Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual Download

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Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual

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POLARIS RANGER 700 4X4 CREW 2009 FACTORY SERVICE REPAIR MANUAL DOWNLOAD:

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Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual

Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

TABLE OF CONTENTS:

Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual

9921885_Chapter_01.pdf..........................................................  1
	GENERAL INFORMATION.........................................................  1
		MODEL INFORMATION.......................................................  2
			Model Identification................................................  2
			Engine Designation Number...........................................  2
			VIN Identification..................................................  2
			Engine Serial Number Location.......................................  2
			Vehicle Identification Number (VIN) Location........................  3
			Transmission I.D. Number Location...................................  3
		VEHICLE DIMENSIONS......................................................  4
			RANGER 4x4 CREW / 6X6 (Height and Width)............................  4
			RANGER 6X6 (Length and Wheel Base)..................................  5
			RANGER 4x4 CREW (Length and Wheel Base).............................  5
		GENERAL SPECIFICATIONS..................................................  6
			MODEL: 2009 RANGER 4X4 CREW.........................................  6
			MODEL: 2009 RANGER 4X4 CREW.........................................  7
			MODEL: 2009 RANGER 6X6..............................................  8
			MODEL: 2009 RANGER 6X6..............................................  9
		VEHICLE INFORMATION..................................................... 10
			Publication Numbers................................................. 10
			Paint Codes......................................................... 10
			Replacement Keys.................................................... 10
		SPECIAL TOOLS........................................................... 10
		MISC. SPECIFICATIONS AND CHARTS......................................... 11
			Conversion Table.................................................... 11
			Standard Torque Specifications...................................... 12
			SAE Tap / Drill Sizes............................................... 13
			Metric Tap / Drill Sizes............................................ 13
			Decimal Equivalents................................................. 13
			Glossary of Terms................................................... 14
9921885_Chapter_02.............................................................. 15
	MAINTENANCE................................................................. 15
		PERIODIC MAINTENANCE CHART.............................................. 17
			Periodic Maintenance Overview....................................... 17
			Break-In Period..................................................... 17
			Maintenance Chart Key............................................... 17
			Pre-Ride - 25 Hour Maintenance Interval............................. 18
			50 - 100 Hour Maintenance Interval.................................. 19
			100 - 300 Hour Maintenance Interval................................. 20
		SERVICE PRODUCTS AND LUBES.............................................. 21
			Polaris Lubricants, Maintenance and Service Products................ 21
		MAINTENANCE REFERENCES.................................................. 22
			Maintenance References, Continued................................... 23
		GENERAL VEHICLE INSPECTION AND MAINTENANCE.............................. 24
			Pre-Ride / Daily Inspection......................................... 24
			Frame, Nuts, Bolts, and Fasteners................................... 24
			Shift Linkage Inspection / Adjustment............................... 24
		FUEL SYSTEM AND AIR INTAKE.............................................. 25
			Fuel System......................................................... 25
			Fuel Lines.......................................................... 25
			Fuel Filter......................................................... 25
			Vent Lines.......................................................... 25
			Throttle Pedal Inspection........................................... 25
			Throttle Freeplay Adjustment........................................ 26
			Air Filter Service.................................................. 26
			Air Intake Inspection............................................... 27
		ENGINE.................................................................. 28
			Compression and Leakdown Test....................................... 28
			Breather Hose Inspection............................................ 28
			Engine Oil Level.................................................... 28
			Engine Oil and Filter Change........................................ 29
			Exhaust Pipe........................................................ 30
		TRANSMISSION AND GEARCASES.............................................. 31
			Transmission Lubrication............................................ 31
			Front Gearcase Lubrication.......................................... 32
			Middle Gearcase Lubrication (6x6)................................... 33
			Rear Gearcase Lubrication (4x4 CREW)................................ 34
			Rear Gearcase Lubrication (6x6)..................................... 35
		COOLING SYSTEM.......................................................... 36
			Liquid Cooling System Overview...................................... 36
			Coolant Level Inspection............................................ 36
			Radiator Coolant Level Inspection................................... 37
			Coolant Strength / Type............................................. 37
			Cooling System Pressure Test........................................ 37
			Cooling System Hoses................................................ 37
			Radiator............................................................ 38
			Coolant Drain / Radiator Removal.................................... 38
		FINAL DRIVE / WHEEL AND TIRE............................................ 39
			Wheel and Hub Torque Table.......................................... 39
