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2009 Ranger 4x4 Crew
Polaris 2009 Ranger 4x4 Crew Manuals
Manuals and User Guides for Polaris 2009 Ranger 4x4 Crew. We have
1
Polaris 2009 Ranger 4x4 Crew manual available for free PDF download: Service And Owner's Manual
Polaris 2009 Ranger 4x4 Crew Service And Owner's Manual (687 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 48.79 MB
Table of Contents
English
116
Installation Instructions
49
Limited Warranty
54
Before You Start
61
Rear Panel
62
Care and Maintenance
65
Tools Required
68
Ordering Replacement Parts
111
Table of Contents
116
General Description
117
Specifications
118
Safety Message to Installers
119
Installation
120
Safety Message to Operators
124
Operation
125
Service
127
Priority Sound Elimination
128
Parts List
141
Safety Guidelines
143
General Safety Precautions
157
Winch Basics
159
How the Winch Works
160
Stretching Wire Rope
161
Before You Pull
162
Pulling
163
Rigging Techniques
165
Maintenance
165
The Final Analysis
165
Français
166
Mesures Générales de Sécurité
167
Comment Fonctionne Le Treuil
170
Étirement Initial du Cable
171
Avant de Treuiller
172
Treuillage
173
En Dernière Analyse
175
Safety First
186
Maintenance
175
Techniques de Câblage
175
Vehicle Identification Numbers
195
Safety
196
Equipment Modifications
204
Features and Controls
213
Diagnostic Mode
219
Mode Button
225
Gear Selector
226
Ignition Switch
229
Operation
231
Starting the Engine
233
Stopping the Engine
234
Driving on Slippery Surfaces
236
Driving Uphill
237
Driving Downhill
238
Driving through Water
239
Driving over Obstacles
240
Driving in Reverse
241
Dumping the Cargo Box
245
Emission Control Systems
250
Maintenance
253
Air Filter
276
Filter Systems
276
Brake Inspection
281
Headlight Lamp Replacement
286
Headlight Beam Adjustment
287
Specifications
301
Polaris Products
305
Troubleshooting
306
Warranty
310
Maintenance Schedule
317
Maintenance Log
319
Index
321
Engine Designation Number
332
Engine Serial Number Location
332
General Information
332
Model Identification
332
Model Information
332
Vin Identification
332
Transmission I.D. Number Location
333
Vehicle Identification Number (Vin) Location
333
Ranger 4X4 Crew / 6X6 (Height and Width)
334
Vehicle Dimensions
334
Ranger 4X4 Crew (Length and Wheel Base)
335
Ranger 6X6 (Length and Wheel Base)
335
General Specifications
336
Paint Codes
340
Publication Numbers
340
Replacement Keys
340
Special Tools
340
Vehicle Information
340
Conversion Table
341
Misc. Specifications and Charts
341
Standard Torque Specifications
342
Metric Tap / Drill Sizes
343
Sae Tap / Drill Sizes
343
Glossary of Terms
344
Break-In Period
347
Maintenance Chart Key
347
Periodic Maintenance Chart
347
Periodic Maintenance Overview
347
Pre-Ride - 25 Hour Maintenance Interval
348
50 - 100 Hour Maintenance Interval
349
Polaris Lubricants, Maintenance and Service Products
351
Service Products and Lubes
351
Maintenance References
352
Maintenance References, Continued
353
Frame, Nuts, Bolts, and Fasteners
354
General Vehicle Inspection and Maintenance
354
Pre-Ride / Daily Inspection
354
Shift Linkage Inspection / Adjustment
354
Fuel Filter
355
Fuel Lines
355
Fuel System
355
Fuel System and Air Intake
355
Throttle Pedal Inspection
355
Vent Lines
355
Air Filter Service
356
Throttle Freeplay Adjustment
356
Air Intake Inspection
357
Breather Hose Inspection
358
Compression and Leakdown Test
358
Engine
358
Engine Oil Level
358
Engine Oil and Filter Change
359
Exhaust Pipe
360
Transmission and Gearcases
361
Transmission Lubrication
361
Front Gearcase Lubrication
362
Middle Gearcase Lubrication (6X6)
363
Rear Gearcase Lubrication (4X4 Crew)
364
Rear Gearcase Lubrication (6X6)
365
