2009 Polaris Ranger 700 EFI 4x4 Crew / 6x6 UTV Service Manual (P/N 9921885)

This Polaris service manual, P/N 9921885, covers the 2009 Ranger 700 EFI 4x4 Crew (R09WH68AC, R09WH68AG, R09WH68AH and R09WH68AR) and 6x6 (R09RF68AF and R09RF68AR). It contains factory repair, maintenance and diagnostic procedures for both UTV configurations.

The publication table references separate owner's and parts manuals: Crew P/N 9921882 and 9921884, respectively; 6x6 P/N 9921871 and 9921874. Those publications are not included.

• Engine repair: Engine removal and installation, cylinder-head assembly, valve-seat reconditioning, piston inspection and crankcase service, supported by exploded views and torque sequences.

• EFI diagnostics: Fuel-pressure and injector testing, diagnostic blink codes, throttle position sensor adjustment and component-specific electrical breakout diagrams for fault tracing.

• PVT and transmission: Drive and driven clutch service, belt inspection, clutch alignment, transmission disassembly and inspection of gears, shift components and bearings.

• Final drive: Centralized Hilliard front gearcase service, AWD diagnosis, inner and outer CV boot replacement, axle bearings and model-specific middle and rear gearcases.

• Chassis and brakes: MacPherson struts, steering alignment, rear spring preload, hydraulic brake bleeding, master-cylinder replacement and front and rear caliper service.

• Electrical systems: Starting and charging diagnostics, switches, relays, instrument-cluster checks, cooling-fan circuits and electric cargo-box lift testing where equipped.

• Service references: Scheduled maintenance intervals, fluid capacities, gearcase lubrication, transmission gear-ratio tables, component wear limits and fastener torque specifications for assembly work.

The procedures suit experienced mechanics with engine-rebuilding and electrical-diagnostic skills; Polaris specifies certified Master Service Dealer technicians and factory-authorized tools for PVT maintenance and repair.

Engine, Lubrication and Cooling

Engine coverage extends to rocker arms, pushrods, hydraulic lifters, starter drive Bendix and the oil pump housing. Inspection specifications address crankshaft runout and piston-to-cylinder clearance, alongside compression and leakdown testing.

The cooling section includes pressure testing, coolant bleeding, water-pump service and model-specific coolant capacities. The Oil Flow Chart and Coolant Flow Diagram show the circulation paths relevant to lubrication and overheating faults.

Oil-system priming after engine reassembly uses the PU-45778 priming adapter. Skipping priming can damage internal engine components during initial startup.

EFI and Electrical Fault Finding

The diagnostic charts connect SAE fault codes and Polaris blink codes with affected circuits. Component testing covers the crankshaft position sensor (CPS), throttle position sensor (TPS) and engine coolant temperature sensor; T-BAP testing requires Digital Wrench.

TPS setup uses the PU-47082 tester adapter harness and 4010264 tester regulator. The fuel pump and regulator are serviced through fuel-tank assembly replacement.

The Starting System Testing Flow Chart, Charging System Testing Flow Chart and EFI breakout diagrams help trace power, ground and wiring faults before replacing components. Disconnecting ECU connectors with the ignition on can create voltage spikes that damage the ECU.

Drivetrain and Chassis Differences

PVT alignment procedures use the PA-49011 alignment tool and explain clutch washer placement. Transmission repair reaches the shift forks, engagement dogs, shift drum and silent chain.

Crew coverage includes independent rear suspension and an electrically operated locking rear differential. The 6x6 sections cover its middle gearcase, rear axle and swingarm, with separate rear-brake procedures for the two configurations.

For the Crew rear gearcase, pinion assembly damage calls for assembly replacement. Pinion disassembly and pinion/ring-gear shimming are outside the documented repair scope.

Parking-brake work includes cable adjustment and pad service. Vehicle support and raised cargo-box precautions accompany chassis work.

Selected Engine and TPS Reference Values

These examples are a small selection of the manual's inspection and adjustment data. For the EH068OLE engine, intake valve-stem diameter is 0.2356 ± 0.00039 in, and cylinder leakdown has a 15% service limit.

Oil pressure with the engine hot at 5,500 rpm is 39 psi standard, with a 35 psi minimum, using Polaris PS-4 PLUS 2W-50 synthetic oil.

For TPS checking with the specified tester connected and the throttle pedal resting at idle, the output specification is 0.660 ± 0.010 VDC.

Bookmarked PDF with Wiring Appendix

Search and diagram detail: Service text is searchable, but some diagram and flowchart labels are not. Embedded chapter and subsection bookmarks support navigation. Small wiring labels require enlargement, and some schematic lines and lettering are faint.

One printable English PDF contains 352 pages in total, including six notes pages and six pages of wiring diagrams.