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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.
More Info : http://www.sitelux.com
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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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Polaris Ranger 2X4 Repair Service Manual 2009.pdf
Source : Sitelux.com
