2008 Polaris Ranger 500 UTV Service & Repair Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 GENERAL: 2008 RANGER 2X4 / 4X4 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2008 RANGER 2X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 DETAILED: 2008 RANGER 4X4 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH50PLE .......................................................................................... Single, L/C, SOHC 4 Stroke, Electric Start VIN Identification Engine Serial Number Location Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the flywheel housing on the right side of engine. } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 8 R B 5 0 A A } 4 X A R B 5 0 A * 8 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 A Engine Serial Number

1.3 GENERAL INFORMATION 1 Unit Serial Number (VIN) Location The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower LH frame rail close to the front drive wheel. The model and serial number are also located on a sticker under the hood (B). Transmission I.D. Number Location A A A B The transmission I.D. number is located on the right side when installed in the machine.

1.4 GENERAL INFORMATION VEHICLE DIMENSIONS 75 in. 190.50 cm 10 in. 25.4 cm 58 in. 147 cm RANGER 2X4, 4X4 RANGER 2X4, 4X4

1.5 GENERAL INFORMATION 1 VEHICLE DIMENSIONS 113 in. 287 cm 58 in. 147 cm 76 in. 193 cm RANGER 2X4, 4X4

1.6 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER 2X4 MODEL NUMBER: R08RB50AA ENGINE MODEL: EH50PLE MODEL: 2008 RANGER 4X4 EFI MODEL NUMBER: R08RH50AF, AR, AT ENGINE MODEL: EH50PLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11 in. / 27.9 cm Turning Radius 148 in. / 376 cm Dry Weight 1105 lbs. / 501 kg Gross Vehicle Weight 2755 lbs. / 1250 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions 54 x 36.5 x 11.5 in. (137 x 92.7 x 29.2 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11 in. / 27.9 cm Turning Radius 148 in. / 376 cm Dry Weight 1185 lbs. / 538 kg Gross Vehicle Weight 2835 lbs. / 1286 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions 54 x 36.5 x 11.5 in. (137 x 92.7 x 29.2 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.7 GENERAL INFORMATION 1 MODEL: 2008 RANGER 2X4 MODEL NUMBER: R08RB50AA ENGINE MODEL: EH50PLE JETTING CHART CLUTCH CHART Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH500PLE169 Engine Displacement 499 cc Number of Cylinders 1 Bore & Stroke 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi Engine Idle Speed 1200 ± 200 RPM Valve Clearance Int./Exh. 0.006 in. (0.152 mm) Engine Hot Light Dash Light Lubrication Pressurized Dry Sump Oil Requirements 0W-40 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.08 L) Exhaust System Single Pipe / Canister Style Carburetion Carburetor model Mikuni BST 34mm CV Main Jet 135 Pilot Jet 42.5 Jet Needle 4MB32-3 Needle Jet P-6 (829) Pilot Screw 2.5 Turns Out (Initial starting point, settings may vary) Pilot Air Jet 160 Float Height 0.51 ± 0.40 in. (13 ± 1 mm) Fuel Delivery Electric Fuel Pump (External) Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 250 watts @ 5000 RPM Lights : Main Headlights 2 - Single Beam 50w / Halogen Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System 12V DC/CDI RPM Limit 6600 RPM Ignition Timing 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR5E / .036 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B Conventional / 30 Amp Hr. / 12 Volt Instrument Panel Type Indicator Lights / Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Transmission Gear Ratio: High Low Reverse 4.43:1 10.08:1 6.87:1 Final Drive Ratio 3.70:1 Shift Type In Line Shift - H / L / N / R Transmission Oil Requirements Polaris Synthetic AGL 15.2 oz. (450 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 18 oz. (532 ml) Belt 3211077 Drive Belt Deflection 1.125 in. (28.58 mm) Center Distance 10 in. (254 mm) Clutch Offset 0.5 in. (12.7 mm) Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. (20.3 cm) Rear Suspension Independent Rear Suspension Rear Travel 9 in. (22.9 cm) Rear Shock Preload Adjustment Cam Adjustment Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Rear Wheel Size 12 x 8 / 10 gauge Front Tire Make / Model / Size Titan / AT489 / 25x10-12 Rear Tire Make / Model / Size Titan / AT489 / 25x11-12 Tire Air Pressure - Front / Rear 8 - 12 psi Brakes - Front / Rear 4 Wheel Hydraulic Disc Parking Brake Hand Actuated (in dash) Brake Fluid DOT 4 Altitude Ambient Temperature Below 40° F Below 5° C +40° F TO +80° F +5° C TO +28° C Meters (Feet) 0-1500 (0-5000) 140 (3130527) 135 (3130563) above 1500 (above 5000) 132.5 (3130562) 127.5 (3130560) Altitude Shift Weight Drive Spring Driven Spring Driven Helix Meters (Feet) 0-1500 (0-5000) 10 MH (5630513) Blu/Grn (7041157) Black (7041782) 45° (5131446) 1500-3700 (5000 - 12000) 10 WH (5630710) Blu/Grn (7041157) Black (7041782) 45° (5131446)

