Polaris 2008 RZR Manuals

Polaris 2008 RZR Manuals

Manuals and User Guides for Polaris 2008 RZR. We have 1 Polaris 2008 RZR manual available for free PDF download: Service Manual

Polaris 2008 RZR Service Manual

Polaris 2008 RZR Service Manual (312 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 37.41 MB

Table of Contents

General Information Chapter

1
- Table of Contents
  1
- Chapter 1
  2
- Engine Designation Number
  2
- Engine Serial Number Location
  2
- General Information
  2
- Model Identification
  2
- Model Information
  2
- Vin Identification
  2
- Unit Serial Number (Vin) Location
  3
- General Specifications
  4
  - Model: 2008 Ranger Razr
    4
- Special Tools
  6
- Vehicle Information
  6
  - Publication Numbers
    6
  - Paint Codes
    6
  - Replacement Keys
    6
- Misc. Specifications and Charts
  7
Maintenance Chapter 2 Maintenance 2

11
- Break-In Period
  13
- Chapter 2
  13
- Maintenance Chart Key
  13
- Periodic Maintenance Chart
  13
- Periodic Maintenance Overview
  13
- Pre-Ride - 25 Hour Maintenance Interval
  14
- 50 - 300 Hour Maintenance Interval
  15
- Component Inspection / Service Locations
  16
  - Front and Rear View
    16
  - Rh and Lh Side Views
    17
- Lubricants / Service Products
  18
  - Polaris Lubricants, Maintenance and Service Products
    18
- Maintenance References
  19
- General Vehicle Inspection and Maintenance
  20
- Fuel System and Air Intake
  21
  - Fuel System
    21
  - Fuel Line
    21
  - Fuel Pump / Fuel Filters
    21
  - Vent Lines
    21
  - Throttle Pedal Inspection
    22
  - Throttle Freeplay Adjustment
    22
  - Air Filter Service
    22
- Engine
  24
- Transmission and Gearcases
  27
- Cooling System
  31
  - Cooling System Overview
    31
  - Coolant Level Inspection
    31
  - Coolant Strength / Type
    31
  - Cooling System Pressure Test
    32
  - Cooling System Hoses
    32
  - Radiator
    32
  - Coolant Drain / Radiator Removal
    32
- Final Drive / Wheel and Tire
  33
  - Wheel, Hub, and Spindle Torque Table
    33
  - Wheel Removal
    33
  - Wheel Installation
    33
  - Tire Inspection
    34
  - Tire Pressure
    34
  - Drive Shaft Boot Inspection
    34
- Electrical and Ignition System
  35
  - Battery Maintenance
    35
  - Battery Removal
    35
  - Battery Installation
    35
  - Battery off Season Storage
    36
  - Battery Charging (Sealed Battery)
    36
  - Spark Plug Service
    36
  - Engine to Frame Ground
    37
- Steering and Suspension
  37
  - Steering
    37
  - Steering Wheel Inspection
    37
  - Steering Inspection / Tie Rod Ends and Hubs
    38
  - Toe Alignment Inspection
    38
  - Toe Adjustment
    39
  - Suspension Spring Preload Adjustment
    39
- Brake System
  40
Engine

41
- Chapter 3
  42
- Crankcase Exploded Views
  42
- Engine Specifications
  42
- Engine Fastener Torque Patterns
  47
- Torque Specifications
  48
- 800 EFI Engine Service Specifications
  49
- Special Tools
  51
- Engine Cooling System
  52
- General Engine Service
  55
  - Engine Lubrication Specifications
    55
  - Accessible Engine Components
    55
  - Oil Pressure Test
    55
  - Oil Flow Chart
    56
  - Engine Removal
    57
  - Engine / Transmission Separation
    63
- Engine Disassembly and Inspection
  64
- Engine Reassembly
  87
  - Crankcase Reassembly
    87
  - Flywheel / Stator Installation
    96
  - Cylinder Head Reassembly
    96
  - Oil Pump Priming
    98
- Engine Installation
  99
  - Engine Assembly and Installation
    99
  - Engine Break-In Period
    101
- Troubleshooting
  102
  - Engine
    102
  - Cooling System
    103
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

