Polaris RANGER RZR 2008 Service Manual
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Polaris RANGER RZR 2008 Service Manual

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2008 RANGER RZR
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 9921278
© 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.

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Summary of Contents for Polaris RANGER RZR 2008

  • Page 1 2008 Service Manual PN 9921278 © 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.
  • Page 2 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 3 GENERAL INFORMATION MAINTENANCE ENGINE FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 4: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .

  • Page 5: Model Information

    GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 8 V H 7 6 A D Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...

  • Page 6: Unit Serial Number (Vin) Location

    GENERAL INFORMATION Unit Serial Number (VIN) Location The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on a portion of the LH frame rail close to the front wheel. The model and VIN numbers are also located on a sticker under the hood (B) or on the lower frame rail in front of the LH rear tire (C).

  • Page 7: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER RZR MODEL NUMBER: R08VH76AD, AG ENGINE MODEL: EH076OLE021 FRONT Category Dimension / Capacity Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 cm Wheel Base 77 in.
  • Page 8 MODEL NUMBER: R08VH76AD, AG Transmission Type Polaris Automatic PVT ENGINE MODEL: EH076OLE021 Gear Ratio: Front / Rear Engine High 3.14:1 8.71:1 Polaris Domestic Twin Cylinder, Platform 5.94:1 Liquid Cooled, 4-Stroke Drive Ratio - Front 3.82:1 Engine Model Number EH076OLE021 Drive Ratio - Final 3.70:1...

  • Page 9: Vehicle Information

    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.

  • Page 10: Misc. Specifications And Charts

    GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C...

  • Page 11: Standard Torque Specifications

    GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

  • Page 12: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes...

  • Page 13: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.

  • Page 14: Maintenance

    LUBRICANTS / SERVICE PRODUCTS ........2.8 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... . 2.8 MAINTENANCE REFERENCES .
  • Page 15 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.25 BATTERY MAINTENANCE .

  • Page 16: Periodic Maintenance Chart

    Polaris dealer. = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death.

  • Page 17: Transmission

    Engine Oil Change 25 H 250 (400) Perform a break-in oil change at one month (Break-In Period) Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 18: Brakes

    Clean out Inspect periodically; adjust when parts are Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
  • Page 19 MAINTENANCE COMPONENT INSPECTION / SERVICE LOCATIONS Front and Rear View...
  • Page 20 MAINTENANCE RH and LH Side Views...

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