2010 Polaris Ranger 800 XP HD CREW 6×6 Side by Side Service Manual

Description

This Official 2010 Polaris Ranger RAZR 800 EFI UTV Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the follow UTVs:

2010 Polaris Ranger XP 800

2010 Polaris Ranger HD 800

2010 Polaris Ranger Crew 800

2010 Polaris Ranger 6X6 800

Table of Contents

General Information
Maintenance
Engine
Electronic Fuel Injection
Body/Steering/Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical

Index of Topics

A
Air Filter Service
Air Intake Inspection, Engine
Air Intake Inspection, PVT
All Wheel Drive (AWD) Coil
Authorization Key
Authorization, Reflash
AWD Diagnostics
AWD, Diagnosis
B
Balance Shaft Gear, Removal
Ball Joint Service
Battery Charging
Battery Fluid Level
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Battery Storage
Battery Terminal Block
Blink Codes
Body Removal
Brake Burnishing
Brake Caliper Assembly, Front
Brake Caliper Assembly, Rear (CREW / 6×6)
Brake Caliper Inspection, Front
Brake Caliper Inspection, Rear (CREW / 6×6)
Brake Caliper Installation, Front
Brake Caliper Installation, Rear (CREW / 6×6)
Brake Caliper Removal, Front
Brake Caliper Removal, Rear (CREW / 6×6)
Brake Caliper, Rear (CREW / 6×6)
Brake Disc, Front
Brake Disc, Rear
Brake Hose and Fitting Inspection
Brake Pad and Disc Inspection
Brake Pad Assembly, Front
Brake Pad Assembly, Rear (CREW / 6×6)
Brake Pad Thickness, Front
Brake Pad Thickness, Rear (CREW / 6×6)
Brake Pads, Front
Brake Pads, Rear (CREW / 6×6)
Brake Pads, Rear (XP / HD)
Brake Pads, Removal, Front
Brake Pads, Removal, Rear (CREW / 6×6)
Brake Pedal, Installation
Brake Pedal, Removal
Brake System Inspection
Brake System, Bleeding
Brake System, Exploded View
Brake System, Operation
Brake System, Troubleshooting
Break-In Period
Breather Hose Inspection
c
Cab Frame, Exploded View / Assembly (CREW)
Cab Frame, Exploded View / Assembly (XP / HD / 6×6)
Caliper, Front
Caliper, Rear (XP / HD)
Cam Gear, Reassembly
Cam Gear, Removal
Cargo Box, Installation
Cargo Box, Removal
Charging System
Charging System, Alternator Tests
Chassis / Main Frame, (6×6)
Chassis / Main Frame, (CREW)
Chassis / Main Frame, (XP / HD)
Circuit Breaker
Clutch Alignment
Combustion Chamber
Communication Problems, Digital Wrench
Compression Test
Conversion Table
Coolant Drain
Coolant Level Inspection
Coolant Strength and Type
Cooling System Bleeding Procedure
Cooling System Hoses
Cooling System Specifications
Cooling System, Troubleshooting
Crankshaft Gear, Removal
Crankshaft Position Sensor (CPS)
CV Shaft Boot Inspection
Cylinder Head Assembly
Cylinder Head Assembly Exploded View
Cylinder Head Disassembly
Cylinder Honing To De-glaze
Cylinder Inspection
D
Dash
Dash Instruments / Controls
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostics, AWD
Diagnostics, Gear Circuit
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software, Overview
Digital Wrench Versions
Digital Wrench, Engine Controller Reprogramming
Digital Wrench, Serial Number Location
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Button to Tower Clearance
Drive Clutch, Cover Bushing Removal / Installation
Drive Clutch, Disassembly
Drive Clutch, Exploded View
Drive Clutch, Moveable Sheave Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spider Removal
Drive Clutch, Spring
Drive Shaft / CV Joint, Handling Tips
Driven Clutch, Assembly
Driven Clutch, Disassembly / Inspection
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
E
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI Troubleshooting
EFI, Component Locations
EFI, Diagnostic Codes
EFI, Exploded View
EFI, Service Notes
Electric Box Lift Actuator
Electrical, Cooling System Breakout Diagram
Electronic Control Unit (ECU)
Electronic Power Steering Circuits (EPS)
Engine Cooling System
Engine Designation Number
Engine Exploded Views
Engine Installation Notes
Engine Lubrication
Engine Oil and Filter Change
Engine Oil Level
Engine Removal
Engine Serial Number Location
Engine Service Specifications
Engine Speed Display
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine Torque Specifications
Engine, Accessible Components
Engine, Balance Shaft Removal
Engine, Camshaft Inspection
Engine, Camshaft Installation
Engine, Crankcase Assembly
Engine, Crankshaft Gear Removal
