Polaris Ranger 4X4 CREW / 6X6 Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Ranger 4X4 CREW / 6X6 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 4X4 CREW
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE

MODEL: 2009 RANGER 6X6
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH068OLE


TABLE OF CONTENTS :

Chapter_01-GENERAL INFORMATION
Chapter_02-MAINTENANCE
Chapter_03-ENGINE
Chapter_04-ELECTRONIC FUEL INJECTION
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 : 9921885
Total Pages : 352


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.

More Info : http://www.sitelux.com

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9921885_Chapter_01-GENERAL INFORMATION
    GENERAL INFORMATION
        MODEL INFORMATION
            Model Identification
            Engine Designation Number
            VIN Identification
            Engine Serial Number Location
            Vehicle Identification Number (VIN) Location
            Transmission I.D. Number Location
        VEHICLE DIMENSIONS
            RANGER 4x4 CREW / 6X6 (Height and Width)
            RANGER 6X6 (Length and Wheel Base)
            RANGER 4x4 CREW (Length and Wheel Base)
        GENERAL SPECIFICATIONS
            MODEL: 2009 RANGER 4X4 CREW
            MODEL: 2009 RANGER 4X4 CREW
            MODEL: 2009 RANGER 6X6
            MODEL: 2009 RANGER 6X6
        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
            
9921885_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 LUBES
            Polaris Lubricants, Maintenance and Service Products
        MAINTENANCE REFERENCES
            Maintenance References, Continued.....
        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
            Air Filter Service
            Air Intake Inspection
        ENGINE
            Compression and Leakdown Test
            Breather Hose Inspection
            Engine Oil Level
            Engine Oil and Filter Change
            Exhaust Pipe
        TRANSMISSION AND GEARCASES
            Transmission Lubrication
            Front Gearcase Lubrication
            Middle Gearcase Lubrication (6x6)
            Rear Gearcase Lubrication (4x4 CREW)
            Rear Gearcase Lubrication (6x6)
        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 (4x4 CREW)
            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
            
9921885_Chapter_03-ENGINE
    ENGINE
        ENGINE SPECIFICATIONS
            Crankcase Exploded Views
            Engine Fastener Torque Patterns
            Torque Specifications
            700 EFI Engine Service Specifications
            Special Tools
        GENERAL ENGINE SERVICE
            Accessible Components
            Piston Identification
            Cooling System Specifications
            Cooling System Pressure Test
            Cooling System Exploded View
            Cooling System Bleeding Procedure
            Valve Cover Removal - 6x6 Models (Engine Installed)
            Engine Removal
            Engine Installation Notes
            Engine Lubrication Specifications
            Oil Pressure Test
            Oil Flow Chart
        ENGINE DISASSEMBLY AND INSPECTION
            Cylinder Head Assembly Exploded View
            Rocker Arms
            Push Rods
            Cylinder Head Removal 
            Cylinder Head Inspection
            Cylinder Head Warp
            Valve Seal / Spring Service (On Engine)
            Cylinder Head Disassembly
            Valve Inspection
            Combustion Chamber
            Valve Seat Reconditioning
            Cylinder Head Reassembly
            Valve Sealing Test
            Cylinder Removal
            Valve Lifter Removal / Inspection
            Piston Removal
            Cylinder Inspection
            Cylinder Hone Selection And Honing Procedure
            Honing To Deglaze
            Cleaning the Cylinder After Honing
            Piston-to-Cylinder Clearance
            Piston / Rod Inspection
            Piston Ring Installed Gap
            Starter Drive Bendix Removal / Inspection 
            Flywheel / Stator Removal / Inspection
            Engine Crankcase Disassembly / Inspection
            Camshaft Inspection
        ENGINE REASSEMBLY
            Crankcase Reassembly
            Flywheel / Stator Installation
            Cylinder Head Reassembly
            Oil Pump Priming
            Engine Break-In
        TROUBLESHOOTING
            Engine
            Cooling System
            
