2010-2012 Polaris Ranger XP 800 ATV Service & Repair 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 LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2010 RANGER XP 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2010 RANGER XP 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL: 2010 RANGER HD 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2010 RANGER HD 800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2010 RANGER CREW 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2010 RANGER CREW 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GENERAL: 2010 RANGER 6X6 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DETAILED: 2010 RANGER 6X6 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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 EH076OLE030 / EH076OLE032 / EH076OLE033 ....................... Twin Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start VIN Identification Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model number and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1). The engine model and serial number can be found on a decal applied to the side of the engine cylinder head (see Figure 1-2). } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 1 0 T H 7 6 A G } 4 X A T 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 Figure 1-1 VIN Figure 1-2 Engine Serial Number

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 PN Parts Manual PN 2010 RANGER XP 800 R10TH76AG, AH, AL, AR, AW, AY 9922522 9922523 2010 RANGER XP 800 EPS R10TY76AZ 9922522 9922523 2010 RANGER HD 800 R10TY76AN 9922522 9922523 2010 RANGER CREW 800 R10WH76AG, AH, AR, AV 9922522 9922540 2010 RANGER 6x6 800 R10HR76AG, AR 9922522 9922527 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

1.4 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2010 RANGER XP 800 / EPS MODEL NUMBER: R10TH76AG, AH, AL, AR, AW, AY MODEL NUMBER: R10TY76AZ (EPS MODEL) ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 114 in. / 289.6 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 76 in. / 193 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 158 in. / 401.3 cm Dry Weight 1237 lbs. / 561 kg Gross Vehicle Weight 2887 lbs. / 1310 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions (inside dimensions) L-36 x W-50 x H-11 in. (91.4 x 127 x 27.9 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes weight of operator, passenger, cargo and accessories. Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.5 GENERAL INFORMATION 1 MODEL: 2010 RANGER XP 800 / EPS MODEL NUMBER: R10TH76AG, AH, AL, AR, AW, AY MODEL NUMBER: R10TY76AZ (EPS MODEL) ENGINE MODEL: EH076OLE CLUTCH CHART Engine Platform High Output Domestic Twin Cyl, Liquid Cooled, 4-Stroke Engine Model Number EH076OLE030 Engine Displacement 760 cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 165-185 psi Engine Idle Speed 1200 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 PLUS Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.1 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Capacity 9 gal. (34 L) Fuel Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Main Headlights 50 Watt / Halogen x 2 Tail Lights 0.3 Watts / L.E.D. x 2 Brake Lights 3.1 Watts / L.E.D. x 2 Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 0° BTDC @ 1200 RPM Spark plug / Gap RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrumentation Multifunction Speedometer DC Outlets (2) - Standard Relays Fan / EFI / Brake Light / Rear Diff Circuit Breaker Fan Motor: 15 Amp Fuses Steering: 30 Amp (EPS Model) Main Chassis: 20 Amp Accessory: 15 Amp EFI: 15 Amp ECM: 15 amp Lights: 15 Amp 120Ω Resistor (EPS Model) Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Ratio: High Low Reverse Front: 3.60:1 / Rear: 11.18:1 Front: 7.70:1 / Rear: 23.91:1 Front: 7.00:1 / Rear: 21.74:1 Front Gearcase Lubricant Requirements Demand Drive Plus 9 oz. (265 ml) Transmission Lubricant Requirements Full Synthetic AGL 33.8 oz. (1000 ml) Drive Belt 3211133 Clutch Center Distance 10.05” (255 mm) Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Dual A-arm Front Travel 9.6 in. (24.4 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment Wheels / Brakes Front Wheel Size / Type 12 x 6 / Steel 12 x 6 / Cast Aluminum Rear Wheel Size / Type 12 x 8 / Steel 12 x 8 / Cast Aluminum Front Tire Make / Model / Size Titan / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12 Tire Air Pressure 8-12 psi (69 kPa) Brake System 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almd (7043167) 1500-3700 (5000 - 12000) 23-58 (5632218) Black (7043594) Blk / Almd (7043167)

