Polaris 2010 Ranger RZR 800 EFI User manual

GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION 1
PRELIMINARY VERSION
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL 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
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2009 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2009 RANGER RZR / RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2009 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7
2010 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
GENERAL: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2010 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GENERAL: 2010 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
DETAILED: 2010 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
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

1.2
GENERAL INFORMATION
PRELIMINARY VERSION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
2009: 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 Location
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).
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
Model
Year
BodyStyle Plant No.
Individual Serial No.
* This could be either
a number or a letter
Powertrain
Emissions
VIN Figure 1-1
Engine Serial
Figure 1-2
Number

1.3
GENERAL INFORMATION
1
PRELIMINARY VERSION
VEHICLE INFORMATION
Publication 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 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.
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/.
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 Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
Key Series
Number
KEY COVER
P/N 5533534

1.4
GENERAL INFORMATION
PRELIMINARY VERSION
2009 GENERAL SPECIFICATIONS
MODEL: 2009 RANGER RZR
MODEL NUMBER: R09VH76AD, AG, AH, AM, AO, AS, AZ
ENGINE MODEL: EH076OLE
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)
740 lbs. / 336.4 kg
(Includesrider(s),cargo,accessories
and trailer tongue weight)
Hitch Towing Capacity 1500 lbs. / 680 kg
HitchTongue Capacity 150 lbs. / 68 kg

1.5
GENERAL INFORMATION
1
PRELIMINARY VERSION
MODEL: 2009 RANGER RZR
MODEL NUMBER: R09VH76AD,AG,AH,AM,AO,AS,AZ
ENGINE MODEL: EH076OLE
CLUTCH CHART
Engine
Platform Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH076OLE022
Engine Displacement 760cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 76.5 mm
Compression Ratio 9.78:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Engine Max Operating RPM 6500 ± 200 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 PLUS Synthetic
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.8 qts. / 4.5 liters
Overheat Warning Instrument Cluster Indicator
Exhaust System Single Headpipe / Single Silencer
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
Fuel Capacity / Requirement 7 gal. (26.5 liters)
87 Octane (minimum)
Electrical
Alternator Max Output 500 Watts @ 3000 RPM
Lights: Main Headlights 2 - Single Beam 55 W / Halogen
Tail / Brake 2 - 5 Watts / 2 - 5 Watts
Starting System Electric Start
Ignition 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 Speedometer
with Multifunction LCD
DC Outlet Standard 12 V
Relays EFI / Fan
Circuit Breaker Fan Motor: 20 Amp
Fuses
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
3.14:1
8.71:1
5.94:1
Drive Ratio - Front 3.82:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Front Gearcase Oil Requirements Polaris Demand Drive Plus
6.75 oz. (200 ml)
Transmission Oil Requirements
Main Gearcase Polaris High Performance AGL 24 oz. (710 ml)
Transmission Oil Requirements
Transfer Case Polaris High Performance AGL 14 oz. (414 ml)
Rear Gearcase Oil Requirements Polaris Premium ADF
26 oz. (769 ml)
Belt 3211113
Steering / Suspension
Front Suspension Independent Dual A-arm
w/Anti-Sway Bar
Front Travel 9 in. / 23 cm
Rear Suspension Rolled IRS w/Anti-Sway Bar
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear Cam Adjustment
Toe Out 1/8-1/4 in. / 3-6.35 mm
Wheels / Brakes
Front Wheel Size
Front Tire Size 12 x 6 / 10 gauge Maxxis / 25 x 8 R12
Rear Wheel Size
Rear Tire Size 12 x 8 / 10 gauge Maxxis / 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 Build
Blk / Almond
(7043167)
1500-3700
(5000 - 12000) 20-58 (5631216) Blue / Red (7043199)
Red or Yellow
(3234452)
Late Build
Blk / Almond
(7043167)

1.6
GENERAL INFORMATION
PRELIMINARY VERSION
MODEL: 2009 RANGER RZR S / INT’L
MODEL NUMBER: R09VH76AX, FX
ENGINE MODEL: EH076OLE
Category Dimension / Capacity
Length 106 in. / 269 cm
Width 60.5 in. / 154 cm
Height 70.5 in. / 179 cm
Wheel Base 77 in. / 196 cm
Ground Clearance 12 in. / 30.5 cm
Dry Weight 1000 lbs. / 454 kg
Gross Vehicle Weight 1782 lbs. / 808 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)
740 lbs. / 336.4 kg
(Includesrider(s),cargo,accessories
and trailer tongue weight)
Hitch Towing Capacity 1500 lbs. / 680 kg
HitchTongueCapacity 150 lbs. / 68 kg

