Polaris Ranger 2X4 Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Ranger 2X4 has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

MODEL: 2009 RANGER 2X4
MODEL NUMBER: R09RB50AF
ENGINE MODEL: EH500PLE16A


TABLE OF CONTENTS :

Chapter_01-GENERAL INFORMATION
Chapter_02-MAINTENANCE
Chapter_03-ENGINE
Chapter_04-CARBURETION SYSTEM
Chapter_05-BODY / STEERING / SUSPENSION
Chapter_06-CLUTCHING
Chapter_07-FINAL DRIVE
Chapter_08-TRANSMISSION
Chapter_09-BRAKES
Chapter_10-ELECTRICAL
WIRE DIAGRAM


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9922040
Total Pages : 264


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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9922040_Chapter_01-GENERAL INFORMATION
    GENERAL INFORMATION
        VEHICLE IDENTIFICATION
            Model Identification
            Engine Designation Number
            VIN Identification
            Engine Serial Number Location
            Vehicle Identification Number (VIN) Location
            Transmission I.D. Number Location
        VEHICLE DIMENSIONS
            vehicle DIMENSIONS
        GENERAL SPECIFICATIONS
            MODEL: 2009 RANGER 2X4
            MODEL: 2009 RANGER 2X4
        VEHICLE INFORMATION
            Publication Numbers
            Paint Codes
            Replacement Keys
        SPECIAL TOOLS
        MISC. SPECIFICATIONS AND CHARTS
            Conversion Table
            Standard Torque Specifications
            SAE Tap / Drill Sizes
            Metric Tap / Drill Sizes
            Decimal Equivalents
            Glossary of Terms
            
9922040_Chapter_02-MAINTENANCE
    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
        SERVICE PRODUCTS AND LUBRICANTS
            Polaris Lubricants, Maintenance and Service Products
        GENERAL COMPONENT LOCATION
            RH Side and Dash View 
            LH Side and Rear View
        MAINTENANCE REFERENCES
            Maintenance Quick Reference
        GENERAL VEHICLE INSPECTION AND MAINTENANCE
            Pre-Ride / Daily Inspection
            Frame, Nuts, Bolts, and Fasteners
            Shift Linkage Inspection / Adjustment
        FUEL SYSTEM AND AIR INTAKE
            Fuel System
            Fuel Lines
            Fuel Filter
            Vent Lines
            Throttle Pedal Inspection
            Throttle Freeplay Adjustment
            Throttle Cable Adjustment
            Choke Adjustment
            Idle Speed Adjustment
            Pilot Screw
            Pilot Screw Adjustment
            Carburetor Draining
            Air Intake Inspection
            Air Filter Service
        ENGINE
            Compression and Leakdown Test
            Breather Filter Inspection
            Breather Hose
            Flywheel Housing
            Engine Oil Level
            Engine Oil and Filter Change
            Oil Pump Priming Procedure
            Valve Clearance
            Intake Valve Clearance Adjustment
            Exhaust Valve Clearance Adjustment
            Exhaust Pipe
        TRANSMISSION / REAR GEARCASE
            Transmission Lubrication
            Rear Gearcase Lubrication
        COOLING SYSTEM
            Liquid Cooling System Overview
            Coolant Level Inspection
            Radiator Coolant Level Inspection
            Coolant Strength / Type
            Cooling System Pressure Test
            Cooling System Hoses
            Radiator
            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 AND SUSPENSION
            Steering
            Tie Rod End / Steering Inspection
            Wheel Toe Alignment Inspection
            Toe Adjustment
            Front Suspension
            Rear Suspension
            Rear Suspension Adjustment
            Rear Spring Adjustment
        BRAKE SYSTEM
            Brake Fluid Inspection
            Brake Hose and Fitting Inspection
            Brake Pad / Disc Inspection
            Parking Brake Cable Adjustment
            Parking Brake Pad Inspection
            
