2009-2010 Polaris RZR 800 UTV Service Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 2009 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL: 2009 RANGER RZR S / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2009 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 2010 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 GENERAL: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GENERAL: 2010 RANGER RZR S / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DETAILED: 2010 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 PartShark.com 877-999-5686

1.2 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number 2009: EH076OLE022 / EH076OLE072 ......................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start 2010: EH076OLE023 / EH076OLE031 ......................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1). The engine serial number can be found on the sticker applied to the cylinder head on the side of engine (see Figure 1-2). } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 1 0 V H 7 6 A D } 4 X A V H 7 6 A * 0 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier Check Digit Model Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions VIN Figure 1-1 Engine Serial Figure 1-2 Number PartShark.com 877-999-5686

1.3 GENERAL INFORMATION 1 VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Model Model No. Owner’s Manual Parts Manual 2009 RANGER RZR R09VH76AD, AG, AH, AM, AO, AP, AS, AZ 9921878 9921879 2009 RANGER RZR S R09VH76AX 9921878 9922130 2009 RANGER RZR S INT’L R09VH76FX 9921878 9922212 2010 RANGER RZR R10VH76AD, AG, AJ, AT 9922531 9922532 2010 RANGER RZR S R10VH76AB, AO, AW 9922531 9922535 2010 RANGER RZR S INT’L R10VH76FX 9922636 9922537 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534 PartShark.com 877-999-5686

1.4 GENERAL INFORMATION 2009 GENERAL SPECIFICATIONS MODEL: 2009 RANGER RZR MODEL NUMBER: R09VH76AD, AG, AH, AM, AO, AP, AS, AZ ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 945 lbs. / 429 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg PartShark.com 877-999-5686

1.5 GENERAL INFORMATION 1 MODEL: 2009 RANGER RZR MODEL NUMBER: R09VH76AD,AG,AH,AM,AO,AP,AS,AZ ENGINE MODEL: EH076OLE CLUTCH CHART Engine Platform Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH076OLE022 Engine Displacement 760cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Engine Max Operating RPM 6500 ± 200 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 PLUS Synthetic Oil Capacity 2 qts. / 1.9 liters Coolant Capacity 4.8 qts. / 4.5 liters Overheat Warning Instrument Cluster Indicator Exhaust System Single Headpipe / Single Silencer Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7 gal. (26.5 liters) 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Lights: Main Headlights 2 - Single Beam 55 W / Halogen Tail / Brake 2 - 5 Watts / 2 - 5 Watts Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 0° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Instrument Type Analog Speedometer with Multifunction LCD DC Outlet Standard 12 V Relays EFI / Fan Circuit Breaker Fan Motor: 20 Amp Fuses Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High Low Rev 3.14:1 8.71:1 5.94:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Oil Requirements Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission Oil Requirements Main Gearcase Polaris High Performance AGL 24 oz. (710 ml) Transmission Oil Requirements Transfer Case Polaris High Performance AGL 14 oz. (414 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 26 oz. (769 ml) Belt 3211113 Steering / Suspension Front Suspension Independent Dual A-arm w/Anti-Sway Bar Front Travel 9 in. / 23 cm Rear Suspension Rolled IRS w/Anti-Sway Bar Rear Travel 9.5 in. / 24 cm Shock Preload Adjustment Front / Rear Cam Adjustment Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size Front Tire Size 12 x 6 / 10 gauge Maxxis / 25 x 8 R12 Rear Wheel Size Rear Tire Size 12 x 8 / 10 gauge Maxxis / 25 x 10 R12 Tire Air Pressure - Front / Rear 8 psi (55 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 20-62 (5631700) Blue / Red (7043199) Red or Yellow (3234452) Late Build Blk / Almond (7043167) 1500-3700 (5000 - 12000) 20-58 (5631216) Blue / Red (7043199) Red or Yellow (3234452) Late Build Blk / Almond (7043167) PartShark.com 877-999-5686

1.6 GENERAL INFORMATION MODEL: 2009 RANGER RZR S / INT’L MODEL NUMBER: R09VH76AX, FX ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 106 in. / 269 cm Width 60.5 in. / 154 cm Height 70.5 in. / 179 cm Wheel Base 77 in. / 196 cm Ground Clearance 12 in. / 30.5 cm Dry Weight 1000 lbs. / 454 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg PartShark.com 877-999-5686

