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2008 RANGER 700
4X4 XP / 4X4 CREW / 6X6
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 9921277
© 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. Printed in U.S.A.
1
GENERAL INFORMATION
2
MAINTENANCE
3
ENGINE
4
ELECTRONIC FUEL INJECTION
5
BODY / STEERING / SUSPENSION
6
CLUTCHING
7
FINAL DRIVE
8
TRANSMISSION
BRAKES 9
ELECTRICAL 10
GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
RANGER 4X4 XP, 4X4 CREW, 6X6 (HEIGHT AND WIDTH) . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 4X4 XP, 6X6 (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
RANGER 4X4 CREW (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2008 RANGER 4X4 XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2008 RANGER 4X4 CREW / 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2008 RANGER 4X4 XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
DETAILED: 2008 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DETAILED: 2008 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
1.2
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
EH068OLE046PLE ............................................................Twin, Liquid Cooled, OHV 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 cylinder head on the side of engine.
}
Machine Model Number Identification
}
}
Model Year
Designation
Basic Chassis
Designation Engine Designation
Emissions &
Model Option
R 0 8 R H 6 8 A G
}
4 X A R H 6 8 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
Year
Body Style
Plant No.
Individual Serial No.
* This could be either
a number or a letter
Powertrain
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
RANGER 4x4 XP, 4x4 CREW, 6X6 (Height and Width)
75 in.
190.5 cm
11.5 in.
29.2 cm
60 in.
152.4 cm
RANGER 4x4
1.5
GENERAL INFORMATION
1
RANGER 4x4 XP, 6X6 (Length and Wheel Base)
120 in.
305 cm
42.5 in.
108 cm
27 in.
69 cm
90 in.
229 cm
113 in.
287 cm
36.5 in.
92.7 cm
76 in.
193 cm
1.6
GENERAL INFORMATION
RANGER 4x4 CREW (Length and Wheel Base)
145 in.
386 cm
108 in.
274 cm
36.5 in.
92.7 cm
1.7
GENERAL INFORMATION
1
GENERAL SPECIFICATIONS
MODEL: 2008 RANGER 4X4 XP
MODEL NUMBER: R08RH68AB, AG, AH, AJ, AK, AP, AR, AS
ENGINE MODEL: EH68OLE
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)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
Pearl White L.E.
Boardwalk Blue L.E.
Turbo Silver L.E.
Stealth Black L.E.
Browning Edition
1.8
GENERAL INFORMATION
MODEL: 2008 RANGER 4X4 CREW
MODEL NUMBER: R08WH68AG
ENGINE MODEL: EH68OLE
MODEL: 2008 RANGER 6X6
MODEL NUMBER: R08RF68AD, AF
ENGINE MODEL: EH068OLE
Category Dimension / Capacity
Length 145 in. / 386 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 108 in. / 274 cm
Ground Clearance 11 in. / 27.9 cm
Turning Radius 224 in. / 569 cm
Dry Weight 1460 lbs. / 664 kg
Gross Vehicle Weight 3360 lbs. / 1524 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
1750 lbs. / 794 kg
(Includes driver and five
passengers)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
Category Dimension / Capacity
Length 120 in. / 305 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 90 in. / 229 cm
Ground Clearance 7.2 in. / 18.3 cm
Turning Radius 186 in. / 472 cm
Dry Weight 1410 lbs. / 640 kg
Gross Vehicle Weight 3310 lbs. / 1501 kg
Cargo Box Capacity 1250 lbs. / 567 kg
Cargo Box Dimensions
54 x 42.5 x 11.5 in.
