09-10 Chapter 01 General

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GENERAL INFORMATION

CHAPTER 1 GENERAL INFORMATIONMODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

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VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2009 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5GENERAL: 2009 RANGER RZR / RZR S / INTL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2009 RANGER RZR S / INTL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

2010 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

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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

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GENERAL: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GENERAL: 2010 RANGER RZR S / INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DETAILED: 2010 RANGER RZR S / INTL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

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PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.1

GENERAL INFORMATIONMODEL INFORMATIONModel IdentificationThe machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 10 VH 76 AD

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Model Year Designation

Emissions & Model Option Basic Chassis Designation Engine Designation

2010: EH076OLE023 / EH076OLE031 ......................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

VIN IdentificationWorld Mfg. ID Vehicle Description Vehicle Identifier

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 * 0 P 0 0 0 0 0 0Engine

Emissions Plant No. Powertrain Check Digit

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Body Style

Model Year

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1).

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The engine serial number can be found on the sticker applied to the cylinder head on the side of engine (see Figure 1-2). Engine Serial Number

VIN Figure 1-1 Figure 1-2

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Vehicle and Engine Serial Number Location

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2009: EH076OLE022 / EH076OLE072 ......................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

* This could be either a number or a letter

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Engine Designation Number

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GENERAL INFORMATIONVEHICLE INFORMATIONPublication NumbersModel 2009 RANGER RZR 2009 RANGER RZR S 2009 RANGER RZR S INTL 2010 RANGER RZR 2010 RANGER RZR S 2010 RANGER RZR S INTL Model No. R09VH76AD, AG, AH, AM, AO, AS, AZ R09VH76AX R09VH76FX R10VH76AD, AG, AJ, AT R10VH76AW R10VH76FX Owners Manual 9921878 9921878 9921878 9922531 9922531 Parts Manual 9921879 9922130 9922212 9922532 9922535 9922537

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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.

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NOTE: When ordering service parts be sure to use the correct parts manual.

KEY COVER P/N 5533534

SPECIAL TOOLSSpecial 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/.

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Key Series Number

Series# 20 21 22 23 27 28 31 32 67 68

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9922636

Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278

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1.3

GENERAL INFORMATION2009 GENERAL SPECIFICATIONSMODEL: 2009 RANGER RZRMODEL NUMBER: R09VH76AD, AG, AH, AM, AO, AS, AZ ENGINE MODEL: EH076OLE Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Storage Capacity Cargo Box Dimension Cargo Box Capacity Maximum Weight Capacity (Payload) Hitch Towing Capacity Hitch Tongue Capacity Dimension / Capacity 102 in. / 259 cm 50 in. / 127 cm 68.5 in. / 174 cm 77 in. / 196 cm 945 lbs. / 429 kg 1727 lbs. / 783 kg 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm 300 lbs. / 136 kg 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) 1500 lbs. / 680 kg 150 lbs. / 68 kg 10 in. / 25.4 cm

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GENERAL INFORMATIONMODEL: 2009 RANGER RZRMODEL NUMBER: R09VH76AD,AG,AH,AM,AO,AS,AZ ENGINE MODEL: EH076OLEEngine Platform Engine Model Number Engine Displacement Number of Cylinders Bore & Stroke (mm) Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating RPM Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Fuel System Type Fuel Delivery Fuel Pressure Fuel Filters Fuel Capacity / Requirement Electrical Alternator Max Output Lights: Main Headlights Tail / Brake Starting System Ignition System Ignition Timing Domestic Twin Cylinder, Liquid Cooled, 4-Stroke EH076OLE022 760cc 2 80 x 76.5 mm 9.78:1 150-170 psi 1150 100 RPM 6500 200 RPM Pressurized Wet Sump PS-4 PLUS Synthetic 2 qts. / 1.9 liters 4.8 qts. / 4.5 liters Instrument Cluster Indicator Single Headpipe / Single Silencer Fuel System Bosch Electronic Fuel Injection Electronic Fuel Pump (in tank) 39 psi See Chapter 4 Front Gearcase Oil Requirements Transmission Oil Requirements Main Gearcase Transmission Oil Requirements Transfer Case Transmission Type Gear Ratio: Front / Rear High Low Rev Drive Ratio - Front Drive Ratio - Final Shift Type Drivetrain Polaris Automatic PVT 3.14:1 8.71:1 5.94:1 3.82:1 3.70:1 In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Polaris High Performance AGL 24 oz. (710 ml) Polaris High Performance AGL 14 oz. (414 ml) Polaris Premium ADF 26 oz. (769 ml) 3211113 Independent Dual A-arm w/Anti-Sway Bar 9 in. / 23 cm Rolled IRS w/Anti-Sway Bar 9.5 in. / 24 cm Cam Adjustment 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 Brake - Front / Rear Brake Fluid 12 x 6 / 10 gauge Maxxis / 25 x 8 R12 12 x 8 / 10 gauge Maxxis / 25 x 10 R12 8 psi (55 kPa) Foot Actuated - 4 Wheel Hydraulic Disc DOT 4

