strut with 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 steps as required until proper alignment is achieved, then assemble the tie rod to strut with washers, bolt and nut.

10. Torque nut to specification and install a NEW cotter pin.

11. HOLD tie rod end parallel with mounting surface. Torque jam nut to specification. Check to be sure rod end rotates freely.

TORQUE

Tie Rod Jam Nut:

14 ft-lb (19 Nm)

2.14

TORQUE

Tie Rod End Nut Torque:

40 ft-lb (54 Nm)

9926595 R01 - 2015-2016 RANGER EV Service Manual

SUSPENSION

MAINTENANCE

SUSPENSION INSPECTION

1. Compress and release front and rear suspension. Damping should be smooth and consistent throughout travel range.

2. Inspect each rear shock and front strut for oil leakage.

3. Check all suspension components for wear or damage.

4. Check all fasteners to be sure they are tight and all cotter pins are installed where applicable. If any fasteners are loose, refer to Chapter 4, Body, Steering 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 chart for service intervals or grease as needed.

STABILIZER BAR PIVOT LUBRICATION

Grease stabilizer bar pivots (A) with a grease gun until old grease is purged from the joint and new grease appears. Inspect link isolators (B) for cracks.

REAR SHOCK SPRING PRE-LOAD ADJUSTMENT

The rear shock absorber springs are pre-load adjustable. Use Spanner Wrench to rotate adjuster cam to increase or decrease spring pre-load. Always adjust both left and right sides equally.

Shock Spanner Wrench:

2871095

2.15

MAINTENANCE

BRAKE SYSTEM

BRAKE FLUID INSPECTION

1. Position the vehicle on a level surface.

2. View the brake fluid level in the reservoir. The level should be between the MAX and MIN level lines.

3. Clean the area around the fill cap. Remove cap and add DOT 4 brake fluid if necessary.

4. Install reservoir cap.

5. Apply brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

2. Inspect brake pad friction material thickness. Pads should be changed when friction material is worn to .040” (1 mm).

3. Visually inspect surface condition of brake discs. If wear is evident, measure thickness of disc at 4 locations 90 degrees apart (A), and in 2 spots within the brake pad contact area (B).

4. Disc(s) should be replaced if severely grooved, worn, warped, or if disc thickness at any measurement point is less than specified service limit (see Chapter 9 for specifications).

BRAKE HOSE AND FITTING INSPECTION

Check brake system hoses and fittings for 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 torque values and repair procedures.

BRAKE PAD / DISC INSPECTION

1. Check brake pads for wear, damage, or looseness.

2.16

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MAINTENANCE

PARKING BRAKE ADJUSTMENT

When the park brake is set and the park brake indicator is illuminated, motor speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.

NOTE

This feature will not operate properly if the park brake

connector or switch (under the hood) malfunctions or

becomes disconnected, or if the switch has moved.

Refer to Chapter 8 (Electrical) for diagnostics.

1. Pull back on the park brake lever.

3. If adjustment is required, return lever to the forward position to release the brake. Adjust cable position in the mounting bracket described in Steps 4-6.

4. Using two open-end wrenches, loosen outer jam nut

and inner jam nute.

5. Adjust cable outward to tighten brake.

6. Tighten both jam nuts securely against bracket.

on the transaxle as

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 lever travel, the vehicle should not roll while parked.

7. Inspect park brake adjustment as described in Steps 1 and 2.

8. Repeat Step 4-6 until the proper adjustment is obtained for the parking brake.

2.17

MAINTENANCE

PARKING BRAKE PAD INSPECTION

Measure the thickness of the rear caliper parking brake pads as described below. Refer to Brakes Chapter for pad replacement procedure.

2.18

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ELECTRICAL SYSTEM

BATTERY MAINTENANCE

Refer to Chapter 1 GENERAL / BATTERY for all battery information.

