Polaris Ranger RZR Repair Service Manual 2008

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This workshop repair service manual PDF download for the ... has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021


TABLE OF CONTENTS :

GENERAL INFORMATION 
MAINTENANCE 
ENGINE 
FUEL INJECTION 
BODY / STEERING / SUSPENSION 
CLUTCHING 
FINAL DRIVE 
TRANSMISSION 
BRAKES 
ELECTRICAL


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921278
Total Pages : 320


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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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

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