105
- Chapter 4
  106
- Electronic Fuel Injection
  106
- General Information
  106
- Special Tools
  106
- Service Notes
  109
- Efi System Exploded View
  110
- Efi System Component Locations
  111
- Fuel Tank
  113
  - Exploded View
    113
  - Fuel Lines - Quick Connect
    114
- Electronic Fuel Injection
  114
  - Principal Components / Efi Operation Overview
    114
  - Initial Priming / Starting Procedure
    115
- Electronic Control Unit (Ecu)
  115
- Temperature and Barometric Air Pressure Sensor (T-Bap)
  116
- Crankshaft Position Sensor (Cps)
  117
  - Cps Test
    117
  - Cps Replacement
    118
- Fuel Injectors
  122
  - Fuel Injector Service
    122
- Fuel Pump
  125
  - Fuel Sender Test
    125
  - Fuel Pump Test
    125
  - Fuel Tank / Fuel Pump Replacement
    127
- Fuel Pressure Regulator
  129
- Throttle Position Sensor (Tps)
  130
  - Tps Test Procedure
    130
  - Tps Initialization
    132
  - Tps Replacement
    133
- Engine Coolant Temperature Sensor (Ect)
  134
- Ignition Coil
  135
- Diagnostic "Blink Codes
  136
  - Efi Troubleshooting
    137
- General Troubleshooting
  136
- Efi System Breakout Diagrams
  138
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

143
- Special Tools
  144
- Torque Specifications
  144
- Cab Frame
  145
- Chapter 5 Assembly / Removal
  145
- Body Exploded Views
  146
  - Dash Instruments / Controls
    146
  - Front Bumper
    147
  - Rear Bumper
    147
  - Hood / Front Body Work
    148
  - Seat Assembly
    149
  - Seat Belts / Mounting
    149
  - Floor / Rocker Panels
    150
  - Rear Cargo Box / Fenders
    151
  - Chassis / Main Frame
    152
- Body Component Removal
  153
  - Seats
    153
  - Rear Service Panel
    153
  - Front Bumper
    153
  - Rear Bumper
    153
  - Hood and Front Body Work
    154
  - Rocker Panels, Console and Floor
    155
- Steering Assembly
  156
  - Exploded View
    156
- Wheel Hubs
  157
  - Front Hub Exploded View
    157
  - Rear Hub Exploded View
    157
- Front A-Arms
  158
  - Removal / Replacement
    158
  - Exploded View
    159
- Ball Joint Service
  159
  - Removal
    159
  - Installation
    160
- Front Stabilizer Bar
  161
  - Sway Bar Linkage Removal
    161
  - Stabilizer Bar Removal
    161
  - Exploded View
    162
- Rear A-Arms
  163
  - Removal
    163
  - Installation
    164
- Rear Stabilizer Bar
  165
  - Removal / Installation
    165
- Decal Replacement
  166
- Shocks / Springs
  166
  - Exploded View
    166
  - Shock Removal / Installation
    166
  - Shock Replacement
    166
Clutching Chapter 6 Clutching

167
- Chapter 6 Pvt System Fastener Torques
  168
- Pvt System Overview
  168
  - General Operation
    168
  - Drive Clutch Operation
    168
  - Driven Clutch Operation
    169
  - Pvt Break-In (Drive Belt / Clutches)
    169
  - Maintenance / Inspection
    169
  - Overheating / Diagnosis
    170
- Special Tools and Supplies
  168
- Torque Specifications
  168
- Pvt System Service
  171
  - Pvt Sealing and Ducting Components
    171
  - Disassembly
    171
  - Assembly
    172
- Drive Belt
  173
  - Belt Removal
    173
  - Belt Inspection
    174
  - Belt Installation
    174
  - Pvt Break-In (Drive Belt / Clutches)
    174
- Drive Clutch Service
  175
  - Spring Specifications
    175
  - Shift Weights
    176
  - Exploded View
    177
  - Clutch Disassembly
    177
  - Spider Removal
    178
  - Roller, Pin, and Thrust Washer Inspection
    179
  - Button to Tower Clearance Inspection
    179
  - Shift Weight Inspection
    179
  - Bearing Inspection
    180
  - Clutch Inspection
    180
  - Moveable Sheave Bushing Inspection
    181
  - Bushing Service
    182
  - Clutch Assembly
    184
- Driven Clutch Service
  185
  - Clutch Disassembly
    185
  - Bushing Service
    187
  - Clutch Assembly
    189
  - Exploded View
    192
- Troubleshooting
  193
Final Drive Chapter 7 Final Drive

