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2008 POLARIS RANGER RZR ATV SERVICE MANUAL DIY FACTORY SERVICE REPAIR MAINTENANCE MANUAL – PDF DOWNLOAD
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2008 POLARIS RANGER RZR ATV SERVICE MANUAL DIY FACTORY SERVICE REPAIR MAINTENANCE MANUAL
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Description
2008 POLARIS RANGER RZR ATV SERVICE MANUAL DIY FACTORY SERVICE REPAIR MAINTENANCE MANUAL
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:320
DOWNLOADABLE:YES
FILE TYPE:PDF
2008 POLARIS RANGER RZR ATV SERVICE MANUAL DIY FACTORY SERVICE REPAIR MAINTENANCE MANUAL – PDF DOWNLOAD:
DESCRIPTION:
2008 POLARIS RANGER RZR ATV SERVICE MANUAL DIY FACTORY SERVICE REPAIR MAINTENANCE MANUAL
FOREWORD:
- ‘This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a property? 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:l Come 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 pining tools as specified. Comments or suggestions about this manual may be directed to: Service Publications Der£@ Polaris Sales Inc- 2100 Hwy 55 Medina Minnesota 553401.
TABLE OF CONTENTS:
2008 POLARIS RANGER RZR ATV SERVICE MANUAL DIY FACTORY SERVICE REPAIR MAINTENANCE MANUAL
2008 RANGER RZR SERVICE MANUAL................................................ 1 FOREWORD.................................................................. 1 UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS......................... 2 TRADEMARKS................................................................ 2 GENERAL INFORMATION........................................................... 4 MODEL INFORMATION......................................................... 5 Model Identification.................................................. 5 Engine Designation Number............................................. 5 VIN Identification.................................................... 5 Engine Serial Number Location......................................... 5 Unit Serial Number (VIN) Location..................................... 6 GENERAL SPECIFICATIONS.................................................... 7 MODEL: 2008 RANGER RZR................................................ 7 MODEL: 2008 RANGER RZR................................................ 8 VEHICLE INFORMATION....................................................... 9 Publication Numbers................................................... 9 Paint Codes........................................................... 9 Replacement Keys...................................................... 9 SPECIAL TOOLS............................................................. 9 MISC. SPECIFICATIONS AND CHARTS........................................... 10 Conversion Table...................................................... 10 Standard Torque Specifications........................................ 11 SAE Tap / Drill Sizes................................................. 12 Metric Tap / Drill Sizes.............................................. 12 Decimal Equivalents................................................... 12 Glossary of Terms..................................................... 13 MAINTENANCE................................................................... 14 PERIODIC MAINTENANCE CHART................................................ 16 Periodic Maintenance Overview......................................... 16 Break-In Period....................................................... 16 Maintenance Chart Key................................................. 16 Pre-Ride - 25 Hour Maintenance Interval............................... 17 50 - 300 Hour Maintenance Interval.................................... 18 COMPONENT INSPECTION / SERVICE LOCATIONS.................................. 19 Front and Rear View................................................... 19 RH and LH Side Views.................................................. 20 LUBRICANTS / SERVICE PRODUCTS............................................. 21 Polaris Lubricants, Maintenance and Service Products.................. 21 MAINTENANCE REFERENCES.................................................... 22 GENERAL VEHICLE INSPECTION AND MAINTENANCE................................ 23 Pre-Ride / Daily Inspection........................................... 23 Frame, Nuts, Bolts, and Fasteners..................................... 23 Shift Cable Inspection / Adjustment................................... 23 FUEL SYSTEM AND AIR INTAKE................................................ 24 Fuel System........................................................... 24 Fuel Line............................................................. 24 Fuel Pump / Fuel Filters.............................................. 24 Vent Lines............................................................ 24 Throttle Pedal Inspection............................................. 25 Throttle Freeplay Adjustment.......................................... 25 Air Filter Service.................................................... 25 ENGINE.................................................................... 27 Engine Oil Level...................................................... 27 Engine Oil and Filter Service......................................... 28 Engine Breather Hose Inspection....................................... 29 Engine and Transmission Mount Locations............................... 29 Compression and Leakdown Test......................................... 29 Exhaust - Spark Arrestor.............................................. 29 TRANSMISSION AND GEARCASES................................................ 30 Transmission / Gearcase Specification Chart........................... 30 Transmission Lubrication.............................................. 30 Front Gearcase Lubrication............................................ 32 Rear Gearcase Lubrication............................................. 33 COOLING SYSTEM............................................................ 34 Cooling System Overview............................................... 34 Coolant Level Inspection.............................................. 34 Coolant Strength / Type............................................... 34 Cooling System Pressure Test.......................................... 35 Cooling System Hoses.................................................. 35 Radiator.............................................................. 35 Coolant Drain / Radiator Removal...................................... 35 FINAL DRIVE / WHEEL AND TIRE.............................................. 36 Wheel, Hub, and Spindle Torque Table.................................. 36 Wheel Removal......................................................... 36 Wheel Installation.................................................... 