(137 x 108 x 29.2 cm)
Vehicle Payload
1750 lbs. / 794 kg
(Includes driver and two
passengers)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
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1.9
GENERAL INFORMATION
1
MODEL: 2008 RANGER 4X4 XP
MODEL NUMBER: R08RH68AB, AG, AH, AJ, AK, AP,
AR, AS
ENGINE MODEL: EH68OLE
CLUTCH CHART
Engine
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE046
Engine Displacement 683cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 68 mm
Compression Ratio 9.40:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Lubrication Pressurized Wet Sump
Oil Requirements 0W-40
Oil Capacity 2 qts. (1.9 L)
Coolant Capacity 3.25 qts. (3.08 L)
Overheat Warning Instrument Cluster Indicator
Exhaust System 2 to 1 Canister Style
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
9 gal. (34 L)
87 Octane (minimum)
Electrical
Alternator Max Output 500 watts @ 3000 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 Bosch EFI (ECU Controlled)
Ignition Timing 7° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Instrument Type Multifunction Speedometer
DC Outlet Standard
Relays Fan / ECU / Rear Diff Solenoid
Circuit Breakers Fan Motor: 15 Amp
Fuses
Main Chassis: 20 Amp
Accessory: 20 Amp
EFI Power: 15 Amp
Speedo / ECU: 6 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
3.63:1 / 3.14:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Polaris Demand Drive LT Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Polaris Synthetic AGL
15.2 oz. (450 ml)
Rear Gearcase Oil Requirements
Polaris Premium ADF
18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 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. (3.2 - 6.35 mm)
Wheels / Brakes
Front Wheel Size
Standard - 12 x 6 / Steel
L.E. - 12 x 6 / Cast Aluminum
Rear Wheel Size
Standard - 12 x 8 / Steel
L.E. - 12 x 8 / Cast Aluminum
Front Tire
Make / Model / Size
Carlisle / PXT / 26 x 8 R12
Rear Tire
Make / Model / Size
Carlisle / PXT / 26 x 11 R12
Tire Air Pressure - Front / Rear 8-12 psi / 8 - 12 psi
Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Parking Brake Hand Actuated (in dash)
Altitude Shift Weight Drive Spring
Driven
Spring
Meters
(Feet)
0-1500
(0-5000)
21-74
(5632117)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1500-3700
(5000 - 12000)
21-70
(5632127)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1.10
GENERAL INFORMATION
MODEL: 2008 RANGER 4X4 CREW
MODEL NUMBER: R08WH68AG
ENGINE MODEL: EH68OLE
CLUTCH CHART
Engine
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE047
Engine Displacement 683cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 68 mm
Compression Ratio 9.40:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Lubrication Pressurized Wet Sump
Oil Requirements 0W-40
Oil Capacity 2 qts. / 1.9 L
Coolant Capacity n/a
Overheat Warning Instrument Cluster Indicator
Exhaust System 2 to 1 Canister Style
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
9 gal. (34 L)
87 Octane (minimum)
Electrical
Alternator Max Output 500 watts @ 3000 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 Bosch EFI (ECU Controlled)
Ignition Timing 7° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Instrument Panel Type Multifunction Speedometer
DC Outlet Standard
Relays Fan / ECU / Rear Diff Solenoid
Circuit Breakers Fan Motor: 15 Amp
Fuses
Main Chassis: 20 Amp
Accessory: 20 Amp
EFI Power: 15 Amp
Speedo / ECU: 6 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
4.43:1 / 3.83:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Polaris Demand Drive LT Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Polaris Synthetic AGL
15.2 oz. (450 ml)
Rear Gearcase Oil Requirements
Polaris Premium ADF
18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 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. (3.2 - 6.35 mm)
Wheels / Brakes
Front Wheel Size 12 x 6 / 10 gauge
Rear Wheel Size 12 x 8 / 10 gauge
Front Tire
Make / Model / Size
Carlisle / PXT / 26 x 9 R12
Rear Tire
Make / Model / Size
Carlisle / PXT / 26 x 11 R12
Tire Air Pressure - Front / Rear 12 psi / 16 psi
Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Parking Brake Hand Actuated (in dash)
Altitude Shift Weight Drive Spring
Driven
Spring
Meters
(Feet)
0-1500
(0-5000)
21-74
(5632117)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1500-3700
(5000 - 12000)
21-70
(5632127)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1.11
GENERAL INFORMATION
1
MODEL: 2008 RANGER 6X6
MODEL NUMBER: R08RF68AD, AF
ENGINE MODEL: EH68OLE
CLUTCH CHART
Engine
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE046
Engine Displacement 683cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 68 mm
Compression Ratio 9.40:1
Compression Pressure 150-170 psi