1.6 GENERAL INFORMATION MODEL: 2010 RANGER HD 800 MODEL NUMBER: R10TY76AN ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 114 in. / 289.6 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 76 in. / 193 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 166 in. / 422 cm Dry Weight 1262 lbs. / 572 kg Gross Vehicle Weight 2912 lbs. / 1321 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions (inside dimensions) L-36 x W-50 x H-11 in. (91.4 x 127 x 27.9 cm) Vehicle Payload 1500 lbs. / 681 kg (Includes weight of operator, passenger, cargo and accessories. Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.7 GENERAL INFORMATION 1 MODEL: 2010 RANGER HD 800 MODEL NUMBER: R10TY76AN ENGINE MODEL: EH076OLE CLUTCH CHART Engine Platform Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH076OLE032 Engine Displacement 760 cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 165-185 psi Engine Idle Speed 1200 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 PLUS Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.08 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Capacity 9 gal. (34 L) Fuel Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Main Headlights 50 Watt / Halogen x 2 Tail Lights 0.3 Watts / L.E.D. x 2 Brake Lights 3.1 Watts / L.E.D. x 2 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 / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrumentation Multifunction Speedometer DC Outlets (2) - Standard Relays Fan / EFI / Brake Light / Rear Diff Circuit Breaker Fan Motor: 15 Amp Fuses Steering: 30 Amp Main Chassis: 20 Amp Accessory: 15 Amp EFI: 15 Amp ECM: 15 amp Lights: 15 Amp 120Ω Resistor (CAN Bus) Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Ratio: High Low Reverse Front: 3.60:1 / Rear: 11.18:1 Front: 7.70:1 / Rear: 23.91:1 Front: 7.00:1 / Rear: 21.74:1 Front Gearcase Lubricant Requirements Demand Drive Plus 9 oz. (265 ml) Transmission Lubricant Requirements Full Synthetic AGL 33.8 oz. (1000 ml) Drive Belt 3211133 Clutch Center Distance 10.05” (255 mm) Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Dual A-arm Front Travel 9.6 in. (24.4 cm) Rear Suspension Self Leveling (IRS) Rear Travel 7.5 in. (19.1 cm) Shock Preload Adjustment Cam Adjustment (front only) Wheels / Brakes Front Wheel Size / Type 12 x 6 / Cast Aluminum Rear Wheel Size / Type 12 x 8 / Cast Aluminum Front Tire Make / Model / Size Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12 Tire Air Pressure 8-12 psi (69 kPa) Brake System Type 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almd (7043167) 1500-3700 (5000 - 12000) 23-58 (5632218) Black (7043594) Blk / Almd (7043167)

1.8 GENERAL INFORMATION MODEL: 2010 RANGER CREW 800 MODEL NUMBER: R10WH76AG, AH, AR, AV ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 145 in. / 386 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 108 in. / 274 cm Ground Clearance 11.5 in. / 29 cm Turning Radius 255 in. / 648 cm Dry Weight 1510 lbs. / 685 kg Gross Vehicle Weight 3410 lbs. / 1547 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions (inside dimensions) L-36 x W-50 x H-11 in. (91.4 x 127 x 27.9 cm) Vehicle Payload 1750 lbs. / 794 kg (Includes weight of operator, passenger, cargo and accessories. Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.9 GENERAL INFORMATION 1 MODEL: 2010 RANGER CREW 800 MODEL NUMBER: R10WH76AG, AH, AR, AV ENGINE MODEL: EH076OLE CLUTCH CHART Engine Platform Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH076OLE033 Engine Displacement 760 cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 165-185 psi Engine Idle Speed 1200 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 PLUS Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.08 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Capacity 9 gal. (34 L) Fuel Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Main Headlights 50 Watt / Halogen x 2 Tail Lights 0.3 Watts / L.E.D. x 2 Brake Lights 3.1 Watts / L.E.D. x 2 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 / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrumentation Multifunction Speedometer DC Outlets (2) - Front (1) - Rear Relays Fan / EFI / Brake Light / Rear Diff Circuit Breaker Fan Motor: 15 Amp Fuses Main Chassis: 20 Amp Accessory: 15 Amp EFI: 15 Amp ECM: 15 amp Lights: 15 Amp Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Ratio: High Low Reverse Front: 4.63:1 / Rear: 14.37:1 Front: 7.70:1 / Rear: 23.91:1 Front: 7.00:1 / Rear: 21.74:1 Front Gearcase Lubricant Requirements Demand Drive Plus 9 oz. (265 ml) Transmission Lubricant Requirements Full Synthetic AGL 33.8 oz. (1000 ml) Drive Belt 3211133 Clutch Center Distance 10.05” (255 mm) Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Dual A-arm Front Travel 9.6 in. (24.4 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment Wheels / Brakes Front Wheel Size / Type 12 x 6 / Steel 12 x 6 / Cast Aluminum Rear Wheel Size / Type 12 x 8 / Steel 12 x 8 / Cast Aluminum Front Tire Make / Model / Size Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12 Tire Air Pressure Front: 12 psi (83 kPa) Rear: 16 psi (110 kPa) Brake System Type 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almd (7043167) 1500-3700 (5000 - 12000) 23-58 (5632218) Black (7043594) Blk / Almd (7043167)

1.10 GENERAL INFORMATION MODEL: 2010 RANGER 6X6 800 MODEL NUMBER: R10HR76AG, AR ENGINE MODEL: EH076OLE Category Dimension / Capacity Length 120 in. / 305 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 90 in. / 229 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 243 in. / 617 cm Dry Weight 1551 lbs. / 703.5 kg Gross Vehicle Weight 3701 lbs. / 1679 kg Storage Box Capacity 250 lbs. / 113 kg Cargo Box Capacity 1250 lbs. / 567 kg Cargo Box Dimensions (inside dimensions) L-43 x W-50 x H-11 in. (109.2 x 127 x 27.9 cm) Vehicle Payload 2000 lbs. / 907 kg (Includes weight of operator, passenger, cargo and accessories. Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg

2010-2012 Polaris Ranger XP 800 ATV Service & Repair Manual

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