ranger flat rate 06-10
TRANSCRIPT
RANGER Flat Rate Manual: MY06 - MY10
RANGER Flat Rate Manual: MY06 - MY10
TABLE OF CONTENTS & TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22010 RANGER FLAT RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32009 RANGER FLAT RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.102006 / 2007 / 2008 RANGER FLAT RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17TABLE OF CONTENTS & TITLE PAGELast Revised: 2/24/10
THE FOLLOWING ITEM(S) DESCRIBE ALL CHANGES THAT WERE MADE IN THIS REVISION OF THE FLATRATE MANUAL.
‐ The throttle cable R&R time has been increased to 1:12 on MY09 500 & XP and on all MY10 full size models.
This Flat Rate Manual is continually updated based on feedback received from the field. It is importantto verify your dealership is using the most up to date Flat Rate Manual available. Warrantyreimbursement for labor time will be given using the Flat Rate Manual in effect the date of warrantyclaim submission.
Refer to the Polaris Warranty Manual for information on warranty policy, claim types and electronic claim filing procedures.
1.1© Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication.Due to constant improvement in the design and quality of production components, some minor discrepancies may result between the actual vehicle andthe information presented in this publication. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the informationcontained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
INTRODUCTION
INTRODUCTIONDear Polaris Dealer,Polaris invests a great deal of time and effort to ensure flat rate times are accurate and reflect “real world” conditions. We do not use power or air tools when determining our flat rate times and we round all times up to the nearest six minute interval.
Flat rate times are determined using the following sources:
Internal Technical Service Representatives: Information is gathered from our internal Technical Service Representatives servicing a fleet of department vehicles.
Technical Service Engineers: Information is gathered while reviewing initial product servicability and development testing.
Technical Publications: As the Technical Publications staff write and photo the processes provided in the Technical Service Manuals, they monitor the time it takes for each outlined procedure.
Validation Testing: Technical Service utilizes off-peak manufacturing workers for true flat rate validation. The people used for this validation are given a used wholegood unit from our testing department, a complete set of hand and specialty tools in a mock shop environment, and the service manual for the given product.
• Validation utilizes a test vehicle so it is representative of a consumer’s unit. • No power or air tools are used during this validation process.• The manufacturing employee is not a seasoned technician, but rather an individual with a strong
mechanical aptitude and personal experience owning and / or operating the product. This person has, in most cases, completed MSD training for the product validated
Dealer Feedback: Our most valuable resource when establishing a flat rate time is input from the dealer network. Polaris frequently reviews flat rate times with select dealers for a “reality check” on a flat rate time. If at any time you believe a flat rate time is too low, or too high, please complete the Warranty Flat Rate Feedback Form in ASK Polaris on the dealer web site. This form is not used for one time exceptions to a flat rate time because of extenuating circumstances, but rather when you beleive the time in general is not at all accurate. We welcome your feedback! The information you provide on the ASK Polaris form is taken seriously. We will review your input, test the procedure, and adjust the time in the flat rate manual, if necessary!
Our Expectations: Several assumptions are made when establishing and reviewing existing flat rate times:
• The person performing the service is Master Service Dealer (MSD) certified.
• The person performing the service has access to a complete set of tools required for the job:• Appropriate Hand Tools• Appropriate Special Tools• Appropriate Technical Service Manual
1.2
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
2010 RANGER FLAT RATES2010 Models
Electric Vehicle Series
Please see LEV Flat Rate Manual
400 Carb Series
RANGER 400 4X4
500 EFI Series
RANGER 4X4
800 EFI Series
RANGER 4X4 XP
RANGER 4X4 HD
RANGER 4X4 CREW
RANGER 6X6
RZR Series
RANGER RZR / EPS
RANGER RZR S
RANGER RZR 4
RANGER RZR 170
1.3when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
2010 RANGER Flat Rate Content2010 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
400
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ RZR
S
RANGER
RZR
4
RANGER
RZR
170
EngineAir Box / Lid :12 :12 :12 :12 :12 :12 :12 :12Cam Chain / Timing Gears √ 2:30 2:30 4:30 4:30 4:30 8:00 8:00 6:48Cam Chain Tensioner :12 :12 ‐ ‐ ‐ :12 :12 :30Camshaft √ 2:00 2:00 6:00 6:00 6:00 8:00 8:00 :30Connecting Rod 6:42 6:42 ‐ ‐ ‐ 8:00 8:00 ‐Crankcase / Bearings √ 6:00 6:00 6:00 6:00 6:00 8:00 8:00 6:48Crankshaft / Counter Balancer √ 6:00 6:00 6:00 6:00 6:00 8:00 8:00 6:48Crankshaft Main Bearings (All) √ 6:30 6:30 6:30 6:30 6:30 8:00 8:00 6:48Crankshaft Seal ‐ LH (PTO) 1:00 1:00 6:00 6:00 6:00 8:00 8:00 6:48Crankshaft Seal ‐ RH (MAG) 1:30 1:30 1:30 1:30 1:30 7:00 7:00 1:18Cylinder / Cyl. Base Gasket √ 2:54 2:54 3:00 3:00 3:00 2:42 2:42 :46Cylinder Head / Gasket √ 2:42 2:42 2:48 2:48 2:48 2:30 2:30 :42
