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
IX.3
IX
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . 4.31
Ignition Coil Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
Indicator, Service Interval
. . . . . . . . . . . . . . . . . . . . . . . 10.8
Instrument Cluster
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
K
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Kilometers to Miles Toggle
. . . . . . . . . . . . . . . . . . . . . . 10.8
L
Leakdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
M
Maintenance, Brake System . . . . . . . . . . . . . . . . . . . . . . 2.30
Maintenance, Cooling System
. . . . . . . . . . . . . . . . . . . . 2.21
Maintenance, Electrical and Ignition
. . . . . . . . . . . . . . . 2.25
Maintenance, Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Maintenance, Final Drive
. . . . . . . . . . . . . . . . . . . . . . . . 2.23
Maintenance, Fuel System
. . . . . . . . . . . . . . . . . . . . . . . 2.11
Maintenance, General Vehicle Inspection
. . . . . . . . . . . 2.10
Maintenance, References
. . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Maintenance, Service Products and Lubricants
. . . . . . . . 2.8
Maintenance, Steering
. . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Maintenance, Transmission and Gearcases
. . . . . . . . . . 2.17
Master Cylinder, Installation
. . . . . . . . . . . . . . . . . . . . . . 9.5
Master Cylinder, Removal
. . . . . . . . . . . . . . . . . . . . . . . . 9.5
Miles to Kilometers Toggle
. . . . . . . . . . . . . . . . . . . . . . 10.8
Model Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
O
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Oil Pump Priming
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
Oil Pump, Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . 3.43
Oil Pump, Reassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Oil Pump, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Periodic Maintenance Chart
. . . . . . . . . . . . . . . . . . . . . . . 2.3
Piston Ring Installed Gap
. . . . . . . . . . . . . . . . . . . . . . . . 3.37
Piston to Cylinder Clearance
. . . . . . . . . . . . . . . . . . . . . 3.36
Piston to Rod Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Pre-Ride / Daily Inspection
. . . . . . . . . . . . . . . . . . . . . . 2.10
Programmable Service Interval
. . . . . . . . . . . . . . . . . . . 10.8
Propshaft Removal / Installation
. . . . . . . . . . . . . . . . . . 7.10
Propshaft, U-Joint Service
. . . . . . . . . . . . . . . . . . . . . . . 7.10
Publication Numbers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PVT System, Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT System, Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT System, Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT System, Overheating Diagnostics
. . . . . . . . . . . . . . 6.4
PVT System, Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT System, Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
PVT, Button to Tower Clearance
. . . . . . . . . . . . . . . . . . 6.13
PVT, Drive Clutch Disassembly
. . . . . . . . . . . . . . . . . . 6.11
PVT, Drive Clutch Spider Removal
. . . . . . . . . . . . . . . . 6.12
PVT, Driven Clutch Bushing Service
. . . . . . . . . . . . . . . 6.21
PVT, Driven Clutch Disassembly
. . . . . . . . . . . . . . . . . .6.19
PVT, Driven Clutch Reassembly
. . . . . . . . . . . . . . . . . .6.23
PVT, EBS Drive Clutch Bushing Service
. . . . . . . . . . . .6.16
PVT, EBS Drive Clutch Cover Bushing Remove/Install
6.17
PVT, Moveable Sheave Inspection
. . . . . . . . . . . . . . . . .6.15
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Radiator, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Rear A-arm, Replacement
. . . . . . . . . . . . . . . . . . . . . . . .5.21
Rear Bearing Carrier
. . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
Rear Bumper
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5, 5.11
Rear Cargo Box / Fenders
. . . . . . . . . . . . . . . . . . . . . . . . .5.9
Rear Driveshaft, CV Joint / Boot Replacement
. . . . . . .7.25
Rear Driveshaft, Installation
. . . . . . . . . . . . . . . . . . . . . .7.29
Rear Driveshaft, Plunging Joint / Boot Replacement
. . .7.27
Rear Driveshaft, Removal
. . . . . . . . . . . . . . . . . . . . . . . .7.24
Rear Fender, Flair, and Tie Down Removal
. . . . . . . . . .5.13
Rear Gearcase
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.31
Rear Gearcase Lubrication
. . . . . . . . . . . . . . . . . . . . . . .2.20
Rear Gearcase, Assembly
. . . . . . . . . . . . . . . . . . . . . . . .7.34
Rear Gearcase, Disassembly
. . . . . . . . . . . . . . . . . . . . . .7.32
Rear Gearcase, Exploded View
. . . . . . . . . . . . . . . . . . . .7.36
Rear Gearcase, Installation
. . . . . . . . . . . . . . . . . . . . . . .7.35
Rear Gearcase, Removal
. . . . . . . . . . . . . . . . . . . . . . . . .7.31
Rear Service Panel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
Rear Stabilizer Bar
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
Relays
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.19
Rocker Panel Removal
. . . . . . . . . . . . . . . . . . . . . . . . . .5.13
S
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
Seat Belts / Mounting
. . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
Seats
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
Service Interval Indicator
. . . . . . . . . . . . . . . . . . . . . . . .10.8
Service Locations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
Shift Cable Inspection and Adjustment
. . . . . . . . . . . . . . .8.3
Shift Lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Lever, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Lever,Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Linkage Inspection and Adjustment
. . . . . . . . . . . .2.10
Shocks and Springs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
Spark Plug Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
Special Tool, Cam Gear Installation Kit
. . . . . . . . . . . . .3.41
Special Tools
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
Special Tools, Body/Steering/Suspension
. . . . . . . . . . . . .5.2
Special Tools, Brakes
. . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2
Special Tools, Clutching
. . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Special Tools, Electrical
. . . . . . . . . . . . . . . . . . . . . . . . .10.3
Special Tools, Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
Special Tools, Final Drive
. . . . . . . . . . . . . . . . . . . . . . . . .7.2
Specification Chart, Maintenance
. . . . . . . . . . . . . . . . . .2.17
Specification, Balance Shaft Gear Bolt Torque
. . . . . . .3.52
Specification, Cam Lobe Height
. . . . . . . . . . . . . . . . . . .3.46
Specification, Cam Thrust Plate Fastener Torque
. . . . . .3.50
Specification, Camshaft Gear Bolt Torque
. . . . . . . . . . .3.52
Specification, Coolant Sensor Resistance
. . . . . . . . . . .10.18