General Information
Contents
1. 1 7 GENERAL INFORMATION MODEL 2006 RANGER 6x6 EFI MODEL NUMBER RO6RF68AA ENGINE MODEL EHO680LE 023 Platform Polaris Twin Cylinder Engine Model Number EH0680LE 023 Number of Cylinders Bore Stroke mm Engine Idle Speed Engine Max Operating Rpm Cooling System Capacity Polaris OW 40 2 qt 1 9 Itr Compression Ratio Compression Pressure Overheat Warning Lubrication Oil Requirements Capacity Exhaust System Single Pipe Fuel System Fuel System Electronic Fuel Injection EF 1 25L per hour at 39 PSI Bosch MSE 1 1 ECU 9 5 gal US 36 ltr 87 Octane minimum 89 Oxygenated Fuel Pump in tank assembly Fuel Filter s Fuel Injector s EFI Controller Capacity Requirement 500 w 6000 RPM 2 Dual Beam 35 watts quartz Twat a Circuit Breakers Fan 20 amp Harness 20 amp Fuel pump ECU 15 amp Instrument Cluster Voltage Regulator 6 amp 1 8 Transmission Type Dual Sensing Automatic PVT Gear Ratio Final Drive Ratio 3 70 1 3 83 1 3 70 1 In Line EZ Shift Hi Low R everse Polaris AGL Gearcase Lube 3211106 1 125 28 57 mm 10 254 5 mm 0 5 12 7 mm See Below Front Drive Ratio Mid Drive Ratio Shift Type Trans Oil Requirements Belt Drive Belt Deflection Center Distance Clutch Offset Springs and Weights Steering Suspension Front Suspension MacPherson Strut 6 25 in 15 9 cm Independent 52. 2006 RANGER XP 4X4 MODEL NUMBER RO5RD68AA RO6RD68AA ENGINE MODEL EH68PLE RANGER XP 4x4 Front 11 in 28 cm Rear 12in 30 5 cm Cargo Box Dimensions 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Vehicle Payload 1500 Ibs 681 kg Includes one driver pas senger box and cargo Hitch Towing Capacity 1750 Ibs 794 kg Hitch Tongue Capacity 150 lbs 68 1 kg MODEL 2006 RANGER 6X6 EFI MODEL NUMBER RO6RF68AA ENGINE MODEL EH68PLE Dimension Capacity RANGER 6x6 EFI 90 in 229 cm Cargo Box Capacity 1250 Ibs 567 kg Cargo Box Dimensions 58 x 48 x 10 in 147 x 122 x 25 4 cm Vehicle Payload 1750 Ibs 794 kg Includes driver cargo and passenger Hitch Towing Capacity 1750 Ibs 794 kg Hitch Tongue Capacity 150 Ibs 68 1 kg 1 6 POLARIS MODEL 2005 2006 RANGER 4x4 XP MODEL NUMBER RO6RD68AA ENGINE MODEL EHO680LE 023 Platform Engine Model Number Engine Displacement Number of Cylinders Bore amp Stroke mm 80 x 68 mm 9 40 1 Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating Rpm Cooling System Capacity Polaris OW 40 2 qt 1 9 Itr Single Pipe Overheat Warning Lubrication Oil Requirements Capacity Exhaust System Fuel System Fuel System Electronic Fuel Injection EF 1 25L per hour at 39 PSI See Chapter 4 Bosch MSE 1 1 ECU 9 5 gal US 36 ltr 87 Octane minimum 89 Oxygenated Fuel
3. Pump in tank assembly Fuel Filter s Fuel Injector s EFI Controller Capacity Requirement 500 w 6000 RPM 2 Dual Beam 35 watts quartz Twat ee 7 BTDC 1200 RPM RC7YC 035 in 0 9 mm Circuit Breakers Fan 20 amp Harness 20 amp Fuel pump ECU 15 amp Instrument Cluster Voltage Regulator 6 amp POLARIS GENERAL INFORMATION Transmission Type Dual Sensing Automatic PVT Transmission Gear Ratio Front Rear High 3 89 1 3 36 1 Low 10 08 1 8 71 1 Rev 6 87 1 5 94 1 Trans Oil Requirements Drive Belt Deflection 1 125 28 57 mm 10 254 5 mm 0 365 9 27 mm Springs and Weights Front Suspension 8 63 in 22 cm Front 11 in 28 cm Rear 12 in 30 5 cm Cam Adjustment 2 2 Twin Tubes Turning Radius 132 in 335 cm Toe Out 1 8 1 4 in 3 6 35 mm Wheel Size Front Wheel Size Rear Foot Actuated Mechanical DOT 3 or DOT 4 Final Drive Ratio Front Drive Ratio Center Distance Clutch Offset Front Travel Rear Suspension Rear Travel Ground Clearance Shock Preload Adjustment Front Rear F R Tire Air Pressure Brake Front Brake Rear Parking Brake Brake Fluid CLUTCH CHART 2 Shift Drive Second Altitude Weight Spring Spring 0 1500 20 60 Blu Gray BIk Almond Meters 0 5000 5631698 7042202 7043167 F eet 1500 3700 20 56 Blu Gray BIk Almond 5000 12000 5631215 7042202 7043167
