Download - 09-10 Chapter 01 General

GENERAL INFORMATION

CHAPTER 1GENERAL INFORMATION 1

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MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2VEHICLE SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42009 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL: 2009 RANGER RZR / RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6DETAILED: 2009 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

2010 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8GENERAL: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8DETAILED: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9GENERAL: 2010 RANGER RZR S / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10DETAILED: 2010 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

1.1

GENERAL INFORMATION

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MODEL INFORMATIONModel IdentificationThe machine model number must be used with any correspondence regarding warranty or service.

Engine Designation Number2009: EH076OLE022 / EH076OLE072 ......................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

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

VIN Identification

Vehicle and Engine Serial Number LocationWhenever 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).

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

}

Machine Model Number Identification} }

Model Year Designation

Basic Chassis Designation Engine Designation

Emissions & Model Option

R 1 0 V H 7 6 A D}

4 X A V 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

ModelYear Body Style

Plant No.

Individual Serial No.

* This could be either a number or a letterPowertrain

Emissions

VINFigure 1-1

Engine Serial

Figure 1-2

Number

1.2

GENERAL INFORMATION

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VEHICLE INFORMATIONPublication 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 fromwww.purepolaris.com.

Replacement KeysReplacement keys can be made from the original key. To identify which series the key is, take the first two digits on the originalkey and refer to the chart to the right for the proper part number.

SPECIAL TOOLSSpecial tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other toolsmaybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polarisproduct. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 oron-line at http://polaris.spx.com/.

Model Model No. Owner’s Manual Parts Manual

2009 RANGER RZR R09VH76AD, AG, AH, AM, AO, AS, AZ 9921878 9921879

2009 RANGER RZR S R09VH76AX 9921878 9922130

2009 RANGER RZR S INT’L R09VH76FX 9921878 9922212

2010 RANGER RZR R10VH76AD, AG, AJ, AT 9922531 9922532

2010 RANGER RZR S R10VH76AW 9922531 9922535

2010 RANGER RZR S INT’L R10VH76FX 9922636 9922537

Series# Part Number20 401027821 401027822 401032123 401032127 401032128 401032131 411014132 411014867 401027868 4010278

Key SeriesNumber

KEY COVERP/N 5533534

1.3

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2009 GENERAL SPECIFICATIONS

MODEL: 2009 RANGER RZRMODEL NUMBER: R09VH76AD, AG, AH, AM, AO, AS, AZENGINE MODEL: EH076OLE

Category Dimension / CapacityLength 102 in. / 259 cmWidth 50 in. / 127 cmHeight 68.5 in. / 174 cmWheel Base 77 in. / 196 cmGround Clearance 10 in. / 25.4 cmDry Weight 945 lbs. / 429 kgGross Vehicle Weight 1727 lbs. / 783 kgFront Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cmCargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

740 lbs. / 336.4 kg(Includes rider(s), cargo, accessories

and trailer tongue weight)Hitch Towing Capacity 1500 lbs. / 680 kgHitch Tongue Capacity 150 lbs. / 68 kg

1.4

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MODEL: 2009 RANGER RZRMODEL NUMBER: R09VH76AD,AG,AH,AM,AO,AS,AZENGINE MODEL: EH076OLE

CLUTCH CHART

Engine

Platform Domestic Twin Cylinder,Liquid Cooled, 4-Stroke

Engine Model Number EH076OLE022Engine Displacement 760ccNumber of Cylinders 2Bore & Stroke (mm) 80 x 76.5 mmCompression Ratio 9.78:1

Compression Pressure 150-170 psiEngine Idle Speed 1150 ± 100 RPM

Engine Max Operating RPM 6500 ± 200 RPMLubrication Pressurized Wet Sump

Oil Requirements PS-4 PLUS SyntheticOil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 litersOverheat Warning Instrument Cluster IndicatorExhaust System Single Headpipe / Single Silencer

Fuel SystemFuel System Type Bosch Electronic Fuel Injection

Fuel Delivery Electronic Fuel Pump (in tank)Fuel Pressure 39 psiFuel Filters See Chapter 4

Fuel Capacity / Requirement 7 gal. (26.5 liters)87 Octane (minimum)

ElectricalAlternator Max Output 500 Watts @ 3000 RPM

Lights: Main Headlights 2 - Single Beam 55 W / HalogenTail / Brake 2 - 5 Watts / 2 - 5 Watts

Starting System Electric StartIgnition System Bosch EFI (ECU Controlled)Ignition Timing 0° BTDC @ 1200 RPM

Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm)

