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
2.8
MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service
Products
NOTE: Each item can be purchased separately at
your local Polaris dealer.
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871281
Premium 4-Cycle Synthetic 0W-40
Engine Oil (Quart) (12 Count)
2871844
Premium 4-Cycle Synthetic 0W-40
Engine Oil (Gallon) (4 Count)
2871567
Premium 4-Cycle Synthetic 0W-40
Engine Oil (16 Gallon) (4-Cycle)
Gearcase / Transmission Lubricants
2873602
AGL - Synthetic ATV Gearcase Lubricant
(1 Qt.) (12 Count)
2873603
AGL - Synthetic ATV Gearcase Lubricant
(1 Gal.) (4 Count)
2873604
AGL - Synthetic ATV Gearcase Lubricant
(2.5 Gal.) (2 Count)
2871653
ATV Angle Drive Fluid
(8 oz.) (12 Count)
2872276
ATV Angle Drive Fluid
(2.5 Gal) (2 Count)
2871654
Premium Demand Drive Fluid LT
(1 Qt.) (12 Count)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
2871312 Grease Gun Kit
2871322
Premium All Season Grease
(3 oz. cartridge) (24 Count)
2871423
Premium All Season Grease
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
2870585 Loctite™ Primer N, Aerosol, 25 g
2871956
Loctite™ Thread Sealant 565
(50 ml.) (6 Count)
2871949
Loctite™ Threadlock 242
(50 ml.) (10 Count)
2871950
Loctite™ Threadlock 242
(6 ml.) (12 Count)
2871951
Loctite™ Threadlock 262
(50 ml.) (10 Count)
2871952
Loctite™ Threadlock 262
(6 ml.) (12 Count)
2871953
Loctite™ Threadlock 271
(6 ml.) (12 Count)
2871954
Loctite™ Threadlock 271
(36 ml.) (6 Count)
2870584
Loctite™ 680-Retaining Compound
(10 ml.)
2870587
Loctite™ 518 Gasket Eliminator / Flange
Sealant (50 ml.) (10 Count)
2871326
Premium Carbon Clean
(12 oz.) (12 Count)
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2872189 DOT 4 Brake Fluid (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)