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.4
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.26
Specification, Cylinder Taper Limit
. . . . . . . . . . . . . . . .3.34
Specification, Cylinder Warp Limit
. . . . . . . . . . . . . . . .3.34
Specification, Oil Pump Bolt Torque
. . . . . . . . . . . . . . .3.51
Specification, Oil Pump Rotor Clearance
. . . . . . . . . . . .3.43
Specification, Timing Gear Alignment
. . . . . . . . . . . . . .3.39
Specification, Valve Seat Contact Width
. . . . . . . . . . . .3.30
Specification, Valve Spring Free Length
. . . . . . . . . . . .3.27
Specification, Valve Stem Diameter
. . . . . . . . . . . . . . . .3.28
Specification, Valve Stem Guide I.D.
. . . . . . . . . . . . . . .3.28
Specification, Wheel Toe-Out
. . . . . . . . . . . . . . . . . . . . .2.28
Specifications, Cam Shaft
. . . . . . . . . . . . . . . . . . . . . . . .3.46
Specifications, Cooling System
. . . . . . . . . . . . . . . . . . . .3.12
Specifications, Crankcase Fastener Torque
. . . . . . . . . . .3.48
Specifications, Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Specifications, Engine Lubrication
. . . . . . . . . . . . 3.15, 3.61
Specifications, Engine Oil Pressure
. . . . . . . . . . . . . . . .3.15
Specifications, General
. . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
Specifications, Oil Baffle Bolt Torque
. . . . . . . . . . . . . .3.47
Specifications, Oil Pick-up Bolt Torque
. . . . . . . . . . . . .3.47
Speed Sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.14
Speedometer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
Speedometer Installation
. . . . . . . . . . . . . . . . . . . . . . . . .10.9
Speedometer Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
Speedometer Troubleshooting Tests
. . . . . . . . . . . . . . .10.10
Starter Armature Testing
. . . . . . . . . . . . . . . . . . . . . . . .10.32
Starter Assembly Exploded View
. . . . . . . . . . . . . . . . .10.35
Starter Brush Inspection / Replacement
. . . . . . . . . . . .10.31
Starter Drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.34
Starter Drive Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
Starter Motor, Removal
. . . . . . . . . . . . . . . . . . . . . . . . .10.31
Starter Reassembly / Installation
. . . . . . . . . . . . . . . . . .10.33
Starter Solenoid, Test
. . . . . . . . . . . . . . . . . . . . . . . . . .10.34
Starter System Flow Chart
. . . . . . . . . . . . . . . . . . . . . .10.36
Starter System, Troubleshooting
. . . . . . . . . . . . . . . . . .10.30
Stator, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
Steering Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
Steering Wheel Freeplay
. . . . . . . . . . . . . . . . . . . . . . . . .2.27
Steering, Alignment
. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
Steering, Exploded View
. . . . . . . . . . . . . . . . . . . . . . . . .5.14
Steering, Toe Adjustment
. . . . . . . . . . . . . . . . . . . . . . . .2.29
Steering, Wheel Toe Alignment
. . . . . . . . . . . . . . . . . . .2.28
Suspension, Spring Preload Adjustment
. . . . . . . . . . . . .2.29
Sway Bar Linkage Removal
. . . . . . . . . . . . . . . . . . . . . .5.19
Switch, AWD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Switch, Brake Light
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Switch, Headlamp
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
Tail Lights
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.16
Tap/Drill Sizes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
Temperature / Barometric Air Pressure Sensor (T-BAP)
4.12
Throttle Freeplay Adjustment
. . . . . . . . . . . . . . . . . . . . .2.12
Throttle Pedal Inspection
. . . . . . . . . . . . . . . . . . . . . . . .2.12
Throttle Position Sensor (TPS)
. . . . . . . . . . . . . . . . . . . .4.26
Throttle Position Sensor Initialization
. . . . . . . . . . . . . . 4.28
Throttle Position Sensor Replacement
. . . . . . . . . . . . . . 4.29
Timing Gear Mark Alignment
. . . . . . . . . . . . . . . . . . . . 3.39
Tire Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Tire Pressure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Toe Alignment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Torque Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Torque Specifications - Engine
. . . . . . . . . . . . . . . . . . . . 3.8
Torque Specifications, Body/Steering/Suspension
. . . . . 5.2
Torque Specifications, Brakes
. . . . . . . . . . . . . . . . . . . . . 9.2
Torque Specifications, Clutching
. . . . . . . . . . . . . . . . . . . 6.2
Torque Specifications, Final Drive
. . . . . . . . . . . . . . . . . 7.2
Torque Specifications, Transmission
. . . . . . . . . . . . . . . . 8.2
Torque Specifications, Wheel, Hub, and Spindle
. . . . . 2.23
Transfer Case, Disassembly
. . . . . . . . . . . . . . . . . . . . . . . 8.4
Transfer Case, Reassembly
. . . . . . . . . . . . . . . . . . . . . . . 8.7
Transmission Lubrication
. . . . . . . . . . . . . . . . . . . . . . . 2.17
Transmission, Exploded View
. . . . . . . . . . . . . . . . . . . . 8.20
Transmission, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Transmission, Shift Housing Disassembly
. . . . . . . . . . . 8.9
Transmission, Shift Housing Reassembly
. . . . . . . . . . . 8.14
Trip Meter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Troubleshooting, Brake Noise
. . . . . . . . . . . . . . . . . . . . . 9.3
Troubleshooting, Brake System
. . . . . . . . . . . . . . . . . . . 9.20
Troubleshooting, Clutching
. . . . . . . . . . . . . . . . . . . . . . 6.27
Troubleshooting, No AWD
. . . . . . . . . . . . . . . . . . . . . 10.10
Troubleshooting, No AWD Hub Safety Limiter
. . . . . 10.12
Troubleshooting, No Fuel Gauge Display
. . . . . . . . . . 10.13
Troubleshooting, No Gear Indicator Display
. . . . . . . . 10.13
Troubleshooting, No Instrument Display
. . . . . . . . . . . 10.11
Troubleshooting, Transmission
. . . . . . . . . . . . . . . . . . . 8.19
Troubleshooting, Vehicle Speed Sensor
. . . . . . . . . . . 10.11
V
Valve Seal/Spring Service . . . . . . . . . . . . . . . . . . . . . . . 3.26
Valve Sealing Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
Valve Seat Reconditioning
. . . . . . . . . . . . . . . . . . . . . . . 3.29
Vent Lines
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VIN Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN Location
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Voltage Drop Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
W
Wheel Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Wheel, Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Wheel, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23