MAINTENANCE

BATTERY INFORMATION

Refer to Index to Battery Information, page 1.17

2.19

MAINTENANCE

NOTES

2.20

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DRIVE MOTOR

CHAPTER 3

DRIVE MOTOR

SPECIAL TOOLS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

DRIVE MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

DRIVE MOTOR INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

DRIVE MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

ROTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

DRIVE MOTOR ASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

DRIVE MOTOR BENCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

3.1

DRIVE MOTOR

SPECIAL TOOLS

PART NUMBER DESCRIPTION

Commercially Available

Bosch Automotive Service Solutions: Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800345-2233 or on-line at http://polaris. service-solutions.

com/

Insulated Drive Ratchet

Insulated Extension 3 inch

Insulated Extension 6 inch

Insulated Socket 1/2 inch

Insulated Wrench Set

3.2

9926595 R01 - 2015-2016 RANGER EV Service Manual

SAFETY INFORMATION

BATTERY HANDLING WARNINGS

Before you begin work on the vehicle, review all battery safety and handling precautions in chapter 1.

WARNING

Use insulated tools or insulate any tools used 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 connector must be disconnected

before working on the electrical system or drive motor.

WARNING

Make sure the vehicle is properly immobilized before

beginning any maintenance or repair.

Always block the chassis securely and set the parking

brake before working under the vehicle.

DRIVE MOTOR

3.3

DRIVE MOTOR

SPECIFICATIONS

TORQUE SPECIFICATIONS

ITEM

Terminal Block Nuts (3 motor cables to motor)

Terminal Cover Screw

Motor Case Bolts

Motor Mounting Bolts (M6) 8 ft-lb (11 Nm)

Motor Mounting Bolt (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)

TORQUE

11 ft-lb (15 Nm)

31 in-lb (4 Nm)

8 ft-lb (11 Nm)

MOTOR SERVICE DATA

DRIVE MOTOR COMPONENT SPECIFICATION

STATOR

TEMPERATURE SENSOR (Thermistor)

Winding Resistance

Winding Resistance to Motor Case Infinite (O.L.)

Sensor Resistance (Black Wire to White Wire in the white harness)

Sensor Resistance (Black Wire or White Wire to Motor Case

580 W (.580 K +/- 20% @ 68° F (20° C)

0.1-0.2 Ω +/- 20%

Infinite (O.L.)

3.4

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DRIVE MOTOR

DRIVE MOTOR ASSEMBLY VIEW

DRIVE MOTOR

Drive End Ring

Rotor

Stator,

Terminal Base

Group Terminal Board

11 ft-lb (15 Nm)

Group Plug,

Temperature Sensor

Harness

Gear Wheel Sensor

Seal, Fitting

Seal, Plate

Cover Plate

Screw, Cover (QTY.4)

31 in-lb (4 Nm)

Connector, Speed

Sensor

Speed Sensor

Screw, Speed Sensor

62 in-lb (7 Nm)

Circlip

Ball Bearing

O-Ring

Circlip

Bolt, Drive Motor

8 ft-lb (11 Nm)

Threaded Plug

3.5

DRIVE MOTOR

DRIVE MOTOR SERVICE

DRIVE MOTOR REMOVAL

1. Turn key switch OFF.

2. Set parking brake.

3. Set direction selector switch to NEUTRAL.

4. Remove seat, storage trays, and cargo box Seat / Storage Trays, page .

5. Disconnect main power connector. See: Main Power 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) so they can be properly connected upon installation. If cables tags are missing, mark cables location before removal.

8. Push tabwto separate wire harness connector at drive motor.

9. Remove the three upper motor mount boltse.

7. Remove three cables from drive motor terminal block.

3.6

10. Remove lower motor mount boltr.

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DRIVE MOTOR

11. Remove support bracket lower fastenerst, upper fastenersyand bracket.

12. Protect cosmetic surfaces with suitable towel. Lift back of motor slightly with a pry bar then alternately push down until motor is loose.

13. Slide motor off transaxle shaft splines and out the back. For drive motor disassembly refer toDrive Motor Disassembly, page .

CAUTION

The drive motor weighs over 80 pounds (36.3 kg). Have an assistant help remove the motor or use a suitable lift.

3. Orient motor as shown so the terminal cover parallel to the ground and install the lower motor mount boltefinger tight.

