2008 RANGER RZR
SERVICE MANUAL
FOREWORD
This service manual is designed prim arily for use by ce rtified Polaris Mas ter Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain pro cedur es require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc .
2100 Hwy 55 Medina Minnesota 55340.
2008 Service Manual PN 9921278
© Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication . Due to constant
improvements in the design and quality of production component s, some minor discrep ancies may result between t he actual vehicle and the inf ormation presented in t his
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.
GENERAL INFORMATION
1
MAINTENANCE
ENGINE
FUEL INJECTION
BODY / STEERING / SUSPENSION
CLUTCHING
2
3
4
5
6
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
7
8
9
10
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2008 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
1
1.1
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
R 0 8 V H 7 6 A D
Model Year
Designation
Engine Designation Number
EH076OLE021.....................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification
World
Mfg. ID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A V H 7 6 A * 8 P 0 0 0 0 0 0
Vehicle Description
}
Basic Chassis
Designation
}
}
}
}
Engine Designation
Vehicle Identifier
}
Emissions &
Model Option
Body Style
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 cylinder head on the side of engine.
Engine
Emissions
Powertrain
Model
Year
Check Digit
Plant No.
Individual Serial No.
* This could be either
a number or a letter
1.2
Unit Serial Number (VIN) Location
GENERAL INFORMATION
The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on
a portion of the LH frame rail close to the front wheel. The model and VIN numbers are also located on a sticker under the hood
(B) or on the lower frame rail in front of the LH rear tire (C).
A
1
B
A
C
1.3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
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)
Hitch Towing Capacity 1500 lbs. / 680 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
740 lbs. / 336.4 kg
(Includes rider(s), cargo,
and accessories)
FRONT
TOP
SIDE
REAR
1.4
GENERAL INFORMATION
MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
Engine
Platform
Engine Model Number EH076OLE021
Engine Displacement 760cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 76.5 mm
Compression Ratio 10:1
Compression Pressure 150-200 psi
Engine Idle Speed 1150 ± 100 RPM
Engine Max Operating RPM 6500 ± 200 RPM
Lubrication Pressurized Wet Sump
Oil Requirements 0W-40
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.8 qts. / 4.5 liters
Overheat Warning Instrument Cluster Indicator
Exhaust System Single Pipe / Silencer
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
Alternator Max Output 500 watts @ 3000 RPM
Lights: Main Headlights 2 - Dual Beam 55 watts / Halogen
Tail / Brake 2 - 27 watts
Worklights 2 - 13 watts
Starting System Electric Start
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 13° BTDC @ 1200 RPM
Spark plug / Gap
Battery
Instrument Type
DC Outlet Standard 12 V
Relays EFI / Fan
Circuit Breaker Fan Motor: 20 Amp
Fuses
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Fuel System
7 gal. (26.5 liters)
87 Octane (minimum)
Electrical
Champion RC7YC3 /
.035 in. (0.9 mm)
Yuasa YTX20HL /
18 Amp Hr. / 310 CCA / 12 Volt
Analog Speedometer
with Multifunction LCD
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
Drive Ratio - Front 3.82:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Polaris Demand Drive LT
Front Gearcase Oil Requirements
Transmission Oil Requirements
Main Gearcase
Transmission Oil Requirements
Transfer Case
Rear Gearcase Oil Requirements
Belt 3211113
Steering / Suspension
Front Suspension Independent Double A-arm
Front Travel 9 in. / 23 cm
Rear Suspension Independent Double A-arm
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear
Toe Out 1/8-1/4 in. / 3-6.35 mm
Wheels / Brakes
Front Wheel Size
Front Tire Size
Rear Wheel Size
Rear Tire Size
Tire Air Pressure - Front / Rear 8 psi (55 kPa)
Brake - Front / Rear
Brake Fluid DOT 4
Polaris High Performance AGL
Polaris High Performance AGL
Foot Actuated - 4 Wheel
3.14:1
8.71:1
5.94:1
Premium Fluid
6.75 oz. (200 ml)
24 oz. (710 ml)
14 oz. (414 ml)
Polaris Premium ADF
18 oz. (532 ml)
Cam Adjustment
12 x 6 / 10 gauge
Maxxis / 25 x 8 R12
12 x 8 / 10 gauge
Maxxis / 25 x 10 R12
Hydraulic Disc
CLUTCH CHART
Altitude Shift Weight Drive Spring
Meters
(Feet)
0-1500
(0-5000)
1500-3700
(5000 - 12000)
20-62
(5631700)
20-58
(5631216)
Blue/Red
(7043199)
Blue/Red
(7043199)
1
Driven
Spring
Red or Yellow
(3234452)
Red or Yellow
(3234452)
1.5
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
Model Model No. Owner’s Manual PN Parts Manual PN
2008 RANGER RZR, Red R08VH76AD 9921181 9921207
2008 RANGER RZR, Green R08VH76AG 9921181 9921207
NOTE: When orde ri ng se rvic e 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
Painted Part Color Description Polaris Number
Frame / Bumpers / Racks Gloss Black P-067
Frame / Bumpers / Racks Matte Black P-458
Plastic - Hood / Dash / Fenders Indy Red P-293
Plastic - Hood / Dash / Fenders Sage Brush Green Metallic P-498
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.
