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Polaris Ranger 400 & 500 Efi Midsize Crew Models Complete Workshop Service Repair Manual 2013 2014 2015

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Introducing the Polaris Ranger Midsize Crew, a versatile side-by-side utility vehicle designed for a range of tasks from farm work to recreational trail riding. Available for the 2013, 2014, and 2015 model years, these vehicles offer seating for up to four occupants and are engineered for reliability and robust performance. With models like the 400 and 500 EFI, they provide a balance of capability and maneuverability, making them a popular choice in the compact utility vehicle segment. Their design emphasizes practicality, featuring a liquid-cooled engine, electronic fuel injection, and a selectable 2WD/4WD system with Active Descent Control, all contributing to their adaptability in various environments. This comprehensive workshop service and repair manual provides in-depth guidance for maintaining and repairing your Polaris Ranger Midsize Crew. It covers essential areas including engine mechanicals, the EFI fuel system, drivetrain components like the automatic transmission and drive systems, chassis elements such as suspension and braking, and the complete electrical system. Detailed procedures for routine maintenance, troubleshooting common issues, and in-depth repair processes are included, along with critical technical specifications, torque values, and clear wiring diagrams. This manual is an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Ranger Midsize Crew Model Variant: 400 & 500 EFI Model Years Covered: 2013, 2014, 2015 Codes Manual Type Code: WSM 👋 Introduction Market Position Vehicle Segment: Compact utility vehicle (UTV), side-by-side, recreational/work vehicle Competitive Analysis Key Competitors: John Deere Gator, Kawasaki Mule, Yamaha Viking, Can-Am Defender (competing in similar utility/recreational UTV segments) Key Features Vehicle Purpose: Designed for versatility, offering seating for up to four occupants, suitable for farm work, trail riding, hunting, and general utility tasks 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service & Repair Page Count Estimated Page Count: Extensive (typical for full workshop manuals, likely 500+ pages) Manual Type Manual Format: PDF Download Manual Content: Workshop Service Repair Manual Language Language: English 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel system (EFI), ignition system, lubrication, cooling system, starting system, charging system, emissions control Drivetrain Systems: Transmission (PVT - Automatic), front drive system (ADC), rear drive system, differentials, CV joints, drive shafts Chassis Systems: Frame, suspension (front and rear), steering system, braking system (hydraulic), wheels and tires Electrical Systems: Wiring diagrams, lighting, instrumentation, accessories, battery, fuses, relays, ECU (Electronic Control Unit) Bodywork And Trim: Body panels, seating, storage compartments, body trim, plastics Procedures Included Maintenance Procedures: Routine maintenance checks, fluid changes (oil, coolant, brake fluid), filter replacements, lubrication points, spark plug service Repair Procedures: Engine overhaul, transmission repair, differential rebuilds, suspension component replacement, brake system repair, steering system service, electrical component repair Troubleshooting Diagnostics: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical system diagnostics, engine performance issues Suspension Alignment: Information on checking and adjusting suspension alignment (if applicable) and wheel alignment parameters. Charging System Diagnosis: Procedures for testing the stator, regulator/rectifier, and battery for proper charging system operation. Fuel Pump And Injector Testing: Diagnostic steps for verifying fuel pump operation and fuel injector function. Technical Depth Depth Of Information: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts Torque Specifications: Detailed torque specifications for all critical fasteners, engine components, chassis bolts, and suspension parts. Schematics And Diagrams: Comprehensive electrical schematics, hydraulic diagrams, and exploded views of various assemblies. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, optimized for digital viewing and printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, Single Cylinder (Likely Polaris ProStar Engine Family) Engine Type 500: 4-stroke, SOHC, 2-valve, Single Cylinder (Likely Polaris ProStar Engine Family) Performance Displacement 400: Approximately 397cc (specific model may vary slightly) Displacement 500: Approximately 499cc (specific model may vary slightly) Horsepower Approximate 400: Around 29-30 HP (typical for this engine size) Horsepower Approximate 500: Around 32-35 HP (typical for this engine size) Fuel System Fuel Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Idle Speed Setting: EFI system manages idle speed; manual will detail diagnostic checks for idle issues. Engine Cooling Cooling System: Liquid-Cooled Lubrication Oil Type Specification: Polaris internally recommends specific synthetic blend or full synthetic oils (e.g., SAE 5W-50 or 10W-40 depending on climate, check manual for exact spec) Engine Timing Valve Lash Adjustment: Requires periodic adjustment as per service schedule 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Drive Modes: 2WD/4WD Selectable with ADC (Active Descent Control) Transmission Fluid Type: Specific Polaris synthetic transmission fluid recommended (check manual for PN and type) Features Gear Selection: High, Low, Neutral, Reverse, Park 📐 Dimensions Exterior Wheelbase: Approx. 77 inches (195.6 cm) for Midsize models Overall Length: Approx. 116.5 inches (295.9 cm) Overall Width:...
