2009-2010 Polaris Ranger 500 4x4 EFI Service & Repair Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2009 RANGER 500 4X4 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2009 RANGER 500 4X4 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH500PLE225 ............................................................................... Single Cylinder, Liquid Cooled, 4-Stroke SOHC, Electric Start VIN Identification Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1). The engine model and serial number can be found on a decal applied to the engine’s magneto cover (see Figure 1-2). } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 9 H H 5 0 A G } 4 X A H H 5 0 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. * This could be either a number or a letter Powertrain Emissions Individual Serial No. Figure 1-1 VIN Figure 1-2 Engine Serial Number

1.3 GENERAL INFORMATION 1 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. 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 500 4x4 EFI R09HH50AG, AR 9921868 9921869 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

1.4 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2009 RANGER 500 4X4 EFI MODEL NUMBER: R09HH50AG, AR ENGINE MODEL: EH500PLE225 Category Dimension / Capacity Length 114 in. / 289.6 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 76 in. / 193 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 158 in. / 401.3 cm Dry Weight 1214 lbs. / 551 kg Gross Vehicle Weight 2864 lbs. / 1299 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions (inside dimensions) L-36 x W-50 x H-11 in. (91.4 x 127 x 27.9 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes weight of operator, passenger, cargo and accessories. Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.5 GENERAL INFORMATION 1 MODEL: 2009 RANGER 500 4X4 EFI MODEL NUMBER: R09HH50AG, AR ENGINE MODEL: EH500PLE225 CLUTCH CHART Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH500PLE225 Engine Displacement 499 cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi Engine Idle Speed 1200 ± 200 RPM Valve Clearance Int./Ext. 0.006 in. (0.152 mm) Engine Hot Light Dash Indicator Panel Lubrication Pressurized Dry Sump Oil Requirements PS-4 PLUS / 2W-50 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.1 L) Exhaust System Single Pipe / Canister Style Fuel System Fuel System Type Visteon EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Capacity 9 gal. (34 L) Fuel Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Main Headlights 50 Watt / Halogen x 2 Tail Lights 0.3 Watts / L.E.D. x 2 Brake Lights 3.1 Watts / L.E.D. x 2 Indicator Panel Lights 1 Watt (ea.) Starting System Electric Start Ignition System Visteon EFI (ECU Controlled) Ignition Timing 10° ± 1° BTDC @ 1150 RPM Spark plug / Gap NGK BKR5E / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / Conventional / 30 Amp Hr. / 12 Volt Instrumentation Indicator Panel Lights / LED Fuel Gauge w/Hour Meter DC Outlets (2) - Standard Relays EFI / Fan / Ign & Fuel Pump / Brake Light / Rear Diff Circuit Breaker Fan Motor: 10 Amp Fuses Main Chassis: 20 Amp Accessory: 15 Amp EFI: 15 Amp Lights: 15 Amp Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Reduction: High Low Reverse 3.85:1 8.71:1 7.91:1 Drive Ratio - Front 3.818:1 Drive Ratio - Rear 3.70:1 Front Gearcase Lubricant Requirements Premium LT Demand Drive Fluid 9.3 oz. (275 ml) Transmission Lubricant Requirements Full Synthetic AGL 43.6 oz. (1290 ml) Rear Gearcase Lubricant Requirements ATV Angle Drive Fluid 18 oz. (532 ml) Drive Belt 3211077 Drive Belt Deflection 1.125 in. (28.58 mm) Center Distance 10 in. (254 mm) Clutch Offset 0.5 in. (12.7 mm) Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Dual A-arm Front Travel 9.6 in. (24.4 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment Wheels / Brakes Front Wheel Size / Type 12 x 6 / Steel Rear Wheel Size / Type 12 x 8 / Steel Front Tire Make / Model / Size Titan / AT489 / 25 x 10 R12 Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 Tire Air Pressure 8-12 psi (69 kPa) Brake System 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 10 MH (5630513) Blu/Grn (7041157) Black (7041782) 1500-3700 (5000 - 12000) 10 WH (5630710) Blu/Grn (7041157) Black (7041782)

1.6 GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F - 32) = °C

1.7 GENERAL INFORMATION 1 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.

1.8 GENERAL INFORMATION SAE Tap / Drill Sizes Metric Tap / Drill Sizes Decimal Equivalents

1.9 GENERAL INFORMATION 1 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.

NOTES GENERAL INFORMATION 1.10

2009-2010 Polaris Ranger 500 4x4 EFI Service & Repair Manual

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