Cylinder Head Valve ‐ Each / Add :12 :12 :12 :12 :12 :12 :12 :12
Decompression Shaft / Spring :18 :18 ‐ ‐ ‐ ‐ ‐ :18Engine Mount ‐ Lower Front (RZR ‐ Lower Right) :24 :24 :24 :24 :24 :18 :18 ‐Engine Mount ‐ Upper (RZR ‐ Rear) :18 :18 :18 :18 :18 :30 :30 ‐Engine Mount ‐ Rear :36 :36 :36 :36 :36 ‐ ‐ ‐Engine Short Block (R&R) √ 3:00 3:00 3:30 3:30 3:30 6:30 6:30 2:48Exhaust ‐ Header Pipe / Manifold / Seals :48 :48 :48 :48 :48 :18 :18 ‐Exhaust ‐ Heat Shield :12 :12 :12 :12 :12 :06 :06 ‐Exhaust ‐ Silencer / Muffler :30 :30 :30 :30 :30 :18 :18 :18Oil Pump Gear / Components √ 6:00 6:00 6:00 6:00 6:00 8:00 8:00 1:48Piston and Rings (Twin Includes Both) √ 3:00 3:00 3:18 3:18 3:18 3:00 3:00 1:00Rocker Arms 1:18 1:18 :30 :30 :30 :30 :30 :18Thermostat :30 :30 :30 :30 :30 :30 :30 ‐Valve Cover / Gasket :24 :24 :24 :24 :24 :24 :24 :12Water Pump Impeller :42 :30 :30 :30 :30 :30 :30 ‐Water Pump Seal (pre autho on RZR only) √ 1:30 1:30 2:00 2:00 2:00 6:42 6:42 ‐
Oil SystemBreather Line or Filter (Not Warranty) :12 :12 :12 :12 :12 :12 :12 :18Oil Dipstick Tube ‐ ‐ :18 :18 :18 :18 :18 :12Oil Filter (Not Covered Under Warranty) :12 :12 :12 :12 :12 :12 :12 ‐Oil Line(s) :30 :30 ‐ ‐ ‐ ‐ ‐ ‐Oil Tank :30 :30 ‐ ‐ ‐ ‐ ‐ ‐
Cooling System (Includes Bleeding)Radiator :42 :48 :48 :48 :48 :42 :42 ‐Radiator Hoses 1:00 1:30 1:30 1:30 1:30 1:30 1:30 ‐Tank Vent Line :06 :06 :06 :06 :06 :06 :06 ‐
1.4Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Fuel Systems ‐ NON EFICarburetor Boot (Airbox Side) :18 ‐ ‐ ‐ ‐ ‐ ‐ :18
Carburetor Assembly :30 ‐ ‐ ‐ ‐ ‐ ‐ :18
Carburetor Components* √ 1:00 ‐ ‐ ‐ ‐ ‐ ‐ :36Carburetor Mount Adapter (Engine Side) √ :30 ‐ ‐ ‐ ‐ ‐ ‐ :18Choke Cable :18 ‐ ‐ ‐ ‐ ‐ ‐ :24Fuel Filter (Not Covered Under Warranty) :06 ‐ ‐ ‐ ‐ ‐ ‐ :06Fuel Line :12 ‐ ‐ ‐ ‐ ‐ ‐ :18Fuel Pump :12 ‐ ‐ ‐ ‐ ‐ ‐ :12Fuel Tank / Fittings / Sender √ :30 ‐ ‐ ‐ ‐ ‐ ‐ :30Throttle Cable :18 ‐ ‐ ‐ ‐ ‐ ‐ :24Throttle Pedal :18 ‐ ‐ ‐ ‐ ‐ ‐ :18Vent Lines :12 ‐ ‐ ‐ ‐ ‐ ‐ :18
Fuel Systems ‐ EFICrank Position Sensor (CPS)* ‐ 2:00 :18 :18 :18 1:00 1:00 ‐ECU* √ ‐ :30 :30 :30 :30 :30 :30 ‐Engine Temperature Sensor (Includes Bleeding)* ‐ :30 :30 :30 :30 :30 :30 ‐Fuel Tank / Fuel Pump / Sender Assembly* √ ‐ :30 :30 :30 :30 :30 :30 ‐IAC Valve* ‐ :12 ‐ ‐ ‐ ‐ ‐ ‐Injector(s)* √ ‐ :18 :18 :18 :18 :18 :18 ‐Intake Air Temperature (IAT) Sensor * ‐ :12 ‐ ‐ ‐ ‐ ‐ ‐Manifold Air Pressure (MAP) Sensor* ‐ :12 ‐ ‐ ‐ ‐ ‐ ‐Temp/Barometric Sensor (T‐Bap)* ‐ ‐ :12 :12 :12 :12 :12 ‐Throttle Body* √ ‐ :18 :18 :18 :18 :18 :18 ‐Throttle Cable ‐ :18 1:12 1:12 1:12 1:12 1:12 ‐Throttle Pedal ‐ :18 :18 :18 :18 :18 :18 ‐Throttle Position Sensor (TPS)* ‐ :18 :18 :18 :18 :24 :24 ‐Vent Lines ‐ :12 :12 :12 :12 :12 :12 ‐
2010 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
400
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ RZR
S
RANGER
RZR
4
RANGER
RZR
170
1.5when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Body & Frame (All times include decals)Bumper ‐ Front :12 :12 :12 :12 :12 ‐ ‐ ‐Bumper ‐ Front Facia :12 :12 :12 :12 :12 :12 :12 :12Bumper ‐ Rear Facia ‐ ‐ ‐ ‐ ‐ :18 :18 :12Box Assembly √ :30 :30 :30 :30 :30 :30 :30 :18Box Latch Assembly :12 :18 :18 :18 :18 ‐ ‐ ‐Box Shock :06 :06 :06 :06 :06 ‐ ‐ ‐Box ‐ Tailgate, Outer Panel √ :12 :12 :12 :12 :12 ‐ ‐ ‐Box ‐ Tailgate, Inner Panel √ :12 :24 :24 :24 :24 ‐ ‐ ‐Box ‐ Side Panel √ ‐ :12 :12 :12 :12 :12 :12 ‐Cab Frame (Per Section) √ :12 :12 :12 :12 :12 :12 :12 :12Dash Assembly ‐ (XP Lower) √ :36 :36 :36 :36 :36 ‐ ‐ ‐Floor ‐ Main/Front √ 1:30 1:30 1:30 1:30 1:30 1:48 :24 1:30Floor ‐ Center Panel / Console (each) √ :12 :12 :12 :12 :12 :12 :12 :12Floor ‐ Rear √ ‐ ‐ ‐ :48 ‐ ‐ 1:48 ‐Fender Flare (each) √ ‐ :06 :06 :06 :06 :06 :06 ‐Fender ‐ (Rocker / Side Panel) (each) √ :12 :12 :12 :12 :12 :12 :12 :12Frame ‐ Main √ 16:00 16:00 16:00 16:00 16:00 16:00 16:00 9:00Head Rest (Each) ‐ :06 :06 :06 :06 ‐‐ ‐‐ ‐Hood (RZR/XP ‐ Front Access Panel) √ :30 :12 :12 :12 :12 :12 :12 ‐Hood & Dash Assembly ‐ Upper (RZR/XP) √ :30 :30 :30 :30 :30 :48 :48 :30Hood Liner ‐ 1:00 1:00 1:00 1:00 ‐ ‐ ‐Hood Strap :06 ‐ ‐ ‐ ‐ ‐ ‐ ‐Rear Sub‐Frame √ ‐ ‐ ‐ ‐ 2:00 ‐ ‐ ‐Rear Close‐off panel (RZR ‐ behind seats) ‐ ‐ ‐ ‐ ‐ :12 :12 :12Seat Back √ :12 :18 :18 :18 :18 :12 :12 :12Seat Base √ :06 :06 :06 :06 :06 :12 :12 :12Seat Belt (Each) :12 :12 :12 :12 :12 :18 :18 :12Skid Plate √ :24 :24 :24 :24 :24 :24 :24 ‐Wheel Well Inner Panel (Each) √ :12 :12 :12 :12 :12 ‐ ‐ ‐
2010 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
400
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ RZR
S
RANGER
RZR
4
RANGER
RZR
170
1.6Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Electrical12 Volt Receptacle :12 :12 :12 :12 :12 :12 :12 ‐AWD / Rear Differential Switch :12 :12 :12 :12 :12 :12 :12 ‐Battery :12 :12 :12 :12 :12 :12 :12 :12Battery Cable (Both) :12 :12 :12 :12 :12 :12 :12 :18Circuit Breaker* :12 :12 :12 :12 :12 :12 :12 ‐Thermistor (Includes Bleeding Cooling System)* :30 :30 :30 :30 :30 :30 :30 ‐Fan Motor Assembly* :30 :54 :54 :54 :54 :18 :18 ‐Flywheel Magneto* :36 :36 :36 :36 :36 6:30 6:30 1:48Fuse* :06 :06 :06 :06 :06 :06 :06 :06Gear Position Switch (Transmission)* :12 :12 :12 :12 :12 :12 :12 6:00Harness (Box)* :12 :12 :12 :12 :12 :12 :12 ‐Harness (Chassis)* ‐ ‐ ‐ ‐ ‐ :12 :12 ‐Harness (Dash)* :12 :12 :12 :12 :12 ‐ ‐ ‐Harness (Headlight) ‐ :06 :06 :06 :06 ‐ ‐ ‐Harness (Main)* 2:00 2:00 2:00 2:00 2:00 2:00 2:00 2:12Headlight Assembly :12 :12 :12 :12 :12 :12 :12 :12Headlight Bulb (Each) (Not Warranty) :06 :06 :06 :06 :06 :06 :06 :06Hour Meter :18 :18 ‐ ‐ ‐ ‐ ‐ ‐Ignition Coil* :12 :12 :12 :12 :12 :12 :12 :18Ignition Switch* :12 :12 :12 :12 :12 :12 :12 :12Indicator Bulb / Instrument Bulb :12 :12 :12 :12 :12 :12 :12 :12Starter Solenoid :12 :12 :12 :12 :12 :12 :12 :18Parking Brake Indicator Light Switch ‐ :12 :12 :12 :12 ‐ ‐ :18PDM / Regulator / Rectifier* :12 :12 :12 :12 :12 :12 :12 :12Solenoid (Rear Gearcase)* :12 :12 :12 :12 :12 ‐ ‐ ‐Spark Plug (Each) (Not Covered Under Warranty) :06 :06 :06 :06 :06 :06 :06 :06Spark Plug Wire (Each) :06 :06 :06 :06 :06 :06 :06 :06Speedometer ‐ ‐ :18 :18 :18 :12 :12 ‐Starter Drive / Bendix :30 :30 :30 :30 :30 6:30 6:30 :48Starter Motor :30 :30 :30 :30 :30 :30 :30 :18Starter Motor Rebuild (Add to R&R of Starter) :18 :18 :18 :18 :18 :18 :18 :18Stator Assembly* 1:00 1:00 1:00 1:00 1:00 6:30 6:30 :48Tail Lamp Assembly :12 :12 :12 :12 :12 :12 :12 :06Tail Lamp Bulb :12 :12 :12 :12 :12 :12 :12 :06Terminal Block :12 :12 :12 :12 :12 ‐ ‐ ‐VCIM* :12 ‐ ‐ ‐ ‐ ‐ ‐ ‐Vehicle Speed Sensor* ‐ ‐ :18 :18 :18 :18 :18 ‐
2010 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
400
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ RZR
S
RANGER
RZR
4
RANGER
RZR
170
1.7when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Steering and Front SuspensionBall Joints (each) :42 :42 :42 :42 :42 :42 :42 ‐Front A‐Arm ‐ Upper √ ‐ :18 :18 :18 :18 :18 :18 ‐Front A‐Arm ‐ Lower :18 :18 :18 :18 :18 :18 :18 :18Front A‐Arm Bushing :18 :18 :18 :18 :18 :18 :18 :18Front Stabilizer Bar ‐ ‐ ‐ ‐ ‐ :24 :24 ‐Front Shock / Strut Cartridge (includes spring) :42 :18 :18 :18 :18 :18 :18 :12Front Shock Rebuild (Each; RZR S) ‐ ‐ ‐ ‐ ‐ :30 :30 ‐Front Strut Housing (Spindle Hub ‐ 2x4) 1:54 ‐ ‐ ‐ ‐ ‐ ‐ ‐Hub Bearings / Retaining Ring 1:18 ‐ ‐ ‐ ‐ ‐ ‐ 1:18Power Steering Unit Assembly (EPS)* (if equipped) √ ‐ ‐ 1:00 1:00 1:00 :24 :24 ‐Steering Rack Assembly (Includes Align) √ 1:48 2:00 2:00 2:00 2:00 2:00 2:00 1:12Steering Shaft (Lower) (W/EPS) 1:30 :18 :18 :18 :18 :18 (:30) :18 (:30) ‐Steering Shaft (Upper) (W/EPS) ‐ :30 :30 :30 :30 :30 (:18) :30 (:18) :30Steering Wheel :12 :24 :24 :24 :24 :24 :24 :06Tie Rod End (Each) :12 :12 :12 :12 :12 :12 :12 :12Tilt Steering Shock ‐ :12 :12 :12 :12 :12 :12 ‐
Independant Rear SuspensionA‐Arm (Rear Lower) :18 :30 :30 :30 :30 :30 :30 ‐A‐Arm (Rear Upper) :24 :30 :30 :30 :30 :30 :30 ‐A‐Arm Bushing (Includes All) (Add) :18 :18 :18 :18 :18 :18 :18 ‐Rear Bearing Carrier (Includes Bearing) :42 :42 :42 :42 :42 :42 :42 ‐Rear Carrier Bearing (Each) :42 :42 :42 :42 :42 :42 :42 ‐Shock / Spring (Each) :30 :30 :30 :30 :30 :30 :30 :12Shock Rebuild (Each; RZR S) ‐ ‐ ‐ ‐ ‐ :30 :30 ‐Stabilizer Bar :18 :18 :18 :18 :18 :18 :18 ‐
Swing Arm SuspensionAxle (Each ‐ Remove / Install) ‐ ‐ ‐ ‐ ‐ ‐ ‐ 1:12Axle Tube (Each ‐ Remove / Install) ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐Bearings ‐ Axle Tube (LH / RH) ‐ ‐ ‐ ‐ ‐ ‐ ‐ (:18 / :30)Swing Arm (Rear ‐ Remove / Install) ‐ ‐ ‐ ‐ ‐ ‐ ‐ 1:12Swing Arm Bushings ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
PVTAir Intake Duct :18 :12 :12 :30 :12 :30 :30 :18Air Outlet Duct :12 :12 :12 :30 :12 :30 :30 :18Cover Assy ‐ Inner (Includes Seal) 1:00 1:00 1:00 1:00 1:00 1:00 1:00 ‐Cover Assy ‐ Outer (Includes Seal) :18 :18 :18 :18 :18 :18 :18 :42Drive Belt * * :30 :30 :30 :30 :30 :30 :30 :42Drive Clutch Assembly √ :42 :42 :42 :42 :42 :42 :42 :42Drive Clutch Moveable Sheave Bushing 1:30 1:30 1:30 1:30 1:30 1:30 1:30 :42Drive Clutch Rollers 1:30 1:30 1:30 1:30 1:30 1:30 1:30 :42Drive Clutch Shift Weights :42 :42 :42 :42 :42 :42 :42 :42Driven Clutch ‐ Ramp Buttons / Rollers :48 :48 :48 :48 :48 :48 :48 :42Driven Clutch Assembly √ :30 :30 :30 :30 :30 :30 :30 :42Driven Clutch Moveable Sheave Bushing 1:00 1:00 1:00 1:00 1:00 1:00 1:00 ‐
**Please refer to your Drive Belt Analysis Poster (9920936) or the Drive Belt Analysis document on the Dealer Website before submitting a claim for a Drive Belt.
2010 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
400
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ RZR
S
RANGER
RZR
4
RANGER
RZR
170
1.8Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Transmission / Gear ShiftShift Linkage Cable :30 :30 :30 :30 :30 :30 :30 :30Shifter (Complete) :30 :30 :30 :30 :30 :30 :30 :18Transmission Assembly √ 2:00 2:00 2:00 2:12 2:12 7:00 7:00 :48Transmission Rebuild √ 3:30 3:30 3:30 3:42 3:42 8:00 8:00 1:48Transmission Output Shaft Bearing ‐ ‐ ‐ ‐ ‐ ‐ ‐ :30
Brakes (includes bleeding)Brake Caliper :24 :24 :24 :24 :24 :24 :24 :24Brake Disc (Each ‐ Front / Rear) √ :42 :42 :42 :42 :42 :42 :42 :30Brake Line (Front) :24 :42 :42 :42 :42 :42 :42 :18Brake Line (Rear) 1:00 1:12 1:12 1:12 1:12 1:12 1:12 :36Brake Pads (Not Covered Under Warranty) :30 :30 :30 :30 :30 :30 :30 :18Brake Pressure Switch :18 :30 :30 :30 :30 :30 :30 :30Brake Pedal :12 :12 :12 :12 :12 :12 :12 :12Master Cylinder Assembly :30 :42 :42 :42 :42 :42 :42 :36Parking Brake Caliper ‐ :24 :24 :24 :24 ‐ ‐ ‐Parking Brake Caliper Rebuild ‐ :48 :48 :48 :48 ‐ ‐ ‐Parking Brake Disc ‐ 1:00 1:00 :30 :48 ‐ ‐ ‐Parking Brake Handle ‐ :30 :30 :30 :30 ‐ ‐ :30Parking Brake Pads (Not Covered Under Warranty) ‐ :30 :30 :48 :30 ‐ ‐ ‐
Front Drive (excludes 2X4)CV Boot √ 1:00 :42 :42 :42 :42 :42 :42 ‐CV Boot Shield :12 :12 :12 :12 :12 :12 :12 ‐Driveshaft Seal 1:30 1:30 1:30 1:30 1:30 1:30 1:30 ‐Front Drive Shaft CV Joint 1:00 :42 :42 :42 :42 :42 :42 ‐Front Drive Shaft Assembly :42 :24 :24 :24 :24 :24 :24 ‐Front Gearcase / Cent Hilliard 1:30 1:30 1:30 1:30 1:30 1:30 1:30 ‐Front Hub / Bearings 1:18 1:18 1:18 1:18 1:18 1:18 1:18 ‐Front Gearcase Components * 2:00 2:00 2:00 2:00 2:00 2:00 2:00 ‐Prop Shaft Front :30 :30 :30 :30 :30 :54 :30 ‐Prop Shaft U‐Joints (Each‐Add to Prop Shaft) :12 :12 :12 :12 :12 :12 :12 ‐
