2008 Polaris Ranger RZR Service Manual
Original Polaris 2008 Ranger RZR ATV service manual.
2008 Service Manual PN 9921278 with thousands of high resolution images, diagrams, technical data and clear procedures on how to repair, service and maintain your ATV.
Manual chapters:
- General Information
- Periodic Maintenance
- Fuel System
- Cooling System
- Engine Top End
- Clutch
- Engine Lubrication System
- Engine Removal/Installation
- Crankshaft/Transmission
- Wheels/Tires
- Final Drive
- Brakes
- Suspension
- Steering
- Frame
- Electrical System
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Full list of manual chapters:
2008 RANGER RZR SERVICE MANUAL
FOREWORD
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
TRADEMARKS
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
Engine Designation Number
VIN Identification
Engine Serial Number Location
Unit Serial Number (VIN) Location
GENERAL SPECIFICATIONS
MODEL: 2008 RANGER RZR
MODEL: 2008 RANGER RZR
VEHICLE INFORMATION
Publication Numbers
Paint Codes
Replacement Keys
SPECIAL TOOLS
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Glossary of Terms
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Break-In Period
Maintenance Chart Key
Pre-Ride - 25 Hour Maintenance Interval
50 - 300 Hour Maintenance Interval
COMPONENT INSPECTION / SERVICE LOCATIONS
Front and Rear View
RH and LH Side Views
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service Products
MAINTENANCE REFERENCES
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Frame, Nuts, Bolts, and Fasteners
Shift Cable Inspection / Adjustment
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Line
Fuel Pump / Fuel Filters
Vent Lines
Throttle Pedal Inspection
Throttle Freeplay Adjustment
Air Filter Service
ENGINE
Engine Oil Level
Engine Oil and Filter Service
Engine Breather Hose Inspection
Engine and Transmission Mount Locations
Compression and Leakdown Test
Exhaust - Spark Arrestor
TRANSMISSION AND GEARCASES
Transmission / Gearcase Specification Chart
Transmission Lubrication
Front Gearcase Lubrication
Rear Gearcase Lubrication
COOLING SYSTEM
Cooling System Overview
Coolant Level Inspection
Coolant Strength / Type
Cooling System Pressure Test
Cooling System Hoses
Radiator
Coolant Drain / Radiator Removal
FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
Drive Shaft Boot Inspection
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Removal
Battery Installation
Battery Off Season Storage
Battery Charging (Sealed Battery)
Spark Plug Service
Engine To Frame Ground
STEERING AND SUSPENSION
Steering Inspection
Steering Wheel Freeplay
Steering Inspection / Tie Rod Ends and Hubs
Toe Alignment Inspection
Toe Adjustment
Suspension Spring Preload Adjustment
BRAKE SYSTEM
Brake Fluid Inspection
Brake Pad / Disc Inspection
Brake Hose and Fitting Inspection
ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded Views
Engine Fastener Torque Patterns
Torque Specifications
800 EFI Engine Service Specifications
Special Tools
ENGINE COOLING SYSTEM
Cooling System Specifications
Cooling System Pressure Test
Cooling System Exploded View
Cooling System Bleeding Procedure
GENERAL ENGINE SERVICE
Engine Lubrication Specifications
Accessible Engine Components
Oil Pressure Test
Oil Flow Chart
Engine Removal
Engine / Transmission Separation
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Rocker Arms
Push Rods
Cylinder Head Removal
Cylinder Head Inspection
Cylinder Head Warp
Valve Seal / Spring Service (On Engine)
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Reassembly
Valve Sealing Test
Cylinder Removal
Valve Lifter Removal / Inspection
Piston Removal
Cylinder Inspection
Cylinder Hone Selection and Honing Procedure
Honing To Deglaze
Cleaning the Cylinder After Honing
Piston-to-Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Starter Drive Bendix Removal / Inspection
Flywheel / Stator Removal / Inspection
Engine Crankcase Disassembly / Inspection
Camshaft Inspection
ENGINE REASSEMBLY
Crankcase Reassembly
Flywheel / Stator Installation
Cylinder Head Reassembly