Engine Idle Speed 1150 ± 100 RPM
Lubrication Pressurized Wet Sump
Oil Requirements 0W-40
Oil Capacity 2 qts. / 1.9 L
Coolant Capacity 3.25 qts. (3.08 L)
Overheat Warning Instrument Cluster Indicator
Exhaust System 2 to 1 Canister Style
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
9 gal. (34 L)
87 Octane (minimum)
Electrical
Alternator Max Output 500 watts @ 3000 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 Bosch EFI (ECU Controlled)
Ignition Timing 7° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Instrument Panel Type Multifunction Speedometer
DC Outlet Standard
Relays Fan / ECU
Circuit Breakers Fan Motor: 15 Amp
Fuses
Main Chassis: 20 Amp
Accessory: 20 Amp
EFI Power: 15 Amp
Speedo / ECU: 6 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
4.43:1 / 3.83:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Shift Type In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Polaris Demand Drive LT Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Polaris Synthetic AGL
15.2 oz. (450 ml)
Mid Gearcase Oil Requirements
Polaris Premium ADF
6.75 oz. (200 ml)
Rear Gearcase Oil Requirements
Polaris Premium ADF
18 oz. (532 ml)
Belt 3211118
Clutch Center Distance 10.05” (255 mm)
Steering / Suspension
Front Suspension MacPherson Strut
Front Travel 8 in. (20.3 cm)
Center Suspension Progressive Rate / Independent
Center Travel 5.25 in. (13.3 cm)
Rear Suspension Swing Arm w/Dual Shocks
Rear Travel 6.25 in. (16 cm)
Rear Shock Preload Adjustment Cam Adjustment
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Wheels / Brakes
Front Wheel Size 12 x 6 / 10 gauge
Middle / Rear Wheel Size 12 x 8 / 10 gauge
Front Tire
Make / Model / Size
Titan / AT489 / 25 x 10 R12
Middle / Rear Tire
Make / Model / Size
Titan / AT489 / 25 x 11 R12
Tire Air Pressure
Front / Middle / Rear
8-12 psi / 8 - 12 psi / 8-12 psi
Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Parking Brake Hand Actuated (in dash)
Altitude Shift Weight Drive Spring
Driven
Spring
Meters
(Feet)
0-1500
(0-5000)
21-74
(5632117)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1500-3700
(5000 - 12000)
21-70
(5632127)
Red/Blue
(7043372)
Blk/Almd
(7043167)
1.12
GENERAL INFORMATION
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.
Paint Codes
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 PN Parts Manual PN
2008 RANGER 4x4 XP R08RH68AB, AG, AH, AJ, AK, AP, AR, AS 9921268 9921275
2008 RANGER 4x4 CREW R08WH68AG 9921279 9921280
2008 RANGER 6x6 R08RF68AD, AF 9921268 9921269
Painted Part Color Description Polaris Number
Main Frame / Cab Frame / Bumpers Medium Gloss Black P-067
Main Frame / Cab Frame / Plastic Gloss Black P-070
Plastic - Hood / Dash Black Metallic P-177
Plastic - Hood / Dash Dark Green P-195
Plastic - Hood / Dash Solar Red P-342
Plastic - Hood / Dash Pearl White P-352
Plastic - Hood / Dash Turbo Silver P-402
Cab Frame / Bumpers Flat Black Wrinkle P-418
Plastic - Hood / Dash Mossy Oak™ P-455
Plastic - Hood / Dash Delta Green P-492
Plastic - Hood / Dash Boardwalk Blue P-524
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

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2008 polaris ranger 6 x6 700 efi service repair manual

  • 1. 2008 RANGER 700 4X4 XP / 4X4 CREW / 6X6 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 9921277 © 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. Printed in U.S.A.
  • 2. 1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 ELECTRONIC FUEL INJECTION 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10
  • 3. GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 RANGER 4X4 XP, 4X4 CREW, 6X6 (HEIGHT AND WIDTH) . . . . . . . . . . . . . . . . . . . . . 1.4 RANGER 4X4 XP, 6X6 (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 RANGER 4X4 CREW (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2008 RANGER 4X4 XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2008 RANGER 4X4 CREW / 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2008 RANGER 4X4 XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 DETAILED: 2008 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DETAILED: 2008 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
  • 4. 1.2 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH068OLE046PLE ............................................................Twin, Liquid Cooled, OHV 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 cylinder head on the side of engine. } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 8 R H 6 8 A G } 4 X A R H 6 8 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 Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions A Engine Serial Number
  • 5. 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.