Prop Shaft Yoke (Each‐Add to Prop Shaft Removal) :12 :12 :12 :12 :12 :12 :12 ‐Final Drive / Shaft Drive / Gear Shift
Gear Selector Handle Assembly :30 :30 :30 :30 :30 :30 :30 :30Propshaft Pillow Block / Bearing ‐ ‐ ‐ :24 ‐ ‐ :24 ‐Mid Gearcase Assembly ‐ ‐ ‐ ‐ :48 ‐ ‐ ‐Propshaft (Rear) ‐ ‐ ‐ :30 :30 ‐ ‐ ‐Propshaft / U‐Joints / Yoke ‐ :30 :30 :30 :30 ‐ ‐ ‐Rear CV / Plunging Joint :42 :42 :42 :42 :42 :42 :42 ‐Rear Drive Shaft :24 :24 :24 :24 :24 :24 :24 ‐Rear Drive Shaft Boot :42 :42 :42 :42 :42 :42 :42 ‐Rear Gear Case Assembly √ ‐ ‐ ‐ ‐ 1:12 1:30 1:30 ‐Rear Hub Carrier :42 1:00 1:00 1:00 1:00 1:00 1:00 ‐Rear Wheel Hub :24 :18 :18 :18 :18 :18 :18 :12Seals ‐ Axle Housing / Gearcase ‐ 1:00 1:00 1:00 1:00 1:00 1:00 ‐Shift Linkage Cable / Bell Crank :30 :30 :30 :30 :30 :18 :18 :30Tire / Wheel (Includes Mounting) √ :18 :18 :18 :18 :18 :18 :18 :18
2010 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
400
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ RZR
S
RANGER
RZR
4
RANGER
RZR
170
1.9when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
2009 RANGER FLAT RATES2009 Models500 Series
RANGER 2X4
RANGER 4X4
700 Series
RANGER 4X4 XP
RANGER 4X4 HD
RANGER 4X4 CREW
RANGER 6X6
RZR Series
RANGER RZR
RANGER RZR S
RANGER RZR 170
1.10Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
2009 RANGER Flat Rate Content
2009 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
2x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ (R
ZR S)
RANGER
RZR
170
EngineAir Box / Lid :12 :12 :12 :12 :12 :12 :12Cam Chain / Timing Gears √ 2:30 2:30 4:30 4:30 4:30 8:00 6:48Cam Chain Tensioner :12 :12 ‐ ‐ ‐ :12 :30Camshaft √ 2:00 2:00 6:00 6:00 6:00 8:00 :30Connecting Rod 6:42 6:42 ‐ ‐ ‐ 8:00 ‐Crankcase / Bearings √ 6:00 6:00 6:00 6:00 6:00 8:00 6:48Crankshaft / Counter Balancer √ 6:00 6:00 6:00 6:00 6:00 8:00 6:48Crankshaft Main Bearings (All) √ 6:30 6:30 6:30 6:30 6:30 8:00 6:48Crankshaft Seal ‐ LH (PTO) 1:00 1:00 6:00 6:00 6:00 8:00 6:48Crankshaft Seal ‐ RH (MAG) 1:30 1:30 1:30 1:30 1:30 7:00 1:18Cylinder / Cyl. Base Gasket √ 2:54 2:54 3:00 3:00 3:18 2:42 :46Cylinder Head / Gasket √ 2:42 2:42 2:48 2:48 3:06 2:30 :42
Cylinder Head Valve ‐ Each / Add :12 :12 :12 :12 :12 :12 :12
Decompression Shaft / Spring :18 :18 ‐ ‐ ‐ ‐ :18Engine Mount ‐ Lower Front (RZR ‐ Lower Right) :24 :24 :24 :24 :24 :18 ‐Engine Mount ‐ Upper (RZR ‐ Rear) :18 :18 :18 :18 :18 :30 ‐Engine Mount ‐ Rear :36 :36 :36 :36 :36 ‐ ‐Engine Short Block (R&R) √ 3:00 3:00 3:30 3:30 3:42 6:30 2:48Exhaust ‐ Header Pipe / Manifold / Seals :48 :48 :48 :48 :48 :18 ‐Exhaust ‐ Heat Shield :12 :12 :12 :12 :12 :06 ‐Exhaust ‐ Silencer / Muffler :30 :30 :30 :30 :30 :18 :18Oil Pump Gear / Components √ 6:00 6:00 6:00 6:00 6:00 8:00 1:48Piston and Rings (Twin Includes Both) √ 3:00 3:00 3:18 3:18 3:36 3:00 1:00Rocker Arms 1:18 1:18 :30 :30 :30 :30 :18Thermostat :30 :30 :30 :30 :30 :30 ‐Valve Cover / Gasket :24 :24 :24 :24 :24 :24 :12Water Pump Impeller :30 :30 :30 :30 :30 :30 ‐Water Pump Seal (pre autho on RZR only) √ 1:30 1:30 2:00 2:00 2:00 6:42 ‐
Oil SystemBreather Line or Filter (Not Warranty) :12 :12 :12 :12 :12 :12 :18Oil Dipstick Tube ‐ ‐ :18 :18 :18 :18 :12Oil Filter (Not Covered Under Warranty) :12 :12 :12 :12 :12 :12 ‐Oil Line(s) :30 :30 ‐ ‐ ‐ ‐ ‐Oil Tank :30 :30 ‐ ‐ ‐ ‐ ‐
Cooling System (Includes Bleeding)Radiator 1:00 :48 :48 1:00 1:00 :42 ‐Radiator Hoses 1:30 1:30 1:30 1:30 1:30 1:30 ‐Tank Vent Line :06 :06 :06 :06 :06 :06 ‐
1.11when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Fuel Systems ‐ NON EFICarburetor Boot (Airbox Side) :30 ‐ ‐ ‐ ‐ ‐ :18
Carburetor Assembly :42 ‐ :18
Carburetor Components* √ 1:00 ‐ ‐ ‐ ‐ ‐ :36Carburetor Mount Adapter (Engine Side) √ :36 ‐ ‐ ‐ ‐ ‐ :18Choke Cable :18 ‐ ‐ ‐ ‐ ‐ :24Fuel Filter (Not Covered Under Warranty) :06 ‐ ‐ ‐ ‐ ‐ :06Fuel Line :12 ‐ ‐ ‐ ‐ ‐ :18Fuel Pump :18 ‐ ‐ ‐ ‐ ‐ :12Fuel Tank / Fittings / Sender √ :30 ‐ ‐ ‐ ‐ ‐ :30Throttle Cable :18 ‐ ‐ ‐ ‐ ‐ :24Throttle Pedal :18 ‐ ‐ ‐ ‐ ‐ :18Vent Lines :12 ‐ ‐ ‐ ‐ ‐ :18
Fuel Systems ‐ EFICrank Position Sensor (CPS)* ‐ 2:00 :18 :18 :18 1:00 ‐ECU* √ ‐ :30 :30 :30 :30 :30 ‐Engine Temperature Sensor (Includes Bleeding)* ‐ :30 :30 :30 :30 :30 ‐Fuel Tank / Fuel Pump / Sender Assembly* √ ‐ :30 :30 :30 :30 :30 ‐IAC Valve* ‐ :12 ‐ ‐ ‐ ‐ ‐Injector(s)* √ ‐ :18 :18 :18 :18 :18 ‐Intake Air Temperature (IAT) Sensor * ‐ :12 ‐ ‐ ‐ ‐ ‐Manifold Air Pressure (MAP) Sensor* ‐ :12 ‐ ‐ ‐ ‐ ‐Temp/Barometric Sensor (T‐Bap)* ‐ ‐ :12 :12 :12 :12 ‐Throttle Body* √ ‐ :18 :18 :18 :18 :18 ‐Throttle Cable ‐ 1:12 1:12 :18 :18 1:12 ‐Throttle Pedal ‐ :18 :18 :18 :18 :18 ‐Throttle Position Sensor (TPS)* ‐ :18 :18 :18 :18 :24 ‐Vent Lines ‐ :12 :12 :12 :12 :12 ‐
2009 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
2x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ (R
ZR S)
RANGER
RZR
170