36 Tire Inspection....................................................... 37 Tire Pressure......................................................... 37 Drive Shaft Boot Inspection........................................... 37 ELECTRICAL AND IGNITION SYSTEM............................................ 38 Battery Maintenance................................................... 38 Battery Removal....................................................... 38 Battery Installation.................................................. 38 Battery Off Season Storage............................................ 39 Battery Charging (Sealed Battery)..................................... 39 Spark Plug Service.................................................... 39 Engine To Frame Ground................................................ 40 STEERING AND SUSPENSION................................................... 40 Steering Inspection................................................... 40 Steering Wheel Freeplay............................................... 40 Steering Inspection / Tie Rod Ends and Hubs .......................... 41 Toe Alignment Inspection.............................................. 41 Toe Adjustment........................................................ 42 Suspension Spring Preload Adjustment.................................. 42 BRAKE SYSTEM.............................................................. 43 Brake Fluid Inspection................................................ 43 Brake Pad / Disc Inspection........................................... 43 Brake Hose and Fitting Inspection..................................... 43 ENGINE........................................................................ 44 ENGINE SPECIFICATIONS..................................................... 45 Crankcase Exploded Views.............................................. 45 Engine Fastener Torque Patterns....................................... 50 Torque Specifications................................................. 51 800 EFI Engine Service Specifications................................. 52 Special Tools......................................................... 54 ENGINE COOLING SYSTEM..................................................... 55 Cooling System Specifications......................................... 55 Cooling System Pressure Test.......................................... 55 Cooling System Exploded View.......................................... 56 Cooling System Bleeding Procedure..................................... 57 GENERAL ENGINE SERVICE.................................................... 58 Engine Lubrication Specifications..................................... 58 Accessible Engine Components.......................................... 58 Oil Pressure Test..................................................... 58 Oil Flow Chart........................................................ 59 Engine Removal........................................................ 60 Engine / Transmission Separation...................................... 66 ENGINE DISASSEMBLY AND INSPECTION......................................... 67 Cylinder Head Assembly Exploded View.................................. 67 Rocker Arms........................................................... 68 Push Rods............................................................. 68 Cylinder Head Removal ................................................ 68 Cylinder Head Inspection.............................................. 69 Cylinder Head Warp.................................................... 69 Valve Seal / Spring Service (On Engine)............................... 69 Cylinder Head Disassembly............................................. 70 Valve Inspection...................................................... 71 Combustion Chamber.................................................... 72 Valve Seat Reconditioning............................................. 72 Cylinder Head Reassembly.............................................. 74 Valve Sealing Test.................................................... 75 Cylinder Removal...................................................... 75 Valve Lifter Removal / Inspection..................................... 75 Piston Removal........................................................ 76 Cylinder Inspection................................................... 77 Cylinder Hone Selection and Honing Procedure.......................... 78 Honing To Deglaze..................................................... 78 Cleaning the Cylinder After Honing.................................... 78 Piston-to-Cylinder Clearance.......................................... 79 Piston / Rod Inspection............................................... 79 Piston Ring Installed Gap............................................. 80 Starter Drive Bendix Removal / Inspection ............................ 80 Flywheel / Stator Removal / Inspection................................ 81 Engine Crankcase Disassembly / Inspection............................. 81 Camshaft Inspection................................................... 89 ENGINE REASSEMBLY......................................................... 90 Crankcase Reassembly.................................................. 90 Flywheel / Stator Installation........................................ 99 Cylinder Head Reassembly.............................................. 99 Oil Pump Priming......................................................101 ENGINE INSTALLATION.......................................................102 Engine Assembly and Installation......................................102 Engine Break-In Period................................................104 TROUBLESHOOTING...........................................................105 Engine................................................................105 Cooling System........................................................106 ELECTRONIC FUEL INJECTION.....................................................107 GENERAL INFORMATION.......................................................108 Special Tools.........................................................108 Service Notes.........................................................111 EFI System Exploded View..............................................112 EFI System Component Locations........................................113 FUEL TANK.................................................................115 Exploded View.........................................................115 Fuel Lines - Quick Connect............................................116 ELECTRONIC FUEL INJECTION.................................................116 Principal Components..................................................116 