Polaris Ranger 500 4X4 EFI Repair Service Manual 2009

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This workshop repair service manual PDF download for the Polaris Ranger 500 4X4 EFI 2009 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 500 4X4 EFI
MODEL NUMBER: R09HH50AG, AR
ENGINE MODEL: EH500PLE225


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_DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921880
Total Pages : 284


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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9921880_Chapter_01-GENERAL INFORMATION
    GENERAL INFORMATION
        VEHICLE IDENTIFICATION
            Model Identification
            Engine Designation Number
            VIN Identification
            Vehicle and Engine Serial Number Locations
        VEHICLE INFORMATION
            Publication Numbers
            Replacement Keys
        SPECIAL TOOLS
        GENERAL SPECIFICATIONS
            MODEL: 2009 RANGER 500 4X4 EFI
            MODEL: 2009 RANGER 500 4X4 EFI
        MISC. SPECIFICATIONS AND CHARTS
            Conversion Table
            Standard Torque Specifications
            SAE Tap / Drill Sizes
            Metric Tap / Drill Sizes
            Decimal Equivalents
            Glossary of Terms
            
9921880_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
            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 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
            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
            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 AND GEARCASES
            Transmission Lubrication
            Front Gearcase Lubrication
            Rear 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
            Shock Position Adjustment
        BRAKE SYSTEM
            Brake Fluid Inspection
            Brake Hose and Fitting Inspection
            Brake Pad / Disc Inspection
            Parking Brake Cable Adjustment
            Parking Brake Pad Inspection
        MAINTENANCE LOG
        
9921880_Chapter_03-ENGINE
    ENGINE
        SPECIAL TOOLS
        SPECIFICATIONS
            Torque Specifications
            Engine Fastener Torque Patterns
            Engine Service Data
            Engine Service Data
        GENERAL ENGINE SERVICE
            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 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
            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
            
9921880_Chapter_04-ELECTRONIC FUEL INJECTION
    ELECTRONIC FUEL INJECTION
        SPECIAL TOOLS
            Part Numbers / Descriptions
        EFI SERVICE NOTES
            General Service Information
        EFI SYSTEM
            Exploded View
        EFI COMPONENTS
            Identification / Location
        FUEL TANK
            Exploded View
        ELECTRONIC FUEL INJECTION
            General Information
            EFI Operation Overview
            Initial Priming / Starting Procedure
        FUEL LINES
            Quick Connect Removal / Installation
        ELECTRONIC CONTROL UNIT (ECU)
            Operation Overview
            ECU Replacement
            ECU Service
        FUEL PUMP ASSEMBLY
            Operation
            Fuel Sender Test
            Fuel Pump Test
            Fuel Pump / Tank Assembly Replacement
        FUEL PRESSURE REGULATOR
            General Information
        FUEL INJECTOR
            General Information
            Fuel Injector Service
            Fuel Injector Test
            Fuel Injector Replacement
        CRANK POSITION SENSOR (CPS)
            General Information
            CPS Test
            CPS Replacement
        MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)
            General Information
            MAP Sensor Test
            MAP Sensor Replacement
        INTAKE AIR TEMPERATURE SENSOR (IAT)
            General Information
            Intake Air Temperature Sensor Test
            Intake Air Temperature Sensor Replacement
        IDLE AIR CONTROL (IAC)
            General Information
            IAC Test
            IAC Replacement
        THROTTLE POSITION SENSOR (TPS)
            General Information
            TPS Resistance Tests
            TPS Tester Kit
            Checking TPS Reading
            TPS Adjustment
            TPS Replacement
        ENGINE TEMPERATURE SENSOR
            General Information
            Engine Temperature Sensor Test
            Engine Temperature Sensor Replacement
        IGNITION COIL
            Operation Overview
            Ignition Coil Tests
            Ignition Coil and HT Lead Replacement
        DIAGNOSTICS USING “BLINK CODES”
            Blink Codes - Operation
        FUEL SYSTEM TROUBLESHOOTING
            Fuel Starvation / Lean Mixture
            Rich Mixture
            Poor Idle
            