1.12Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Body & Frame (All times include decals)Bumper ‐ Front :12 :12 :12 :12 :12 ‐ ‐Bumper ‐ Front Facia :12 :12 :12 :12 :12 :12 :12Bumper ‐ Rear Facia ‐ ‐ ‐ ‐ ‐ :18 :12Box Assembly √ :30 :30 :30 :30 :30 :30 :18Box Latch Assembly :18 :18 :18 :18 :18 ‐ ‐Box Shock :06 :06 :06 :06 :06 ‐ ‐Box ‐ Tailgate, Outer Panel √ :12 :12 :12 :12 :12 ‐ ‐Box ‐ Tailgate, Inner Panel √ :24 :24 :24 :24 :24 ‐ ‐Box ‐ Side Panel √ :12 :12 :12 :12 :12 :12 ‐Cab Frame (Per Section) √ :12 :12 :12 :12 :12 :12 :12Dash Assembly ‐ (XP Lower) √ 1:18 :36 :36 1:18 1:18 ‐ ‐Floor ‐ Main √ 1:48 1:30 1:30 1:48 1:48 1:48 1:30Floor ‐ Center Panel / Console (each) √ :12 :12 :12 :12 :12 :12 :12Floor ‐ Rear √ ‐ ‐ ‐ :12 ‐ ‐ ‐Fender Flare (each) √ ‐ :06 :06 ‐ ‐ :06 ‐Fender ‐ (Rocker / Side Panel) (each) √ :12 :12 :12 :12 :12 :12 :12Frame ‐ Main √ 16:00 16:00 16:00 16:00 16:00 16:00 9:00Head Rest (Each) :06 :06 :06 :06 :06 ‐‐ ‐Hood (RZR/XP ‐ Front Access Panel) √ :30 :12 :12 :30 :30 :12 ‐Hood & Dash Assembly ‐ Upper (RZR/XP) √ ‐ :30 :30 ‐ ‐ :48 :30Hood Liner :30 1:00 1:00 :30 :30 ‐ ‐Hood Strap :06 ‐ ‐ :06 :06 ‐ ‐Rear Sub‐Frame √ ‐ ‐ ‐ 2:00 2:00 ‐ ‐Rear Close‐off panel (RZR ‐ behind seats) ‐ ‐ ‐ ‐ ‐ :12 :12Seat Back √ :18 :18 :18 :18 :18 :12 :12Seat Base √ :06 :06 :06 :06 :06 :12 :12Seat Belt (Each) :12 :12 :12 :12 :12 :18 :12Skid Plate √ :24 :24 :24 :24 :24 :24 ‐Wheel Well Inner Panel (Each) √ :12 :12 :12 :12 :12 ‐ ‐
2009 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
2x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ (R
ZR S)
RANGER
RZR
170
1.13when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Electrical12 Volt Receptacle :12 :12 :12 :12 :12 :12 ‐AWD / Rear Differential Switch :12 :12 :12 :12 :12 :12 ‐Battery :12 :12 :12 :12 :12 :12 :12Battery Cable (Both) :12 :12 :12 :12 :12 :12 :18Circuit Breaker* :12 :12 :12 :12 :12 :12 ‐Thermistor (Includes Bleeding Cooling System)* :30 :30 :30 :30 :30 :30 ‐Fan Motor Assembly* :30 :54 :54 :30 :30 :18 ‐Flywheel Magneto* :36 :36 :36 :36 :36 6:30 1:48Fuse* :06 :06 :06 :06 :06 :06 :06Gear Position Switch (Transmission)* :12 :12 :12 :12 :12 :12 6:00Harness (Box)* :12 :12 :12 :12 :12 :12 ‐Harness (Chassis)* ‐ ‐ ‐ ‐ ‐ :12 ‐Harness (Dash)* :12 :12 :12 :12 :12 ‐ ‐Harness (Headlight) :06 :06 :06 :06 :06 ‐ ‐Harness (Main)* 2:00 2:00 2:00 2:00 2:00 2:00 2:12Headlight Assembly :12 :12 :12 :12 :12 :12 :12Headlight Bulb (Each) (Not Warranty) :06 :06 :06 :06 :06 :06 :06Hour Meter :18 :18 ‐ ‐ ‐ ‐ ‐Ignition Coil* :12 :12 :12 :12 :12 :12 :18Ignition Switch* :12 :12 :12 :12 :12 :12 :12Indicator Bulb / Instrument Bulb :12 :12 :12 :12 :12 :12 :12Starter Solenoid :12 :12 :12 :12 :12 :12 :18Parking Brake Indicator Light Switch :12 :12 :12 :12 :12 ‐ :18PDM / Regulator / Rectifier* :12 :12 :12 :12 :12 :12 :12Solenoid (Rear Gearcase)* :12 :12 :12 :12 ‐ ‐ ‐Spark Plug (Each) (Not Covered Under Warranty) :06 :06 :06 :06 :06 :06 :06Spark Plug Wire (Each) ‐ :06 :06 :06 :06 :06 :06Speedometer ‐ ‐ :18 :18 :18 :12 ‐Starter Drive / Bendix :30 :30 :30 :30 :30 6:30 :48Starter Motor :30 :30 :30 :30 :30 :30 :18Starter Motor Rebuild (Add to R&R of Starter) :18 :18 :18 :18 :18 :18 :18Stator Assembly* 1:00 1:00 1:00 1:00 1:00 6:30 :48Tail Lamp Assembly :12 :12 :12 :12 :12 :12 :06Tail Lamp Bulb :12 :12 :12 :12 :12 :12 :06Terminal Block :12 :12 :12 :12 :12 ‐ ‐Vehicle Speed Sensor* ‐ ‐ :18 :18 :18 :18 ‐
2009 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
2x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ (R
ZR S)
RANGER
RZR
170
1.14Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Steering and Front SuspensionBall Joints (each) :42 :42 :42 :42 :42 :42 ‐Front A‐Arm ‐ Upper √ ‐ :18 :18 ‐ ‐ :18 ‐Front A‐Arm ‐ Lower :30 :18 :18 :30 :30 :18 :18Front A‐Arm Bushing :30 :18 :18 :30 :30 :18 :18Front Stabilizer Bar ‐ ‐ ‐ ‐ ‐ :24 ‐Front Shock / Strut Cartridge (includes spring) :42 :18 :18 :42 :42 :18 :12Front Shock Rebuild (Each; RZR S) ‐ ‐ ‐ ‐ ‐ :30 ‐Front Strut Housing (Spindle Hub ‐ 2x4) 1:54 ‐ ‐ 1:54 1:54 ‐ ‐Hub Bearings / Retaining Ring 1:18 ‐ ‐ 1:18 1:18 ‐ 1:18Power Steering Unit Assembly (EPS)* √ ‐ ‐ 1:00 ‐ ‐ ‐ ‐Steering Rack Assembly (Includes Align) √ 2:00 2:00 2:00 2:00 2:00 2:00 1:12Steering Shaft (Lower) :18 :18 :18 :18 :18 :18 ‐Steering Shaft (Upper) :30 :30 :30 :30 :30 :30 :30Steering Wheel :24 :24 :24 :24 :24 :24 :06Tie Rod End (Each) :12 :12 :12 :12 :12 :12 :12Tilt Steering Shock ‐ :12 :12 ‐ ‐ :12 ‐
Independant Rear SuspensionA‐Arm (Rear Lower) :30 :30 :30 :30 :30 :30 ‐A‐Arm (Rear Upper) :30 :30 :30 :30 :30 :30 ‐A‐Arm Bushing (Includes All) :18 :18 :18 :18 :18 :18 ‐Rear Bearing Carrier (Includes Bearing) :42 :42 :42 :42 :42 :42 ‐Rear Carrier Bearing (Each) :42 :42 :42 :42 :42 :42 ‐Shock / Spring (Each) :30 :30 :30 :30 :30 :30 :12Shock Rebuild (Each; RZR S) ‐ ‐ ‐ ‐ ‐ :30 ‐Stabilizer Bar :18 :18 :18 :18 ‐ :18 ‐
Swing Arm SuspensionAxle (Each ‐ Remove / Install) ‐ ‐ ‐ ‐ 1:12 ‐ 1:12Axle Tube (Each ‐ Remove / Install) ‐ ‐ ‐ ‐ 1:12 ‐ ‐Bearings ‐ Axle Tube (LH / RH) ‐ ‐ ‐ ‐ :42 ‐ (:18 / :30)Swing Arm (Rear ‐ Remove / Install) ‐ ‐ ‐ ‐ 1:30 ‐ 1:12Swing Arm Bushings ‐ ‐ ‐ ‐ 1:00 ‐ ‐
PVTAir Intake Duct :30 :12 :12 :30 :30 :30 :18Air Outlet Duct :30 :12 :12 :30 :30 :30 :18Cover Assy ‐ Inner (Includes Seal) 1:00 1:00 1:00 1:00 1:00 1:00 ‐Cover Assy ‐ Outer (Includes Seal) :18 :18 :18 :18 :18 :18 :42Drive Belt * * :30 :30 :30 :30 :30 :30 :42Drive Clutch Assembly √ :42 :42 :42 :42 :42 :42 :42Drive Clutch Moveable Sheave Bushing 1:30 1:30 1:30 1:30 1:30 1:30 :42Drive Clutch Rollers 1:30 1:30 1:30 1:30 1:30 1:30 :42Drive Clutch Shift Weights :42 :42 :42 :42 :42 :42 :42Driven Clutch ‐ Ramp Buttons / Rollers :48 :48 :48 :48 :48 :48 :42Driven Clutch Assembly √ :30 :30 :30 :30 :30 :30 :42Driven Clutch Moveable Sheave Bushing 1:00 1:00 1:00 1:00 1:00 1:00 ‐
**Please refer to your Drive Belt Analysis Poster (9920936) or the Drive Belt Analysis document on the Dealer Website before submitting a claim for a Drive Belt.