Oil Pump Priming
ENGINE INSTALLATION
Engine Assembly and Installation
Engine Break-In Period
TROUBLESHOOTING
Engine
Cooling System
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION
Special Tools
Service Notes
EFI System Exploded View
EFI System Component Locations
FUEL TANK
Exploded View
Fuel Lines - Quick Connect
ELECTRONIC FUEL INJECTION
Principal Components
EFI Operation Overview
Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
ECU Service
ECU Replacement
TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
Operation Overview
T-BAP Test
T-BAP Replacement
CRANKSHAFT POSITION SENSOR (CPS)
Operation Overview
CPS Test
CPS Replacement
FUEL INJECTORS
Operation Overview
Fuel Injector Service
Fuel Injector Test
Fuel Injector Replacement
FUEL PUMP
Operation Overview
Fuel Sender Test
Fuel Pump Test
Fuel Tank / Fuel Pump Replacement
FUEL PRESSURE REGULATOR
Operation Overview
Fuel Pressure Regulator Test
Fuel Pressure Regulator Replacement
THROTTLE POSITION SENSOR (TPS)
Operation Overview
TPS Test Procedure
TPS Initialization
TPS Replacement
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Operation Overview
ECT Sensor Test
ECT Sensor Replacement
IGNITION COIL
Operation Overview
Ignition Coil Tests
Ignition Coil / HT Lead Replacement
GENERAL TROUBLESHOOTING
Diagnostic "Blink Codes"
EFI Troubleshooting
EFI SYSTEM BREAKOUT DIAGRAMS
Diagnostic Connector Circuit
Malfunction Indicator Lamp (MIL) Circuit
Fuel Injector (PTO) Circuit
Fuel Injector (MAG) Circuit
Engine Coolant Temperature Sensor (ECT) Circuit
Engine Overheat Lamp Driver Circuit
Crankshaft Position Sensor (CPS) Circuit
Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit
Throttle Position Sensor (TPS) Circuit
Fuel Pump Circuit
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
SPECIAL TOOLS
Multi-Function Pliers
CAB FRAME
Assembly / Removal
BODY EXPLODED VIEWS
Dash Instruments / Controls
Front Bumper
Rear Bumper
Hood / Front Body Work
Seat Assembly
Seat Belts / Mounting
Floor / Rocker Panels
Rear Cargo Box / Fenders
Chassis / Main Frame
BODY COMPONENT REMOVAL
Seats
Rear Service Panel
Front Bumper
Rear Bumper
Hood and Front Body Work
Rocker Panels, Console and Floor
Rear Fender, Flair and Tie Down Removal
Cargo Box Assembly Removal
STEERING ASSEMBLY
Exploded View
WHEEL HUBS
Front Hub Exploded View
Rear Hub Exploded View
FRONT A-ARMS
Removal / Replacement
Exploded View
BALL JOINT SERVICE
Removal
Installation
FRONT STABILIZER BAR
Sway Bar Linkage Removal
Stabilizer Bar Removal
Exploded View
REAR A-ARMS
Removal
Installation
Exploded View
REAR STABILIZER BAR
Removal / Installation
SHOCKS / SPRINGS
Exploded View
Shock Removal / Installation
Shock Replacement
DECAL REPLACEMENT
CLUTCHING
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
Drive Clutch Operation
Driven Clutch Operation
PVT Break-In (Drive Belt / Clutches)
Maintenance / Inspection
Overheating / Diagnosis
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
Disassembly
Assembly
DRIVE BELT
Belt Removal
Belt Inspection
Belt Installation
PVT Break-In (Drive Belt / Clutches)
DRIVE CLUTCH SERVICE
Spring Specifications
Shift Weights
Exploded View
Clutch Disassembly
Spider Removal
Roller, Pin, and Thrust Washer Inspection
Button To Tower Clearance Inspection
Shift Weight Inspection
Bearing Inspection
Clutch Inspection
Moveable Sheave Bushing Inspection
Bushing Service
Clutch Assembly
DRIVEN CLUTCH SERVICE
Clutch Disassembly
Bushing Service
Clutch Assembly
Exploded View
TROUBLESHOOTING
FINAL DRIVE
SPECIAL TOOLS
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
FRONT BEARING CARRIER
Bearing Carrier Inspection / Removal
Bearing Replacement
Bearing Carrier Installation
FRONT DRIVE SHAFT
Drive Shaft Removal
Drive Shaft / CV Joint Handling Tips
CV Joint / Boot Replacement
Drive Shaft Installation
PROPSHAFT SERVICE
Removal / Installation
PROPSHAFT U-JOINT SERVICE
Disassembly
Assembly
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
All Wheel Drive Operation
AWD Diagnosis
Gearcase Removal
Gearcase Disassembly / Inspection
Gearcase Assembly / Inspection