Battery Yuasa YTX20HL /18 Amp Hr. / 310 CCA / 12 Volt

Instrument Type Analog Speedometerwith Multifunction LCD

DC Outlet Standard 12 V

Relays EFI / Fan

Circuit Breaker Fan Motor: 20 Amp

Fuses

Chassis: 20 AmpEFI: 15 Amp

Lights: 15 AmpAccessory: 15 Amp

Speedo/ECU: 5 Amp

DrivetrainTransmission Type Polaris Automatic PVT

Gear Ratio: Front / RearHighLowRev

3.14:18.71:15.94:1

Drive Ratio - Front 3.82:1Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase Oil Requirements Polaris Demand Drive Plus6.75 oz. (200 ml)

Transmission Oil Requirements Main Gearcase

Polaris High Performance AGL24 oz. (710 ml)

Transmission Oil Requirements Transfer Case


Rear Gearcase Oil Requirements Polaris Premium ADF26 oz. (769 ml)

Belt 3211113Steering / Suspension

Front Suspension Independent Dual A-arm w/Anti-Sway Bar

Front Travel 9 in. / 23 cmRear Suspension Rolled IRS w/Anti-Sway Bar

Rear Travel 9.5 in. / 24 cmShock Preload Adjustment

Front / Rear Cam Adjustment

Toe Out 1/8-1/4 in. / 3-6.35 mmWheels / Brakes

Front Wheel SizeFront Tire Size

12 x 6 / 10 gaugeMaxxis / 25 x 8 R12

Rear Wheel SizeRear Tire Size

12 x 8 / 10 gaugeMaxxis / 25 x 10 R12

Tire Air Pressure - Front / Rear 8 psi (55 kPa)

Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc

Brake Fluid DOT 4

Altitude Shift Weight Drive Spring Driven Spring

Meters(Feet)

0-1500(0-5000)

20-62(5631700)

Blue / Red(7043199)

Red or Yellow(3234452)

Late BuildBlk / Almond

(7043167)

1500-3700(5000 - 12000)

20-58(5631216)

Blue / Red(7043199)


Late BuildBlk / Almond

(7043167)

1.5

GENERAL INFORMATION

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MODEL: 2009 RANGER RZR S / INT’LMODEL NUMBER: R09VH76AX, FXENGINE MODEL: EH076OLE

Category Dimension / CapacityLength 106 in. / 269 cmWidth 60.5 in. / 154 cmHeight 70.5 in. / 179 cmWheel Base 77 in. / 196 cmGround Clearance 12 in. / 30.5 cmDry Weight 1000 lbs. / 454 kgGross Vehicle Weight 1782 lbs. / 808 kgFront Storage Capacity 25 lbs. / 11.3 kg





1.6

GENERAL INFORMATION

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MODEL: 2009 RANGER RZR S / INT’LMODEL NUMBER: R09VH76AX, FXENGINE MODEL: EH076OLE

CLUTCH CHART

Engine

Platform High Output Domestic Twin Cyl., Liquid Cooled, 4-Stroke

Engine Model Number EH076OLE072Engine Displacement 760cc H.O.Number of Cylinders 2Bore & Stroke (mm) 80 x 76.5 mmCompression Ratio 11:1




Coolant Capacity 4.8 qts. / 4.5 litersOverheat Warning Instrument Cluster IndicatorExhaust System Dual Headpipe / Single Silencer











Relays EFI / Fan


Fuses



Speedo/ECU: 5 Amp



3.14:18.71:15.94:1









Rear Gearcase Oil Requirements Differential (INT’L)

Polaris Premium ADF18 oz. (532 ml)


Front Suspension / Shock Independent Dual A-armFOX™ PODIUM X

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock Rolled IRS w/Anti-Sway Bar FOX™ PODIUM X

Rear Travel 12 in. / 30.5 cmShock Preload Adjustment

Front / RearThreaded Shock Adjustment

with Spanner WrenchToe Out 1/8-1/4 in. / 3-6.35 mm

Wheels / BrakesFront Wheel SizeFront Tire Size

12 x 6 / Cast AluminumMaxxis Bighorn / 26 x 9 R12





Brake Fluid DOT 4


Meters(Feet)

0-1500(0-5000)

21-74(5632117)

Red / White(7043349)


1500-3700(5000 - 12000)

21-70(5632127)

Red / White(7043349)


1.7

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2010 GENERAL SPECIFICATIONS

MODEL: 2010 RANGER RZRMODEL NUMBER: R10VH76AD, AG, AJ, ATENGINE MODEL: EH076OLE

Category Dimension / CapacityLength 102 in. / 259 cmWidth 50 in. / 127 cmHeight 68.5 in. / 174 cmWheel Base 77 in. / 196 cmGround Clearance 10 in. / 25.4 cmDry Weight 945 lbs. / 429 kgGross Vehicle Weight 1727 lbs. / 783 kgFront Storage Capacity 25 lbs. / 11.3 kg