2009 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
2x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ (R
ZR S)
RANGER
RZR
170
1.15when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Transmission / Gear ShiftShift Linkage Cable :30 :30 :30 :30 :30 :30 :30Shifter (Complete) :30 :30 :30 :30 :30 :30 :18Transmission Assembly √ 2:00 2:00 2:00 2:00 2:00 7:00 :48Transmission Rebuild √ 3:00 3:00 3:00 3:00 3:00 8:00 1:48Transmission Output Shaft Bearing 1:12 1:12 1:12 1:12 1:12 ‐ :30
Brakes (includes bleeding)Brake Caliper :24 :24 :24 :24 :24 :24 :24Brake Disc (Each ‐ Front / Rear) √ :42 :42 :42 :42 :42 :42 :30Brake Line (Front) :42 :42 :42 :42 :42 :42 :18Brake Line (Rear) 1:12 1:12 1:12 1:12 1:12 1:12 :36Brake Pads (Not Covered Under Warranty) :30 :30 :30 :30 :30 :30 :18Brake Pressure Switch :30 :30 :30 :30 :30 :30 :30Brake Pedal :12 :12 :12 :12 :12 :12 :12Master Cylinder Assembly :42 :42 :42 :42 :42 :42 :36Parking Brake Caliper :24 :24 :24 :24 :24 ‐ ‐Parking Brake Caliper Rebuild :48 :48 :48 :48 :48 ‐ ‐Parking Brake Disc 1:00 1:00 1:00 1:00 1:00 ‐ ‐Parking Brake Handle :30 :30 :30 :30 :30 ‐ :30Parking Brake Pads (Not Covered Under Warranty) :30 :30 :30 :30 :30 ‐ ‐
Front Drive (excludes 2X4)CV Boot √ ‐ :42 :42 1:00 1:00 :42 ‐CV Boot Shield ‐ :12 :12 :12 :12 :12 ‐Driveshaft Seal ‐ 1:30 1:30 1:30 1:30 1:30 ‐Front Drive Shaft CV Joint ‐ :42 :42 1:00 1:00 :42 ‐Front Drive Shaft Assembly ‐ :24 :24 :42 :42 :24 ‐Front Gearcase / Cent Hilliard ‐ 1:30 1:30 1:30 1:30 1:30 ‐Front Hub / Bearings ‐ 1:18 1:18 1:18 1:18 1:18 ‐Front Gearcase Components * ‐ 2:00 2:00 2:00 2:00 2:00 ‐Prop Shaft Front ‐ :30 :30 :30 :30 :54 ‐Prop Shaft U‐Joints (Each‐Add to Prop Shaft) ‐ :12 :12 :12 :12 :12 ‐
Prop Shaft Yoke (Each‐Add to Prop Shaft Removal) ‐ :12 :12 :12 :12 :12 ‐
Final Drive / Shaft Drive / Gear Shift
Gear Selector Handle Assembly :30 :30 :30 :30 :30 :30 :30Gearcase Components ‐ Add :18 :18 :18 :18 :18 ‐ ‐Mid Gearcase Assembly ‐ ‐ ‐ ‐ 1:12 ‐ ‐Propshaft (Rear) :30 :30 :30 :30 :30 ‐ ‐Propshaft / U‐Joints / Yoke :30 :30 :30 :30 :30 ‐ ‐Rear CV / Plunging Joint :42 :42 :42 :42 :42 :42 ‐Rear Drive Shaft :24 :24 :24 :24 :24 :24 ‐Rear Drive Shaft Boot :42 :42 :42 :42 :42 :42 ‐Rear Gear Case Assembly √ 1:12 1:12 1:12 1:12 1:12 1:30 (1:42) ‐Rear Hub Carrier 1:00 1:00 1:00 1:00 1:00 1:00 ‐Rear Wheel Hub :18 :18 :18 :18 :18 :18 :12Seals ‐ Axle Housing / Gearcase 1:00 1:00 1:00 1:00 1:00 1:00 ‐Shift Linkage Cable / Bell Crank :30 :30 :30 :30 :30 :18 :30Tire / Wheel (Includes Mounting) √ :18 :18 :18 :18 :18 :18 :18
2009 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
2x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / HD
RANGER
4x4 Crew
RANGER
6x6
RANGER
RZR
/ (R
ZR S)
RANGER
RZR
170
1.16Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
2006 / 2007 / 2008 RANGER FLAT RATES2006 Models
2007 Models
2008 Models
RANGER TM
RANGER 2X4
RANGER 4X4
RANGER 4X4 XP
RANGER 6X6
RANGER 4X4 500 EFI
RANGER 2X4
RANGER 4X4 500 Carb
RANGER 4X4 500 EFI
RANGER 4X4 XP
RANGER 6X6
RANGER RZR 4X4
RANGER 2X4
RANGER 4X4 500 EFI
RANGER 4X4 XP
RANGER 6X6
RANGER 4X4 CREW
1.17when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
2006 / 2007 / 2008 RANGER Flat Rate Content2006 / 2007 / 2008 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
Carb 2x4 / 4x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / Crew
RANGER
6x6
RANGER
RZR
EngineAir Box / Lid :12 :12 :12 :12 :12Cam Chain / Timing Gears ÷ 2:30 2:30 4:30 4:30 8:00Cam Chain Tensioner :12 :12 ‐ ‐ :12Camshaft ÷ 2:00 2:00 6:00 6:00 8:00Connecting Rod 6:42 6:42 ‐ ‐ 8:00Crankcase / Bearings ÷ 6:00 6:00 6:00 6:00 8:00Crankshaft / Counter Balancer ÷ 6:00 6:00 6:00 6:00 8:00Crankshaft Main Bearings (All) ÷ 6:30 6:30 6:30 6:30 8:00Crankshaft Seal ‐ LH (PTO) 1:00 1:00 6:00 6:00 8:00Crankshaft Seal ‐ RH (MAG) 1:30 1:30 6:00 6:00 8:00Cylinder / Cyl. Base Gasket ÷ 2:54 2:54 3:00 3:18 2:42Cylinder Head / Gasket ÷ 2:42 2:42 2:48 3:06 2:30Cylinder Head Valve ‐ Each / Add :12 :12 :12 :12 :12Decompression Shaft / Spring :18 :18 ‐ ‐ ‐Engine Mount ‐ Lower Front (RZR ‐ Lower Right) :24 :24 :24 :24 :18Engine Mount ‐ Upper (RZR ‐ Rear) :18 :18 :18 :18 :30Engine Mount ‐ Rear :36 :36 :36 :36 ‐Engine Short Block (R&R) ÷ 3:00 3:00 3:30 3:42 6:30Exhaust ‐ Header Pipe / Manifold / Seals :48 :48 :48 :48 :18Exhaust ‐ Heat Shield :12 :12 :12 :12 :06Exhaust ‐ Silencer / Muffler :30 :30 :30 :30 :18Oil Line(s) :30 :30 ‐ ‐ ‐Oil Pump Gear / Components ÷ 6:00 6:00 6:00 6:00 8:00Piston and Rings (Twin Includes Both) ÷ 3:00 3:00 3:18 3:36 3:00Rocker Arms 1:18 1:18 :30 :30 :30Thermostat Valve Cover / Gasket :24 :24 :24 :24 :24Water Pump Impeller :30 :30 :30 :30 :30Water Pump Seal (pre autho on RZR only) ÷ 1:30 1:30 2:00 2:00 6:42
Oil SystemBreather Line or Filter (Not Covered Under Warranty)
:12 :12 :12 :12 :12
Oil Dipstick Tube ‐ ‐ :18 :18 :18Oil Filter (Not Covered Under Warranty) :12 :12 :12 :12 :12Oil Line(s) :30 :30 ‐ ‐ ‐Oil Tank :30 :30 ‐ ‐ ‐