EFI Operation Overview................................................116 Initial Priming / Starting Procedure..................................117 ELECTRONIC CONTROL UNIT (ECU).............................................117 Operation Overview....................................................117 ECU Service...........................................................118 ECU Replacement.......................................................118 TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....................118 Operation Overview....................................................118 T-BAP Test............................................................118 T-BAP Replacement.....................................................118 CRANKSHAFT POSITION SENSOR (CPS)..........................................119 Operation Overview....................................................119 CPS Test..............................................................119 CPS Replacement.......................................................120 FUEL INJECTORS............................................................124 Operation Overview....................................................124 Fuel Injector Service.................................................124 Fuel Injector Test....................................................125 Fuel Injector Replacement.............................................125 FUEL PUMP.................................................................127 Operation Overview....................................................127 Fuel Sender Test......................................................127 Fuel Pump Test........................................................127 Fuel Tank / Fuel Pump Replacement.....................................129 FUEL PRESSURE REGULATOR...................................................131 Operation Overview....................................................131 Fuel Pressure Regulator Test..........................................131 Fuel Pressure Regulator Replacement...................................131 THROTTLE POSITION SENSOR (TPS)............................................132 Operation Overview....................................................132 TPS Test Procedure....................................................132 TPS Initialization....................................................134 TPS Replacement.......................................................135 ENGINE COOLANT TEMPERATURE SENSOR (ECT)...................................136 Operation Overview....................................................136 ECT Sensor Test.......................................................136 ECT Sensor Replacement................................................136 IGNITION COIL.............................................................137 Operation Overview....................................................137 Ignition Coil Tests...................................................137 Ignition Coil / HT Lead Replacement...................................137 GENERAL TROUBLESHOOTING...................................................138 Diagnostic “Blink Codes”..............................................138 EFI Troubleshooting...................................................139 EFI SYSTEM BREAKOUT DIAGRAMS..............................................140 Diagnostic Connector Circuit..........................................140 Malfunction Indicator Lamp (MIL) Circuit..............................140 Fuel Injector (PTO) Circuit...........................................141 Fuel Injector (MAG) Circuit...........................................141 Engine Coolant Temperature Sensor (ECT) Circuit.......................142 Engine Overheat Lamp Driver Circuit...................................142 Crankshaft Position Sensor (CPS) Circuit..............................143 Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit....143 Throttle Position Sensor (TPS) Circuit................................144 Fuel Pump Circuit.....................................................144 BODY / STEERING / SUSPENSION..................................................145 TORQUE SPECIFICATIONS.....................................................146 SPECIAL TOOLS.............................................................146 Multi-Function Pliers.................................................146 CAB FRAME.................................................................147 Assembly / Removal....................................................147 BODY EXPLODED VIEWS.......................................................148 Dash Instruments / Controls...........................................148 Front Bumper..........................................................149 Rear Bumper...........................................................149 Hood / Front Body Work................................................150 Seat Assembly.........................................................151 Seat Belts / Mounting.................................................151 Floor / Rocker Panels.................................................152 Rear Cargo Box / Fenders..............................................153 Chassis / Main Frame..................................................154 BODY COMPONENT REMOVAL....................................................155 Seats.................................................................155 Rear Service Panel....................................................155 Front Bumper..........................................................155 Rear Bumper...........................................................155 Hood and Front Body Work..............................................156 Rocker Panels, Console and Floor......................................157 Rear Fender, Flair and Tie Down Removal...............................157 Cargo Box Assembly Removal............................................157 STEERING ASSEMBLY.........................................................158 Exploded View.........................................................158 WHEEL HUBS................................................................159 Front Hub Exploded View...............................................159 Rear Hub Exploded View................................................159 FRONT A-ARMS..............................................................160 Removal / Replacement.................................................160 Exploded View.........................................................161 BALL JOINT SERVICE........................................................161 Removal...............................................................161 Installation..........................................................162 FRONT