Polaris 2009 RANGER 700 Manuals

Manuals and User Guides for Polaris 2009 RANGER 700. We have 1 Polaris 2009 RANGER 700 manual available for free PDF download: Service Manual

Polaris 2009 RANGER 700 Service Manual

Polaris 2009 RANGER 700 Service Manual (362 pages)

4X4 CREW / 6X6

Brand: Polaris | Category: Utility Vehicle | Size: 21.4 MB

Table of Contents

General Information Chapter 1 1

6
- Table of Contents
  6
- Chapter 1
  7
- Engine Designation Number
  7
- Engine Serial Number Location
  7
- Model Identification
  7
- Model Information
  7
- Vin Identification
  7
- Transmission I.D. Number Location
  8
- Vehicle Identification Number (Vin) Location
  8
- Vehicle Dimensions
  9
- General Specifications
  11
  - General: 2009 Ranger 4X4 Crew
    15
  - General: 2009 Ranger 6X6
    15
- Special Tools
  15
- Vehicle Information
  15
  - Publication Numbers
    15
  - Paint Codes
    15
  - Replacement Keys
    15
- Misc. Specifications and Charts
  16
  - Conversion Table
    16
  - Standard Torque Specifications
    17
  - Sae Tap / Drill Sizes
    18
  - Metric Tap / Drill Sizes
    18
  - Glossary of Terms
    19
  - General Information
    19
Maintenance Chapter 2 Maintenance

20
- Break-In Period
  22
- Chapter 2
  22
- Maintenance Chart Key
  22
- Periodic Maintenance Chart
  22
- Periodic Maintenance Overview
  22
- Pre-Ride - 25 Hour Maintenance Interval
  23
- 50 - 100 Hour Maintenance Interval
  24
- Service Products and Lubes
  26
  - Polaris Lubricants, Maintenance and Service Products
    26
    
    Brakes
    27
- Transmission
  26
- Maintenance References
  27
  - Maintenance References, Continued
    28
- General Vehicle Inspection and Maintenance
  29
- Fuel System and Air Intake
  30
  - Fuel System
    30
  - Fuel Lines
    30
  - Fuel Filter
    30
  - Vent Lines
    30
  - Throttle Pedal Inspection
    30
  - Throttle Freeplay Adjustment
    31
  - Air Filter Service
    31
  - Air Intake Inspection
    32
- Engine
  33
  - Compression and Leakdown Test
    33
  - Breather Hose Inspection
    33
  - Engine Oil Level
    33
  - Engine Oil and Filter Change
    34
  - Exhaust Pipe
    35
- Transmission and Gearcases
  36
- Cooling System
  41
  - Liquid Cooling System Overview
    41
  - Coolant Level Inspection
    41
  - Radiator Coolant Level Inspection
    42
  - Coolant Strength / Type
    42
  - Cooling System Pressure Test
    42
  - Cooling System Hoses
    42
  - Radiator
    43
  - Coolant Drain / Radiator Removal
    43
- Final Drive / Wheel and Tire
  44
  - Wheel and Hub Torque Table
    44
  - CV Shaft Boot Inspection
    44
  - Wheel Removal
    44
  - Wheel Installation
    44
  - Tire Inspection
    45
  - Tire Pressure
    45
- Electrical and Ignition System
  45
  - Battery Maintenance
    45
  - Battery Fluid Level (Conventional Battery)
    46
  - Battery Removal
    46
  - Battery Installation
    46
  - Battery Storage
    46
  - Battery Charging
    46
  - Spark Plug Service
    47
  - Engine to Frame Ground
    47
- Steering and Suspension
  48
  - Steering
    48
  - Tie Rod End / Steering Inspection
    48
  - Wheel Toe Alignment Inspection
    48
  - Front Suspension
    49
  - Toe Adjustment
    49
  - Rear Suspension
    50
  - Rear Suspension Adjustment (4X4 Crew)
    50
  - Rear Spring Adjustment
    50
- Brake System
  51
Chapter 3 Engine

