Polaris Ranger RZR Repair Service Manual 2009-2010

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This workshop repair service manual PDF download for the 2009-2010 Polaris Ranger RZR 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 - Model No. 
2009 RANGER RZR - R09VH76AD, AG, AH, AM, AO, AP, AS, AZ 
2009 RANGER RZR S - R09VH76AX 
2009 RANGER RZR S INT’L - R09VH76FX 
2010 RANGER RZR - R10VH76AD, AG, AJ, AT 
2010 RANGER RZR S - R10VH76AB, AO, AW 
2010 RANGER RZR S INT’L - R10VH76FX 


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 : 9922534
Total Pages : 361


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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9922534_Chapter_01-GENERAL INFORMATION
    GENERAL INFORMATION
        MODEL INFORMATION
            Model Identification
            Engine Designation Number
            VIN Identification
            Vehicle and Engine Serial Number Location
        VEHICLE INFORMATION
            Publication Numbers
            Replacement Keys
        SPECIAL TOOLS
        2009 GENERAL SPECIFICATIONS
            MODEL: 2009 RANGER RZR
            MODEL: 2009 RANGER RZR
            MODEL: 2009 RANGER RZR S / INT’L
            MODEL: 2009 RANGER RZR S / INT’L
        2010 GENERAL SPECIFICATIONS
            MODEL: 2010 RANGER RZR
            MODEL: 2010 RANGER RZR
            MODEL: 2010 RANGER RZR S / INT’L
            MODEL: 2010 RANGER RZR S / INT’L
        MISC. SPECIFICATIONS AND CHARTS
            Conversion Table
            Standard Torque Specifications
            SAE Tap / Drill Sizes
            Metric Tap / Drill Sizes
            Decimal Equivalents
            Glossary of Terms
            
9922534_Chapter_02-MAINTENANCE
    MAINTENANCE
        PERIODIC MAINTENANCE CHART
            Periodic Maintenance Overview
            Break-In Period
            Maintenance Chart Key
            Pre-Ride - 25 Hour Maintenance Interval
            50 - 300 Hour Maintenance Interval
        COMPONENT INSPECTION / SERVICE LOCATIONS
            Front and Rear View
            RH and LH Side Views
        LUBRICANTS / SERVICE PRODUCTS
            Polaris Lubricants, Maintenance and Service Products
        MAINTENANCE REFERENCES
        GENERAL VEHICLE INSPECTION AND MAINTENANCE
            Pre-Ride / Daily Inspection
            Frame, Nuts, Bolts, and Fasteners
            Shift Cable Inspection / Adjustment
        FUEL SYSTEM AND AIR INTAKE
            Fuel System
            Fuel Line
            Fuel Pump / Fuel Filters
            Vent Lines
            Throttle Pedal Inspection
            Throttle Freeplay Adjustment
            Throttle Cable Replacement
            Air Filter Service
        ENGINE
            Engine Oil Level
            Engine Oil and Filter Service
            Engine Breather Hose Inspection
            Engine and Transmission Mount Locations
            Compression and Leakdown Test
            Exhaust - Spark Arrestor
        TRANSMISSION AND GEARCASES
            Transmission / Gearcase Specification Chart
            Transmission Lubrication
            Front Gearcase Lubrication
            Rear Gearcase Lubrication
        COOLING SYSTEM
            Cooling System Overview
            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
            Wheel Removal
            Wheel Installation
            Tire Inspection
            Tire Pressure
            Drive Shaft Boot Inspection
        ELECTRICAL AND IGNITION SYSTEM
            Battery Maintenance
            Battery Removal
            Battery Installation
            Battery Off Season Storage
            Battery Charging (Maintenance Free)
            Spark Plug Service
            Engine To Frame Ground
        STEERING
            Steering Inspection
            Steering Wheel Freeplay
            Steering Inspection / Tie Rod Ends and Hubs 
            Toe Alignment Inspection
            Toe Adjustment
        SUSPENSION (RZR)
            Spring Preload Adjustment
        SUSPENSION (RZR S)
            Spring Preload Adjustment
            Shock Compression Adjustment
        BRAKE SYSTEM
            Brake Fluid Inspection
            Brake Pad / Disc Inspection
            Brake Hose and Fitting Inspection
        MAINTENANCE LOG
        
9922534_Chapter_03-ENGINE
    ENGINE
        ENGINE SPECIFICATIONS
            Crankcase Exploded Views
            Engine Fastener Torque Patterns
            Torque Specifications
            800 EFI Engine Service Specifications
            Special Tools
        ENGINE COOLING SYSTEM
            Cooling System Specifications
            Cooling System Pressure Test
            Cooling System Exploded View
            Cooling System Bleeding Procedure
        GENERAL ENGINE SERVICE
            Engine Lubrication Specifications
            Accessible Engine Components
            Oil Pressure Test
            Oil Flow Chart
            Engine Removal
            Engine / Transmission Separation
        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 INSTALLATION
            Engine Assembly and Installation
            Engine Break-In Period
        TROUBLESHOOTING
            Engine
            Cooling System
            