STABILIZER BAR......................................................163 Sway Bar Linkage Removal..............................................163 Stabilizer Bar Removal................................................163 Exploded View.........................................................164 REAR A-ARMS...............................................................165 Removal...............................................................165 Installation..........................................................166 Exploded View.........................................................166 REAR STABILIZER BAR.......................................................167 Removal / Installation................................................167 SHOCKS / SPRINGS..........................................................168 Exploded View.........................................................168 Shock Removal / Installation..........................................168 Shock Replacement.....................................................168 DECAL REPLACEMENT.........................................................168 CLUTCHING.....................................................................169 SPECIAL TOOLS AND SUPPLIES................................................170 TORQUE SPECIFICATIONS.....................................................170 PVT System Fastener Torques...........................................170 PVT SYSTEM OVERVIEW.......................................................170 General Operation.....................................................170 Drive Clutch Operation................................................170 Driven Clutch Operation...............................................171 PVT Break-In (Drive Belt / Clutches)..................................171 Maintenance / Inspection..............................................171 Overheating / Diagnosis...............................................172 PVT SYSTEM SERVICE........................................................173 PVT Sealing and Ducting Components....................................173 Disassembly...........................................................173 Assembly..............................................................174 DRIVE BELT................................................................175 Belt Removal..........................................................175 Belt Inspection.......................................................176 Belt Installation.....................................................176 PVT Break-In (Drive Belt / Clutches)..................................176 DRIVE CLUTCH SERVICE......................................................177 Spring Specifications.................................................177 Shift Weights.........................................................178 Exploded View.........................................................179 Clutch Disassembly....................................................179 Spider Removal........................................................180 Roller, Pin, and Thrust Washer Inspection.............................181 Button To Tower Clearance Inspection..................................181 Shift Weight Inspection...............................................181 Bearing Inspection....................................................182 Clutch Inspection.....................................................182 Moveable Sheave Bushing Inspection....................................183 Bushing Service.......................................................184 Clutch Assembly.......................................................186 DRIVEN CLUTCH SERVICE.....................................................187 Clutch Disassembly ...................................................187 Bushing Service.......................................................189 Clutch Assembly.......................................................191 Exploded View.........................................................194 TROUBLESHOOTING...........................................................195 FINAL DRIVE...................................................................197 SPECIAL TOOLS.............................................................198 TORQUE SPECIFICATIONS.....................................................198 Wheel, Hub, and Spindle Torque Table..................................198 FRONT BEARING CARRIER.....................................................198 Bearing Carrier Inspection / Removal..................................198 Bearing Replacement...................................................199 Bearing Carrier Installation..........................................200 FRONT DRIVE SHAFT.........................................................202 Drive Shaft Removal...................................................202 Drive Shaft / CV Joint Handling Tips..................................203 CV Joint / Boot Replacement...........................................203 Drive Shaft Installation..............................................204 PROPSHAFT SERVICE.........................................................206 Removal / Installation................................................206 PROPSHAFT U-JOINT SERVICE.................................................206 Disassembly...........................................................206 Assembly..............................................................207 FRONT GEARCASE / CENTRALIZED HILLIARD.....................................208 Centralized Hilliard Exploded View....................................208 All Wheel Drive Operation.............................................209 AWD Diagnosis.........................................................210 Gearcase Removal......................................................211 Gearcase Disassembly / Inspection.....................................211 Gearcase Assembly / Inspection........................................213 Backlash Thrust Plate Adjustment......................................215 Gearcase Installation.................................................216 REAR BEARING CARRIER......................................................217 Bearing Carrier Inspection / Removal..................................217 Bearing Replacement...................................................218 Bearing Carrier Bushing Replacement...................................218 Bearing Carrier Installation..........................................219 REAR DRIVE SHAFT..........................................................220 Removal...............................................................220 Outer CV Joint / Boot Replacement.....................................221 Inner Plunging Joint / Boot Replacement...............................223 