54
- Crankcase Exploded Views
  55
- Engine Specifications
  55
- Engine Fastener Torque Patterns
  62
- Torque Specifications
  63
- 700 EFI Engine Service Specifications
  64
- General Engine Service
  66
  - Accessible Components
    66
  - Piston Identification
    66
  - Cooling System Specifications
    66
  - Cooling System Pressure Test
    67
  - Cooling System Exploded View
    68
  - Cooling System Bleeding Procedure
    68
  - Valve Cover Removal - 6X6 Models (Engine Installed)
    70
  - Engine Removal
    71
  - Engine Installation Notes
    72
  - Engine Lubrication Specifications
    73
  - Oil Pressure Test
    73
  - Oil Flow Chart
    74
- Special Tools
  66
- Engine Disassembly and Inspection
  75
  - Cylinder Head Assembly Exploded View
    75
  - Rocker Arms / Push Rods
    76
  - Cylinder Head Removal
    76
  - Cylinder Head Inspection / Warp
    77
  - Valve Seal / Spring Service (on Engine)
    77
  - Cylinder Head Disassembly
    78
  - Valve Inspection
    79
  - Combustion Chamber
    80
  - Valve Seat Reconditioning
    80
  - Cylinder Head Reassembly
    82
  - Valve Sealing Test
    83
  - Cylinder Removal
    83
  - Valve Lifter Removal / Inspection
    83
  - Piston Removal
    84
  - Cylinder Inspection
    85
  - Cylinder Hone Selection and Honing Procedure
    86
  - Honing to Deglaze
    86
  - Cleaning the Cylinder after Honing
    86
  - Piston-To-Cylinder Clearance
    87
  - Piston / Rod Inspection
    87
  - Piston Ring Installed Gap
    88
  - Starter Drive Bendix Removal / Inspection
    88
  - Flywheel / Stator Removal / Inspection
    89
  - Engine Crankcase Disassembly / Inspection
    89
  - Camshaft Inspection
    97
- Engine Reassembly
  98
  - Crankcase Reassembly
    98
  - Flywheel / Stator Installation
    107
  - Cylinder Head Reassembly
    108
  - Oil Pump Priming
    110
  - Engine Break-In
    110
- Troubleshooting
  111
  - Engine
    111
  - Cooling System
    112
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

114
- Chapter 4
  115
- General Information
  115
- Special Tools
  115
- Efi Service Notes
  118
- Fuel Tank Exploded View
  119
- Efi System Exploded View
  120
- Efi System Component Locations
  121
- Throttle Body
  121
- Electronic Fuel Injection
  122
  - Principal Components / Efi Operation Overview
    123
  - Initial Priming / Starting Procedure
    123
- Fuel Lines - Quick Connect Removal / Installation
  122
- Electronic Control Unit (Ecu)
  124
- Fuel Pump
  125
  - Fuel Sender Test
    125
  - Fuel Pump Test
    125
  - Fuel Pump / Tank Assembly Replacement
    126
- Fuel Pressure Regulator
  127
- Fuel Injectors
  128
- Crankshaft Position Sensor (Cps)
  129
  - Cps Test
    129
  - Cps Replacement
    129
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  130
- Throttle Position Sensor (Tps)
  130
  - Tps Adjustment
    132
  - Tps Replacement
    133
- Engine Coolant Temperature Sensor (Ect)
  133
- Ignition Coil
  134
  - Ignition Coil Tests
    134
  - Ignition Coil / Ht Lead Replacement
    134
- Diagnostic "Blink Codes
  135
  - Efi Troubleshooting
    136
- General Troubleshooting
  135
- Efi System Break-Out Diagrams
  137
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

142
- Body / Steering / Suspension
  142
- Special Tools
  143
- Torque Specifications
  143
- Body Component Removal
  144
- Chapter 5
  144
- Removal Procedures
  144
- Lower Body, Floor and Fenders (4X4 Crew)
  145
- Lower Body, Floor and Fenders (6X6)
  146
- Hood / Dash Components
  147
- Dash Instruments and Controls
  148
- Cab Frame
  149
  - Assembly / Removal (6X6)
    149
  - Assembly / Removal (4X4 Crew)
    150
- Seat / Head Rest
  151
- Chassis / Main Frame (4X4 Crew)
  152
- Chassis / Main Frame (6X6)
  153
- Steering Assembly
  154
- Steering and Suspension
  155
- Front A-Arm
  156
- Front Strut
  157
  - Front Strut Cartridge Replacement
    158
  - Ball Joint Replacement
    158
- MID Axle A-Arm (6X6)
  159
- Rear A-Arm (4X4 Crew)
  160
- Rear Stabilizer Bar (4X4 Crew)
  162
- Swing Arm (6X6)
  163
- Rear Drive Axle and Swing Arm Exploded View (6X6)
  164
- Rear Cargo Box
  165
  - Cargo Box - Panels
    165
  - Cargo Box - Tailgate / Box Support
    166
- Decal Replacement
  168
- Storage Box (4X4 Crew)
  168
Clutching Chapter 6 Clutching