Engine, Crankshaft Installation
Engine, Cylinder Head Assembly
Engine, Cylinder Head Inspection
Engine, Cylinder Head Removal
Engine, Cylinder Head Warp
Engine, Cylinder Honing
Engine, Cylinder Inspection
Engine, Cylinder Installation
Engine, Cylinder Removal
Engine, Flywheel / Stator Removal
Engine, Flywheel and Stator Installation
Engine, Flywheel Removal
Engine, Gear / Stator Housing Seal Replacement
Engine, Gear Installation
Engine, Gear(s) Removal
Engine, Oil Flow Chart
Engine, Oil Pressure Test
Engine, Oil Pump Installation
Engine, Oil Pump Priming
Engine, Oil Pump Removal
Engine, Piston Installation
Engine, Piston Removal, Inspection
Engine, Piston Ring Installed Gap
Engine, Piston to Cylinder Clearance
Engine, Piston to Rod Clearance
Engine, Push Rod Inspection
Engine, Rocker Arm Inspection
Engine, Starter Drive Removal
Engine, Stator Gear Cover Seal(s) Installation
Engine, Stator Installation
Engine, Troubleshooting
Engine, Valve Inspection
Engine, Valve Lifter Removal, Inspection
Engine, Valve Seal/Spring Service
Engine, Valve Sealing Test
Engine, Valve Seat Reconditioning
EPS, Circuit Breakout
EPS, Operation
EPS, Troubleshooting
Exhaust Pipe
F
Fan Control Circuit Bypass Test
Fan Control Circuit Operation
Floor (CREW)
Floor (XP / HD / 6×6)
Flywheel / Stator Removal
Flywheel, Removal
Front A-arm, Replacement
Front Bearing Carrier
Front Bumper
Front Caliper, Piston Bore ID
Front Drive Shaft, Removal
Front Driveshaft, Installation
Front Fascia
Front Fenders
Front Gearcase – Ring Gear Backlash Adjustment
Front Gearcase Lubrication
Front Gearcase, Assembly / Inspection
Front Gearcase, Centralized Hilliard
Front Gearcase, Coil Resistance
Front Gearcase, Disassembly / Inspection
Front Gearcase, Exploded View
Front Gearcase, Installation
Front Gearcase, Removal
Front Propshaft, Removal (6×6)
Front Propshaft, Removal (CREW)
Front Propshaft, Removal (XP / HD)
Fuel Filter
Fuel Injectors
Fuel Lines
Fuel Pressure Regulator
Fuel Pump Assembly
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics, Digital Wrench
Fuel Tank, Exploded View
Fuel Tank, Replacement
Fuses
G
Gear Circuit Diagnostics
Gear Position Indicator Switch Test
General Specifications, Brakes
Glove Box
Guided Diagnostics
H
Head Lights
Hood
Hour Meter
I
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Indicator, Service Interval
Inner Plunging Joint / Boot Replacement
Instrument Cluster
Instrument Cluster, Installation
Instrument Cluster, Removal
Instrument Cluster, Troubleshooting Tests
K
Key, Reprogramming Authorization
Keys, Replacement
Kilometers to Miles Toggle
L
Leakdown Test
Lower Seat Base
Lubrication Grease Points
M
Maintenance Quick Reference Chart
Maintenance Schedule
Maintenance, Brake System
Maintenance, Cooling System
Maintenance, Electrical and Ignition
Maintenance, Engine
Maintenance, Final Drive
Maintenance, Fuel System
Maintenance, General Vehicle Inspection
Maintenance, References
Maintenance, Service Products and Lubricants
Maintenance, Steering
Maintenance, Transmission and Gearcases
Master Cylinder, Installation
Master Cylinder, Removal
Mechanical Seal Installation
Mid / Rear Fenders (CREW)
Mid A-arm, Replacement
Mid Bearing Carrier
Mid Drive Gearcase (6×6)
Mid Drive Shaft, Installation
Mid Drive Shaft, Removal
Mid Gearcase Lubrication (6×6)
Miles to Kilometers Toggle
Model Identification
o
Odometer
Oil Pump Priming
Oil Pump, Disassembly
Oil Pump, Reassembly
Oil Pump, Removal
Outer CV Joint / Boot Replacement
P
Parking Brake Caliper, Disassembly / Inspection (4×4)
Parking Brake Caliper, Disassembly / Inspection (6×6)
Parking Brake Caliper, Exploded View (4×4)
Parking Brake Caliper, Exploded View (6×6)
Parking Brake Caliper, Installation (4×4)
Parking Brake Caliper, Installation (6×6)
Parking Brake Caliper, Pad Installation (4×4)
Parking Brake Caliper, Pad Installation (6×6)
Parking Brake Caliper, Removal (4×4)
Parking Brake Caliper, Removal (6×6)
Parking Brake Disc
Parking Brake Pad Inspection
Parking Brake, Adjustment
Parking Brake, Exploded View (6×6)
Parking Brake, Exploded View (XP / HD / CREW)
Parking Brake, Inspection
Periodic Maintenance Chart
Piston Ring Installed Gap
Piston to Cylinder Clearance
Piston to Rod Inspection
Power Steering Unit, Installation
Power Steering Unit, Removal
Power Steering, Exploded View
