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2009 RANGER 700
Polaris 2009 RANGER 700 User Manual
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5.7
BODY / STEERING / SUSPENSION
5
Dash Instrument
s and Controls
C
D
E
F
G
A. S
peedometer
B. Headlight Switch
C. 2WD/A
WD Switch
D. 12 V
olt A
ccessory Receptacle
E. S
peedometer “Mode” Button
F
. Key Switch
G
. S
peed
ometer Mount Plate
B
C
D
B
E
F
G
A
A
147
149
Table of Contents
General Information Chapter 1 1
6
Table of Contents
6
Chapter 1
7
Engine Designation Number
7
Engine Serial Number Location
7
Model Identification
7
Model Information
7
Vin Identification
7
Transmission I.D. Number Location
8
Vehicle Identification Number (Vin) Location
8
Vehicle Dimensions
9
Ranger 4X4 Crew / 6X6 (Height and Width)
9
Ranger 6X6 (Length and Wheel Base)
10
Ranger 4X4 Crew (Length and Wheel Base)
10
General Specifications
11
General: 2009 Ranger 4X4 Crew
15
General: 2009 Ranger 6X6
15
Special Tools
15
Vehicle Information
15
Publication Numbers
15
Paint Codes
15
Replacement Keys
15
Misc. Specifications and Charts
16
Conversion Table
16
Standard Torque Specifications
17
Sae Tap / Drill Sizes
18
Metric Tap / Drill Sizes
18
Glossary of Terms
19
General Information
19
Maintenance Chapter 2 Maintenance
20
Break-In Period
22
Chapter 2
22
Maintenance Chart Key
22
Periodic Maintenance Chart
22
Periodic Maintenance Overview
22
Pre-Ride - 25 Hour Maintenance Interval
23
50 - 100 Hour Maintenance Interval
24
Service Products and Lubes
26
Polaris Lubricants, Maintenance and Service Products
26
Brakes
27
Transmission
26
Maintenance References
27
Maintenance References, Continued
28
General Vehicle Inspection and Maintenance
29
Pre-Ride / Daily Inspection
29
Frame, Nuts, Bolts, and Fasteners
29
Shift Linkage Inspection / Adjustment
29
Fuel System and Air Intake
30
Fuel System
30
Fuel Lines
30
Fuel Filter
30
Vent Lines
30
Throttle Pedal Inspection
30
Throttle Freeplay Adjustment
31
Air Filter Service
31
Air Intake Inspection
32
Engine
33
Compression and Leakdown Test
33
Breather Hose Inspection
33
Engine Oil Level
33
Engine Oil and Filter Change
34
Exhaust Pipe
35
Transmission and Gearcases
36
Transmission Lubrication
36
Front Gearcase Lubrication
37
Middle Gearcase Lubrication (6X6)
38
Rear Gearcase Lubrication (4X4 Crew)
39
Rear Gearcase Lubrication (6X6)
40
Cooling System
41
Liquid Cooling System Overview
41
Coolant Level Inspection
41
Radiator Coolant Level Inspection
42
Coolant Strength / Type
42
Cooling System Pressure Test
42
Cooling System Hoses
42
Radiator
43
Coolant Drain / Radiator Removal
43
Final Drive / Wheel and Tire
44
Wheel and Hub Torque Table
44
CV Shaft Boot Inspection
44
Wheel Removal
44
Wheel Installation
44
Tire Inspection
45
Tire Pressure
45
Electrical and Ignition System
45
Battery Maintenance
45
Battery Fluid Level (Conventional Battery)
46
Battery Removal
46
Battery Installation
46
Battery Storage
46
Battery Charging
46
Spark Plug Service
47
Engine to Frame Ground
47
Steering and Suspension
48
Steering
48
Tie Rod End / Steering Inspection
48
Wheel Toe Alignment Inspection
48
Front Suspension
49
Toe Adjustment
49
Rear Suspension
50
Rear Suspension Adjustment (4X4 Crew)
50
Rear Spring Adjustment
50
Brake System
51
Brake Fluid Inspection
51
Brake Hose and Fitting Inspection
51
Brake Pad / Disc Inspection
51
Parking Brake Cable Adjustment
51
Parking Brake Pad Inspection
52
Chapter 3 Engine
54
Crankcase Exploded Views
55
Engine Specifications
55
Engine Fastener Torque Patterns
62
Torque Specifications