			CV Shaft Boot Inspection............................................ 39
			Wheel Removal....................................................... 39
			Wheel Installation.................................................. 39
			Tire Inspection..................................................... 40
			Tire Pressure....................................................... 40
		ELECTRICAL AND IGNITION SYSTEM.......................................... 40
			Battery Maintenance................................................. 40
			Battery Fluid Level (Conventional Battery).......................... 41
			Battery Removal..................................................... 41
			Battery Installation................................................ 41
			Battery Storage..................................................... 41
			Battery Charging.................................................... 41
			Spark Plug Service.................................................. 42
			Engine To Frame Ground.............................................. 42
		STEERING AND SUSPENSION................................................. 43
			Steering............................................................ 43
			Tie Rod End / Steering Inspection................................... 43
			Wheel Toe Alignment Inspection...................................... 43
			Toe Adjustment...................................................... 44
			Front Suspension.................................................... 44
			Rear Suspension..................................................... 45
			Rear Suspension Adjustment (4x4 CREW)............................... 45
			Rear Spring Adjustment.............................................. 45
		BRAKE SYSTEM............................................................ 46
			Brake Fluid Inspection.............................................. 46
			Brake Hose and Fitting Inspection................................... 46
			Brake Pad / Disc Inspection......................................... 46
			Parking Brake Cable Adjustment...................................... 46
			Parking Brake Pad Inspection........................................ 47
9921885_Chapter_03.............................................................. 49
	ENGINE...................................................................... 49
		ENGINE SPECIFICATIONS................................................... 50
			Crankcase Exploded Views............................................ 50
			Engine Fastener Torque Patterns..................................... 57
			Torque Specifications............................................... 58
			700 EFI Engine Service Specifications............................... 59
			Special Tools....................................................... 61
		GENERAL ENGINE SERVICE.................................................. 61
			Accessible Components............................................... 61
			Piston Identification............................................... 61
			Cooling System Specifications....................................... 61
			Cooling System Pressure Test........................................ 62
			Cooling System Exploded View........................................ 63
			Cooling System Bleeding Procedure................................... 63
			Valve Cover Removal - 6x6 Models (Engine Installed)................. 65
			Engine Removal...................................................... 66
			Engine Installation Notes........................................... 67
			Engine Lubrication Specifications................................... 68
			Oil Pressure Test................................................... 68
			Oil Flow Chart...................................................... 69
		ENGINE DISASSEMBLY AND INSPECTION....................................... 70
			Cylinder Head Assembly Exploded View................................ 70
			Rocker Arms......................................................... 71
			Push Rods........................................................... 71
			Cylinder Head Removal .............................................. 71
			Cylinder Head Inspection............................................ 72
			Cylinder Head Warp.................................................. 72
			Valve Seal / Spring Service (On Engine)............................. 72
			Cylinder Head Disassembly........................................... 73
			Valve Inspection.................................................... 74
			Combustion Chamber.................................................. 75
			Valve Seat Reconditioning........................................... 75
			Cylinder Head Reassembly............................................ 77
			Valve Sealing Test.................................................. 78
			Cylinder Removal.................................................... 78
			Valve Lifter Removal / Inspection................................... 78
			Piston Removal...................................................... 79
			Cylinder Inspection................................................. 80
			Cylinder Hone Selection And Honing Procedure........................ 81
			Honing To Deglaze................................................... 81
			Cleaning the Cylinder After Honing.................................. 81
			Piston-to-Cylinder Clearance........................................ 82
			Piston / Rod Inspection............................................. 82
			Piston Ring Installed Gap........................................... 83
			Starter Drive Bendix Removal / Inspection .......................... 83
			Flywheel / Stator Removal / Inspection.............................. 84
			Engine Crankcase Disassembly / Inspection........................... 84
			Camshaft Inspection................................................. 92
		ENGINE REASSEMBLY....................................................... 93
			Crankcase Reassembly................................................ 93
			Flywheel / Stator Installation......................................102
			Cylinder Head Reassembly............................................103
			Oil Pump Priming....................................................105
			Engine Break-In.....................................................105
		TROUBLESHOOTING.........................................................106
			Engine..............................................................106
			Cooling System......................................................107