Pre-Ride / Daily Inspection
Programmable Service Interval
Propshaft, Mid Drive (6×6)
Publication Numbers
PVT Break-In
PVT System, Assembly
PVT System, Disassembly
PVT System, Maintenance
PVT System, Overview
PVT System, Service
PVT Troubleshooting
R
Radiator
Rear A-arm, Replacement
Rear Bearing Carrier
Rear Caliper, Piston Bore ID (CREW / 6×6)
Rear Cargo Box
Rear Drive Shaft, Installation
Rear Drive Shaft, Removal
Rear Fenders (CREW)
Rear Fenders (XP / HD / 6×6)
Rear Gearcase (6×6)
Rear Gearcase Lubrication (6×6)
Rear Propshaft Service (6×6)
Rear Stabilizer Bar
Rear Storage Box (6×6)
Rectifier Test
Reflash Authorization
Regulator / Rectifier Test
Relays
Reprogramming Authorization
Resistor, Power Steering
Restrictor Plate, Engine Intake
s
Seat Assembly
Seat Belts
Self-Leveling Suspension (HD)
Service Interval Indicator
Shift Cable, Adjustment
Shift Cable, Adjustment (6×6)
Shift Cable, Adjustment (XP / HD / CREW)
Shift Cable, Inspection
Shift Lever, Installation
Shift Lever, Removal
Shock Disposal, Nivomat (HD)
Shock Operation, Nivomat (HD)
Shock, Adjustment
Shocks and Springs
Software Version
Solenoid, Rear Differential
Spark Plug Service
Special Tool, Cam Gear Installation Kit
Special Tools
Special Tools, Body/Steering/Suspension
Special Tools, Brakes
Special Tools, Clutching
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Special Tools, Transmission
Specification, Balance Shaft Gear Bolt Torque
Specification, Cam Lobe Height
Specification, Cam Thrust Plate Fastener Torque
Specification, Camshaft Gear Bolt Torque
Specification, Coolant Temperature Sensor Resistance
Specification, Cylinder Head Warp
Specification, Cylinder Taper Limit
Specification, Cylinder Warp Limit
Specification, Oil Pump Bolt Torque
Specification, Oil Pump Rotor Clearance
Specification, Timing Gear Alignment
Specification, Transmission Silent Chain Length
Specification, Valve Seat Contact Width
Specification, Valve Spring Free Length
Specification, Valve Stem Diameter
Specification, Valve Stem Guide ID
Specification, Wheel Toe-Out
Specifications, Camshaft
Specifications, Cooling System
Specifications, Crankcase Fastener Torque
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Specifications, General
Specifications, Oil Baffle Bolt Torque
Specifications, Oil Pick-up Bolt Torque
Speedometer
Starter Drive
Starter Drive Removal
Starter Motor Assembly, Exploded View
Starter Motor, Armature Testing
Starter Motor, Brush Inspection / Replacement
Starter Motor, Reassembly / Installation
Starter Motor, Removal
Starter Solenoid, Operation
Starter Solenoid, Test
Starter System, Troubleshooting
Starting System Testing Flow Chart
Stator, Removal
Steering
Steering, Exploded View
Storage Panel
Suspension Inspection
Suspension Spring Preload Adjustment
Switch, AWD / 2WD / TURF
Switch, Brake Light
Switch, Headlight
Switch, Parking Brake
T
Tachometer
Tail Lights
Tailgate
Tap/Drill Sizes
Temperature / Barometric Air Pressure Sensor (T-BAP)
Throttle Freeplay Adjustment
Throttle Pedal Inspection
Throttle Position Sensor (TPS)
Tie Rod End and Steering Inspection
Timing Gear Mark Alignment
Tire Inspection
Tire Pressure
Toe Adjustment
Torque Chart
Torque Specification, Wheel and Hub
Torque Specifications – Engine
Torque Specifications, Body/Steering/Suspension
Torque Specifications, Brakes
Torque Specifications, Clutching
Torque Specifications, Final Drive
Torque Specifications, Transmission
TPS Replacement
TPS, Adjustment
Transmission Lubrication (6×6)
Transmission Lubrication (XP / HD / CREW)
Transmission, Assembly
Transmission, Disassembly
Transmission, Exploded View
Transmission, Install
Transmission, Installation
Transmission, Operation
Transmission, Output Shaft Backlash Procedure
Transmission, Removal
Trip Meter
Troubleshooting, Brake Noise
Troubleshooting, Clutching
Troubleshooting, No AWD
Troubleshooting, No AWD Hub Safety Limiter
Troubleshooting, No Fuel Gauge Display
Troubleshooting, No Gear Indicator Display
Troubleshooting, No Instrument Display
Troubleshooting, Transmission
Troubleshooting, Wheel Speed Sensor
V
Valve Seal/Spring Service
Valve Sealing Test
Valve Seat Reconditioning
Vent Lines
Version, Software
VIN Identification
VIN Location
Voltage Drop Test
w
Wheel Alignment
Wheel Well Panels
Wheel, Installation
Wheel, Removal