GENERAL INFORMATION
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
1.1
GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service.
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Machine Model Number Identification R 09 WH 68 AG Emissions & Model Option
Model Year Designation
Basic Chassis Designation
Engine Designation
Engine Designation Number EH068OLE046PLE ............................................................Twin, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification World Mfg. ID
Vehicle Identifier
Vehicle Description
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A W H 6 8 A * 9 P 0 0 0 0 0 0 Model Year
Engine Body Style Emissions Powertrain
Plant No.
Check Digit
Individual Serial No. * This could be either a number or a letter
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. Engine Serial Number
1.2
A
GENERAL INFORMATION 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
1
The transmission I.D. number is located on the right side when installed in the vehicle.
A
A
B
1.3
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
1.4
GENERAL INFORMATION RANGER 6X6 (Length and Wheel Base)
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120 in. 305 cm
42.5 in. 108 cm
27 in. 69 cm 90 in. 229 cm
RANGER 4x4 CREW (Length and Wheel Base) 145 in. 386 cm
36.5 in. 92.7 cm
108 in. 274 cm
1.5
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 54 x 36.5 x 11.5 in. Cargo Box Dimensions (137 x 92.7 x 29.2 cm) 1750 lbs. / 794 kg Vehicle Payload (Includes driver and five passengers) Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg
1.6
GENERAL INFORMATION MODEL: 2009 RANGER 4X4 CREW MODEL NUMBER: R09WH68AC, AG, AH, AR ENGINE MODEL: EH68OLE Engine Platform
Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke
Engine Model Number
EH068OLE049
Engine Displacement
683cc
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) 3211118
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
Belt
Oil Requirements
PS-4 PLUS 2W-50 Synthetic
Clutch Center Distance
Oil Capacity
2 qts. / 1.9 L
10.05” (255 mm)
Steering / Suspension
Coolant Capacity
n/a
Front Suspension
MacPherson Strut
Overheat Warning
Instrument Cluster Indicator
Front Travel
8 in. (20.3 cm)
2 to 1 Canister Style
Rear Suspension
Independent Rear Suspension
Rear Travel
9 in. (22.9 cm)
Exhaust System Fuel System Fuel System Type
Bosch Electronic Fuel Injection
Rear Shock Preload Adjustment
Cam Adjustment
Fuel Delivery
Electronic Fuel Pump (in tank)
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm) Wheels / Brakes
Fuel Pressure
39 psi
Fuel Filters
See Chapter 4
Front Wheel Size
12 x 6
Fuel Capacity / Requirement
9 gal. (34 L) 87 Octane (minimum)
Rear Wheel Size
12 x 8
Front Tire Make / Model / Size
Carlisle / PXT / 26 x 9 R12 Carlisle / PXT / 26 x 11 R12
Electrical Alternator Max Output
500 Watts @ 3000 RPM
Lights: Main Headlights
2 - Single Beam 50W / Halogen
Rear Tire Make / Model / Size
Tail
5 Watts x 2
Tire Air Pressure - Front / Rear
12 psi / 16 psi
Brake
5 Watts x 2
Brakes / Brake Fluid
4 Wheel Hydraulic Disc / DOT 4
Indicator Panel Lights
1 Watt (ea.)
Parking Brake
Hand Actuated (in dash)
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
CLUTCH CHART Altitude
Meters (Feet)
Shift Weight Drive Spring
Driven Spring
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)
1.7
1
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 54 x 42.5 x 11.5 in. Cargo Box Dimensions (137 x 108 x 29.2 cm) 1750 lbs. / 794 kg Vehicle Payload (Includes driver and two passengers) Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg
1.8
GENERAL INFORMATION MODEL: 2009 RANGER 6X6
Drivetrain
MODEL NUMBER: R09RF68AF, AR ENGINE MODEL: EH68OLE Engine Platform
Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke
Engine Model Number
EH068OLE048
Engine Displacement
683cc
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) 3211118
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
Belt
Coolant Capacity
3.25 qts. (3.08 L)
Clutch Center Distance
Overheat Warning
Instrument Cluster Indicator
Exhaust System
2 to 1 Canister Style
10.05” (255 mm)
Steering / Suspension Front Suspension
MacPherson Strut
Front Travel
8 in. (20.3 cm)
Bosch Electronic Fuel Injection
Center Suspension
Progressive Rate / Independent
Fuel Delivery
Electronic Fuel Pump (in tank)
Center Travel
5.25 in. (13.3 cm)
Fuel Pressure
39 psi
Rear Suspension
Swing Arm w/Dual Shocks
Fuel Filters
See Chapter 4
Rear Travel
6.25 in. (16 cm)
9 gal. (34 L) 87 Octane (minimum)
Rear Shock Preload Adjustment
Cam Adjustment
Fuel Capacity / Requirement
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm)
Alternator Max Output
500 Watts @ 3000 RPM
Front Wheel Size
12 x 6 / 10 gauge
Lights: Main Headlights
2 - Single Beam 50W / Halogen
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
Fuel System Fuel System Type
Wheels / Brakes
Electrical
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)
Tire Air Pressure Front / Middle / Rear
8 - 12 psi
Ignition Timing
7° BTDC @ 1200 RPM
Brakes / Brake Fluid
4 Wheel Hydraulic Disc / DOT 4
Spark plug / Gap
Champion RC7YC3 / .035 in. (0.9 mm)
Parking Brake
Hand Actuated (in dash)
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
CLUTCH CHART Altitude
Meters (Feet)
Shift Weight Drive Spring
Driven Spring
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)
1.9
1
GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers Model
Model No.
Owner’s Manual PN
Parts Manual PN
2009 RANGER 4x4 CREW R09WH68AC, AG, AH, AR
9921882
9921884
2009 RANGER 6x6
9921871
9921874
R09RF68AF, AR
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 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
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.
KEY COVER P/N 5533534
Key Series Number
Series#
Part Number
20
4010278
21
4010278
22
4010321
23
4010321
27
4010321
28
4010321
31
4110141
32
4110148
67
4010278
68
4010278
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/.
1.10
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GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS
1
Conversion Table
°C to °F: 9/5(°C + 32) = °F
°F to °C: 5/9(°F - 32) = °C
1.11
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.
1.12