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2009 RANGER 700
4X4 CREW / 6X6
SERVICE MANUAL
PN 9921885
2009 RANGER 700 4X4 CREW / 6X6
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com
.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc.
2100 Hwy 55 Medina Minnesota 55340.
Publication Printed August 2008 (PN 9921885)
© Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.
WARNING
CAUTION
CAUTION
1
GENERAL INFORMATION
2
MAINTENANCE
3
ENGINE
4
ELECTRONIC FUEL INJECTION
5
BODY / STEERING / SUSPENSION
6
CLUTCHING
7
FINAL DRIVE
8
TRANSMISSION
BRAKES
9
ELECTRICAL
10
GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 4X4 CREW / 6X6 (HEIGHT AND WIDTH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 6X6 (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
RANGER 4X4 CREW (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2009 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2009 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2009 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2009 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
1.2
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
EH068OLE046PLE............................................................Twin, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification
Engine Serial Number Location
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be
found on the sticker applied to the cylinder head on the side of engine.
}
Machine Model Number Identification
}
}
Model Year
Designation
Basic Chassis
Designation
Engine Designation
Emissions &
Model Option
R 0 9 W H 6 8 A G
}
4 X A W H 6 8 A * 9 P 0 0 0 0 0 0
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Description
Vehicle Identifier
Check Digit
Model
Year
Body Style
Plant No.
Individual Serial No.
* This could be either
a number or a letter
Powertrain
Emissions
A
Engine Serial Number
1.3
GENERAL INFORMATION
1
Vehicle Identification Number (VIN) Location
The machine model number and serial number are important for
vehicle identification. The vehicle identification number (A) is
stamped on the lower LH frame rail close to the front drive
wheel. The model and serial numbers are also located on a
sticker under the hood (B).
Transmission I.D. Number Location
A
A
B
The transmission I.D. number is located on the
right side when installed in the vehicle.
1.4
GENERAL INFORMATION
VEHICLE DIMENSIONS
RANGER 4x4 CREW / 6X6 (Height and Width)
75 in.
190.5 cm
11.5 in.
29.2 cm
60 in.
152.4 cm
1.5
GENERAL INFORMATION
1
RANGER 6X6 (Length and Wheel Base)
RANGER 4x4 CREW (Length and Wheel Base)
120 in.
305 cm
42.5 in.
108 cm
27 in.
69 cm
90 in.
229 cm
145 in.
386 cm
108 in.
274 cm
36.5 in.
92.7 cm
1.6
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2009 RANGER 4X4 CREW
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE
Category Dimension / Capacity
Length 145 in. / 386 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 108 in. / 274 cm
Ground Clearance 11 in. / 27.9 cm
Turning Radius 224 in. / 569 cm
Dry Weight 1460 lbs. / 664 kg
Gross Vehicle Weight 3360 lbs. / 1524 kg
Cargo Box Capacity 1000 lbs. / 454 kg
Cargo Box Dimensions
54 x 36.5 x 11.5 in.
(137 x 92.7 x 29.2 cm)
Vehicle Payload
1750 lbs. / 794 kg
(Includes driver and five
passengers)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
1.7
GENERAL INFORMATION
1
MODEL: 2009 RANGER 4X4 CREW
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE
CLUTCH CHART
Engine
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE049
Engine Displacement 683cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 68 mm
Compression Ratio 9.40:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 PLUS 2W-50 Synthetic
Oil Capacity 2 qts. / 1.9 L
Coolant Capacity n/a
Overheat Warning Instrument Cluster Indicator
Exhaust System 2 to 1 Canister Style
Fuel System
Fuel System Type Bosch Electronic Fuel Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 39 psi
Fuel Filters See Chapter 4
Fuel Capacity / Requirement
9 gal. (34 L)
87 Octane (minimum)
Electrical
Alternator Max Output 500 Watts @ 3000 RPM
Lights: Main Headlights 2 - Single Beam 50W / Halogen
Tail 5 Watts x 2
Brake 5 Watts x 2
Indicator Panel Lights 1 Watt (ea.)
Starting System Electric Start
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 7° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Instrument Panel Type Multifunction Speedometer
DC Outlet Standard
Relays Fan / Power / Rear Diff Solenoid
Circuit Breakers Fan Motor: 15 Amp
Fuses
Main Chassis: 20 Amp
Accessory: 20 Amp
Power Relay: 15 Amp
ECU: 6 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
4.43:1 / 3.83:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Polaris Demand Drive Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Polaris Full Synthetic AGL
43.6 oz. (1290 ml)
Rear Gearcase Oil Requirements
Polaris ATV Angle Drive Fluid
18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 mm)
Steering / Suspension
Front Suspension MacPherson Strut
Front Travel 8 in. (20.3 cm)
Rear Suspension Independent Rear Suspension
Rear Travel 9 in. (22.9 cm)
Rear Shock Preload Adjustment Cam Adjustment
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Wheels / Brakes
Front Wheel Size 12 x 6
Rear Wheel Size 12 x 8
Front Tire
Make / Model / Size
Carlisle / PXT / 26 x 9 R12
Rear Tire
Make / Model / Size
Carlisle / PXT / 26 x 11 R12
Tire Air Pressure - Front / Rear 12 psi / 16 psi
Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Parking Brake Hand Actuated (in dash)
Altitude Shift Weight Drive Spring
Driven
Spring
Meters
(Feet)
0-1500
(0-5000)
21-74
(5632117)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1500-3700
(5000 - 12000)
21-70
(5632127)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1.8
GENERAL INFORMATION
MODEL: 2009 RANGER 6X6
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH068OLE
Category Dimension / Capacity
Length 120 in. / 305 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 90 in. / 229 cm
Ground Clearance 7.2 in. / 18.3 cm
Turning Radius 186 in. / 472 cm
Dry Weight 1410 lbs. / 640 kg
Gross Vehicle Weight 3310 lbs. / 1501 kg
Cargo Box Capacity 1250 lbs. / 567 kg
Cargo Box Dimensions
54 x 42.5 x 11.5 in.