9921885_Chapter_04..............................................................109
	ELECTRONIC FUEL INJECTION...................................................109
		GENERAL INFORMATION.....................................................110
			Special Tools.......................................................110
			EFI Service Notes...................................................113
			Fuel Tank Exploded View.............................................114
			EFI System Exploded View............................................115
			EFI System Component Locations......................................116
			Fuel Lines - Quick Connect Removal / Installation...................117
		ELECTRONIC FUEL INJECTION...............................................118
			Principal Components................................................118
			EFI Operation Overview..............................................118
			Initial Priming / Starting Procedure................................118
		ELECTRONIC CONTROL UNIT (ECU)...........................................119
			Operation Overview..................................................119
			ECU Service.........................................................119
			ECU Replacement.....................................................119
		FUEL PUMP...............................................................120
			Operation Overview..................................................120
			Fuel Sender Test....................................................120
			Fuel Pump Test......................................................120
			Fuel Pump / Tank Assembly Replacement...............................121
		FUEL PRESSURE REGULATOR.................................................122
			Operation Overview..................................................122
			Fuel Pressure Regulator Test........................................122
			Fuel Pressure Regulator Replacement.................................122
		FUEL INJECTORS..........................................................123
			Operation Overview..................................................123
			Fuel Injector Service...............................................123
			Fuel Injector Replacement...........................................123
		CRANKSHAFT POSITION SENSOR (CPS)........................................124
			Operation Overview..................................................124
			CPS Test............................................................124
			CPS Replacement.....................................................124
		TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....................125
			Operation Overview..................................................125
			T-BAP Test..........................................................125
			T-BAP Replacement...................................................125
		THROTTLE POSITION SENSOR (TPS)..........................................125
			Operation Overview..................................................125
			TPS Tester / Regulator..............................................125
			Checking TPS Reading................................................127
			TPS Adjustment......................................................127
			TPS Replacement.....................................................128
		ENGINE COOLANT TEMPERATURE SENSOR (ECT).................................128
			Operation Overview..................................................128
			ECT Sensor Test.....................................................128
			ECT Sensor Replacement..............................................128
		IGNITION COIL...........................................................129
			Operation Overview..................................................129
			Ignition Coil Tests.................................................129
			Ignition Coil / HT Lead Replacement.................................129
		GENERAL TROUBLESHOOTING.................................................130
			Diagnostic “Blink Codes”............................................130
			EFI Troubleshooting.................................................131
		EFI SYSTEM BREAK-OUT DIAGRAMS...........................................132
			Fuel Injector Circuit (PTO).........................................132
			Fuel Injector Circuit (MAG).........................................132
			Crankshaft Position Sensor (CPS) Circuit............................133
			Fuel Pump Circuit...................................................133
			Engine Coolant Temperature Sensor (ECT) ............................134
			Temperature Overheat Indicator Lamp Circuit.........................134
			Throttle Position Sensor (TPS) Circuit..............................135
			Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit....135
			Diagnostic Connector Circuit........................................136
			Diagnostic Indicator Lamp Circuit...................................136
9921885_Chapter_05..............................................................137
	BODY / STEERING / SUSPENSION................................................137
		TORQUE SPECIFICATIONS...................................................138
		SPECIAL TOOLS...........................................................138
		BODY COMPONENT REMOVAL..................................................139
			Removal Procedures..................................................139
			Lower Body, Floor and Fenders (4x4 CREW)............................140
			Lower Body, Floor and Fenders (6x6).................................141
			Hood / Dash Components..............................................142
			Dash Instruments and Controls.......................................143
		CAB FRAME...............................................................144
			Assembly / Removal (6x6)............................................144
			Assembly / Removal (4x4 CREW).......................................145
		SEAT / HEAD REST........................................................146
			Seat Back / Head Rests..............................................146
		CHASSIS / MAIN FRAME (4X4 CREW).........................................147
			Exploded View.......................................................147
		CHASSIS / MAIN FRAME (6X6)..............................................148
			Exploded View.......................................................148
		STEERING ASSEMBLY.......................................................149