  • 6. 1.4 GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4x4 XP, 4x4 CREW, 6X6 (Height and Width) 75 in. 190.5 cm 11.5 in. 29.2 cm 60 in. 152.4 cm RANGER 4x4
  • 7. 1.5 GENERAL INFORMATION 1 RANGER 4x4 XP, 6X6 (Length and Wheel Base) 120 in. 305 cm 42.5 in. 108 cm 27 in. 69 cm 90 in. 229 cm 113 in. 287 cm 36.5 in. 92.7 cm 76 in. 193 cm
  • 8. 1.6 GENERAL INFORMATION RANGER 4x4 CREW (Length and Wheel Base) 145 in. 386 cm 108 in. 274 cm 36.5 in. 92.7 cm
  • 9. 1.7 GENERAL INFORMATION 1 GENERAL SPECIFICATIONS MODEL: 2008 RANGER 4X4 XP MODEL NUMBER: R08RH68AB, AG, AH, AJ, AK, AP, AR, AS ENGINE MODEL: EH68OLE 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) Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg Pearl White L.E. Boardwalk Blue L.E. Turbo Silver L.E. Stealth Black L.E. Browning Edition
  • 10. 1.8 GENERAL INFORMATION MODEL: 2008 RANGER 4X4 CREW MODEL NUMBER: R08WH68AG ENGINE MODEL: EH68OLE MODEL: 2008 RANGER 6X6 MODEL NUMBER: R08RF68AD, AF ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 145 in. / 386 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 108 in. / 274 cm Ground Clearance 11 in. / 27.9 cm Turning Radius 224 in. / 569 cm Dry Weight 1460 lbs. / 664 kg Gross Vehicle Weight 3360 lbs. / 1524 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 1750 lbs. / 794 kg (Includes driver and five passengers) Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg Category Dimension / Capacity Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in. / 18.3 cm Turning Radius 186 in. / 472 cm Dry Weight 1410 lbs. / 640 kg Gross Vehicle Weight 3310 lbs. / 1501 kg Cargo Box Capacity 1250 lbs. / 567 kg Cargo Box Dimensions 54 x 42.5 x 11.5 in. (137 x 108 x 29.2 cm) Vehicle Payload 1750 lbs. / 794 kg (Includes driver and two passengers) Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg
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  • 12. 1.9 GENERAL INFORMATION 1 MODEL: 2008 RANGER 4X4 XP MODEL NUMBER: R08RH68AB, AG, AH, AJ, AK, AP, AR, AS ENGINE MODEL: EH68OLE CLUTCH CHART Engine Platform Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH068OLE046 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.08 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style 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 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 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 Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrument Type Multifunction Speedometer DC Outlet Standard Relays Fan / ECU / Rear Diff Solenoid Circuit Breakers Fan Motor: 15 Amp Fuses Main Chassis: 20 Amp Accessory: 20 Amp EFI Power: 15 Amp Speedo / ECU: 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Transmission Gear Ratio: Front / Rear High Low Reverse 3.63:1 / 3.14:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1 Shift Type In Line Shift - H / L / N / R Front Gearcase Oil Requirements Polaris Demand Drive LT Fluid 5 oz. (150 ml) Transmission Oil Requirements Polaris Synthetic AGL 15.2 oz. (450 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 18 oz. (532 ml) Belt 3211118 Clutch Center Distance 10.05” (255 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. (3.2 - 6.35 mm) Wheels / Brakes Front Wheel Size Standard - 12 x 6 / Steel L.E. - 12 x 6 / Cast Aluminum Rear Wheel Size Standard - 12 x 8 / Steel L.E. - 12 x 8 / Cast Aluminum Front Tire Make / Model / Size Carlisle / PXT / 26 x 8 R12 Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12 Tire Air Pressure - Front / Rear 8-12 psi / 8 - 12 psi Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 21-74 (5632117) Red/Blue (7043372) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 21-70 (5632127) Red/Blue (7043372) Blk/Almd (7043167)