9922534_Chapter_04-ELECTRONIC FUEL INJECTION
    ELECTRONIC FUEL INJECTION
        GENERAL INFORMATION
            Special Tools
            Service Notes
            EFI System Exploded View
            EFI System Component Locations
        FUEL TANK
            Exploded View
            Fuel Lines - Quick Connect
        ELECTRONIC FUEL INJECTION
            Principal Components
            EFI Operation Overview
            Initial Priming / Starting Procedure
        ELECTRONIC CONTROL UNIT (ECU)
            Operation Overview
            ECU Service
            ECU Replacement
        TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
            Operation Overview
            T-BAP Test
            T-BAP Replacement
        CRANKSHAFT POSITION SENSOR (CPS)
            Operation Overview
            CPS Test
            CPS Replacement
        FUEL INJECTORS
            Operation Overview
            Fuel Injector Service
            Fuel Injector Test
            Fuel Injector Replacement
        FUEL PUMP
            Operation Overview
            Fuel Sender Test
            Fuel Pump Test
            Fuel Pump Replacement
            Fuel Tank Removal
            Fuel Tank Installation
        THROTTLE POSITION SENSOR (TPS)
            Operation Overview
            TPS Learn Function (2010 Models)
            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
        DIGITAL WRENCH™ OPERATION
            Digital Wrench™ Diagnostic Software Overview
            Special Tools (also refer to page 4.2)
            Diagnostic Software Version
            ECU Replacement
            Guided Diagnostic Available
            Digital Wrench™ Communication Errors
            Digital Wrench™ - Diagnostic Connector
            Digital Wrench™ Serial Number Location
            Digital Wrench™ Version and Update ID
            Digital Wrench™ Updates
            Digital Wrench™ Feature Map
            Engine Controller Reprogramming (Reflash)
            
9922534_Chapter_05-BODY / STEERING / SUSPENSION
    BODY / STEERING / SUSPENSION
        TORQUE SPECIFICATIONS
        SPECIAL TOOLS
            Multi-Function Pliers
        CAB FRAME (RZR)
            Assembly / Removal
        CAB FRAME (RZR S)
            Assembly / Removal
        BODY EXPLODED VIEWS
            Dash Instruments / Controls (RZR / RZR S)
            Dash Instruments / Controls (RZR S INT’L)
            Front Bumper
            Rear Bumper
            Hood / Front Body Work
            Seat Assembly
            Seat Belts / Mounting
            Floor / Rocker Panels
            Rear Cargo Box / Fenders
            Chassis / Main Frame
        BODY COMPONENT REMOVAL
            Seats
            Rear Service Panel
            Front Bumper
            Rear Bumper
            Hood and Front Body Work
            Rocker Panels, Console and Floor
            Rear Fender, Flair and Tie Down Removal
            Cargo Box Assembly Removal
        STEERING ASSEMBLY
            Exploded View (RZR / RZR S)
            Exploded View (RZR S INT’L)
            Steering Wheel Removal
            Steering Shaft Removal
            Steering Shaft Bearing Replacement
        WHEEL HUBS
            Front Hub Exploded View
            Rear Hub Exploded View
        FRONT A-ARMS
            Removal / Replacement
            Exploded View (RZR)
            Exploded View (RZR S)
        BALL JOINT SERVICE
            Removal
            Installation
        FRONT STABILIZER BAR (RZR / RZR S INT’L)
            Sway Bar Linkage Removal
            Stabilizer Bar Removal
            Exploded View
        REAR A-ARMS
            Removal
            Installation
            Exploded View (RZR)
            Exploded View (RZR S)
        REAR STABILIZER BAR (RZR)
            Removal / Installation
        REAR STABILIZER BAR (RZR S)
            Removal / Installation
        DECAL REPLACEMENT
        SHOCKS / SPRINGS (RZR)
            Exploded View
            Shock Removal / Installation
            Shock Replacement
        FOX™ SHOCK EXPLODED VIEW (RZR S)
            FOX™ PODIUM X ‘Piggyback’ Shock
        FOX™ SHOCK SERVICE (RZR S)
            General Service Information
            Front Shock Service Information
            Rear Shock Service Information
            FOX™ PODIUM X Shock Rebuild Information
            FOX™ Podium X Shock Disassembly
            FOX™ Podium X Shock Rebuild
            FOX™ Podium X Shock Reassembly
            
9922534_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 and Ducting Components
            Disassembly
            Assembly
        DRIVE BELT
            Belt Removal
            Belt Inspection
            Belt Installation
            PVT Break-In (Drive Belt / Clutches)
        DRIVE CLUTCH SERVICE
            Spring Specifications
            2009 Shift Weights
            2010 Shift Weights
            2009 Non-Braking Exploded View (RZR)
            2009 EBS Exploded View (RZR S)
            2010 Non-Braking Exploded View (RZR / RZR S)
            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 (EARLY BUILD 2009 RZR / ALL 2009 RZR S)
            Clutch Disassembly 
            Bushing Service
            Clutch Assembly
            Exploded View (Early Build 2009 RZR / All 2009 RZR S)
        DRIVEN CLUTCH SERVICE (LATE BUILD 2009 RZR / ALL 2010 MODELS)
            Exploded View
            Clutch Disassembly / Inspection
            Clutch Assembly
        TROUBLESHOOTING
        