1.8 GENERAL INFORMATION MODEL: 2008 RANGER 4X4 EFI MODEL NUMBER: R08RH50AF, AR, AT ENGINE MODEL: EH50PLE CLUTCH CHART Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH500PLE224 Engine Displacement 499 cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi Engine Idle Speed 1200 ± 200 RPM Valve Clearance Int./Ext. 0.006 in. (0.152 mm) Engine Hot Light Dash Light Lubrication Pressurized Dry Sump Oil Requirements 0W-40 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.08 L) Exhaust System Single Pipe / Canister Style Fuel System Fuel System Type Visteon Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters 30 micron (in tank) Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights : Main Headlights 2 - Single Beam 50w / Halogen Tail 2 - 5 watts Brake 2 - 5 watts Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Visteon EFI (ECU Controlled) Ignition Timing 10° ± 1° BTDC @ 1150 RPM Spark plug / Gap NGK BKR5E / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B Conventional / 30 Amp Hr. / 12 Volt Instrument Panel Type Indicator Lights / Hour Meter DC Outlet Standard Relays Fan / ECU / Ignition Coil & Fuel Pump Circuit Breakers Fan Motor: 10 Amp Fuses Main Chassis: 20 Amp Accessory: 20 Amp ECU Relay: 15 Amp ECU Relay: 5 or 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Transmission Gear Ratio: Front / Rear High Low Reverse 4.43:1 / 3.83:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1 Final Drive Ratio 3.70:1 Drive Ratio - Front 3.818:1 Shift Type In Line Shift - H / L / N / R Front Gearcase Oil Requirements Polaris Demand Drive LT Premium Fluid 5 oz. (150 ml) Transmission Oil Requirements Polaris Synthetic AGL 15.2 oz. (450 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 18 oz. (532 ml) Belt 3211077 Drive Belt Deflection 1.125 in. (28.58 mm) Center Distance 10 in. (254 mm) Clutch Offset 0.5 in. (12.7 mm) Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. (20.3 cm) Rear Suspension Independent Rear Suspension Rear Travel 9 in. (22.9 cm) Rear Shock Preload Adjustment Cam Adjustment Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Rear Wheel Size 12 x 8 / 10 gauge Front Tire Make / Model / Size Titan / AT489 / 25x10-12 Rear Tire Make / Model / Size Titan / AT489 / 25x11-12 Tire Air Pressure - Front / Rear 8 - 12 psi Brakes - Front / Rear 4 Wheel Hydraulic Disc Parking Brake Hand Actuated (in dash) Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Driven Helix Meters (Feet) 0-1500 (0-5000) 10 MH (5630513) Blu/Grn (7041157) Black (7041782) 45° (5131446) 1500-3700 (5000 - 12000) 10 WH (5630710) Blu/Grn (7041157) Black (7041782) 45° (5131446)

1.9 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. Paint Codes 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 PN Parts Manual PN 2008 RANGER 2x4 R08RB50AA 9921264 9921265 2008 RANGER 4x4 EFI R08RH50AF, AR, AT 9921272 9921273 Painted Part Color Description Polaris Number Frame / Cab Medium Gloss Black P-067 RANGER 2x4, 4x4 EFI - Plastic - Hood / Dash Dark Green P-195 RANGER 4x4 EFI - Plastic - Hood / Dash Solar Red P-342 RANGER 4x4 EFI - Plastic - Hood / Dash Midnight Blue P-485 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

1.10 GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F - 32) = °C

2008 Polaris Ranger 500 UTV Service & Repair Manual

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