			Exploded View.......................................................149
		STEERING AND SUSPENSION.................................................150
			Exploded View.......................................................150
		FRONT A-ARM.............................................................151
			Replacement.........................................................151
		FRONT STRUT.............................................................152
			Exploded View.......................................................152
			Front Strut Cartridge Replacement...................................153
			Ball Joint Replacement..............................................153
		MID AXLE A-ARM (6X6)....................................................154
			Replacement.........................................................154
		REAR A-ARM (4X4 CREW)...................................................155
			Replacement.........................................................155
		REAR STABILIZER BAR (4X4 CREW)..........................................157
			Removal / Installation..............................................157
		SWING ARM (6X6).........................................................158
			Removal.............................................................158
			Installation........................................................158
		REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6).......................159
		REAR CARGO BOX..........................................................160
			Cargo Box - Panels..................................................160
			Cargo Box - Tailgate / Box Support..................................161
			Box Removal.........................................................162
			Box Installation....................................................162
		STORAGE BOX (4X4 CREW)..................................................163
			Removal.............................................................163
			Installation........................................................163
		DECAL REPLACEMENT.......................................................163
9921885_Chapter_06..............................................................165
	CLUTCHING...................................................................165
		SPECIAL TOOLS AND SUPPLIES..............................................166
		TORQUE SPECIFICATIONS...................................................166
			PVT System Fastener Torques.........................................166
		PVT SYSTEM OVERVIEW.....................................................166
			General Operation...................................................166
			Drive Clutch Operation..............................................166
			Driven Clutch Operation.............................................167
			PVT Break-In (Drive Belt / Clutches)................................167
			Maintenance / Inspection............................................167
			Overheating / Diagnosis.............................................168
		PVT SYSTEM SERVICE......................................................169
			PVT Sealing, Guard, and Ducting Components..........................169
			Disassembly.........................................................169
			Assembly............................................................170
		DRIVE BELT..............................................................171
			Belt Removal........................................................171
			Belt Inspection.....................................................172
			Belt Installation...................................................172
			PVT Break-In (Drive Belt / Clutches)................................172
		CLUTCH ALIGNMENT........................................................172
			Clutch Alignment Tool Use...........................................172
		CLUTCH CENTER DISTANCE..................................................173
		DRIVE CLUTCH SERVICE....................................................174
			Spring Specifications...............................................174
			Shift Weights.......................................................175
			Exploded View.......................................................176
			Clutch Disassembly..................................................176
			Spider Removal......................................................177
			Roller, Pin, and Thrust Washer Inspection...........................178
			Button To Tower Clearance Inspection................................178
			Shift Weight Inspection.............................................178
			Bearing Inspection..................................................179
			Clutch Inspection...................................................179
			Moveable Sheave Bushing Inspection..................................180
			Bushing Service.....................................................181
			Clutch Assembly.....................................................183
		DRIVEN CLUTCH SERVICE...................................................184
			Exploded View.......................................................184
			Clutch Disassembly / Inspection.....................................184
			Clutch Assembly.....................................................186
		TROUBLESHOOTING.........................................................187
9921885_Chapter_07..............................................................189
	FINAL DRIVE.................................................................189
		SPECIAL TOOLS...........................................................191
		TORQUE SPECIFICATIONS...................................................191
			Wheel, Hub, and Spindle Torque Table................................191
		FRONT HUB...............................................................191
			Hub Removal / Inspection............................................191
			Hubstrut Bearing Replacement........................................192
			Hub Installation....................................................193
			Front Hub Exploded View.............................................194
		FRONT DRIVE SHAFT.......................................................195
			Removal.............................................................195
			Drive Shaft / CV Joint Handling Tips................................196
			Outer CV Joint / Boot Replacement...................................196
