FOREWORD
This service manual is designed primarily for use by certified Polaris Master 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 procedures 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 9921277
© 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 components, some minor discrepancies may result between the actual vehicle and the information presented in this 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.
2008 RANGER 700 4X4 XP / 4X4 CREW / 6X6 SERVICE MANUAL
1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 ELECTRONIC FUEL INJECTION 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10
CHAPTER 1
GENERAL INFORMATION 1
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
RANGER 4X4 XP, 4X4 CREW, 6X6 (HEIGHT AND WIDTH) . . . . . . . . . . . . . . . . . . . . .1.4
RANGER 4X4 XP, 6X6 (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . .1.5
RANGER 4X4 CREW (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2008 RANGER 4X4 XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7
GENERAL: 2008 RANGER 4X4 CREW / 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
DETAILED: 2008 RANGER 4X4 XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
DETAILED: 2008 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
DETAILED: 2008 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11
VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
GENERAL INFORMATION 1.1
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 EH068OLE046PLE ............................................................Twin, Liquid Cooled, OHV 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 cylinder head on the side of engine. } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 8 R H 6 8 A G } 4 X A R H 6 8 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
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).
A B
Transmission I.D. Number Location A
The transmission I.D. number is located on the right side when installed in the machine.
1.3 GENERAL INFORMATION 1
VEHICLE DIMENSIONS
RANGER 4x4 XP, 4x4 CREW, 6X6 (Height and Width)
75 in. 190.5 cm
RANGER 4x4
11.5 in. 29.2 cm
60 in. 152.4 cm
1.4 GENERAL INFORMATION
RANGER 4x4 XP, 6X6 (Length and Wheel Base)
120 in. 305 cm 42.5 in. 108 cm 27 in. 69 cm 90 in. 229 cm 113 in. 287 cm 36.5 in. 92.7 cm 76 in. 193 cm
1.5 GENERAL INFORMATION 1
RANGER 4x4 CREW (Length and Wheel Base)
145 in. 386 cm 108 in. 274 cm
36.5 in. 92.7 cm
1.6 GENERAL INFORMATION
MODEL: 2008 RANGER 4X4 XP
MODEL NUMBER: R08RH68AB, AG, AH, AJ, AK, AP, AR, AS
ENGINE MODEL: EH68OLE
CategoryDimension / Capacity
Length113 in. / 287 cm
Width60 in. / 152.4 cm
Height75 in. / 190.5 cm
Wheel Base76 in. / 193 cm
Ground Clearance11 in. / 27.9 cm
Turning Radius148 in. / 376 cm
Dry Weight1185 lbs. / 538 kg
Gross Vehicle Weight2835 lbs. / 1286 kg
Cargo Box Capacity1000 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)
Hitch Towing Capacity2000 lbs. / 907 kg
Hitch Tongue Capacity150 lbs. / 68 kg
1.7 GENERAL INFORMATION 1
GENERAL SPECIFICATIONS
White L.E.
Blue L.E.
Silver L.E.
Pearl
Boardwalk
Turbo
Stealth Black L.E. Browning Edition
GENERAL INFORMATION
MODEL: 2008 RANGER 4X4 CREW
MODEL NUMBER: R08WH68AG
ENGINE MODEL: EH68OLE
CategoryDimension / Capacity
Length145 in. / 386 cm
Width60 in. / 152.4 cm
Height75 in. / 190.5 cm
Wheel Base108 in. / 274 cm
Ground Clearance11 in. / 27.9 cm
Turning Radius224 in. / 569 cm
Dry Weight1460 lbs. / 664 kg
Gross Vehicle Weight3360 lbs. / 1524 kg
Cargo Box Capacity1000 lbs. / 454 kg
Cargo Box Dimensions 54 x 36.5 x 11.5 in. (137 x 92.7 x 29.2 cm)
Vehicle Payload
1750 lbs. / 794 kg (Includes driver and five passengers)
Hitch Towing Capacity2000 lbs. / 907 kg
Hitch Tongue Capacity150 lbs. / 68 kg
MODEL: 2008 RANGER 6X6
MODEL NUMBER: R08RF68AD, AF
ENGINE MODEL: EH068OLE
CategoryDimension / Capacity
Length120 in. / 305 cm
