2008 POLARIS RANGER RZR ATV SERVICE FACTORY SERVICE REPAIR MAINTENANCE MANUAL Download!
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Pages: 320 + General Information Maintenance Engine Fuel System (Carburetion or EFI) Body & Steering Clutching & Belt System Final Drive & 4wd System Transmission Brakes Electrical System Wiring Diagrams Troubleshooting
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2008 POLARIS RANGER RZR ATV SERVICE FACTORY SERVICE REPAIR MAINTENANCE MANUAL for sale
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Air Filter Service 2.12 All Wheel Drive (AWD) Coil . 10.14 AWD Diagnostics 10.7 AWD, Diagnosis . 7.14 AWD, Operation . 7.13 B Balance Shaft Gear, Removal . 3.42 Ball Joint Service 5.17 Battery Charging . 2.26 Battery Installation . 2.25 Battery Maintenance 2.25 Battery Removal . 2.25 Battery Service . 10.24 Battery Storage 2.26 Battery, Conventional 10.24 Battery, Sealed Low Maintenance 10.28 Body Removal 5.11 Brake Burnishing 9.8, 9.15 Brake Caliper Assembly, Front . 9.9, 9.11 Brake Caliper Assembly, Rear 9.16 Brake Caliper Inspection, Front . 9.11 Brake Caliper Installation, Front 9.12 Brake Caliper Removal, Front . 9.9 Brake Disc, Front 9.13 Brake Disc, Rear . 9.19 Brake Front Pad Assembly 9.8 Brake Hose and Fitting Inspection . 2.30 Brake Pad Assembly, Front . 9.8 Brake Pad Inspection . 2.30 Brake Pad Thickness, Front . 9.7 Brake Pad, Rear . 9.14 Brake Pads, Front . 9.7 Brake Pads, Removal, Front . 9.7 Brake Pedal, Installation 9.5 Brake Pedal, Removal . 9.5 Brake System Inspection 2.30 Brake System, Bleeding 9.6 Brake System, Exploded View . 9.4 Brake System, Operation . 9.4 Break-In Period . 2.3 Break-In, PVT System (Belt) 6.3 Breather Hose Inspection 2.16 C Cab Frame, Assembly / Removal . 5.3 Caliper, Front 9.9 Caliper, Rear 9.16 Cam Gear, Reassembly 3.41 Cam Gear, Removal 3.40 Cargo Box Removal 5.13 Centralized Hilliard, Exploded View . 7.12 Charging System 10.21 Charging System, Alternator Tests 10.22 Chassis / Main Frame . 5.10 Circuit Breaker .10.20 Clock, Setting .10.6 Combustion Chamber .3.29 Compression Test 2.16 Console and Floor Panel Removal .5.13 Conversion Table .1.7 Coolant Level Inspection 2.21 Coolant Strength and Type .2.21 Cooling System Bleeding Procedure 3.14 Cooling System Hoses 2.22 Cooling System Specifications 3.12 Cooling System, Pressure Test 3.12 Crankshaft Gear, Removal .3.42 Crankshaft Position Sensor (CPS) 4.13 CV Shaft Boot Inspection 2.24 Cylinder Head Assembly 3.31 Cylinder Head Assembly Exploded View .3.24 Cylinder Head Disassembly 3.27 Cylinder Honing To De-glaze .3.35 Cylinder Inspection .3.34 D Dash Instruments / Controls .5.4 Decal Replacement .5.24 Decimal Equivalent Chart .1.9 Diagnostic Codes, Instrument Cluster .10.8 Diagnostics, AWD .10.7 Diagnostics, Gear Circuit 10.7 Drive Belt, Inspection 6.8 Drive Belt, Installation .6.8 Drive Belt, Removal .6.7 Drive Clutch, Assembly .6.18 Drive Clutch, Exploded View .6.11 Drive Clutch, Operation 6.2 Drive Clutch, Service 6.9 Drive Clutch, Shift Weights 6.10 Drive Clutch, Spring .6.9 Driven Clutch Service .6.19 Driven Clutch, Exploded View 6.26 Driven Clutch, Operation .6.3 Driveshaft / CV Joint, Handling Tips 7.7 E EFI Operation Overview .4.10 EFI Priming / Starting Procedure 4.11 EFI System Breakout Diagrams .4.34 Electrical Breakout Diagrams 10.37 Electrical, Cooling System Breakout Diagram .10.17 Electronic Control Unit (ECU) 4.11 Engine and Transmission Separation .3.23 Engine Assembly and Installation 3.59 Engine Balance Shaft Removal 3.46 Engine Break-In Period 3.61 Engine Camshaft Inspection 3.46 Engine Camshaft Installation .3.48 Engine Coolant Temperature Sensor (ECT) 4.30 Engine Cooling System 3.12 IX.2 Engine Cooling System Troubleshooting 3.63 Engine Crankcase Assembly 3.47 Engine Crankshaft Gear Removal 3.43 Engine Crankshaft Installation 3.48 Engine Cylinder Head Assembly . 