			Inner Plunging Joint / Boot Replacement.............................198
			Exploded View.......................................................199
			Installation........................................................199
		FRONT PROPSHAFT.........................................................200
			6x6 Removal.........................................................200
			4x4 CREW Removal....................................................200
			Front Propshaft Components..........................................200
		PROPSHAFT U-JOINT SERVICE...............................................201
			Disassembly.........................................................201
			Assembly............................................................201
		FRONT GEARCASE / CENTRALIZED HILLIARD...................................203
			Centralized Hilliard Exploded View..................................203
			All Wheel Drive Operation...........................................204
			AWD Diagnosis.......................................................205
			Gearcase Removal....................................................206
			Gearcase Disassembly / Inspection...................................207
			Gearcase Reassembly / Inspection....................................209
			Backlash Pad (Thrust Pad) Adjustment................................211
			Gearcase Installation...............................................212
		MID DRIVE HUB / BEARING CARRIER (6X6)...................................212
			Removal.............................................................212
			Hub Disassembly.....................................................213
			Hub Assembly........................................................213
			Hub Installation....................................................214
			Mid Drive Exploded View.............................................215
		MID DRIVE SHAFT (6X6)...................................................215
			Removal.............................................................215
			Disassembly / Assembly..............................................215
			Installation........................................................216
		MID PROPSHAFT (6X6).....................................................216
			Removal.............................................................216
		MID DRIVE GEARCASE (6X6)................................................217
			Gearcase Removal....................................................217
			Gearcase Disassembly................................................218
			Gearcase Assembly...................................................220
			Gearcase Installation...............................................223
			Mid Gearcase Exploded...............................................224
		REAR HUB / BEARING CARRIER (4X4)........................................225
			Hub Inspection......................................................225
			Hub Removal.........................................................225
			Hub Disassembly.....................................................226
			Hub Assembly........................................................226
			Hub Installation....................................................227
			Exploded View.......................................................228
		REAR DRIVE SHAFT (4X4 CREW).............................................229
			Removal.............................................................229
			Outer CV Joint / Boot Replacement...................................229
			Inner Plunging Joint / Boot Replacement.............................232
			Drive Shaft Exploded View...........................................234
			Installation........................................................235
		REAR PROPSHAFT (4X4 CREW)...............................................236
			Removal.............................................................236
			Installation........................................................236
		REAR GEARCASE (4X4 CREW)................................................237
			General Operation...................................................237
			Operation Modes.....................................................238
			Gearcase Removal....................................................239
			Gearcase Disassembly................................................239
			Rear Gearcase Assembly..............................................242
			Rear Gearcase Installation..........................................244
			Rear Gearcase Exploded View (4x4 CREW)..............................245
		REAR AXLE / GEARCASE SERVICE (6X6)......................................246
			Rear Axle Removal...................................................246
			Axle Tube Removal...................................................247
			Axle Tube Bearing Replacement.......................................248
			Gearcase Disassembly / Inspection...................................248
			Gearcase Assembly...................................................249
			Gearcase / Axle Installation........................................250
			Rear Gearcase Exploded View (6x6)...................................253
9921885_Chapter_08..............................................................255
	TRANSMISSION................................................................255
		TORQUE SPECIFICATIONS...................................................256
		SHIFT LEVER.............................................................256
			Removal.............................................................256
			Installation........................................................256
		SHIFT LINKAGE...........................................................256
			Inspection..........................................................256
			Adjustment..........................................................257
		TRANSMISSION SERVICE....................................................257
			Transmission Removal................................................257
			Transmission Disassembly............................................259
			Transmission Assembly...............................................264
			Transmission Installation...........................................268
		TROUBLESHOOTING.........................................................269
			Troubleshooting Checklist...........................................269
		TRANSMISSION EXPLODED VIEW..............................................270
			Exploded View.......................................................270