Width60 in. / 152.4 cm
Height75 in. / 190.5 cm
Wheel Base90 in. / 229 cm
Ground Clearance7.2 in. / 18.3 cm
Turning Radius186 in. / 472 cm
Dry Weight1410 lbs. / 640 kg
Gross Vehicle Weight3310 lbs. / 1501 kg
Cargo Box Capacity1250 lbs. / 567 kg
Cargo Box Dimensions 54 x 42.5 x 11.5 in. (137 x 108 x 29.2 cm)
Vehicle Payload
1750 lbs. / 794 kg (Includes driver and two passengers)
Hitch Towing Capacity2000 lbs. / 907 kg
Hitch Tongue Capacity150 lbs. / 68 kg
1.8
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MODEL: 2008 RANGER 4X4 XP
MODEL NUMBER: R08RH68AB, AG, AH, AJ, AK, AP, AR, AS
ENGINE MODEL: EH68OLE
Engine
Platform
Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke
Engine Model NumberEH068OLE046
Engine Displacement683cc
Number of Cylinders2
Bore & Stroke (mm)80 x 68 mm
Compression Ratio9.40:1
Compression Pressure150-170 psi
Engine Idle Speed1150 ± 100 RPM
LubricationPressurized Wet Sump
Oil Requirements0W-40
Oil Capacity2 qts. (1.9 L)
Coolant Capacity3.25 qts. (3.08 L)
Overheat WarningInstrument Cluster Indicator Exhaust System2 to 1 Canister Style
Fuel System
Fuel System TypeBosch Electronic Fuel Injection
Fuel DeliveryElectronic Fuel Pump (in tank)
Fuel Pressure39 psi
Fuel FiltersSee Chapter 4
Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum)
Electrical
Alternator Max Output500 watts @ 3000 RPM
Lights: Main Headlights2 - Single Beam 50w / Halogen Tail5 watts x 2 Brake5 watts x 2
Indicator Panel Lights1 watt (ea.)
Starting SystemElectric Start
Ignition SystemBosch EFI (ECU Controlled)
Ignition Timing7° 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
Instrument TypeMultifunction Speedometer
DC Outlet Standard
RelaysFan / ECU / Rear Diff Solenoid
Circuit BreakersFan Motor: 15 Amp
Fuses Main Chassis: 20 Amp
Accessory: 20 Amp EFI Power: 15 Amp Speedo / ECU: 6 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Transmission Gear Ratio: Front / Rear High Low Reverse
3.63:1 / 3.14:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Transmission Oil Requirements
Rear Gearcase Oil Requirements
Polaris Demand Drive LT Fluid 5 oz. (150 ml)
Polaris Synthetic AGL 15.2 oz. (450 ml)
Polaris Premium ADF 18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 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
Standard - 12 x 6 / Steel L.E. - 12 x 6 / Cast Aluminum
Rear Wheel Size Standard - 12 x 8 / Steel L.E. - 12 x 8 / Cast Aluminum
Front Tire Make / Model / Size Carlisle / PXT / 26 x 8 R12
Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12
Tire Air Pressure - Front / Rear 8-12 psi / 8 - 12 psi Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4 Parking Brake Hand Actuated (in dash)
CLUTCH CHART
1.9 GENERAL INFORMATION 1
AltitudeShift WeightDrive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 21-74 (5632117) Red/Blue (7043372) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 21-70 (5632127) Red/Blue (7043372) Blk/Almd (7043167)
GENERAL INFORMATION
MODEL: 2008 RANGER 4X4 CREW
MODEL NUMBER: R08WH68AG
ENGINE MODEL: EH68OLE
Engine
Platform
Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke
Engine Model NumberEH068OLE047
Engine Displacement683cc
Number of Cylinders2
Bore & Stroke (mm)80 x 68 mm
Compression Ratio9.40:1
Compression Pressure150-170 psi
Engine Idle Speed1150 ± 100 RPM
LubricationPressurized Wet Sump
Oil Requirements0W-40
Oil Capacity2 qts. / 1.9 L
Coolant Capacityn/a
Overheat WarningInstrument Cluster Indicator Exhaust System2 to 1 Canister Style
Fuel System
Fuel System TypeBosch Electronic Fuel Injection
Fuel DeliveryElectronic Fuel Pump (in tank)
Fuel Pressure39 psi
Fuel FiltersSee Chapter 4
Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum)
Electrical
Alternator Max Output500 watts @ 3000 RPM
Lights: Main Headlights2 - Single Beam 50w / Halogen Tail5 watts x 2 Brake5 watts x 2
Indicator Panel Lights1 watt (ea.)