9922040_Chapter_03-ENGINE
    ENGINE
        SPECIAL TOOLS
        SPECIFICATIONS
            Torque Specifications
            Engine Service Data
            Engine Service Data
            Engine Fastener Torque Patterns
        GENERAL ENGINE SERVICE
            Piston Identification
            Accessible Components
            Engine Removal
            Engine Installation Notes
            Crankshaft Straightening
            Engine Lubrication - EH50PL
            Oil Pressure Test - EH50PL
            Oil Flow - EH50PL
            EH50PL Oil Flow Diagram
            EH50PL Engine Exploded View
        COOLING SYSTEM
            Cooling System Specifications
            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, EH50PL
            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 (Intake and Exhaust)
            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 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
            
9922040_Chapter_04-CARBURETION SYSTEM
    CARBURETION SYSTEM
        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
        CARBURETOR SERVICE
            Carburetor Removal
            Carburetor Disassembly
            Carburetor Cleaning
            Carburetor Inspection
            Float Height Adjustment
            Needle and Seat Leakage Test
            Fuel Level
            Carburetor Assembly
        AIR BOX ASSEMBLY
            Exploded View
        FUEL TANK ASSEMBLY
            Fuel Tank / Fuel Pump Exploded View
            Fuel Tank Removal
            Fuel Tank Installation
        FUEL PUMP
            Replacement
        TROUBLESHOOTING
            Fuel Starvation / Lean Mixture
            Rich Mixture
            Idle Too High
            Idle Too Low
            Erratic Idle
            
9922040_Chapter_05-BODY / STEERING / SUSPENSION
    BODY / STEERING / SUSPENSION
        TORQUE SPECIFICATIONS
        SPECIAL TOOLS
        BODY COMPONENT REMOVAL
            Removal Procedures
            Lower Body Components
            Hood / Dash Components
            Dash Instruments and Controls
        CAB FRAME
            Assembly / Removal
        CHASSIS / MAIN FRAME
            Exploded View
        SEAT / HEAD REST
            Seat Back / Head Rests
        STEERING ASSEMBLY
            Exploded View
        STEERING AND SUSPENSION
            Exploded View
        FRONT A-ARM
            Replacement
        FRONT STRUT
            Exploded View
            Front Strut Cartridge Replacement
            Ball Joint Replacement
        REAR A-ARM
            Replacement
        REAR STABILIZER BAR
            Removal / Installation
        REAR CARGO BOX
            Cargo Box - Panels
            Cargo Box - Tailgate / Box Support
            Box Removal
            Box Installation
        DECAL REPLACEMENT
        
9922040_Chapter_06-CLUTCHING
    CLUTCHING
        SPECIAL TOOLS AND SUPPLIES
        TORQUE SPECIFICATIONS
            PVT System Fastener Torques
        PVT SYSTEM OVERVIEW
            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
            Clutch Center Distance
        DRIVE CLUTCH SERVICE
            Spring Specifications
            Shift Weights
            Exploded View
            Clutch 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
        
9922040_Chapter_07-FINAL DRIVE
    FINAL DRIVE
        SPECIAL TOOLS
        TORQUE SPECIFICATIONS
            Wheel, Hub, and Spindle Torque Table
        FRONT HUB
            Hub Removal / Inspection
            Hub Installation
            Exploded View
        REAR HUB / BEARING CARRIER
            Hub Inspection
            Hub Removal
            Hub Disassembly
            Hub Assembly
            Hub Installation
            Exploded View
        REAR DRIVE SHAFT
            Removal
            Outer CV Joint / Boot Replacement
            Inner Plunging Joint / Boot Replacement
            Drive Shaft Exploded View
            Installation
        REAR PROPSHAFT
            Removal
            Installation
        REAR GEARCASE
            General Operation
            Operation Modes
            Gearcase Removal
            Gearcase Disassembly
            Rear Gearcase Assembly
            Rear Gearcase Installation
            Rear Gearcase Exploded View
            
9922040_Chapter_08-TRANSMISSION
    TRANSMISSION
        TORQUE SPECIFICATIONS
        SHIFT LEVER
            Removal
            Installation
        SHIFT LINKAGE
            Inspection
            Adjustment
        TRANSMISSION SERVICE
            Transmission Removal
            Transmission Disassembly
            Transmission Assembly
            Transmission Installation
        TROUBLESHOOTING
            Troubleshooting Checklist
        TRANSMISSION EXPLODED VIEW
            Exploded View
            
