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2.5

MAINTENANCE

2

50 - 300 Hour Maintenance Interval

 Perform these procedures more often for vehicles subjected to severe use.

 E  

Emission Control System Service (California)

  Have an authorized Polaris dealer perform these services.

 

   Item

   Maintenance Interval

   (whichever comes first)

  

Remarks

Hours

  Calendar

  Miles

  

(KM)

E

Throttle Cable / Throttle 
Pedal

50 H

6 M

300 (500)

Inspect; adjust; lubricate; replace if 
necessary

E

Throttle Body Air Intake 
Ducts / Flange

50 H

6 M

300 (500)

Inspect ducts for proper sealing / air leaks

General Lubrication

50 H

3 M

500 (800)

Lubricate all fittings, pivots, cables, etc.

Shift Linkage

50 H

6 M

500 (800)

Inspect, lubricate, adjust

Steering

50 H

6 M

500 (800)

Lubricate

Front Suspension

50 H

6 M

500 (800)

Lubricate

Rear Suspension

50 H

6 M

500 (800)

Lubricate

Cooling System 

50 H

6 M

500 (800)

Inspect coolant strength seasonally; 
pressure test system yearly

E

Fuel System

100 H

12 M

600 (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 (1600)

Perform a break-in oil change at 25 hours or 
one month / always replace oil filter when 
changing engine oil

Drive Belt

100 H

12 M

1000 (1600)

Inspect; replace as needed

Radiator

100 H

12 M

1000 (1600)

Inspect; clean external surfaces

Cooling Hoses

100 H

12 M

1000 (1600)

Inspect for leaks

Engine Assembly Mounts

100 H

12 M

1000 (1600)

Inspect, torque to specification

Exhaust Muffler / Pipe

100 H

12 M

1000 (1600)

Inspect

Wiring

100 H

12 M

1000 (1600)

Inspect for wear, routing, security; apply 
dielectric grease to connectors subjected to 
water, mud, etc.

Clutches (Drive and Driven) 100 H

12 M

1000 (1600)

Inspect; clean; replace worn parts

Front Wheel Bearings

100 H

12 M

1000 (1600)

Inspect; replace as needed

Brake Fluid

200 H

24 M

2000 (3200)

Change every two years (DOT 4)

Spark Arrestor

300 H

36 M

3000 (4800)

Clean out 

Toe Adjustment

-

Inspect periodically; adjust when parts are 
replaced

Headlight Aim

-

Adjust as needed

Содержание RANGER RZR 2008

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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