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 EH068OLE048 .................................................................................... Twin Cylinder, Liquid Cooled, 4-Cycle OHV, 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 number 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 side of the engine cylinder head (see Figure 1-2). } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 9 H H 6 8 A B } 4 X A H 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 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 700 4x4 XP R09HH68AB, AG, AH, AL, AM, AR 9922035 9921872 2009 RANGER 700 4x4 HD R09HH68AN 9922035 9921872 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 700 4X4 XP MODEL NUMBER: R09HH68AB, AG, AH, AL, AM, AR ENGINE MODEL: EH68OLE048 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 1237 lbs. / 561 kg Gross Vehicle Weight 2887 lbs. / 1310 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 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg
1.5 GENERAL INFORMATION 1 MODEL: 2009 RANGER 700 4X4 XP MODEL NUMBER: R09HH68AB, AG, AH, AL, AM, AR ENGINE MODEL: EH68OLE048 CLUTCH CHART Engine Platform 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 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.1 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch 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 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 Instrumentation Multifunction Speedometer DC Outlets (2) - Standard Relays Fan / EFI / Brake Light / Rear Diff Circuit Breaker Fan Motor: 15 Amp Fuses Main Chassis: 20 Amp Accessory: 15 Amp EFI: 15 Amp ECM: 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 3.05:1 7.49:1 6.81:1 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 3211118 Clutch Center Distance 10.05” (255 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 12 x 6 / Cast Aluminum Rear Wheel Size / Type 12 x 8 / Steel 12 x 8 / Cast Aluminum Front Tire Make / Model / Size Titan / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 Carlisle / PXT / 26 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) 21-74 (5632117) Red / Blue (7043372) Blk / Almd (7043167) 1500-3700 (5000 - 12000) 21-70 (5632127) Red / Blue (7043372) Blk / Almd (7043167)
1.6 GENERAL INFORMATION MODEL: 2009 RANGER 700 4X4 HD MODEL NUMBER: R09HH68AN ENGINE MODEL: EH68OLE048 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 166 in. / 422 cm Dry Weight 1262 lbs. / 572 kg Gross Vehicle Weight 2912 lbs. / 1321 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 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg
1.7 GENERAL INFORMATION 1 MODEL: 2009 RANGER 700 4X4 HD MODEL NUMBER: R09HH68AN ENGINE MODEL: EH68OLE048 CLUTCH CHART Engine Platform 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 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 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 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 Instrumentation Multifunction Speedometer DC Outlets (2) - Standard Relays Fan / EFI / Brake Light / Rear Diff Circuit Breaker Fan Motor: 15 Amp Fuses Steering: 30 Amp Main Chassis: 20 Amp Accessory: 15 Amp EFI: 15 Amp ECM: 15 amp Lights: 15 Amp 120Ω Resistor (CAN Bus) Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Reduction: High Low Reverse 3.05:1 7.49:1 6.81:1 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 3211118 Clutch Center Distance 10.05” (255 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 Self Leveling Suspension Independent (IRS) Rear Travel 7.5 in. (19.1 cm) Shock Preload Adjustment Cam Adjustment (front only) Wheels / Brakes Front Wheel Size / Type 12 x 6 / Cast Aluminum Rear Wheel Size / Type 12 x 8 / Cast Aluminum 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 8-12 psi (69 kPa) Brake System Type 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) 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 MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F - 32) = °C Unit of Measure Mu ltiplied by Converts to ft . Ibs. x12 _ in . lbs. in. lbs. x.0833 - ft. Ibs. ft . Ibs. x 1.356 _Nm in. lbs. x .0115 _ kg-m Nm x.7376 _ ft.lbs_ kg-m x 7.233 - ft. Ibs. kg -m x 86.796 _ in . lbs. kg-m x10 Nm in _ x 25.4 mm mm x.03937 in. in. x 2.54 em mile (mi.) x 1.6 _ km km x.6214 _ mile (mi.) Ounces (oz) x 28.35 Grams (9) Fluid Ounces (fl. oz.) x 29.57 - Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 _ Fluid Ounces ( 11. oz.) Grams (g) x 0.035 - Ounces (oz) lb. x .454 - kg kg x 2.2046 - lb. Cubic inches (cu in) x 16.387 - Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 _ Cubic inches (cu in) Imperial pints (Imp pI) x 0.568 _ Liters {Il Liters (I) x 1.76 - Imperial pints (Imp pt) Imperial quarts (Imp qt) x1 .137 _ Liters (I) Liters (I) x 0.88 _ Imperial quarts (Imp qt) Imperial quarts (Imp ql) x 1.201 US quarts (US qt) US quarts (US qt) x 0.833 _ Imperial quarts (Imp qt) US quarts (US qt) x 0.946 _ Liters (I) Liters (I) x 1.057 - US quarts (US qt) US gallons (US gal) x 3.785 _Liters (I) Liters (I) x 0.264 US gallons (US gal) Pounds - force per square inch (psi) x 6.895 - Kitopascals (kPa) Kilopascals (kPa) xO.145 - Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 - Kilograms - force per square cm Kilograms - force per square cm x 98.1 - Kilopascals (kPa) :rt (3 . 14) x W x H (height) _ Cylinder Volume
1.9 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. o Bolt Size Threads/In Grade 2 Grade 5 Grade e Torgue in. Ibs. (Nm) #10 24 .............. 27 (3.1) ............. . . . 43 (5.0) ....... .... ... 60 (6.9) #10 32 ........ • ..... 31 (3 .6) ................ 49 (5 .6) ...... • ....... 68 (7.8) Torque ft. Ibs. {Nm}* 1/4 20 ............. . 5 (7) .................. 8 (1 1) ................ 12 (16) 1/4 28 .............. 6 (8) .. ................ 10 (14) .............. 14 ( 19) 5/16 18 .............. 11 (15) .. . ............. 17 (23) .............. 25 (35) 5/16 24 ........ • ..... 12 (16) ................ 19 (26) .............. 29 (40) 3/8 16 .............. 20 (27) ................ 30 (40) .............. 45 (62) 3/8 24 ....... . ...... 23 (32) ..... ..... ...... 35 (48) ....... . ...... 50 (69) 7/ 16 14 ....... . .... .. 30 (40) ..... ..... ...... 50 (69) ....... . ...... 70 (9 7) 7/ 16 20 ... .... . .... .. 35 (48) ..... ..... ...... 55 (76) ....... . ...... 80 (11 0) 1/2 13 .............. 50(69) ................ 75(104) ............. 11 0(152) 1/2 20 .............. 55 (76) ................ 90 (124) ............. 120 (166) Metrle 6x1.0 72 -781n.lbs. 8x1.25 14-18ft.lbs. 10x 1,25 26-30tt.lbs. *To convert ft Ibs . to Nm multiply foot pounds by 1.382 '"To convert Nm to ft . Ibs . multiply Nm by .7376. SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section .
This Workshop Service Repair Manual is the most comprehensive guide for the 2009 Polaris Ranger 4X4 700 EFI. It includes high-quality diagrams and detailed instructions covering maintenance, engine, electronic fuel injection, body, steering, suspension, clutching, final drive, transmission, brakes, electrical systems, wire diagrams, and more.
Whether you're a professional mechanic or a DIY enthusiast, this manual is essential for servicing and repairing your motorcycle from the front bumper to the rear.
General information
Maintenance
Engine
Electronic fuel injection
Body / steering / suspension
Clutching
Final drive
Transmission
Brakes
Electrical
Wire diagram
And More......
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2009 Polaris Ranger 4X4 700 EFI Workshop Service Repair Manual