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1.10

GENERAL INFORMATION

Glossary of Terms

ABDC:

 After bottom dead center.

ACV:

 Alternating current voltage.

Alternator:

 Electrical generator producing voltage alternating current.

ATDC:

 After top dead center.

BBDC:

 Before bottom dead center.

BDC:

 Bottom dead center.

BTDC:

 Before top dead center.

CC:

 Cubic centimeters.

Center Distance:

 Distance between center of crankshaft and center of driven clutch shaft.

Chain Pitch:

 Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.

CI:

 Cubic inches.

Clutch Buttons:

 Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.

Clutch Offset:

 Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.

Clutch Weights:

 Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to

close and grip the drive belt.

Crankshaft Run-Out:

 Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers

on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV:

 Direct current voltage

CVT: 

Centrifugal Variable Transmission (Drive Clutch System)

DCV:

 Direct current voltage.

Dial Bore Gauge:

 A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the

cylinder bore.

Electrical Open:

 Open circuit. An electrical circuit which isn't complete.

Electrical Short:

 Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire

touching the chassis).

End Seals:

 Rubber seals at each end of the crankshaft.

Engagement RPM:

 Engine RPM at which the drive clutch engages to make contact with the drive belt.

ft.:

 Foot/feet.

Foot Pound:

 Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.

g:

 Gram. Unit of weight in the metric system.

gal.: 

Gallon.

ID: 

Inside diameter.

in.:

 Inch/inches.

Inch Pound: 

In. lb. 12 in. lbs. = 1 ft. lb.

kg/cm²: 

Kilograms per square centimeter.

kg-m:

 Kilogram meters.

Kilogram/meter:

 A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.

l or ltr:

 Liter.

lbs/in²: 

Pounds per square inch.

Left or Right Side:

 Always referred to based on normal operating position of the driver.

m:

 Meter/meters.

Mag:

 Magneto.

Magnetic Induction:

 As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

mi.:

 Mile/miles.

mm:

 Millimeter. Unit of length in the metric system. 1 mm = approximately .040".

Nm:

 Newton meters.

OD:

 Outside diameter.

Ohm:

 The unit of electrical resistance opposing current flow.

oz.:

 Ounce/ounces.

Piston Clearance:

 Total distance between piston and cylinder wall.

psi.:

 Pounds per square inch.

PTO:

 Power take off.

PVT:

   Polaris Variable Transmission (Drive Clutch system)

qt.:

 Quart/quarts.

Regulator:

 Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.

Reservoir Tank:

 The fill tank in the liquid cooling system.

Resistance:

 In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.

RPM: 

Revolutions per minute.

Seized Piston:

 Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.

Possible causes:

 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.

Stator Plate:

 The plate mounted under the flywheel supporting the battery charging coils.

TDC:

 Top dead center. Piston's most outward travel from crankshaft.

Volt:

 The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.

Watt:

 Unit of electrical power. Watts = amperes x volts.

WOT:

 Wide open throttle.

Summary of Contents for RANGER RZR 2008

Page 1: ...al tools Use only the proper tools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2008 Service...

Page 2: ...g instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Locti...

Page 3: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL INJECTION 5 BODY STEERING SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10...

Page 4: ...1 2 UNIT SERIAL NUMBER VIN LOCATION 1 3 GENERAL SPECIFICATIONS 1 4 MODEL 2008 RANGER RZR 1 5 VEHICLE INFORMATION 1 6 PUBLICATION NUMBERS 1 6 PAINT CODES 1 6 REPLACEMENT KEYS 1 6 SPECIAL TOOLS 1 6 MIS...

Page 5: ...fer to the engine model number and serial number This information can be found on the sticker applied to the cylinder head on the side of engine Machine Model Number Identification Model Year Designat...

Page 6: ...serial number VIN are important for vehicle identification The VIN number A is stamped on a portion of the LH frame rail close to the front wheel The model and VIN numbers are also located on a stick...

Page 7: ...Base 77 in 196 cm Ground Clearance 10 in 25 4 cm Dry Weight 945 lbs 429 kg Gross Vehicle Weight 1727 lbs 783 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension 42 in x 22 in 107 cm x 56 cm...

Page 8: ...edometer 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 Trans...

Page 9: ...aybe substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool s...

Page 10: ...1 7 GENERAL INFORMATION 1 MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C...

Page 11: ...following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section fo...

Page 12: ...1 9 GENERAL INFORMATION 1 SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents...

Page 13: ...end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm Ki...

Page 14: ...INES 2 11 THROTTLE PEDAL INSPECTION 2 12 THROTTLE FREEPLAY ADJUSTMENT 2 12 AIR FILTER SERVICE 2 12 ENGINE 2 14 ENGINE OIL LEVEL 2 14 ENGINE OIL AND FILTER SERVICE 2 15 ENGINE BREATHER HOSE INSPECTION...

Page 15: ...6 SPARK PLUG SERVICE 2 26 ENGINE TO FRAME GROUND 2 27 STEERING AND SUSPENSION 2 27 STEERING INSPECTION 2 27 STEERING WHEEL FREEPLAY 2 27 STEERING INSPECTION TIE ROD ENDS AND HUBS 2 28 TOE ALIGNMENT IN...

Page 16: ...gins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operatio...

Page 17: ...as needed Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation apply dielectric grease if replacing E Air Filter Main Element Weekly Inspect rep...

Page 18: ...1000 Check for leaks at tank cap fuel line fuel pump and fuel rail Replace lines every two years E Spark Plug 100 H 12 M 600 1000 Inspect replace as needed E Engine Oil Filter Change 100 H 6 M 1000 16...

Page 19: ...2 6 MAINTENANCE COMPONENT INSPECTION SERVICE LOCATIONS Front and Rear View...

Page 20: ...2 7 MAINTENANCE 2 RH and LH Side Views...

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