4. Loosely install the three upper motor mount boltsr.

DRIVE MOTOR INSTALLATION

1. Apply a light film of anti-seize compound to transaxle shaft splines

2. With the aid of an assistant or a mechanical lift or hoist, lift the motor into position near the transaxle shaft. Align splines of transaxle shaft with motor shaft and slide motor toward transaxle housing until seated.

3.7

DRIVE MOTOR

5. Loosely install rear support bracket with upper and lower fastenerstandy. Do not tighten support bracket bolts at this time.

6. Tighten motor mount bolts evenly by hand until motor is drawn tight against transaxle.

7. Torque lower motor mount bolt to specification first, then torque the upper motor mount bolts.

TORQUE

Motor Mount Bolt (M8):

17 ft-lb (23 Nm)

12. Connect cable marked “W” and install washer and nut.

13. Hold cable centered in terminal cover and torque each nut to specification.

TORQUE

Motor Cable Nuts:

11 ft-lb (15 Nm)

14. Connect sensor wire harness to drive motor careful to align connector halves and avoid pin damage.

. Be

TORQUE

Motor Mount Bolts (M6):

8 ft-lb (11 Nm)

8. Tighten three upper (M6) rear support bracket screws evenly by hand until all are hand tight, then torque all three bolts to specification.

TORQUE

Rear Support Bracket - Upper Bolts:

8 ft-lb (11 Nm)

9. Tighten three lower (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 (marked “U”) to terminal block and install washer and nut.

11. Connect cable marked “V” and install washer and nut.

3.8

15. Check all wiring and fasteners for proper assembly.

16. Re-connect main power connector.

17. Install storage trays, seat, and cargo box.

18. Test drive vehicle.

DRIVE MOTOR DISASSEMBLY

Also refer to Drive Motor Assembly View, page 3.5.

1. Mark casing and drive end housing for reference during reassembly.

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DRIVE MOTOR

2. Remove speed sensor screwqand speed sensor.

3. Remove the three nutswsecuring terminal leads to the terminal block.

4. Remove the cover plate screwse, cover plate and gasket.

5. Lift terminal leads and remove guide blockr.

6. Remove motor case bolts blocky.

and remove terminal

3.9

DRIVE MOTOR

7. Tap housing lightly to separate the rear housing / rotor assembly from the stator assembly.

8. Carefully pull wires through cover and slide rotor and housing out of stator.

2. Remove circlip

3. Support housing. Select a suitable arbor which is slightly smaller than the rotor shaft. Carefully press rotor from bearing. Be prepared to catch rotor.

from end of rotor.

9. For bench tests see Drive Motor Bench Tests, page

3.13.

ROTOR REMOVAL

1. Remove threaded capqfrom housing.

3.10

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DRIVE MOTOR

4. Inspect rotor for damage.

BEARING REPLACEMENT

BEARING MUST BE REPLACED IF REMOVED

1. Remove internal snap-ringq.

2. Support cover as shown. Tap or press bearing from cover.

3. Clean bearing bore and retaining ring groove. Remove any burrs.

4. Install a new O-ring and lubricate O-ring 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° C). Do not exceed 150° F or bearing may be damaged.

6. Press bearing past O-ring and into bore by hand (if possible).

7. If bearing cannot be installed by hand, select a suitable arbor that will press on the outer race of the bearing. The bearing should install with minimal press effort.

8. Install the internal snap-ring. Be sure it is fully seated in the groove.

3.11

DRIVE MOTOR

DRIVE MOTOR ASSEMBLY

1. Press rotor into bearing until seated and circlip and threaded capwcan be installed.

2. Slide the rotor into the motor housing feeding the three terminal leads motor end capr.

through the access port in the

4. Install drive end housing with mounting boss positioned as shown.

5. Install motor case bolts specification.

and torque to

3. With the motor end cap seated, slide the terminal lead guidetinto position, fit the terminal block onto the motor.

3.12

TORQUE

Motor Case Bolts:

8 ft-lb (11 Nm)

6. Install motor end cap access cover and gasket. Torque to specification.

TORQUE

Access Cover Screws:

31 in-lb (4 Nm)

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DRIVE MOTOR

7. Install nuts on wire terminal block to secure leads to the block and torque to specification.

TORQUE

Terminal Block Nuts:

11 ft-lb (15 Nm)

8. Install drive motor (Drive Motor Installation, page

3.7).