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Polaris Ranger 400 & 500 Efi Midsize Crew Models Complete Workshop Service Repair Manual 2013 2014 2015Polaris Ranger 400 & 500 Efi Midsize Crew Models Complete Workshop Service Repair Manual 2013 2014 2015Polaris Ranger 400 & 500 Efi Midsize Crew Models Complete Workshop Service Repair Manual 2013 2014 2015Polaris Ranger 400 & 500 Efi Midsize Crew Models Complete Workshop Service Repair Manual 2013 2014 2015
Introducing the Polaris Ranger Midsize Crew, a versatile side-by-side utility vehicle designed for a range of tasks from farm work to recreational trail riding. Available for the 2013, 2014, and 2015 model years, these vehicles offer seating for up to four occupants and are engineered for reliability and robust performance. With models like the 400 and 500 EFI, they provide a balance of capability and maneuverability, making them a popular choice in the compact utility vehicle segment. Their design emphasizes practicality, featuring a liquid-cooled engine, electronic fuel injection, and a selectable 2WD/4WD system with Active Descent Control, all contributing to their adaptability in various environments. This comprehensive workshop service and repair manual provides in-depth guidance for maintaining and repairing your Polaris Ranger Midsize Crew. It covers essential areas including engine mechanicals, the EFI fuel system, drivetrain components like the automatic transmission and drive systems, chassis elements such as suspension and braking, and the complete electrical system. Detailed procedures for routine maintenance, troubleshooting common issues, and in-depth repair processes are included, along with critical technical specifications, torque values, and clear wiring diagrams. This manual is an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Ranger Midsize Crew
Model Variant:
400 & 500 EFI
Model Years Covered:
2013, 2014, 2015
Codes
Manual Type Code:
WSM
👋 Introduction
Market Position
Vehicle Segment:
Compact utility vehicle (UTV), side-by-side, recreational/work vehicle
Competitive Analysis
Key Competitors:
John Deere Gator, Kawasaki Mule, Yamaha Viking, Can-Am Defender (competing in similar utility/recreational UTV segments)
Key Features
Vehicle Purpose:
Designed for versatility, offering seating for up to four occupants, suitable for farm work, trail riding, hunting, and general utility tasks
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Workshop Service & Repair
Page Count
Estimated Page Count:
Extensive (typical for full workshop manuals, likely 500+ pages)
Manual Type
Manual Format:
PDF Download
Manual Content:
Workshop Service Repair Manual
Language
Language:
English
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel system (EFI), ignition system, lubrication, cooling system, starting system, charging system, emissions control
Drivetrain Systems:
Transmission (PVT - Automatic), front drive system (ADC), rear drive system, differentials, CV joints, drive shafts
Chassis Systems:
Frame, suspension (front and rear), steering system, braking system (hydraulic), wheels and tires
Electrical Systems:
Wiring diagrams, lighting, instrumentation, accessories, battery, fuses, relays, ECU (Electronic Control Unit)
Bodywork And Trim:
Body panels, seating, storage compartments, body trim, plastics
Procedures Included
Maintenance Procedures:
Routine maintenance checks, fluid changes (oil, coolant, brake fluid), filter replacements, lubrication points, spark plug service
Repair Procedures:
Engine overhaul, transmission repair, differential rebuilds, suspension component replacement, brake system repair, steering system service, electrical component repair
Troubleshooting Diagnostics:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical system diagnostics, engine performance issues
Suspension Alignment:
Information on checking and adjusting suspension alignment (if applicable) and wheel alignment parameters.
Charging System Diagnosis:
Procedures for testing the stator, regulator/rectifier, and battery for proper charging system operation.
Fuel Pump And Injector Testing:
Diagnostic steps for verifying fuel pump operation and fuel injector function.
Technical Depth
Depth Of Information:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts
Torque Specifications:
Detailed torque specifications for all critical fasteners, engine components, chassis bolts, and suspension parts.