9921885_Chapter_04-ELECTRONIC FUEL INJECTION
    ELECTRONIC FUEL INJECTION
        GENERAL INFORMATION
            Special Tools
            EFI Service Notes
            Fuel Tank Exploded View
            EFI System Exploded View
            EFI System Component Locations
            Fuel Lines - Quick Connect Removal / Installation
        ELECTRONIC FUEL INJECTION
            Principal Components
            EFI Operation Overview
            Initial Priming / Starting Procedure
        ELECTRONIC CONTROL UNIT (ECU)
            Operation Overview
            ECU Service
            ECU Replacement
        FUEL PUMP
            Operation Overview
            Fuel Sender Test
            Fuel Pump Test
            Fuel Pump / Tank Assembly Replacement
        FUEL PRESSURE REGULATOR
            Operation Overview
            Fuel Pressure Regulator Test
            Fuel Pressure Regulator Replacement
        FUEL INJECTORS
            Operation Overview
            Fuel Injector Service
            Fuel Injector Replacement
        CRANKSHAFT POSITION SENSOR (CPS)
            Operation Overview
            CPS Test
            CPS Replacement
        TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
            Operation Overview
            T-BAP Test
            T-BAP Replacement
        THROTTLE POSITION SENSOR (TPS)
            Operation Overview
            TPS Tester / Regulator
            Checking TPS Reading
            TPS Adjustment
            TPS Replacement
        ENGINE COOLANT TEMPERATURE SENSOR (ECT)
            Operation Overview
            ECT Sensor Test
            ECT Sensor Replacement
        IGNITION COIL
            Operation Overview
            Ignition Coil Tests
            Ignition Coil / HT Lead Replacement
        GENERAL TROUBLESHOOTING
            Diagnostic “Blink Codes”
            EFI Troubleshooting
        EFI SYSTEM BREAK-OUT DIAGRAMS
            Fuel Injector Circuit (PTO)
            Fuel Injector Circuit (MAG)
            Crankshaft Position Sensor (CPS) Circuit
            Fuel Pump Circuit
            Engine Coolant Temperature Sensor (ECT) 
            Temperature Overheat Indicator Lamp Circuit
            Throttle Position Sensor (TPS) Circuit
            Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit
            Diagnostic Connector Circuit
            Diagnostic Indicator Lamp Circuit
            
9921885_Chapter_05-BODY / STEERING / SUSPENSION
    BODY / STEERING / SUSPENSION
        TORQUE SPECIFICATIONS
        SPECIAL TOOLS
        BODY COMPONENT REMOVAL
            Removal Procedures
            Lower Body, Floor and Fenders (4x4 CREW)
            Lower Body, Floor and Fenders (6x6)
            Hood / Dash Components
            Dash Instruments and Controls
        CAB FRAME
            Assembly / Removal (6x6)
            Assembly / Removal (4x4 CREW)
        SEAT / HEAD REST
            Seat Back / Head Rests
        CHASSIS / MAIN FRAME (4X4 CREW)
            Exploded View
        CHASSIS / MAIN FRAME (6X6)
            Exploded View
        STEERING ASSEMBLY
            Exploded View
        STEERING AND SUSPENSION
            Exploded View
        FRONT A-ARM
            Replacement
        FRONT STRUT
            Exploded View
            Front Strut Cartridge Replacement
            Ball Joint Replacement
        MID AXLE A-ARM (6X6)
            Replacement
        REAR A-ARM (4X4 CREW)
            Replacement
        REAR STABILIZER BAR (4X4 CREW)
            Removal / Installation
        SWING ARM (6X6)
            Removal
            Installation
        REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6)
        REAR CARGO BOX
            Cargo Box - Panels
            Cargo Box - Tailgate / Box Support
            Box Removal
            Box Installation
        STORAGE BOX (4X4 CREW)
            Removal
            Installation
        DECAL REPLACEMENT
        
9921885_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 Removal
            Belt Inspection
            Belt Installation
            PVT Break-In (Drive Belt / Clutches)
        CLUTCH ALIGNMENT
            Clutch Alignment Tool Use
        CLUTCH CENTER DISTANCE
        DRIVE CLUTCH SERVICE
            Spring Specifications
            Shift Weights
            Exploded View
            Clutch Disassembly
            Spider Removal
            Roller, Pin, and Thrust Washer Inspection
            Button To Tower Clearance Inspection
            Shift Weight Inspection
            Bearing Inspection
            Clutch Inspection
            Moveable Sheave Bushing Inspection
            Bushing Service
            Clutch Assembly
        DRIVEN CLUTCH SERVICE
            Exploded View
            Clutch Disassembly / Inspection
            Clutch Assembly
        TROUBLESHOOTING
        
