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