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
1.5
GENERAL INFORMATION
1
MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
CLUTCH CHART
Engine
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH076OLE021
Engine Displacement 760cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 76.5 mm
Compression Ratio 10:1
Compression Pressure 150-200 psi
Engine Idle Speed 1150 ± 100 RPM
Engine Max Operating RPM 6500 ± 200 RPM
Lubrication Pressurized Wet Sump
Oil Requirements 0W-40
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.8 qts. / 4.5 liters
Overheat Warning Instrument Cluster Indicator
Exhaust System Single Pipe / Silencer
Fuel System
Fuel System Type Bosch Electronic Fuel Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 39 psi
Fuel Filters See Chapter 4
Fuel Capacity / Requirement
7 gal. (26.5 liters)
87 Octane (minimum)
Electrical
Alternator Max Output 500 watts @ 3000 RPM
Lights: Main Headlights 2 - Dual Beam 55 watts / Halogen
Tail / Brake 2 - 27 watts
Worklights 2 - 13 watts
Starting System Electric Start
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 13° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery
Yuasa YTX20HL /
18 Amp Hr. / 310 CCA / 12 Volt
Instrument Type
Analog Speedometer
with Multifunction LCD
DC Outlet Standard 12 V
Relays EFI / Fan
Circuit Breaker Fan Motor: 20 Amp
Fuses
Chassis: 20 Amp
EFI: 15 Amp
Lights: 15 Amp
Accessory: 15 Amp
Speedo/ECU: 5 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Gear Ratio: Front / Rear
High
Low
Rev
3.14:1
8.71:1
5.94:1
Drive Ratio - Front 3.82:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Front Gearcase Oil Requirements
Polaris Demand Drive LT
Premium Fluid
6.75 oz. (200 ml)
Transmission Oil Requirements
Main Gearcase
Polaris High Performance AGL
24 oz. (710 ml)
Transmission Oil Requirements
Transfer Case
Polaris High Performance AGL
14 oz. (414 ml)
Rear Gearcase Oil Requirements
Polaris Premium ADF
18 oz. (532 ml)
Belt 3211113
Steering / Suspension
Front Suspension Independent Double A-arm
Front Travel 9 in. / 23 cm
Rear Suspension Independent Double A-arm
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear
Cam Adjustment
Toe Out 1/8-1/4 in. / 3-6.35 mm
Wheels / Brakes
Front Wheel Size
Front Tire Size
12 x 6 / 10 gauge
Maxxis / 25 x 8 R12
Rear Wheel Size
Rear Tire Size
12 x 8 / 10 gauge
Maxxis / 25 x 10 R12
Tire Air Pressure - Front / Rear 8 psi (55 kPa)
Brake - Front / Rear
Foot Actuated - 4 Wheel
Hydraulic Disc
Brake Fluid DOT 4
Altitude Shift Weight Drive Spring
Driven
Spring
Meters
(Feet)
0-1500
(0-5000)
20-62
(5631700)
Blue/Red
(7043199)
Red or Yellow
(3234452)
1500-3700
(5000 - 12000)
20-58
(5631216)
Blue/Red
(7043199)
Red or Yellow
(3234452)