GENERAL INFORMATION
1
MAINTENANCE
2
ENGINE
3
FUEL INJECTION
4
BODY / STEERING / SUSPENSION
5
CLUTCHING
6
FINAL DRIVE
7
TRANSMISSION
8
BRAKES
9
ELECTRICAL
10
GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION
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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 TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 VEHICLE DIMENSIONS RANGER 4X4, 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
1.1
GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service.
Model Year Designation
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Machine Model Number Identification R 07 RH 68 AG Emissions & Model Option
Basic Chassis Designation
Engine Designation
Engine Designation Number EH068OLE043PLE ............................................................Twin, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification World Mfg. ID
Vehicle Identifier
Vehicle Description
Body Style
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R H 6 8 A * 7 P 0 0 0 0 0 0 Model Year
Engine Emissions
Powertrain
Plant No.
Check Digit
Individual Serial No. * This could be either a number or a letter
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 Serial Number
1.2
A
GENERAL INFORMATION Unit Serial Number (VIN) Location
Transmission I.D. Number 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).
1
The transmission I.D. number is located on the right side when installed in the machine.
A
A
A
B
1.3
GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4X4, 6X6
75 in. 190.50 cm
RANGER 4x4
10 in. 25.4 cm
58 in. 147 cm
1.4
GENERAL INFORMATION Vehicle Dimensions RANGER 4X4, 6X6
1
120 in. 305 cm
58 in. 147 cm
27 in. 69 cm 90 in. 229 cm 113 in. 287 cm
58 in. 147 cm
76 in. 193 cm
1.5
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GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE 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 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1185 lbs. / 537 kg Gross Vehicle Weight 2750 lbs. / 1247 kg Cargo Box Capacity 1000 lbs. / 454 kg 58 x 42 x 10 in. Cargo Box Dimensions (147 x 106.7 x 25.4 cm) 1500 lbs. / 681 kg Vehicle Payload (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg
MODEL: RANGER XP 6X6 MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in. / (18.25 cm) Turning Radius 180 in. / 457 cm Dry Weight 1410 lbs. / 640 kg Gross Vehicle Weight 2900 lbs. / 1315 kg Cargo Box Capacity 1250 lbs. / 567 kg 58 x 48 x 10 in. Cargo Box Dimensions (147 x 122 x 25.4 cm) 1750 lbs. / 794 kg Vehicle Payload (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1750 lbs. / 794 kg Hitch Tongue Capacity 150 lbs. / 68 kg
1.6
GENERAL INFORMATION MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE Engine Polaris Domestic Twin Cylinder, Platform Liquid Cooled, 4-Stroke Engine Model Number EH068OLE044 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 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 Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 9 gal. (34 l) Fuel Capacity / Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Champion RC7YC3 / Spark plug / Gap .035 in. (0.9 mm) Yuasa YB30L-B / Battery / Model / Amp Hr 30 Amp Hr. / 12 Volt Instrument Type Multifunction Speedometer DC Outlet Standard Fan: 20 Amp Dash Harness: 20 Amp Circuit Breakers Accessory Terminal: 20 Amp Power Relay: 15 Amp ECU Battery Supply: 6 Amp
Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High 3.34:1 / 2.89:1 Low 8.67:1 / 7.49:1 Rev 5.92:1 / 5.11:1 Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.365” / 9.27 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Rear Suspension Independent Rear Suspension Rear Travel 9 in. / 23 cm Ground Clearance 11.5 in. / 29 cm Shock Preload Adjustment Cam Adjustment Front / Rear 2-2” Twin Tubes Turning Radius 132 in. / 335 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes 12 x 6 / 10 gauge Front Wheel Size L.E. Model AW - 14 x 7 12 x 8 / 10 gauge Rear Wheel Size L.E. Model AW - 14 x 8 Carlisle / PXT / 26 x 8 R12 Front Tire L.E. Model AW - Kenda / Radial Make / Model / Size Bounty Hunter / 26 x 10 R14 Carlisle / PXT / 26 x 11 R12 Rear Tire L.E. Model AW - Kenda / Radial Make / Model / Size Bounty Hunter / 26 x 12 R14 F/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Foot Actuated - 4 Wheel Brake - Front / Rear Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4
CLUTCH CHART Altitude
Meters (Feet)
Shift Weight Drive Spring
Driven Spring
0-1500 (0-5000)
20-60 (5631698)
Blu/Gray (7042202)
Blk/Almd (7043167)
1500-3700 (5000 - 12000)
20-56 (5631215)
Blu/Gray (7042202)
Blk/Almd (7043167)
1.7
1
GENERAL INFORMATION MODEL: RANGER XP 6X6 MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE Engine Polaris Domestic Twin Cylinder, Platform Liquid Cooled, 4-Stroke Engine Model Number EH068OLE044 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 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 Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 9 gal. (34 l) Fuel Capacity / Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Champion RC7YC3 / Spark plug / Gap .035 in. (0.9 mm) Yuasa YB30L-B / Battery / Model / Amp Hr 30 Amp Hr. / 12 Volt Instrument Panel Type Multifunction Speedometer DC Outlet Standard Fan: 20 Amp Dash Harness: 20 Amp Circuit Breakers Accessory Terminal: 20 Amp Power Relay: 15 Amp ECU Battery Supply: 6 Amp
1.8
Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High 3.89:1 / 3.36:1 Low 10.08:1 / 8.71:1 Rev 6.87:1 / 5.94:1 Drive Ratio - Front 3.818:1 Drive Ratio - Mid 3.70:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.365” / 9.27 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Center Suspension Progressive Rate / Independent Center Travel 5.25 in. / 13 cm Rear Suspension Swing Arm w/Dual Shocks Rear Travel 6.25 in. / 16 cm Ground Clearance 7.2 in. / 18.25 cm Shock Preload Adjustment Cam Adjustment Front / Rear 2-2” Twin Tubes Turning Radius 180 in. / 457 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Middle / Rear Wheel Size 12 x 8 / 10 gauge Front Tire Titan / AT489 / 25 x 10 R12 Make / Model / Size Middle / Rear Tire Titan / AT489 / 25 x 11 R12 Make / Model / Size F/M/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Foot Actuated - 4 Wheel Brake - Front / Rear Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4
CLUTCH CHART Altitude
Meters (Feet)
Shift Weight Drive Spring
Driven Spring
0-1500 (0-5000)
20-60 (5631698)
Blu/Gray (7042202)
Blk/Almd (7043167)
1500-3700 (5000 - 12000)
20-56 (5631215)
Blu/Gray (7042202)
Blk/Almd (7043167)
GENERAL INFORMATION V
1
P M 20 20 NOTE: NOTE: www.purepolaris.com.
Paint Codes Painted Part
Color Description
Polaris Number
Frame / Cab
Medium Gloss Black
P-067
RANGER XP 4x4 - Plastic - Hood / Dash
Black Metallic
P-177
RANGER XP 6x6 - Plastic - Hood / Dash
Dark Green
P-195
RANGER XP 4x4 - Plastic - Hood / Dash
Turbo Silver
P-402
RANGER XP 4x4 - Plastic - Hood / Dash
Mossy Oak™
P-455
RANGER XP 4x4 - Plastic - Hood / Dash
Delta Green
P-492
RANGER XP 4x4 - Plastic - Hood / Dash
Sunset Red Metallic
P-520
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# 20 21 22 23 27 28 31 32 67 68
Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 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, 1-800-328-6657.
1.9
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F
1.10
°F to °C: (°F + 40) ÷ 9 - 40 = °C
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.
1.11
1