DRIVE MOTOR BENCH TESTS

The main components of the drive motor can be tested with an Ohmmeter. In addition to the bench tests outlined here, look for physical damage, corrosion, and discoloration 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 stator (white harness). Compare reading to specification.

2. Connect one meter lead to either of the two wires and the other to the motor case. There should be no continuity to the case (Infinite or O.L.).

3. Connect one lead of an Ohmmeter to each stator lead and the other to the stator case. There should be no continuity to the case on any of the three leads.

STATOR WINDINGS TO GROUND

Ω (OL)

TEMPERATURE SENSOR RESISTANCE

580 Ω ± 10% @ 68° F (20° C)

SENSOR WIRE(S) TO MOTOR CASE:

Ω (OL)

3.13

DRIVE MOTOR

4. Connect one lead of an Ohmmeter to one stator lead and the other Ohmmeter lead to each of the other two. There should be good continuity (less than .5 Ohms) between 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 displayed on meter. Subtract this value from stator winding resistance measurement.

OHMMETER

LEAD 1

OHMMETER

LEAD 2

RESISTANCE

(+/- 20%)

Stator Phase 1 Stator Phase 2 0.1 - 0.2 Ω

Stator Phase 1 Stator Phase 3 0.1 - 0.2 Ω

Stator Phase 2 Stator Phase 3 0.1 - 0.2 Ω

3.14

9926595 R01 - 2015-2016 RANGER EV Service Manual

BODY / STEERING / SUSPENSION

CHAPTER 4

BODY / STEERING / SUSPENSION

GENERAL SPECIFICATIONS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

RIGHT SIDE VIEW .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

CHASSIS / MAIN FRAME / BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

DASH SWITCHES AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

DASH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

HOOD / FRONT FASCIA / MIRRORS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

SEAT MOUNTING / SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

FLOOR / REAR FENDER / SIDE PANEL / CORNER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

CARGO BOX / TAILGATE / CARGO BOX 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 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

HOOD / DASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

FLOOR... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15

STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16

FRONT A-ARM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16

BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16

FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18

FRONT STRUT EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19

REAR A-ARM REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20

REAR A-ARM INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21

REAR A-ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22

REAR STABILIZER BAR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22

EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23

SHOCK REMOVAL / INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23

SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24

SHOCKS EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24

DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24

DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25

4.1

BODY / STEERING / SUSPENSION

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

NOTE

Refer to exploded views throughout this chapter for

torque specifications, component identification, and

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION

2870872

2870623 2876389 Multi-Function Pliers 2870871 Strut and Ball Joint Tool Set 2871573

2871574

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/ Included in the tool kit, the multifunction pliers are designed to remove the plastic push rivets used to fasten body components.

location of components.

Shock Spanner Wrench

Shock Spring Compressor Tool

Strut Spring Compressor (LH)

Strut Spring Compressor (RH)

4.2

9926595 R01 - 2015-2016 RANGER EV Service Manual

COMPONENT LOCATIONS

BODY / STEERING / SUSPENSION

RIGHT SIDE VIEW

FRONT VIEW

REAR VIEW

4.3

BODY / STEERING / SUSPENSION

EXPLODED VIEWS

CHASSIS / MAIN FRAME / BUMPER

NUMBER PART DESCRIPTION

1 Battery Tray

2 Cab Support

3 Main Frame

6 Seat Base, Cab Support

10 Bolt - M8 x 1.25 x 20 (QTY.32) 8 ft-lbs (10.8 Nm)

Floor Support, Left

Floor Support, Right

Skid Plate

Screw - M8 x 1.25 x 55 (QTY.4) 22 ft-lbs (29.8 Nm)

Screw - 1/4 - 20 x 5/8 (QTY.13) 8 ft-lbs (10.8 Nm)

Nut - M8 x 1.25 (QTY.4) 22 ft-lbs (29.8 Nm)

Washer, Skid Plate (QTY.13)

TORQUE (IF APPLICABLE)