1.7 GENERAL INFORMATION 1 MODEL: 2009 RANGER RZR S / INT’L MODEL NUMBER: R09VH76AX, FX ENGINE MODEL: EH076OLE CLUTCH CHART Engine Platform High Output Domestic Twin Cyl., Liquid Cooled, 4-Stroke Engine Model Number EH076OLE072 Engine Displacement 760cc H.O. Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 11:1 Compression Pressure 165-185 psi Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 6600 ± 200 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 PLUS Synthetic Oil Capacity 2 qts. / 1.9 liters Coolant Capacity 4.8 qts. / 4.5 liters Overheat Warning Instrument Cluster Indicator Exhaust System Dual Headpipe / Single Silencer Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7 gal. (26.5 liters) 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Lights: Main Headlights 2 - Single Beam 55 W / Halogen Tail / Brake 2 - 5 Watts / 2 - 5 Watts Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 0° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Instrument Type Analog Speedometer with Multifunction LCD DC Outlet Standard 12 V Relays EFI / Fan Circuit Breaker Fan Motor: 20 Amp Fuses Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High Low Rev 3.14:1 8.71:1 5.94:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Oil Requirements Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission Oil Requirements Main Gearcase Polaris High Performance AGL 24 oz. (710 ml) Transmission Oil Requirements Transfer Case Polaris High Performance AGL 14 oz. (414 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 26 oz. (769 ml) Rear Gearcase Oil Requirements Differential (INT’L) Polaris Premium ADF 22 oz. (650 ml) Belt 3211133 Steering / Suspension Front Suspension / Shock Independent Dual A-arm FOX™ PODIUM X Front Travel 12 in. / 30.5 cm Rear Suspension / Shock Rolled IRS w/Anti-Sway Bar FOX™ PODIUM X Rear Travel 12 in. / 30.5 cm Shock Preload Adjustment Front / Rear Threaded Shock Adjustment with Spanner Wrench Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size Front Tire Size 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 Rear Wheel Size Rear Tire Size 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 Tire Air Pressure - Front / Rear 8 psi (55 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 21-74 (5632117) Red / White (7043349) Red or Yellow (3234452) 1500-3700 (5000 - 12000) 21-70 (5632127) Red / White (7043349) Red or Yellow (3234452) PartShark.com 877-999-5686

1.8 GENERAL INFORMATION 2010 GENERAL SPECIFICATIONS MODEL: 2010 RANGER RZR MODEL NUMBER: R10VH76AD, AG, AJ, AT ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 945 lbs. / 429 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg PartShark.com 877-999-5686

1.9 GENERAL INFORMATION 1 MODEL: 2010 RANGER RZR MODEL NUMBER: R10VH76AD, AG, AJ, AT ENGINE MODEL: EH076OLE CLUTCH CHART Engine Platform Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH076OLE023 Engine Displacement 760cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Engine Max Operating RPM 6500 ± 200 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 PLUS Synthetic Oil Capacity 2 qts. / 1.9 liters Coolant Capacity 4.8 qts. / 4.5 liters Overheat Warning Instrument Cluster Indicator Exhaust System Single Headpipe / Single Silencer Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7 gal. (26.5 liters) 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Lights: Main Headlights 2 - Single Beam 55 W / Halogen Tail / Brake 2 - 5 Watts / 2 - 5 Watts Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 0° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Instrument Type Analog Speedometer with Multifunction LCD DC Outlet Standard 12 V Relays EFI / Fan Circuit Breaker Fan Motor: 20 Amp Fuses Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High Low Rev 3.14:1 8.71:1 5.94:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Oil Requirements Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission Oil Requirements Main Gearcase Polaris High Performance AGL 24 oz. (710 ml) Transmission Oil Requirements Transfer Case Polaris High Performance AGL 14 oz. (414 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 26 oz. (769 ml) Belt 3211113 Steering / Suspension Front Suspension Independent Dual A-arm w/Anti-Sway Bar Front Travel 9 in. / 23 cm Rear Suspension Rolled IRS w/Anti-Sway Bar Rear Travel 9.5 in. / 24 cm Shock Preload Adjustment Front / Rear Cam Adjustment Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size Front Tire Size 12 x 6 / 10 gauge Maxxis / 25 x 8 R12 Rear Wheel Size Rear Tire Size 12 x 8 / 10 gauge Maxxis / 25 x 10 R12 Tire Air Pressure - Front / Rear 8 psi (55 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almond (7043167) 1500-3700 (5000 - 12000) 23-58 (5632218) Black (7043594) Blk / Almond (7043167) PartShark.com 877-999-5686

1.10 GENERAL INFORMATION MODEL: 2010 RANGER RZR S / INT’L MODEL NUMBER: R10VH76AB, AO, AW, FX ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 106 in. / 269 cm Width 60.5 in. / 154 cm Height 70.5 in. / 179 cm Wheel Base 77 in. / 196 cm Ground Clearance 12 in. / 30.5 cm Dry Weight 1000 lbs. / 454 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg PartShark.com 877-999-5686

2009-2010 Polaris RZR 800 UTV Service Manual

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