9922534_Chapter_07-FINAL DRIVE
    FINAL DRIVE
        SPECIAL TOOLS
        TORQUE SPECIFICATIONS
            Wheel and Hub Torque Table
        FRONT BEARING CARRIER
            Bearing Carrier Inspection / Removal
            Bearing Replacement
            Bearing Carrier Installation
        FRONT DRIVE SHAFT
            Drive Shaft Removal
            Drive Shaft / CV Joint Handling Tips
            Outer CV Joint / Boot Replacement
            Inner Plunging Joint / Boot Replacement
            Drive Shaft Installation
        PROPSHAFT SERVICE
            Removal / Installation
        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 Assembly / Inspection
            Backlash Thrust Plate Adjustment
            Gearcase Installation
        REAR BEARING CARRIER
            Bearing Carrier Inspection / Removal
            Bearing Replacement
            Bearing Carrier Bushing Replacement
            Bearing Carrier Installation
        REAR DRIVE SHAFT
            Drive Shaft Removal
            Outer CV Joint / Boot Replacement
            Inner Plunging Joint / Boot Replacement
            Drive Shaft Exploded View
            Drive Shaft Installation
        REAR GEARCASE
            Gearcase Removal
            Gearcase Disassembly
            Gearcase Assembly
            Gearcase Installation
            Gearcase Exploded View
        REAR GEARCASE (RZR S INT’L)
            General Operation
            Gearcase Removal
            Gearcase Disassembly
            Differential Disassembly
            Differential Assembly
            Gearcase Assembly
            Gearcase Installation
            Gearcase Exploded View
        WHEEL HUBS
            Front Hub Exploded View
            Rear Hub Exploded View
            
9922534_Chapter_08-TRANSMISSION
    TRANSMISSION
        TORQUE VALUES / SPECIFICATIONS
        SHIFT LEVER
            Removal
            Installation
            Shift Cable Inspection / Adjustment
        TRANSMISSION SERVICE
            Transmission Removal / Service Notes
            Transfer Case Disassembly
            Transfer Case Reassembly
            Transmission Shift Housing Disassembly
            Transmission Shift Housing Reassembly
        TROUBLESHOOTING
            Troubleshooting Checklist
        2009 TRANSMISSION EXPLODED VIEW
            Shift Housing / Transfer Case Exploded View 
        2010 TRANSMISSION EXPLODED VIEW
            Shift Housing / Transfer Case Exploded View 
            
9922534_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
        BRAKE PEDAL LEVER
            Pedal Removal
            Pedal Installation
        BRAKE BLEEDING / FLUID CHANGE
        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 PAD
            Pad Removal
            Pad Inspection
            Pad Assembly / Installation
            Brake Burnishing Procedure
        REAR CALIPER SERVICE
            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
            
9922534_Chapter_10-ELECTRICAL
    ELECTRICAL
        GENERAL INFORMATION
            Special Tools
            Electrical Service Notes
            Under-Dash Components
        SWITCHES / CONTROLS
            Headlamp Switch
            Ignition Switch
            Turn Signal Switch (2010 INT’L Models)
            Brake Light Switch
            AWD / 2WD Switch
            AWD / 2WD / TURF Switch (INT’L Models)
            Differential Solenoid (INT’L Models)
        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 - Vehicle Speed Sensor
            TEST 4 - No AWD Hub Safety Limiter
            TEST 5 - Fuel Gauge Display Not Working 
            TEST 6 - Gear Indicator Not Working (Transmission Switch)
        ALL WHEEL DRIVE COIL
            Operation Overview
            Diagnosing System Failures
        GEAR POSITION INDICATOR SWITCH
            Switch Resistance Value Table
        SPEED SENSOR
            Location / Testing 
        HEAD LIGHTS
            Headlight Adjustment
            Headlamp Bulb Replacement
            Headlamp Housing Removal
            Headlamp Housing Installation
        TAIL / BRAKE LIGHTS
            Bulb Replacement
        COOLING SYSTEM SCHEMATIC
            Cooling System Break-Out Diagram
            Fan Control Circuit Operation / Testing
            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
            Regulator / Rectifier Test
            Charging System Testing Flow Chart
        BATTERY SERVICE
            General Battery Information
            Battery Removal / Installation
            Charging Procedure (Maintenance Free)
            Maintenance Free Battery Testing
            OCV - Open Circuit Voltage Test
            Load Test
            Off Season Storage
        STARTING 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. 
            
9922534_WIRE_DIAGRAMS

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