  • 13. 1.10 GENERAL INFORMATION MODEL: 2008 RANGER 4X4 CREW MODEL NUMBER: R08WH68AG ENGINE MODEL: EH68OLE CLUTCH CHART Engine Platform Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH068OLE047 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity n/a Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style 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 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 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 Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrument Panel Type Multifunction Speedometer DC Outlet Standard Relays Fan / ECU / Rear Diff Solenoid Circuit Breakers Fan Motor: 15 Amp Fuses Main Chassis: 20 Amp Accessory: 20 Amp EFI Power: 15 Amp Speedo / ECU: 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Transmission Gear Ratio: Front / Rear High Low Reverse 4.43:1 / 3.83:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1 Shift Type In Line Shift - H / L / N / R Front Gearcase Oil Requirements Polaris Demand Drive LT Fluid 5 oz. (150 ml) Transmission Oil Requirements Polaris Synthetic AGL 15.2 oz. (450 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 18 oz. (532 ml) Belt 3211118 Clutch Center Distance 10.05” (255 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. (3.2 - 6.35 mm) Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Rear Wheel Size 12 x 8 / 10 gauge Front Tire Make / Model / Size Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12 Tire Air Pressure - Front / Rear 12 psi / 16 psi Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 21-74 (5632117) Red/Blue (7043372) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 21-70 (5632127) Red/Blue (7043372) Blk/Almd (7043167)
  • 14. 1.11 GENERAL INFORMATION 1 MODEL: 2008 RANGER 6X6 MODEL NUMBER: R08RF68AD, AF ENGINE MODEL: EH68OLE CLUTCH CHART Engine Platform Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Model Number EH068OLE046 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity 3.25 qts. (3.08 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style 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 9 gal. (34 L) 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 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 Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Spark plug / Gap Champion RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrument Panel Type Multifunction Speedometer DC Outlet Standard Relays Fan / ECU Circuit Breakers Fan Motor: 15 Amp Fuses Main Chassis: 20 Amp Accessory: 20 Amp EFI Power: 15 Amp Speedo / ECU: 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Transmission Gear Ratio: Front / Rear High Low Reverse 4.43:1 / 3.83:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1 Shift Type In Line Shift - H / L / N / R Front Gearcase Oil Requirements Polaris Demand Drive LT Fluid 5 oz. (150 ml) Transmission Oil Requirements Polaris Synthetic AGL 15.2 oz. (450 ml) Mid Gearcase Oil Requirements Polaris Premium ADF 6.75 oz. (200 ml) Rear Gearcase Oil Requirements Polaris Premium ADF 18 oz. (532 ml) Belt 3211118 Clutch Center Distance 10.05” (255 mm) Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. (20.3 cm) Center Suspension Progressive Rate / Independent Center Travel 5.25 in. (13.3 cm) Rear Suspension Swing Arm w/Dual Shocks Rear Travel 6.25 in. (16 cm) Rear Shock Preload Adjustment Cam Adjustment Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Middle / Rear Wheel Size 12 x 8 / 10 gauge Front Tire Make / Model / Size Titan / AT489 / 25 x 10 R12 Middle / Rear Tire Make / Model / Size Titan / AT489 / 25 x 11 R12 Tire Air Pressure Front / Middle / Rear 8-12 psi / 8 - 12 psi / 8-12 psi Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 21-74 (5632117) Red/Blue (7043372) Blk/Almd (7043167) 1500-3700 (5000 - 12000) 21-70 (5632127) Red/Blue (7043372) Blk/Almd (7043167)
  • 15. 1.12 GENERAL INFORMATION 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. Paint Codes 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 PN Parts Manual PN 2008 RANGER 4x4 XP R08RH68AB, AG, AH, AJ, AK, AP, AR, AS 9921268 9921275 2008 RANGER 4x4 CREW R08WH68AG 9921279 9921280 2008 RANGER 6x6 R08RF68AD, AF 9921268 9921269 Painted Part Color Description Polaris Number Main Frame / Cab Frame / Bumpers Medium Gloss Black P-067 Main Frame / Cab Frame / Plastic Gloss Black P-070 Plastic - Hood / Dash Black Metallic P-177 Plastic - Hood / Dash Dark Green P-195 Plastic - Hood / Dash Solar Red P-342 Plastic - Hood / Dash Pearl White P-352 Plastic - Hood / Dash Turbo Silver P-402 Cab Frame / Bumpers Flat Black Wrinkle P-418 Plastic - Hood / Dash Mossy Oak™ P-455 Plastic - Hood / Dash Delta Green P-492 Plastic - Hood / Dash Boardwalk Blue P-524 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