This is the Highly Detailed factory service repair manual for the2008 POLARIS RANGER 4X4 500 EFI, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. They are specifically written for the do-it-yourself-er as well as the experienced mechanic.2008 POLARIS RANGER 4X4 500 EFI Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

1. Polaris Ranger Series 11 Service Manual
2. 2003 Polaris Ranger Series 11 Service Manual
3. 2003 Polaris Professional Series Parts

Service Repair Manual Covers: General Information Maintenance Engine Carburetion Electronic Fuel Injection Body / Steering / Suspension Clutching Final Drive Transmission Brakes Electrical Wire Diagrams File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2008 POLARIS RANGER 4X4 500 EFI Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: Thanks for visiting! 2008 Polaris Ranger 4X4 500 EFI Service Repair Manual.

1. 2008 RANGER 500 2X4 / 4X4 EFI SERVICE MANUAL 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 9921267 © 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.

Polaris Ranger Series 11 Service Manual

Printed in U.S.A. UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. Fluke, Registered Trademark of John Fluke Mfg.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION. 1GENERAL INFORMATION 2MAINTENANCE 3ENGINE 4CARBURETION / EFI 5BODY / STEERING / SUSPENSION 6CLUTCHING 7FINAL DRIVE 8TRANSMISSION BRAKES 9 ELECTRICAL 10. GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION.

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 GENERAL SPECIFICATIONS. 1.6 GENERAL: 2008 RANGER 2X4 / 4X4 EFI. 1.6 DETAILED: 2008 RANGER 2X4. 1.7 DETAILED: 2008 RANGER 4X4 EFI. 1.8 VEHICLE INFORMATION. 1.9 PUBLICATION NUMBERS.

2003 Polaris Ranger Series 11 Service Manual

1.9 PAINT CODES. 1.9 REPLACEMENT KEYS.

1.9 SPECIAL TOOLS. SPECIFICATIONS AND CHARTS. 1.10 CONVERSION TABLE. 1.10 STANDARD TORQUE SPECIFICATIONS. 1.11 SAE TAP / DRILL SIZES. 1.12 METRIC TAP / DRILL SIZES.

1.12 DECIMAL EQUIVALENTS. 1.12 GLOSSARY OF TERMS. 1.13. 1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service.

Engine Designation Number EH50PLE.Single, L/C, SOHC 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 flywheel housing on the right side of engine. Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 8 R B 5 0 A A 4 X A R B 5 0 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 YearBody Style Plant No.

Individual Serial No. This could be either a number or a letterPowertrain Emissions A Engine Serial Number. 1.3 GENERAL INFORMATION 1 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). Transmission I.D. Number Location A A A B The transmission I.D. Number is located on the right side when installed in the machine. 1.4 GENERAL INFORMATION VEHICLE DIMENSIONS 75 in.

190.50 cm 10 in. 25.4 cm 58 in. 147 cm RANGER 2X4, 4X4 RANGER 2X4, 4X4. 1.5 GENERAL INFORMATION 1 VEHICLE DIMENSIONS 113 in. 287 cm 58 in. 147 cm 76 in. 193 cm RANGER 2X4, 4X4.

1.6 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER 2X4 MODEL NUMBER: R08RB50AA ENGINE MODEL: EH50PLE MODEL: 2008 RANGER 4X4 EFI MODEL NUMBER: R08RH50AF, AR, AT ENGINE MODEL: EH50PLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11 in.

/ 27.9 cm Turning Radius 148 in. / 376 cm Dry Weight 1105 lbs. / 501 kg Gross Vehicle Weight 2755 lbs. / 1250 kg Cargo Box Capacity 1000 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 - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in.

/ 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11 in. / 27.9 cm Turning Radius 148 in. / 376 cm Dry Weight 1185 lbs.

/ 538 kg Gross Vehicle Weight 2835 lbs. / 1286 kg Cargo Box Capacity 1000 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 - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs.

/ 68 kg. 1.7 GENERAL INFORMATION 1 MODEL: 2008 RANGER 2X4 MODEL NUMBER: R08RB50AA ENGINE MODEL: EH50PLE JETTING CHART CLUTCH CHART Engine Platform Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled Engine Model Number EH500PLE169 Engine Displacement 499 cc Number of Cylinders 1 Bore & Stroke 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi Engine Idle Speed 1200 ± 200 RPM Valve Clearance Int./Exh. (0.152 mm) Engine Hot Light Dash Light Lubrication Pressurized Dry Sump Oil Requirements 0W-40 Oil Capacity 2 qts.

(1.9 L) Coolant Capacity 3.25 qts. (3.08 L) Exhaust System Single Pipe / Canister Style Carburetion Carburetor model Mikuni BST 34mm CV Main Jet 135 Pilot Jet 42.5 Jet Needle 4MB32-3 Needle Jet P-6 (829) Pilot Screw 2.5 Turns Out (Initial starting point, settings may vary) Pilot Air Jet 160 Float Height 0.51 ± 0.40 in. (13 ± 1 mm) Fuel Delivery Electric Fuel Pump (External) Fuel Capacity / Requirement 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 250 watts @ 5000 RPM Lights: Main Headlights 2 - Single Beam 50w / Halogen Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System 12V DC/CDI RPM Limit 6600 RPM Ignition Timing 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR5E /.036 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B Conventional / 30 Amp Hr.

2003 Polaris Professional Series Parts

/ 12 Volt Instrument Panel Type Indicator Lights / Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Transmission Gear Ratio: High Low Reverse 4.43:1 10.08:1 6.87:1 Final Drive Ratio 3.70:1 Shift Type In Line Shift - H / L / N / R Transmission Oil Requirements Polaris Synthetic AGL 15.2 oz. (450 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 18 oz. (532 ml) Belt 3211077 Drive Belt Deflection 1.125 in. (28.58 mm) Center Distance 10 in. (254 mm) Clutch Offset 0.5 in. (12.7 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.