Polaris Ranger 6X6 700 EFI 2006 User manual

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)

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

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

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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Polaris Ranger 6X6 700 EFI 2006 User manual

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