170
- Chapter 6 Pvt System Fastener Torques
  171
- Pvt System Overview
  171
  - General Operation
    171
  - Drive Clutch Operation
    171
  - Driven Clutch Operation
    172
  - Pvt Break-In (Drive Belt / Clutches)
    172
  - Maintenance / Inspection
    172
  - Overheating / Diagnosis
    173
- Special Tools and Supplies
  171
- Torque Specifications
  171
- Pvt System Service
  174
  - Pvt Sealing, Guard, and Ducting Components
    174
  - Disassembly
    174
  - Assembly
    175
- Drive Belt
  176
  - Belt Removal
    176
  - Pvt Break-In (Drive Belt / Clutches)
    177
- Clutch Alignment
  177
- Clutch Center Distance
  178
- Drive Clutch Service
  179
  - Spring Specifications
    179
  - Shift Weights
    181
  - Exploded View
    181
  - Spider Removal
    182
  - Roller, Pin, and Thrust Washer Inspection
    183
  - Button to Tower Clearance Inspection
    183
  - Shift Weight Inspection
    183
  - Bearing Inspection
    184
  - Clutch Inspection
    184
  - Moveable Sheave Bushing Inspection
    185
  - Bushing Service
    186
  - Clutch Assembly
    188
- Driven Clutch Service
  189
  - Exploded View
    189
  - Clutch Disassembly / Inspection
    189
  - Clutch Assembly
    191
- Troubleshooting
  192
Chapter 7 Final Drive

194
- Front Hub
  196
  - Hub Removal / Inspection
    196
  - Hubstrut Bearing Replacement
    197
  - Hub Installation
    198
  - Front Hub Exploded View
    199
- Special Tools
  196
- Torque Specifications
  196
  - Final Drive
    196
- Front Drive Shaft
  200
  - Removal
    200
  - Drive Shaft / CV Joint Handling Tips
    201
  - Outer CV Joint / Boot Replacement
    201
  - Inner Plunging Joint / Boot Replacement
    203
  - Exploded View
    204
  - Installation
    204
- Front Propshaft
  205
  - Front Propshaft Components
    205
- Propshaft U-Joint Service
  206
  - Centralized Hilliard Exploded View
    208
  - All Wheel Drive Operation
    209
  - Awd Diagnosis
    210
  - Gearcase Removal
    211
  - Gearcase Disassembly / Inspection
    212
  - Gearcase Reassembly / Inspection
    214
  - Backlash Pad (Thrust Pad) Adjustment
    216
  - Gearcase Installation
    217
- MID Drive Hub / Bearing Carrier (6X6)
  217
  - Removal
    217
  - Hub Installation
    219
  - MID Drive Exploded View
    220
- MID Drive Shaft (6X6)
  220
  - Removal
    220
  - Disassembly / Assembly
    220
  - Installation
    221
- MID Propshaft (6X6)
  221
  - Removal
    221
- MID Drive Gearcase (6X6)
  222
  - Gearcase Removal
    222
  - Gearcase Disassembly
    223
  - Gearcase Assembly
    225
  - Gearcase Installation
    228
  - MID Gearcase Exploded
    229
- Rear Drive Shaft (4X4 Crew)
  234
  - Removal
    234
  - Outer CV Joint / Boot Replacement
    234
  - Inner Plunging Joint / Boot Replacement
    237
  - Drive Shaft Exploded View
    239
  - Installation
    240
- Rear Propshaft (4X4 Crew)
  241
  - Removal
    241
  - Installation
    241
- Rear Gearcase (4X4 Crew)
  242
  - General Operation
    242
  - Operation Modes
    243
  - Gearcase Removal
    244
  - Gearcase Disassembly
    244
  - Rear Gearcase Assembly
    247
  - Rear Gearcase Installation
    249
  - Rear Gearcase Exploded View (4X4 Crew)
    250
- Rear Axle / Gearcase Service (6X6)
  251
  - Rear Axle Removal
    251
  - Axle Tube Removal
    252
  - Axle Tube Bearing Replacement
    253
  - Gearcase Disassembly / Inspection
    253
  - Gearcase Assembly
    254
  - Gearcase / Axle Installation
    255
  - Rear Gearcase Exploded View (6X)
    258
Transmission Chapter 8 Transmission

260
- Chapter 8
  261
- Installation
  261
- Removal
  261
- Shift Lever
  261
- Shift Linkage
  261
  - Inspection
    261
  - Adjustment
    262
- Torque Specifications
  261
- Transmission Service
  262
  - Transmission Removal
    262
  - Transmission Disassembly
    264
  - Transmission Assembly
    269
  - Transmission Installation
    273
- Troubleshooting
  274
  - Troubleshooting Checklist
    274
- Transmission Exploded Views
  275
  - Exploded View
    275
Brakes Chapter 9 Brakes

