Description
This 2008 Polaris Ranger RZR 800 Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this 2008 Polaris Ranger RZR 800 Service Manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read this 2008 Polaris Ranger RZR 800 Service Manual and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
This 2008 Polaris Ranger RZR 800 Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2008 Polaris Ranger RAZR 800 EFI UTVs.
2008 Polaris Ranger RZR 800 Service Manual Table of Contents
GENERAL INFORMATION
Model Information
Model Identification
Engine Designation Number
Vin Identification
Engine Serial Number Location
Unit Serial Number (VIN) Location
General Specifications
Model: 2008 Ranger Rzr
Vehicle Information
Publication Numbers
Paint Codes
Replacement Keys
Special Tools
Misc Specifications And Charts
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap/drill Sizes
Decimal Equivalents
Glossary Of Terms
MAINTENANCE
Periodic Maintenance Chart
Periodic Maintenance Overview
Breakin Period
Maintenance Chart Key
Preride 25 Hour Maintenance Interval
50 300 Hour Maintenance Interval
Component Inspection / Service Locations
Front And Rear View
Rhandlh Side Views
Lubricants / Service Products
Polaris Lubricants, Maintenance And Service Products
Maintenance References
General Vehicle Inspection And Maintenance
Preride I Daily Inspection
Frame, Nuts Bolts, And Fasteners
Shift Cable Inspection / Adjustment
Fuel System And Air Intake
Fuel System
Fuel Line
Fuel Pump / Fuel Filters
Vent Lines
Throttle Pedal Inspection
Throttle Freeplay Adjustment
Air Filter Service
Engine
Engine Oil Level
Engine Oil And Filter Service
Engine Breather Hose Inspection
Engine And Transmission Mount Locations
Compression And Leakdown Test
Exhaust Spark Arrestor
Transmission And Gearcases
Transmission I Gearcase Specification Chart
Transmission Lubrication
Front Gearcase Lubrication
Rear Gearcase Lubrication
Cooling System
Cooling System Overview
Coolant Level Inspection
Coolant Strength / Type
Cooling System Pressure Test
Cooling System Hoses
Radiator
Coolant Drain I Radiator Removal
Final Drive / Wheel And Tire
Wheel, Hub And Spindle Torque Table
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
Drive Shaft Boot Inspection
Electrical And Ignition System
Battery Maintenance
Battery Removal
Battery Installation
Battery Off Season Storage
Battery Charging (sealed Battery)
Spark Plug Service
Engine To Frame Ground
Steering And Suspension
Steering Inspection
Steering Wheel Freeplay
Steering Inspection / Tie Rod Ends And Hubs
Toe Alignment Inspection
Toe Adjustment
Suspension Spring Preload Adjustment
Brake System
Brake Fluid Inspection
Brake Pad / Disc Inspection
Brake Hose And Fitting Inspection
ENGINE
FUEL INJECTION
BODY I STEERING I SUSPENSION
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
2008 Polaris Ranger RZR 800 Service Manual Index of Topics
A
Air Filter Service
All Wheel Drive (AWD) Coil
AWD Diagnostics
AWD, Diagnosis
AWD, Operation
B
Balance Shaft Gear, Removal
Ball Joint Service
Batter)’ Charging
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Batteiy Storage
Batteiy, Conventional
Battery, Sealed Low Maintenance
Body Removal
Brake Burnishing
Brake Caliper Assembly, Front
Brake Caliper Assembly, Rear
Brake Caliper Inspection, Front
Brake Caliper Installation, Front
Brake Caliper Removal, Front
Brake Disc, Front
Brake Disc, Rear
Brake Front Pad Assembly
Brake Hose and Fitting Inspection
Brake Pad Assembly, Front
Brake Pad Inspection