3.31, 3.56 Engine Cylinder Head Inspection 3.26 Engine Cylinder Head Removal .3.25 Engine Cylinder Head Warp 3.26 Engine Cylinder Honing .3.35 Engine Cylinder Inspection .3.34 Engine Cylinder Installation 3.49 Engine Cylinder Removal 3.32 Engine Designation Number .1.2 Engine Diagnostic Codes 4.32 Engine Exploded Views .3.2, 3.3, 3.4, 3.6 Engine Fastener Torques 3.7 Engine Flywheel / Stator Installation .3.56 Engine Flywheel / Stator Removal .3.38 Engine Flywheel Removal .3.39 Engine Gear(s) Removal .3.39 Engine Gears, Installation 3.51 Engine Lubrication 3.15, 3.61 Engine Oil and Filter Change .2.15 Engine Oil Flow Chart 3.16 Engine Oil Level .2.14 Engine Oil Pressure Test .3.15 Engine Oil Priming .3.59 Engine Oil Pump Installation .3.50 Engine Oil Pump Removal .3.43 Engine Piston Installation 3.49 Engine Piston Removal, Inspection 3.33 Engine Piston Ring Installed Gap 3.37 Engine Piston to Cylinder Clearance .3.36 Engine Piston to Rod Clearance .3.36 Engine Pushrod Inspection .3.25 Engine Removal .3.17 Engine Rocker Arm Inspection 3.25 Engine Serial Number Location 1.2 Engine Service Specifications 3.9 Engine Speed Display .10.6 Engine Starter Drive Removal 3.37 Engine Starter Removal .3.39 Engine Stator Gear Cover Seal(s) Installation 3.53 Engine Stator Installation 3.56 Engine Temperature Sensor Replacement .4.30 Engine Temperature Sensor Test 4.30 Engine Torque Table .3.8 Engine Troubleshooting .3.62 Engine Valve Inspection .3.28 Engine Valve Lifter Removal, Inspection 3.32 Engine Valve Seal/Spring Service .3.26 Engine Valve Sealing Test .3.32 Engine Valve Seat Reconditioning .3.29 Engine, Accessible Components .3.15 Exhaust, Spark Arrestor .2.16 F Fan Control Circuit Bypass Test . 10.18 Fan Control Circuit Operation . 10.18 Floor / Rocker Panels 5.8 Flywheel / Stator Removal . 3.38 Flywheel, Removal 3.38 Front A-arm, Replacement . 5.16 Front Bearing Carrier 7.2 Front Body / Dash Removal 5.12 Front Bumper 5.5, 5.11 Front Caliper, Piston Bore I.D 9.11 Front Driveshaft, CV Joint / Boot Replacement . 7.7 Front Driveshaft, Installation 7.8 Front Driveshaft, Removal 7.6 Front Fender Flair Removal 5.12 Front Gearcase Lubrication 2.19 Front Gearcase, Assembly . 7.17 Front Gearcase, Backlash Adjustment 7.19 Front Gearcase, Centralized Hilliard . 7.12 Front Gearcase, Disassembly / Inspection . 7.15 Front Gearcase, Installation 7.20 Front Gearcase, Removal 7.15 Front Stabilizer Bar 5.19 Fuel Filter 2.11 Fuel Injection Troubleshooting . 4.33 Fuel Injection, Component Locations . 4.7 Fuel Injection, Exploded View 4.6 Fuel Injection, Service Notes 4.5 Fuel Injection, Special Tools 4.2 Fuel Injectors . 4.18 Fuel Lines 2.11 Fuel Lines, Quick Connect . 4.10 Fuel Pressure Regulator . 4.25 Fuel Pump / Tank Assembly . 4.21 Fuel Pump Test . 4.21 Fuel Sender Test 4.21, 10.18 Fuel System 2.11 Fuel Tank Replacement . 4.23 Fuel Tank, Exploded View . 4.9 Fuse Box . 10.19 Fuses . 