Service Manual
Table Of Contents
- 2008 RANGER RZR SERVICE MANUAL
- GENERAL INFORMATION
- MAINTENANCE
- PERIODIC MAINTENANCE CHART
- COMPONENT INSPECTION / SERVICE LOCATIONS
- LUBRICANTS / SERVICE PRODUCTS
- MAINTENANCE REFERENCES
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- FUEL SYSTEM AND AIR INTAKE
- ENGINE
- TRANSMISSION AND GEARCASES
- COOLING SYSTEM
- FINAL DRIVE / WHEEL AND TIRE
- ELECTRICAL AND IGNITION SYSTEM
- STEERING AND SUSPENSION
- BRAKE SYSTEM
- ENGINE
- ENGINE SPECIFICATIONS
- ENGINE COOLING SYSTEM
- GENERAL ENGINE SERVICE
- 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
- ENGINE INSTALLATION
- TROUBLESHOOTING
- ELECTRONIC FUEL INJECTION
- GENERAL INFORMATION
- FUEL TANK
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
- CRANKSHAFT POSITION SENSOR (CPS)
- FUEL INJECTORS
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- GENERAL 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
- CLUTCHING
- FINAL DRIVE
- TRANSMISSION
- BRAKES
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OPERATION
- BRAKE SYSTEM EXPLODED VIEW
- MASTER CYLINDER
- BRAKE PEDAL LEVER
- BRAKE BLEEDING / FLUID CHANGE
- FRONT BRAKE PADS
- FRONT CALIPER SERVICE
- FRONT BRAKE DISC
- REAR BRAKE PAD
- REAR CALIPER SERVICE
- REAR BRAKE DISC
- TROUBLESHOOTING
- ELECTRICAL
- General Information
- Switches / Controls
- Instrument Cluster
- Instrument Cluster Troubleshooting Tests
- All Wheel Drive Coil
- Gear Position Indicator Switch
- Speed Sensor
- Head Lights
- Tail / Brake / Work Lights
- Cooling System Schematic
- EFI Diagnostics
- Fuel Sender
- Relays
- Fuse Box Layout
- Fuses / Circuit Breaker
- Charging System
- Battery Service
- Conventional Battery
- Low Maintenance Battery
- Starting System
- Starting System Testing Flow Chart
- Electrical BreakOut Diagrams
- INDEX
- WIRE DIAGRAMS
5.13
BODY / STEERING / SUSPENSION
5
Rocker Panels, Console and Floor
Rocker Panel Removal
1. Remove the (11) push rivets and (4) Torx screws from the
RH rocker panel and remove panel from the vehicle.
Remove the (12) push rivets and (4) Torx screws from the
LH rocker panel and remove panel from the vehicle.
Console and Floor Panel Removal
1. Remove both rocker panels as previously described.
2. Remove the front body / dash (see “BODY COMPONENT
REMOVAL - Front Body / Dash Removal”).
3. Remove the (2) push rivets from the rear portion of the
console and remove the (9) Torx screws retaining the
console to the floor panel.
4. Remove the shift handle knob and remove the console.
5. Remove the (6) Torx screws from the upper front portion
of the floor panel.
6. Remove the (4) fasteners retaining the foot pedal bracket.
Disconnect the brake and throttle cables from the pedals
and remove pedals from the vehicle.
7. Remove the (3) push rivets retaining the fuse box.
8. Remove the (2) push rivets retaining the rear fender wells
to the floor panel.
9. Remove steering shaft and remove floor panel from the
vehicle.
Rear Fender, Flair and Tie Down Removal
1. Remove the rear bumper (see “BODY COMPONENT
REMOVAL - Rear Bumper”).
2. Remove the (8) push rivets that retain the rear portion of
the rocker panels to the rear fenders.
3. Remove the (3) push rivets and remove the fender flair from
the rear fender.
4. Remove the (3) Torx screws from the bottom side of the
fender and the upper push rivet from the top side. Remove
the fender from the vehicle.
5. Remove the (4) fasteners that retain the tie-down brackets
to the cargo box and remove from vehicle.
Cargo Box Assembly Removal
1. Remove the seats and rear service panel (see “Seats” and
“Rear Service Panel”).
2. Remove the (4) Torx screws retaining the lower portion of
the rear bumper to the frame (see “Rear Bumper”).
3. Remove the (4) screws from the middle of the cargo box.
4. Remove the (4) Torx screws that attach the front portion of
the cargo box to the frame.
5. Remove the (8) push rivets that attach the rocker panels to
the cargo box on each side.
6. Cut the panduit strap, disconnect taillight/worklight wire
connections and remove the box assembly from the vehicle.
Push
Rivets
Torx
Screws
Push
Rivets
Console
Floor
Panel
Fender
Fender
Flair
Tie-Down
Push
Rivets
Torx
Screws
Push
Rivet