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
10.12
ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter
5$,6( $79 :+((/6 2)) *5281' $1'
6833257 ,1 $ 6$)( 0$11(5
021,725 92/7$*( $7 +8% &2,/
&211(&725 %(7:((1 %52:1:+,7(
$1' *5281'
,1 1(875$/
72**/( 72 7$&+20(7(5
6(77,1* 5(9 (1*,1(
+2/' 817,/ ',63/$< 67$%,/,=(6
'2(6 ,7 $33($5
$&&85$7("
,6
63(('2
)81&7,21,1*
&255(&7/<"
<
&+(&.
63(('2
7(67
5(029( 3,1
&211(&725 )520
%$&. 2)
,167580(17
&/867(5
(1*,1( ,'/,1*
0($685( $& 92/7$*(
%(7:((1 3,1 $1'
3,1
29(5 9$&"
<
5(3/$&(
63(('20(7(5
1
&+(&. &+$5*,1* 6<67(0
67$725 5(*8/$725
$1' :,5,1*
1
7851
$:' 2))
67$57 7+( (1*,1(
5(9 $1' +2/' 7+(
530·6 $%29(
7851 $:' 21
'2(6 )5217
'5,9(
(1*$*("
,6 7+(
$:',&2121"
0(&+$1,&$/ 352%/(0
1
,163(&7
+8% &2,/ :,5,1*
)25 6+257 &,5&8,76
72 *5281' ',6&211(&7
&211(&725 0($685(
%(7:((1 +8% &2,/
%52:1:+7
*5281'
5(3$,5 +8% &2,/ :,5,1*
5(3/$&(
63(('20(7(5
12 352%/(0
1
1
<
<
<
127( ,) 7+( $:' ,&21 '2(6 127 &20( 21 25 ,)
9'& ,6 127 5(*,67(5,1* $1' $:' ,6 (1*$*,1*
$%29( 530,7 0$< %( $ 0(&+$1,&$/ 352%/(0
1
67$57 +(5(
7851 .(< 6:,7&+ 2))
5(67$57
<
5HG 9 &RQVWDQW
5HG:KLWH 9 6ZLWFKHG
*UH\2UDQJH 0RGHEXWWRQ
1&
*UHHQ
%OXH
<HOORZ 530 ,QSXW
%URZQ *URXQG
%OXH :KLWH (QJLQH 2YHUKHDW 6ZLWFK
1&
%ON :KLWH 0DOIXQFWLRQ ,QGLFDWRU
9LROHW :KLWH )XHO *DXJH
%URZQ 5HG *URXQG
:KLWH*HDU,QGLFDWRU,QSXW
1&
%URZQ :KLWH $:' &RQWURO
3LQ &RQQHFWRU