4. 25 in 13 3 cm Swing Arm w Dual Shocks 6 25 in 15 9 cm 7 2 in 180 mm Cam Adjustment 2 2 Twin Tubes 186 in 472 4 cm 1 8 1 4 in 3 6 35 mm Front Travel Center Suspension Center Travel Rear Suspension Rear Travel Ground Clearance Shock P reload Adjustment Front Rear Turning Radius Toe Out Wheels Brakes Wheel Size Front Wheel Size Rear 25x10 12 25x11 12 Recommended Air Pressure 8 12 psi Front F R 8 12 psiRear CLUTCH CHART Altitude Shift Drive Second Weight Spring Spring 0 1500 20 60 Blu Gray BIk Almond Meters 0 5000 5631698 7042202 7043167 F eet 1500 3700 20 56 Blu Gray BIk Almond 5000 12000 5631215 7042202 7043167 POLARIS A GENERAL INFORMATION CR PUBLICATION NUMBERS Model No Owner s Service Parts Parts Manual PN Manual PN Manual PN Micro Fiche PN ee RANGER XP 4x4 EFI 2006 RO6RF 68AA 9920220 9920224 9920225 9920226 RANGER 6x6 EFI 2006 RO6RD68AA 9920220 9920224 9920221 9920222 RANGER XP 4x4 EFI NOTE When ordering service parts be sure to use the correct parts manual NOTE Some Polaris factory publications can be found at www polarisindustries com or purchased from www purepolaris com PAINT CODES PART DESCRIPTION NUMBER RANGER 6x6 EFI Cab Frame amp Front Bumper Flat Black Wrinkle P 418 RANGER 6x6 EFI Plastic Eddie Bauer Green P 195 Order direct from Midwest Industr
5. A 45658 Main Crank Seal Saver PA 45401 Water Pump Seal Saver PU 45778 Oil Pump Priming Tool POLARIS Standard Tools and Engine Tools Ba PU 47315 Throttle Body Adjustment Screwdriver 2870459 Dial Indicator N ea on er Klm JU y PV 35667 A a Leak down Tester 2872105 Water Pump Seal Puller POLARIS GENERAL INFORMATION 2871283 Crank Water Pump Seal Install Kit Clutch PVT Tools 2870913 Driven Clutch Puller H PA 47346 Clutch Align Tool na 9914177 A Drive Clutch Holding Tool 2871358 Clutch Holding F ixture 1 13 GENERAL INFORMATION Clutch PVT Tools 2870341 Drive Clutch Spider Removal Tool 2870910 Roll Pin Tool Ye ER 2871226 Clutch Bushing Replacement Kit 2870338 Spider Nut Socket Suspension amp Transmission Tools pa 2870872 Shock Spanner Wrench Be 2872608 Roll Pin Removal Tool 1 14 4 Se 2870871 ATV Ball oint Tool Kit d 2871071 Shock Body Holding Tool 2871573 amp 2871574 Strut Spring Compressor 8700225 amp 8700226 CV Boot Clamp Pliers POLARIS PU 47063 Digital Wrencht Software PU 47151 Interface Cable PV 43568 Fluket 77 Multimeter xX 2460761 Hall Sensor Probe Harness Y PV 39617 Current Clamp SN we 2870836 Battery Hydrometer bist En 8712500 PV 39951 A Tachometer Tachometer POLARIS G
6. ENERAL INFORMATION Electrical Tools zz 2870630 Timing Light PV 39991 Peak Reading Adapter NG D Ed 0 PV 37453 Christie Se Sulfating Multi Battery Charger PV 63070 Christie Multi Battery Charger Fuel amp Brake Systems 2870975 Mity Vact 1 15 GENERAL INFORMATION is STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual section for torque values of fasteners before using standard torque DUE Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in Ibs Nm 10 7 aaa 27 3A sec sen 43 5 0 60 6 9 10 GER SHEN CEFA o A 49 5 0 een 68 7 8 Torque ft Ibs Nm 1 4 a HALT miis Bo BRD EE 12 16 14 LORA OO dia a SA Gan San 10 14 14 19 5 16 1 1 ULI a KC 25 35 5 16 KREE A EE ES eieiei ees 29 40 3 8 CP 20 27 een 30 40 cee eae 45 62 3 8 Daria ada ai E ME KEE 35 48 50 69 7 16 VAR 20401 50 69 70 97 7 16 GEES 35 48 wo ccc eee ee ees 55 76 nennen 80 110 12 Vara URL WEE 75 104 110 152 1 2 KEE 55 pl 90 124 120 166 Metric 6x1 0 72 78 In lbs 8x1 25 14 18 ft Ibs 10x1 25 26 30 ft lbs To convert ft Ibs to Nm multiply foot pounds by 1 382 To convert Nm to ft Ibs mu