1.8

GENERAL INFORMATION

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MODEL: 2010 RANGER RZRMODEL NUMBER: R10VH76AD, AG, AJ, ATENGINE MODEL: EH076OLE

CLUTCH CHART

Engine

Platform Domestic Twin Cylinder,Liquid Cooled, 4-Stroke

Engine Model Number EH076OLE023Engine Displacement 760ccNumber of Cylinders 2Bore & Stroke (mm) 80 x 76.5 mmCompression Ratio 9.78:1




Coolant Capacity 4.8 qts. / 4.5 litersOverheat Warning Instrument Cluster IndicatorExhaust System Single Headpipe / Single Silencer











Relays EFI / Fan


Fuses



Speedo/ECU: 5 Amp



3.14:18.71:15.94:1










Front Suspension Independent Dual A-arm w/Anti-Sway Bar

Front Travel 9 in. / 23 cmRear Suspension Rolled IRS w/Anti-Sway Bar

Rear Travel 9.5 in. / 24 cmShock Preload Adjustment

Front / Rear Cam Adjustment

Toe Out 1/8-1/4 in. / 3-6.35 mmWheels / Brakes

Front Wheel SizeFront Tire Size

12 x 6 / 10 gaugeMaxxis / 25 x 8 R12


12 x 8 / 10 gaugeMaxxis / 25 x 10 R12



Brake Fluid DOT 4


Meters(Feet)

0-1500(0-5000)

23-62(5632337)

Black(7043594)

Blk / Almond(7043167)

1500-3700(5000 - 12000)

23-58(5632218)

Black(7043594)


1.9

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MODEL: 2010 RANGER RZR S / INT’LMODEL NUMBER: R10VH76AW / R10VH76FXENGINE MODEL: EH076OLE

Category Dimension / CapacityLength 106 in. / 269 cmWidth 60.5 in. / 154 cmHeight 70.5 in. / 179 cmWheel Base 77 in. / 196 cmGround Clearance 12 in. / 30.5 cmDry Weight 1000 lbs. / 454 kgGross Vehicle Weight 1782 lbs. / 808 kgFront Storage Capacity 25 lbs. / 11.3 kg





1.10

GENERAL INFORMATION

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MODEL: 2010 RANGER RZR S / INT’LMODEL NUMBER: R10VH76AW / R10VH76FXENGINE MODEL: EH076OLE

CLUTCH CHART

Engine

Platform High Output Domestic Twin Cyl., Liquid Cooled, 4-Stroke

Engine Model Number EH076OLE031Engine Displacement 760cc H.O.Number of Cylinders 2Bore & Stroke (mm) 80 x 76.5 mmCompression Ratio 11:1




Coolant Capacity 4.8 qts. / 4.5 litersOverheat Warning Instrument Cluster IndicatorExhaust System Dual Headpipe / Single Silencer











Relays EFI / Fan


Fuses



Speedo/ECU: 5 Amp



3.14:18.71:15.94:1









Rear Gearcase Oil Requirements Differential (INT’L)

Polaris Premium ADF18 oz. (532 ml)


Front Suspension / Shock Independent Dual A-armFOX™ PODIUM X

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock Rolled IRS w/Anti-Sway Bar FOX™ PODIUM X

Rear Travel 12 in. / 30.5 cmShock Preload Adjustment

Front / RearThreaded Shock Adjustment

with Spanner WrenchToe Out 1/8-1/4 in. / 3-6.35 mm

Wheels / BrakesFront Wheel SizeFront Tire Size






Brake Fluid DOT 4


Meters(Feet)

0-1500(0-5000)

23-62(5632337)

Black(7043594)


1500-3700(5000 - 12000)

23-58(5632218)

Black(7043594)


1.11

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MISC. SPECIFICATIONS AND CHARTSConversion Table

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

1.12

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Standard Torque Specifications

The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, andengine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

1.13

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SAE Tap / Drill Sizes

Metric Tap / Drill Sizes

Decimal Equivalents

1.14

GENERAL INFORMATION

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Glossary 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 toclose and grip the drive belt.Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centerson V blocks or resting in crankcase. Measure at various points especially at PTO.DCV: Direct current voltageCVT: 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 thecylinder 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 wiretouching 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 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.

1.15

GENERAL INFORMATION

NOTES

1.16

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