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
2.23
MAINTENANCE
2
Radiator Removal
1. Remove the front bumper (see Chapter 5).
2. Remove the upper engine outlet hose and recovery hose
from the top of the radiator.
3. Remove the (2) upper radiator retaining bolts and the (4)
bolts retaining the lower radiator mount bracket. Remove
the bracket from the frame.
4. Disconnect the fan motor and remove the radiator from the
vehicle. Take care not to damage the cooling fins.
5. Reverse procedure for installation.
FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table
NOTE: Do not lubricate the stud or the lug nut.
Wheel Removal
1. Position the vehicle on a level surface.
2. Place the transmission in PARK (P) and stop the engine.
3. Loosen the wheel nuts slightly. If wheel hub removal is
required, remove the cotter pin and loosen the hub nut
slightly.
4. Elevate the appropriate side of the vehicle by placing a
suitable stand under the frame.
5. Remove the wheel nuts and remove the wheel.
6. If hub removal is required, remove the hub nut and washers.
Wheel Installation
1. Verify the transmission is still in PARK (P).
2. Install the wheel hub, washers, and hub nut, if previously
removed.
3. Place the wheel in the correct position on the wheel hub.
Be sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.
4. Attach the wheel nuts and finger tighten them.
Recovery
Engine
T-Fitting
Radiator
Fan Motor Asm.
Screws
Grommets
Inserts
Hose
Outlet Hose
Engine
Inlet Hose
Item Nut Type Specification
Aluminum Wheels
(Cast)
Lug Nut
#1
90 ft. lbs. (122 Nm)
Steel Wheels
(Black / Camo)
Flange Nut
#2
27 ft. lbs. (37 Nm)
Hub Retaining Nuts
(Front & Rear)
- 80 ft. lbs. (108 Nm)
Steel Wheel
27 ft. lbs. (37 Nm)
Aluminum Wheel
90 ft. lbs. (122 Nm)
#1
#2