9921885_Chapter_09..............................................................273
	BRAKES......................................................................273
		GENERAL SPECIFICATIONS..................................................274
		TORQUE SPECIFICATIONS...................................................274
		SPECIAL TOOLS...........................................................274
		BRAKE SYSTEM SERVICE NOTES..............................................275
		BRAKE NOISE TROUBLESHOOTING.............................................275
		HYDRAULIC BRAKE SYSTEM OPERATION........................................276
		BRAKE SYSTEM EXPLODED VIEW..............................................277
			6x6.................................................................277
			4x4 CREW............................................................277
		MASTER CYLINDER.........................................................278
			Removal.............................................................278
			Installation........................................................278
		FOOT BRAKE PEDAL........................................................278
			Pedal Removal.......................................................278
			Pedal Installation..................................................278
		BRAKE BLEEDING / FLUID CHANGE...........................................279
		PARKING BRAKE...........................................................280
			Exploded View (4x4 CREW)............................................280
			Exploded View (6x6).................................................281
			Inspection..........................................................282
			Cable Tension Adjustment............................................282
		PARKING BRAKE CALIPER SERVICE...........................................283
			Exploded View.......................................................283
			Caliper Removal.....................................................283
			Caliper Disassembly / Inspection....................................284
			New Brake Pad Installation..........................................285
			Caliper Installation................................................285
		PARKING BRAKE DISC SERVICE..............................................285
			Disc Inspection / Removal...........................................285
		FRONT BRAKE PADS........................................................286
			Pad Removal.........................................................286
			Pad Inspection......................................................286
			Pad Assembly / Installation.........................................287
			Brake Burnishing Procedure..........................................287
		FRONT CALIPER SERVICE...................................................288
			Caliper Exploded View...............................................288
			Caliper Removal ....................................................288
			Caliper Disassembly.................................................289
			Caliper Inspection..................................................290
			Caliper Assembly....................................................290
			Caliper Installation................................................291
		FRONT BRAKE DISC........................................................292
			Disc Inspection.....................................................292
			Disc Replacement....................................................292
		REAR BRAKE PADS (6X6)...................................................293
			Pad Removal.........................................................293
			Pad Inspection......................................................293
			Pad Installation....................................................294
		REAR BRAKE PADS (4X4 CREW)..............................................294
			Pad Removal.........................................................294
			Pad Inspection......................................................295
			Pad Assembly / Installation.........................................295
			Brake Burnishing Procedure..........................................296
		REAR CALIPER SERVICE (6X6)..............................................297
			Rear Caliper Exploded View..........................................297
			Caliper Removal.....................................................297
			Caliper Disassembly.................................................298
			Caliper Inspection..................................................298
			Caliper Assembly....................................................299
			Caliper Installation................................................299
		REAR CALIPER SERVICE (4X4 CREW).........................................300
			Rear Caliper Exploded View..........................................300
			Caliper Removal ....................................................300
			Caliper Disassembly.................................................301
			Caliper Inspection..................................................302
			Caliper Assembly....................................................302
			Caliper Installation................................................303
		REAR BRAKE DISC.........................................................304
			Disc Inspection.....................................................304
			Disc Replacement....................................................304
		TROUBLESHOOTING.........................................................305
			Brakes Squeal / Poor Brake Performance..............................305
			Pedal Vibration.....................................................305
			Caliper Overheats (Brakes Drag).....................................305
			Brakes Lock.........................................................305
9921885_Chapter_10..............................................................307
	ELECTRICAL..................................................................307
		GENERAL INFORMATION.....................................................309
			Special Tools.......................................................309
			Electrical Service Notes............................................309
			Under-Hood Components...............................................309
		SWITCHES / CONTROLS.....................................................310
			Headlight Switch....................................................310