195
- Chapter 7 Wheel, Hub, and Spindle Torque Table
  196
- Front Bearing Carrier
  196
  - Bearing Carrier Inspection / Removal
    196
  - Bearing Replacement
    197
  - Bearing Carrier Installation
    198
- Special Tools
  196
- Torque Specifications
  196
- Front Drive Shaft
  200
  - Drive Shaft Removal
    200
  - Drive Shaft / CV Joint Handling Tips
    201
  - CV Joint / Boot Replacement
    201
  - Drive Shaft Installation
    202
- Propshaft Service
  204
  - Removal / Installation
    204
- Propshaft U-Joint Service
  204
  - Disassembly
    204
  - Assembly
    205
- Front Gearcase / Centralized Hilliard
  206
  - Centralized Hilliard Exploded View
    206
  - All Wheel Drive Operation
    207
  - Awd Diagnosis
    208
  - Gearcase Removal
    209
  - Gearcase Disassembly / Inspection
    209
  - Gearcase Assembly / Inspection
    211
  - Backlash Thrust Plate Adjustment
    213
  - Gearcase Installation
    214
- Rear Bearing Carrier
  215
  - Bearing Carrier Inspection / Removal
    215
  - Bearing Replacement
    216
  - Bearing Carrier Bushing Replacement
    216
  - Bearing Carrier Installation
    217
  - Wheel Hub
    217
- Rear Drive Shaft
  218
  - Removal
    218
  - CV Joint / Boot Replacement
    219
  - Installation
    221
- Rear Gearcase
  223
  - Gearcase Removal
    223
  - Gearcase Disassembly
    224
  - Gearcase Assembly
    226
  - Gearcase Installation
    227
  - Gearcase Exploded View
    228
- Wheel Hubs
  229
  - Front Hub Exploded View
    229
  - Rear Hub Exploded View
    229
Transmission Chapter 8 Transmission

231
- Chapter 8
  232
- Installation
  232
- Removal
  232
- Shift Lever
  232
- Torques / Specifications
  232
- Shift Cable Inspection / Adjustment
  233
- Transmission Service
  234
  - Transmission Removal
    234
  - Transfer Case Disassembly
    234
  - Transfer Case Reassembly
    237
  - Transmission Shift Housing Disassembly
    239
  - Transmission Shift Housing Reassembly
    244
- Troubleshooting
  249
  - Troubleshooting Checklist
    249
- Transmission Exploded Views
  250
  - Shift Housing / Transfer Case Exploded View
    250
Brakes Chapter 9 Brakes