9921880_Chapter_05-BODY / STEERING / SUSPENSION
    BODY / STEERING / SUSPENSION
        TORQUE SPECIFICATIONS
        SPECIAL TOOLS
            Multi-Function Pliers
        CHASSIS / MAIN FRAME
            Exploded View
        CAB FRAME
            Exploded View / Assembly
        SEAT BACK / HEADREST / PVT AIR INTAKE BAFFLE BOX
            Exploded View / Assembly
        BODY EXPLODED VIEWS
            Dash Instruments / Controls
            Hood / Dash / Front Fenders / Front Fascia
            Floor / Rear Fenders
            Seat Mounting / Seat Belts
        REAR CARGO BOX
            Cargo Box - Panels
            Cargo Box - Tailgate / Box Support
            Box Removal
            Box Installation
        BODY COMPONENT REMOVAL
            Lower Seat Base
            Wheel Well Panels
            Front Bumper
            Front Fascia
            Front Fenders
            Hood / Dash
            Glove Box / Storage Panel
            Rear Fenders
            Floor
        STEERING ASSEMBLY
            Exploded View
        FRONT A-ARMS
            Removal / Replacement
            Exploded View
        BALL JOINT SERVICE
            Removal
            Installation
        REAR A-ARMS
            Removal / Replacement
            Installation
            Exploded View
        REAR STABILIZER BAR
            Removal / Installation
            Exploded View
        SHOCKS / SPRINGS
            Exploded View
            Shock Removal / Installation
            Shock Replacement
        DECAL REPLACEMENT
        
9921880_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
        
9921880_Chapter_07-FINAL DRIVE
    FINAL DRIVE
        SPECIAL TOOLS
        TORQUE SPECIFICATIONS
            Wheel, Hub, and Spindle Torque Table
        FRONT BEARING CARRIER
            Bearing Carrier Inspection / Removal
            Bearing Replacement
            Bearing Carrier Installation
        FRONT DRIVE SHAFT
            Removal
            Installation
        FRONT PROPSHAFT
            Removal
            Installation
            Front Propshaft Components
        PROPSHAFT U-JOINT SERVICE
            Disassembly
            Assembly
        FRONT GEARCASE - CENTRALIZED HILLIARD
            Exploded View
            Operation
            AWD Diagnosis
            Gearcase Removal
            Disassembly / Inspection
            Reassembly / Inspection
            Setting Ring Gear Backlash
            Gearcase Installation
        REAR HUB / BEARING CARRIER
            Hub Inspection
            Hub Removal
            Hub Disassembly
            Hub Assembly
            Hub Installation
            Exploded View
        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
        REAR PROPSHAFT
            Removal
            Installation
        REAR GEARCASE
            General Operation
            Operation Modes
            Gearcase Removal
            Gearcase Disassembly
            Rear Gearcase Assembly
            Rear Gearcase Installation
            Rear Gearcase Exploded View
            
9921880_Chapter_08-TRANSMISSION
    TRANSMISSION
        TORQUE SPECIFICATIONS
        SHIFT LEVER
            Removal
            Installation
        SHIFT CABLE
            Inspection
            Adjustment
        TRANSMISSION SERVICE
            Transmission Removal
            Transmission Disassembly
            Transmission Assembly
            Transmission Installation
        TROUBLESHOOTING
            Troubleshooting Checklist
        TRANSMISSION EXPLODED VIEW
            Exploded View
            
9921880_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 Runout
            Disc Inspection
            Disc Removal / Replacement
        REAR BRAKE PADS
            Pad Removal
            Pad Inspection
            Pad Installation
            Brake Burnishing Procedure
        REAR CALIPER SERVICE
            Rear Caliper Exploded View
            Caliper Removal
            Caliper Disassembly
            Caliper Inspection
            Caliper Assembly
            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
            
9921880_Chapter_10-ELECTRICAL
    ELECTRICAL
        GENERAL INFORMATION
            Special Tools
            Electrical Service Notes
            Components Under Hood 
            Components Behind Dash Panel
        SWITCHES / CONTROLS
            Headlight Switch
            AWD / 2WD / TURF Switch
            Differential Solenoid
            Brake Light Switch
            Parking Brake Switch
            Gear Indicator Light Circuit Operation
            Indicator Lamp Replacement
            Fuel / 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
            Cooling System Break-Out Diagram
            Fan Control Circuit Operation
            Fan Control Circuit Bypass Test
        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
            Regulator / Rectifier Test
            Charging System Testing Flow Chart
        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
            Condition: Starter fails to turn over the engine. 
        ELECTRIC BOX LIFT ACTUATOR
            DIAGNOSIS (if equipped)
            
9921880_WIRE_DIAGRAMS

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