7. found on the sticker applied to the top side of the crank case A An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow TRANSMISSION I D NUMBER The transmission I D number is located on LOCATION the right side of machine Be Mt t cu POLARIS s 8 GENERAL INFORMATION MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification The machine serial number A is stamped on the lower frame rail close to the front drive wheel The model and serial number B are also located on a sticker on the hood liner 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 KEY BOOT P N 5533534 Series Part Number ao JE 4010278 gt pz joma 31XX 23 4010321 Key Seri 4010321 Number ze oa 4110141 4110148 4010278 SP POLARIS A 13 GENERAL INFORMATION MACHINE DIMENSIONS RANGER XP 6x6 EF 75 in 190 50 cm 1 4 ER POLARIS GENERAL INFORMATION MACHINE DIMENSIONS RANGER XP 6x6 EFI POLARIS 120 in 305 cm 1 5 GENERAL INFORMATION is MODEL 2005
8. ia GENERAL INFORMATION CHAPTER 7 GENERAL Model Identification 1 2 Serial Number Location 1 2 Models Numbers Replacement Key 1 3 Machine Dimensions 1 4 1 5 Specifications RANGER 1 6 1 8 Publication Numbers sn uses she 1 9 Pal GOES so tas 1 9 Starting the RANGER 1 10 Pre Ride Inspection o ooooomooom o 1 10 RANGER Accessories 1 11 Sp cial TOOS errar en 1 12 1 15 Standard Torque Specifications 1 16 Decimal Equivalent Chart 1 17 Tap Dril C Karts zer seat ee 1 17 Glossary of TermS ana KA ie 1 18 POLARIS o did GENERAL INFORMATION is MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service Machine Model Number Identification R 06 RD 68 AA BA S Emissions amp Model Year Model Option Desianati Basic Chassis esignation Designation Engine Designation Engine Designation Number EHO680LE023 Twin Liquid cooled OHV 4 Stroke Electric Start VIN Identification World Mfg ID Vehicle Description Vehicle Identifier Body Style Emissions Model This could be either Engine Year Individual Serial No a number or a letter Powertrain Check Digit Plant No ENGINE SERIAL NUMBER LOCATION Be sure to refer to the engine model number and serial number whenever corresponding about an engine This information can be
9. ial Coatings 952 942 1840 Mix as directed Frost Plug Heater PN 2873069 ACCESSORY ENGINE HEATER For Domestic Twin Cylinder Engines A frost plug heater is available for Polaris domestic twin cylinder en gines Contact your local Polaris dealer to order this kit EA DD 19 DDD Y AN N POLARIS 0 19 GENERAL INFORMATION is PRE RIDE DAILY INSPECTION Perform the following pre ride inspection daily and S Wheels check for tightness of wheel nuts when servicing the vehicle ateach scheduled mainte and axle nuts check to be sure axle nuts are nance secured by cotter pins S Tires check condition and pressures S Air cleaner element check for dirt clean or S Fuel and oil tanks fill both tanks to their replace S Steering check for free operation noting proper level Do not overfill oil tank any unusual looseness in any area S All brakes check operation and adjustment S Loose parts visually inspect vehicle for includes auxiliary brake any damaged or loose nuts bolts or fasten S Throttle check for free operation and clos ers ing S Engine coolant check for proper level at S Headlight Taillight Brakelight check opera the recovery bottle tion of all indicator lights and switches STARTING THE RANGER NOTICE Refer to your owners manual for machine operating procedures and safety pre caustions 1 While seated in the drivers seat with seat belt onds release the ignition switch and wait five