4.4

9926595 R01 - 2015-2016 RANGER EV Service Manual

DASH SWITCHES AND INSTRUMENTS

BODY / STEERING / SUSPENSION

NUMBER PART DESCRIPTION

7 AWD Switch

8 Drive Mode Switch

Hour Meter / Battery Discharge Indicator

Indicator Light Panel

Key Switch (OFF / ON)

Headlight Switch

Drive Direction Selector

Charge Status Indicator

12V Accessory Socket

4.5

BODY / STEERING / SUSPENSION

DASH MOUNTING

NUMBER PART DESCRIPTION

Screw - M6 x 1.0 x 25 (QTY.2) 8 ft-lbs (10.8 Nm)

Rivet (QTY.11)

TORQUE

4.6

9926595 R01 - 2015-2016 RANGER EV Service Manual

HOOD / FRONT FASCIA / MIRRORS

BODY / STEERING / SUSPENSION

NUMBER PART DESCRIPTION

Hood

Front Fascia

Dash Panel

Glove Box Lid

Hood Strap

Hood Hinge Pins

Push Rivet

Hood Latch

4.7

BODY / STEERING / SUSPENSION

SEAT MOUNTING / SEAT BELTS

NUMBER PART DESCRIPTION

Shoulder Anchor, Seat Belt

Buckle, Seat Belt Driver

Buckle, Seat Belt Passenger -

Seat, Back

Seat, Base

Washer - Seat Belt, Rubber

Screw, Seat Back (QTY.8) 24 in-lb (3 Nm)

Bolt, Seat Belt Buckle - M12 x 1.75 (QTY.4) -

Nut, Seat Belt Buckle (QTY.4) 40 ft-lb (52 Nm)

TORQUE (IF APPLICABLE)

4.8

9926595 R01 - 2015-2016 RANGER EV Service Manual

FLOOR / REAR FENDER / SIDE PANEL / CORNER PANEL

BODY / STEERING / SUSPENSION

NUMBER PART DESCRIPTION

Front Floor

Main Floor

Floor Cover

Cup Holder -

Push Rivet

Screw:

TORQUE (IF APPLICABLE)

5 ft-lb (7 Nm)

4.9

BODY / STEERING / SUSPENSION

CARGO BOX / TAILGATE / CARGO BOX SUPPORT

NUMBER PART DESCRIPTION

Cargo Box -

Box Frame

Tailgate Inner Panel -

Tailgate Outer Panel -

Box Tilt Shock

Box Tilt Latch

Heat Shield

Tailgate Tube -

Tailgate Mount Bracket -

Bushing -

Tailgate Latch -

Screw

TORQUE (IF APPLICABLE)

8 ft-lb (11 Nm)

5 ft-lb (7 Nm)

4.10

9926595 R01 - 2015-2016 RANGER EV Service Manual

CAB FRAME EXPLODED VIEW

BODY / STEERING / SUSPENSION

NUMBER PART DESCRIPTION

Cab Frame, LH

Cab Frame, RH

Cab Frame, Lower / Rear

Cab Support, Rear -

Windshield Mount, Upper -

Grab Handle

Bolt - M8 x 1.25 x 20 (QTY.8) 18 ft-lb (24 Nm)

Bolt - M10 x 1.5 x 20 (QTY.6) 36 ft-lb (49 Nm)

Bolt - M8 x 1.25 x 20 (QTY.2) 18 ft-lb (24 Nm)

Screw - M10 x 1.25 x 30 (QTY.4) 36 ft-lb (49 Nm)

Screw - M6 x 1.0 x 25 (QTY.2) 8 ft-lb (11 Nm)

Screw - M10 x 1.5 x 75 (QTY.4) 36 ft-lb (49 Nm)

Screw - M10 x 1.5 x 30 (QTY.4) 36 ft-lb (49 Nm)

Nut - M10 x 1.5 (QTY.6) -

Nut - M10 x 1.25 (QTY.4) -

TORQUE (IF APPLICABLE)

4.11

BODY / STEERING / SUSPENSION

BODY COMPONENT REMOVAL

SEAT / STORAGE TRAYS

1. Lift rear edge of seat to release the retainerq.

2. Rotate rear of seat upward until the front hinge can be released from the retaining bracket.

FRONT BUMPER / GRILL

1. Unlatch the hood and disconnect the head lamp harnesses. Remove the two pivot screws retaining the hood and remove the hood from the bumper.