Coolant Level Inspection
366
Cooling System
366
Liquid Cooling System Overview
366
Coolant Strength / Type
367
Cooling System Hoses
367
Cooling System Pressure Test
367
Radiator Coolant Level Inspection
367
Coolant Drain / Radiator Removal
368
Radiator
368
CV Shaft Boot Inspection
369
Final Drive / Wheel and Tire
369
Wheel and Hub Torque Table
369
Wheel Installation
369
Wheel Removal
369
Battery Maintenance
370
Electrical and Ignition System
370
Tire Inspection
370
Tire Pressure
370
Battery Charging
371
Battery Fluid Level (Conventional Battery)
371
Battery Installation
371
Battery Removal
371
Battery Storage
371
Engine to Frame Ground
372
Spark Plug Service
372
Steering
373
Steering and Suspension
373
Tie Rod End / Steering Inspection
373
Front Suspension
374
Toe Adjustment
374
Rear Spring Adjustment
375
Rear Suspension
375
Rear Suspension Adjustment (4X4 Crew)
375
Brake Fluid Inspection
376
Brake Hose and Fitting Inspection
376
Brake Pad / Disc Inspection
376
Brake System
376
Parking Brake Cable Adjustment
376
Parking Brake Pad Inspection
377
Crankcase Exploded Views
380
Engine Specifications
380
Engine Fastener Torque Patterns
387
Torque Specifications
388
700 EFI Engine Service Specifications
389
Accessible Components
391
Cooling System Specifications
391
General Engine Service
391
Piston Identification
391
Special Tools
391
Cooling System Pressure Test
392
Cooling System Bleeding Procedure
393
Cooling System Exploded View
393
Valve Cover Removal - 6X6 Models (Engine Installed)
395
Engine Removal
396
Engine Installation Notes
397
Engine Lubrication Specifications
398
Oil Pressure Test
398
Oil Flow Chart
399
Cylinder Head Assembly Exploded View
400
Engine Disassembly and Inspection
400
Cylinder Head Removal
401
Rocker Arms / Push Rods
401
Cylinder Head Inspection / Warp
402
Valve Seal / Spring Service (on Engine)
402
Cylinder Head Disassembly
403
Valve Inspection
404
Combustion Chamber
405
Valve Seat Reconditioning
405
Cylinder Head Reassembly
407
Cylinder Removal
408
Valve Lifter Removal / Inspection
408
Valve Sealing Test
408
Piston Removal
409
Cylinder Inspection
410
Cleaning the Cylinder after Honing
411
Cylinder Hone Selection and Honing Procedure
411
Honing to Deglaze
411
Piston / Rod Inspection
412
Piston-To-Cylinder Clearance
412
Piston Ring Installed Gap
413
Starter Drive Bendix Removal / Inspection
413
Engine Crankcase Disassembly / Inspection
414
Flywheel / Stator Removal / Inspection
414
Camshaft Inspection
422
Crankcase Reassembly
423
Engine Reassembly
423
Flywheel / Stator Installation
432
Cylinder Head Reassembly
433
Engine Break-In
435
Oil Pump Priming
435
Engine
436
Troubleshooting
436
Cooling System
437
General Information
440
Special Tools
440
Efi Service Notes
443
Fuel Tank Exploded View
444
Efi System Exploded View
445
Efi System Component Locations
446
Electronic Fuel Injection
447
Fuel Lines - Quick Connect Removal / Installation
447
Initial Priming / Starting Procedure
448
Principal Components / Efi Operation Overview
448
Electronic Control Unit (Ecu)
449
Fuel Pump
450
Fuel Pump Test
450
Fuel Sender Test
450
Fuel Pump / Tank Assembly Replacement
451
Fuel Pressure Regulator
452
Fuel Injectors
453
Crankshaft Position Sensor (Cps)
454
Operation Overview
454
Temperature / Barometric Air Pressure Sensor (T-Bap)
455
Throttle Position Sensor (Tps)
455
Engine Coolant Temperature Sensor (Ect)
458
Tps Replacement
458
Ignition Coil
459
Ignition Coil / Ht Lead Replacement
459
Ignition Coil Tests
459
Diagnostic "Blink Codes
460
General Troubleshooting
460
Efi Troubleshooting
461
Efi System Break-Out Diagrams
462
Fuel Injector Circuit (Mag)
462
Fuel Injector Circuit (Pto)
462
Crankshaft Position Sensor (Cps) Circuit
463
Fuel Pump Circuit
463
Engine Coolant Temperature Sensor (Ect)
464
Temperature Overheat Indicator Lamp Circuit
464
Air Temperature / Barometric Air Pressure Sensor (T-Bap) Circuit
465
Throttle Position Sensor (Tps) Circuit
465
Diagnostic Connector Circuit
466
Diagnostic Indicator Lamp Circuit
466
Body / Steering / Suspension
468
Special Tools
468
Torque Specifications
468
Body Component Removal
469
Removal Procedures
469
Lower Body, Floor and Fenders (4X4 Crew)
470
Lower Body, Floor and Fenders (6X6)
471
Hood / Dash Components
472
Dash Instruments and Controls
473
Assembly / Removal (6X6)
474
Cab Frame
474
Assembly / Removal (4X4 Crew)
475
Seat / Head Rest
476
Chassis / Main Frame (4X4 Crew)
477
Chassis / Main Frame (6X6)
478
Steering Assembly
479
Steering and Suspension
480
Front A-Arm
481
Front Strut
482
Ball Joint Replacement
483
Front Strut Cartridge Replacement
483
MID Axle A-Arm (6X6)
484
Rear A-Arm (4X4 Crew)
485
Rear Stabilizer Bar (4X4 Crew)
487
Swing Arm (6X6)
488
Rear Drive Axle and Swing Arm Exploded View (6X6)
489
Cargo Box - Panels
490
Rear Cargo Box
490
Cargo Box - Tailgate / Box Support
491
Decal Replacement
493
Storage Box (4X4 Crew)
493
Drive Clutch Operation
496
General Operation
496
Pvt System Fastener Torques
496
Pvt System Overview
496
Special Tools and Supplies
496
Torque Specifications
496
Driven Clutch Operation
497
Maintenance / Inspection
497
Pvt Break-In (Drive Belt / Clutches)
497
Overheating / Diagnosis
498
Disassembly
499
Pvt Sealing, Guard, and Ducting Components
499
Pvt System Service
499
Assembly
500
Belt Removal
501
Drive Belt
501
Clutch Alignment
502
Pvt Break-In (Drive Belt / Clutches)
502
Clutch Center Distance
503
Drive Clutch Service
504
Spring Specifications
504
Shift Weights
505
Clutch Disassembly
506
Exploded View
506
Spider Removal
507
Button to Tower Clearance Inspection
508
Roller, Pin, and Thrust Washer Inspection
508
Shift Weight Inspection
508
Bearing Inspection
509
Clutch Inspection
509
Moveable Sheave Bushing Inspection
510
Bushing Service
511
Clutch Assembly
513
Clutch Disassembly / Inspection
514
Driven Clutch Service
514
Exploded View
514
Clutch Assembly
516
Troubleshooting
517
Front Hub
521
Hub Removal / Inspection
521
Special Tools
521
Torque Specifications
521
Wheel, Hub, and Spindle Torque Table
521
Hubstrut Bearing Replacement
522
Hub Installation
523
Front Hub Exploded View
524
Front Drive Shaft
525
Removal
525
Drive Shaft / CV Joint Handling Tips
526
Outer CV Joint / Boot Replacement
526
Inner Plunging Joint / Boot Replacement
528
Exploded View
529
Installation
529
Front Propshaft
530
Front Propshaft Components
530
Propshaft U-Joint Service
531
Centralized Hilliard Exploded View
533
Awd Diagnosis
535
Gearcase Removal
536
Gearcase Disassembly / Inspection
537
Gearcase Reassembly / Inspection
539
Backlash Pad (Thrust Pad) Adjustment
541
Gearcase Installation
542
MID Drive Hub / Bearing Carrier (6X6)
542
Removal
542
Hub Installation
544
Disassembly / Assembly
545
MID Drive Exploded View
545
MID Drive Shaft (6X6)
545
Removal
545
Installation
546
MID Propshaft (6X6)
546
Removal
546
Gearcase Removal
547
MID Drive Gearcase (6X6)
547
Gearcase Disassembly
548
Gearcase Assembly
550
Gearcase Installation
553
MID Gearcase Exploded
554
Rear Hub / Bearing Carrier (4X4)
555
Hub Assembly
556
Hub Disassembly
556
Hub Installation
557
Exploded View
558
Outer CV Joint / Boot Replacement
559
Rear Drive Shaft (4X4 Crew)
559
Removal
559
Inner Plunging Joint / Boot Replacement
562
Drive Shaft Exploded View
564
Installation
565
Installation
566
Rear Propshaft (4X4 Crew)
566
Removal
566
General Operation
567
Rear Gearcase (4X4 Crew)
567
Operation Modes
568
Gearcase Disassembly
569
Gearcase Removal
569
Rear Gearcase Assembly
572
Rear Gearcase Installation
574
Rear Gearcase Exploded View (4X4 Crew)
575
Rear Axle / Gearcase Service (6X6)
576
Rear Axle Removal
576
Axle Tube Removal
577
Axle Tube Bearing Replacement
578
Gearcase Disassembly / Inspection
578
Gearcase Assembly
579
Gearcase / Axle Installation
580
Rear Gearcase Exploded View (6X)
583
Inspection
586
Installation
586
Removal
586
Shift Lever
586
Shift Linkage
586
Torque Specifications
586
Adjustment
587
Transmission Removal
587
Transmission Service
587
Transmission Disassembly
589
Transmission Assembly
594
Transmission Installation
598
Troubleshooting
599
Troubleshooting Checklist
599
Exploded View
600
Transmission Exploded Views
600
General Specifications
604
Special Tools
604
Torque Specifications
604
Brake Noise Troubleshooting
605
Brake System Service Notes
605
Hydraulic Brake System Operation
606
Brake System Exploded View
607
Foot Brake Pedal
608
Master Cylinder
608
Brake Bleeding / Fluid Change
609
Exploded View (4X4 Crew)
610
Parking Brake
610
Exploded View (6X6)
611
Caliper Removal
613
Exploded View
613
Parking Brake Caliper Service
613
Caliper Disassembly / Inspection
614
Caliper Installation
615
New Brake Pad Installation
615
Parking Brake Disc Service
615
Front Brake Pads
616
Brake Burnishing Procedure
617
Pad Assembly / Installation
617
Caliper Removal
618
Front Caliper Service
618
Caliper Disassembly
619
Caliper Installation
621
Front Brake Disc
622
Rear Brake Pads (6X6)
623
Pad Installation
624
Pad Removal
624
Rear Brake Pads (4X4 Crew)
624
Brake Burnishing Procedure
626
Caliper Removal
627
Rear Caliper Service (6X6)
627
Caliper Removal
630
Rear Caliper Service (4X4 Crew)
630
Caliper Disassembly
631
Caliper Installation
633
Rear Brake Disc
634
Troubleshooting
635
Electrical Service Notes
639
General Information
639
Special Tools
639
Under-Hood Components
639
Awd / 2Wd / Turf Switch (4X4 Crew)
640
Differential Solenoid (4X4 Crew)
640
Headlight Switch
640
Switches / Controls
640
Brake Light Switch
641
Parking Brake Switch
642
Instrument Cluster
643
Rider Information Display
643
Diagnostic Display Mode
644
Standard Display Modes
644
Viewing Diagnostic Codes
646
Instrument Cluster Troubleshooting Tests
648
Test 1 - no All Wheel Drive
648
Test 2 - no Display
649
Test 3 - Wheel Speed Sensor
649
Test 4 - no Awd Hub Safety Limiter
650
Test 5 - Fuel Gauge Display Not Working
651
Test 6 - Shift Indicator Not Working (Transmission Switch)
651
All Wheel Drive (Awd) Coil
652
Gear Position Indicator Switch
652
Headlight Housing Removal
653
Lamp Replacement
654
Headlights
653
Headlight Housing Installation
654
Tail Light / Brake Light
654
Cooling System
655
Cooling System Break-Out Diagram
655
Coolant Temperature Sensor
656
Efi Diagnostics
656
Fuel Sender
656
Relays
657
Fuses / Circuit Breaker
658
Charging System
659
Charging System "Break Even" Test
659
Current Draw - Key off
659
Charging System Alternator Tests
660
Charging System Testing Flow Chart
661
Battery Activation
662
Battery Service
662
Battery Inspection
663
Battery Testing
663
Starter Motor Removal / Disassembly
665
Starter System
665
Troubleshooting
665
Voltage Drop Test
665
Brush Inspection / Replacement
666
Armature Testing
667
Starter Reassembly / Installation
667
Starter Drive
668
Starter Solenoid Bench Test
669
Starter Solenoid Operation
669
Starter Exploded View
670
Starting System Testing Flow Chart
671
Diagnosis (if Equipped)
672
Electric Box Lift Actuator
672
Electrical Break-Out Diagrams
673
Key-On Power Circuit
673
Starting Circuit
673
Awd Circuit
674
Transmission Switch Circuit
674
Charging System Circuit
675
Speed Sensor Circuit
675
Cooling Fan Circuit
676
Fuel Display / Fuel Pump Circuit
676
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