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Rear Gearcase Oil Requirements Belt

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7 gal. (26.5 liters) 87 Octane (minimum)

500 Watts @ 3000 RPM

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Bosch EFI (ECU Controlled) 0 BTDC @ 1200 RPM Champion RC7YC3 / .035 in. (0.9 mm)

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2 - Single Beam 55 W / Halogen 2 - 5 Watts / 2 - 5 Watts Electric Start

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Spark plug / Gap Battery

Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Analog Speedometer with Multifunction LCD Standard 12 V EFI / Fan Fan Motor: 20 Amp Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp

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Front Suspension Front Travel Rear Travel

Rear Suspension

Shock Preload Adjustment Front / Rear

CLUTCH CHARTAltitude Shift Weight Drive Spring Driven Spring Red or Yellow (3234452) Late Build Blk / Almond (7043167) Red or Yellow (3234452) Late Build Blk / Almond (7043167)

Instrument Type DC Outlet Relays Circuit Breaker

0-1500 (0-5000) Meters (Feet) 1500-3700 (5000 - 12000)

SI O20-62 (5631700) 20-58 (5631216)

Steering / Suspension

Fuses

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Blue / Red (7043199)

Blue / Red (7043199)

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GENERAL INFORMATIONMODEL: 2009 RANGER RZR S / INTLMODEL NUMBER: R09VH76AX, FX ENGINE MODEL: EH076OLE Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Storage Capacity Cargo Box Dimension Cargo Box Capacity Maximum Weight Capacity (Payload) Hitch Towing Capacity Hitch Tongue Capacity Dimension / Capacity 106 in. / 269 cm 60.5 in. / 154 cm 70.5 in. / 179 cm 77 in. / 196 cm 12 in. / 30.5 cm 1000 lbs. / 454 kg 1782 lbs. / 808 kg 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm 300 lbs. / 136 kg 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) 1500 lbs. / 680 kg 150 lbs. / 68 kg

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GENERAL INFORMATIONMODEL: 2009 RANGER RZR S / INTLMODEL NUMBER: R09VH76AX, FX ENGINE MODEL: EH076OLEEngine Platform Engine Model Number Engine Displacement Number of Cylinders Bore & Stroke (mm) Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating RPM Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Fuel System Type Fuel Delivery Fuel Pressure Fuel Filters Fuel Capacity / Requirement Electrical Alternator Max Output Lights: Main Headlights Tail / Brake Starting System Ignition System Ignition Timing High Output Domestic Twin Cyl., Liquid Cooled, 4-Stroke EH076OLE072 760cc H.O. 2 80 x 76.5 mm 11:1 165-185 psi 1250 100 RPM 6600 200 RPM Pressurized Wet Sump PS-4 PLUS Synthetic 2 qts. / 1.9 liters 4.8 qts. / 4.5 liters Instrument Cluster Indicator Dual Headpipe / Single Silencer Fuel System Bosch Electronic Fuel Injection Electronic Fuel Pump (in tank) 39 psi See Chapter 4 Front Gearcase Oil Requirements Transmission Oil Requirements Main Gearcase Transmission Oil Requirements Transfer Case Transmission Type Gear Ratio: Front / Rear High Low Rev Drive Ratio - Front Drive Ratio - Final Shift Type Drivetrain Polaris Automatic PVT 3.14:1 8.71:1 5.94:1 3.82:1 3.70:1 In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Polaris High Performance AGL 24 oz. (710 ml) Polaris High Performance AGL 14 oz. (414 ml) Polaris Premium ADF 26 oz. (769 ml) Polaris Premium ADF 18 oz. (532 ml) 3211133 Steering / Suspension Independent Dual A-arm FOX PODIUM X 12 in. / 30.5 cm Rolled IRS w/Anti-Sway Bar FOX PODIUM X 12 in. / 30.5 cm Threaded Shock Adjustment with Spanner Wrench 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 Brake - Front / Rear Brake Fluid 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 8 psi (55 kPa) Foot Actuated - 4 Wheel Hydraulic Disc DOT 4

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Rear Gearcase Oil Requirements Rear Gearcase Oil Requirements Differential (INTL) Belt

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7 gal. (26.5 liters) 87 Octane (minimum)