63
700 EFI Engine Service Specifications
64
General Engine Service
66
Accessible Components
66
Piston Identification
66
Cooling System Specifications
66
Cooling System Pressure Test
67
Cooling System Exploded View
68
Cooling System Bleeding Procedure
68
Valve Cover Removal - 6X6 Models (Engine Installed)
70
Engine Removal
71
Engine Installation Notes
72
Engine Lubrication Specifications
73
Oil Pressure Test
73
Oil Flow Chart
74
Special Tools
66
Engine Disassembly and Inspection
75
Cylinder Head Assembly Exploded View
75
Rocker Arms / Push Rods
76
Cylinder Head Removal
76
Cylinder Head Inspection / Warp
77
Valve Seal / Spring Service (on Engine)
77
Cylinder Head Disassembly
78
Valve Inspection
79
Combustion Chamber
80
Valve Seat Reconditioning
80
Cylinder Head Reassembly
82
Valve Sealing Test
83
Cylinder Removal
83
Valve Lifter Removal / Inspection
83
Piston Removal
84
Cylinder Inspection
85
Cylinder Hone Selection and Honing Procedure
86
Honing to Deglaze
86
Cleaning the Cylinder after Honing
86
Piston-To-Cylinder Clearance
87
Piston / Rod Inspection
87
Piston Ring Installed Gap
88
Starter Drive Bendix Removal / Inspection
88
Flywheel / Stator Removal / Inspection
89
Engine Crankcase Disassembly / Inspection
89
Camshaft Inspection
97
Engine Reassembly
98
Crankcase Reassembly
98
Flywheel / Stator Installation
107
Cylinder Head Reassembly
108
Oil Pump Priming
110
Engine Break-In
110
Troubleshooting
111
Engine
111
Cooling System
112
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
114
Chapter 4
115
General Information
115
Special Tools
115
Efi Service Notes
118
Fuel Tank Exploded View
119
Efi System Exploded View
120
Efi System Component Locations
121
Throttle Body
121
Electronic Fuel Injection
122
Principal Components / Efi Operation Overview
123
Initial Priming / Starting Procedure
123
Fuel Lines - Quick Connect Removal / Installation
122
Electronic Control Unit (Ecu)
124
Fuel Pump
125
Fuel Sender Test
125
Fuel Pump Test
125
Fuel Pump / Tank Assembly Replacement
126
Fuel Pressure Regulator
127
Fuel Injectors
128
Crankshaft Position Sensor (Cps)
129
Cps Test
129
Cps Replacement
129
Temperature / Barometric Air Pressure Sensor (T-Bap)
130
Throttle Position Sensor (Tps)
130
Tps Adjustment
132
Tps Replacement
133
Engine Coolant Temperature Sensor (Ect)
133
Ignition Coil
134
Ignition Coil Tests
134
Ignition Coil / Ht Lead Replacement
134
Diagnostic "Blink Codes
135
Efi Troubleshooting
136
General Troubleshooting
135
Efi System Break-Out Diagrams
137
Fuel Injector Circuit (Pto)
137
Fuel Injector Circuit (Mag)
137
Crankshaft Position Sensor (Cps) Circuit
138
Fuel Pump Circuit
138
Engine Coolant Temperature Sensor (Ect)
139
Temperature Overheat Indicator Lamp Circuit
139
Throttle Position Sensor (Tps) Circuit
140
Air Temperature / Barometric Air Pressure Sensor (T-Bap) Circuit
140
Diagnostic Connector Circuit
141
Diagnostic Indicator Lamp Circuit
141
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
142
Body / Steering / Suspension
142
Special Tools
143
Torque Specifications
143
Body Component Removal
144
Chapter 5
144
Removal Procedures
144
Lower Body, Floor and Fenders (4X4 Crew)
145
Lower Body, Floor and Fenders (6X6)
146
Hood / Dash Components
147
Dash Instruments and Controls
148
Cab Frame
149
Assembly / Removal (6X6)
149
Assembly / Removal (4X4 Crew)
150
Seat / Head Rest
151
Chassis / Main Frame (4X4 Crew)
152
Chassis / Main Frame (6X6)
153
Steering Assembly
154
Steering and Suspension
155
Front A-Arm
156
Front Strut
157
Front Strut Cartridge Replacement