Installation..........................................................225 REAR GEARCASE.............................................................227 Gearcase Removal......................................................227 Gearcase Disassembly..................................................228 Gearcase Assembly.....................................................230 Gearcase Installation.................................................231 Gearcase Exploded View................................................232 WHEEL HUBS................................................................233 Front Hub Exploded View...............................................233 Rear Hub Exploded View................................................233 TRANSMISSION..................................................................234 TORQUES / SPECIFICATIONS..................................................235 SHIFT LEVER...............................................................235 Removal...............................................................235 Installation..........................................................235 Shift Cable Inspection / Adjustment...................................236 TRANSMISSION SERVICE......................................................237 Transmission Removal / Service Notes..................................237 Transfer Case Disassembly.............................................237 Transfer Case Reassembly..............................................240 Transmission Shift Housing Disassembly................................242 Transmission Shift Housing Reassembly.................................247 TROUBLESHOOTING...........................................................252 Troubleshooting Checklist.............................................252 TRANSMISSION EXPLODED VIEWS...............................................253 Shift Housing / Transfer Case Exploded View ..........................253 BRAKES........................................................................254 GENERAL SPECIFICATIONS....................................................255 TORQUE SPECIFICATIONS.....................................................255 SPECIAL TOOLS.............................................................255 BRAKE SYSTEM SERVICE NOTES................................................256 BRAKE NOISE TROUBLESHOOTING...............................................256 HYDRAULIC BRAKE SYSTEM OPERATION..........................................257 BRAKE SYSTEM EXPLODED VIEW................................................257 MASTER CYLINDER...........................................................258 Removal...............................................................258 Installation..........................................................258 BRAKE PEDAL LEVER.........................................................258 Pedal Removal.........................................................258 Pedal Installation....................................................258 BRAKE BLEEDING / FLUID CHANGE.............................................259 FRONT BRAKE PADS..........................................................260 Pad Removal...........................................................260 Pad Inspection........................................................260 Pad Assembly / Installation...........................................261 Brake Burnishing Procedure............................................261 FRONT CALIPER SERVICE.....................................................262 Caliper Exploded View.................................................262 Caliper Removal ......................................................262 Caliper Disassembly...................................................263 Caliper Inspection....................................................264 Caliper Assembly......................................................264 Caliper Installation..................................................265 FRONT BRAKE DISC..........................................................266 Disc Inspection.......................................................266 Disc Replacement......................................................266 REAR BRAKE PAD............................................................267 Pad Removal...........................................................267 Pad Inspection........................................................268 Pad Assembly / Installation...........................................268 Brake Burnishing Procedure............................................268 REAR CALIPER SERVICE......................................................269 Caliper Exploded View.................................................269 Caliper Removal.......................................................269 Caliper Disassembly...................................................270 Caliper Inspection....................................................270 Caliper Assembly......................................................271 Caliper Installation..................................................271 REAR BRAKE DISC...........................................................272 Disc Inspection.......................................................272 Disc Replacement......................................................272 TROUBLESHOOTING...........................................................273 Brakes Squeal / Poor Brake Performance................................273 Pedal Vibration.......................................................273 Caliper Overheats (Brakes Drag).......................................273 Brakes Lock...........................................................273 ELECTRICAL....................................................................274 General Information.......................................................276 Special Tools.........................................................276 Electrical Service Notes..............................................276 Under-Dash Components.................................................276 Switches / Controls.......................................................277 Headlamp Switch.......................................................277 AWD Switch............................................................277 Brake Light Switch....................................................277 Instrument Cluster........................................................278 Overview..............................................................278 Rider Information Display.............................................278 Standard Display Modes................................................279 Diagnostic Display Mode...............................................279 Viewing Diagnostic