500 Watts @ 3000 RPM

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Spark plug / Gap Battery

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Bosch EFI (ECU Controlled) 0 BTDC @ 1200 RPM Champion RC7YC3 / .035 in. (0.9 mm)

Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Analog Speedometer with Multifunction LCD Standard 12 V EFI / Fan Fan Motor: 20 Amp Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp

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Instrument Type DC Outlet Relays Circuit Breaker

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Front Suspension / Shock Front Travel

Rear Suspension / Shock Rear Travel Shock Preload Adjustment Front / Rear

CLUTCH CHARTAltitude 0-1500 (0-5000) 1500-3700 (5000 - 12000) Shift Weight Drive Spring 21-74 (5632117) 21-70 (5632127) Driven Spring

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Meters (Feet)

Fuses

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Red / White Red or Yellow (7043349) (3234452) Red / White Red or Yellow (7043349) (3234452)

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GENERAL INFORMATION2010 GENERAL SPECIFICATIONSMODEL: 2010 RANGER RZRMODEL NUMBER: R10VH76AD, AG, AJ, AT ENGINE MODEL: EH076OLE Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Storage Capacity Cargo Box Dimension Cargo Box Capacity Maximum Weight Capacity (Payload) Hitch Towing Capacity Hitch Tongue Capacity Dimension / Capacity 102 in. / 259 cm 50 in. / 127 cm 68.5 in. / 174 cm 77 in. / 196 cm 945 lbs. / 429 kg 1727 lbs. / 783 kg 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm 300 lbs. / 136 kg 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) 1500 lbs. / 680 kg 150 lbs. / 68 kg 10 in. / 25.4 cm

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GENERAL INFORMATIONMODEL: 2010 RANGER RZRMODEL NUMBER: R10VH76AD, AG, AJ, AT ENGINE MODEL: EH076OLEEngine Platform Engine Model Number Engine Displacement Number of Cylinders Bore & Stroke (mm) Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating RPM Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Fuel System Type Fuel Delivery Fuel Pressure Fuel Filters Fuel Capacity / Requirement Electrical Alternator Max Output Lights: Main Headlights Tail / Brake Starting System Ignition System Ignition Timing Domestic Twin Cylinder, Liquid Cooled, 4-Stroke EH076OLE023 760cc 2 80 x 76.5 mm 9.78:1 150-170 psi 1150 100 RPM 6500 200 RPM Pressurized Wet Sump PS-4 PLUS Synthetic 2 qts. / 1.9 liters 4.8 qts. / 4.5 liters Instrument Cluster Indicator Single Headpipe / Single Silencer Fuel System Bosch Electronic Fuel Injection Electronic Fuel Pump (in tank) 39 psi See Chapter 4 Front Gearcase Oil Requirements Transmission Oil Requirements Main Gearcase Transmission Oil Requirements Transfer Case Transmission Type Gear Ratio: Front / Rear High Low Rev Drive Ratio - Front Drive Ratio - Final Shift Type Drivetrain Polaris Automatic PVT 3.14:1 8.71:1 5.94:1 3.82:1 3.70:1 In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Polaris High Performance AGL 24 oz. (710 ml) Polaris High Performance AGL 14 oz. (414 ml) Polaris Premium ADF 26 oz. (769 ml) 3211113 Independent Dual A-arm w/Anti-Sway Bar 9 in. / 23 cm Rolled IRS w/Anti-Sway Bar 9.5 in. / 24 cm Cam Adjustment 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 Brake - Front / Rear Brake Fluid 12 x 6 / 10 gauge Maxxis / 25 x 8 R12 12 x 8 / 10 gauge Maxxis / 25 x 10 R12 8 psi (55 kPa) Foot Actuated - 4 Wheel Hydraulic Disc DOT 4

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Rear Gearcase Oil Requirements Belt

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7 gal. (26.5 liters) 87 Octane (minimum)

500 Watts @ 3000 RPM

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Bosch EFI (ECU Controlled) 0 BTDC @ 1200 RPM Champion RC7YC3 / .035 in. (0.9 mm)

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2 - Single Beam 55 W / Halogen 2 - 5 Watts / 2 - 5 Watts Electric Start

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Spark plug / Gap Battery

Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Analog Speedometer with Multifunction LCD Standard 12 V EFI / Fan Fan Motor: 20 Amp Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp

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Front Suspension Front Travel Rear Travel

Rear Suspension

Shock Preload Adjustment Front / Rear

CLUTCH CHARTAltitude 0-1500 (0-5000) 1500-3700 (5000 - 12000) Shift Weight Drive Spring 23-62 (5632337) 23-58 (5632218) Black (7043594) Black (7043594) Driven Spring Blk / Almond (7043167) Blk / Almond (7043167)