Brake Pad Thickness, Front
Brake Pad, Rear
Brake Pads, Front
Brake Pads, Removal, Front
Brake Pedal, Installation
Brake Pedal, Removal
Brake System Inspection
Brake System, Bleeding
Brake System, Exploded View
Brake System, Operation
BreakIn Period
BreakIn, PVT System (Belt)
Breather Hose Inspection
c
Cab Frame, Assembly i Removal ,
Caliper, Front
Caliper, Rear
Cam Gear, Reassembly
Cam Gear, Removal
Cargo Box Removal
Centralized Hilliard, Exploded View
Charging System
Charging System, Alternator Tests
Chassis / Main Frame
Circuit Breaker
Clock, Setting
Combustion Chamber
Compression Test
Console and Floor Panel Removal
Conversion Table
Coolant Level Inspection
Coolant Strength and TVpe
Cooling System Bleeding Procedure
Cooling System Hoses
Cooling System Specifications
Cooling System, Pressure Test
Crankshaft Gear, Removal
Crankshaft Position Sensor (CPS)
CV Shaft Boot Inspection
Cylinder Head Assembly
Cylinder Head Assembly Exploded View
Cylinder Head Disassembly
Cylinder Honing To Deglaze
Cylinder Inspection
D
Dash Instruments / Controls
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostics, AWD
Diagnostics, Gear Circuit
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal
Drive Clutch, Assembly
Drive Clutch, Exploded View
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spring
Driven Clutch Service
Driven Clutch, Exploded View
Driven Clutch, Operation
Driveshaft / CV Joint, Handling Tips
E
EFI Operation Overview
EFI Priming / Starting Procedure
EFI System Breakout Diagrams
Electrical Breakout Diagrams
Electrical, Cooling System Breakout Diagram
Electronic Control Unit (ECU)
Engine and Transmission Separation
Engine Assembly and Installation
Engine Balance Shaft Removal
Engine BreakIn Period
Engine Camshaft Inspection
Engine Camshaft Installation
Engine Coolant Temperature Sensor (ECT)
Engine Cooling System
Engine Cooling System Troubleshooting
Engine Crankcase Assembly
Engine Crankshaft Gear Removal
Engine Crankshaft Installation
Engine Cylinder Head Assembly
Engine Cylinder Head Inspection
Engine Cylinder Head Removal
Engine Cylinder Head Warp
Engine Cylinder Honing
Engine Cylinder Inspection
Engine Cylinder Installation
Engine Cylinder Removal
Engine Designation Number
Engine Diagnostic Codes
Engine Exploded Views
Engine Fastener Torques
Engine Flywheel / Stator Installation
Engine Flywheel / Stator Removal
Engine Flywheel Removal
Engine Gear(s) Removal
Engine Gears, Installation
Engine Lubrication
Engine Oil and Filter Change
Engine Oil Flow Chart
Engine Oil Level
Engine Oil Pressure Test
Engine Oil Priming
Engine Oil Pump Installation
Engine Oil Pump Removal
Engine Piston Installation
Engine Piston Removal, Inspection
Engine Piston Ring Installed Gap
Engine Piston to Cylinder Clearance
Engine Piston to Rod Clearance
Engine Pushrod Inspection
Engine Removal
Engine Rocker Arm Inspection
Engine Serial Number Location
Engine Sendee Specifications
Engine Speed Display
Engine Starter Drive Removal
Engine Starter Removal
Engine Stator Gear Cover Seal(s) Installation
Engine Stator Installation
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine Torque Table
Engine Troubleshooting
Engine Valve Inspection
Engine Valve Lifter Removal, Inspection
Engine Valve Seal/Spring Service
Engine Valve Scaling Test
Engine Valve Scat Reconditioning
Engine, Accessible Components
Exhaust, Spark Arrestor
F
Fan Control Circuit Bypass Test
Fan Control Circuit Operation
Floor / Rocker Panels
Flywheel / Stator Removal
Flywheel, Removal
Front Aarm, Replacement