(137 x 108 x 29.2 cm)
Vehicle Payload
1750 lbs. / 794 kg
(Includes driver and two
passengers)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
1.9
GENERAL INFORMATION
1
MODEL: 2009 RANGER 6X6
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH68OLE
CLUTCH CHART
Engine
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE048
Engine Displacement 683cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 68 mm
Compression Ratio 9.40:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 PLUS 2W-50 Synthetic
Oil Capacity 2 qts. / 1.9 L
Coolant Capacity 3.25 qts. (3.08 L)
Overheat Warning Instrument Cluster Indicator
Exhaust System 2 to 1 Canister Style
Fuel System
Fuel System Type Bosch Electronic Fuel Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 39 psi
Fuel Filters See Chapter 4
Fuel Capacity / Requirement
9 gal. (34 L)
87 Octane (minimum)
Electrical
Alternator Max Output 500 Watts @ 3000 RPM
Lights: Main Headlights 2 - Single Beam 50W / Halogen
Tail 5 Watts x 2
Brake 5 Watts x 2
Indicator Panel Lights 1 Watt (ea.)
Starting System Electric Start
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 7° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Instrument Panel Type Multifunction Speedometer
DC Outlet Standard
Relays Fan / Power
Circuit Breakers Fan Motor: 15 Amp
Fuses
Main Chassis: 20 Amp
Accessory: 20 Amp
Power Relay: 15 Amp
ECU: 6 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
4.43:1 / 3.83:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Polaris Demand Drive Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Polaris Full Synthetic AGL
43.6 oz. (1290 ml)
Mid Gearcase Oil Requirements
Polaris ATV Angle Drive Fluid
6.75 oz. (200 ml)
Rear Gearcase Oil Requirements
Polaris ATV Angle Drive Fluid
10 oz. (300 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 mm)
Steering / Suspension
Front Suspension MacPherson Strut
Front Travel 8 in. (20.3 cm)
Center Suspension Progressive Rate / Independent
Center Travel 5.25 in. (13.3 cm)
Rear Suspension Swing Arm w/Dual Shocks
Rear Travel 6.25 in. (16 cm)
Rear Shock Preload Adjustment Cam Adjustment
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Wheels / Brakes
Front Wheel Size 12 x 6 / 10 gauge
Middle / Rear Wheel Size 12 x 8 / 10 gauge
Front Tire
Make / Model / Size
Titan / AT489 / 25 x 10 R12
Middle / Rear Tire
Make / Model / Size
Titan / AT489 / 25 x 11 R12
Tire Air Pressure
Front / Middle / Rear
8 - 12 psi
Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Parking Brake Hand Actuated (in dash)
Altitude Shift Weight Drive Spring
Driven
Spring
Meters
(Feet)
0-1500
(0-5000)
21-74
(5632117)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1500-3700
(5000 - 12000)
21-70
(5632127)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1.10
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.
Paint Codes
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original
key and refer to the chart to the right for the proper part number.
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools
maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris
product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or
on-line at http://polaris.spx.com/
.
Model Model No. Owner’s Manual PN Parts Manual PN
2009 RANGER 4x4 CREW R09WH68AC, AG, AH, AR 9921882 9921884
2009 RANGER 6x6 R09RF68AF, AR 9921871 9921874
Painted Part Color Description Polaris Number
Main Frame / Cab Frame / Bumpers Medium Gloss Black P-067
Main Frame / Cab Frame / Plastic Gloss Black P-070
Plastic - Hood / Dash Dark Green P-195
Plastic - Hood / Dash Solar Red P-342
Cab Frame / Bumpers Flat Black Wrinkle P-418
Plastic - Hood / Dash
Mossy Oak
™
P-455
Plastic - Hood / Dash Delta Green P-492
Plastic - Hood / Dash Cherry Metallic P-554
Series# Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
Key Series
Number
KEY COVER
P/N 5533534
1.11
GENERAL INFORMATION
1
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
°C to °F:
9/5
(°C + 32) = °F °F to °C:
5/9
(°F - 32) = °C
1.12
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.13
GENERAL INFORMATION
1
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
1.14
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to
close and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm²: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in²: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
MAINTENANCE
2.1
CHAPTER 2
MAINTENANCE
2
PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
SERVICE PRODUCTS AND LUBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.7
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
MAINTENANCE REFERENCES, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT LINKAGE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR INTAKE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL AND FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
MIDDLE GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
REAR GEARCASE LUBRICATION (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
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