2. Remove the three bolts the bumper.

from the lower portion of

FOOT PADS / CORNER PANEL / SIDE PANEL

1. FRONT - Remove the lower T27 Torx-head screws

retaining the foot pads.

2. Remove the two push rivets retaining the front fender and remove the fender from the vehicle.

3. Repeat this procedure to remove the other front fender.

4. REAR - Remove the lower T27 Torx-head screws retaining the foot pads.

5. Remove the three T27 Torx-head screws retaining the rear panel.

6. Repeat this procedure to remove the other rear fender.

3. Remove the two fastenersqfrom each side of the upper portion of the bumper.

4. Carefully remove the bumper from the vehicle.

4.12

CARGO BOX REMOVAL

1. Remove the screwqthat secures the hinge pin to the frame on both sides.

9926595 R01 - 2015-2016 RANGER EV Service Manual

BODY / STEERING / SUSPENSION

2. Lift the cargo box into the dump position.

3. Disconnect the rear wire harness attached to the tail lights.

4. Remove the upper clip shock to the cargo box.

and pineattaching the

CAUTION

Safely support the box during the remainder of the

removal process. The box is not as stable with the

shock removed.

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 and clip.

6. Lower the box and secure the latch.

HOOD / DASH

1. Hood Removal - Unlatch the hood and disconnect the head lamp harnesses. Remove the two clips and pivot pins retaining the hood and remove the hood from the bumper.

2. Dash Removal (continued) - Remove the three Torx-head screws retaining the front of the dash to the frame.

3. Open the glove box and remove the Torx-head screw from the dash.

5. Remove the hinge pin from both sides.

CAUTION

Safely support the box during the remainder of the

removal process. The box is not as stable with the

hinge pins removed.

6. With both hinge pins removed, remove the box from the frame. Two people may be needed to remove the box from the frame.

CAUTION

Use caution when removing the box. It is recommended

to have two people carefully remove the box from the

frame.

CARGO BOX INSTALLATION

1. If the shock was replaced, install the lower portion of the shock to the frame and secure it with the pin and clip.

2. Place the cargo box onto the frame. Align the hinges of the box with the bracket on the frame.

3. Install the box hinges on both sides.

4. Remove the Torx-head screw retaining the left portion of the dash.

5. Remove the eight fasteners from each side of the dash where it attaches to the front and rear fenders.

6. Remove the rubber boot from around shift lever.

7. Remove the five push rivets from under the dash panel. Unhook all electrical components to allow the panel to be completely removed.

8. Carefully remove the dash assembly from the vehicle.

FLOOR

1. Remove the Foot pads.

2. Remove the rear fender push rivets.

3. Remove the seven Torx-head screws retaining the center floor.

4. Remove the Torx-head screws retaining the front floor cover.

4.13

BODY / STEERING / SUSPENSION

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 adequate clearance to remove the front floor section.

4.14

9926595 R01 - 2015-2016 RANGER EV Service Manual

STEERING

STEERING ASSEMBLY EXPLODED VIEW

BODY / STEERING / SUSPENSION

4.15

BODY / STEERING / SUSPENSION

SUSPENSION

FRONT A-ARM REMOVAL / INSTALLATION

1. Elevate and safely support vehicle with weight removed from front wheel(s).

2. Remove cotter pin from ball joint stud and remove nut.

3. Separate A-arm from ball joint using a tie rod fork.

4. Loosen two bolts on A-arm bushing by alternating each about 1/3 of the way until A-arm can be removed.

5. Inspect A-arm bushings and A-arm shafts. Replace if worn. Discard hardware.

6. Insert A-arm bushings and A-arm shaft into A-arm.

7. Install CV joint shields.

8. Install 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 reuse old bolts.

Serious injury or death could result if fasteners come

loose during operation.