Schematics And Diagrams:
Comprehensive electrical schematics, hydraulic diagrams, and exploded views of various assemblies.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution, optimized for digital viewing and printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type 400:
4-stroke, SOHC, 2-valve, Single Cylinder (Likely Polaris ProStar Engine Family)
Engine Type 500:
4-stroke, SOHC, 2-valve, Single Cylinder (Likely Polaris ProStar Engine Family)
Performance
Displacement 400:
Approximately 397cc (specific model may vary slightly)
Displacement 500:
Approximately 499cc (specific model may vary slightly)
Horsepower Approximate 400:
Around 29-30 HP (typical for this engine size)
Horsepower Approximate 500:
Around 32-35 HP (typical for this engine size)
Fuel System
Fuel Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Idle Speed Setting:
EFI system manages idle speed; manual will detail diagnostic checks for idle issues.
Engine Cooling
Cooling System:
Liquid-Cooled
Lubrication
Oil Type Specification:
Polaris internally recommends specific synthetic blend or full synthetic oils (e.g., SAE 5W-50 or 10W-40 depending on climate, check manual for exact spec)
Engine Timing
Valve Lash Adjustment:
Requires periodic adjustment as per service schedule
🔧 Transmission
Standard
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Drive Modes:
2WD/4WD Selectable with ADC (Active Descent Control)
Transmission Fluid Type:
Specific Polaris synthetic transmission fluid recommended (check manual for PN and type)
Features
Gear Selection:
High, Low, Neutral, Reverse, Park
📐 Dimensions
Exterior
Wheelbase:
Approx. 77 inches (195.6 cm) for Midsize models
Overall Length:
Approx. 116.5 inches (295.9 cm)
Overall Width:
Approx. 56.5 inches (143.5 cm)
Overall Height:
Approx. 73 inches (185.4 cm)
Cargo
Cargo Bed Capacity:
Approx. 400 lbs (181.4 kg)
Weights
Dry Weight:
Approx. 1050-1100 lbs (476-499 kg) depending on configuration
Towing Capacity:
Up to 1500 lbs (680 kg)
Payload Capacity:
Approx. 937 lbs (425 kg)
🛡️ Safety Features
Ratings
Rollover Protection:
ROPS (Roll-Over Protective Structure) certified
Active Features
Braking System:
Hydraulic disc brakes, front and rear
Parking Brake:
Foot-operated parking brake
Passive Features
Seatbelts:
3-point seatbelts for all occupants
Lighting:
Halogen headlights, LED taillights/brake lights
Doors:
Full doors for enhanced protection
💡 Technology Features
Infotainment
Instrument Cluster:
Digital instrument cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter, engine hour meter, warning lights.
Driver Assistance
Adc:
Active Descent Control (ADC) for controlled downhill descents.
Connectivity
Accessories Integration:
Pre-wired for accessories such as winches, lights, and auxiliary power outlets.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 100 hours or 12 months, whichever comes first. (Refer to manual for precise intervals)
Air Filter Cleaning Replacement:
Check every 50 hours, clean or replace as needed, especially in dusty conditions.
Spark Plug Replacement:
Recommended replacement around 100-200 hours or as per manual. Specific spark plug part number should be cross-referenced.
Transmission Fluid Change:
Typically every 200 hours or 24 months. (Refer to manual for precise intervals and fluid type)
Fluid Specifications
Coolant Type:
Polaris recommends specific ethylene glycol-based antifreeze/coolant (e.g., 50/50 mix). Check manual for correct type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation).
Engine Oil Capacity Approx:
Approximately 1.8-2.0 quarts (check manual for exact capacity with filter change)
Cooling System Capacity Approx:
Approximately 1.5-2.0 gallons (check manual for exact capacity)
Known Issues
Common Wear Items:
Drive belts (PVT), suspension bushings, wheel bearings, CV boots can be common wear items in rigorous use.
Efi System Considerations:
EFI systems require clean fuel and proper functioning of sensors (TPS, MAP, O2) for optimal performance.
📚 Vehicle History
Brand Heritage
Polaristracking:
Polaris has a long history in powersports, originating in snowmobiles and expanding into ATVs, UTVs, and other off-road vehicles.
Model Evolution
Ranger Lineup:
The Ranger series has evolved significantly, with 'Midsize Crew' models introduced to offer more passenger capacity and versatility within the Polaris UTV range.
Production
Manufacturing Location:
Primarily manufactured by Polaris Industries in the USA.
🏆 Awards & Recognition
Recognitions
Industry Perception:
Polaris Ranger models are generally well-regarded for their versatility, performance, and robust build quality within the utility UTV market.
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