Instrument Type DC Outlet Relays Circuit Breaker

Meters (Feet)

Fuses

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Steering / Suspension

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GENERAL INFORMATIONMODEL: 2010 RANGER RZR S / INTLMODEL NUMBER: R10VH76AW / R10VH76FX ENGINE MODEL: EH076OLE Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Storage Capacity Cargo Box Dimension Cargo Box Capacity Maximum Weight Capacity (Payload) Hitch Towing Capacity Hitch Tongue Capacity Dimension / Capacity 106 in. / 269 cm 60.5 in. / 154 cm 70.5 in. / 179 cm 77 in. / 196 cm 12 in. / 30.5 cm 1000 lbs. / 454 kg 1782 lbs. / 808 kg 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm 300 lbs. / 136 kg 740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight) 1500 lbs. / 680 kg 150 lbs. / 68 kg

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GENERAL INFORMATIONMODEL: 2010 RANGER RZR S / INTLMODEL NUMBER: R10VH76AW / R10VH76FX ENGINE MODEL: EH076OLEEngine Platform Engine Model Number Engine Displacement Number of Cylinders Bore & Stroke (mm) Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating RPM Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Fuel System Type Fuel Delivery Fuel Pressure Fuel Filters Fuel Capacity / Requirement Electrical Alternator Max Output Lights: Main Headlights Tail / Brake Starting System Ignition System Ignition Timing High Output Domestic Twin Cyl., Liquid Cooled, 4-Stroke EH076OLE031 760cc H.O. 2 80 x 76.5 mm 11:1 165-185 psi 1250 100 RPM 6600 200 RPM Pressurized Wet Sump PS-4 PLUS Synthetic 2 qts. / 1.9 liters 4.8 qts. / 4.5 liters Instrument Cluster Indicator Dual Headpipe / Single Silencer Fuel System Bosch Electronic Fuel Injection Electronic Fuel Pump (in tank) 39 psi See Chapter 4 Front Gearcase Oil Requirements Transmission Oil Requirements Main Gearcase Transmission Oil Requirements Transfer Case Transmission Type Gear Ratio: Front / Rear High Low Rev Drive Ratio - Front Drive Ratio - Final Shift Type Drivetrain Polaris Automatic PVT 3.14:1 8.71:1 5.94:1 3.82:1 3.70:1 In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Polaris High Performance AGL 24 oz. (710 ml) Polaris High Performance AGL 14 oz. (414 ml) Polaris Premium ADF 26 oz. (769 ml) Polaris Premium ADF 18 oz. (532 ml) 3211133 Steering / Suspension Independent Dual A-arm FOX PODIUM X 12 in. / 30.5 cm Rolled IRS w/Anti-Sway Bar FOX PODIUM X 12 in. / 30.5 cm Threaded Shock Adjustment with Spanner Wrench 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 Brake - Front / Rear Brake Fluid 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 8 psi (55 kPa) Foot Actuated - 4 Wheel Hydraulic Disc DOT 4

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Rear Gearcase Oil Requirements Rear Gearcase Oil Requirements Differential (INTL) Belt

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7 gal. (26.5 liters) 87 Octane (minimum)

500 Watts @ 3000 RPM

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Spark plug / Gap Battery

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Bosch EFI (ECU Controlled) 0 BTDC @ 1200 RPM Champion RC7YC3 / .035 in. (0.9 mm)

Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Analog Speedometer with Multifunction LCD Standard 12 V EFI / Fan Fan Motor: 20 Amp Chassis: 20 Amp EFI: 15 Amp Lights: 15 Amp Accessory: 15 Amp Speedo/ECU: 5 Amp

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Instrument Type DC Outlet Relays Circuit Breaker

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Front Suspension / Shock Front Travel

Rear Suspension / Shock Rear Travel Shock Preload Adjustment Front / Rear

CLUTCH CHARTAltitude 0-1500 (0-5000) 1500-3700 (5000 - 12000) Shift Weight Drive Spring 23-62 (5632337) 23-58 (5632218) Black (7043594) Black (7043594) Driven Spring Blk / Almond (7043167) Blk / Almond (7043167)

Meters (Feet)

Fuses

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GENERAL INFORMATIONMISC. SPECIFICATIONS AND CHARTSConversion Table

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C to F: 9/5(C + 32) = F

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1.12

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GENERAL INFORMATIONStandard Torque SpecificationsThe 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.

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GENERAL INFORMATIONSAE Tap / Drill Sizes Decimal Equivalents

1.14

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Metric Tap / Drill Sizes

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GENERAL INFORMATIONGlossary of TermsABDC: 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 in 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/cm: 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/in: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position 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.

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GENERAL INFORMATION

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