Starting SystemElectric Start
Ignition SystemBosch EFI (ECU Controlled)
Ignition Timing7° 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
Instrument Panel Type Multifunction Speedometer
DC Outlet Standard RelaysFan / ECU / Rear Diff Solenoid
Circuit BreakersFan Motor: 15 Amp
Main Chassis: 20 Amp Accessory: 20 Amp
Fuses
EFI Power: 15 Amp Speedo / ECU: 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
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Transmission Oil Requirements
Rear Gearcase Oil Requirements
Polaris Demand Drive LT Fluid 5 oz. (150 ml)
Polaris Synthetic AGL 15.2 oz. (450 ml)
Polaris Premium ADF 18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 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 Carlisle / PXT / 26 x 9 R12
Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12
Tire Air Pressure - Front / Rear 12 psi / 16 psi Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4 Parking Brake Hand Actuated (in dash)
CLUTCH CHART
1.10
AltitudeShift WeightDrive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 21-74 (5632117) Red/Blue (7043372) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 21-70 (5632127) Red/Blue (7043372) Blk/Almd (7043167)
MODEL: 2008 RANGER 6X6
MODEL NUMBER: R08RF68AD, AF
ENGINE MODEL: EH68OLE
Engine
Platform
Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke
Engine Model NumberEH068OLE046
Engine Displacement683cc
Number of Cylinders2
Bore & Stroke (mm)80 x 68 mm Compression Ratio9.40:1
Compression Pressure150-170 psi
Engine Idle Speed1150 ± 100 RPM
LubricationPressurized Wet Sump
Oil Requirements0W-40
Oil Capacity2 qts. / 1.9 L
Coolant Capacity3.25 qts. (3.08 L)
Overheat WarningInstrument Cluster Indicator Exhaust System2 to 1 Canister Style
Fuel System
Fuel System TypeBosch Electronic Fuel Injection
Fuel DeliveryElectronic Fuel Pump (in tank)
Fuel Pressure39 psi
Fuel FiltersSee Chapter 4
Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum)
Electrical
Alternator Max Output500 watts @ 3000 RPM
Lights: Main Headlights2 - Single Beam 50w / Halogen Tail5 watts x 2 Brake5 watts x 2
Indicator Panel Lights1 watt (ea.)
Starting SystemElectric Start
Ignition SystemBosch EFI (ECU Controlled)
Ignition Timing7° 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
Instrument Panel TypeMultifunction Speedometer
DC Outlet Standard
RelaysFan / ECU
Circuit BreakersFan Motor: 15 Amp
Fuses
Main Chassis: 20 Amp Accessory: 20 Amp EFI Power: 15 Amp Speedo / ECU: 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
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements Polaris Demand Drive LT Fluid 5 oz. (150 ml)
Transmission Oil Requirements
Mid Gearcase Oil Requirements
Rear Gearcase Oil Requirements
Polaris Synthetic AGL 15.2 oz. (450 ml)
Polaris Premium ADF 6.75 oz. (200 ml)
Polaris Premium ADF 18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 mm)
Steering / Suspension
Front Suspension MacPherson Strut
Front Travel 8 in. (20.3 cm)
Center Suspension Progressive Rate / Independent Center Travel 5.25 in. (13.3 cm)
Rear Suspension Swing Arm w/Dual Shocks Rear Travel 6.25 in. (16 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
Middle / Rear Wheel Size 12 x 8 / 10 gauge
Front Tire Make / Model / Size Titan / AT489 / 25 x 10 R12
Middle / Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12
Tire Air Pressure Front / Middle / Rear 8-12 psi / 8 - 12 psi / 8-12 psi
Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4 Parking Brake Hand Actuated (in dash)
CLUTCH CHART
1.11
INFORMATION 1
GENERAL
WeightDrive Spring Driven Spring Meters (Feet)
(0-5000) 21-74 (5632117) Red/Blue (7043372) Blk/Almd
12000) 21-70 (5632127)
AltitudeShift
0-1500
(7043167) 1500-3700 (5000 -
Red/Blue (7043372) Blk/Almd (7043167)
VEHICLE INFORMATION
Publication Numbers
ModelModel No.Owner’s Manual PNParts Manual PN
2008 RANGER 4x4 XPR08RH68AB, AG, AH, AJ, AK, AP, AR, AS99212689921275
2008 RANGER 4x4 CREWR08WH68AG99212799921280
2008 RANGER 6x6R08RF68AD, AF99212689921269
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
Painted PartColor
DescriptionPolaris Number
Main Frame / Cab Frame / BumpersMedium Gloss BlackP-067
Main Frame / Cab Frame / PlasticGloss BlackP-070
Plastic - Hood / DashBlack MetallicP-177
Plastic - Hood / DashDark GreenP-195
Plastic - Hood / DashSolar RedP-342
Plastic - Hood / DashPearl WhiteP-352
Plastic - Hood / DashTurbo SilverP-402
Cab Frame / BumpersFlat Black WrinkleP-418
Plastic - Hood / Dash Mossy Oak™ P-455
Plastic - Hood / DashDelta GreenP-492
Plastic - Hood / DashBoardwalk BlueP-524
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/
1.12 GENERAL INFORMATION
Series#Part Number 204010278 214010278 224010321 234010321 274010321 284010321 314110141 324110148 674010278 684010278 Key Series Number KEY COVER P/N 5533534