Backlash Thrust Plate Adjustment
Gearcase Installation
REAR BEARING CARRIER
Bearing Carrier Inspection / Removal
Bearing Replacement
Bearing Carrier Bushing Replacement
Bearing Carrier Installation
REAR DRIVE SHAFT
Removal
Outer CV Joint / Boot Replacement
Inner Plunging Joint / Boot Replacement
Installation
REAR GEARCASE
Gearcase Removal
Gearcase Disassembly
Gearcase Assembly
Gearcase Installation
Gearcase Exploded View
WHEEL HUBS
Front Hub Exploded View
Rear Hub Exploded View
TRANSMISSION
TORQUES / SPECIFICATIONS
SHIFT LEVER
Removal
Installation
Shift Cable Inspection / Adjustment
TRANSMISSION SERVICE
Transmission Removal / Service Notes
Transfer Case Disassembly
Transfer Case Reassembly
Transmission Shift Housing Disassembly
Transmission Shift Housing Reassembly
TROUBLESHOOTING
Troubleshooting Checklist
TRANSMISSION EXPLODED VIEWS
Shift Housing / Transfer Case Exploded View
BRAKES
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
MASTER CYLINDER
Removal
Installation
BRAKE PEDAL LEVER
Pedal Removal
Pedal Installation
BRAKE BLEEDING / FLUID CHANGE
FRONT BRAKE PADS
Pad Removal
Pad Inspection
Pad Assembly / Installation
Brake Burnishing Procedure
FRONT CALIPER SERVICE
Caliper Exploded View
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
FRONT BRAKE DISC
Disc Inspection
Disc Replacement
REAR BRAKE PAD
Pad Removal
Pad Inspection
Pad Assembly / Installation
Brake Burnishing Procedure
REAR CALIPER SERVICE
Caliper Exploded View
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
REAR BRAKE DISC
Disc Inspection
Disc Replacement
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
Pedal Vibration
Caliper Overheats (Brakes Drag)
Brakes Lock
ELECTRICAL
General Information
Special Tools
Electrical Service Notes
Under-Dash Components
Switches / Controls
Headlamp Switch
AWD Switch
Brake Light Switch
Instrument Cluster
Overview
Rider Information Display
Standard Display Modes
Diagnostic Display Mode
Viewing Diagnostic Codes
Instrument Cluster Removal
Instrument Cluster Installation
Instrument Cluster Troubleshooting Tests
TEST 1 - No All Wheel Drive
TEST 2 - No Display
TEST 3 - Vehicle Speed Sensor
TEST 4 - No AWD Hub Safety Limiter
TEST 5 - Fuel Gauge Display Not Working
TEST 6 - Gear Indicator Not Working (Transmission Switch)
All Wheel Drive Coil
Operation Overview
Diagnosing System Failures
Gear Position Indicator Switch
Test Diagram
Speed Sensor
Location / Testing
Head Lights
Headlight Adjustment
Headlamp Bulb Replacement
Headlamp Housing Removal
Headlamp Housing Installation
Tail / Brake / Work Lights
Bulb Replacement
Cooling System Schematic
Cooling System Break-Out Diagram
Fan Control Circuit Operation / Testing
Fan Control Circuit Bypass Test
Coolant Temperature Sensor
EFI Diagnostics
EFI Component Testing
Fuel Sender
Testing
Relays
Operation
Fuse Box Layout
Fuses / Circuit Breaker
Operation
Charging System
Current Draw - Key Off
Charging System "Break Even" Test
Charging System Alternator Tests
Charging System Testing Flow Chart
Battery Service
Battery Identification
Conventional Battery
Battery Activation
Battery Inspection
Battery Removal
Battery Installation
Conventional Battery Testing
OCV - Open Circuit Voltage Test
Specific Gravity Test
Load Test
Off Season Storage
Charging Procedure (Conventional)
Low Maintenance Battery
General Battery Information
Battery Removal
Battery Installation
Battery Testing
OCV - Open Circuit Voltage Test
Load Test
Off-Season Storage
Charging Procedure (Low Maintenance)
Starting System
Troubleshooting
Voltage Drop Test
Starter Motor Removal / Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly / Installation
Starter Drive
Starter Solenoid Bench Test
Starter Solenoid Operation
Starter Exploded View
Starting System Testing Flow Chart
Condition: Starter fails to turn over the engine.
Electrical BreakOut Diagrams
12V Key-On Power Circuit
Starting System Circuit
Instrument Cluster Circuit
Transmission Switch Circuit
Wheel Speed Sensor Circuit
AWD Circuit
Fuel Gauge Display Circuit
Cooling Fan Circuit
Charging System Circuit
INDEX
WIRE DIAGRAMS