KEY COVER
P/N 5533534
Key Series
Number
Series# Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
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/
.
1.6
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
GENERAL INFORMATION
1
°C to °F:
9/5
(°C + 32) = °F °F to °C:
5/9
(°F - 32) = °C
1.7
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.8
GENERAL INFORMATION
SAE Tap / Drill Sizes
Decimal Equivalents
1
Metric Tap / Drill Sizes
1.9
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to
close and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round i n the
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm²: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in²: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating posit ion of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.10
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4
50 - 300 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5
COMPONENT INSPECTION / SERVICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . .2.8
MAINTENANCE REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
FUEL PUMP / FUEL FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
THROTTLE PEDAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
ENGINE BREATHER HOSE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
ENGINE AND TRANSMISSION MOUNT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . .2.16
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION / GEARCASE SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . .2.17
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLING SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
2
2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
BATTERY CHARGING (SEALED BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING AND SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.28
TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE FLUID INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
2
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.
Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment
of a new engine and drive components will result in more efficient performance and longer life for these components.
• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
2.3
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Maintenance Interval
Item
Hours Calendar
Steering - Pre-Ride -
Front Suspension - Pre-Ride -
Rear Suspension - Pre-Ride -
Tires - Pre-Ride Brake Fluid Level - Pre-Ride -
Brake Pedal Travel - Pre-Ride -
Brake Systems - Pre-Ride Wheels / Fasteners - Pre-Ride Frame Fasteners - Pre-Ride -
Engine Oil Level - Pre-Ride -
E
Air Filter / Pre-Filter - Pre-Ride - Inspect; clean often; replace as needed
E
Coolant Level - Daily -
Head Lamp / Tail Lamp - Daily Air Filter,
Main Element
E
Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Front Gearcase Oil
(Demand Drive Fluid LT)
Rear Gearcase Oil
(ATV Angle Drive Fluid)
Transmission - Main
(AGL Gearcase Lubricant)
Transmission - Transfer
(AGL Gearcase Lubricant)
Engine Breather
E
Filter (if equipped)
Engine Oil Change
E
(Break-In Period)
25 H Monthly 250 (400) Inspect level; change yearly
25 H Monthly 250 (400) Inspect level; change yearly
25 H Monthly 250 (400) Inspect level; change yearly
25 H Monthly 250 (400) Inspect level; change yearly
25 H Monthly 250 (400) Inspect; replace if necessary
25 H 1 M 250 (400) Perform a break-in oil change at one month
(whichever comes first)
Miles
(KM)
Make adjustments as needed.
See Pre-Ride Checklist on Page 2.9.
Check level daily, change coolant every 2
years
Check operation; apply dielectric grease if
replacing
- Weekly - Inspect; replace as needed
Remarks
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.4
MAINTENANCE
50 - 300 Hour Maintenance Interval
Maintenance Interval
Item
Throttle Cable / Throttle
E
Pedal
Throttle Body Air Intake
E
Ducts / Flange
General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust
Steering 50 H 6 M 500 (800) Lubricate
Front Suspension 50 H 6 M 500 (800) Lubricate
Rear Suspension 50 H 6 M 500 (800) Lubricate
Cooling System 50 H 6 M 500 (800)
Fuel System 100 H 12 M 600 (1000)
E
Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed
E
Engine Oil & Filter Change 100 H 6 M 1000 (1600)
E
Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed
Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces
Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification
Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect
Wiring 100 H 12 M 1000 (1600)
Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 300 H 36 M 3000 (4800) Clean out
Toe Adjustment -
Headlight Aim - Adjust as needed
(whichever comes first)
Hours Calendar
50 H 6 M 300 (500)
50 H 6 M 300 (500) Inspect ducts for proper sealing / air leaks
Miles
(KM)
Inspect; adjust; lubricate; replace if
necessary
Inspect coolant strength seasonally;
pressure test system yearly
Check for leaks at tank cap, fuel line, fuel
pump, and fuel rail.
Replace lines every two years.
Perform a break-in oil change at 25 hours or
one month / always replace oil filter when
changing engine oil
Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to
water, mud, etc.
Inspect periodically; adjust when parts are
replaced
Remarks
2
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.5
MAINTENANCE
COMPONENT INSPECTION / SERVICE LOCATIONS
Front and Rear View
2.6
RH and LH Side Views
MAINTENANCE
2
2.7
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