Description
This Official 2014 Polaris Ranger 400 Factory Service Manual Provides detailed service information, step-by-step repair instruction and maintenance specifications for 2014 Polaris Ranger 400 ATVs.
2014 Polaris Ranger 400 Service Manual Table of Contents
Chapter 1: General Information
Chapter 2: Maintenance
Chapter 3: Engine
Chapter 4: Fuel System – Carbureted
Chapter 5: Body / Steering / Suspension
Chapter 6: Clutching
Chapter 7: Final Drive
Chapter 8: Transmission
Chapter 9: Brakes
Chapter 10: Electrical
2014 Polaris Ranger 400 Service Manual Index of Topics
Chapter 1 General Information
Vehicle Identification
Model Number Designation
Vehicle Identification Number (vin) Designation
Engine Designation Number
Vin And Engine Serial Number Locations
Vin And Engine Serial Number Locations
Vehicle Information
Publication Numbers
Replacement Keys
Special Tools
General Specifications
Model: Ranger 400 Midsize
Model: Ranger 400 Midsize
Misc Specifications And Charts
Conversion Table
Standard Bolt Torque Specification
Metric Bolt Torque Specification
Sae Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Chapter 2 Maintenance
Periodic Maintenance Chart
Periodic Maintenance Overview
Break-in Period
Maintenance Chart Key
Pre-ride – 25 Hour Maintenance Interval
50- 100 Hour Maintenance Interval
100 – 300 Hour Maintenance Interval
Grease Lubrication Points
Service Products And Lubricants
Polaris Lubricants, Maintenance And Service Products
Fluid Maintenance References
Component Quick Reference
Component Quick Reference, Continued
General Vehicle Inspection And Maintenance
Pre-ride / Daily Inspection
Frame, Nuts, Bolts, And Fasteners
Shift Cable Inspection
Shift Cable Adjustment
Fuel System And Air Intake
Fuel System
Fuel Lines
Fuel Pump/filter
Vent Lines
Throttle Pedal Inspection
Throttle Freeplayadjustment
Air Filter Service
Engine Air Intake Inspection
Pvt Air Intake Inspection
Air Intake Exploded View
Engine
Compression And Leakdown Test
Breather Filter Inspection
Breather Hose
Flywheel Housing Drain Plug (if Equipped)
Engine Oil Level
Engine Oil And Filter Change
Oil Pump Priming Procedure
Valve Clearance
Intake Valve Clearance Adjustment
Exhaust Valve Clearance Adjustment
Exhaust Pipe Clean Out
Transmission And Gearcases
Transmission Lubrication
Front Gearcase Lubrication
Cooling System
Liquid Cooling System Overview
Coolant Level Inspection
Coolant Strength / Type
Cooling System Hoses
Radiator Inspection / Cleaning
Coolant Drain / Radiator Removal
Final Drive / Wheel And Tire
Wheel And Hub Torque Table
Cv Shaft Boot Inspection
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
Electrical And Ignition System
Battery Maintenance
Battery Fluid Level (conventional Battery)
Battery Removal
Battery Installation
Battery Storage
Battery Charging
Spark Plug Service
Engine To Frame Ground
Steering
Steering
Tie Rod End / Steering Inspection
Wheel Toe Alignment Inspection
Toe Adjustment
Suspension
Suspension Inspection
Spring Pre-load Adjustment
Stabilizer Bar Pivot Lubrication
Suspension Pivot Point Lubrication
Brake System
Brake Fluid Inspection
Brake Hose And Fitting Inspection
Brake Pad / Disc Inspection
Chapter 3 Engine
Specifications
Torque Specifications
Engine Fastener Torque Patterns
Ranger 400 Midsize Engine Service Data (eh46ple 455cc Carbureted)
Ranger 400 Midsize Engine Service Data (eh46ple 455cc Carbureted)
Special Tools
Special Tools
General Engine Service
Accessible Components
Engine Removal
Engine Installation Notes
Crankshaft Straightening
Engine Lubrication –
Oil Pressure Test-
Oil Flow-
Oil Flow Diagram
Engine Exploded View
Cooling System
Cooling System Layout And Testing
Engine Disassembly
Engine Removal
Cam Chain Tensioner / Rocker Arm /camshaft Removal
Cam Chain Tensioner Inspection
Rocker Arm/shaft Inspection
Camshaft Removal
Automatic Compression Release Removal / Inspection
Automatic Compression Release Installation
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Exploded View
Cylinder Head Inspection