			AWD / 2WD / TURF Switch (4x4 CREW)..................................310
			Differential Solenoid (4x4 CREW)....................................310
			Brake Light Switch..................................................311
			Parking Brake Switch................................................312
		INSTRUMENT CLUSTER......................................................313
			Overview............................................................313
			Rider Information Display...........................................313
			Standard Display Modes..............................................314
			Diagnostic Display Mode.............................................314
			Viewing Diagnostic Codes............................................316
			Instrument Cluster Removal..........................................317
			Instrument Cluster Installation.....................................317
		INSTRUMENT CLUSTER TROUBLESHOOTING TESTS................................318
			Test 1 - No All Wheel Drive.........................................318
			TEST 2 - No Display.................................................319
			TEST 3 - Wheel Speed Sensor.........................................319
			TEST 4 - No AWD Hub Safety Limiter..................................320
			TEST 5 - Fuel Gauge Display Not Working ............................321
			TEST 6 - Shift Indicator Not Working (Transmission Switch)..........321
		ALL WHEEL DRIVE (AWD) COIL..............................................322
			Operation Overview..................................................322
			Diagnosing System Failures..........................................322
		GEAR POSITION INDICATOR SWITCH..........................................322
			Test Diagram........................................................322
		HEADLIGHTS..............................................................323
			Headlight Adjustment................................................323
			Headlight Bulb Replacement..........................................323
			Headlight Housing Removal...........................................323
			Headlight Housing Installation......................................324
		TAIL LIGHT / BRAKE LIGHT................................................324
			Lamp Replacement....................................................324
		COOLING SYSTEM..........................................................325
			Cooling System Break-Out Diagram....................................325
			Fan Control Circuit Operation.......................................326
			Fan Control Circuit Bypass Test.....................................326
			Coolant Temperature Sensor..........................................326
		EFI DIAGNOSTICS.........................................................326
			EFI Component Testing...............................................326
		FUEL SENDER.............................................................326
			Testing.............................................................326
		RELAYS..................................................................327
			Operation...........................................................327
		FUSES / CIRCUIT BREAKER.................................................328
			Operation...........................................................328
		CHARGING SYSTEM.........................................................329
			Current Draw - Key Off..............................................329
			Charging System “Break Even” Test...................................329
			Charging System Alternator Tests....................................330
			Charging System Testing Flow Chart..................................331
		BATTERY SERVICE.........................................................332
			Battery Terminals / Bolts...........................................332
			Battery Terminal Block..............................................332
			Battery Activation..................................................332
			Battery Inspection..................................................333
			Battery Removal / Installation......................................333
			Battery Testing.....................................................333
			OCV - Open Circuit Voltage Test.....................................333
			Specific Gravity Test...............................................334
			Load Test...........................................................334
			Off Season Storage..................................................334
			Charging Procedure..................................................334
		STARTER SYSTEM..........................................................335
			Troubleshooting.....................................................335
			Voltage Drop Test...................................................335
			Starter Motor Removal / Disassembly ................................335
			Brush Inspection / Replacement......................................336
			Armature Testing....................................................337
			Starter Reassembly / Installation...................................337
			Starter Drive.......................................................338
			Starter Solenoid Bench Test.........................................339
			Starter Solenoid Operation..........................................339
			Starter Exploded View...............................................340
		STARTING SYSTEM TESTING FLOW CHART......................................341
			Condition: Starter fails to turn over the engine. ..................341
		ELECTRIC BOX LIFT ACTUATOR..............................................342
			DIAGNOSIS (if equipped).............................................342
		ELECTRICAL BREAK-OUT DIAGRAMS...........................................343
			Starting Circuit....................................................343
			Key-On Power Circuit................................................343
			Transmission Switch Circuit.........................................344
			AWD Circuit.........................................................344
			Speed Sensor Circuit................................................345
			Charging System Circuit.............................................345
			Cooling Fan Circuit.................................................346
			Fuel Display / Fuel Pump Circuit....................................346
9921885_Wire_Diagrams...........................................................347

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