10.20 G Gear / Stator Housing Seal Replacement 3.53 Gear Circuit Diagnostics 10.7 Gear Position Indicator Switch Test 10.14 General Specifications, Brakes 9.2 Ground, Engine . 2.27 H Head Lights . 10.15 Hood / Front Body Work . 5.6 Hood Removal 5.12 Hour Meter . 10.6 I Ignition Coil 4.31 IX.3 IX Ignition Coil Replacement . 4.31 Ignition Coil Test 4.31 Indicator, Service Interval . 10.8 Instrument Cluster . 10.5 K Keys, Replacement 1.6 Kilometers to Miles Toggle 10.8 L Leakdown Test 2.16 M Maintenance, Brake System 2.30 Maintenance, Cooling System 2.21 Maintenance, Electrical and Ignition . 2.25 Maintenance, Engine . 2.14 Maintenance, Final Drive 2.23 Maintenance, Fuel System . 2.11 Maintenance, General Vehicle Inspection . 2.10 Maintenance, References . 2.9 Maintenance, Service Products and Lubricants 2.8 Maintenance, Steering 2.27 Maintenance, Transmission and Gearcases 2.17 Master Cylinder, Installation 9.5 Master Cylinder, Removal 9.5 Miles to Kilometers Toggle 10.8 Model Identification . 1.2 O Odometer 10.6 Oil Pump Priming 3.58 Oil Pump, Disassembly . 3.43 Oil Pump, Reassembly 3.44 Oil Pump, Removal 3.43 P Paint Codes pecno1 1.6 Periodic Maintenance Chart . 2.3 Piston Ring Installed Gap 3.37 Piston to Cylinder Clearance . 3.36 Piston to Rod Inspection . 3.36 Pre-Ride / Daily Inspection 2.10 Programmable Service Interval . 10.8 Propshaft Removal / Installation 7.10 Propshaft, U-Joint Service . 7.10 Publication Numbers 1.6 PVT System, Assembly 6.6 PVT System, Disassembly 6.5 PVT System, Maintenance 6.3 PVT System, Overheating Diagnostics 6.4 PVT System, Overview 6.2 PVT System, Service 6.5 PVT Troubleshooting . 6.28 PVT, Button to Tower Clearance 6.13 PVT, Drive Clutch Disassembly 6.11 PVT, Drive Clutch Spider Removal 6.12 PVT, Driven Clutch Bushing Service . 6.21 PVT, Driven Clutch Disassembly 6.19 PVT, Driven Clutch Reassembly 6.23 PVT, EBS Drive Clutch Bushing Service 6.16 PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.17 PVT, Moveable Sheave Inspection .6.15 R Radiator 2.22 Radiator, Removal 2.22 Rear A-arm, Replacement 5.21 Rear Bearing Carrier 7.21 Rear Bumper 5.5, 5.11 Rear Cargo Box / Fenders .5.9 Rear Driveshaft, CV Joint / Boot Replacement .7.25 Rear Driveshaft, Installation 7.29 Rear Driveshaft, Plunging Joint / Boot Replacement .7.27 Rear Driveshaft, Removal 7.24 Rear Fender, Flair, and Tie Down Removal 5.13 Rear Gearcase .7.31 Rear Gearcase Lubrication .2.20 Rear Gearcase, Assembly 7.34 Rear Gearcase, Disassembly 7.32 Rear Gearcase, Exploded View 7.36 Rear Gearcase, Installation .7.35 Rear Gearcase, Removal .7.31 Rear Service Panel .5.11 Rear Stabilizer Bar .5.23 Relays 10.19 Rocker Panel Removal 5.13 S Seat Assembly 5.7 Seat Belts / Mounting 5.7 Seats 5.11 Service Interval Indicator 10.8 Service Locations .2.6 Shift Cable Inspection and Adjustment .8.3 Shift Lever .8.2 Shift Lever, Removal 8.2 Shift Lever,Installation .8.2 Shift Linkage Inspection and Adjustment 2.10 Shocks and Springs .5.24 Spark Plug Service .2.26 Special Tool, Cam Gear Installation Kit .3.41 Special Tools .1.6 Special Tools, Body/Steering/Suspension .5.2 Special Tools, Brakes 9.2 Special Tools, Clutching 6.2 Special Tools, Electrical .10.3 Special Tools, Engine .3.11 Special Tools, Final Drive .7.2 Specification Chart, Maintenance 2.17 Specification, Balance Shaft Gear Bolt Torque .3.52 Specification, Cam Lobe Height .3.46 Specification, Cam Thrust Plate Fastener Torque 3.50 Specification, Camshaft Gear Bolt Torque .3.52 Specification, Coolant Sensor Resistance .10.18 IX.4 Specification, Cylinder Head Warp .3.26 Specification, Cylinder Taper Limit 3.34 Specification, Cylinder Warp Limit 3.34 Specification, Oil Pump Bolt Torque .3.51 Specification, Oil Pump Rotor Clearance 3.43 Specification, Timing Gear Alignment 3.39 Specification, Valve Seat Contact Width 3.30 Specification, Valve Spring Free Length 3.27 Specification, Valve Stem Diameter 3.28 Specification, Valve Stem Guide I.D 3.28 Specification, Wheel Toe-Out .2.28 Specifications, Cam Shaft 3.46 Specifications, Cooling System 3.12 Specifications, Crankcase Fastener Torque .3.48 Specifications, Engine 3.2 Specifications, Engine Lubrication 3.15, 3.61 Specifications, Engine Oil Pressure 3.15 Specifications, General .1.4 Specifications, Oil Baffle Bolt Torque 3.47 Specifications, Oil Pick-up Bolt Torque .3.47 Speed Sensor .10.14 Speedometer 10.5 Speedometer Installation .10.9 Speedometer Removal .10.9 Speedometer Troubleshooting Tests .10.10 Starter Armature Testing 10.32 Starter Assembly Exploded View .10.35 Starter Brush Inspection / Replacement 10.31 Starter Drive .10.34 Starter Drive Removal .3.37 Starter Motor, Removal .10.31 Starter Reassembly / Installation 10.33 Starter Solenoid, Test 10.34 Starter System Flow Chart 10.36 Starter System, Troubleshooting 10.30 Stator, Removal 3.38 Steering Inspection .2.28 Steering Wheel Freeplay .2.27 Steering, Alignment 2.27 Steering, Exploded View .5.14 Steering, Toe Adjustment 2.29 Steering, Wheel Toe Alignment .2.28 Suspension, Spring Preload Adjustment .2.29 Sway Bar Linkage Removal 5.19 Switch, AWD .10.4 Switch, Brake Light .10.4 Switch, Headlamp 10.4 T Tachometer .10.6 Tail Lights .10.16 Tap/Drill Sizes 1.9 Temperature / Barometric Air Pressure Sensor (T-BAP) 4.12 Throttle Freeplay Adjustment .2.12 Throttle Pedal Inspection 2.12 Throttle Position Sensor (TPS) 4.26 Throttle Position Sensor Initialization 4.28 Throttle Position Sensor Replacement 4.29 Timing Gear Mark Alignment 3.39 Tire Inspection 2.24 Tire Pressure . 2.24 Toe Alignment 2.29 Torque Chart 1.8 Torque Specifications - Engine 3.8 Torque Specifications, Body/Steering/Suspension . 5.2 Torque Specifications, Brakes . 9.2 Torque Specifications, Clutching . 6.2 Torque Specifications, Final Drive . 7.2 Torque Specifications, Transmission 8.2 Torque Specifications, Wheel, Hub, and Spindle . 2.23 Transfer Case, Disassembly . 8.4 Transfer Case, Reassembly . 8.7 Transmission Lubrication . 2.17 Transmission, Exploded View 8.20 Transmission, Removal 8.4 Transmission, Shift Housing Disassembly . 8.9 Transmission, Shift Housing Reassembly . 8.14 Trip Meter . 10.6 Troubleshooting, Brake Noise . 9.3 Troubleshooting, Brake System . 9.20 Troubleshooting, Clutching 6.27 Troubleshooting, No AWD . 10.10 Troubleshooting, No AWD Hub Safety Limiter . 10.12 Troubleshooting, No Fuel Gauge Display 10.13 Troubleshooting, No Gear Indicator Display 10.13 Troubleshooting, No Instrument Display . 10.11 Troubleshooting, Transmission . 8.19 Troubleshooting, Vehicle Speed Sensor . 10.11 V Valve Seal/Spring Service . 3.26 Valve Sealing Test . 3.32 Valve Seat Reconditioning . 3.29 Vent Lines . 2.11 VIN Identification 1.2 VIN Location 1.3 Voltage Drop Test 10.31 W Wheel Hubs 5.15 Wheel, Installation . 2.23 Wheel, Removal . 2.23

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2008 POLARIS RANGER RZR ATV SERVICE FACTORY SERVICE REPAIR MAINTENANCE MANUAL
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