9921885_Chapter_07-FINAL DRIVE
    FINAL DRIVE
        SPECIAL TOOLS
        TORQUE SPECIFICATIONS
            Wheel, Hub, and Spindle Torque Table
        FRONT HUB
            Hub Removal / Inspection
            Hubstrut Bearing Replacement
            Hub Installation
            Front Hub Exploded View
        FRONT DRIVE SHAFT
            Removal
            Drive Shaft / CV Joint Handling Tips
            Outer CV Joint / Boot Replacement
            Inner Plunging Joint / Boot Replacement
            Exploded View
            Installation
        FRONT PROPSHAFT
            6x6 Removal
            4x4 CREW Removal
            Front Propshaft Components
        PROPSHAFT U-JOINT SERVICE
            Disassembly
            Assembly
        FRONT GEARCASE / CENTRALIZED HILLIARD
            Centralized Hilliard Exploded View
            All Wheel Drive Operation
            AWD Diagnosis
            Gearcase Removal
            Gearcase Disassembly / Inspection
            Gearcase Reassembly / Inspection
            Backlash Pad (Thrust Pad) Adjustment
            Gearcase Installation
        MID DRIVE HUB / BEARING CARRIER (6X6)
            Removal
            Hub Disassembly
            Hub Assembly
            Hub Installation
            Mid Drive Exploded View
        MID DRIVE SHAFT (6X6)
            Removal
            Disassembly / Assembly
            Installation
        MID PROPSHAFT (6X6)
            Removal
        MID DRIVE GEARCASE (6X6)
            Gearcase Removal
            Gearcase Disassembly
            Gearcase Assembly
            Gearcase Installation
            Mid Gearcase Exploded
        REAR HUB / BEARING CARRIER (4X4)
            Hub Inspection
            Hub Removal
            Hub Disassembly
            Hub Assembly
            Hub Installation
            Exploded View
        REAR DRIVE SHAFT (4X4 CREW)
            Removal
            Outer CV Joint / Boot Replacement
            Inner Plunging Joint / Boot Replacement
            Drive Shaft Exploded View
            Installation
        REAR PROPSHAFT (4X4 CREW)
            Removal
            Installation
        REAR GEARCASE (4X4 CREW)
            General Operation
            Operation Modes
            Gearcase Removal
            Gearcase Disassembly
            Rear Gearcase Assembly
            Rear Gearcase Installation
            Rear Gearcase Exploded View (4x4 CREW)
        REAR AXLE / GEARCASE SERVICE (6X6)
            Rear Axle Removal
            Axle Tube Removal
            Axle Tube Bearing Replacement
            Gearcase Disassembly / Inspection
            Gearcase Assembly
            Gearcase / Axle Installation
            Rear Gearcase Exploded View (6x6)
            
9921885_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
            
9921885_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
            6x6
            4x4 CREW
        MASTER CYLINDER
            Removal
            Installation
        FOOT BRAKE PEDAL
            Pedal Removal
            Pedal Installation
        BRAKE BLEEDING / FLUID CHANGE
        PARKING BRAKE
            Exploded View (4x4 CREW)
            Exploded View (6x6)
            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 (6X6)
            Pad Removal
            Pad Inspection
            Pad Installation
        REAR BRAKE PADS (4X4 CREW)
            Pad Removal
            Pad Inspection
            Pad Assembly / Installation
            Brake Burnishing Procedure
        REAR CALIPER SERVICE (6X6)
            Rear Caliper Exploded View
            Caliper Removal
            Caliper Disassembly
            Caliper Inspection
            Caliper Assembly
            Caliper Installation
        REAR CALIPER SERVICE (4X4 CREW)
            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
            
9921885_Chapter_10-ELECTRICAL
    ELECTRICAL
        GENERAL INFORMATION
            Special Tools
            Electrical Service Notes
            Under-Hood Components
        SWITCHES / CONTROLS
            Headlight Switch
            AWD / 2WD / TURF Switch (4x4 CREW)
            Differential Solenoid (4x4 CREW)
            Brake Light Switch
            Parking Brake Switch
        INSTRUMENT CLUSTER
            Overview
            Rider Information Display
            Standard Display Modes
            Diagnostic Display Mode
            Viewing Diagnostic Codes
            Instrument Cluster Removal
            Instrument Cluster Installation
        INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
            Test 1 - No All Wheel Drive
            TEST 2 - No Display
            TEST 3 - Wheel Speed Sensor
            TEST 4 - No AWD Hub Safety Limiter
            TEST 5 - Fuel Gauge Display Not Working 
            TEST 6 - Shift Indicator Not Working (Transmission Switch)
        ALL WHEEL DRIVE (AWD) COIL
            Operation Overview
            Diagnosing System Failures
        GEAR POSITION INDICATOR SWITCH
            Test Diagram
        HEADLIGHTS
            Headlight Adjustment
            Headlight Bulb Replacement
            Headlight Housing Removal
            Headlight Housing Installation
        TAIL LIGHT / BRAKE LIGHT
            Lamp Replacement
        COOLING SYSTEM
            Cooling System Break-Out Diagram
            Fan Control Circuit Operation
            Fan Control Circuit Bypass Test
            Coolant Temperature Sensor
        EFI DIAGNOSTICS
            EFI Component Testing
        FUEL SENDER
            Testing
        RELAYS
            Operation
        FUSES / CIRCUIT BREAKER
            Operation
        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 Removal / Disassembly 
            Brush Inspection / Replacement
            Armature Testing
            Starter Reassembly / Installation
            Starter Drive
            Starter Solenoid Bench Test
            Starter Solenoid Operation
            Starter Exploded View
        STARTING SYSTEM TESTING FLOW CHART
            Condition: Starter fails to turn over the engine. 
        ELECTRIC BOX LIFT ACTUATOR
            DIAGNOSIS (if equipped)
        ELECTRICAL BREAK-OUT DIAGRAMS
            Starting Circuit
            Key-On Power Circuit
            Transmission Switch Circuit
            AWD Circuit
            Speed Sensor Circuit
            Charging System Circuit
            Cooling Fan Circuit
            Fuel Display / Fuel Pump Circuit
            
9921885_WIRE DIAGRAM

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