1.7
GENERAL INFORMATION
1
PRELIMINARY VERSION
MODEL: 2009 RANGER RZR S / INT’L
MODEL NUMBER: R09VH76AX, FX
ENGINE MODEL: EH076OLE
CLUTCH CHART
Engine
Platform HighOutputDomestic TwinCyl.,
Liquid Cooled, 4-Stroke
Engine Model Number EH076OLE072
Engine Displacement 760cc H.O.
Number of Cylinders 2
Bore & Stroke (mm) 80 x 76.5 mm
Compression Ratio 11:1
Compression Pressure 165-185 psi
Engine Idle Speed 1250 ± 100 RPM
Engine Max Operating RPM 6600 ± 200 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 PLUS Synthetic
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.8 qts. / 4.5 liters
Overheat Warning Instrument Cluster Indicator
Exhaust System Dual Headpipe / Single Silencer
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
Fuel Capacity / Requirement 7 gal. (26.5 liters)
87 Octane (minimum)
Electrical
Alternator Max Output 500 Watts @ 3000 RPM
Lights: Main Headlights 2 - Single Beam 55 W / Halogen
Tail / Brake 2 - 5 Watts / 2 - 5 Watts
Starting System Electric Start
Ignition 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 Speedometer
with Multifunction LCD
DC Outlet Standard 12 V
Relays EFI / Fan
Circuit Breaker Fan Motor: 20 Amp
Fuses
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
3.14:1
8.71:1
5.94:1
Drive Ratio - Front 3.82:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Front Gearcase Oil Requirements Polaris Demand Drive Plus
6.75 oz. (200 ml)
Transmission Oil Requirements
Main Gearcase Polaris High Performance AGL 24 oz. (710 ml)
Transmission Oil Requirements
Transfer Case Polaris High Performance AGL 14 oz. (414 ml)
Rear Gearcase Oil Requirements Polaris Premium ADF
26 oz. (769 ml)
Rear Gearcase Oil Requirements
Differential (INT’L) Polaris Premium ADF 18 oz. (532 ml)
Belt 3211133
Steering / Suspension
Front Suspension / Shock Independent Dual A-arm
FOX™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 cm
Shock Preload Adjustment
Front / Rear Threaded Shock Adjustment with Spanner Wrench
Toe Out 1/8-1/4 in. / 3-6.35 mm
Wheels / Brakes
Front Wheel Size
Front Tire Size 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12
Rear Wheel Size
Rear Tire Size 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 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) 21-74 (5632117) Red / White (7043349) Red or Yellow (3234452)
1500-3700
(5000 - 12000) 21-70 (5632127) Red / White (7043349) Red or Yellow (3234452)

1.8
GENERAL INFORMATION
PRELIMINARY VERSION
2010 GENERAL SPECIFICATIONS
MODEL: 2010 RANGER RZR
MODEL NUMBER: R10VH76AD, AG, AJ, AT
ENGINE MODEL: EH076OLE
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)
740 lbs. / 336.4 kg
(Includesrider(s),cargo,accessories
and trailer tongue weight)
Hitch Towing Capacity 1500 lbs. / 680 kg
HitchTongue Capacity 150 lbs. / 68 kg

1.9
GENERAL INFORMATION
1
PRELIMINARY VERSION
MODEL: 2010 RANGER RZR
MODEL NUMBER: R10VH76AD, AG, AJ, AT
ENGINE MODEL: EH076OLE
CLUTCH CHART
Engine
Platform Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH076OLE023
Engine Displacement 760cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 76.5 mm
Compression Ratio 9.78:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Engine Max Operating RPM 6500 ± 200 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 PLUS Synthetic
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.8 qts. / 4.5 liters
Overheat Warning Instrument Cluster Indicator
Exhaust System Single Headpipe / Single Silencer
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
Fuel Capacity / Requirement 7 gal. (26.5 liters)
87 Octane (minimum)
Electrical
Alternator Max Output 500 Watts @ 3000 RPM
Lights: Main Headlights 2 - Single Beam 55 W / Halogen
Tail / Brake 2 - 5 Watts / 2 - 5 Watts
Starting System Electric Start
Ignition 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 Speedometer
with Multifunction LCD
DC Outlet Standard 12 V
Relays EFI / Fan
Circuit Breaker Fan Motor: 20 Amp
Fuses
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
3.14:1
8.71:1
5.94:1
Drive Ratio - Front 3.82:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Front Gearcase Oil Requirements Polaris Demand Drive Plus
6.75 oz. (200 ml)
Transmission Oil Requirements
Main Gearcase Polaris High Performance AGL 24 oz. (710 ml)
Transmission Oil Requirements
Transfer Case Polaris High Performance AGL 14 oz. (414 ml)
Rear Gearcase Oil Requirements Polaris Premium ADF
26 oz. (769 ml)
Belt 3211113
Steering / Suspension
Front Suspension Independent Dual A-arm
w/Anti-Sway Bar
Front Travel 9 in. / 23 cm
Rear Suspension Rolled IRS w/Anti-Sway Bar
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear Cam Adjustment
Toe Out 1/8-1/4 in. / 3-6.35 mm
Wheels / Brakes
Front Wheel Size
Front Tire Size 12 x 6 / 10 gauge Maxxis / 25 x 8 R12
Rear Wheel Size
Rear Tire Size 12 x 8 / 10 gauge Maxxis / 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) 23-62 (5632337) Black (7043594) Blk / Almond (7043167)
1500-3700
(5000 - 12000) 23-58 (5632218) Black (7043594) Blk / Almond (7043167)

1.10
GENERAL INFORMATION
PRELIMINARY VERSION
MODEL: 2010 RANGER RZR S / INT’L
MODEL NUMBER: R10VH76AW / R10VH76FX
ENGINE MODEL: EH076OLE
Category Dimension / Capacity
Length 106 in. / 269 cm
Width 60.5 in. / 154 cm
Height 70.5 in. / 179 cm
Wheel Base 77 in. / 196 cm
Ground Clearance 12 in. / 30.5 cm
Dry Weight 1000 lbs. / 454 kg
Gross Vehicle Weight 1782 lbs. / 808 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)
740 lbs. / 336.4 kg
(Includesrider(s),cargo,accessories
and trailer tongue weight)
Hitch Towing Capacity 1500 lbs. / 680 kg
HitchTongueCapacity 150 lbs. / 68 kg