Cylinder Head Warpage
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Valve Clearance Adjustment
Cylinder / Piston Removal And Inspection
Piston Removal
Cylinder Inspection
Cylinder Hone Selection / Honing Procedure
Honing To Oversize
Cleaning The Cylinder After Honing
Piston-to-cylinder Clearance
Piston / Rod Inspection
Piston Identification
Piston Ring Installed Gap
Crankcase Disassembly
Starter Drive Removal / Inspection
Flywheel And Stator Removal / Inspection
Cam Chain/tensioner Blade
One Way Valve
Crankcase Separation
Oil Pump Removal / Inspection
Oil Pump Assembly
Counter Balancer Shaft Removal / Inspection
Crankshaft Removal / Inspection
Crankcase Bearing Inspection
Oil Seal / Mechanical Seal Removal(engine Disassembled)
Crankcase Inspection
Bearing Installation
End Play Inspection / Adjustment
Crankshaft End Play Adjustment
Counter Balancer Shaft End Play Adjustment
Oil Pump Shaft End Play Adjustment
Engine Reassembly
Pump Shaft Oil Seal Installation
Crankshaft/ Counter Balance / Oil Pump Installation
Crankcase Assembly
Water Pump Mechanical Seal Installation
Water Pump Mechanical Seal Removal(engine Installed)
One Way Valve Installation
Cam Chain Drive Sprocket Installation
Tensioner Blade Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head Installation
Cam Chain / Camshaft Installation
Camshaft Timing
Camshaft Timing Illustration
Cam Chain Tensioner Installation
Stator, Flywheel And Starter Drive Installation
Rocker Shaft / Rocker Arm Assembly Installation
Thermostat Installation
Oil Pipes
Oil Pump Priming Procedure
Troubleshooting
Engine
Spark Plug Fouling
Cooling Troubleshooting
Chapter 4 Fuel System – Carbureted
Special Tools
Carburetor Jetting
Jetting Guidelines
Mikuni Jet Part Numbers
Mikuni Cv Carburetor
Exploded View
System Function – Mikuni Cv Carb
Vent Systems – Mikuni Cv Carb
Operation – Mikuni Cv Carb
Pilot System (idle And Slow Speed)
Starter System (choke Or Enrichment)
Float System
Main System
Pilot Screw
Air/fuel Mixture Ratio
Jet Needle
Needle Jet
Throttle Opening Vs Fuel Flow
Carburetor Service
Carburetor Removal
Carburetor Disassembly
Carburetor Cleaning
Carburetor Inspection
Float Height Adjustment
Needle And Seat Leak Test
Fuel Level
Carburetor Assembly
Air Box Assembly
Fuel Tank Assembly
Fuel Tank/fuel Pump Exploded View
Fuel Tank Removal
Fuel Tank Installation
Fuel Pump
Replacement
Fuel Filter Replacement
Troubleshooting
Fuel Starvation / Lean Mixture
Rich Mixture
Idle Too High
Idle Too Low
Erratic Idle
Chapter 5 Body I Steering I Suspension
Torque Specifications
Special Tools
Multi-function Pliers
Chassis/main Frame
Exploded View
Body Exploded Views
Dash Instruments / Controls
Hood / Dash / Front Fascia
Floor/rear Fenders
Seat Mounting /seat Belts
Rear Cargo Box
Cargo Box – Tailgate / Box Support
Box Removal
Box Installation
Body Component Removal
Lower Seat Base
Front Bumper
Wheel Well Panels
Fenders/foot Pads
Hood/dash
Floors
Steering Assembly
Exploded View
Front A-arm
Replacement
Front Strut
Exploded View
Front Strut Cartridge Replacement
Ball Joint Replacement
Rear A-arms
Removal/replacement
Installation
Exploded View
Rear Stabilizer Bar / Linkage
Removal / Installation
Exploded View
Shocks/springs
Exploded View
Shock Removal/installation
Shock Replacement
Decal Replacement
Chapter 6 Clutching
Special Tools And Supplies
Torque Specifications
Pvt System Fastener Torques
Pvt System Overview
Clutching Chart
General Operation
Drive Clutch Operation
Driven Clutch Operation
Pvt Break-in (drive Belt / Clutches)
Maintenance/inspection
Overheating /diagnosis
Pvt System Service
Pvt Sealing, Guard, And Ducting Components
Disassembly
Assembly
Drive Belt
Belt Deflection (tension)
Belt Removal
Belt Inspection
Belt Installation
Pvt Break-in (drive Belt/clutches)
Clutch Alignment / Offset / Center Distance
Clutch Alignment
Clutch Offset
Setting Center-to-center Distance
Drive Clutch Service
Exploded View
Clutch Inspection
Shift Weight Inspection
Clutch Disassembly
Spider Removal
Roller, Pin, And Thrust Washer Inspection