9. Attach A-arm to hub strut ball joint. Tighten ball joint nut to specification. If cotter pin holes are not aligned, tighten nut slightly to align.

TORQUE

Ball Joint Nut:

30 ft-lb (41 Nm)

10. Install a new cotter pin with open ends toward front of vehicle. Bend both ends in opposite directions around nut.

WARNING

Upon A-arm installation completion, test vehicle at low

speeds before putting into regular service.

BALL JOINT REPLACEMENT

1. Loosen front wheel nuts slightly.

4.16

9926595 R01 - 2015-2016 RANGER EV Service Manual

BODY / STEERING / SUSPENSION

2. Elevate and safely support machine under footrest/ frame area.

WARNING

Serious injury may result if machine tips or falls. Be

sure machine is secure before beginning this service

procedure.

3. Remove wheel nuts and wheels.

4. Remove cotter pin (A) from ball joint castlenut.

5. Remove castle nut (B) and separate A-arm (C) from ball joint stud.

6. Remove screws (D) and ball joint retaining plate (E).

7. Using ball joint 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 ease removal.

• Thread bolt (K) with nut (J) onto ball joint stud as

shown.

• Apply heat to ease removal.

• Hold bolt (K) and turn nut (J) clockwise until ball joint is

removed from strut housing.

•

8. To install new ball joint:

• Remove extension cap and attach puller guide using

short bolts provided in the kit.

• Insert new ball joint (L) into driver (M).

• Slide ball joint / driver assembly into guide.

• Apply heat to ease installation.

• Drive new joint into strut housing until fully seated.

4.17

BODY / STEERING / SUSPENSION

9. Apply Loctite® 242 (PN 2871949) to threads of retaining plate screws or install new screws with preapplied locking agent. Torque screws to specification.

TORQUE

Ball Joint Retaining Plate Screws:

8 ft-lb (11 Nm)

10. Install dust boot over ball joint stud.

11. Install A-arm on ball joint and torque castle nut to specification.

TORQUE

Ball Joint Nut:

30 ft-lb (41 Nm)

12. Reinstall cotter pin with open ends toward rear of machine.

FRONT STRUT CARTRIDGE REPLACEMENT

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 strut pivot assembly.

4. Remove coil spring and collapse strut cartridge.

5. Remove two pinch bolts from strut casting.

6. Remove strut cartridge.

7. Install cartridge until bottomed in strut casting.

8. Install pinch bolts with wire clamp (s). Torque pinch bolts to specification.

TORQUE

Strut Pinch Bolts:

17 ft-lb (23 Nm)

9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully.

10. Torque strut rod nut to specification. Do not over torque nut.

TORQUE

Strut Rod Nut:

15 ft-lbs (21 Nm)

4.18

9926595 R01 - 2015-2016 RANGER EV Service Manual

FRONT STRUT EXPLODED VIEW

BODY / STEERING / SUSPENSION

4.19

BODY / STEERING / SUSPENSION

REAR A-ARM REMOVAL / REPLACEMENT

The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. Repeat the following steps to remove the A-arm (s) from the opposite side.

NOTE

Refer to Rear A-arm Exploded View, page 4.22 for

reference during the procedure.

1. Elevate and safely support the rear of vehicle off the ground and remove the rear wheel.

3. Remove the fastener attaching the upper A-arm to the bearing carrier.

4. Remove the fasteners attaching the upper A-arm to the frame and remove the upper A-arm from the vehicle.

Upper A-arm Removal

2. Remove the fastener retaining the lower portion of the shock and stabilizer linkage to the upper A-arm.

5. Examine A-arm and bearing carrier bushings and pivot tubes (see “Exploded View”). Replace if worn. Discard hardware.

WARNING

The locking agent on the existing bolts was destroyed

during removal. DO NOT reuse old hardware. Serious

injury or death could result if fasteners come loose

during operation.

6. If not replacing the A-arm, thoroughly clean the aarm and pivot tubes.

7. Insert new A-arm bushings and pivot tubes into the new A-arm.

Lower A-arm Removal

4.20

9926595 R01 - 2015-2016 RANGER EV Service Manual

Polaris RANGER EV (2015) Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual