Polaris Ranger ATV Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Polaris Ranger ATV, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Polaris Ranger ATVs workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 2,910 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

 'Polaris '07 Ranger 700 4X4, 6X6, Ranger XP 700 4X4, 6X6 Service Repair Manual.pdf
 'Polaris '08 Ranger RZR_RZR 'S' Service Repair Manual.pdf
 'Polaris '09 Ranger 4X4 CREW, Ranger 6x6 Service Repair Manual.pdf
 'Polaris '09 Ranger 500 2x4 Service Repair Manual.pdf
 'Polaris '09 Ranger 500 4x4 EFI Service Repair Manual.pdf
 'Polaris '09 Ranger RZR 170 Service Repair Manual.pdf
 'Polaris '09 Ranger RZR_RZR 'S' Service Repair Manual.pdf
 'Polaris '09 Ranger XP700_HD700 4X4 Service Repair Manual.pdf
 'Polaris '11-'14 Ranger Diesel_Crew Service Repair Manual.pdf

TABLE OF CONTENTS
Polaris  '07 Ranger 700 4X4, 6X6, Ranger XP 700 4X4, 6X6 Service Repair Manual....1
  RANGER XP 700 EFI 4X4 / 6X6 SERVICE MANUAL....2
    GENERAL INFORMATION....3
      MODEL INFORMATION....4
        Model Identification....4
        Engine Designation Number....4
        VIN Identification....4
        Engine Serial Number Location....4
        Unit Serial Number (VIN) Location....5
        Transmission I.D. Number Location....5
      VEHICLE DIMENSIONS....6
        RANGER 4X4, 6X6....6
        Vehicle Dimensions RANGER 4X4, 6X6....7
      GENERAL SPECIFICATIONS....8
        MODEL: 2007 RANGER XP 4X4....8
        MODEL: 2007 RANGER XP 6X6....8
        MODEL: 2007 RANGER XP 4X4....9
        MODEL: 2007 RANGER XP 6X6....10
      VEHICLE INFORMATION....11
        Publication Numbers....11
        Paint Codes....11
        Replacement Keys....11
      SPECIAL TOOLS....11
      MISC. SPECIFICATIONS AND CHARTS....12
        Conversion Table....12
        Standard Torque Specifications....13
        SAE Tap / Drill Sizes....14
        Metric Tap / Drill Sizes....14
        Decimal Equivalents....14
        Glossary of Terms....15
    MAINTENANCE....16
      PERIODIC MAINTENANCE CHART....18
        Periodic Maintenance Overview....18
        Maintenance Chart Key....18
        Pre-Ride - 25 Hour Maintenance Interval....19
        50 - 100 Hour Maintenance Interval....20
        100 - 300 Hour Maintenance Interval....21
      GENERAL COMPONENT LOCATIONS....22
        RH Side (4X4) and Dash View....22
        LH Side and Rear View (4X4)....23
        LH Side and RH Side Views (6X6)....24
      SERVICE PRODUCTS AND LUBES....25
        Polaris Lubricants, Maintenance and Service Products....25
      MAINTENANCE REFERENCES....26
        Maintenance References, Continued.......27
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....28
        Pre-Ride / Daily Inspection....28
        Frame, Nuts, Bolts, and Fasteners....28
        Shift Linkage Inspection / Adjustment....28
      FUEL SYSTEM AND AIR INTAKE....29
        Fuel System....29
        Fuel Lines....29
        Fuel Filter....29
        Vent Lines....29
        Throttle Pedal Inspection....29
        Throttle Freeplay Adjustment....30
        Air Filter Service....30
        Air Intake Inspection....31
      ENGINE....32
        Compression and Leakdown Test....32
        Breather Hose Inspection....32
        Engine Oil Level....32
        Engine Oil and Filter Change....33
        Exhaust Pipe....34
      TRANSMISSION AND GEARCASES....35
        Transmission Lubrication....35
        Front Gearcase Lubrication....36
        Middle Gearcase Lubrication (6x6)....37
        Rear Gearcase Lubrication (4x4)....38
        Rear Gearcase Lubrication (6x6)....39
      COOLING SYSTEM....40
        Liquid Cooling System Overview....40
        Coolant Level Inspection....40
        Radiator Coolant Level Inspection....41
        Coolant Strength / Type....41
        Cooling System Pressure Test....41
        Cooling System Hoses....41
        Radiator....42
        Coolant Drain / Radiator Removal....42
      FINAL DRIVE / WHEEL AND TIRE....42
        Wheel, Hub, and Spindle Torque Table....42
        CV Shaft Boot Inspection....43
        Wheel Removal....43
        Wheel Installation....43
        Tire Inspection....43
        Tire Pressure....44
      ELECTRICAL AND IGNITION SYSTEM....44
        Battery Maintenance....44
        Battery Fluid Level (Conventional Battery)....44
        Battery Removal....44
        Battery Installation....45
        Battery Storage....45
        Battery Charging....45
        Spark Plug Service....45
        Engine To Frame Ground....46
      STEERING AND SUSPENSION....46
        Steering....46
        Tie Rod End / Steering Inspection....46
        Camber and Caster....46
        Wheel Toe Alignment Inspection....47
        Toe Adjustment....47
        Front Suspension....48
        Rear Suspension....48
        Rear Suspension Adjustment (4x4)....49
        Rear Spring Adjustment....49
      BRAKE SYSTEM....49
        Brake System Inspection....49
        Brake Pad Inspection....49
        Parking Brake Pad Inspection....50
        Brake Hose and Fitting Inspection....50
    ENGINE....51
      ENGINE SPECIFICATIONS....52
        Crankcase Exploded Views....52
        Engine Fastener Torque Patterns....59
        Torque Specifications....60
        700 EFI Engine Service Specifications....61
        Special Tools....63
      GENERAL ENGINE SERVICE....63
        Accessible Components....63
        Piston Identification....63
        Cooling System Specifications....63
        Cooling System Pressure Test....64
        Cooling System Exploded View....65
        Cooling System Bleeding Procedure....65
        Valve Cover Removal - 6x6 Models (Engine Installed)....67
        Engine Removal....68
        Engine Installation Notes....69
        Cylinder Hone Selection And Honing Procedure....70
        Honing To Deglaze....70
        Cleaning the Cylinder After Honing....71
        Engine Lubrication Specifications....71
        Oil Pressure Test....71
        Oil Flow Chart....72
      ENGINE DISASSEMBLY AND INSPECTION....73
        Cylinder Head Assembly Exploded View....73
        Rocker Arms....74
        Push Rods....74
        Cylinder Head Removal ....74
        Cylinder Head Inspection....75
        Cylinder Head Warp....75
        Valve Seal / Spring Service (On Engine)....75
        Cylinder Head Disassembly....76
        Valve Inspection....77
        Combustion Chamber....78
        Valve Seat Reconditioning....78
        Cylinder Head Reassembly....80
        Valve Sealing Test....81
        Cylinder Removal....81
        Valve Lifter Removal / Inspection....81
        Piston Removal....82
        Cylinder Inspection....83
        Piston-to-Cylinder Clearance....84
        Piston / Rod Inspection....84
        Piston Ring Installed Gap....85
        Starter Drive Bendix Removal / Inspection ....85
        Flywheel / Stator Removal / Inspection....86
        Engine Crankcase Disassembly / Inspection....86
        Camshaft Inspection....94
      ENGINE REASSEMBLY....95
        Crankcase Reassembly....95
        Flywheel / Stator Installation....104
        Cylinder Head Reassembly....104
        Oil Pump Priming....107
      TROUBLESHOOTING....108
        Engine....108
        Cooling System....109
    ELECTRONIC FUEL INJECTION....110
      GENERAL INFORMATION....111
        Special Tools....111
        Service Notes....113
        EFI System Exploded View....114
        EFI System Component Locations....115
      FUEL TANK....117
        Exploded View....117
        Fuel Lines - Quick Connect....118
      ELECTRONIC FUEL INJECTION....118
        Principal Components....118
        EFI Operation Overview....118
        Initial Priming / Starting Procedure....119
      ELECTRONIC CONTROL UNIT (ECU)....119
        Operation Overview....119
        ECU Service....120
        ECU Replacement....120
      FUEL PUMP....120
        Operation Overview....120
        Fuel Pump Test....121
        Fuel Pump / Tank Assembly Replacement....121
      FUEL PRESSURE REGULATOR....123
        Operation Overview....123
        Fuel Pressure Regulator Test....123
        Fuel Pressure Regulator Replacement....123
      FUEL INJECTORS....123
        Operation Overview....123
        Fuel Injector Service....124
        Fuel Injector Replacement....124
      CRANKSHAFT POSITION SENSOR (CPS)....124
        Operation Overview....124
        CPS Test....125
        CPS Replacement....125
      TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....125
        Operation Overview....125
        T-BAP Test....125
        T-BAP Replacement....125
      THROTTLE POSITION SENSOR (TPS)....126
        Operation Overview....126
        TPS Test....126
        TPS Initialization....127
        TPS Replacement....128
      ENGINE COOLANT TEMPERATURE SENSOR (ECT)....128
        Operation Overview....128
        ECT Sensor Test....129
        ECT Sensor Replacement....129
      GENERAL TROUBLESHOOTING....130
        Diagnostic “Blink Codes”....130
        EFI Troubleshooting....131
    BODY / STEERING / SUSPENSION....132
      TORQUE SPECIFICATIONS....133
      SPECIAL TOOLS....133
      BODY COMPONENT REMOVAL....134
        Removal Procedures....134
        Lower Body Components....135
        Hood / Dash Components....136
        Dash Instruments and Controls....137
      CAB FRAME....138
        Assembly / Removal....138
      CHASSIS / MAIN FRAME (4x4)....139
        Exploded View....139
      CHASSIS / MAIN FRAME (6x6)....140
        Exploded View....140
      SEAT / HEAD REST....141
        Seat Base / Seat Back / Head Rest Assembly....141
      STEERING ASSEMBLY....142
        Exploded View....142
      STEERING AND SUSPENSION....143
        Exploded View....143
      FRONT A-ARM....144
        Replacement....144
      FRONT STRUT....145
        Exploded View....145
        Front Strut Cartridge Replacement....146
        Ball Joint Replacement....146
      MID AXLE A-ARM (6x6)....147
        Replacement....147
      REAR A-ARM (4x4)....148
        Replacement....148
      REAR STABILIZER BAR (4x4)....150
        Removal / Installation....150
      SWING ARM (6X6)....151
        Removal....151
        Installation....151
      REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6x6)....152
      REAR CARGO BOX....153
        Cargo Box - Panels....153
        Cargo Box - Tailgate / Box Support....154
        Box Removal....155
        Box Installation....155
      STORAGE BOX....156
        Removal....156
        Installation....156
      DECAL REPLACEMENT....156
    CLUTCHING....157
      SPECIAL TOOLS AND SUPPLIES....158
      TORQUE SPECIFICATIONS....158
        PVT System Fastener Torques....158
      PVT SYSTEM OVERVIEW....158
        General Operation....158
        Drive Clutch Operation....158
        Driven Clutch Operation....159
        Maintenance / Inspection....159
        Overheating / Diagnosis....160
      PVT SYSTEM SERVICE....161
        PVT Sealing, Guard, and Ducting Components....161
        Disassembly....161
        Assembly....162
      DRIVE BELT....163
        Belt Deflection (Tension)....163
        Belt Removal....163
        Belt Inspection....164
        Belt Installation....165
      CLUTCH ALIGNMENT / OFFSET....165
        Clutch Alignment....165
        Clutch Offset....166
      DRIVE CLUTCH SERVICE....167
        Spring Specifications....167
        Shift Weights....168
        Exploded View....169
        Clutch Inspection....169
        Clutch Disassembly....170
        Spider Removal....171
        Roller, Pin, and Thrust Washer Inspection....171
        Bushing Service....172
        Moveable Sheave - Bushing Removal....172
        Moveable Sheave - Bushing Installation....172
        Clutch Cover - Bushing Removal....173
        Clutch Cover - Bushing Installation....173
        Clutch Assembly....174
      DRIVEN CLUTCH SERVICE....175
        Exploded View....175
        Clutch Disassembly / Inspection....175
        Clutch Assembly....177
      TROUBLESHOOTING....178
    FINAL DRIVE....180
      SPECIAL TOOLS....182
      TORQUE SPECIFICATIONS....182
        Wheel, Hub, and Spindle Torque Table....182
      FRONT HUB....182
        Hub Removal / Inspection....182
        Hubstrut Bearing Replacement....183
        Hub Installation....184
        Front Hub Exploded View....185
      DRIVE SHAFT / PROPSHAFT....186
        Exploded View....186
      DRIVESHAFT / CV JOINT HANDLING TIPS....187
      FRONT DRIVE SHAFT....187
        Removal....187
        CV Joint / Boot Replacement....188
        Installation....190
      FRONT PROPSHAFT REMOVAL....190
      PROPSHAFT U-JOINT SERVICE....191
        Disassembly....191
        Assembly....192
      FRONT GEARCASE CENTRALIZED HILLIARD....193
        AWD Operation....193
        Centralized Hilliard Exploded View....194
        AWD Diagnosis....195
        Gearcase Removal....196
        Gearcase Disassembly / Inspection....197
        Gearcase Reassembly / Inspection....199
        Backlash Pad (Thrust Pad) Adjustment....201
        Gearcase Installation....202
      MID DRIVE HUB / BEARING CARRIER (6x6)....202
        Removal....202
        Hub Disassembly....203
        Hub Assembly....203
        Hub Installation....204
        Mid Drive Exploded View....205
      MID DRIVE SHAFT (6x6)....206
        Removal....206
        Disassembly / Assembly....206
        Installation....206
      MID PROP SHAFT (6x6)....207
        Removal....207
      MID DRIVE GEARCASE (6x6)....207
        Gearcase Removal....207
        Gearcase Disassembly....208
        Gearcase Assembly....211
        Gearcase Installation....213
        Mid Gearcase Exploded....214
      REAR DRIVE (4x4)....215
        Exploded View....215
      REAR HUB / BEARING CARRIER (4x4)....215
        Hub Inspection....215
        Hub Removal....215
        Hub Disassembly....216
        Hub Assembly....217
        Hub Installation....217
      REAR DRIVE SHAFT (4X4)....218
        Removal....218
        CV Joint / Boot Replacement....219
        Installation....221
      REAR PROPSHAFT (4x4)....222
        Removal....222
        Installation....222
      REAR GEARCASE (4x4)....223
        General Operation....223
        Operation Modes....224
        Differential Removal....225
        Differential Disassembly....225
        Differential Assembly....228
        Differential Installation....230
        Differential Exploded View....231
      REAR AXLE / GEARCASE SERVICE (6x6)....232
        Rear Axle Removal....232
        Axle Tube Removal....233
        Axle Tube Bearing Replacement....234
        Gearcase Disassembly / Inspection....234
        Gearcase Assembly....235
        Gearcase / Axle Installation....236
        Gearcase Exploded View....239
    TRANSMISSION....240
      TORQUE SPECIFICATIONS....241
      SHIFT LEVER....241
        Removal....241
        Installation....241
      SHIFT LINKAGE....241
        Inspection....241
        Adjustment....242
      TRANSMISSION SERVICE....242
        Transmission Removal....242
        Transmission Disassembly....244
        Transmission Assembly....249
        Transmission Installation....253
      TROUBLESHOOTING....254
        Troubleshooting Checklist....254
      TRANSMISSION EXPLODED VIEW....255
        Exploded View (4x4, 6x6)....255
    BRAKES....257
      GENERAL SPECIFICATIONS....258
      TORQUE SPECIFICATIONS....258
      SPECIAL TOOLS....258
      BRAKE SYSTEM SERVICE NOTES....259
      BRAKE NOISE TROUBLESHOOTING....259
      HYDRAULIC BRAKE SYSTEM OPERATION....260
      BRAKE SYSTEM EXPLODED VIEW....261
      MASTER CYLINDER....262
        Removal....262
        Installation....262
      FOOT BRAKE PEDAL....262
        Pedal Removal....262
        Pedal Installation....262
      BRAKE BLEEDING / FLUID CHANGE....263
      PARKING BRAKE....264
        Exploded View....264
        Inspection....265
        Adjustment....265
      PARKING BRAKE CALIPER SERVICE....266
        Exploded View....266
        Caliper Removal....266
        Caliper Disassembly / Inspection....267
        New Brake Pad Installation....268
        Caliper Installation....268
      PARKING BRAKE DISC SERVICE....268
        Disc Removal / Inspection....268
      FRONT BRAKE PADS....269
        Pad Removal / Disassembly....269
        Pad Inspection....269
        Pad Assembly / Installation....270
        Pad Adjustment....270
      FRONT CALIPER....271
        Front Caliper Exploded View....271
        Caliper Removal....271
        Caliper Disassembly....271
        Caliper Inspection....272
        Caliper Assembly....272
        Caliper Installation....273
      FRONT BRAKE DISC....274
        Disc Inspection....274
        Disc Removal / Replacement....274
      REAR BRAKE PAD (4x4)....274
        Pad Removal....274
        Pad Inspection....275
        Pad Installation....275
      REAR BRAKE PAD (6x6)....276
        Pad Removal....276
        Pad Inspection....277
        Pad Installation....277
      REAR CALIPER....278
        Rear Caliper Exploded View....278
        Caliper Removal (4x4)....278
        Caliper Removal (6x6)....279
        Caliper Disassembly....279
        Caliper Inspection....280
        Caliper Assembly....280
        Caliper Installation (4x4, 6x6)....281
      REAR BRAKE DISC....281
        Disc Inspection....281
      TROUBLESHOOTING....282
        Brakes Squeal / Poor Brake Performance....282
        Pedal Vibration....282
        Caliper Overheats (Brakes Drag)....282
        Brakes Lock....282
    ELECTRICAL....283
      GENERAL INFORMATION....285
        Special Tools....285
        Electrical Service Notes....285
        Under-Hood Components....285
      SWITCHES / CONTROLS....286
        Headlamp Switch....286
        AWD / Rear Differential Switch (4x4)....286
        Differential Solenoid (4x4)....286
        Brake Light Switch....287
        Parking Brake Switch....288
      INSTRUMENT CLUSTER....289
        Overview....289
        Rider Information Display....289
        Standard Display Modes....290
        Diagnostic Display Mode....290
        Viewing Diagnostic Codes....292
        Instrument Cluster Removal....293
        Instrument Cluster Installation....293
      INSTRUMENT CLUSTER TROUBLESHOOTING TESTS....294
        Test 1 - No All Wheel Drive....294
        TEST 2 - No Display....295
        TEST 3 - Wheel Speed Sensor....295
        TEST 4 - No AWD Hub Safety Limiter....296
        TEST 5 - Fuel Gauge Display Not Working ....297
        TEST 6 - Shift Indicator Not Working (Transmission Switch)....297
      ALL WHEEL DRIVE (AWD) COIL....298
        Operation Overview....298
        Diagnosing System Failures....298
      GEAR POSITION INDICATOR SWITCH....298
        Test Diagram....298
      HEAD LIGHTS....299
        High Beam Headlight Adjustment....299
        Headlamp Bulb Replacement....299
        Headlamp Housing Removal....299
        Headlamp Housing Installation....300
      TAIL LIGHT / BRAKE LIGHT....300
        Lamp Replacement....300
      COOLING SYSTEM....301
        Cooling System Break-Out Diagram....301
        Fan Control Circuit Operation / Testing....302
        Fan Control Circuit Bypass Test....302
        Coolant Temperature Sensor....302
      EFI DIAGNOSTICS....302
        EFI Component Testing....302
      FUEL SENDER....302
        Testing....302
      RELAYS....303
        Operation....303
      FUSES / CIRCUIT BREAKER....304
        Operation....304
      CHARGING SYSTEM....304
        Current Draw - Key Off....304
        Charging System “Break Even” Test....305
        Charging System Alternator Tests....305
        Charging System Testing Flow Chart....307
      BATTERY TERMINAL BLOCK....308
      BATTERY SERVICE....308
        Battery Terminals / Bolts....308
        Battery Identification....308
      CONVENTIONAL BATTERY....309
        Battery Activation....309
        Battery Inspection....309
        Battery Removal....310
        Battery Installation....310
        Conventional Battery Testing....310
        OCV - Open Circuit Voltage Test....310
        Specific Gravity Test....310
        Load Test....311
        Off Season Storage....311
        Charging Procedure....311
      LOW MAINTENANCE BATTERY....312
        Battery Check....312
        Battery Inspection ....312
        Battery Removal....312
        Battery Installation....313
        Battery Testing....313
        OCV - Open Circuit Voltage Test....313
        Load Test....313
        Off-Season Storage....314
        Battery Charging ....314
      STARTER SYSTEM....315
        Troubleshooting....315
        Voltage Drop Test....315
        Starter Motor Removal / Disassembly ....315
        BRUSH INSPECTION / REPLACEMENT....316
        Armature Testing....317
        Starter Reassembly / Installation....317
        Starter Solenoid Bench Test....318
        Starter Drive....318
        Starter Exploded View....319
      STARTER SYSTEM TESTING FLOW CHART....320
        Condition: Starter fails to turn over the engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test....320
      ELECTRIC BOX LIFT ACTUATOR....321
        DIAGNOSIS (if equipped)....321
    INDEX....322
    WIRE DIAGRAMS....326
Polaris  '08 Ranger RZR_RZR  'S ' Service Repair Manual....330
  2008 RANGER RZR SERVICE MANUAL....330
    FOREWORD....330
    UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS....331
    TRADEMARKS....331
  GENERAL INFORMATION....333
    MODEL INFORMATION....334
      Model Identification....334
      Engine Designation Number....334
      VIN Identification....334
      Engine Serial Number Location....334
      Unit Serial Number (VIN) Location....335
    GENERAL SPECIFICATIONS....336
      MODEL: 2008 RANGER RZR....336
      MODEL: 2008 RANGER RZR....337
    VEHICLE INFORMATION....338
      Publication Numbers....338
      Paint Codes....338
      Replacement Keys....338
    SPECIAL TOOLS....338
    MISC. SPECIFICATIONS AND CHARTS....339
      Conversion Table....339
      Standard Torque Specifications....340
      SAE Tap / Drill Sizes....341
      Metric Tap / Drill Sizes....341
      Decimal Equivalents....341
      Glossary of Terms....342
  MAINTENANCE....343
    PERIODIC MAINTENANCE CHART....345
      Periodic Maintenance Overview....345
      Break-In Period....345
      Maintenance Chart Key....345
      Pre-Ride - 25 Hour Maintenance Interval....346
      50 - 300 Hour Maintenance Interval....347
    COMPONENT INSPECTION / SERVICE LOCATIONS....348
      Front and Rear View....348
      RH and LH Side Views....349
    LUBRICANTS / SERVICE PRODUCTS....350
      Polaris Lubricants, Maintenance and Service Products....350
    MAINTENANCE REFERENCES....351
    GENERAL VEHICLE INSPECTION AND MAINTENANCE....352
      Pre-Ride / Daily Inspection....352
      Frame, Nuts, Bolts, and Fasteners....352
      Shift Cable Inspection / Adjustment....352
    FUEL SYSTEM AND AIR INTAKE....353
      Fuel System....353
      Fuel Line....353
      Fuel Pump / Fuel Filters....353
      Vent Lines....353
      Throttle Pedal Inspection....354
      Throttle Freeplay Adjustment....354
      Air Filter Service....354
    ENGINE....356
      Engine Oil Level....356
      Engine Oil and Filter Service....357
      Engine Breather Hose Inspection....358
      Engine and Transmission Mount Locations....358
      Compression and Leakdown Test....358
      Exhaust - Spark Arrestor....358
    TRANSMISSION AND GEARCASES....359
      Transmission / Gearcase Specification Chart....359
      Transmission Lubrication....359
      Front Gearcase Lubrication....361
      Rear Gearcase Lubrication....362
    COOLING SYSTEM....363
      Cooling System Overview....363
      Coolant Level Inspection....363
      Coolant Strength / Type....363
      Cooling System Pressure Test....364
      Cooling System Hoses....364
      Radiator....364
      Coolant Drain / Radiator Removal....364
    FINAL DRIVE / WHEEL AND TIRE....365
      Wheel, Hub, and Spindle Torque Table....365
      Wheel Removal....365
      Wheel Installation....365
      Tire Inspection....366
      Tire Pressure....366
      Drive Shaft Boot Inspection....366
    ELECTRICAL AND IGNITION SYSTEM....367
      Battery Maintenance....367
      Battery Removal....367
      Battery Installation....367
      Battery Off Season Storage....368
      Battery Charging (Sealed Battery)....368
      Spark Plug Service....368
      Engine To Frame Ground....369
    STEERING AND SUSPENSION....369
      Steering Inspection....369
      Steering Wheel Freeplay....369
      Steering Inspection / Tie Rod Ends and Hubs ....370
      Toe Alignment Inspection....370
      Toe Adjustment....371
      Suspension Spring Preload Adjustment....371
    BRAKE SYSTEM....372
      Brake Fluid Inspection....372
      Brake Pad / Disc Inspection....372
      Brake Hose and Fitting Inspection....372
  ENGINE....373
    ENGINE SPECIFICATIONS....374
      Crankcase Exploded Views....374
      Engine Fastener Torque Patterns....379
      Torque Specifications....380
      800 EFI Engine Service Specifications....381
      Special Tools....383
    ENGINE COOLING SYSTEM....384
      Cooling System Specifications....384
      Cooling System Pressure Test....384
      Cooling System Exploded View....385
      Cooling System Bleeding Procedure....386
    GENERAL ENGINE SERVICE....387
      Engine Lubrication Specifications....387
      Accessible Engine Components....387
      Oil Pressure Test....387
      Oil Flow Chart....388
      Engine Removal....389
      Engine / Transmission Separation....395
    ENGINE DISASSEMBLY AND INSPECTION....396
      Cylinder Head Assembly Exploded View....396
      Rocker Arms....397
      Push Rods....397
      Cylinder Head Removal ....397
      Cylinder Head Inspection....398
      Cylinder Head Warp....398
      Valve Seal / Spring Service (On Engine)....398
      Cylinder Head Disassembly....399
      Valve Inspection....400
      Combustion Chamber....401
      Valve Seat Reconditioning....401
      Cylinder Head Reassembly....403
      Valve Sealing Test....404
      Cylinder Removal....404
      Valve Lifter Removal / Inspection....404
      Piston Removal....405
      Cylinder Inspection....406
      Cylinder Hone Selection and Honing Procedure....407
      Honing To Deglaze....407
      Cleaning the Cylinder After Honing....407
      Piston-to-Cylinder Clearance....408
      Piston / Rod Inspection....408
      Piston Ring Installed Gap....409
      Starter Drive Bendix Removal / Inspection ....409
      Flywheel / Stator Removal / Inspection....410
      Engine Crankcase Disassembly / Inspection....410
      Camshaft Inspection....418
    ENGINE REASSEMBLY....419
      Crankcase Reassembly....419
      Flywheel / Stator Installation....428
      Cylinder Head Reassembly....428
      Oil Pump Priming....430
    ENGINE INSTALLATION....431
      Engine Assembly and Installation....431
      Engine Break-In Period....433
    TROUBLESHOOTING....434
      Engine....434
      Cooling System....435
  ELECTRONIC FUEL INJECTION....436
    GENERAL INFORMATION....437
      Special Tools....437
      Service Notes....440
      EFI System Exploded View....441
      EFI System Component Locations....442
    FUEL TANK....444
      Exploded View....444
      Fuel Lines - Quick Connect....445
    ELECTRONIC FUEL INJECTION....445
      Principal Components....445
      EFI Operation Overview....445
      Initial Priming / Starting Procedure....446
    ELECTRONIC CONTROL UNIT (ECU)....446
      Operation Overview....446
      ECU Service....447
      ECU Replacement....447
    TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....447
      Operation Overview....447
      T-BAP Test....447
      T-BAP Replacement....447
    CRANKSHAFT POSITION SENSOR (CPS)....448
      Operation Overview....448
      CPS Test....448
      CPS Replacement....449
    FUEL INJECTORS....453
      Operation Overview....453
      Fuel Injector Service....453
      Fuel Injector Test....454
      Fuel Injector Replacement....454
    FUEL PUMP....456
      Operation Overview....456
      Fuel Sender Test....456
      Fuel Pump Test....456
      Fuel Tank / Fuel Pump Replacement....458
    FUEL PRESSURE REGULATOR....460
      Operation Overview....460
      Fuel Pressure Regulator Test....460
      Fuel Pressure Regulator Replacement....460
    THROTTLE POSITION SENSOR (TPS)....461
      Operation Overview....461
      TPS Test Procedure....461
      TPS Initialization....463
      TPS Replacement....464
    ENGINE COOLANT TEMPERATURE SENSOR (ECT)....465
      Operation Overview....465
      ECT Sensor Test....465
      ECT Sensor Replacement....465
    IGNITION COIL....466
      Operation Overview....466
      Ignition Coil Tests....466
      Ignition Coil / HT Lead Replacement....466
    GENERAL TROUBLESHOOTING....467
      Diagnostic “Blink Codes”....467
      EFI Troubleshooting....468
    EFI SYSTEM BREAKOUT DIAGRAMS....469
      Diagnostic Connector Circuit....469
      Malfunction Indicator Lamp (MIL) Circuit....469
      Fuel Injector (PTO) Circuit....470
      Fuel Injector (MAG) Circuit....470
      Engine Coolant Temperature Sensor (ECT) Circuit....471
      Engine Overheat Lamp Driver Circuit....471
      Crankshaft Position Sensor (CPS) Circuit....472
      Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit....472
      Throttle Position Sensor (TPS) Circuit....473
      Fuel Pump Circuit....473
  BODY / STEERING / SUSPENSION....474
    TORQUE SPECIFICATIONS....475
    SPECIAL TOOLS....475
      Multi-Function Pliers....475
    CAB FRAME....476
      Assembly / Removal....476
    BODY EXPLODED VIEWS....477
      Dash Instruments / Controls....477
      Front Bumper....478
      Rear Bumper....478
      Hood / Front Body Work....479
      Seat Assembly....480
      Seat Belts / Mounting....480
      Floor / Rocker Panels....481
      Rear Cargo Box / Fenders....482
      Chassis / Main Frame....483
    BODY COMPONENT REMOVAL....484
      Seats....484
      Rear Service Panel....484
      Front Bumper....484
      Rear Bumper....484
      Hood and Front Body Work....485
      Rocker Panels, Console and Floor....486
      Rear Fender, Flair and Tie Down Removal....486
      Cargo Box Assembly Removal....486
    STEERING ASSEMBLY....487
      Exploded View....487
    WHEEL HUBS....488
      Front Hub Exploded View....488
      Rear Hub Exploded View....488
    FRONT A-ARMS....489
      Removal / Replacement....489
      Exploded View....490
    BALL JOINT SERVICE....490
      Removal....490
      Installation....491
    FRONT STABILIZER BAR....492
      Sway Bar Linkage Removal....492
      Stabilizer Bar Removal....492
      Exploded View....493
    REAR A-ARMS....494
      Removal....494
      Installation....495
      Exploded View....495
    REAR STABILIZER BAR....496
      Removal / Installation....496
    SHOCKS / SPRINGS....497
      Exploded View....497
      Shock Removal / Installation....497
      Shock Replacement....497
    DECAL REPLACEMENT....497
  CLUTCHING....498
    SPECIAL TOOLS AND SUPPLIES....499
    TORQUE SPECIFICATIONS....499
      PVT System Fastener Torques....499
    PVT SYSTEM OVERVIEW....499
      General Operation....499
      Drive Clutch Operation....499
      Driven Clutch Operation....500
      PVT Break-In (Drive Belt / Clutches)....500
      Maintenance / Inspection....500
      Overheating / Diagnosis....501
    PVT SYSTEM SERVICE....502
      PVT Sealing and Ducting Components....502
      Disassembly....502
      Assembly....503
    DRIVE BELT....504
      Belt Removal....504
      Belt Inspection....505
      Belt Installation....505
      PVT Break-In (Drive Belt / Clutches)....505
    DRIVE CLUTCH SERVICE....506
      Spring Specifications....506
      Shift Weights....507
      Exploded View....508
      Clutch Disassembly....508
      Spider Removal....509
      Roller, Pin, and Thrust Washer Inspection....510
      Button To Tower Clearance Inspection....510
      Shift Weight Inspection....510
      Bearing Inspection....511
      Clutch Inspection....511
      Moveable Sheave Bushing Inspection....512
      Bushing Service....513
      Clutch Assembly....515
    DRIVEN CLUTCH SERVICE....516
      Clutch Disassembly ....516
      Bushing Service....518
      Clutch Assembly....520
      Exploded View....523
    TROUBLESHOOTING....524
  FINAL DRIVE....526
    SPECIAL TOOLS....527
    TORQUE SPECIFICATIONS....527
      Wheel, Hub, and Spindle Torque Table....527
    FRONT BEARING CARRIER....527
      Bearing Carrier Inspection / Removal....527
      Bearing Replacement....528
      Bearing Carrier Installation....529
    FRONT DRIVE SHAFT....531
      Drive Shaft Removal....531
      Drive Shaft / CV Joint Handling Tips....532
      CV Joint / Boot Replacement....532
      Drive Shaft Installation....533
    PROPSHAFT SERVICE....535
      Removal / Installation....535
    PROPSHAFT U-JOINT SERVICE....535
      Disassembly....535
      Assembly....536
    FRONT GEARCASE / CENTRALIZED HILLIARD....537
      Centralized Hilliard Exploded View....537
      All Wheel Drive Operation....538
      AWD Diagnosis....539
      Gearcase Removal....540
      Gearcase Disassembly / Inspection....540
      Gearcase Assembly / Inspection....542
      Backlash Thrust Plate Adjustment....544
      Gearcase Installation....545
    REAR BEARING CARRIER....546
      Bearing Carrier Inspection / Removal....546
      Bearing Replacement....547
      Bearing Carrier Bushing Replacement....547
      Bearing Carrier Installation....548
    REAR DRIVE SHAFT....549
      Removal....549
      Outer CV Joint / Boot Replacement....550
      Inner Plunging Joint / Boot Replacement....552
      Installation....554
    REAR GEARCASE....556
      Gearcase Removal....556
      Gearcase Disassembly....557
      Gearcase Assembly....559
      Gearcase Installation....560
      Gearcase Exploded View....561
    WHEEL HUBS....562
      Front Hub Exploded View....562
      Rear Hub Exploded View....562
  TRANSMISSION....563
    TORQUES / SPECIFICATIONS....564
    SHIFT LEVER....564
      Removal....564
      Installation....564
      Shift Cable Inspection / Adjustment....565
    TRANSMISSION SERVICE....566
      Transmission Removal / Service Notes....566
      Transfer Case Disassembly....566
      Transfer Case Reassembly....569
      Transmission Shift Housing Disassembly....571
      Transmission Shift Housing Reassembly....576
    TROUBLESHOOTING....581
      Troubleshooting Checklist....581
    TRANSMISSION EXPLODED VIEWS....582
      Shift Housing / Transfer Case Exploded View ....582
  BRAKES....583
    GENERAL SPECIFICATIONS....584
    TORQUE SPECIFICATIONS....584
    SPECIAL TOOLS....584
    BRAKE SYSTEM SERVICE NOTES....585
    BRAKE NOISE TROUBLESHOOTING....585
    HYDRAULIC BRAKE SYSTEM OPERATION....586
    BRAKE SYSTEM EXPLODED VIEW....586
    MASTER CYLINDER....587
      Removal....587
      Installation....587
    BRAKE PEDAL LEVER....587
      Pedal Removal....587
      Pedal Installation....587
    BRAKE BLEEDING / FLUID CHANGE....588
    FRONT BRAKE PADS....589
      Pad Removal....589
      Pad Inspection....589
      Pad Assembly / Installation....590
      Brake Burnishing Procedure....590
    FRONT CALIPER SERVICE....591
      Caliper Exploded View....591
      Caliper Removal ....591
      Caliper Disassembly....592
      Caliper Inspection....593
      Caliper Assembly....593
      Caliper Installation....594
    FRONT BRAKE DISC....595
      Disc Inspection....595
      Disc Replacement....595
    REAR BRAKE PAD....596
      Pad Removal....596
      Pad Inspection....597
      Pad Assembly / Installation....597
      Brake Burnishing Procedure....597
    REAR CALIPER SERVICE....598
      Caliper Exploded View....598
      Caliper Removal....598
      Caliper Disassembly....599
      Caliper Inspection....599
      Caliper Assembly....600
      Caliper Installation....600
    REAR BRAKE DISC....601
      Disc Inspection....601
      Disc Replacement....601
    TROUBLESHOOTING....602
      Brakes Squeal / Poor Brake Performance....602
      Pedal Vibration....602
      Caliper Overheats (Brakes Drag)....602
      Brakes Lock....602
  ELECTRICAL....603
    General Information....605
      Special Tools....605
      Electrical Service Notes....605
      Under-Dash Components....605
    Switches / Controls....606
      Headlamp Switch....606
      AWD Switch....606
      Brake Light Switch....606
    Instrument Cluster....607
      Overview....607
      Rider Information Display....607
      Standard Display Modes....608
      Diagnostic Display Mode....608
      Viewing Diagnostic Codes....610
      Instrument Cluster Removal....611
      Instrument Cluster Installation....611
    Instrument Cluster Troubleshooting Tests....612
      TEST 1 - No All Wheel Drive....612
      TEST 2 - No Display....613
      TEST 3 - Vehicle Speed Sensor....613
      TEST 4 - No AWD Hub Safety Limiter....614
      TEST 5 - Fuel Gauge Display Not Working ....615
      TEST 6 - Gear Indicator Not Working (Transmission Switch)....615
    All Wheel Drive Coil....616
      Operation Overview....616
      Diagnosing System Failures....616
    Gear Position Indicator Switch....616
      Test Diagram....616
    Speed Sensor....616
      Location / Testing ....616
    Head Lights....617
      Headlight Adjustment....617
      Headlamp Bulb Replacement....617
      Headlamp Housing Removal....618
      Headlamp Housing Installation....618
    Tail / Brake / Work Lights....618
      Bulb Replacement....618
    Cooling System Schematic....619
      Cooling System Break-Out Diagram....619
      Fan Control Circuit Operation / Testing....620
      Fan Control Circuit Bypass Test....620
      Coolant Temperature Sensor....620
    EFI Diagnostics....620
      EFI Component Testing....620
    Fuel Sender....620
      Testing....620
    Relays....621
      Operation....621
    Fuse Box Layout....621
    Fuses / Circuit Breaker....622
      Operation....622
    Charging System....623
      Current Draw - Key Off....623
      Charging System “Break Even” Test....623
      Charging System Alternator Tests....624
      Charging System Testing Flow Chart....625
    Battery Service....626
      Battery Identification....626
    Conventional Battery....626
      Battery Activation....626
      Battery Inspection....627
      Battery Removal....627
      Battery Installation....627
      Conventional Battery Testing....627
      OCV - Open Circuit Voltage Test....628
      Specific Gravity Test....628
      Load Test....628
      Off Season Storage....629
      Charging Procedure (Conventional)....629
    Low Maintenance Battery....630
      General Battery Information....630
      Battery Removal....630
      Battery Installation....630
      Battery Testing....631
      OCV - Open Circuit Voltage Test....631
      Load Test....631
      Off-Season Storage....631
      Charging Procedure (Low Maintenance)....632
    Starting System....632
      Troubleshooting....632
      Voltage Drop Test....633
      Starter Motor Removal / Disassembly ....633
      Brush Inspection / Replacement....633
      Armature Testing....634
      Starter Reassembly / Installation....635
      Starter Drive....636
      Starter Solenoid Bench Test....636
      Starter Solenoid Operation....636
      Starter Exploded View....637
    Starting System Testing Flow Chart....638
      Condition: Starter fails to turn over the engine. ....638
    Electrical BreakOut Diagrams....639
      12V Key-On Power Circuit....639
      Starting System Circuit....639
      Instrument Cluster Circuit....640
      Transmission Switch Circuit....640
      Wheel Speed Sensor Circuit....641
      AWD Circuit....641
      Fuel Gauge Display Circuit....642
      Cooling Fan Circuit....642
      Charging System Circuit....643
  INDEX....644
  WIRE DIAGRAMS....648
Polaris  '09 Ranger 4X4 CREW, Ranger 6x6 Service Repair Manual....650
  9921885_Chapter_01.pdf....650
    GENERAL INFORMATION....650
      MODEL INFORMATION....651
        Model Identification....651
        Engine Designation Number....651
        VIN Identification....651
        Engine Serial Number Location....651
        Vehicle Identification Number (VIN) Location....652
        Transmission I.D. Number Location....652
      VEHICLE DIMENSIONS....653
        RANGER 4x4 CREW / 6X6 (Height and Width)....653
        RANGER 6X6 (Length and Wheel Base)....654
        RANGER 4x4 CREW (Length and Wheel Base)....654
      GENERAL SPECIFICATIONS....655
        MODEL: 2009 RANGER 4X4 CREW....655
        MODEL: 2009 RANGER 4X4 CREW....656
        MODEL: 2009 RANGER 6X6....657
        MODEL: 2009 RANGER 6X6....658
      VEHICLE INFORMATION....659
        Publication Numbers....659
        Paint Codes....659
        Replacement Keys....659
      SPECIAL TOOLS....659
      MISC. SPECIFICATIONS AND CHARTS....660
        Conversion Table....660
        Standard Torque Specifications....661
        SAE Tap / Drill Sizes....662
        Metric Tap / Drill Sizes....662
        Decimal Equivalents....662
        Glossary of Terms....663
  9921885_Chapter_02....664
    MAINTENANCE....664
      PERIODIC MAINTENANCE CHART....666
        Periodic Maintenance Overview....666
        Break-In Period....666
        Maintenance Chart Key....666
        Pre-Ride - 25 Hour Maintenance Interval....667
        50 - 100 Hour Maintenance Interval....668
        100 - 300 Hour Maintenance Interval....669
      SERVICE PRODUCTS AND LUBES....670
        Polaris Lubricants, Maintenance and Service Products....670
      MAINTENANCE REFERENCES....671
        Maintenance References, Continued.......672
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....673
        Pre-Ride / Daily Inspection....673
        Frame, Nuts, Bolts, and Fasteners....673
        Shift Linkage Inspection / Adjustment....673
      FUEL SYSTEM AND AIR INTAKE....674
        Fuel System....674
        Fuel Lines....674
        Fuel Filter....674
        Vent Lines....674
        Throttle Pedal Inspection....674
        Throttle Freeplay Adjustment....675
        Air Filter Service....675
        Air Intake Inspection....676
      ENGINE....677
        Compression and Leakdown Test....677
        Breather Hose Inspection....677
        Engine Oil Level....677
        Engine Oil and Filter Change....678
        Exhaust Pipe....679
      TRANSMISSION AND GEARCASES....680
        Transmission Lubrication....680
        Front Gearcase Lubrication....681
        Middle Gearcase Lubrication (6x6)....682
        Rear Gearcase Lubrication (4x4 CREW)....683
        Rear Gearcase Lubrication (6x6)....684
      COOLING SYSTEM....685
        Liquid Cooling System Overview....685
        Coolant Level Inspection....685
        Radiator Coolant Level Inspection....686
        Coolant Strength / Type....686
        Cooling System Pressure Test....686
        Cooling System Hoses....686
        Radiator....687
        Coolant Drain / Radiator Removal....687
      FINAL DRIVE / WHEEL AND TIRE....688
        Wheel and Hub Torque Table....688
        CV Shaft Boot Inspection....688
        Wheel Removal....688
        Wheel Installation....688
        Tire Inspection....689
        Tire Pressure....689
      ELECTRICAL AND IGNITION SYSTEM....689
        Battery Maintenance....689
        Battery Fluid Level (Conventional Battery)....690
        Battery Removal....690
        Battery Installation....690
        Battery Storage....690
        Battery Charging....690
        Spark Plug Service....691
        Engine To Frame Ground....691
      STEERING AND SUSPENSION....692
        Steering....692
        Tie Rod End / Steering Inspection....692
        Wheel Toe Alignment Inspection....692
        Toe Adjustment....693
        Front Suspension....693
        Rear Suspension....694
        Rear Suspension Adjustment (4x4 CREW)....694
        Rear Spring Adjustment....694
      BRAKE SYSTEM....695
        Brake Fluid Inspection....695
        Brake Hose and Fitting Inspection....695
        Brake Pad / Disc Inspection....695
        Parking Brake Cable Adjustment....695
        Parking Brake Pad Inspection....696
  9921885_Chapter_03....698
    ENGINE....698
      ENGINE SPECIFICATIONS....699
        Crankcase Exploded Views....699
        Engine Fastener Torque Patterns....706
        Torque Specifications....707
        700 EFI Engine Service Specifications....708
        Special Tools....710
      GENERAL ENGINE SERVICE....710
        Accessible Components....710
        Piston Identification....710
        Cooling System Specifications....710
        Cooling System Pressure Test....711
        Cooling System Exploded View....712
        Cooling System Bleeding Procedure....712
        Valve Cover Removal - 6x6 Models (Engine Installed)....714
        Engine Removal....715
        Engine Installation Notes....716
        Engine Lubrication Specifications....717
        Oil Pressure Test....717
        Oil Flow Chart....718
      ENGINE DISASSEMBLY AND INSPECTION....719
        Cylinder Head Assembly Exploded View....719
        Rocker Arms....720
        Push Rods....720
        Cylinder Head Removal ....720
        Cylinder Head Inspection....721
        Cylinder Head Warp....721
        Valve Seal / Spring Service (On Engine)....721
        Cylinder Head Disassembly....722
        Valve Inspection....723
        Combustion Chamber....724
        Valve Seat Reconditioning....724
        Cylinder Head Reassembly....726
        Valve Sealing Test....727
        Cylinder Removal....727
        Valve Lifter Removal / Inspection....727
        Piston Removal....728
        Cylinder Inspection....729
        Cylinder Hone Selection And Honing Procedure....730
        Honing To Deglaze....730
        Cleaning the Cylinder After Honing....730
        Piston-to-Cylinder Clearance....731
        Piston / Rod Inspection....731
        Piston Ring Installed Gap....732
        Starter Drive Bendix Removal / Inspection ....732
        Flywheel / Stator Removal / Inspection....733
        Engine Crankcase Disassembly / Inspection....733
        Camshaft Inspection....741
      ENGINE REASSEMBLY....742
        Crankcase Reassembly....742
        Flywheel / Stator Installation....751
        Cylinder Head Reassembly....752
        Oil Pump Priming....754
        Engine Break-In....754
      TROUBLESHOOTING....755
        Engine....755
        Cooling System....756
  9921885_Chapter_04....758
    ELECTRONIC FUEL INJECTION....758
      GENERAL INFORMATION....759
        Special Tools....759
        EFI Service Notes....762
        Fuel Tank Exploded View....763
        EFI System Exploded View....764
        EFI System Component Locations....765
        Fuel Lines - Quick Connect Removal / Installation....766
      ELECTRONIC FUEL INJECTION....767
        Principal Components....767
        EFI Operation Overview....767
        Initial Priming / Starting Procedure....767
      ELECTRONIC CONTROL UNIT (ECU)....768
        Operation Overview....768
        ECU Service....768
        ECU Replacement....768
      FUEL PUMP....769
        Operation Overview....769
        Fuel Sender Test....769
        Fuel Pump Test....769
        Fuel Pump / Tank Assembly Replacement....770
      FUEL PRESSURE REGULATOR....771
        Operation Overview....771
        Fuel Pressure Regulator Test....771
        Fuel Pressure Regulator Replacement....771
      FUEL INJECTORS....772
        Operation Overview....772
        Fuel Injector Service....772
        Fuel Injector Replacement....772
      CRANKSHAFT POSITION SENSOR (CPS)....773
        Operation Overview....773
        CPS Test....773
        CPS Replacement....773
      TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....774
        Operation Overview....774
        T-BAP Test....774
        T-BAP Replacement....774
      THROTTLE POSITION SENSOR (TPS)....774
        Operation Overview....774
        TPS Tester / Regulator....774
        Checking TPS Reading....776
        TPS Adjustment....776
        TPS Replacement....777
      ENGINE COOLANT TEMPERATURE SENSOR (ECT)....777
        Operation Overview....777
        ECT Sensor Test....777
        ECT Sensor Replacement....777
      IGNITION COIL....778
        Operation Overview....778
        Ignition Coil Tests....778
        Ignition Coil / HT Lead Replacement....778
      GENERAL TROUBLESHOOTING....779
        Diagnostic “Blink Codes”....779
        EFI Troubleshooting....780
      EFI SYSTEM BREAK-OUT DIAGRAMS....781
        Fuel Injector Circuit (PTO)....781
        Fuel Injector Circuit (MAG)....781
        Crankshaft Position Sensor (CPS) Circuit....782
        Fuel Pump Circuit....782
        Engine Coolant Temperature Sensor (ECT) ....783
        Temperature Overheat Indicator Lamp Circuit....783
        Throttle Position Sensor (TPS) Circuit....784
        Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit....784
        Diagnostic Connector Circuit....785
        Diagnostic Indicator Lamp Circuit....785
  9921885_Chapter_05....786
    BODY / STEERING / SUSPENSION....786
      TORQUE SPECIFICATIONS....787
      SPECIAL TOOLS....787
      BODY COMPONENT REMOVAL....788
        Removal Procedures....788
        Lower Body, Floor and Fenders (4x4 CREW)....789
        Lower Body, Floor and Fenders (6x6)....790
        Hood / Dash Components....791
        Dash Instruments and Controls....792
      CAB FRAME....793
        Assembly / Removal (6x6)....793
        Assembly / Removal (4x4 CREW)....794
      SEAT / HEAD REST....795
        Seat Back / Head Rests....795
      CHASSIS / MAIN FRAME (4X4 CREW)....796
        Exploded View....796
      CHASSIS / MAIN FRAME (6X6)....797
        Exploded View....797
      STEERING ASSEMBLY....798
        Exploded View....798
      STEERING AND SUSPENSION....799
        Exploded View....799
      FRONT A-ARM....800
        Replacement....800
      FRONT STRUT....801
        Exploded View....801
        Front Strut Cartridge Replacement....802
        Ball Joint Replacement....802
      MID AXLE A-ARM (6X6)....803
        Replacement....803
      REAR A-ARM (4X4 CREW)....804
        Replacement....804
      REAR STABILIZER BAR (4X4 CREW)....806
        Removal / Installation....806
      SWING ARM (6X6)....807
        Removal....807
        Installation....807
      REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6)....808
      REAR CARGO BOX....809
        Cargo Box - Panels....809
        Cargo Box - Tailgate / Box Support....810
        Box Removal....811
        Box Installation....811
      STORAGE BOX (4X4 CREW)....812
        Removal....812
        Installation....812
      DECAL REPLACEMENT....812
  9921885_Chapter_06....814
    CLUTCHING....814
      SPECIAL TOOLS AND SUPPLIES....815
      TORQUE SPECIFICATIONS....815
        PVT System Fastener Torques....815
      PVT SYSTEM OVERVIEW....815
        General Operation....815
        Drive Clutch Operation....815
        Driven Clutch Operation....816
        PVT Break-In (Drive Belt / Clutches)....816
        Maintenance / Inspection....816
        Overheating / Diagnosis....817
      PVT SYSTEM SERVICE....818
        PVT Sealing, Guard, and Ducting Components....818
        Disassembly....818
        Assembly....819
      DRIVE BELT....820
        Belt Removal....820
        Belt Inspection....821
        Belt Installation....821
        PVT Break-In (Drive Belt / Clutches)....821
      CLUTCH ALIGNMENT....821
        Clutch Alignment Tool Use....821
      CLUTCH CENTER DISTANCE....822
      DRIVE CLUTCH SERVICE....823
        Spring Specifications....823
        Shift Weights....824
        Exploded View....825
        Clutch Disassembly....825
        Spider Removal....826
        Roller, Pin, and Thrust Washer Inspection....827
        Button To Tower Clearance Inspection....827
        Shift Weight Inspection....827
        Bearing Inspection....828
        Clutch Inspection....828
        Moveable Sheave Bushing Inspection....829
        Bushing Service....830
        Clutch Assembly....832
      DRIVEN CLUTCH SERVICE....833
        Exploded View....833
        Clutch Disassembly / Inspection....833
        Clutch Assembly....835
      TROUBLESHOOTING....836
  9921885_Chapter_07....838
    FINAL DRIVE....838
      SPECIAL TOOLS....840
      TORQUE SPECIFICATIONS....840
        Wheel, Hub, and Spindle Torque Table....840
      FRONT HUB....840
        Hub Removal / Inspection....840
        Hubstrut Bearing Replacement....841
        Hub Installation....842
        Front Hub Exploded View....843
      FRONT DRIVE SHAFT....844
        Removal....844
        Drive Shaft / CV Joint Handling Tips....845
        Outer CV Joint / Boot Replacement....845
        Inner Plunging Joint / Boot Replacement....847
        Exploded View....848
        Installation....848
      FRONT PROPSHAFT....849
        6x6 Removal....849
        4x4 CREW Removal....849
        Front Propshaft Components....849
      PROPSHAFT U-JOINT SERVICE....850
        Disassembly....850
        Assembly....850
      FRONT GEARCASE / CENTRALIZED HILLIARD....852
        Centralized Hilliard Exploded View....852
        All Wheel Drive Operation....853
        AWD Diagnosis....854
        Gearcase Removal....855
        Gearcase Disassembly / Inspection....856
        Gearcase Reassembly / Inspection....858
        Backlash Pad (Thrust Pad) Adjustment....860
        Gearcase Installation....861
      MID DRIVE HUB / BEARING CARRIER (6X6)....861
        Removal....861
        Hub Disassembly....862
        Hub Assembly....862
        Hub Installation....863
        Mid Drive Exploded View....864
      MID DRIVE SHAFT (6X6)....864
        Removal....864
        Disassembly / Assembly....864
        Installation....865
      MID PROPSHAFT (6X6)....865
        Removal....865
      MID DRIVE GEARCASE (6X6)....866
        Gearcase Removal....866
        Gearcase Disassembly....867
        Gearcase Assembly....869
        Gearcase Installation....872
        Mid Gearcase Exploded....873
      REAR HUB / BEARING CARRIER (4X4)....874
        Hub Inspection....874
        Hub Removal....874
        Hub Disassembly....875
        Hub Assembly....875
        Hub Installation....876
        Exploded View....877
      REAR DRIVE SHAFT (4X4 CREW)....878
        Removal....878
        Outer CV Joint / Boot Replacement....878
        Inner Plunging Joint / Boot Replacement....881
        Drive Shaft Exploded View....883
        Installation....884
      REAR PROPSHAFT (4X4 CREW)....885
        Removal....885
        Installation....885
      REAR GEARCASE (4X4 CREW)....886
        General Operation....886
        Operation Modes....887
        Gearcase Removal....888
        Gearcase Disassembly....888
        Rear Gearcase Assembly....891
        Rear Gearcase Installation....893
        Rear Gearcase Exploded View (4x4 CREW)....894
      REAR AXLE / GEARCASE SERVICE (6X6)....895
        Rear Axle Removal....895
        Axle Tube Removal....896
        Axle Tube Bearing Replacement....897
        Gearcase Disassembly / Inspection....897
        Gearcase Assembly....898
        Gearcase / Axle Installation....899
        Rear Gearcase Exploded View (6x6)....902
  9921885_Chapter_08....904
    TRANSMISSION....904
      TORQUE SPECIFICATIONS....905
      SHIFT LEVER....905
        Removal....905
        Installation....905
      SHIFT LINKAGE....905
        Inspection....905
        Adjustment....906
      TRANSMISSION SERVICE....906
        Transmission Removal....906
        Transmission Disassembly....908
        Transmission Assembly....913
        Transmission Installation....917
      TROUBLESHOOTING....918
        Troubleshooting Checklist....918
      TRANSMISSION EXPLODED VIEW....919
        Exploded View....919
  9921885_Chapter_09....922
    BRAKES....922
      GENERAL SPECIFICATIONS....923
      TORQUE SPECIFICATIONS....923
      SPECIAL TOOLS....923
      BRAKE SYSTEM SERVICE NOTES....924
      BRAKE NOISE TROUBLESHOOTING....924
      HYDRAULIC BRAKE SYSTEM OPERATION....925
      BRAKE SYSTEM EXPLODED VIEW....926
        6x6....926
        4x4 CREW....926
      MASTER CYLINDER....927
        Removal....927
        Installation....927
      FOOT BRAKE PEDAL....927
        Pedal Removal....927
        Pedal Installation....927
      BRAKE BLEEDING / FLUID CHANGE....928
      PARKING BRAKE....929
        Exploded View (4x4 CREW)....929
        Exploded View (6x6)....930
        Inspection....931
        Cable Tension Adjustment....931
      PARKING BRAKE CALIPER SERVICE....932
        Exploded View....932
        Caliper Removal....932
        Caliper Disassembly / Inspection....933
        New Brake Pad Installation....934
        Caliper Installation....934
      PARKING BRAKE DISC SERVICE....934
        Disc Inspection / Removal....934
      FRONT BRAKE PADS....935
        Pad Removal....935
        Pad Inspection....935
        Pad Assembly / Installation....936
        Brake Burnishing Procedure....936
      FRONT CALIPER SERVICE....937
        Caliper Exploded View....937
        Caliper Removal ....937
        Caliper Disassembly....938
        Caliper Inspection....939
        Caliper Assembly....939
        Caliper Installation....940
      FRONT BRAKE DISC....941
        Disc Inspection....941
        Disc Replacement....941
      REAR BRAKE PADS (6X6)....942
        Pad Removal....942
        Pad Inspection....942
        Pad Installation....943
      REAR BRAKE PADS (4X4 CREW)....943
        Pad Removal....943
        Pad Inspection....944
        Pad Assembly / Installation....944
        Brake Burnishing Procedure....945
      REAR CALIPER SERVICE (6X6)....946
        Rear Caliper Exploded View....946
        Caliper Removal....946
        Caliper Disassembly....947
        Caliper Inspection....947
        Caliper Assembly....948
        Caliper Installation....948
      REAR CALIPER SERVICE (4X4 CREW)....949
        Rear Caliper Exploded View....949
        Caliper Removal ....949
        Caliper Disassembly....950
        Caliper Inspection....951
        Caliper Assembly....951
        Caliper Installation....952
      REAR BRAKE DISC....953
        Disc Inspection....953
        Disc Replacement....953
      TROUBLESHOOTING....954
        Brakes Squeal / Poor Brake Performance....954
        Pedal Vibration....954
        Caliper Overheats (Brakes Drag)....954
        Brakes Lock....954
  9921885_Chapter_10....956
    ELECTRICAL....956
      GENERAL INFORMATION....958
        Special Tools....958
        Electrical Service Notes....958
        Under-Hood Components....958
      SWITCHES / CONTROLS....959
        Headlight Switch....959
        AWD / 2WD / TURF Switch (4x4 CREW)....959
        Differential Solenoid (4x4 CREW)....959
        Brake Light Switch....960
        Parking Brake Switch....961
      INSTRUMENT CLUSTER....962
        Overview....962
        Rider Information Display....962
        Standard Display Modes....963
        Diagnostic Display Mode....963
        Viewing Diagnostic Codes....965
        Instrument Cluster Removal....966
        Instrument Cluster Installation....966
      INSTRUMENT CLUSTER TROUBLESHOOTING TESTS....967
        Test 1 - No All Wheel Drive....967
        TEST 2 - No Display....968
        TEST 3 - Wheel Speed Sensor....968
        TEST 4 - No AWD Hub Safety Limiter....969
        TEST 5 - Fuel Gauge Display Not Working ....970
        TEST 6 - Shift Indicator Not Working (Transmission Switch)....970
      ALL WHEEL DRIVE (AWD) COIL....971
        Operation Overview....971
        Diagnosing System Failures....971
      GEAR POSITION INDICATOR SWITCH....971
        Test Diagram....971
      HEADLIGHTS....972
        Headlight Adjustment....972
        Headlight Bulb Replacement....972
        Headlight Housing Removal....972
        Headlight Housing Installation....973
      TAIL LIGHT / BRAKE LIGHT....973
        Lamp Replacement....973
      COOLING SYSTEM....974
        Cooling System Break-Out Diagram....974
        Fan Control Circuit Operation....975
        Fan Control Circuit Bypass Test....975
        Coolant Temperature Sensor....975
      EFI DIAGNOSTICS....975
        EFI Component Testing....975
      FUEL SENDER....975
        Testing....975
      RELAYS....976
        Operation....976
      FUSES / CIRCUIT BREAKER....977
        Operation....977
      CHARGING SYSTEM....978
        Current Draw - Key Off....978
        Charging System “Break Even” Test....978
        Charging System Alternator Tests....979
        Charging System Testing Flow Chart....980
      BATTERY SERVICE....981
        Battery Terminals / Bolts....981
        Battery Terminal Block....981
        Battery Activation....981
        Battery Inspection....982
        Battery Removal / Installation....982
        Battery Testing....982
        OCV - Open Circuit Voltage Test....982
        Specific Gravity Test....983
        Load Test....983
        Off Season Storage....983
        Charging Procedure....983
      STARTER SYSTEM....984
        Troubleshooting....984
        Voltage Drop Test....984
        Starter Motor Removal / Disassembly ....984
        Brush Inspection / Replacement....985
        Armature Testing....986
        Starter Reassembly / Installation....986
        Starter Drive....987
        Starter Solenoid Bench Test....988
        Starter Solenoid Operation....988
        Starter Exploded View....989
      STARTING SYSTEM TESTING FLOW CHART....990
        Condition: Starter fails to turn over the engine. ....990
      ELECTRIC BOX LIFT ACTUATOR....991
        DIAGNOSIS (if equipped)....991
      ELECTRICAL BREAK-OUT DIAGRAMS....992
        Starting Circuit....992
        Key-On Power Circuit....992
        Transmission Switch Circuit....993
        AWD Circuit....993
        Speed Sensor Circuit....994
        Charging System Circuit....994
        Cooling Fan Circuit....995
        Fuel Display / Fuel Pump Circuit....995
  9921885_Wire_Diagrams....996
Polaris  '09 Ranger 500 2x4 Service Repair Manual....1002
  9922040_Chapter_01.pdf....1002
    GENERAL INFORMATION....1002
      VEHICLE IDENTIFICATION....1003
        Model Identification....1003
        Engine Designation Number....1003
        VIN Identification....1003
        Engine Serial Number Location....1003
        Vehicle Identification Number (VIN) Location....1004
        Transmission I.D. Number Location....1004
      VEHICLE DIMENSIONS....1005
        vehicle DIMENSIONS....1006
      GENERAL SPECIFICATIONS....1007
        MODEL: 2009 RANGER 2X4....1007
        MODEL: 2009 RANGER 2X4....1008
      VEHICLE INFORMATION....1009
        Publication Numbers....1009
        Paint Codes....1009
        Replacement Keys....1009
      SPECIAL TOOLS....1009
      MISC. SPECIFICATIONS AND CHARTS....1010
        Conversion Table....1010
        Standard Torque Specifications....1011
        SAE Tap / Drill Sizes....1012
        Metric Tap / Drill Sizes....1012
        Decimal Equivalents....1012
        Glossary of Terms....1013
  9922040_Chapter_02....1014
    MAINTENANCE....1014
      PERIODIC MAINTENANCE CHART....1016
        Periodic Maintenance Overview....1016
        Break-In Period....1016
        Maintenance Chart Key....1016
        Pre-Ride - 25 Hour Maintenance Interval....1017
        50 - 100 Hour Maintenance Interval....1018
        100 - 300 Hour Maintenance Interval....1019
      SERVICE PRODUCTS AND LUBRICANTS....1020
        Polaris Lubricants, Maintenance and Service Products....1020
      GENERAL COMPONENT LOCATION....1021
        RH Side and Dash View ....1021
        LH Side and Rear View....1022
      MAINTENANCE REFERENCES....1023
        Maintenance Quick Reference....1023
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....1024
        Pre-Ride / Daily Inspection....1024
        Frame, Nuts, Bolts, and Fasteners....1024
        Shift Linkage Inspection / Adjustment....1024
      FUEL SYSTEM AND AIR INTAKE....1025
        Fuel System....1025
        Fuel Lines....1025
        Fuel Filter....1025
        Vent Lines....1025
        Throttle Pedal Inspection....1025
        Throttle Freeplay Adjustment....1026
        Throttle Cable Adjustment....1026
        Choke Adjustment....1026
        Idle Speed Adjustment....1027
        Pilot Screw....1027
        Pilot Screw Adjustment....1028
        Carburetor Draining....1028
        Air Intake Inspection....1029
        Air Filter Service....1029
      ENGINE....1030
        Compression and Leakdown Test....1030
        Breather Filter Inspection....1031
        Breather Hose....1031
        Flywheel Housing....1031
        Engine Oil Level....1031
        Engine Oil and Filter Change....1032
        Oil Pump Priming Procedure....1033
        Valve Clearance....1034
        Intake Valve Clearance Adjustment....1035
        Exhaust Valve Clearance Adjustment....1035
        Exhaust Pipe....1035
      TRANSMISSION / REAR GEARCASE....1036
        Transmission Lubrication....1036
        Rear Gearcase Lubrication....1037
      COOLING SYSTEM....1038
        Liquid Cooling System Overview....1038
        Coolant Level Inspection....1038
        Radiator Coolant Level Inspection....1039
        Coolant Strength / Type....1039
        Cooling System Pressure Test....1039
        Cooling System Hoses....1039
        Radiator....1040
        Coolant Drain / Radiator Removal....1040
      FINAL DRIVE / WHEEL AND TIRE....1041
        Wheel and Hub Torque Table....1041
        CV Shaft Boot Inspection....1041
        Wheel Removal....1041
        Wheel Installation....1041
        Tire Inspection....1042
        Tire Pressure....1042
      ELECTRICAL AND IGNITION SYSTEM....1042
        Battery Maintenance....1042
        Battery Fluid Level (Conventional Battery)....1043
        Battery Removal....1043
        Battery Installation....1043
        Battery Storage....1043
        Battery Charging....1043
        Spark Plug Service....1044
        Engine To Frame Ground....1044
      STEERING AND SUSPENSION....1044
        Steering....1044
        Tie Rod End / Steering Inspection....1045
        Wheel Toe Alignment Inspection....1045
        Toe Adjustment....1046
        Front Suspension....1046
        Rear Suspension....1047
        Rear Suspension Adjustment....1047
        Rear Spring Adjustment....1047
      BRAKE SYSTEM....1048
        Brake Fluid Inspection....1048
        Brake Hose and Fitting Inspection....1048
        Brake Pad / Disc Inspection....1048
        Parking Brake Cable Adjustment....1049
        Parking Brake Pad Inspection....1049
  9922040_Chapter_03....1050
    ENGINE....1050
      SPECIAL TOOLS....1052
      SPECIFICATIONS....1052
        Torque Specifications....1052
        Engine Service Data....1053
        Engine Service Data....1054
        Engine Fastener Torque Patterns....1055
      GENERAL ENGINE SERVICE....1055
        Piston Identification....1055
        Accessible Components....1056
        Engine Removal....1056
        Engine Installation Notes....1059
        Crankshaft Straightening....1059
        Engine Lubrication - EH50PL....1060
        Oil Pressure Test - EH50PL....1060
        Oil Flow - EH50PL....1060
        EH50PL Oil Flow Diagram....1061
        EH50PL Engine Exploded View....1062
      COOLING SYSTEM....1063
        Cooling System Specifications....1063
        Cooling System Layout and Testing....1063
      ENGINE DISASSEMBLY....1065
        Engine Removal....1065
        Cam Chain Tensioner / Rocker Arm / Camshaft Removal....1065
        Cam Chain Tensioner Inspection....1065
        Rocker Arm / Shaft Inspection....1066
        Camshaft Removal....1067
        Automatic Compression Release Removal / Inspection....1068
        Automatic Compression Release Installation....1068
        Camshaft Inspection....1069
        Cylinder Head Removal....1069
        Cylinder Head Exploded View, EH50PL....1070
        Cylinder Head Inspection....1071
        Cylinder Head Warpage....1071
        Cylinder Head Disassembly....1071
        Valve Inspection....1072
        Combustion Chamber....1072
        Valve Seat Reconditioning....1073
        Cylinder Head Assembly....1075
        Valve Sealing Test....1076
        Valve Clearance Adjustment (Intake and Exhaust)....1076
        Cylinder / Piston Removal and Inspection....1076
        Piston Removal....1077
        Cylinder Inspection....1078
        Cylinder Hone Selection / Honing Procedure....1078
        Honing to Oversize....1079
        Cleaning the Cylinder After Honing....1079
        Piston-to-Cylinder Clearance....1079
        Piston / Rod Inspection....1080
        Piston Ring Installed Gap....1080
        Crankcase Disassembly....1081
        Starter Drive Removal / Inspection....1081
        Flywheel and Stator Removal / Inspection....1081
        Cam Chain / Tensioner Blade....1082
        One Way Valve....1082
        Crankcase Separation....1083
        Oil Pump Removal / Inspection....1083
        Oil Pump Assembly....1084
        Counter Balancer Shaft Removal / Inspection....1084
        Crankshaft Removal / Inspection....1085
        Crankcase Bearing Inspection ....1085
        Oil Seal / Mechanical Seal Removal (Engine Disassembled)....1086
        Crankcase Inspection ....1086
        Bearing Installation....1086
        End Play Inspection / Adjustment....1086
        Crankshaft End Play Adjustment....1086
        Counter Balancer Shaft End Play Adjustment....1088
        Oil Pump Shaft End Play Adjustment....1088
      ENGINE REASSEMBLY....1089
        Pump Shaft Oil Seal Installation....1089
        Crankshaft / Counter Balance / Oil Pump Installation....1089
        Crankcase Assembly....1089
        Water Pump Mechanical Seal Installation....1089
        Water Pump Mechanical Seal Removal (Engine Installed)....1090
        One Way Valve Installation....1091
        Cam Chain Drive Sprocket Installation....1091
        Tensioner Blade Installation....1091
        Piston Ring Installation....1091
        Piston Installation....1092
        Cylinder Installation....1092
        Cylinder Head Installation....1093
        Cam Chain / Camshaft Installation....1094
        Camshaft Timing....1094
        Camshaft Timing Illustration....1095
        Cam Chain Tensioner Installation....1096
        Stator, Flywheel and Starter Drive Installation....1096
        Rocker Shaft / Rocker Arm Assembly Installation....1097
        Thermostat Installation....1097
        Oil Pipes....1097
        Oil Pump Priming Procedure....1098
      TROUBLESHOOTING....1099
        Engine....1099
        Spark Plug Fouling....1100
        Cooling Troubleshooting....1100
  9922040_Chapter_04....1102
    CARBURETION SYSTEM....1102
      SPECIAL TOOLS....1103
      CARBURETOR JETTING....1103
        Jetting Guidelines....1103
        Mikuni Jet Part Numbers....1103
      MIKUNI CV CARBURETOR....1104
        Exploded View....1104
        System Function - Mikuni CV Carb ....1105
        Vent Systems - Mikuni CV Carb....1105
        Operation - Mikuni CV Carb ....1105
        Pilot System (Idle and Slow Speed)....1106
        Starter System (Choke or Enrichment)....1107
        Float System ....1107
        Main System....1108
        Pilot Screw....1108
      CARBURETOR SERVICE....1109
        Carburetor Removal....1109
        Carburetor Disassembly....1109
        Carburetor Cleaning....1110
        Carburetor Inspection....1111
        Float Height Adjustment....1111
        Needle and Seat Leakage Test....1111
        Fuel Level....1112
        Carburetor Assembly....1112
      AIR BOX ASSEMBLY....1113
        Exploded View....1113
      FUEL TANK ASSEMBLY....1114
        Fuel Tank / Fuel Pump Exploded View....1114
        Fuel Tank Removal....1115
        Fuel Tank Installation....1115
      FUEL PUMP....1116
        Replacement....1116
      TROUBLESHOOTING....1117
        Fuel Starvation / Lean Mixture....1117
        Rich Mixture....1117
        Idle Too High....1117
        Idle Too Low....1117
        Erratic Idle....1117
  9922040_Chapter_05....1118
    BODY / STEERING / SUSPENSION....1118
      TORQUE SPECIFICATIONS....1119
      SPECIAL TOOLS....1119
      BODY COMPONENT REMOVAL....1120
        Removal Procedures....1120
        Lower Body Components....1121
        Hood / Dash Components....1122
        Dash Instruments and Controls....1123
      CAB FRAME....1124
        Assembly / Removal....1124
      CHASSIS / MAIN FRAME....1125
        Exploded View....1125
      SEAT / HEAD REST....1126
        Seat Back / Head Rests....1126
      STEERING ASSEMBLY....1127
        Exploded View....1127
      STEERING AND SUSPENSION....1128
        Exploded View....1128
      FRONT A-ARM....1129
        Replacement....1129
      FRONT STRUT....1130
        Exploded View....1130
        Front Strut Cartridge Replacement....1131
        Ball Joint Replacement....1131
      REAR A-ARM....1132
        Replacement....1132
      REAR STABILIZER BAR....1134
        Removal / Installation....1134
      REAR CARGO BOX....1135
        Cargo Box - Panels....1135
        Cargo Box - Tailgate / Box Support....1136
        Box Removal....1137
        Box Installation....1137
      DECAL REPLACEMENT....1138
  9922040_Chapter_06....1140
    CLUTCHING....1140
      SPECIAL TOOLS AND SUPPLIES....1141
      TORQUE SPECIFICATIONS....1141
        PVT System Fastener Torques....1141
      PVT SYSTEM OVERVIEW....1141
        General Operation....1141
        Drive Clutch Operation....1141
        Driven Clutch Operation....1142
        PVT Break-In (Drive Belt / Clutches)....1142
        Maintenance / Inspection....1142
        Overheating / Diagnosis....1143
      PVT SYSTEM SERVICE....1144
        PVT Sealing, Guard, and Ducting Components....1144
        Disassembly....1144
        Assembly....1145
      DRIVE BELT....1146
        Belt Deflection (Tension)....1146
        Belt Removal....1147
        Belt Inspection....1147
        Belt Installation....1147
        PVT Break-In (Drive Belt / Clutches)....1147
      CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE....1148
        Clutch Alignment....1148
        Clutch Offset....1148
        Clutch Center Distance....1148
      DRIVE CLUTCH SERVICE....1149
        Spring Specifications....1149
        Shift Weights....1150
        Exploded View....1151
        Clutch Inspection....1151
        Clutch Disassembly....1152
        Spider Removal....1153
        Roller, Pin, and Thrust Washer Inspection....1153
        Bushing Service....1154
        Moveable Sheave - Bushing Removal....1154
        Moveable Sheave - Bushing Installation....1154
        Clutch Cover - Bushing Removal....1155
        Clutch Cover - Bushing Installation....1155
        Clutch Assembly....1156
      DRIVEN CLUTCH SERVICE....1157
        Exploded View....1157
        Clutch Disassembly / Inspection....1157
        Bushing Service....1158
        Moveable Sheave - Bushing Installation....1159
        Clutch Assembly....1160
      TROUBLESHOOTING....1162
  9922040_Chapter_07....1164
    FINAL DRIVE....1164
      SPECIAL TOOLS....1165
      TORQUE SPECIFICATIONS....1165
        Wheel, Hub, and Spindle Torque Table....1165
      FRONT HUB....1165
        Hub Removal / Inspection....1165
        Hub Installation....1166
        Exploded View....1167
      REAR HUB / BEARING CARRIER....1168
        Hub Inspection....1168
        Hub Removal....1168
        Hub Disassembly....1169
        Hub Assembly....1169
        Hub Installation....1170
        Exploded View....1171
      REAR DRIVE SHAFT....1172
        Removal....1172
        Outer CV Joint / Boot Replacement....1172
        Inner Plunging Joint / Boot Replacement....1175
        Drive Shaft Exploded View....1177
        Installation....1178
      REAR PROPSHAFT....1179
        Removal....1179
        Installation....1179
      REAR GEARCASE....1180
        General Operation....1180
        Operation Modes....1181
        Gearcase Removal....1182
        Gearcase Disassembly....1182
        Rear Gearcase Assembly....1185
        Rear Gearcase Installation....1187
        Rear Gearcase Exploded View....1188
  9922040_Chapter_08....1190
    TRANSMISSION....1190
      TORQUE SPECIFICATIONS....1191
      SHIFT LEVER....1191
        Removal....1191
        Installation....1191
      SHIFT LINKAGE....1191
        Inspection....1191
        Adjustment....1192
      TRANSMISSION SERVICE....1192
        Transmission Removal....1192
        Transmission Disassembly....1194
        Transmission Assembly....1199
        Transmission Installation....1203
      TROUBLESHOOTING....1204
        Troubleshooting Checklist....1204
      TRANSMISSION EXPLODED VIEW....1205
        Exploded View....1205
  9922040_Chapter_09....1208
    BRAKES....1208
      GENERAL SPECIFICATIONS....1209
      TORQUE SPECIFICATIONS....1209
      SPECIAL TOOLS....1209
      BRAKE SYSTEM SERVICE NOTES....1210
      BRAKE NOISE TROUBLESHOOTING....1210
      HYDRAULIC BRAKE SYSTEM OPERATION....1211
      BRAKE SYSTEM EXPLODED VIEW....1211
      MASTER CYLINDER....1212
        Removal....1212
        Installation....1212
      FOOT BRAKE PEDAL....1212
        Pedal Removal....1212
        Pedal Installation....1212
      BRAKE BLEEDING / FLUID CHANGE....1213
      PARKING BRAKE....1214
        Exploded View....1214
        Inspection....1215
        Cable Tension Adjustment....1215
      PARKING BRAKE CALIPER SERVICE....1216
        Exploded View....1216
        Caliper Removal....1216
        Caliper Disassembly / Inspection....1217
        New Brake Pad Installation....1218
        Caliper Installation....1218
      PARKING BRAKE DISC SERVICE....1218
        Disc Inspection / Removal....1218
      FRONT BRAKE PADS....1219
        Pad Removal....1219
        Pad Inspection....1219
        Pad Assembly / Installation....1220
        Brake Burnishing Procedure....1220
      FRONT CALIPER SERVICE....1221
        Caliper Exploded View....1221
        Caliper Removal ....1221
        Caliper Disassembly....1222
        Caliper Inspection....1223
        Caliper Assembly....1223
        Caliper Installation....1224
      FRONT BRAKE DISC....1225
        Disc Inspection....1225
        Disc Replacement....1225
      REAR BRAKE PADS....1226
        Pad Removal....1226
        Pad Inspection....1226
        Pad Installation....1227
      REAR CALIPER SERVICE....1228
        Rear Caliper Exploded View....1228
        Caliper Removal....1228
        Caliper Disassembly....1229
        Caliper Inspection....1229
        Caliper Assembly....1230
        Caliper Installation....1230
      REAR BRAKE DISC....1231
        Disc Inspection....1231
        Disc Replacement....1231
      TROUBLESHOOTING....1232
        Brakes Squeal / Poor Brake Performance....1232
        Pedal Vibration....1232
        Caliper Overheats (Brakes Drag)....1232
        Brakes Lock....1232
  9922040_Chapter_10....1234
    ELECTRICAL....1234
      GENERAL INFORMATION....1235
        Special Tools....1235
        Electrical Service Notes....1235
        Under-Hood Components....1235
      SWITCHES / CONTROLS....1236
        Headlight Switch....1236
        Rear Differential Switch....1236
        Differential Solenoid....1237
        Parking Brake Switch....1238
        Indicator Lamp Circuit Operation....1239
        Indicator Lamp Replacement....1239
      HEADLIGHTS....1240
        Headlight Adjustment....1240
        Headlight Bulb Replacement....1240
        Headlight Housing Removal....1240
        Headlight Housing Installation....1241
      TAIL LIGHT / BRAKE LIGHT....1241
        Lamp Replacement....1241
      POWER DISTRIBUTION MODULE....1242
        Functional Description....1242
        PDM Block Diagram....1242
        PDM Troubleshooting....1242
        Solid State Circuit Breaker #1 (SSCB #1)....1243
        Solid State Circuit Breaker #2 (SSCB #2)....1243
        PDM Fan Motor Troubleshooting....1243
        PDM Chassis Power Troubleshooting....1243
      TIMING CHECK PROCEDURE....1244
      COOLING SYSTEM....1245
        Cooling System Break-Out Diagram....1245
        Fan Control Circuit Operation / Testing....1246
        Fan Control Circuit Bypass Test....1246
        Coolant Temperature Sensor Test....1246
      DC / CDI IGNITION SYSTEM....1247
        DC / CDI Ignition System Overview....1247
        Ignition System Troubleshooting....1247
        Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter....1248
        Resistance Tests....1248
        Flywheel Identification....1248
        Ignition System Testing Flow Chart....1249
        Components of DC / CDI Ignition....1250
      CHARGING SYSTEM....1251
        Current Draw - Key Off....1251
        Charging System “Break Even” Test....1251
        Charging System Alternator Tests....1252
        Charging System Testing Flow Chart....1253
      BATTERY SERVICE....1254
        Battery Terminals / Bolts....1254
        Battery Terminal Block....1254
        Battery Activation....1254
        Battery Inspection....1255
        Battery Removal / Installation....1255
        Battery Testing....1255
        OCV - Open Circuit Voltage Test....1255
        Specific Gravity Test....1256
        Load Test....1256
        Off Season Storage....1256
        Charging Procedure....1256
      STARTER SYSTEM....1257
        Troubleshooting....1257
        Voltage Drop Test....1257
        Starter Motor Disassembly....1257
        Brush Inspection / Replacement....1258
        Armature Testing....1259
        Starter Assembly....1259
        Starter Drive....1260
        Starter Solenoid Bench Test....1260
        Starter Solenoid Operation....1260
      STARTING SYSTEM TESTING FLOW CHART....1261
        Condition: Starter fails to turn over the engine. ....1261
      ELECTRIC BOX LIFT ACTUATOR....1262
        DIAGNOSIS (if equipped)....1262
  9922040_Wire_Diagram....1264
Polaris  '09 Ranger 500 4x4 EFI Service Repair Manual....1266
  9921880_Chapter_01.pdf....1266
    GENERAL INFORMATION....1266
      VEHICLE IDENTIFICATION....1267
        Model Identification....1267
        Engine Designation Number....1267
        VIN Identification....1267
        Vehicle and Engine Serial Number Locations....1267
      VEHICLE INFORMATION....1268
        Publication Numbers....1268
        Replacement Keys....1268
      SPECIAL TOOLS....1268
      GENERAL SPECIFICATIONS....1269
        MODEL: 2009 RANGER 500 4X4 EFI....1269
        MODEL: 2009 RANGER 500 4X4 EFI....1270
      MISC. SPECIFICATIONS AND CHARTS....1271
        Conversion Table....1271
        Standard Torque Specifications....1272
        SAE Tap / Drill Sizes....1273
        Metric Tap / Drill Sizes....1273
        Decimal Equivalents....1273
        Glossary of Terms....1274
  9921880_Chapter_02....1276
    MAINTENANCE....1276
      PERIODIC MAINTENANCE CHART....1278
        Periodic Maintenance Overview....1278
        Break-In Period....1278
        Maintenance Chart Key....1278
        Pre-Ride - 25 Hour Maintenance Interval....1279
        50 - 100 Hour Maintenance Interval....1280
        100 - 300 Hour Maintenance Interval....1281
        Grease Lubrication Points....1281
      SERVICE PRODUCTS AND LUBRICANTS....1282
        Polaris Lubricants, Maintenance and Service Products....1282
      FLUID MAINTENANCE REFERENCES....1283
        Component Quick Reference....1283
        Component Quick Reference, Continued.......1284
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....1285
        Pre-Ride / Daily Inspection....1285
        Frame, Nuts, Bolts, and Fasteners....1285
        Shift Linkage Inspection / Adjustment....1285
      FUEL SYSTEM AND AIR INTAKE....1286
        Fuel System....1286
        Fuel Lines....1286
        Fuel Filter....1286
        Vent Lines....1286
        Throttle Pedal Inspection....1286
        Throttle Freeplay Adjustment....1286
        Air Filter Service....1287
        Engine Air Intake Inspection....1287
        PVT Air Intake Inspection....1287
        Air Intake Exploded View....1288
      ENGINE....1289
        Compression and Leakdown Test....1289
        Breather Filter Inspection....1289
        Breather Hose....1289
        Flywheel Housing Drain Plug....1289
        Engine Oil Level....1290
        Engine Oil and Filter Change....1290
        Oil Pump Priming Procedure....1292
        Valve Clearance....1292
        Intake Valve Clearance Adjustment....1293
        Exhaust Valve Clearance Adjustment....1293
        Exhaust Pipe....1294
      TRANSMISSION AND GEARCASES....1295
        Transmission Lubrication....1295
        Front Gearcase Lubrication....1296
        Rear Gearcase Lubrication....1297
      COOLING SYSTEM....1298
        Liquid Cooling System Overview....1298
        Coolant Level Inspection....1298
        Coolant Strength / Type....1299
        Cooling System Hoses....1299
        Radiator Inspection / Cleaning....1300
        Coolant Drain / Radiator Removal....1300
      FINAL DRIVE / WHEEL AND TIRE....1302
        Wheel and Hub Torque Table....1302
        CV Shaft Boot Inspection....1302
        Wheel Removal....1302
        Wheel Installation....1302
        Tire Inspection....1303
        Tire Pressure....1303
      ELECTRICAL AND IGNITION SYSTEM....1303
        Battery Maintenance....1303
        Battery Fluid Level (Conventional Battery)....1304
        Battery Removal....1304
        Battery Installation....1304
        Battery Storage....1305
        Battery Charging....1305
        Spark Plug Service....1305
        Engine To Frame Ground....1305
      STEERING....1306
        Steering....1306
        Tie Rod End / Steering Inspection....1306
        Wheel Toe Alignment Inspection....1306
        Toe Adjustment....1307
      SUSPENSION....1307
        Suspension Inspection....1307
        Spring Pre-Load Adjustment....1307
        Shock Position Adjustment....1308
      BRAKE SYSTEM....1308
        Brake Fluid Inspection....1308
        Brake Hose and Fitting Inspection....1308
        Brake Pad / Disc Inspection....1309
        Parking Brake Cable Adjustment....1309
        Parking Brake Pad Inspection....1309
      MAINTENANCE LOG....1310
  9921880_Chapter_03....1312
    ENGINE....1312
      SPECIAL TOOLS....1314
      SPECIFICATIONS....1314
        Torque Specifications....1314
        Engine Fastener Torque Patterns....1314
        Engine Service Data....1315
        Engine Service Data....1316
      GENERAL ENGINE SERVICE....1317
        Accessible Components....1317
        Engine Removal....1317
        Engine Installation Notes....1319
        Crankshaft Straightening....1319
        Engine Lubrication - EH50PL....1320
        Oil Pressure Test - EH50PL....1320
        Oil Flow - EH50PL....1320
        EH50PL Oil Flow Diagram....1321
        EH50PL Engine Exploded View....1322
      COOLING SYSTEM....1323
        Cooling System Layout and Testing....1323
      ENGINE DISASSEMBLY....1324
        Engine Removal....1324
        Cam Chain Tensioner / Rocker Arm / Camshaft Removal....1324
        Cam Chain Tensioner Inspection....1324
        Rocker Arm / Shaft Inspection....1325
        Camshaft Removal....1326
        Automatic Compression Release Removal / Inspection....1327
        Automatic Compression Release Installation....1327
        Camshaft Inspection....1328
        Cylinder Head Removal....1328
        Cylinder Head Exploded View, EH50PL....1329
        Cylinder Head Inspection....1330
        Cylinder Head Warpage....1330
        Cylinder Head Disassembly....1330
        Valve Inspection....1331
        Combustion Chamber....1331
        Valve Seat Reconditioning....1332
        Cylinder Head Assembly....1334
        Valve Sealing Test....1335
        Valve Clearance Adjustment....1335
        Cylinder / Piston Removal and Inspection....1335
        Piston Removal....1336
        Cylinder Inspection....1337
        Cylinder Hone Selection / Honing Procedure....1337
        Honing to Oversize....1338
        Cleaning the Cylinder After Honing....1338
        Piston-to-Cylinder Clearance....1338
        Piston / Rod Inspection....1339
        Piston Identification....1339
        Piston Ring Installed Gap....1340
        Crankcase Disassembly....1340
        Starter Drive Removal / Inspection....1340
        Flywheel and Stator Removal / Inspection....1341
        Cam Chain / Tensioner Blade....1341
        One Way Valve....1342
        Crankcase Separation....1342
        Oil Pump Removal / Inspection....1342
        Oil Pump Assembly....1343
        Counter Balancer Shaft Removal / Inspection....1344
        Crankshaft Removal / Inspection....1344
        Crankcase Bearing Inspection ....1345
        Oil Seal / Mechanical Seal Removal (Engine Disassembled)....1345
        Crankcase Inspection ....1345
        Bearing Installation....1345
        End Play Inspection / Adjustment....1346
        Crankshaft End Play Adjustment....1346
        Counter Balancer Shaft End Play Adjustment....1347
        Oil Pump Shaft End Play Adjustment....1347
      ENGINE REASSEMBLY....1348
        Pump Shaft Oil Seal Installation....1348
        Crankshaft / Counter Balance / Oil Pump Installation....1348
        Crankcase Assembly....1348
        Water Pump Mechanical Seal Installation....1348
        Water Pump Mechanical Seal Removal (Engine Installed)....1349
        One Way Valve Installation....1350
        Cam Chain Drive Sprocket Installation....1350
        Tensioner Blade Installation....1350
        Piston Ring Installation....1350
        Piston Installation....1351
        Cylinder Installation....1351
        Cylinder Head Installation....1352
        Cam Chain / Camshaft Installation....1353
        Camshaft Timing....1353
        Camshaft Timing Illustration....1354
        Cam Chain Tensioner Installation....1355
        Stator, Flywheel and Starter Drive Installation....1355
        Rocker Shaft / Rocker Arm Assembly Installation....1356
        Thermostat Installation....1356
        Oil Pipes....1356
        Oil Pump Priming Procedure....1356
      TROUBLESHOOTING....1357
        Engine....1357
        Spark Plug Fouling....1358
        Cooling Troubleshooting....1358
  9921880_Chapter_04....1360
    ELECTRONIC FUEL INJECTION....1360
      SPECIAL TOOLS....1361
        Part Numbers / Descriptions....1361
      EFI SERVICE NOTES....1363
        General Service Information....1363
      EFI SYSTEM....1364
        Exploded View....1364
      EFI COMPONENTS....1365
        Identification / Location....1365
      FUEL TANK....1367
        Exploded View....1367
      ELECTRONIC FUEL INJECTION....1368
        General Information....1368
        EFI Operation Overview....1368
        Initial Priming / Starting Procedure....1368
      FUEL LINES....1369
        Quick Connect Removal / Installation....1369
      ELECTRONIC CONTROL UNIT (ECU)....1369
        Operation Overview....1369
        ECU Replacement....1370
        ECU Service....1370
      FUEL PUMP ASSEMBLY....1371
        Operation....1371
        Fuel Sender Test....1371
        Fuel Pump Test....1371
        Fuel Pump / Tank Assembly Replacement....1372
      FUEL PRESSURE REGULATOR....1373
        General Information....1373
      FUEL INJECTOR....1374
        General Information....1374
        Fuel Injector Service....1374
        Fuel Injector Test....1374
        Fuel Injector Replacement....1375
      CRANK POSITION SENSOR (CPS)....1375
        General Information....1375
        CPS Test....1375
        CPS Replacement....1376
      MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)....1376
        General Information....1376
        MAP Sensor Test....1376
        MAP Sensor Replacement....1376
      INTAKE AIR TEMPERATURE SENSOR (IAT)....1377
        General Information....1377
        Intake Air Temperature Sensor Test....1377
        Intake Air Temperature Sensor Replacement....1377
      IDLE AIR CONTROL (IAC)....1377
        General Information....1377
        IAC Test....1377
        IAC Replacement....1377
      THROTTLE POSITION SENSOR (TPS)....1378
        General Information....1378
        TPS Resistance Tests....1378
        TPS Tester Kit....1378
        Checking TPS Reading....1379
        TPS Adjustment....1380
        TPS Replacement....1380
      ENGINE TEMPERATURE SENSOR....1381
        General Information....1381
        Engine Temperature Sensor Test....1381
        Engine Temperature Sensor Replacement....1381
      IGNITION COIL....1381
        Operation Overview....1381
        Ignition Coil Tests....1381
        Ignition Coil and HT Lead Replacement....1382
      DIAGNOSTICS USING “BLINK CODES”....1383
        Blink Codes - Operation....1383
      FUEL SYSTEM TROUBLESHOOTING....1385
        Fuel Starvation / Lean Mixture....1385
        Rich Mixture....1385
        Poor Idle....1385
  9921880_Chapter_05....1386
    BODY / STEERING / SUSPENSION....1386
      TORQUE SPECIFICATIONS....1387
      SPECIAL TOOLS....1387
        Multi-Function Pliers....1387
      CHASSIS / MAIN FRAME....1388
        Exploded View....1388
      CAB FRAME....1389
        Exploded View / Assembly....1389
      SEAT BACK / HEADREST / PVT AIR INTAKE BAFFLE BOX....1390
        Exploded View / Assembly....1390
      BODY EXPLODED VIEWS....1391
        Dash Instruments / Controls....1391
        Hood / Dash / Front Fenders / Front Fascia....1392
        Floor / Rear Fenders....1393
        Seat Mounting / Seat Belts....1394
      REAR CARGO BOX....1395
        Cargo Box - Panels....1395
        Cargo Box - Tailgate / Box Support....1396
        Box Removal....1397
        Box Installation....1397
      BODY COMPONENT REMOVAL....1398
        Lower Seat Base....1398
        Wheel Well Panels....1398
        Front Bumper....1398
        Front Fascia....1398
        Front Fenders....1399
        Hood / Dash....1399
        Glove Box / Storage Panel....1399
        Rear Fenders....1400
        Floor....1400
      STEERING ASSEMBLY....1401
        Exploded View....1401
      FRONT A-ARMS....1402
        Removal / Replacement....1402
        Exploded View....1403
      BALL JOINT SERVICE....1403
        Removal....1403
        Installation....1404
      REAR A-ARMS....1405
        Removal / Replacement....1405
        Installation....1406
        Exploded View....1406
      REAR STABILIZER BAR....1407
        Removal / Installation....1407
        Exploded View....1407
      SHOCKS / SPRINGS....1408
        Exploded View....1408
        Shock Removal / Installation....1408
        Shock Replacement....1408
      DECAL REPLACEMENT....1408
  9921880_Chapter_06....1410
    CLUTCHING....1410
      SPECIAL TOOLS AND SUPPLIES....1411
      TORQUE SPECIFICATIONS....1411
        PVT System Fastener Torques....1411
      PVT SYSTEM OVERVIEW....1411
        General Operation....1411
        Drive Clutch Operation....1411
        Driven Clutch Operation....1412
        PVT Break-In (Drive Belt / Clutches)....1412
        Maintenance / Inspection....1412
        Overheating / Diagnosis....1413
      PVT SYSTEM SERVICE....1414
        PVT Sealing, Guard, and Ducting Components....1414
        Disassembly....1414
        Assembly....1415
      DRIVE BELT....1416
        Belt Deflection (Tension)....1416
        Belt Removal....1417
        Belt Inspection....1417
        Belt Installation....1417
        PVT Break-In (Drive Belt / Clutches)....1417
      CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE....1418
        Clutch Alignment....1418
        Clutch Offset....1418
        Clutch Center Distance....1418
      DRIVE CLUTCH SERVICE....1419
        Spring Specifications....1419
        Shift Weights....1420
        Exploded View....1421
        Clutch Inspection....1421
        Clutch Disassembly....1422
        Spider Removal....1423
        Roller, Pin, and Thrust Washer Inspection....1423
        Bushing Service....1424
        Moveable Sheave - Bushing Removal....1424
        Moveable Sheave - Bushing Installation....1424
        Clutch Cover - Bushing Removal....1425
        Clutch Cover - Bushing Installation....1425
        Clutch Assembly....1426
      DRIVEN CLUTCH SERVICE....1427
        Exploded View....1427
        Clutch Disassembly / Inspection....1427
        Bushing Service....1428
        Moveable Sheave - Bushing Installation....1429
        Clutch Assembly....1430
      TROUBLESHOOTING....1432
  9921880_Chapter_07....1434
    FINAL DRIVE....1434
      SPECIAL TOOLS....1435
      TORQUE SPECIFICATIONS....1435
        Wheel, Hub, and Spindle Torque Table....1435
      FRONT BEARING CARRIER....1435
        Bearing Carrier Inspection / Removal....1435
        Bearing Replacement....1436
        Bearing Carrier Installation....1437
      FRONT DRIVE SHAFT....1439
        Removal....1439
        Installation....1439
      FRONT PROPSHAFT....1440
        Removal....1440
        Installation....1440
        Front Propshaft Components....1440
      PROPSHAFT U-JOINT SERVICE....1441
        Disassembly....1441
        Assembly....1441
      FRONT GEARCASE - CENTRALIZED HILLIARD....1443
        Exploded View....1443
        Operation....1444
        AWD Diagnosis....1445
        Gearcase Removal....1446
        Disassembly / Inspection....1446
        Reassembly / Inspection....1449
        Setting Ring Gear Backlash....1450
        Gearcase Installation....1451
      REAR HUB / BEARING CARRIER....1452
        Hub Inspection....1452
        Hub Removal....1452
        Hub Disassembly....1453
        Hub Assembly....1453
        Hub Installation....1454
        Exploded View....1455
      REAR DRIVE SHAFT....1456
        Removal....1456
        Installation....1456
      DRIVE SHAFT SERVICE....1457
        Drive Shaft / CV Joint Handling Tips....1457
        Outer CV Joint / Boot Replacement....1457
        Inner Plunging Joint / Boot Replacement....1459
        Drive Shaft Exploded View....1461
      REAR PROPSHAFT....1462
        Removal....1462
        Installation....1462
      REAR GEARCASE....1463
        General Operation....1463
        Operation Modes....1464
        Gearcase Removal....1465
        Gearcase Disassembly....1465
        Rear Gearcase Assembly....1468
        Rear Gearcase Installation....1470
        Rear Gearcase Exploded View....1471
  9921880_Chapter_08....1472
    TRANSMISSION....1472
      TORQUE SPECIFICATIONS....1473
      SHIFT LEVER....1473
        Removal....1473
        Installation....1473
      SHIFT CABLE....1473
        Inspection....1473
        Adjustment....1473
      TRANSMISSION SERVICE....1474
        Transmission Removal....1474
        Transmission Disassembly....1475
        Transmission Assembly....1480
        Transmission Installation....1485
      TROUBLESHOOTING....1486
        Troubleshooting Checklist....1486
      TRANSMISSION EXPLODED VIEW....1487
        Exploded View....1487
  9921880_Chapter_09....1490
    BRAKES....1490
      GENERAL SPECIFICATIONS....1491
      TORQUE SPECIFICATIONS....1491
      SPECIAL TOOLS....1491
      BRAKE SYSTEM SERVICE NOTES....1492
      BRAKE NOISE TROUBLESHOOTING....1492
      HYDRAULIC BRAKE SYSTEM OPERATION....1493
      BRAKE SYSTEM EXPLODED VIEW....1493
      MASTER CYLINDER....1494
        Removal....1494
        Installation....1494
      FOOT BRAKE PEDAL....1494
        Pedal Removal....1494
        Pedal Installation....1494
      BRAKE BLEEDING / FLUID CHANGE....1495
      PARKING BRAKE....1496
        Exploded View....1496
        Inspection....1497
        Cable Tension Adjustment....1497
      PARKING BRAKE CALIPER SERVICE....1498
        Exploded View....1498
        Caliper Removal....1498
        Caliper Disassembly / Inspection....1499
        New Brake Pad Installation....1500
        Caliper Installation....1500
      PARKING BRAKE DISC SERVICE....1500
        Disc Inspection / Removal....1500
      FRONT BRAKE PADS....1501
        Pad Removal....1501
        Pad Inspection....1501
        Pad Assembly / Installation....1502
        Brake Burnishing Procedure....1502
      FRONT CALIPER SERVICE....1503
        Caliper Exploded View....1503
        Caliper Removal ....1503
        Caliper Disassembly....1504
        Caliper Inspection....1505
        Caliper Assembly....1505
        Caliper Installation....1506
      FRONT BRAKE DISC....1507
        Disc Runout....1507
        Disc Inspection....1507
        Disc Removal / Replacement....1507
      REAR BRAKE PADS....1508
        Pad Removal....1508
        Pad Inspection....1509
        Pad Installation....1509
        Brake Burnishing Procedure....1509
      REAR CALIPER SERVICE....1510
        Rear Caliper Exploded View....1510
        Caliper Removal....1510
        Caliper Disassembly....1511
        Caliper Inspection....1511
        Caliper Assembly....1512
        Caliper Installation....1512
      REAR BRAKE DISC....1513
        Disc Runout....1513
        Disc Inspection....1513
        Disc Removal / Replacement....1513
      TROUBLESHOOTING....1514
        Brakes Squeal / Poor Brake Performance....1514
        Pedal Vibration....1514
        Caliper Overheats (Brakes Drag)....1514
        Brakes Lock....1514
  9921880_Chapter_10....1516
    ELECTRICAL....1516
      GENERAL INFORMATION....1517
        Special Tools....1517
        Electrical Service Notes....1517
        Components Under Hood ....1517
        Components Behind Dash Panel....1517
      SWITCHES / CONTROLS....1518
        Headlight Switch....1518
        AWD / 2WD / TURF Switch....1518
        Differential Solenoid....1518
        Brake Light Switch....1519
        Parking Brake Switch....1520
        Gear Indicator Light Circuit Operation....1521
        Indicator Lamp Replacement....1521
        Fuel / Hour Gauge....1522
      ALL WHEEL DRIVE (AWD) COIL....1523
        Operation Overview....1523
        Diagnosing System Failures....1523
      HEADLIGHTS....1523
        Headlight Adjustment....1523
        Headlight Bulb Replacement....1524
        Headlight Housing Removal....1524
        Headlight Housing Installation....1525
      TAIL LIGHT / BRAKE LIGHT....1526
        LED Lamp Replacement....1526
      COOLING SYSTEM....1527
        Cooling System Break-Out Diagram....1527
        Fan Control Circuit Operation....1528
        Fan Control Circuit Bypass Test....1528
      EFI DIAGNOSTICS....1528
        EFI Component Testing....1528
      FUEL SENDER....1528
        Testing....1528
      RELAYS....1529
        Operation....1529
      FUSES / CIRCUIT BREAKER....1530
        Operation....1530
      CHARGING SYSTEM....1531
        Current Draw - Key Off....1531
        Charging System “Break Even” Test....1531
        Charging System Alternator Tests....1532
        Regulator / Rectifier Test....1533
        Charging System Testing Flow Chart....1534
      BATTERY SERVICE....1535
        Battery Terminals / Bolts....1535
        Battery Terminal Block....1535
        Battery Activation....1535
        Battery Inspection....1536
        Battery Removal / Installation....1536
        Conventional Battery Testing....1537
        OCV - Open Circuit Voltage Test....1537
        Specific Gravity Test....1537
        Load Test....1537
        Charging Procedure....1538
        Off Season Storage....1538
      STARTER SYSTEM....1538
        Troubleshooting....1538
        Voltage Drop Test....1539
        Starter Motor Disassembly....1539
        Brush Inspection / Replacement....1539
        Armature Testing....1540
        Starter Reassembly....1541
        Starter Drive....1541
        Starter Solenoid Bench Test....1542
        Starter Solenoid Operation....1542
      STARTING SYSTEM TESTING FLOW CHART....1543
        Condition: Starter fails to turn over the engine. ....1543
      ELECTRIC BOX LIFT ACTUATOR....1544
        DIAGNOSIS (if equipped)....1544
  9921880_WIRE_DIAGRAMS....1546
Polaris  '09 Ranger RZR 170 Service Repair Manual....1550
  9922134_Ch_01.pdf....1550
    TABLE OF CONTENTS....1550
      MODEL INFORMATION....1551
        Model Identification....1551
        Engine Designation Number....1551
        VIN Identification....1551
        Engine Serial Number Location....1551
        Unit Serial Number (VIN) and Emissions Decal Locations....1552
      VEHICLE INFORMATION....1553
        Publication Numbers....1553
        Paint Codes....1553
        Replacement Keys....1553
      SPECIAL TOOLS....1553
      GENERAL SPECIFICATIONS....1554
        MODEL: 2009 RANGER RZR 170....1554
        MODEL: 2009 RANGER RZR 170....1555
      MISC. SPECIFICATIONS AND CHARTS....1556
        Conversion Table....1556
        Standard Torque Specifications....1557
        SAE Tap / Drill Sizes....1558
        Metric Tap / Drill Sizes....1558
        Decimal Equivalents....1558
        Glossary of Terms....1559
  9922134_Ch_02....1560
    TABLE OF CONTENTS....1560
      PERIODIC MAINTENANCE CHART....1562
        Periodic Maintenance Overview....1562
        Maintenance Chart Key....1562
        Pre-Ride - 25 Hour Maintenance Interval....1563
        30 - 100 Hour Maintenance Interval....1564
      MAINTENANCE REFERENCES / SERVICE LOCATIONS....1565
        Front and Rear View....1565
        RH and LH Side Views....1566
      LUBRICANTS / SERVICE PRODUCTS....1567
        Polaris Lubricants, Maintenance and Service Products....1567
      MAINTENANCE REFERENCES....1568
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....1569
        Pre-Ride / Daily Inspection....1569
        Frame, Nuts, Bolts, and Fasteners....1569
        Shift Cable Inspection / Adjustment....1569
        Shift Cable Replacement....1570
      FUEL SYSTEM AND AIR INTAKE....1571
        Air Filter Service....1571
        Choke Cable Adjustment....1572
        Choke Cable Replacement....1572
        Idle Speed Adjustment....1573
        Pilot Air Screw Adjustment....1573
        Vent Lines....1574
        Fuel System....1574
        Fuel Filter....1574
        Fuel Valve Location....1575
        Carburetor Draining....1575
        Fuel Pump / Fuel Lines....1575
        Throttle Pedal Inspection....1576
        Throttle Stop Speed Control....1576
        Throttle Freeplay Adjustment....1577
        Throttle Cable Replacement....1577
      ENGINE....1579
        Engine Oil Level....1579
        Engine Oil Change ....1579
        Engine Crankcase Ventilation System Inspection....1580
        Engine/Transmission Mount Locations....1580
        Compression / Leakdown Test....1581
        Intake Valve Clearance Adjustment....1581
        Exhaust Valve Clearance Adjustment....1581
        Exhaust - Spark Arrestor....1582
      TRANSMISSION....1583
        Transmission Specification Chart....1583
        Transmission Oil Change....1583
      FINAL DRIVE / WHEEL AND TIRE....1584
        Wheel, Hub, and Spindle Torque Table....1584
        Wheel Removal....1584
        Wheel Installation....1584
        Tire Inspection....1585
        Tire Pressure....1585
        Drive Chain Lubrication and Adjustment....1585
      ELECTRICAL AND IGNITION SYSTEM....1586
        Battery Maintenance....1586
        Battery Removal....1587
        Battery Installation....1587
        Battery Off Season Storage....1587
        Battery Charging (Maintenance Free)....1587
        Spark Plug Service....1588
        Engine To Frame Ground....1588
      STEERING....1589
        Steering Inspection....1589
        Steering Wheel Freeplay....1589
        Steering Inspection / Tie Rod Ends and Hubs ....1589
        Toe Alignment Inspection....1590
        Toe Adjustment....1590
      SUSPENSION....1591
        Spring Preload Adjustment....1591
      BRAKE SYSTEM....1591
        Brake Fluid Inspection....1591
        Brake Pad / Disc Inspection....1592
        Brake Hose and Fitting Inspection....1592
      MAINTENANCE LOG....1593
  9922134_Ch_03....1594
    TABLE OF CONTENTS....1594
      TOOLS....1596
        Special Tools....1596
      TORQUE SPECIFICATIONS....1596
        Engine Torque Specifications....1596
        Torque Patterns....1596
      ENGINE INFORMATION....1597
        Engine Exploded Views....1597
        Engine Lubrication....1598
        Piston Identification....1598
        Accessible Components....1598
        Engine Service Data....1599
        Engine Service Data....1600
        Oil Flow Diagram....1601
      ENGINE SYSTEMS SERVICE....1602
        Breather / Oil Separator....1602
        Emissions Secondary Air System....1603
        Cooling Shroud Removal/Installation....1604
        Engine Removal....1605
        Engine Installation Notes....1605
      TOP-END DISASSEMBLY....1606
        Engine Removal/Installation....1606
        Finding Top Dead Center (TDC)....1606
        Cam Chain Tensioner Inspection....1606
        Rocker Assembly Disassembly and Inspection....1607
        Camshaft Removal....1608
        Camshaft Inspection....1608
        Cylinder Head Removal....1609
        Cylinder Head Inspection....1610
        Cylinder Head Warp Inspection....1610
        Combustion Chamber Inspection....1610
        Cylinder Head Disassembly....1610
        Valve Inspection....1611
        Valve Seat Reconditioning....1612
        Cylinder Head Assembly....1614
        Valve Sealing Test....1615
        Cylinder Removal....1615
        Cam Chain Follower / Tensioner Guide Removal....1615
        Piston Removal....1616
        Cylinder Inspection....1616
        Cylinder Hone Selection / Honing Procedure....1617
        Honing to Deglaze....1617
        Piston Inspection....1617
        Piston Ring Installed Gap....1618
      BOTTOM-END DISASSEMBLY....1619
        Starter Drive Gear Removal and Inspection....1619
        Flywheel Removal / Inspection....1620
        Crankshaft One Way Gear / Drive Sprocket Removal and Inspection....1621
        Starter Drive One-way Clutch Removal and Inspection....1622
        Balance Shaft Sprocket Removal and Inspection....1622
        Oil Pump Removal / Drive Chain Inspection....1623
      CRANKCASE DISASSEMBLY....1625
        Crankcase Separation and Cam Chain Removal....1625
        Crankshaft Removal....1625
        Crankshaft / Cam Chain / Sprocket Inspection....1626
        Crankcase / Bearing Inspection....1626
        Crankcase Oil Strainer Inspection....1626
      ENGINE REASSEMBLY....1627
        Bearing / Seal Installation....1627
        Crankcase Reassembly....1627
        Chain Guide/Tensioner Installation....1628
        Crankshaft, Balance Shaft and Starter Drive Gear Installation....1628
        Oil Pump and Chain Installation....1629
        Piston Ring Installation....1630
        Piston Installation....1631
        Cylinder Installation....1632
        Cylinder Head and Camshaft Installation....1632
        Camshaft Timing....1633
        Rocker Arm / Shaft Assembly....1637
        Rocker Assembly Installation....1637
        Cam Chain Tensioner Installation....1638
        Intake Valve Clearance Adjustment....1638
        Exhaust Valve Clearance Adjustment....1638
        Starter Drive Assembly....1639
        Flywheel Installation....1639
        Stator Installation....1639
        Stator Housing Installation....1640
        Exhaust System....1641
      TROUBLESHOOTING....1642
        Spark Plug Fouling ....1642
        General Troubleshooting....1642
  9922134_Ch_05....1644
    TABLE OF CONTENTS....1644
      GENERAL INFORMATION....1645
        Special Tools....1645
        Torque Specifications....1645
      BODY REMOVAL....1645
        Seat Removal....1645
        Seat Installation....1646
        Front Bumper Removal / Installation....1646
        Front Cab Removal / Installation....1646
        Rocker Panel Removal....1648
        Rear Bumper Removal / Installation....1648
        Rear Cab Removal....1648
        Service Panel (Seat Shield) Removal....1649
        Console Cover Removal....1649
        Key Switch / Indicator Light Replacement....1650
        Decal Replacement....1651
        Body Exploded View....1652
      CAB FRAME....1653
        Exploded View....1653
        Cab Frame Assembly....1653
      MAIN FRAME....1654
        Exploded View....1654
      FRONT A-ARMS....1655
        Exploded View....1655
        A-arm Replacement....1656
      FRONT HUB....1657
        Hub Removal....1657
        Hub Seal and Bearing Replacement....1657
        Hub Installation....1658
      SHOCKS....1659
        Shock Exploded View....1659
        Shock Removal....1659
        Shock Replacement....1659
        Shock Installation....1659
      Rear Swing Arm....1660
        Exploded View....1660
        Swing Arm Removal....1661
        Swing Arm Installation....1662
      Rear Axle....1663
        Axle Housing Removal....1663
        Axle Housing Service....1664
        Axle Housing Installation....1664
        Axle Removal....1665
        Axle Installation....1665
      STEERING....1666
        Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View....1666
        Steering Shaft Removal....1667
        Steering Shaft Installation....1667
        Steering Gearbox Removal....1668
        Steering Gearbox Installation....1668
      Tie Rod....1669
        Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View....1669
        Tie Rod Removal / Installation....1670
      WHEELs....1671
        Front Wheel Exploded View....1671
        Rear Wheel Exploded View....1671
        Wheel Removal....1672
        Wheel Installation....1672
  9922134_Ch_06....1674
    TABLE OF CONTENTS....1674
      GENERAL SPECIFICATIONS....1675
      TORQUE SPECIFICATIONS....1675
      SPECIAL TOOLS....1675
      BRAKE SYSTEM SERVICE NOTES....1676
      BRAKE NOISE TROUBLESHOOTING....1676
      HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION....1677
      BRAKE SYSTEM - MECHANICAL COMPONENTS....1677
        Brake System - Mechanical Components....1677
      BRAKE SYSTEM - HYDRAULIC COMPONENTS....1678
      BRAKE BLEEDING / FLUID CHANGE....1679
      BRAKE PEDAL....1680
        Brake Pedal Removal....1680
        Pedal Installation....1680
        Brake Pedal Inspection / Adjustment....1681
      PARKING BRAKE....1681
        Parking Brake Adjustment....1681
        Parking Brake Cable Replacement....1682
      FRONT BRAKE PADS....1684
        Front Pad Removal....1684
        Pad Inspection....1684
        Front Brake Pad Assembly / Caliper Installation....1685
      FRONT BRAKE DISC....1686
        Disc Inspection....1686
        Disc Replacement....1686
      FRONT CALIPER....1687
        Front Caliper Removal ....1687
        Caliper Installation....1687
      REAR BRAKE PAD....1688
        Rear Brake Pad Removal....1688
        Rear Brake Pad Inspection....1689
        Rear Brake Pad Assembly / Caliper Installation....1690
        Brake Burnishing Procedure....1691
      REAR BRAKE DISC....1691
        Disc Inspection....1691
        Rear Brake Disc Replacement....1691
      REAR CALIPER SERVICE....1692
        Rear Caliper Removal....1692
        Rear Brake Caliper Installation....1693
      MASTER CYLINDER....1694
        Removal....1694
        Installation....1694
      TROUBLESHOOTING....1695
        Brakes Squeal / Poor Brake Performance....1695
        Pedal Vibration....1695
        Caliper Overheats (Brakes Drag)....1695
        Brakes Lock....1695
        Parking Brake Drags or Ineffective Brake....1695
  9922134_Ch_07....1696
    TABLE OF CONTENTS....1696
      SPECIFICATIONS / TOOLS....1697
        Torque Specifications....1697
        Special Tools....1697
      CVT SYSTEM....1698
        CVT Maintenance / Inspection....1698
        Drive Clutch Operation....1698
        Driven Clutch Operation....1698
        CVT System Drying....1699
        CVT Overheating / Water Ingestion Diagnostics....1699
        Clutch (CVT) Cover Removal / Inspection....1700
        Clutch (CVT) Cover Installation....1700
        Drive Belt Removal....1701
        Drive Belt Inspection....1701
        Drive Belt Installation....1701
      Drive Clutch Service....1702
        Drive Clutch Removal, Disassembly and Inspection....1702
        Drive Clutch Assembly....1703
      Driven Clutch Service....1704
        Driven Clutch Removal, Disassembly, Inspection....1704
        Driven Clutch Assembly....1706
        Driven Clutch Installation....1706
      TRANSMISSION SERVICE....1707
        Transmission Disassembly and Inspection....1707
        Input Shaft Removal / Inspection....1710
        Transmission Main Shaft Assembly View....1711
        Transmission Assembly ....1712
        Output Gear Pinion Depth Adjustment....1714
        Output Shaft Housing Disassembly / Assembly....1715
  9922134_Ch_08....1716
    TABLE OF CONTENTS....1716
      General Information....1717
        Special Tools....1717
        Electrical System Service Notes....1717
      Switches and Controls....1717
        Key Switch....1717
        Brake Pedal / Parking Brake Switches....1718
        Electronic Throttle Control (ETC)....1719
        ETC Operation....1719
        ETC Switch Adjustment....1719
      Daytime Running Lights....1720
        “DRL” Test....1720
        “DRL” Lamp Replacement....1720
      Tail Light....1721
        Tail Light Lamp Replacement....1721
      Indicator lamps....1721
        Indicator Lamp Replacement....1721
      Transmission Switch....1722
        Transmission Switch - Circuit Breakout....1722
        Testing....1722
        Removal....1723
        Installation....1723
      Ignition System....1723
        Overview....1723
        Ignition System Troubleshooting....1723
        Ignition System Testing....1724
        RPM Ignition Limiter Functions....1725
        RPM Limiter Specifications....1726
        Ignition Coil Test....1726
        CDI Output Test Using Peak Reading Adaptor....1726
        Pulser Coil Output / Resistance Tests ....1726
      Charging System....1727
        Charging System Testing....1727
        Main Fuse / Fuse Holder Location....1728
        Voltage Regulator / Rectifier....1728
        Stator / Alternator Tests....1728
      Battery....1729
        Battery Maintenance Service Notes....1729
        New Battery Activation....1729
        Battery Removal....1730
        Battery Cleaning....1730
        Battery Installation....1730
        Battery Voltage Test....1730
        Battery Load Test....1730
        Battery Charging Procedure....1731
        Battery Storage....1731
      Starter System....1731
        Starter Relay....1731
        Starter Motor Service....1732
        Starter Disassembly....1732
        Starter Brush Inspection / Replacement....1733
        Armature Test....1733
        Starter Reassembly....1734
        Voltage Drop Test....1734
        Starter System Troubleshooting....1734
        Starter System Testing ....1735
  9922134_WIRE_DIAGRAM....1736
Polaris  '09 Ranger RZR_RZR  'S ' Service Repair Manual....1737
  General Information....1737
    GENERAL INFORMATION....1737
      MODEL INFORMATION....1738
        Model Identification....1738
        Engine Designation Number....1738
        VIN Identification....1738
        Engine Serial Number Location....1738
        Unit Serial Number (VIN) Location....1739
      VEHICLE INFORMATION....1740
        Publication Numbers....1740
        Paint Codes....1740
        Replacement Keys....1740
      SPECIAL TOOLS....1740
      GENERAL SPECIFICATIONS....1741
        MODEL: 2009 RANGER RZR....1741
        MODEL: 2009 RANGER RZR “S?....1741
        MODEL: 2009 RANGER RZR....1742
        MODEL: 2009 RANGER RZR “S?....1743
      MISC. SPECIFICATIONS AND CHARTS....1744
        Conversion Table....1744
        Standard Torque Specifications....1745
        SAE Tap / Drill Sizes....1746
        Metric Tap / Drill Sizes....1746
        Decimal Equivalents....1746
        Glossary of Terms....1747
  Maintenance....1749
    MAINTENANCE....1749
      PERIODIC MAINTENANCE CHART....1751
        Periodic Maintenance Overview....1751
        Break-In Period....1751
        Maintenance Chart Key....1751
        Pre-Ride - 25 Hour Maintenance Interval....1752
        50 - 300 Hour Maintenance Interval....1753
      COMPONENT INSPECTION / SERVICE LOCATIONS....1754
        Front and Rear View....1754
        RH and LH Side Views....1755
      LUBRICANTS / SERVICE PRODUCTS....1756
        Polaris Lubricants, Maintenance and Service Products....1756
      MAINTENANCE REFERENCES....1757
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....1758
        Pre-Ride / Daily Inspection....1758
        Frame, Nuts, Bolts, and Fasteners....1758
        Shift Cable Inspection / Adjustment....1758
      FUEL SYSTEM AND AIR INTAKE....1759
        Fuel System....1759
        Fuel Line....1759
        Fuel Pump / Fuel Filters....1759
        Vent Lines....1759
        Throttle Pedal Inspection....1760
        Throttle Freeplay Adjustment....1760
        Throttle Cable Replacement....1760
        Air Filter Service....1762
      ENGINE....1764
        Engine Oil Level....1764
        Engine Oil and Filter Service....1765
        Engine Breather Hose Inspection....1766
        Engine and Transmission Mount Locations....1766
        Compression and Leakdown Test....1766
        Exhaust - Spark Arrestor....1766
      TRANSMISSION AND GEARCASES....1767
        Transmission / Gearcase Specification Chart....1767
        Transmission Lubrication....1767
        Front Gearcase Lubrication....1769
        Rear Gearcase Lubrication....1770
      COOLING SYSTEM....1771
        Cooling System Overview....1771
        Coolant Level Inspection....1771
        Coolant Strength / Type....1771
        Cooling System Pressure Test....1772
        Cooling System Hoses....1772
        Radiator....1772
        Coolant Drain / Radiator Removal....1772
      FINAL DRIVE / WHEEL AND TIRE....1773
        Wheel, Hub, and Spindle Torque Table....1773
        Wheel Removal....1773
        Wheel Installation....1773
        Tire Inspection....1774
        Tire Pressure....1774
        Drive Shaft Boot Inspection....1774
      ELECTRICAL AND IGNITION SYSTEM....1775
        Battery Maintenance....1775
        Battery Removal....1775
        Battery Installation....1775
        Battery Off Season Storage....1776
        Battery Charging (Maintenance Free)....1776
        Spark Plug Service....1776
        Engine To Frame Ground....1777
      STEERING....1777
        Steering Inspection....1777
        Steering Wheel Freeplay....1777
        Steering Inspection / Tie Rod Ends and Hubs ....1778
        Toe Alignment Inspection....1778
        Toe Adjustment....1779
      SUSPENSION (RZR)....1779
        Spring Preload Adjustment....1779
      SUSPENSION (RZR “S?)....1780
        Spring Preload Adjustment....1780
        Shock Compression Adjustment....1780
      BRAKE SYSTEM....1781
        Brake Fluid Inspection....1781
        Brake Pad / Disc Inspection....1781
        Brake Hose and Fitting Inspection....1781
      MAINTENANCE LOG....1782
  Engine....1783
    ENGINE....1783
      ENGINE SPECIFICATIONS....1784
        Crankcase Exploded Views....1784
        Engine Fastener Torque Patterns....1789
        Torque Specifications....1790
        800 EFI Engine Service Specifications....1791
        Special Tools....1793
      ENGINE COOLING SYSTEM....1794
        Cooling System Specifications....1794
        Cooling System Pressure Test....1794
        Cooling System Exploded View....1795
        Cooling System Bleeding Procedure....1796
      GENERAL ENGINE SERVICE....1797
        Engine Lubrication Specifications....1797
        Accessible Engine Components....1797
        Oil Pressure Test....1797
        Oil Flow Chart....1798
        Engine Removal....1799
        Engine / Transmission Separation....1805
      ENGINE DISASSEMBLY AND INSPECTION....1806
        Cylinder Head Assembly Exploded View....1806
        Rocker Arms....1807
        Push Rods....1807
        Cylinder Head Removal ....1807
        Cylinder Head Inspection....1808
        Cylinder Head Warp....1808
        Valve Seal / Spring Service (On Engine)....1808
        Cylinder Head Disassembly....1809
        Valve Inspection....1810
        Combustion Chamber....1811
        Valve Seat Reconditioning....1811
        Cylinder Head Reassembly....1813
        Valve Sealing Test....1814
        Cylinder Removal....1814
        Valve Lifter Removal / Inspection....1814
        Piston Removal....1815
        Cylinder Inspection....1816
        Cylinder Hone Selection and Honing Procedure....1817
        Honing To Deglaze....1817
        Cleaning the Cylinder After Honing....1817
        Piston-to-Cylinder Clearance....1818
        Piston / Rod Inspection....1818
        Piston Ring Installed Gap....1819
        Starter Drive Bendix Removal / Inspection ....1819
        Flywheel / Stator Removal / Inspection....1820
        Engine Crankcase Disassembly / Inspection....1820
        Camshaft Inspection....1828
      ENGINE REASSEMBLY....1829
        Crankcase Reassembly....1829
        Flywheel / Stator Installation....1838
        Cylinder Head Reassembly....1838
        Oil Pump Priming....1840
      ENGINE INSTALLATION....1841
        Engine Assembly and Installation....1841
        Engine Break-In Period....1842
      TROUBLESHOOTING....1843
        Engine....1843
        Cooling System....1844
  Electronic Fuel Injection....1845
    ELECTRONIC FUEL INJECTION....1845
      GENERAL INFORMATION....1846
        Special Tools....1846
        Service Notes....1848
        EFI System Exploded View....1849
        EFI System Component Locations....1850
      FUEL TANK....1852
        Exploded View....1852
        Fuel Lines - Quick Connect....1853
      ELECTRONIC FUEL INJECTION....1853
        Principal Components....1853
        EFI Operation Overview....1853
        Initial Priming / Starting Procedure....1854
      ELECTRONIC CONTROL UNIT (ECU)....1854
        Operation Overview....1854
        ECU Service....1855
        ECU Replacement....1855
      TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....1855
        Operation Overview....1855
        T-BAP Test....1855
        T-BAP Replacement....1855
      CRANKSHAFT POSITION SENSOR (CPS)....1856
        Operation Overview....1856
        CPS Test....1856
        CPS Replacement....1857
      FUEL INJECTORS....1861
        Operation Overview....1861
        Fuel Injector Service....1861
        Fuel Injector Test....1862
        Fuel Injector Replacement....1862
      FUEL PUMP....1864
        Operation Overview....1864
        Fuel Sender Test....1864
        Fuel Pump Test....1864
        Fuel Tank / Fuel Pump Replacement....1866
      THROTTLE POSITION SENSOR (TPS)....1868
        Operation Overview....1868
        TPS Tester / Regulator....1868
        Checking TPS Reading....1869
        TPS Adjustment....1870
        TPS Replacement....1870
      ENGINE COOLANT TEMPERATURE SENSOR (ECT)....1871
        Operation Overview....1871
        ECT Sensor Test....1871
        ECT Sensor Replacement....1871
      IGNITION COIL....1872
        Operation Overview....1872
        Ignition Coil Tests....1872
        Ignition Coil / HT Lead Replacement....1872
      GENERAL TROUBLESHOOTING....1873
        Diagnostic “Blink Codes?....1873
        EFI Troubleshooting....1874
      EFI SYSTEM BREAKOUT DIAGRAMS....1875
        Diagnostic Connector Circuit....1875
        Malfunction Indicator Lamp (MIL) Circuit....1875
        Fuel Injector (PTO) Circuit....1876
        Fuel Injector (MAG) Circuit....1876
        Engine Coolant Temperature Sensor (ECT) Circuit....1877
        Engine Overheat Lamp Driver Circuit....1877
        Crankshaft Position Sensor (CPS) Circuit....1878
        Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit....1878
        Throttle Position Sensor (TPS) Circuit....1879
        Fuel Pump Circuit....1879
  Body / Steering  / Suspension....1881
    BODY / STEERING / SUSPENSION....1881
      TORQUE SPECIFICATIONS....1882
      SPECIAL TOOLS....1882
        Multi-Function Pliers....1882
      CAB FRAME (RZR)....1883
        Assembly / Removal....1883
      CAB FRAME (RZR “S?)....1884
        Assembly / Removal....1884
      BODY EXPLODED VIEWS....1885
        Dash Instruments / Controls....1885
        Front Bumper....1886
        Rear Bumper....1886
        Hood / Front Body Work....1887
        Seat Assembly....1888
        Seat Belts / Mounting....1888
        Floor / Rocker Panels....1889
        Rear Cargo Box / Fenders....1890
        Chassis / Main Frame....1891
      BODY COMPONENT REMOVAL....1892
        Seats....1892
        Rear Service Panel....1892
        Front Bumper....1892
        Rear Bumper....1892
        Hood and Front Body Work....1893
        Rocker Panels, Console and Floor....1894
        Rear Fender, Flair and Tie Down Removal....1894
        Cargo Box Assembly Removal....1894
      STEERING ASSEMBLY....1895
        Exploded View....1895
        Steering Wheel Removal....1896
        Steering Shaft Removal....1896
        Steering Shaft Bearing Replacement....1896
      WHEEL HUBS....1897
        Front Hub Exploded View....1897
        Rear Hub Exploded View....1897
      FRONT A-ARMS....1898
        Removal / Replacement....1898
        Exploded View (RZR)....1899
        Exploded View (RZR “S?)....1899
      BALL JOINT SERVICE....1900
        Removal....1900
        Installation....1901
      FRONT STABILIZER BAR (RZR)....1901
        Sway Bar Linkage Removal....1901
        Stabilizer Bar Removal....1901
        Exploded View....1902
      REAR A-ARMS....1903
        Removal....1903
        Installation....1904
        Exploded View (RZR)....1905
        Exploded View (RZR “S?)....1905
      REAR STABILIZER BAR (RZR)....1906
        Removal / Installation....1906
      REAR STABILIZER BAR (RZR “S?)....1907
        Removal / Installation....1907
      DECAL REPLACEMENT....1908
      SHOCKS / SPRINGS (RZR)....1908
        Exploded View....1908
        Shock Removal / Installation....1908
        Shock Replacement....1908
      FOX? SHOCK EXPLODED VIEW (RZR “S?)....1909
        FOX? PODIUM X ‘Piggyback’ Shock....1909
      FOX? SHOCK SERVICE (RZR “S?)....1910
        General Service Information....1910
        Front Shock Service Information....1910
        Rear Shock Service Information....1910
        FOX? PODIUM X Shock Rebuild Information....1911
        FOX? Podium X Shock Disassembly....1912
        FOX? Podium X Shock Rebuild....1914
        FOX? Podium X Shock Reassembly....1915
  Clutching....1919
    CLUTCHING....1919
      SPECIAL TOOLS AND SUPPLIES....1920
      TORQUE SPECIFICATIONS....1920
        PVT System Fastener Torques....1920
      PVT SYSTEM OVERVIEW....1920
        General Operation....1920
        Drive Clutch Operation....1920
        Driven Clutch Operation....1921
        PVT Break-In (Drive Belt / Clutches)....1921
        Maintenance / Inspection....1921
        Overheating / Diagnosis....1922
      PVT SYSTEM SERVICE....1923
        PVT Sealing and Ducting Components....1923
        Disassembly....1923
        Assembly....1924
      DRIVE BELT....1925
        Belt Removal....1925
        Belt Inspection....1926
        Belt Installation....1926
        PVT Break-In (Drive Belt / Clutches)....1926
      DRIVE CLUTCH SERVICE....1927
        Spring Specifications....1927
        Shift Weights....1928
        Non-Braking Exploded View (RZR)....1929
        EBS Exploded View (RZR “S?)....1929
        Clutch Disassembly....1930
        Spider Removal....1930
        Roller, Pin, and Thrust Washer Inspection....1931
        Button To Tower Clearance Inspection....1932
        Shift Weight Inspection....1932
        Bearing Inspection....1932
        Clutch Inspection....1933
        Moveable Sheave Bushing Inspection....1934
        Bushing Service....1934
        Clutch Assembly....1936
      DRIVEN CLUTCH SERVICE....1937
        Clutch Disassembly ....1937
        Bushing Service....1940
        Clutch Assembly....1941
        Exploded View....1945
      DRIVEN CLUTCH SERVICE (LATE BUILD RZR)....1946
        Exploded View....1946
        Clutch Disassembly / Inspection....1946
        Clutch Assembly....1948
      TROUBLESHOOTING....1949
  Final Drive....1951
    FINAL DRIVE....1951
      SPECIAL TOOLS....1952
      TORQUE SPECIFICATIONS....1952
        Wheel, Hub, and Spindle Torque Table....1952
      FRONT BEARING CARRIER....1952
        Bearing Carrier Inspection / Removal....1952
        Bearing Replacement....1953
        Bearing Carrier Installation....1954
      FRONT DRIVE SHAFT....1956
        Drive Shaft Removal....1956
        Drive Shaft / CV Joint Handling Tips....1957
        Outer CV Joint / Boot Replacement....1957
        Inner Plunging Joint / Boot Replacement....1958
        Drive Shaft Installation....1960
      PROPSHAFT SERVICE....1961
        Removal / Installation....1961
      PROPSHAFT U-JOINT SERVICE....1962
        Disassembly....1962
        Assembly....1962
      FRONT GEARCASE / CENTRALIZED HILLIARD....1964
        Centralized Hilliard Exploded View....1964
        All Wheel Drive Operation....1965
        AWD Diagnosis....1966
        Gearcase Removal....1967
        Gearcase Disassembly / Inspection....1967
        Gearcase Assembly / Inspection....1969
        Backlash Thrust Plate Adjustment....1971
        Gearcase Installation....1972
      REAR BEARING CARRIER....1973
        Bearing Carrier Inspection / Removal....1973
        Bearing Replacement....1974
        Bearing Carrier Bushing Replacement....1974
        Bearing Carrier Installation....1975
      REAR DRIVE SHAFT....1976
        Removal....1976
        Outer CV Joint / Boot Replacement....1977
        Inner Plunging Joint / Boot Replacement....1980
        Drive Shaft Exploded View....1982
        Installation....1982
      REAR GEARCASE....1984
        Gearcase Removal....1984
        Gearcase Disassembly....1985
        Gearcase Assembly....1987
        Gearcase Installation....1988
        Gearcase Exploded View....1989
      WHEEL HUBS....1990
        Front Hub Exploded View....1990
        Rear Hub Exploded View....1990
  Transmission....1991
    TRANSMISSION....1991
      TORQUES / SPECIFICATIONS....1992
      SHIFT LEVER....1992
        Removal....1992
        Installation....1992
        Shift Cable Inspection / Adjustment....1993
      TRANSMISSION SERVICE....1994
        Transmission Removal / Service Notes....1994
        Transfer Case Disassembly....1994
        Transfer Case Reassembly....1997
        Transmission Shift Housing Disassembly....1999
        Transmission Shift Housing Reassembly....2004
      TROUBLESHOOTING....2009
        Troubleshooting Checklist....2009
      TRANSMISSION EXPLODED VIEWS....2010
        Shift Housing / Transfer Case Exploded View ....2010
  Brakes....2011
    BRAKES....2011
      GENERAL SPECIFICATIONS....2012
      TORQUE SPECIFICATIONS....2012
      SPECIAL TOOLS....2012
      BRAKE SYSTEM SERVICE NOTES....2013
      BRAKE NOISE TROUBLESHOOTING....2013
      HYDRAULIC BRAKE SYSTEM OPERATION....2014
      BRAKE SYSTEM EXPLODED VIEW....2014
      MASTER CYLINDER....2015
        Removal....2015
        Installation....2015
      BRAKE PEDAL LEVER....2015
        Pedal Removal....2015
        Pedal Installation....2015
      BRAKE BLEEDING / FLUID CHANGE....2016
      FRONT BRAKE PADS....2017
        Pad Removal....2017
        Pad Inspection....2017
        Pad Assembly / Installation....2018
        Brake Burnishing Procedure....2018
      FRONT CALIPER SERVICE....2019
        Caliper Exploded View....2019
        Caliper Removal ....2019
        Caliper Disassembly....2020
        Caliper Inspection....2021
        Caliper Assembly....2021
        Caliper Installation....2022
      FRONT BRAKE DISC....2023
        Disc Inspection....2023
        Disc Replacement....2023
      REAR BRAKE PAD....2024
        Pad Removal....2024
        Pad Inspection....2025
        Pad Assembly / Installation....2025
        Brake Burnishing Procedure....2025
      REAR CALIPER SERVICE....2026
        Caliper Exploded View....2026
        Caliper Removal....2026
        Caliper Disassembly....2027
        Caliper Inspection....2027
        Caliper Assembly....2028
        Caliper Installation....2028
      REAR BRAKE DISC....2029
        Disc Inspection....2029
        Disc Replacement....2029
      TROUBLESHOOTING....2030
        Brakes Squeal / Poor Brake Performance....2030
        Pedal Vibration....2030
        Caliper Overheats (Brakes Drag)....2030
        Brakes Lock....2030
  Electrical....2031
    ELECTRICAL....2031
      GENERAL INFORMATION....2033
        Special Tools....2033
        Electrical Service Notes....2033
        Under-Dash Components....2033
      SWITCHES / CONTROLS....2034
        Headlamp Switch....2034
        AWD Switch....2034
        Brake Light Switch....2034
      INSTRUMENT CLUSTER....2035
        Overview....2035
        Rider Information Display....2035
        Standard Display Modes....2036
        Diagnostic Display Mode....2036
        Viewing Diagnostic Codes....2038
        Instrument Cluster Removal....2039
        Instrument Cluster Installation....2039
      INSTRUMENT CLUSTER TROUBLESHOOTING TESTS....2040
        TEST 1 - No All Wheel Drive....2040
        TEST 2 - No Display....2041
        TEST 3 - Vehicle Speed Sensor....2041
        TEST 4 - No AWD Hub Safety Limiter....2042
        TEST 5 - Fuel Gauge Display Not Working ....2043
        TEST 6 - Gear Indicator Not Working (Transmission Switch)....2043
      ALL WHEEL DRIVE COIL....2044
        Operation Overview....2044
        Diagnosing System Failures....2044
      GEAR POSITION INDICATOR SWITCH....2044
        Switch Resistance Value Table....2044
      SPEED SENSOR....2044
        Location / Testing ....2044
      HEAD LIGHTS....2045
        Headlight Adjustment....2045
        Headlamp Bulb Replacement....2045
        Headlamp Housing Removal....2046
        Headlamp Housing Installation....2046
      TAIL / BRAKE LIGHTS....2046
        Bulb Replacement....2046
      COOLING SYSTEM SCHEMATIC....2047
        Cooling System Break-Out Diagram....2047
        Fan Control Circuit Operation / Testing....2048
        Fan Control Circuit Bypass Test....2048
        Coolant Temperature Sensor....2048
      EFI DIAGNOSTICS....2048
        EFI Component Testing....2048
      FUEL SENDER....2048
        Testing....2048
      RELAYS....2049
        Operation....2049
      FUSE BOX LAYOUT....2049
      FUSES / CIRCUIT BREAKER....2050
        Operation....2050
      CHARGING SYSTEM....2051
        Current Draw - Key Off....2051
        Charging System “Break Even? Test....2051
        Charging System Alternator Tests....2052
        Charging System Testing Flow Chart....2053
      BATTERY SERVICE....2054
        General Battery Information....2054
        Battery Removal / Installation....2054
        Charging Procedure (Maintenance Free)....2054
        Maintenance Free Battery Testing....2054
        OCV - Open Circuit Voltage Test....2054
        Load Test....2054
        Off Season Storage....2054
      STARTING SYSTEM....2055
        Troubleshooting....2055
        Voltage Drop Test....2055
        Starter Motor Removal / Disassembly ....2055
        Brush Inspection / Replacement....2056
        Armature Testing....2057
        Starter Reassembly / Installation....2057
        Starter Drive....2058
        Starter Solenoid Bench Test....2059
        Starter Solenoid Operation....2059
        Starter Exploded View....2060
      STARTING SYSTEM TESTING FLOW CHART....2061
        Condition: Starter fails to turn over the engine. ....2061
      ELECTRICAL BREAKOUT DIAGRAMS....2062
        12V Key-On Power Circuit....2062
        Starting System Circuit....2062
        Instrument Cluster Circuit....2063
        Transmission Switch Circuit....2063
        Wheel Speed Sensor Circuit....2064
        AWD Circuit....2064
        Fuel Gauge Display Circuit....2065
        Cooling Fan Circuit....2065
        Charging System Circuit....2066
  Wire_Diagram....2067
Polaris  '09 Ranger XP700_HD700 4X4 Service Repair Manual....2069
  9922036_Chapter_01.pdf....2069
    GENERAL INFORMATION....2069
      MODEL INFORMATION....2070
        Model Identification....2070
        Engine Designation Number....2070
        VIN Identification....2070
        Vehicle and Engine Serial Number Locations....2070
      VEHICLE INFORMATION....2071
        Publication Numbers....2071
        Replacement Keys....2071
      SPECIAL TOOLS....2071
      GENERAL SPECIFICATIONS....2072
        MODEL: 2009 RANGER XP 700 4X4....2072
        MODEL: 2009 RANGER XP 700 4X4....2073
        MODEL: 2009 RANGER HD 700 4X4....2074
        MODEL: 2009 RANGER HD 700 4X4....2075
      MISC. SPECIFICATIONS AND CHARTS....2076
        Conversion Table....2076
        Standard Torque Specifications....2077
        SAE Tap / Drill Sizes....2078
        Metric Tap / Drill Sizes....2078
        Decimal Equivalents....2078
        Glossary of Terms....2079
  9922036_Chapter_02....2081
    MAINTENANCE....2081
      PERIODIC MAINTENANCE CHART....2083
        Periodic Maintenance Overview....2083
        Break-In Period....2083
        Maintenance Chart Key....2083
        Pre-Ride - 25 Hour Maintenance Interval....2084
        50 - 100 Hour Maintenance Interval....2085
        100 - 300 Hour Maintenance Interval....2086
        Grease Lubrication Points....2086
      SERVICE PRODUCTS AND LUBRICANTS....2087
        Polaris Lubricants, Maintenance and Service Products....2087
      FLUID MAINTENANCE REFERENCES....2088
        Component Quick Reference....2088
        Component Quick Reference, Continued.......2089
      GENERAL VEHICLE INSPECTION AND MAINTENANCE....2090
        Pre-Ride / Daily Inspection....2090
        Frame, Nuts, Bolts, and Fasteners....2090
        Shift Linkage Inspection / Adjustment....2090
      FUEL SYSTEM AND AIR INTAKE....2091
        Fuel System....2091
        Fuel Lines....2091
        Fuel Filter....2091
        Vent Lines....2091
        Throttle Pedal Inspection....2091
        Throttle Freeplay Adjustment....2091
        Air Filter Service....2092
        Engine Air Intake Inspection....2092
        PVT Air Intake Inspection....2092
        Air Intake Exploded View....2093
      ENGINE....2094
        Compression and Leakdown Test....2094
        Breather Hose Inspection....2094
        Engine Oil Level....2094
        Engine Oil and Filter Change....2095
        Exhaust Pipe....2096
      TRANSMISSION AND GEARCASES....2097
        Transmission Lubrication....2097
        Front Gearcase Lubrication....2098
        Rear Gearcase Lubrication....2100
      COOLING SYSTEM....2101
        Liquid Cooling System Overview....2101
        Coolant Level Inspection....2101
        Coolant Strength / Type....2102
        Cooling System Hoses....2102
        Radiator Inspection / Cleaning....2102
        Coolant Drain / Radiator Removal....2102
      FINAL DRIVE / WHEEL AND TIRE....2104
        Wheel and Hub Torque Table....2104
        CV Shaft Boot Inspection....2104
        Wheel Removal....2105
        Wheel Installation....2105
        Tire Inspection....2105
        Tire Pressure....2105
      ELECTRICAL AND IGNITION SYSTEM....2106
        Battery Maintenance....2106
        Battery Fluid Level (Conventional Battery)....2106
        Battery Removal....2106
        Battery Installation....2107
        Battery Storage....2107
        Battery Charging....2107
        Spark Plug Service....2108
        Engine To Frame Ground....2108
      STEERING....2109
        Steering Inspection....2109
        Tie Rod End / Steering Inspection....2109
        Wheel Toe Alignment Inspection....2109
        Toe Adjustment....2110
      SUSPENSION....2110
        Suspension Inspection....2110
        Spring Pre-Load Adjustment....2110
        Shock Position Adjustment....2111
      BRAKE SYSTEM....2111
        Brake Fluid Inspection....2111
        Brake Hose and Fitting Inspection....2111
        Brake Pad / Disc Inspection....2112
        Parking Brake Cable Adjustment....2112
        Parking Brake Pad Inspection....2112
      MAINTENANCE LOG....2113
  9922036_Chapter_03....2115
    ENGINE....2115
      ENGINE SPECIFICATIONS....2116
        Crankcase Exploded Views....2116
        Engine Fastener Torque Patterns....2123
        Torque Specifications....2124
        700 EFI Engine Service Specifications....2125
        Special Tools....2127
      GENERAL ENGINE SERVICE....2127
        Accessible Components....2127
        Piston Identification....2127
        Cooling System Specifications....2127
        Cooling System Layout and Testing....2128
        Cooling System Bleeding Procedure....2129
        Engine Removal....2130
        Engine Installation Notes....2132
        Engine Lubrication Specifications....2132
        Oil Pressure Test....2132
        Oil Flow Chart....2133
      ENGINE DISASSEMBLY AND INSPECTION....2134
        Cylinder Head Assembly Exploded View....2134
        Rocker Arms....2135
        Push Rods....2135
        Cylinder Head Removal ....2135
        Cylinder Head Inspection....2136
        Cylinder Head Warp....2136
        Valve Seal / Spring Service (On Engine)....2136
        Cylinder Head Disassembly....2137
        Valve Inspection....2138
        Combustion Chamber....2139
        Valve Seat Reconditioning....2139
        Cylinder Head Reassembly....2141
        Valve Sealing Test....2142
        Cylinder Removal....2142
        Valve Lifter Removal / Inspection....2142
        Piston Removal....2143
        Cylinder Inspection....2144
        Cylinder Hone Selection And Honing Procedure....2145
        Honing To Deglaze....2145
        Cleaning the Cylinder After Honing....2145
        Piston-to-Cylinder Clearance....2146
        Piston / Rod Inspection....2146
        Piston Ring Installed Gap....2147
        Starter Drive Bendix Removal / Inspection ....2147
        Flywheel / Stator Removal / Inspection....2148
        Engine Crankcase Disassembly / Inspection....2148
        Camshaft Inspection....2156
      ENGINE REASSEMBLY....2157
        Crankcase Reassembly....2157
        Flywheel / Stator Installation....2166
        Cylinder Head Reassembly....2167
        Oil Pump Priming....2169
        Engine Break-In....2169
      TROUBLESHOOTING....2170
        Engine....2170
        Cooling System....2171
  9922036_Chapter_04....2173
    ELECTRONIC FUEL INJECTION....2173
      GENERAL INFORMATION....2174
        Special Tools....2174
        EFI Service Notes....2176
        Fuel Tank Exploded View....2177
        EFI System Exploded View....2178
        EFI System Component Locations....2179
        Fuel Lines - Quick Connect Removal / Installation....2180
      ELECTRONIC FUEL INJECTION....2181
        Principal Components....2181
        EFI Operation Overview....2181
        Initial Priming / Starting Procedure....2181
      ELECTRONIC CONTROL UNIT (ECU)....2182
        Operation Overview....2182
        ECU Service....2182
        ECU Replacement....2182
      FUEL PUMP....2183
        Operation Overview....2183
        Fuel Sender Test....2183
        Fuel Pump Test....2183
        Fuel Pump / Tank Assembly Replacement....2184
      FUEL PRESSURE REGULATOR....2185
        Operation Overview....2185
        Fuel Pressure Regulator Test....2185
        Fuel Pressure Regulator Replacement....2185
      FUEL INJECTORS....2186
        Operation Overview....2186
        Fuel Injector Service....2186
        Fuel Injector Replacement....2186
      CRANKSHAFT POSITION SENSOR (CPS)....2187
        Operation Overview....2187
        CPS Test....2187
        CPS Replacement....2187
      TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....2188
        Operation Overview....2188
        T-BAP Test....2188
        T-BAP Replacement....2188
      THROTTLE POSITION SENSOR (TPS)....2188
        Operation Overview....2188
        TPS Tester / Regulator....2188
        Checking TPS Reading....2190
        TPS Adjustment....2190
        TPS Replacement....2191
      ENGINE COOLANT TEMPERATURE SENSOR (ECT)....2191
        Operation Overview....2191
        ECT Sensor Test....2191
        ECT Sensor Replacement....2191
      IGNITION COIL....2192
        Operation Overview....2192
        Ignition Coil Tests....2192
        Ignition Coil / HT Lead Replacement....2192
      GENERAL TROUBLESHOOTING....2193
        Diagnostic “Blink Codes”....2193
        EFI Troubleshooting....2194
  9922036_Chapter_05....2195
    BODY / STEERING / SUSPENSION....2195
      TORQUE SPECIFICATIONS....2196
      SPECIAL TOOLS....2196
        Multi-Function Pliers....2196
      CHASSIS / MAIN FRAME....2197
        Exploded View....2197
      CAB FRAME....2198
        Exploded View / Assembly....2198
      SEAT BACK / HEADREST / PVT AIR INTAKE BAFFLE BOX....2199
        Exploded View / Assembly....2199
      BODY EXPLODED VIEWS....2200
        Dash Instruments / Controls....2200
        Hood / Dash / Front Fenders / Front Fascia....2201
        Floor / Rear Fenders....2202
        Seat Mounting / Seat Belts....2203
      REAR CARGO BOX....2204
        Cargo Box - Panels....2204
        Cargo Box - Tailgate / Box Support....2205
        Box Removal....2206
        Box Installation....2206
      BODY COMPONENT REMOVAL....2207
        Lower Seat Base....2207
        Wheel Well Panels....2207
        Front Bumper....2207
        Front Fascia....2207
        Front Fenders....2208
        Hood / Dash....2208
        Glove Box / Storage Panel....2208
        Rear Fenders....2209
        Floor....2209
      STEERING ASSEMBLY....2210
        Exploded View....2210
      POWER STEERING ASSEMBLY (HD)....2211
        Exploded View....2211
        Power Steering Unit Removal....2212
        Power Steering Unit Installation....2214
      FRONT A-ARMS....2215
        Removal / Replacement....2215
        Exploded View....2216
      BALL JOINT SERVICE....2216
        Removal....2216
        Installation....2217
      REAR A-ARMS....2218
        Removal / Replacement....2218
        Installation....2219
        Exploded View....2219
      REAR STABILIZER BAR....2220
        Removal / Installation....2220
        Exploded View....2220
      DECAL REPLACEMENT....2221
      SHOCKS / SPRINGS....2221
        Exploded View....2221
        Shock Removal / Installation....2221
        Shock Replacement....2221
      SELF-LEVELING SUSPENSION (HD)....2222
        Nivomat® Shock Operation....2222
        Nivomat® Shock Disposal / Replacement....2222
  9922036_Chapter_06....2223
    CLUTCHING....2223
      SPECIAL TOOLS AND SUPPLIES....2224
      TORQUE SPECIFICATIONS....2224
        PVT System Fastener Torques....2224
      PVT SYSTEM OVERVIEW....2224
        General Operation....2224
        Drive Clutch Operation....2224
        Driven Clutch Operation....2225
        PVT Break-In (Drive Belt / Clutches)....2225
        Maintenance / Inspection....2225
        Overheating / Diagnosis....2226
      PVT SYSTEM SERVICE....2227
        PVT Sealing, Guard, and Ducting Components....2227
        Disassembly....2227
        Assembly....2228
      DRIVE BELT....2229
        Belt Removal....2229
        Belt Inspection....2230
        Belt Installation....2230
        PVT Break-In (Drive Belt / Clutches)....2230
      CLUTCH ALIGNMENT....2230
        Clutch Alignment Tool Use....2230
      CLUTCH CENTER DISTANCE....2231
      DRIVE CLUTCH SERVICE....2232
        Spring Specifications....2232
        Shift Weights....2233
        Exploded View....2234
        Clutch Disassembly....2234
        Spider Removal....2235
        Roller, Pin, and Thrust Washer Inspection....2236
        Button To Tower Clearance Inspection....2236
        Shift Weight Inspection....2236
        Bearing Inspection....2237
        Clutch Inspection....2237
        Moveable Sheave Bushing Inspection....2238
        Bushing Service....2239
        Clutch Assembly....2241
      DRIVEN CLUTCH SERVICE....2242
        Exploded View....2242
        Clutch Disassembly / Inspection....2242
        Clutch Assembly....2244
      TROUBLESHOOTING....2245
  9922036_Chapter_07....2247
    FINAL DRIVE....2247
      SPECIAL TOOLS....2248
      TORQUE SPECIFICATIONS....2248
        Wheel, Hub, and Spindle Torque Table....2248
      FRONT BEARING CARRIER....2248
        Bearing Carrier Inspection / Removal....2248
        Bearing Replacement....2249
        Bearing Carrier Installation....2250
      FRONT DRIVE SHAFT....2252
        Removal....2252
        Installation....2252
      FRONT PROPSHAFT....2253
        Removal....2253
        Installation....2253
        Front Propshaft Components....2253
      PROPSHAFT U-JOINT SERVICE....2254
        Disassembly....2254
        Assembly....2254
      FRONT GEARCASE - CENTRALIZED HILLIARD....2256
        Exploded View....2256
        Operation....2257
        AWD Diagnosis....2258
        Gearcase Removal....2259
        Disassembly / Inspection....2259
        Reassembly / Inspection....2262
        Setting Ring Gear Backlash....2263
        Gearcase Installation....2264
      REAR HUB / BEARING CARRIER....2265
        Hub Inspection....2265
        Hub Removal....2265
        Hub Disassembly....2266
        Hub Assembly....2266
        Hub Installation....2267
        Exploded View....2268
      REAR DRIVE SHAFT....2269
        Removal....2269
        Installation....2269
      DRIVE SHAFT SERVICE....2270
        Drive Shaft / CV Joint Handling Tips....2270
        Outer CV Joint / Boot Replacement....2270
        Inner Plunging Joint / Boot Replacement....2272
        Drive Shaft Exploded View....2274
      REAR PROPSHAFT....2275
        Removal....2275
        Installation....2275
      REAR GEARCASE....2276
        General Operation....2276
        Operation Modes....2277
        Gearcase Removal....2278
        Gearcase Disassembly....2278
        Rear Gearcase Assembly....2281
        Rear Gearcase Installation....2283
        Rear Gearcase Exploded View....2284
  9922036_Chapter_08....2285
    TRANSMISSION....2285
      TORQUE SPECIFICATIONS....2286
      SHIFT LEVER....2286
        Removal....2286
        Installation....2286
      SHIFT CABLE....2286
        Inspection....2286
        Adjustment....2286
      TRANSMISSION SERVICE....2287
        Transmission Removal....2287
        Transmission Disassembly....2288
        Transmission Assembly....2293
        Transmission Installation....2298
      TROUBLESHOOTING....2299
        Troubleshooting Checklist....2299
      TRANSMISSION EXPLODED VIEW....2300
        Exploded View....2300
  9922036_Chapter_09....2303
    BRAKES....2303
      GENERAL SPECIFICATIONS....2304
      TORQUE SPECIFICATIONS....2304
      SPECIAL TOOLS....2304
      BRAKE SYSTEM SERVICE NOTES....2305
      BRAKE NOISE TROUBLESHOOTING....2305
      HYDRAULIC BRAKE SYSTEM OPERATION....2306
      BRAKE SYSTEM EXPLODED VIEW....2306
      MASTER CYLINDER....2307
        Removal....2307
        Installation....2307
      FOOT BRAKE PEDAL....2307
        Pedal Removal....2307
        Pedal Installation....2307
      BRAKE BLEEDING / FLUID CHANGE....2308
      PARKING BRAKE....2309
        Exploded View....2309
        Inspection....2310
        Cable Tension Adjustment....2310
      PARKING BRAKE CALIPER SERVICE....2311
        Exploded View....2311
        Caliper Removal....2311
        Caliper Disassembly / Inspection....2312
        New Brake Pad Installation....2313
        Caliper Installation....2313
      PARKING BRAKE DISC SERVICE....2313
        Disc Inspection / Removal....2313
      FRONT BRAKE PADS....2314
        Pad Removal....2314
        Pad Inspection....2314
        Pad Assembly / Installation....2315
        Brake Burnishing Procedure....2315
      FRONT CALIPER SERVICE....2316
        Caliper Exploded View....2316
        Caliper Removal ....2316
        Caliper Disassembly....2317
        Caliper Inspection....2318
        Caliper Assembly....2318
        Caliper Installation....2319
      FRONT BRAKE DISC....2320
        Disc Runout....2320
        Disc Inspection....2320
        Disc Removal / Replacement....2320
      REAR BRAKE PADS....2321
        Pad Removal....2321
        Pad Inspection....2322
        Pad Installation....2322
        Brake Burnishing Procedure....2322
      REAR CALIPER SERVICE....2323
        Rear Caliper Exploded View....2323
        Caliper Removal....2323
        Caliper Disassembly....2324
        Caliper Inspection....2324
        Caliper Assembly....2325
        Caliper Installation....2325
      REAR BRAKE DISC....2326
        Disc Runout....2326
        Disc Inspection....2326
        Disc Removal / Replacement....2326
      TROUBLESHOOTING....2327
        Brakes Squeal / Poor Brake Performance....2327
        Pedal Vibration....2327
        Caliper Overheats (Brakes Drag)....2327
        Brakes Lock....2327
  9922036_Chapter_10....2329
    ELECTRICAL....2329
      GENERAL INFORMATION....2331
        Special Tools....2331
        Electrical Service Notes....2331
        Components Under Hood ....2331
        Components Behind Dash Panel ....2331
      SWITCHES / CONTROLS....2332
        Headlight Switch....2332
        AWD / 2WD / TURF Switch....2332
        Differential Solenoid....2332
        Brake Light Switch....2333
        Parking Brake Switch....2334
      INSTRUMENT CLUSTER....2335
        Overview....2335
        Rider Information Display....2335
        Standard Display Modes....2336
        Diagnostic Display Mode....2336
        Viewing Diagnostic Codes....2338
        Instrument Cluster Removal....2339
        Instrument Cluster Installation....2339
      INSTRUMENT CLUSTER TROUBLESHOOTING TESTS....2340
        Test 1 - No All Wheel Drive....2340
        TEST 2 - No Display....2341
        TEST 3 - Wheel Speed Sensor....2341
        TEST 4 - No AWD Hub Safety Limiter....2342
        TEST 5 - Fuel Gauge Display Not Working ....2343
        TEST 6 - Shift Indicator Not Working (Transmission Switch)....2343
      ALL WHEEL DRIVE (AWD) COIL....2344
        Operation Overview....2344
        Diagnosing System Failures....2344
      GEAR POSITION INDICATOR SWITCH....2344
        Test Diagram....2344
      HEADLIGHTS....2345
        Headlight Adjustment....2345
        Headlight Bulb Replacement....2345
        Headlight Housing Removal....2346
        Headlight Housing Installation....2347
      TAIL LIGHT / BRAKE LIGHT....2347
        LED Lamp Replacement....2347
      COOLING SYSTEM....2348
        Cooling System Break-Out Diagram....2348
        Fan Control Circuit Operation....2349
        Fan Control Circuit Bypass Test....2349
        Coolant Temperature Sensor....2349
      EFI DIAGNOSTICS....2349
        EFI Component Testing....2349
      FUEL SENDER....2349
        Testing....2349
      RELAYS....2350
        Operation....2350
      FUSES / CIRCUIT BREAKER / RESISTOR....2351
        Operation....2351
      CHARGING SYSTEM....2352
        Current Draw - Key Off....2352
        Charging System “Break Even” Test....2352
        Charging System Alternator Tests....2353
        Regulator / Rectifier Test....2354
        Charging System Testing Flow Chart....2355
      BATTERY SERVICE....2356
        Battery Terminals / Bolts....2356
        Battery Terminal Block....2356
        Battery Activation....2356
        Battery Inspection....2357
        Battery Removal / Installation....2357
        Conventional Battery Testing....2358
        OCV - Open Circuit Voltage Test....2358
        Specific Gravity Test....2358
        Load Test....2358
        Charging Procedure....2359
        Off Season Storage....2359
      STARTER SYSTEM....2359
        Troubleshooting....2359
        Voltage Drop Test....2360
        Starter Motor Removal / Disassembly ....2360
        Brush Inspection / Replacement....2360
        Armature Testing....2361
        Starter Reassembly / Installation....2362
        Starter Drive....2363
        Starter Solenoid Bench Test....2363
        Starter Solenoid Operation....2363
        Starter Exploded View....2364
      STARTING SYSTEM TESTING FLOW CHART....2365
        Condition: Starter fails to turn over the engine. ....2365
      ELECTRONIC POWER STEERING (EPS)....2366
        EPS System Breakout (HD Model)....2366
        EPS Operation....2367
        EPS 8-Way Wire Harness Connector....2367
        EPS Malfunction Indicator Light (MIL)....2367
        EPS Troubleshooting (Power Steering Non-Functional with EPS MIL ON)....2368
        EPS Troubleshooting (Power Steering Non-Functional with EPS MIL OFF)....2369
        EPS Troubleshooting (Power Steering Functional with EPS MIL ON)....2370
      ELECTRIC BOX LIFT ACTUATOR....2371
        DIAGNOSIS (if equipped)....2371
  9922036_WIRE_DIAGRAMS....2373
Polaris  '11- '14 Ranger Diesel_Crew Service Repair Manual....2381
  9924884 RGR Diesel....2381
    9924884 2011-2014 RGR Diesel....2381
      2011–2014 RANGER Diesel / Crew ....2381
      Copyright Info ....2382
      Understanding Manual Safety Labels and Directions ....2382
      Trademarks ....2383
        VEHICLE IDENTIFICATION ....2388
          MODEL NUMBER DESIGNATION ....2388
          VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ....2388
          ENGINE NUMBER DESIGNATION ....2388
          VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS ....2389
        VEHICLE INFORMATION ....2389
          PUBLICATION NUMBERS ....2389
          REPLACEMENT KEYS ....2390
          SPECIAL TOOLS ....2391
        GENERAL SPECIFICATIONS ....2392
          MODEL: 2011-2014 RANGER DIESEL ....2392
          MODEL: 2011-2014 RANGER DIESEL ....2392
          CLUTCH CHART ....2393
        GENERAL SPECIFICATIONS ....2394
          MODEL: 2012-2014 RANGER DIESEL CREW ....2394
          MODEL: 2012-2014 RANGER DIESEL CREW ....2394
          CLUTCH CHART ....2395
        GENERAL SPECIFICATIONS ....2396
          VEHICLE CONTROLS / GAUGES ....2396
        FUEL INFORMATION, USAGE AND RECOMMENDATIONS ....2397
          FUEL INFORMATION / RECOMMENDATIONS ....2397
          BIO-DIESEL FUELS ....2397
          B5 DIESEL FUEL REQUIREMENTS ....2397
          BIO-FUEL PRECAUTIONS ....2397
          B6 TO B20 BIO-DIESEL FUEL BLEND ....2398
          ENGINE WARRANTY ....2398
          COLD WEATHER OPERATION ....2398
          BLOCK HEATER USAGE ....2398
        MISC. SPECIFICATIONS AND CHARTS ....2399
          CONVERSION TABLE ....2399
          STANDARD BOLT TORQUE SPECIFICATION ....2400
          METRIC BOLT TORQUE SPECIFICATION ....2400
          SAE TAP / DRILL SIZES ....2401
          METRIC TAP / DRILL SIZES ....2401
          DECIMAL EQUIVALENTS ....2402
        PERIODIC MAINTENANCE CHART ....2405
          PERIODIC MAINTENANCE OVERVIEW ....2405
          BREAK-IN PERIOD ....2405
          MAINTENANCE CHART KEY ....2405
          PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL ....2406
          50 - 100 HOUR MAINTENANCE INTERVAL ....2407
          100 - 300 HOUR MAINTENANCE INTERVAL ....2408
          GREASE LUBRICATION POINTS ....2408
        SERVICE PRODUCTS AND LUBRICANTS ....2409
          POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ....2409
        SPECIAL TOOLS ....2409
        FLUID MAINTENANCE REFERENCES ....2410
          COMPONENT QUICK REFERENCE ....2410
          COMPONENT QUICK REFERENCE (CONTINUED) ....2411
        GENERAL VEHICLE INSPECTION AND MAINTENANCE ....2412
          PRE-RIDE / DAILY INSPECTION ....2412
          FRAME, NUTS, BOLTS, AND FASTENERS ....2412
          SHIFT CABLE INSPECTION ....2412
          SHIFT CABLE ADJUSTMENT ....2412
        FUEL SYSTEM AND AIR INTAKE ....2413
          FUEL SYSTEM ....2413
          FUEL LINES ....2413
          VENT LINES ....2413
          THROTTLE PEDAL INSPECTION ....2413
          THROTTLE FREEPLAY ADJUSTMENT ....2413
          AIR FILTER SERVICE ....2414
          ENGINE AIR INTAKE INSPECTION ....2415
          PVT AIR INTAKE INSPECTION ....2415
          AIR INTAKE EXPLODED VIEW ....2417
        FUEL FILTER / WATER SEPARATOR ....2418
          GENERAL INFORMATION ....2418
          FUEL FILTER / WATER SEPARATOR DRAINING ....2418
          FUEL FILTER / WATER SEPARATOR REPLACEMENT ....2418
        ENGINE ....2419
          COMPRESSION AND LEAKDOWN TEST ....2419
          SPECIAL TOOLS ....2419
          ENGINE OIL LEVEL ....2419
          ENGINE OIL AND FILTER CHANGE ....2420
          EXHAUST PIPE ....2421
        TRANSMISSION AND GEARCASES ....2422
          TRANSMISSION LUBRICATION ....2422
          FRONT GEARCASE LUBRICATION ....2423
          REAR GEARCASE LUBRICATION ....2425
        COOLING SYSTEM ....2426
          LIQUID COOLING SYSTEM OVERVIEW ....2426
          COOLANT LEVEL INSPECTION ....2426
          COOLANT STRENGTH / TYPE ....2427
          COOLING SYSTEM HOSES ....2427
          RADIATOR INSPECTION / CLEANING ....2428
          RADIATOR REMOVAL (2011) ....2428
          RADIATOR REMOVAL (2012–2014) ....2430
        FINAL DRIVE / WHEEL AND TIRE ....2432
          WHEEL AND HUB TORQUE TABLE ....2432
          CV SHAFT BOOT INSPECTION ....2433
          WHEEL REMOVAL ....2433
          WHEEL INSTALLATION ....2433
          TIRE INSPECTION ....2433
          TIRE PRESSURE ....2434
        ELECTRICAL SYSTEM ....2434
          BATTERY REMOVAL ....2434
          BATTERY INSTALLATION ....2435
          BATTERY STORAGE ....2435
          BATTERY CHARGING ....2435
          ENGINE GROUND ....2435
        STEERING ....2436
          STEERING INSPECTION ....2436
          TIE ROD END / STEERING INSPECTION ....2436
          WHEEL TOE ALIGNMENT INSPECTION ....2436
          TOE ADJUSTMENT ....2437
        SUSPENSION ....2438
          SUSPENSION INSPECTION ....2438
          SPRING PRE-LOAD ADJUSTMENT ....2438
          SHOCK POSITION ADJUSTMENT ....2438
        BRAKE SYSTEM ....2439
          BRAKE FLUID INSPECTION ....2439
          BRAKE HOSE AND FITTING INSPECTION ....2439
          BRAKE PAD / DISC INSPECTION ....2439
          PARKING BRAKE CABLE ADJUSTMENT ....2440
          PARKING BRAKE PAD INSPECTION ....2440
        SPECIAL TOOLS ....2442
          SPECIAL TOOLS ....2442
        GENERAL ENGINE SERVICE ....2442
          ACCESSIBLE COMPONENTS ....2442
          ENGINE LUBRICATION SPECIFICATIONS ....2442
          OIL PRESSURE TEST ....2443
          ENGINE/TRANSMISSION ASSEMBLY REMOVAL ....2443
          ENGINE INSTALLATION ....2446
        ENGINE / TRANSMISSION MOUNTING ....2448
          EXPLODED VIEW / TORQUE VALUES ....2448
        ENGINE EXHAUST SYSTEM ....2449
          EXPLODED VIEW - ENGINE EXHAUST SYSTEM ....2449
        ENGINE COOLING SYSTEM ....2450
          COOLING SYSTEM SPECIFICATIONS AND TESTING ....2450
          COOLING FAN ON/OFF & HOT LIGHT ON/OFF ....2450
          COOLING SYSTEM BLEEDING PROCEDURE ....2452
        GENERAL INFORMATION ....2456
          SPECIAL TOOLS ....2456
          DIESEL SERVICE NOTES ....2456
          FUEL TANK EXPLODED VIEW ....2457
          FUEL INJECTION SYSTEM EXPLODED VIEW ....2458
          FUEL SYSTEM COMPONENT LOCATIONS ....2459