9922040_Chapter_09-BRAKES
    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
        FOOT BRAKE PEDAL
            Pedal Removal
            Pedal Installation
        BRAKE BLEEDING / FLUID CHANGE
        PARKING BRAKE
            Exploded View
            Inspection
            Cable Tension Adjustment
        PARKING BRAKE CALIPER SERVICE
            Exploded View
            Caliper Removal
            Caliper Disassembly / Inspection
            New Brake Pad Installation
            Caliper Installation
        PARKING BRAKE DISC SERVICE
            Disc Inspection / Removal
        FRONT BRAKE PADS
            Pad Removal
            Pad Inspection
            Pad Assembly / Installation
            Brake Burnishing Procedure
        FRONT CALIPER SERVICE
            Caliper Exploded View
            Caliper Removal 
            Caliper Disassembly
            Caliper Inspection
            Caliper Assembly
            Caliper Installation
        FRONT BRAKE DISC
            Disc Inspection
            Disc Replacement
        REAR BRAKE PADS
            Pad Removal
            Pad Inspection
            Pad Installation
        REAR CALIPER SERVICE
            Rear Caliper Exploded View
            Caliper Removal
            Caliper Disassembly
            Caliper Inspection
            Caliper Assembly
            Caliper Installation
        REAR BRAKE DISC
            Disc Inspection
            Disc Replacement
        TROUBLESHOOTING
            Brakes Squeal / Poor Brake Performance
            Pedal Vibration
            Caliper Overheats (Brakes Drag)
            Brakes Lock
            
9922040_Chapter_10-ELECTRICAL
    ELECTRICAL
        GENERAL INFORMATION
            Special Tools
            Electrical Service Notes
            Under-Hood Components
        SWITCHES / CONTROLS
            Headlight Switch
            Rear Differential Switch
            Differential Solenoid
            Parking Brake Switch
            Indicator Lamp Circuit Operation
            Indicator Lamp Replacement
        HEADLIGHTS
            Headlight Adjustment
            Headlight Bulb Replacement
            Headlight Housing Removal
            Headlight Housing Installation
        TAIL LIGHT / BRAKE LIGHT
            Lamp Replacement
        POWER DISTRIBUTION MODULE
            Functional Description
            PDM Block Diagram
            PDM Troubleshooting
            Solid State Circuit Breaker #1 (SSCB #1)
            Solid State Circuit Breaker #2 (SSCB #2)
            PDM Fan Motor Troubleshooting
            PDM Chassis Power Troubleshooting
        TIMING CHECK PROCEDURE
        COOLING SYSTEM
            Cooling System Break-Out Diagram
            Fan Control Circuit Operation / Testing
            Fan Control Circuit Bypass Test
            Coolant Temperature Sensor Test
        DC / CDI IGNITION SYSTEM
            DC / CDI Ignition System Overview
            Ignition System Troubleshooting
            Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter
            Resistance Tests
            Flywheel Identification
            Ignition System Testing Flow Chart
            Components of DC / CDI Ignition
        CHARGING SYSTEM
            Current Draw - Key Off
            Charging System “Break Even” Test
            Charging System Alternator Tests
            Charging System Testing Flow Chart
        BATTERY SERVICE
            Battery Terminals / Bolts
            Battery Terminal Block
            Battery Activation
            Battery Inspection
            Battery Removal / Installation
            Battery Testing
            OCV - Open Circuit Voltage Test
            Specific Gravity Test
            Load Test
            Off Season Storage
            Charging Procedure
        STARTER SYSTEM
            Troubleshooting
            Voltage Drop Test
            Starter Motor Disassembly
            Brush Inspection / Replacement
            Armature Testing
            Starter Assembly
            Starter Drive
            Starter Solenoid Bench Test
            Starter Solenoid Operation
        STARTING SYSTEM TESTING FLOW CHART
            Condition: Starter fails to turn over the engine. 
        ELECTRIC BOX LIFT ACTUATOR
            DIAGNOSIS (if equipped)
            
9922040_WIRE DIAGRAM

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