158
Ball Joint Replacement
158
MID Axle A-Arm (6X6)
159
Rear A-Arm (4X4 Crew)
160
Rear Stabilizer Bar (4X4 Crew)
162
Swing Arm (6X6)
163
Rear Drive Axle and Swing Arm Exploded View (6X6)
164
Rear Cargo Box
165
Cargo Box - Panels
165
Cargo Box - Tailgate / Box Support
166
Decal Replacement
168
Storage Box (4X4 Crew)
168
Clutching Chapter 6 Clutching
170
Chapter 6 Pvt System Fastener Torques
171
Pvt System Overview
171
General Operation
171
Drive Clutch Operation
171
Driven Clutch Operation
172
Pvt Break-In (Drive Belt / Clutches)
172
Maintenance / Inspection
172
Overheating / Diagnosis
173
Special Tools and Supplies
171
Torque Specifications
171
Pvt System Service
174
Pvt Sealing, Guard, and Ducting Components
174
Disassembly
174
Assembly
175
Drive Belt
176
Belt Removal
176
Pvt Break-In (Drive Belt / Clutches)
177
Clutch Alignment
177
Clutch Center Distance
178
Drive Clutch Service
179
Spring Specifications
179
Shift Weights
181
Exploded View
181
Spider Removal
182
Roller, Pin, and Thrust Washer Inspection
183
Button to Tower Clearance Inspection
183
Shift Weight Inspection
183
Bearing Inspection
184
Clutch Inspection
184
Moveable Sheave Bushing Inspection
185
Bushing Service
186
Clutch Assembly
188
Driven Clutch Service
189
Exploded View
189
Clutch Disassembly / Inspection
189
Clutch Assembly
191
Troubleshooting
192
Chapter 7 Final Drive
194
Front Hub
196
Hub Removal / Inspection
196
Hubstrut Bearing Replacement
197
Hub Installation
198
Front Hub Exploded View
199
Special Tools
196
Torque Specifications
196
Final Drive
196
Front Drive Shaft
200
Removal
200
Drive Shaft / CV Joint Handling Tips
201
Outer CV Joint / Boot Replacement
201
Inner Plunging Joint / Boot Replacement
203
Exploded View
204
Installation
204
Front Propshaft
205
Front Propshaft Components
205
Propshaft U-Joint Service
206
Centralized Hilliard Exploded View
208
All Wheel Drive Operation
209
Awd Diagnosis
210
Gearcase Removal
211
Gearcase Disassembly / Inspection
212
Gearcase Reassembly / Inspection
214
Backlash Pad (Thrust Pad) Adjustment
216
Gearcase Installation
217
MID Drive Hub / Bearing Carrier (6X6)
217
Removal
217
Hub Installation
219
MID Drive Exploded View
220
MID Drive Shaft (6X6)
220
Removal
220
Disassembly / Assembly
220
Installation
221
MID Propshaft (6X6)
221
Removal
221
MID Drive Gearcase (6X6)
222
Gearcase Removal
222
Gearcase Disassembly
223
Gearcase Assembly
225
Gearcase Installation
228
MID Gearcase Exploded
229
Rear Drive Shaft (4X4 Crew)
234
Removal
234
Outer CV Joint / Boot Replacement
234
Inner Plunging Joint / Boot Replacement
237
Drive Shaft Exploded View
239
Installation
240
Rear Propshaft (4X4 Crew)
241
Removal
241
Installation
241
Rear Gearcase (4X4 Crew)
242
General Operation
242
Operation Modes
243
Gearcase Removal
244
Gearcase Disassembly
244
Rear Gearcase Assembly
247
Rear Gearcase Installation
249
Rear Gearcase Exploded View (4X4 Crew)
250
Rear Axle / Gearcase Service (6X6)
251
Rear Axle Removal
251
Axle Tube Removal
252
Axle Tube Bearing Replacement
253
Gearcase Disassembly / Inspection
253
Gearcase Assembly
254
Gearcase / Axle Installation
255
Rear Gearcase Exploded View (6X)
258
Transmission Chapter 8 Transmission
260
Chapter 8
261
Installation
261
Removal
261
Shift Lever
261
Shift Linkage
261
Inspection
261
Adjustment
262
Torque Specifications
261
Transmission Service
262
Transmission Removal
262
Transmission Disassembly
264
Transmission Assembly
269
Transmission Installation
273
Troubleshooting
274
Troubleshooting Checklist
274
Transmission Exploded Views