          FUEL LINE REMOVAL / INSTALLATION ....2459
        FUEL INJECTION ....2460
          PRINCIPAL COMPONENTS ....2460
          OPERATION OVERVIEW ....2460
          INITIAL PRIMING / STARTING PROCEDURE ....2460
        FUEL TRANSFER PUMP ....2460
          OPERATION OVERVIEW ....2460
          FUEL PUMP TEST ....2460
          FUEL PUMP REPLACEMENT / INSTALLATION ....2461
          FUEL TANK ASSEMBLY REMOVAL ....2461
          FUEL TANK INSTALLATION ....2463
        FUEL FILTER / WATER SEPARATOR ....2463
          GENERAL INFORMATION ....2463
          FUEL FILTER / WATER SEPARATOR DRAINING ....2463
          FUEL FILTER / WATER SEPARATOR REPLACEMENT ....2464
        FUEL SENDER ....2464
          FUEL SENDER TEST ....2464
          FUEL SENDER REPLACEMENT / INSTALLATION ....2464
        GENERAL TROUBLESHOOTING ....2465
          FUEL SYSTEM TROUBLESHOOTING ....2465
        TORQUE SPECIFICATIONS ....2469
          TORQUE SPECIFICATIONS ....2469
        SPECIAL TOOLS ....2469
          SPECIAL TOOLS ....2469
          MULTI-FUNCTION PLIERS ....2469
        DECAL REPLACEMENT ....2470
        CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (NON CREW) ....2471
          EXPLODED VIEW / ASSEMBLY ....2471
        CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (CREW) ....2473
        CHASSIS / MAIN FRAME (NON CREW) ....2475
          EXPLODED VIEW ....2475
        CHASSIS / MAIN FRAME (CREW) ....2476
          EXPLODED VIEW ....2476
        BODY EXPLODED VIEWS ....2477
          DASH INSTRUMENTS / CONTROLS ....2477
          HOOD / DASH / FRONT FENDERS / FRONT FASCIA ....2478
          FLOOR / REAR FENDERS (2011 NON CREW) ....2479
          FLOOR / REAR FENDERS (2012-2013 NON CREW) ....2480
          FLOOR / REAR FENDERS (CREW) ....2481
          SEAT MOUNTING / SEAT BELTS (NON CREW) ....2482
          SEAT MOUNTING / SEAT BELTS (CREW) ....2483
          CARGO BOX - PANELS ....2484
          CARGO BOX - TAILGATE / BOX SUPPORT ....2485
        BODY COMPONENT REMOVAL ....2486
          BOX REMOVAL ....2486
          BOX INSTALLATION ....2487
          LOWER SEAT BASE ....2487
          WHEEL WELL PANELS ....2487
          FRONT BUMPER ....2488
          FRONT FASCIA ....2488
          FRONT FENDERS ....2488
          HOOD / DASH ....2488
          GLOVE BOX / STORAGE PANEL ....2489
        STEERING ASSEMBLY ....2490
          EXPLODED VIEW ....2490
          STEERING WHEEL REMOVAL ....2491
          STEERING SHAFT REMOVAL ....2491
          STEERING SHAFT BEARING REPLACEMENT ....2491
        FRONT A-ARMS ....2493
          REMOVAL / REPLACEMENT ....2493
          EXPLODED VIEW ....2494
        BALL JOINT SERVICE ....2494
          SERVICE PREPARATION ....2494
          BALL JOINT REMOVAL ....2495
          BALL JOINT INSTALLATION ....2495
        REAR A-ARMS ....2497
          REMOVAL / REPLACEMENT ....2497
          INSTALLATION ....2498
          EXPLODED VIEW ....2499
        REAR STABILIZER BAR / LINKAGE ....2500
          REMOVAL / INSTALLATION ....2500
          EXPLODED VIEW ....2500
        SHOCKS / SPRINGS ....2501
          EXPLODED VIEW ....2501
          SHOCK REMOVAL / INSTALLATION ....2501
          SHOCK REPLACEMENT ....2501
        SPECIAL TOOLS AND SUPPLIES ....2505
          SPECIAL TOOLS ....2505
          2871358-A FIXTURE MODIFICATION ....2505
          SPECIAL SUPPLIES ....2505
        TORQUE SPECIFICATIONS ....2505
          PVT SYSTEM FASTENER TORQUES ....2505
        PVT SYSTEM OVERVIEW ....2506
          GENERAL OPERATION ....2506
          DRIVE CLUTCH OPERATION ....2506
          SHIFT WEIGHTS ....2506
          DRIVEN CLUTCH OPERATION ....2506
          PVT BREAK-IN (DRIVE BELT / CLUTCHES) ....2507
          MAINTENANCE / INSPECTION ....2507
          OVERHEATING / DIAGNOSIS ....2508
      PVT SYSTEM SERVICE ....2509
        PVT SEALING AND DUCTING COMPONENTS ....2509
        PVT DISASSEMBLY ....2510
        PVT ASSEMBLY ....2511
      DRIVE BELT ....2512
        BELT REMOVAL ....2512
        BELT INSPECTION ....2512
        BELT INSTALLATION ....2513
        PVT BREAK-IN (DRIVE BELT / CLUTCHES) ....2513
      2011 DRIVE CLUTCH SERVICE ....2514
        2011 DRIVE CLUTCH EXPLODED VIEW ....2514
        CLUTCH DISASSEMBLY AND INSPECTION ....2514
        BUTTON TO TOWER CLEARANCE INSPECTION ....2516
        SHIFT WEIGHT INSPECTION ....2516
        SPIDER REMOVAL ....2517
        STATIONARY SHEAVE INSPECTION ....2517
        MOVEABLE SHEAVE INSPECTION ....2518
        CLUTCH ASSEMBLY ....2518
      2012-2014 DRIVE CLUTCH SERVICE ....2521
        2012-2014 DRIVE CLUTCH EXPLODED VIEW ....2521
        CLUTCH DISASSEMBLY AND INSPECTION ....2521
        DRIVE CLUTCH SPRING INSPECTION ....2522
        NEEDLE BEARING INSPECTION ....2522
        BUTTON TO TOWER CLEARANCE INSPECTION ....2523
        SPIDER REMOVAL ....2523
        SHIFT WEIGHT INSPECTION ....2524
        CLUTCH INSPECTION ....2525
        MOVEABLE SHEAVE INSPECTION ....2526
        DRIVE CLUTCH ASSEMBLY ....2526
      DRIVEN CLUTCH SERVICE (2011 - 2014) ....2528
        EXPLODED VIEW ....2528
        CLUTCH DISASSEMBLY / INSPECTION ....2528
        CLUTCH ASSEMBLY ....2530
      CLUTCH OFFSET PROCEDURE ....2532
        CLUTCH OFFSET ADJUSTMENT ....2532
      TROUBLESHOOTING ....2533
        PVT TROUBLESHOOTING ....2533
      SPECIAL TOOLS ....2537
        SPECIAL TOOLS ....2537
      TORQUE SPECIFICATIONS ....2537
        WHEEL AND HUB TORQUE TABLE ....2537
      FRONT BEARING CARRIER ....2538
        BEARING CARRIER INSPECTION / REMOVAL ....2538
        BEARING REPLACEMENT ....2539
        BEARING CARRIER INSTALLATION ....2540
      FRONT DRIVE SHAFT ....2542
        DRIVE SHAFT REMOVAL ....2542
        DRIVE SHAFT INSTALLATION ....2543
      FRONT PROPSHAFT ....2543
        REMOVAL / INSTALLATION ....2543
        SUPPORT BEARING REPLACEMENT ....2544
      PROPSHAFT U-JOINT SERVICE ....2545
        DISASSEMBLY ....2545
        ASSEMBLY ....2546
      FRONT GEARCASE - CENTRALIZED HILLIARD ....2548
        CENTRALIZED HILLIARD EXPLODED VIEW ....2548
        OPERATION ....2549
        AWD DIAGNOSIS ....2550
        GEARCASE REMOVAL ....2551
        GEARCASE DISASSEMBLY / INSPECTION ....2551
        GEARCASE ASSEMBLY ....2555
        GEARCASE INSTALLATION ....2558
      REAR BEARING CARRIER ....2559
        INSPECTION ....2559
        REMOVAL ....2559
        DISASSEMBLY ....2560
        ASSEMBLY ....2560
        INSTALLATION ....2561
      REAR DRIVE SHAFT ....2562
        REMOVAL ....2562
        INSTALLATION ....2563
      DRIVE SHAFT SERVICE ....2564
        DRIVE SHAFT / CV JOINT HANDLING TIPS ....2564
        OUTER CV JOINT / BOOT REPLACEMENT ....2564
        INNER PLUNGING JOINT / BOOT REPLACEMENT ....2566
        DRIVE SHAFT EXPLODED VIEW ....2569
      REAR PROPSHAFT ....2569
        REMOVAL ....2569
        INSTALLATION ....2569
      REAR GEARCASE ....2570
        GENERAL OPERATION ....2570
        GEARCASE REMOVAL ....2572
        GEARCASE DISASSEMBLY ....2572
        REAR GEARCASE ASSEMBLY ....2575
        REAR GEARCASE INSTALLATION ....2578
        REAR GEARCASE EXPLODED VIEW ....2580
      SPECIAL TOOLS ....2582
        SPECIAL TOOLS ....2582
      TRANSMISSION SPECIFICATIONS ....2582
        TORQUE SPECIFICATIONS ....2582
        LUBRICATION SPECIFICATIONS ....2582
      SHIFT LEVER ....2583
        REMOVAL ....2583
        INSTALLATION ....2583
      SHIFT CABLE ....2583
        INSPECTION ....2583
      TRANSMISSION SERVICE ....2585
        TRANSMISSION REMOVAL ....2585
        TRANSMISSION DISASSEMBLY ....2586
        TRANSMISSION SHAFT SERVICE ....2590
        COMPENSATOR SHAFT PRELOAD CHECK AND ADJUSTMENT PROCEDURE ....2592
        TRANSMISSION ASSEMBLY ....2595
        TRANSMISSION INSTALLATION ....2599
        TROUBLESHOOTING CHECKLIST ....2602
        TRANSMISSION EXPLODED VIEW ....2603
      GENERAL SPECIFICATIONS ....2609
        SPECIFICATIONS AND SERVICE LIMITS ....2609
      TORQUE SPECIFICATIONS ....2609
        TORQUE SPECIFICATIONS ....2609
      SPECIAL TOOLS ....2609
        SPECIAL TOOLS ....2609
      BRAKE SYSTEM GENERAL INFORMATION ....2610
        BRAKE SYSTEM SERVICE NOTES ....2610
        BRAKE NOISE TROUBLESHOOTING ....2610
        HYDRAULIC BRAKE SYSTEM OPERATION ....2611
        BRAKE SYSTEM EXPLODED VIEW ....2612
      MASTER CYLINDER ....2613
        REMOVAL ....2613
        INSTALLATION ....2613
      FOOT BRAKE PEDAL ....2613
        PEDAL REMOVAL ....2613
        PEDAL INSTALLATION ....2613
      BRAKE BLEEDING / FLUID CHANGE ....2614
        BRAKE BLEEDING PROCEDURE ....2614
      FRONT BRAKE PADS ....2615
        PAD REMOVAL ....2615
        PAD INSPECTION ....2616
        PAD ASSEMBLY / INSTALLATION ....2617
        BRAKE BURNISHING PROCEDURE ....2617
      FRONT CALIPER SERVICE ....2618
        CALIPER EXPLODED VIEW ....2618
        CALIPER REMOVAL ....2618
        CALIPER DISASSEMBLY ....2619
        CALIPER INSPECTION ....2620
        CALIPER ASSEMBLY ....2621
        CALIPER INSTALLATION ....2621
      REAR BRAKE PADS (NON CREW) ....2622
        PAD REMOVAL ....2622
        PAD INSPECTION ....2623
        PAD INSTALLATION ....2623
        BRAKE BURNISHING PROCEDURE ....2623
      REAR CALIPER SERVICE (NON CREW) ....2624
        REAR CALIPER EXPLODED VIEW ....2624
        CALIPER REMOVAL ....2624
        CALIPER DISASSEMBLY ....2625
        CALIPER INSPECTION ....2625
        CALIPER ASSEMBLY ....2626
        CALIPER INSTALLATION ....2626
      REAR CALIPER SERVICE (CREW) ....2628
        REAR CALIPER EXPLODED VIEW ....2628
        CALIPER REMOVAL ....2628
        CALIPER DISASSEMBLY ....2629
        CALIPER INSPECTION ....2630
        CALIPER ASSEMBLY ....2631
        CALIPER INSTALLATION ....2631
      FRONT BRAKE DISC ....2632
        DISC RUNOUT ....2632
        DISC INSPECTION ....2632
        DISC REMOVAL / REPLACEMENT ....2633
      REAR BRAKE DISC ....2634
        DISC RUNOUT ....2634
        DISC INSPECTION ....2634
        DISC REMOVAL / REPLACEMENT ....2635
        BRAKE BURNISHING PROCEDURE ....2636
      PARKING BRAKE ....2637
        EXPLODED VIEW ....2637
        INSPECTION ....2638
        CABLE TENSION ADJUSTMENT ....2638
      PARKING BRAKE CALIPER SERVICE ....2639
        EXPLODED VIEW ....2639
        CALIPER REMOVAL ....2639
        CALIPER DISASSEMBLY / INSPECTION ....2640
        NEW BRAKE PAD INSTALLATION ....2641
        CALIPER INSTALLATION ....2641
      PARKING BRAKE DISC SERVICE ....2642
        DISC INSPECTION / REMOVAL ....2642
      TROUBLESHOOTING ....2642
        BRAKES SQUEAL / POOR BRAKE PERFORMANCE ....2642
        PEDAL VIBRATION ....2642
        CALIPER OVERHEATS (BRAKES DRAG) ....2642
        BRAKES LOCK ....2642
      GENERAL INFORMATION ....2645
        SPECIAL TOOLS ....2645
        ELECTRICAL SERVICE NOTES ....2645
        BATTERY CONDUCTANCE ANALYZER ....2645
        COMPONENTS UNDER SEAT ....2646
        COMPONENTS BEHIND DASH PANEL / UNDER HOOD ....2646
      SWITCHES / CONTROLS ....2646
        HEADLIGHT SWITCH ....2646
        AWD / 2WD / TURF SWITCH ....2647
        DIFFERENTIAL SOLENOID ....2647
        BRAKE LIGHT SWITCH ....2648
        PARKING BRAKE SWITCH ....2648
      INSTRUMENT CLUSTER ....2649
        OVERVIEW ....2649
        RIDER INFORMATION DISPLAY ....2650
        STANDARD DISPLAY MODES ....2650
        DIAGNOSTIC DISPLAY MODE ....2650
        INSTRUMENT CLUSTER REMOVAL ....2653
        INSTRUMENT CLUSTER INSTALLATION ....2653
      INSTRUMENT CLUSTER TROUBLESHOOTING TESTS ....2654
        TEST 1 - NO ALL WHEEL DRIVE ....2654
        TEST 2 - NO DISPLAY ....2655
        TEST 3 - SPEED SENSORS (MPH & RPM) ....2655
        TEST 4 - NO AWD HUB SAFETY LIMITER ....2656
        TEST 5 - FUEL GAUGE DISPLAY NOT WORKING ....2657
        TEST 6 - SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) ....2657
      ALL WHEEL DRIVE (AWD) COIL ....2658
        OPERATION OVERVIEW ....2658
        DIAGNOSING SYSTEM FAILURES ....2658
      GEAR POSITION INDICATOR SWITCH ....2658
        TEST DIAGRAM ....2658
      HEADLIGHTS ....2659
        HEADLIGHT ADJUSTMENT ....2659
        HEADLIGHT BULB REPLACEMENT ....2659
        HEADLIGHT HOUSING REMOVAL ....2660
        HEADLIGHT HOUSING INSTALLATION ....2660
        RANGER DIESEL LIGHTING SYSTEM DIAGRAM (SIMPLIFIED) ....2662
      TAIL LIGHT / BRAKE LIGHT ....2663
        LED LAMP REPLACEMENT ....2663
      COOLING SYSTEM ....2664
        COOLING SYSTEM BREAK-OUT DIAGRAM ....2664
        FAN CONTROL CIRCUIT OPERATION ....2665
        FAN CONTROL CIRCUIT BYPASS TEST ....2665
        COOLANT TEMPERATURE SENSOR ....2665
        COOLING FAN ON/OFF & HOT LIGHT ON/OFF ....2665
      FUEL SENDER ....2666
        TESTING ....2666
      RELAYS ....2666
        FAN RELAY ....2666
        CHASSIS RELAY ....2667
        START RELAY ....2667
        PARK RELAY ....2668
        GLOW PLUG RELAY ....2668
        FUEL PULL-IN COIL RELAY ....2669
      FUSES / CIRCUIT BREAKER / RESISTOR ....2670
        OPERATION ....2670
      VEHICLE CONTROL MODULE ....2671
      OPERATION ....2671
      FUEL SOLENOID WIRING DIAGRAM ....2672
      CHARGING SYSTEM ....2673
      CHARGING SYSTEM RATING ....2673
      CURRENT DRAW - KEY OFF ....2673
      CHARGING SYSTEM “BREAK EVEN” TEST ....2673
      CHARGING SYSTEM ALTERNATOR WIRING DIAGRAM ....2674
      BATTERY SERVICE ....2675
      BATTERY INFORMATION ....2675
      LOW MAINTENANCE BATTERY INSPECTION ....2675
      BATTERY TERMINAL BLOCKS ....2676
      BATTERY TERMINALS / BOLTS ....2676
      BATTERY REMOVAL / INSTALLATION ....2676
      CONVENTIONAL BATTERY TESTING ....2676
      BATTERY CONDUCTANCE ANALYZER ....2677
      OCV - OPEN CIRCUIT VOLTAGE TEST ....2677
      LOAD TEST ....2677
      CHARGING PROCEDURE ....2678
      OFF SEASON STORAGE ....2678
      STARTER SYSTEM AND WIRING DIAGRAM ....2678
      TROUBLESHOOTING ....2678
      VOLTAGE DROP TEST ....2679
    9924084_Chapter_11....2681
      CH 11 - YANMAR ENGINE SERVICE....2681
        Yanmar Service Manual....2683
          Table of Contents....2685
          Introduction....2687
          Warranty....2689
            Emission System Warranty....2690
            Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only....2690
              Your Warranty Rights and Obligations:....2690
                California....2690
              Manufacturer’s Warranty Period:....2690
          Safety....2691
            Safety Statements....2693
            Safety Precautions....2693
          General Service Information....2699
            Safety Precautions....2701
            Component Identification....2701
            Location of Labels....2702
              Engine Nameplate (Typical)....2702
            EPA / CARB Emission Control Regulations - USA Only....2702
            Emission Control Labels....2703
              EPA / ARB Labels (Typical)....2703
            The 97/68/EC Directive Certified Engines....2703
            Engine Family....2704
            Function of Major Engine Components....2705
            Function of Cooling System Components....2707
            Diesel Fuel....2708
              Diesel Fuel Specifications....2708
                Additional Technical Fuel Requirements....2708
                Bio-Diesel Fuels....2708
              Filling the Fuel Tank....2710
              Priming the Fuel System....2711
            Engine Oil....2712
              Engine Oil Specifications....2712
              Service Categories....2712
                Definitions....2712
                Additional Technical Engine oil Requirements:....2713
              Engine Oil Viscosity....2713
              Checking Engine Oil....2713
              Adding Engine Oil....2713
              Engine Oil Capacity (Typical)....2714
            Engine Coolant....2714
              Engine Coolant Specifications....2714
                Additional Technical Coolant Specifications:....2714
                Alternative Engine Coolant....2715
              Filling Radiator with Engine Coolant....2715
              Engine Coolant Capacity (Typical)....2716
            Specifications....2717
              Description of Model Number....2717
              Engine Speed Specifications....2717
              Engine General Specifications....2718
            Principal Engine Specifications....2719
              3TNM68 (EPA Tier 4)....2719
              3TNM72 (EPA Tier 4)....2720
            Engine Service Information....2721
            Tightening Torques for Standard Bolts and Nuts....2722
            Abbreviations and Symbols....2724
              Abbreviations....2724
              Symbols....2724
            Unit Conversions....2725
              Unit Prefixes....2725
              Units of Length....2725
              Units of Volume....2725
              Units of Mass....2725
              Units of Force....2725
              Units of Torque....2725
              Units of Pressure....2725
              Units of Power....2725
              Units of Temperature....2725
          Periodic Maintenance....2727
            Safety Precautions....2729
            Introduction....2729
            Precautions....2729
              The Importance of Periodic Maintenance....2729
              Performing Periodic Maintenance....2729
              Yanmar Replacement Parts....2729
              Required EPA / ARB Maintenance - USA Only....2729
              EPA / ARB Installation Requirements - USA Only....2729
            Periodic Maintenance Schedule....2730
            Periodic Maintenance Procedures....2732
              After Initial 50 Hours of Operation....2732
                Replace Engine Oil and Engine Oil Filter....2732
                Check and Adjust Cooling Fan V-Belt....2733
              Every 50 Hours of Operation....2735
                Drain Fuel Filter / Water Separator....2735
                Check Battery....2736
              Every 250 Hours of Operation....2737
                Drain Fuel Tank....2737
                Replace Engine Oil and Engine Oil Filter....2738
                Check and Clean Radiator Fins....2738
                Check and Adjust Cooling Fan V-Belt....2739
                Check and Adjust the Governor Lever and Engine Speed Control....2739
                Clean Air Cleaner Element....2739
              Every 500 Hours of Operation....2741
                Replace Air Cleaner Element....2741
                Replace Fuel Filter....2741
                Clean Fuel Filter / Water Separator....2742
              Every 1000 Hours of Operation....2743
                Drain, Flush and Refill Cooling System with New Coolant....2743
                Adjust Intake / Exhaust Valve Clearance....2744
              Every 1500 Hours of Operation....2745
                Inspect, Clean and Test Fuel Injectors....2745
                Inspect Crankcase Breather System....2745
              Every 2000 Hours of Operation....2746
                Check and Replace Fuel Hoses and Engine Coolant Hoses....2746
                Lap the Intake and Exhaust Valves....2746
          Fuel System....2805
            Safety Precautions....2807
            Introduction....2808
              Fuel Injection Pump....2808
              Stop Solenoid....2809
            Fuel System Specifications....2810
              Special Torque Chart....2810
              Test and Adjustment Specifications....2810
            Special Service Tools....2811
            Measuring Instruments....2811
            Fuel System Diagram....2812
            Fuel System Components....2813
            Fuel Injection Lines....2814
              Removal of High-Pressure Fuel Injection Lines....2814
              Installation of High-Pressure Fuel Injection Lines....2815
              Removal of Fuel Return Line....2815
              Installation of Fuel Return Line....2815
            Fuel Injection Pump....2816
              Removal of Fuel Injection Pump....2816
              Installation of Fuel Injection Pump....2819
            Checking and Adjusting Fuel Injection Timing....2820
              Checking Fuel Injection Timing....2820
              Adjusting Fuel Injection Timing....2824
              Injection Timing (FID)....2824
            Fuel Injectors....2825
              Removal of Fuel Injectors....2825
              Testing of Fuel Injectors....2825
                Fuel Injector Test Results....2827
              Disassembly and Inspection of Fuel Injectors....2828
              Adjusting Fuel Injector Pressure....2829
              Reassembly of Fuel Injectors....2830
              Installation of the Fuel Injectors....2830
          Cooling System....2831
            Safety Precautions....2833
            Introduction....2833
            Cooling System Diagram....2834
            Engine Coolant Pump Components....2835
            Engine Coolant System Check....2836
            Engine Coolant Pump....2836
              Disassembly of Engine Coolant Pump....2836
              Cleaning and Inspection....2837
                Temperature Switch....2837
                Thermostat....2837
                Radiator Cap....2838
              Reassembly of Engine Coolant Pump....2838
          Lubrication System....2841
            Safety Precautions....2843
            Introduction....2843
            Oil Pump Service Information....2843
              Engine Oil Pressure....2843
              Outer Rotor Outside Clearance....2843
              Outer Rotor Side Clearance....2843
              Outer Rotor to Inner Rotor Tip Clearance....2843
            Lubrication System Diagram....2844
            Trochoid Oil Pump....2845
              Components....2845
              Disassembly of Oil Pump....2845
              Cleaning and Inspection....2846
                Check Outer Rotor Outside Clearance....2846
                Outer Rotor to Inner Rotor Tip Clearance....2846
                Check Outer Rotor Side Clearance....2847
                Check Rotor Shaft Clearance....2847
              Reassembly of Oil Pump....2847
          Starter Motor....2849
            Safety Precautions....2851
            Introduction....2851
            Starter Motor Information....2852
            Starter Motor Specifications....2853
            Starter Motor Troubleshooting....2854
            Starter Motor Components....2855
            Starter Motor....2856
              Removal of Starter Motor....2856
              Disassembly of Starter Motor....2857
              Cleaning and Inspection....2859
                Armature....2859
                Field Coil....2861
                Brush Holder....2861
                Solenoid Switch....2862
                Pinion Clutch Assembly....2863
              Reassembly of Starter Motor....2863
              Check Pinion Projection Length....2865
              No-Load Test....2866
              Installation of Starter Motor....2867
          Alternator....2869
            Safety Precautions....2871
            Introduction....2871
            Standard and Optional Alternator Information....2872
            Alternator Specifications....2873
            Alternator Troubleshooting....2874
            Alternator Components....2875
            Alternator Wiring Diagram....2876
            Alternator Standard Output....2877
            Alternator....2878
              Removal of Alternator....2878
              Disassembly of Alternator....2878
              Reassembly of Alternator....2880
          Troubleshooting....2883
            Safety Precautions....2885
            Special Service Tools....2885
            Troubleshooting By Measuring Compression Pressure....2886
              Compression Pressure Measurement Method....2886
              Standard Compression Pressure....2887
              Measured Value and Troubleshooting....2887
            Quick Reference Table for Troubleshooting....2887
              Troubleshooting Charts....2889

Polaris Ranger ATV Repair Service Manual