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 !!!!

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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 4×4 CREW / 6X6 (Height and Width)
RANGER 6X6 (Length and Wheel Base)
RANGER 4×4 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 (6×6)
Rear Gearcase Lubrication (4×4 CREW)
Rear Gearcase Lubrication (6×6)
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 (4×4 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 – 6×6 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 (4×4 CREW)
Lower Body, Floor and Fenders (6×6)
Hood / Dash Components
Dash Instruments and Controls
CAB FRAME
Assembly / Removal (6×6)
Assembly / Removal (4×4 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
6×6 Removal
4×4 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 (4×4 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 (6×6)

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
6×6
4×4 CREW
MASTER CYLINDER
Removal
Installation
FOOT BRAKE PEDAL
Pedal Removal
Pedal Installation
BRAKE BLEEDING / FLUID CHANGE
PARKING BRAKE
Exploded View (4×4 CREW)
Exploded View (6×6)
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 (4×4 CREW)
Differential Solenoid (4×4 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