251
- Chapter 9
  252
- General Specifications
  252
- Special Tools
  252
- Torque Specifications
  252
- Brake Noise Troubleshooting
  253
- Brake System Service Notes
  253
- Brake System Exploded View
  254
- Hydraulic Brake System Operation
  254
- Brake Pedal Lever
  255
  - Pedal Removal
    255
  - Pedal Installation
    255
- Master Cylinder
  255
  - Removal
    255
  - Installation
    255
- Brake Bleeding / Fluid Change
  256
- Front Brake Pads
  257
  - Pad Removal
    257
  - Pad Inspection
    257
  - Pad Assembly / Installation
    258
  - Brake Burnishing Procedure
    258
- Front Caliper Service
  259
  - Caliper Exploded View
    259
  - Caliper Removal
    259
  - Caliper Disassembly
    260
  - Caliper Inspection
    261
  - Caliper Assembly
    261
  - Caliper Installation
    262
- Front Brake Disc
  263
  - Disc Inspection
    263
  - Disc Replacement
    263
- Rear Brake Pad
  264
  - Pad Removal
    264
  - Pad Inspection
    265
  - Pad Assembly / Installation
    265
  - Brake Burnishing Procedure
    265
- Rear Caliper Service
  266
  - Caliper Exploded View
    266
  - Caliper Removal
    266
  - Caliper Disassembly
    267
  - Caliper Inspection
    267
  - Caliper Assembly
    268
  - Caliper Installation
    268
- Rear Brake Disc
  269
  - Disc Inspection
    269
  - Disc Replacement
    269
- Troubleshooting
  270
  - Brakes Squeal / Poor Brake Performance
    270
  - Pedal Vibration
    270
  - Caliper Overheats (Brakes Drag)
    270
  - Brakes Lock
    270
Electrical Chapter 10 Electrical

271
- Chapter 10
  273
- Electrical Service Notes
  273
- General Information
  273
- Special Tools
  273
- Under-Dash Components
  273
- Switches / Controls
  274
  - Headlamp Switch
    274
  - Awd Switch
    274
  - Brake Light Switch
    274
- Instrument Cluster
  275
  - Overview
    275
  - Rider Information Display
    275
  - Standard Display Modes
    276
  - Diagnostic Display Mode
    276
  - Viewing Diagnostic Codes
    278
  - Instrument Cluster Removal
    279
  - Instrument Cluster Installation
    279
- Instrument Cluster Troubleshooting Tests
  280
- All Wheel Drive Coil
  284
  - Operation Overview
    284
  - Diagnosing System Failures
    284
- Gear Position Indicator Switch
  284
  - Test Diagram
    284
- Speed Sensor
  284
  - Location / Testing
    284
- Head Lights
  285
  - Headlight Adjustment
    285
  - Headlamp Bulb Replacement
    285
- Tail / Brake / Work Lights
  286
  - Bulb Replacement
    286
- Cooling System Schematic
  287
- Efi Diagnostics
  288
  - Efi Component Testing
    288
- Fuel Sender
  288
  - Testing
    288
- Fuse Box Layout
  289
- Relays
  289
- Fuses / Circuit Breaker
  290
- Charging System
  291
  - Current Draw - Key off
    291
  - Charging System "Break Even" Test
    291
  - Charging System Alternator Tests
    292
  - Charging System Testing Flow Chart
    293
- Battery Service
  294
  - Battery Identification
    294
- Conventional Battery
  294
  - Battery Activation
    294
  - Battery Inspection
    295
  - Conventional Battery Testing
    295
  - Off Season Storage
    297
  - Charging Procedure (Conventional)
    297
- Low Maintenance Battery
  298
  - General Battery Information
    298
  - Battery Testing
    299
  - Ocv - Open Circuit Voltage Test
    299
  - Load Test
    299
  - Off-Season Storage
    299
  - Charging Procedure (Low Maintenance)
    300
- Starting System
  300
  - Troubleshooting
    300
  - Voltage Drop Test
    301
  - Starter Motor Removal / Disassembly
    301
  - Brush Inspection / Replacement
    301
  - Armature Testing
    302
  - Starter Reassembly / Installation
    303
  - Starter Drive
    304
  - Starter Exploded View
    305
- Starting System Testing Flow Chart
  306
  - Condition: Starter Fails to Turn over the Engine
    306
- Electrical Breakout Diagrams
  307
  - 12V Key-On Power Circuit
    307
  - Starting System Circuit
    307
  - Instrument Cluster Circuit
    308
  - Transmission Switch Circuit
    308
  - Wheel Speed Sensor Circuit
    309
  - Awd Circuit
    309
  - Fuel Gauge Display Circuit
    310
  - Cooling Fan Circuit
    310
  - Charging System Circuit
    311

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