Cooling System (Includes bleeding)Radiator 1:00 1:00 1:00 1:00 :42Radiator Hoses 1:30 1:30 1:30 1:30 1:30Tank Vent Line :06 :06 :06 :06 :06
1.18Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Fuel Systems ‐ NON EFICarburetor Boot (Airbox Side) :30 ‐ ‐ ‐ ‐Carburetor Components* √ 1:00 ‐ ‐ ‐ ‐Carburetor Mount Adapter (Engine Side) √ :36 ‐ ‐ ‐ ‐Choke Cable :18 ‐ ‐ ‐ ‐Fuel Filter (Not Covered Under Warranty) :06 ‐ ‐ ‐ ‐Fuel Line :12 ‐ ‐ ‐ ‐Fuel Pump :18 ‐ ‐ ‐ ‐Fuel Tank / Fittings / Sender √ :30 ‐ ‐ ‐ ‐Throttle Cable :18 ‐ ‐ ‐ ‐Throttle Pedal :18 ‐ ‐ ‐ ‐Vent Lines :12 ‐ ‐ ‐ ‐Carburetor Boot (Airbox Side) :30 ‐ ‐ ‐ ‐Carburetor Components* √ 1:00 ‐ ‐ ‐ ‐
Fuel Systems ‐ EFICrank Position Sensor (CPS)* ‐ 2:00 :18 :18 1:00ECU* √ ‐ :30 :30 :30 :30Engine Temperature Sensor (Includes Bleeding)* ‐ :30 :30 :30 :30Fuel Tank / Fuel Pump / Sender Assembly* √ ‐ :30 :30 :30 :30IAC Valve* ‐ :12 ‐ ‐ ‐Injector(s)* √ ‐ :18 :18 :18 :18Intake Air Temperature (IAT) Sensor * ‐ :12 ‐ ‐ ‐Manifold Air Pressure (MAP) Sensor* ‐ :12 ‐ ‐ ‐Temp/Barometric Sensor (T‐Bap)* ‐ ‐ :12 :12 :12Throttle Body* √ ‐ :18 :18 :18 :18Throttle Cable ‐ :18 :18 :18 1:12Throttle Pedal ‐ :18 :18 :18 :18Throttle Position Sensor (TPS)* ‐ :18 :18 :18 :24Vent Lines ‐ :12 :12 :12 :12
2006 / 2007 / 2008 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
Carb 2x4 / 4x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / Crew
RANGER
6x6
RANGER
RZR
1.19when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Body & Frame (all times include decals)Bumper ‐ Front :12 :12 :12 :12 :12Bumper ‐ Rear ‐ ‐ ‐ ‐ :18Cab Frame (Per Section) √ :12 :12 :12 :12 :12Cargo Box Assembly (RZR) √ ‐ ‐ ‐ ‐ :30Center Console (RZR) √ ‐ ‐ ‐ ‐ :12Dash Assembly √ 1:18 1:18 1:18 1:18 ‐Dump Box Latch Assembly :18 :18 :18 :18 ‐Dump Box Shock :06 :06 :06 :06 ‐Frame ‐ Main √ 16:00 16:00 16:00 16:00 16:00Front Wheel Well Panel (Each) √ :12 :12 :12 :12 ‐‐Head Rest (Each) :06 :06 :06 :06 ‐‐Hood (Includes Decals) (RZR ‐ Front Access Panel) √ :30 :30 :30 :30 :12Hood & Dash Assembly (RZR) √ ‐ ‐ ‐ ‐ :48Hood Liner :30 :30 :30 :30 ‐Hood Strap :06 :06 :06 :06 ‐Main Floor (Includes Floor Cover) √ 1:48 1:48 1:48 1:48 1:48Rear Fender Panel (Each) √ :12 :12 :12 :12 :12Rear Sub‐Frame √ 2:00 2:00 2:00 2:00 ‐Rear Close‐off panel (RZR ‐ behind seats) ‐ ‐ ‐ ‐ :12Seat Back √ :18 :18 :18 :18 :12Seat Base √ :06 :06 :06 :06 :12Seat Belt (Each) :12 :12 :12 :12 :18Skid Plate √ :24 :24 :24 :24 :24
2006 / 2007 / 2008 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
Carb 2x4 / 4x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / Crew
RANGER
6x6
RANGER
RZR
1.20Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Electrical12 Volt Receptacle :12 :12 :12 :12 :12AWD / Rear Differential Switch :12 :12 :12 :12 :12Battery :12 :12 :12 :12 :12Battery Cable (Both) :12 :12 :12 :12 :12Brake Pressure Switch (Includes Bleeding) :30 :30 :30 :30 :30Circuit Breaker* :12 :12 :12 :12 :12Thermistor (Includes Bleeding Cooling System)* :30 :30 :30 :30 :30Fan Motor Assembly* :30 :30 :30 :30 :18Flywheel Magneto* :36 :36 :36 :36 6:30Fuse* :06 :06 :06 :06 :06Gear Position Switch (Transmission)* :12 :12 :12 :12 :12Harness (Box)* :12 :12 :12 :12 :12Harness (Chassis)* ‐ ‐ ‐ ‐ :12Harness (Dash)* :12 :12 :12 :12 ‐Harness (Headlight) :06 :06 :06 :06 ‐Harness (Main)* 2:00 2:00 2:00 2:00 2:00Headlight Assembly :12 :12 :12 :12 :12Headlight Bulb (Each) (Not Covered Under Warranty)
:06 :06 :06 :06 :06
Hour Meter :18 :18 ‐ ‐ ‐Ignition Coil* :12 :12 :12 :12 :12Ignition Switch* :12 :12 :12 :12 :12Indicator Bulb / Instrument Bulb :12 :12 :12 :12 :12Starter Solenoid :12 :12 :12 :12 :12Parking Brake Indicator Light Switch :12 :12 :12 :12 ‐PDM / Regulator / Rectifier* :12 :12 :12 :12 :12Solenoid (Rear Gearcase) :12 :12 :12 ‐ ‐Spark Plug (Each) (Not Covered Under Warranty) :06 :06 :06 :06 :06Spark Plug Wire (Each) ‐ :06 :06 :06 :06Speedometer ‐ ‐ :18 :18 :12Starter Drive / Bendix :30 :30 :30 :30 6:30Starter Motor :30 :30 :30 :30 :30Starter Motor Rebuild (Add to R&R of Starter) :18 :18 :18 :18 :18Stator Assembly* 1:00 1:00 1:00 1:00 6:30Tail Lamp Assembly :12 :12 :12 :12 :12Tail Lamp Bulb :12 :12 :12 :12 :12Terminal Block :12 :12 :12 :12 ‐Vehicle Speed Sensor (RZR) ‐ ‐ ‐ ‐ :18Wheel Speed Sensor* ‐ ‐ :18 :18 ‐
2006 / 2007 / 2008 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
Carb 2x4 / 4x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / Crew
RANGER
6x6
RANGER
RZR
1.21when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Steering & Front SuspensionBall Joints (Strut) :42 :42 :42 :42 ‐Front A‐Arm ÷ :30 :30 :30 :30 :30Front A‐Arm Bushing :30 :30 :30 :30 :30Front Stabilizer Bar :24Front Strut Cartridge :42 :42 :42 :42 :42Front Strut Housing (Spindle Hub ‐ 2x4) 1:54 1:54 1:54 1:54 ‐Hub Bearings / Retaining Ring 1:18 1:18 1:18 1:18 ‐Prop Shaft Front :30 :30 :30 :30 :54Prop Shaft U‐Joints (Each‐Add to Prop Shaft) Removal)