Codes..............................................281 Instrument Cluster Removal............................................282 Instrument Cluster Installation.......................................282 Instrument Cluster Troubleshooting Tests..................................283 TEST 1 - No All Wheel Drive...........................................283 TEST 2 - No Display...................................................284 TEST 3 - Vehicle Speed Sensor.........................................284 TEST 4 - No AWD Hub Safety Limiter....................................285 TEST 5 - Fuel Gauge Display Not Working ..............................286 TEST 6 - Gear Indicator Not Working (Transmission Switch).............286 All Wheel Drive Coil......................................................287 Operation Overview....................................................287 Diagnosing System Failures............................................287 Gear Position Indicator Switch............................................287 Test Diagram..........................................................287 Speed Sensor..............................................................287 Location / Testing ...................................................287 Head Lights...............................................................288 Headlight Adjustment..................................................288 Headlamp Bulb Replacement.............................................288 Headlamp Housing Removal..............................................289 Headlamp Housing Installation.........................................289 Tail / Brake / Work Lights................................................289 Bulb Replacement......................................................289 Cooling System Schematic..................................................290 Cooling System Break-Out Diagram......................................290 Fan Control Circuit Operation / Testing...............................291 Fan Control Circuit Bypass Test.......................................291 Coolant Temperature Sensor............................................291 EFI Diagnostics...........................................................291 EFI Component Testing.................................................291 Fuel Sender...............................................................291 Testing...............................................................291 Relays....................................................................292 Operation.............................................................292 Fuse Box Layout...........................................................292 Fuses / Circuit Breaker...................................................293 Operation.............................................................293 Charging System...........................................................294 Current Draw - Key Off................................................294 Charging System “Break Even” Test.....................................294 Charging System Alternator Tests......................................295 Charging System Testing Flow Chart....................................296 Battery Service...........................................................297 Battery Identification................................................297 Conventional Battery......................................................297 Battery Activation....................................................297 Battery Inspection....................................................298 Battery Removal.......................................................298 Battery Installation..................................................298 Conventional Battery Testing..........................................298 OCV - Open Circuit Voltage Test.......................................299 Specific Gravity Test.................................................299 Load Test.............................................................299 Off Season Storage....................................................300 Charging Procedure (Conventional).....................................300 Low Maintenance Battery...................................................301 General Battery Information...........................................301 Battery Removal.......................................................301 Battery Installation..................................................301 Battery Testing.......................................................302 OCV - Open Circuit Voltage Test.......................................302 Load Test.............................................................302 Off-Season Storage....................................................302 Charging Procedure (Low Maintenance)..................................303 Starting System...........................................................303 Troubleshooting.......................................................303 Voltage Drop Test.....................................................304 Starter Motor Removal / Disassembly ..................................304 Brush Inspection / Replacement........................................304 Armature Testing......................................................305 Starter Reassembly / Installation.....................................306 Starter Drive.........................................................307 Starter Solenoid Bench Test...........................................307 Starter Solenoid Operation............................................307 Starter Exploded View.................................................308 Starting System Testing Flow Chart........................................309 Condition: Starter fails to turn over the engine. ....................309 Electrical BreakOut Diagrams..............................................310 12V Key-On Power Circuit..............................................310 Starting System Circuit...............................................310 Instrument Cluster Circuit............................................311 Transmission Switch Circuit...........................................311 Wheel Speed Sensor Circuit............................................312 AWD Circuit...........................................................312 Fuel Gauge Display Circuit............................................313 Cooling Fan Circuit...................................................313 Charging System Circuit...............................................314 INDEX.........................................................................315 WIRE DIAGRAMS.................................................................319
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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