10. ltiply Nm by 7376 SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate sectionTorque Conversions LI WT 000000000000 T aeeE POLARIS ia GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS Thread Size Drill Size Thread Size Drill Size 1 1 mm 3 0394 S 1 2 13 27 64 1 2 20 29 64 9 16 12 31 64 2 mm 0787 9 16 18 33 64 i 3mm 1181 5 8 11 17 32 5 8 18 37 64 3 4 16 11 16 3 16 5 mm 1969 7 8 9 49 64 7 8 14 13 16 7 1 8 7 8 6 mm 2362 1 12 59 64 7mm 2756 1 1 8 7 63 64 9 32 1 1 8 12 1 3 64 i 1 Wi 11 4 7 1 7 64 la 1 1 4 12 1 11 64 9 mm 3 3543 1 1 2 6 1 11 32 i 1 1 2 12 1 27 64 e A T 1 3 4 5 1 9 16 1 3 4 12 1 43 64 11mm 4331 2 4 1 2 1 25 32 1116 2 12 1 59 64 12 mm 4724 2 1 4 4 1 2 2 1 32 2 1 2 4 2 1 4 5 13 mm 5118 2 3 4 4 2 1 2 3 4 2 3 4 14 mm 2 5512 9 16 15 mm 5906 62 16 mm 6299 Decimal Nearest 17 mm 6693 Equiva Fraction lent 18mm 7087 l 19 mm 7480 20 mm 7874 21 mm 8268 22 mm 8661 23 mm 3 9055 24 mm 3 9449 25 MM 9843 POLARIS 7 GENERAL INFORMATION is GLOSSARY OF TERMS ABDC 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 t
11. nd 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 Ib 12 in lbs 1 ft lb 2 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 lor ltr Liter Ibs 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 1mm approximately 040 Nm Newton meters OD Outside diameter Ohm The unit of electrical resistance opposing current flow 0z 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
12. op 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 Cl 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 offsetso that drive beltwill stay nearly straightas 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 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 Pou
13. sec fastened Engage the park brake onds Repeat the starting process 2 P n the brak and turn the tano R er EDEN 3 Oncethe engine is started letthe engine warm up for a few moments Vary the throttle to aid in NOTE If the engine does not start within five sec engine warm up tarting the RANGER Ignition Key 1 1 01m POLARIS ia GENERAL INFORMATION RANGER ACCESSORIES Lock amp Ride Latch System H Standard Cab System ps o 7 Horn Kit 2 Receiver Hitch POLARIS BE EE Mud Flaps 4 0 Cl Warnt Winch Cargo Box Lift RANGER ACCESSORIES A variety of accessories are available Glacier Plow System for your RANGER Contact your dealer for pricing and availability POLARIS da GENERAL INFORMATION SPECIAL TOOLS Special Tools maybe required while servicing your machine Some of the tools listed are mandatory and other tools maybe substituted with a similar tool if available Polaris recommends the use of Polaris special tools when servicing any Polaris product Standard Tools and Engine Tools PU 45432 Caliper or A Basic Caliper Basic Micrometer 2871043 Flywheel Puller m A 2870773 C Clip Install Tool Ki PA 2870386 Piston Pin Puller O 2871445 Piston Pin Puller Adapter 1 12 Sta lt 2870390 Piston Support Block o PA 44995 Water Pump Mechanical Seal Install Tool PA 45483 Main Seal Installer P
14. the electrical sense ohms resulting in energy conversion to heat RPM Revolutions per minute Seized Piston Galling ofthe sides ofa 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 18 POLARIS
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