:12 :12 :12 :12 :12
Prop Shaft Yoke (Each‐Add to Prop Shaft Removal) :12 :12 :12 :12 :12Steering Rack Assembly (Includes Align) ÷ 2:00 2:00 2:00 2:00 2:00Steering Shaft (Lower) :18 :18 :18 :18 :18Steering Shaft (Upper) :30 :30 :30 :30 :30Steering Wheel :24 :24 :24 :24 :24Strut Spring :24 :24 :24 :24 :24Tie Rod End (Each) :12 :12 :12 :12 :12
Independant Rear SuspensionA‐Arm (Rear Lower) :30 :30 :30 :30 :30A‐Arm (Rear Upper) :30 :30 :30 :30 :30A‐Arm Bushing (Includes All) :18 :18 :18 :18 :18Rear Bearing Carrier (Includes Bearing) :42 :42 :42 :42 :42Rear Carrier Bearing (Each) :42 :42 :42 :42 :42Shock / Spring (Each) :30 :30 :30 :30 :30Stabilizer Bar :18 :18 :18 ‐ :18A‐Arm (Rear Lower) :30 :30 :30 :30 :30
Swing Arm SuspensionAxle (Each ‐ Remove / Install) ‐ ‐ ‐ 1:12 ‐Axle Tube (Each ‐ Remove / Install) ‐ ‐ ‐ 1:12 ‐Bearings ‐ Axle Tube ‐ ‐ ‐ :42 ‐Swing Arm (Rear ‐ Remove / Install) ‐ ‐ ‐ 1:30 ‐Swing Arm Bushings ‐ ‐ ‐ 1:00 ‐
PVTAir Intake Duct :30 :30 :30 :30 :30Air Outlet Duct :30 :30 :30 :30 :30Cover Assy ‐ Inner (Includes Seal) 1:00 1:00 1:00 1:00 1:00Cover Assy ‐ Outer (Includes Seal) :18 :18 :18 :18 :18Drive Belt * * :30 :30 :30 :30 :30Drive Clutch Assembly ÷ :42 :42 :42 :42 :42Drive Clutch Moveable Sheave Bushing 1:30 1:30 1:30 1:30 1:30Drive Clutch Rollers 1:30 1:30 1:30 1:30 1:30Drive Clutch Shift Weights :42 :42 :42 :42 :42Driven Clutch ‐ Ramp Buttons / Rollers :48 :48 :48 :48 :48Driven Clutch Assembly ÷ :30 :30 :30 :30 :30Driven Clutch Moveable Sheave Bushing 1:00 1:00 1:00 1:00 1:00
**Please refer to your Drive Belt Analysis Poster (9920936) or the Drive Belt Analysis document on the Dealer Website before submitting a claim for a Drive Belt.
2006 / 2007 / 2008 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
Carb 2x4 / 4x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / Crew
RANGER
6x6
RANGER
RZR
1.22Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time, when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
RANGER Flat Rate Manual: MY06 - MY10
Times are Remove and Replace unless otherwise noted. Items with an “*” and bolded allow for up to an additional 30 minutes of test and diagnostic time,
Transmission / Gear ShiftShift Linkage Cable :30 :30 :30 :30 :30Shifter (Complete) :30 :30 :30 :30 :30Transmission Assembly √ 2:00 2:00 2:00 2:00 7:00Transmission Rebuild √ 3:00 3:00 3:00 3:00 8:00Transmission Output Shaft Bearing 1:12 1:12 1:12 1:12 ‐
Brakes (includes bleedingBrake Caliper :24 :24 :24 :24 :24Brake Disc (Each ‐ Front / Rear) √ :42 :42 :42 :42 :42Brake Line (Front) :42 :42 :42 :42 :42Brake Line (Rear) 1:12 1:12 1:12 1:12 1:12Brake Pads (Not Covered Under Warranty) :30 :30 :30 :30 :30Brake Pressure Switch :18 :18 :18 :18 :18Brake Pedal :12 :12 :12 :12 :12Master Cylinder Assembly :42 :42 :42 :42 :42Parking Brake Caliper :24 :24 :24 :24 ‐Parking Brake Caliper Rebuild :48 :48 :48 :48 ‐Parking Brake Disc 1:00 1:00 1:00 1:00 ‐Parking Brake Handle :30 :30 :30 :30 ‐Parking Brake Pads (Not Covered Under Warranty) :30 :30 :30 :30 ‐
Front Drive (excludes 2X4)CV Boot √ 1:30 1:30 1:30 1:30 1:30CV Boot Shield :12 :12 :12 :12 :12Driveshaft Seal 1:30 1:30 1:30 1:30 1:30Front Drive Shaft / CV Joint 1:42 1:42 1:42 1:42 1:42Front Drive Shaft Assembly :30 :30 :30 :30 :30Front Gearcase / Cent Hilliard 1:30 1:30 1:30 1:30 1:30Front Hub / Bearings 1:18 1:18 1:18 1:18 1:18Prop Shaft Front :30 :30 :30 :30 :54Prop Shaft U‐Joints (Each‐Add to Prop Shaft) Removal)
:12 :12 :12 :12 :12
Prop Shaft Yoke (Each‐Add to Prop Shaft Removal) :12 :12 :12 :12 :12Hilliard Clutch Components * ‐ 2:00 2:00 2:00 2:00
Final Drive / Shaft Drive / Gear ShiftGear Selector Handle Assembly :30 :30 :30 :30 :30Gearcase Components ‐ Add :18 :18 :18 :18 ‐Mid Gearcase Assembly ‐ ‐ ‐ 1:12 ‐Propshaft (Rear) :30 :30 :30 :30 ‐Propshaft / U‐Joints / Yoke :30 :30 :30 :30 ‐Rear CV / Plunging Joint :30 :30 :30 :30 :30Rear Drive Shaft :30 :30 :30 :30 :30Rear Drive Shaft / U‐Joint :12 :12 :12 :12 :12Rear Drive Shaft Boot :30 :30 :30 :30 :30Rear Gear Case Assembly √ 1:12 1:12 1:12 1:12 1:30Rear Hub Carrier 1:00 1:00 1:00 1:00 1:00Rear Wheel Hub :18 :18 :18 :18 :18Seals ‐ Axle Housing / Gearcase 1:00 1:00 1:00 1:00 1:00Shift Linkage Cable / Bell Crank :30 :30 :30 :30 :18Tire / Wheel (Includes Mounting) √ :18 :18 :18 :18 :18
2006 / 2007 / 2008 RANGER Flat Rate
Requ
ires Pre‐Autho
rizatio
n
RANGER
500
Carb 2x4 / 4x4
RANGER
4x4 500
EFI
RANGER
4x4 XP / Crew
RANGER
6x6
RANGER
RZR
1.23when needed, without pre‐approval. When requesting up to 30 minutes of diagnostic time, please provide a clear explanation in the warranty claim comments regarding why additional time was needed. Test and Diagnostic time exceeding 30 minutes requires prior approval. In addition to items checked as requiring pre‐authorization, any repair exceeding $1000 in the United States, $500 Internationally, or $1250 in Canada requires pre‐authorization.
1.
RANGER Flat Rate Manual: MY06 - MY10
24