Polaris RANGER RZR 2008 Service Manual Download Page 15 | Manualshive

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Polaris RANGER RZR 2008 Service Manual Download Page 15

2.2

MAINTENANCE

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

BATTERY MAINTENANCE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY OFF SEASON STORAGE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BATTERY CHARGING (SEALED BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
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 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
SUSPENSION SPRING PRELOAD ADJUSTMENT  . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

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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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