278
- Chapter 9
  279
- General Specifications
  279
- Special Tools
  279
- Torque Specifications
  279
- Brake Noise Troubleshooting
  280
- Brake System Service Notes
  280
- Hydraulic Brake System Operation
  281
- Brake System Exploded View
  282
- Foot Brake Pedal
  283
- Master Cylinder
  283
- Brake Bleeding / Fluid Change
  284
- Parking Brake
  285
  - Exploded View (4X4 Crew)
    285
  - Exploded View (6X6)
    286
- Parking Brake Caliper Service
  288
  - Exploded View
    288
  - Caliper Removal
    288
  - Caliper Disassembly / Inspection
    289
  - New Brake Pad Installation
    290
  - Caliper Installation
    290
- Parking Brake Disc Service
  290
- Front Brake Pads
  291
  - Pad Assembly / Installation
    292
  - Brake Burnishing Procedure
    292
- Front Caliper Service
  293
  - Caliper Removal
    293
  - Caliper Disassembly
    294
  - Caliper Installation
    296
- Front Brake Disc
  297
- Rear Brake Pads (6X6)
  298
  - Pad Installation
    299
- Rear Brake Pads (4X4 Crew)
  299
  - Pad Removal
    299
  - Brake Burnishing Procedure
    301
- Rear Caliper Service (6X6)
  302
  - Caliper Removal
    302
- Rear Caliper Service (4X4 Crew)
  305
  - Caliper Removal
    305
  - Caliper Disassembly
    306
  - Caliper Installation
    308
- Rear Brake Disc
  309
  - Brakes Lock
    310
  - Pedal Vibration
    310
- Troubleshooting
  310
Electrical Chapter 10 Electrical

312
- Chapter 10
  314
- Electrical Service Notes
  314
- General Information
  314
- Special Tools
  314
- Under-Hood Components
  314
- Switches / Controls
  315
  - Headlight Switch
    315
  - Awd / 2Wd / Turf Switch (4X4 Crew)
    315
  - Differential Solenoid (4X4 Crew)
    315
  - Brake Light Switch
    316
  - Parking Brake Switch
    317
- Instrument Cluster
  318
  - Rider Information Display
    318
  - Standard Display Modes
    319
  - Diagnostic Display Mode
    319
  - Viewing Diagnostic Codes
    321
  - Instrument Cluster Installation
    322
  - Instrument Cluster Removal
    322
- Instrument Cluster Troubleshooting Tests
  323
- All Wheel Drive (Awd) Coil
  327
- Gear Position Indicator Switch
  327
- Headlights
  328
  - Headlight Bulb Replacement
    328
  - Headlight Housing Removal
    328
  - Headlight Housing Installation
    329
- Tail Light / Brake Light
  329
- Cooling System
  330
  - Cooling System Break-Out Diagram
    330
  - Coolant Temperature Sensor
    331
- Efi Diagnostics
  331
- Fuel Sender
  331
- Relays
  332
  - Power Relay
    332
- Fuses / Circuit Breaker
  333
- Charging System
  334
  - Current Draw - Key off
    334
  - Charging System "Break Even" Test
    334
  - Charging System Alternator Tests
    335
  - Charging System Testing Flow Chart
    336
- Battery Service
  337
  - Battery Activation
    337
  - Battery Inspection
    338
  - Off Season Storage
    339
    
    Charging Procedure
    339
    
    Load Test
    339
  - Troubleshooting
    340
- Starter System
  340
  - Voltage Drop Test
    340
  - Starter Motor Removal / Disassembly
    340
  - Brush Inspection / Replacement
    341
  - Armature Testing
    342
  - Starter Reassembly / Installation
    342
  - Starter Drive
    343
  - Starter Solenoid Bench Test
    344
  - Starter Solenoid Operation
    344
  - Starter Exploded View
    345
- Starting System Testing Flow Chart
  346
- Electric Box Lift Actuator
  347
  - Diagnosis (if Equipped)
    347
- Electrical Break-Out Diagrams
  348
  - Starting Circuit
    348
  - Key-On Power Circuit
    348
  - Transmission Switch Circuit
    349
  - Awd Circuit
    349
  - Speed Sensor Circuit
    350
  - Charging System Circuit
    350
  - Cooling Fan Circuit
    351
  - Fuel Display / Fuel Pump Circuit
    351

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