275
Exploded View
275
Brakes Chapter 9 Brakes
278
Chapter 9
279
General Specifications
279
Special Tools
279
Torque Specifications
279
Brake Noise Troubleshooting
280
Brake System Service Notes
280
Hydraulic Brake System Operation
281
Brake System Exploded View
282
Foot Brake Pedal
283
Master Cylinder
283
Brake Bleeding / Fluid Change
284
Parking Brake
285
Exploded View (4X4 Crew)
285
Exploded View (6X6)
286
Parking Brake Caliper Service
288
Exploded View
288
Caliper Removal
288
Caliper Disassembly / Inspection
289
New Brake Pad Installation
290
Caliper Installation
290
Parking Brake Disc Service
290
Front Brake Pads
291
Pad Assembly / Installation
292
Brake Burnishing Procedure
292
Front Caliper Service
293
Caliper Removal
293
Caliper Disassembly
294
Caliper Installation
296
Front Brake Disc
297
Rear Brake Pads (6X6)
298
Pad Installation
299
Rear Brake Pads (4X4 Crew)
299
Pad Removal
299
Brake Burnishing Procedure
301
Rear Caliper Service (6X6)
302
Caliper Removal
302
Rear Caliper Service (4X4 Crew)
305
Caliper Removal
305
Caliper Disassembly
306
Caliper Installation
308
Rear Brake Disc
309
Brakes Lock
310
Pedal Vibration
310
Troubleshooting
310
Electrical Chapter 10 Electrical
312
Chapter 10
314
Electrical Service Notes
314
General Information
314
Special Tools
314
Under-Hood Components
314
Switches / Controls
315
Headlight Switch
315
Awd / 2Wd / Turf Switch (4X4 Crew)
315
Differential Solenoid (4X4 Crew)
315
Brake Light Switch
316
Parking Brake Switch
317
Instrument Cluster
318
Rider Information Display
318
Standard Display Modes
319
Diagnostic Display Mode
319
Viewing Diagnostic Codes
321
Instrument Cluster Installation
322
Instrument Cluster Removal
322
Instrument Cluster Troubleshooting Tests
323
Test 1 - no All Wheel Drive
323
Test 2 - no Display
324
Test 3 - Wheel Speed Sensor
324
Test 4 - no Awd Hub Safety Limiter
325
Test 5 - Fuel Gauge Display Not Working
326
Test 6 - Shift Indicator Not Working (Transmission Switch)
326
All Wheel Drive (Awd) Coil
327
Gear Position Indicator Switch
327
Headlights
328
Headlight Bulb Replacement
328
Headlight Housing Removal
328
Headlight Housing Installation
329
Tail Light / Brake Light
329
Cooling System
330
Cooling System Break-Out Diagram
330
Coolant Temperature Sensor
331
Efi Diagnostics
331
Fuel Sender
331
Relays
332
Power Relay
332
Fuses / Circuit Breaker
333
Charging System
334
Current Draw - Key off
334
Charging System "Break Even" Test
334
Charging System Alternator Tests
335
Charging System Testing Flow Chart
336
Battery Service
337
Battery Activation
337
Battery Inspection
338
Off Season Storage
339
Charging Procedure
339
Load Test
339
Troubleshooting
340
Starter System
340
Voltage Drop Test
340
Starter Motor Removal / Disassembly
340
Brush Inspection / Replacement
341
Armature Testing
342
Starter Reassembly / Installation
342
Starter Drive
343
Starter Solenoid Bench Test
344
Starter Solenoid Operation
344
Starter Exploded View
345
Starting System Testing Flow Chart
346
Electric Box Lift Actuator
347
Diagnosis (if Equipped)
347
Electrical Break-Out Diagrams
348
Starting Circuit
348
Key-On Power Circuit
348
Transmission Switch Circuit
349
Awd Circuit
349
Speed Sensor Circuit
350
Charging System Circuit
350
Cooling Fan Circuit
351
Fuel Display / Fuel Pump Circuit
351
4
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Polaris 2009 RANGER 700 Specifications
General
Brand
Polaris
Model
2009 RANGER 700
Category
Utility Vehicle
Language
English
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