Bushing Service
Moveable Sheave – Bushing Removal
Moveable Sheave – Bushing Installation
Clutch Cover – Bushing Removal
Clutch Cover – Bushing Installation
Clutch Assembly
Driven Clutch Service
Exploded View
Clutch Disassembly / Inspection
Bushing Service
Moveable Sheave – Bushing Installation
Clutch Assembly
Troubleshooting
Chapter 7 Final Drive
Special Tools
Torque Specifications
Wheel And Hub Torque Table
Front Hub/bearing
Hub Removal/inspection
Hubstrut Bearing Replacement
Hub Installation
Front Hub/wheel Exploded View
Front Drive Shaft
Removal
Installation
Front Gearcase – Centralized Hilliard
Exploded View
All Wheel Drive Operation
Awd Diagnosis
Gearcase Removal
Gearcase Installation
Disassembly / Inspection
Assembly/inspection
Setting Ring Gear Backlash
Rear Bearing Carrier
Inspection
Removal
Disassembly
Assembly
Installation
Rear Drive Shaft
Removal
Installation
Drive Shaft Service
Drive Shaft/cv Joint Handling Tips
Outer Cv Joint / Boot Replacement
Inner Plunging Joint / Boot Replacement
Drive Shaft Exploded View
Propshaft U-joint Service
Removal / Installation
Front Propshaft Components
Disassembly
Assembly
Chapter 8 Transmission
Specifications
Torque Specifications
Lubrication
Shift Lever
Removal
Installation
Shift Cable
Inspection
Adjustment
Transmission Service
General Operation
Transmission Removal
Transmission Disassembly
Snorkel / Output Gear Backlash Procedure
Transmission Assembly
Transmission Installation
Troubleshooting
Troubleshooting Checklist
Transmission Exploded View
Ranger 400
Chapter 9 Brakes
General Specifications
Torque Specifications
Special Tools
Brake System Service Notes
Brake Noise Troubleshooting
Hydraulic Brake System Operation
Brake System Exploded View
Master Cylinder
Removal
Installation
Brake Pressure Switch
Foot Brake Pedal
Pedal Removal
Pedal Installation
Brake Bleeding / Fluid Change
Front Brake Pads
Pad Removal / Disassembly
Pad Inspection
Pad Assembly / Installation
Pad Adjustment
Front Caliper
Front Caliper Exploded View
Caliper Removal
Front Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
Front Brake Disc
Disc Inspection
Disc Removal / Replacement
Rear Brake Pad Service
Pad Removal
Pad Inspection
Rear Pad Installation
Rear Brake Caliper Service
Caliper Exploded View
Caliper Removal
Rear Caliper Disassembly
Rear Caliper Inspection
Rear Caliper Assembly
Rear Caliper Installation
Rear Brake Disc
Disc Runout
Disc Inspection
Disc Removal / Replacement
Troubleshooting
Brakes Squeal / Poor Brake Performance
Pedal Vibration
Caliper Overheats (brakes Drag)
Brakes Lock
Chapter 10 Electrical
General Information
Special Tools
Electrical Service Notes
Battery Conductance Analyzer
Components Under Hood
Switches / Controls
Headlight Switch
Awd / 2wd / Turf Switch
Differential Solenoid
Brake Pressure Switch
Gear Indicator Light Circuit Operation
Indicator Lamp Replacement
Hour Gauge
All Wheel Drive (awd) Coil
Operation Overview
Diagnosing System Failures
Headlights
Headlight Adjustment
Headlight Bulb Replacement
Headlight Housing Removal
Headlight Housing Installation
Tail Light / Brake Light
Led Lamp Replacement
Cooling System
Coolant Temperature Sensor
Cooling System Diagram / Overview
Fan Control Circuit Operation
Fan Control Circuit Bypass Test
Relays / Solenoid Driver
Operation
Fuses / Circuit Breaker
Operation
Acs-hub Module / Fan Relay
Operation
Charging System
Current Draw – Key Off
Charging System “break Even” Test
Charging System Alternator Tests
Regulator / Rectifier Test
Charging System Testing Flowchart
Battery Service
Battery Terminals/bolts
Battery Terminal Block
Battery Activation
Battery Inspection
Battery Removal / Installation
Conventional Battery Testing
Ocv- Open Circuit Voltage Test
Specific Gravity Test
Load Test
Charging Procedure
Off Season Storage
Starter System
Troubleshooting
Voltage Drop Test
Starter Motor Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly
Starter Drive
Starter Solenoid Bench Test
Starter Solenoid Operation
Starting System Testing Flow Chart