Front Bearing Carrier
Front Body / Dash Removal
Front Bumper
Front Caliper, Piston Bore ID
Front Driveshaft, CV Joint / Boot Replacement
Front Driveshaft, Installation
Front Driveshaft, Removal
Front Fender Flair Removal
Front Gcarcasc Lubrication
Front Gcarcasc, Assembly
Front Gcarcasc, Backlash Adjustment
Front Gcarcasc, Centralized Hilliard
Front Gcarcasc, Disassembly / Inspection
Front Gcarcasc, Installation
Front Gcarcase, Removal
Front Stabilizer Bar
Fuel Filter
Fuel Injection Troubleshooting
Fuel Injection, Component Locations
Fuel Injection, Exploded View
Fuel Injection, Service Notes
Fuel Injection, Special Tools
Fuel Injectors
Fuel Lines
Fuel Lines, Quick Connect
Fuel Pressure Regulator
Fuel Pump / Tank Assembly
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel Tank Replacement
Fuel Tank, Exploded View
Fuse Box
Fuses
G
Gear / Stator Housing Seal Replacement
Gear Circuit Diagnostics
Gear Position Indicator Switch Test
General Specifications, Brakes
Ground Engine
H
Head Lights
Hood / Front Body Work
Hood Removal
Hour Meter
I
Ignition Coil
Ignition Coil Replacement
Ignition Coil Test
Indicator Service Interval
Instrument Cluster
K
Keys, Replacement
Kilometers to Miles Toggle
L
Leakdown Test
M
Maintenance, Brake System
Maintenance, Cooling System
Maintenance, Electrical and Ignition
Maintenance, Engine
Maintenance, Final Drive
Maintenance, Fuel System
Maintenance, General Vehicle Inspection
Maintenance, References
Maintenance, Service Products and Lubricants
Maintenance, Steering
Maintenance, Transmission and Gearcases
Master Cylinder, Installation
Master Cylinder, Removal
Miles to Kilometers Toggle
Model Identification
o
Odometer
Oil Pump Priming
Oil Pump, Disassembly
Oil Pump, Reassembly
Oil Pump, Removal
P
Paint Codes
Periodic Maintenance Chart
Piston Ring Installed Gap
Piston to Cylinder Clearance
Piston to Rod Inspection
PreRide / Daily Inspection
Programmable Service Interval
Propshaft Removal / Installation
Propshaft, UJoint Service
Publication Numbers
PVT System, Assembly
PVT System, Disassembly
PVT System, Maintenance
PVT System, Overheating Diagnostics
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Button to Tower Clearance
PVT, Drive Clutch Disassembly
PVT, Drive Clutch Spider Removal
PVT, Driven Clutch Bushing Service
PVT, Driven Clutch Disassembly
PVT, Driven Clutch Reassembly
PVT, EBS Drive Clutch Bushing Service
PVT, EBS Drive Clutch Cover Bushing Remove/Install
PVT, Moveable Sheave Inspection
R
Radiator
Radiator, Removal
Rear Aarm, Replacement
Rear Bearing Carrier
Rear Bumper
Rear Cargo Box / Fenders
Rear Drive Shaft, CV Joint / Boot Replacement___________
Rear Drive Shaft, Plunging Joint / Boot Replacement
Rear Driveshaft, Installation
Rear Driveshaft, Removal
Rear Fender, Flair, and Tie Down Removal
Rear Gearcase
Rear Gearcase Lubrication
Rear Gearcase, Assembly
Rear Gearcase, Disassembly
Rear Gearcase, Exploded View
Rear Gearcase, Installation
Rear Gearcase, Removal
Rear Service Panel
Rear Stabilizer Bar
Relays
Rocker Panel Removal
s
Seat Assembly
Seat Belts / Mounting
Seats
Service Interval Indicator
Service Locations
Shift Cable Inspection and Adjustment
Shift Lever
Shift Lever, Removal
Shift Lever Installation
Shift Linkage Inspection and Adjustment
Shocks and Springs
Spark Plug Service
Special Tool, Cam Gear Installation Kit
Special Tools
Special Tools, Body/Steering/Suspension
Special Tools, Brakes
Special Tools Clutching
Special Tools Electrical
Special Tools Engine
Special Tools, Final Drive
Specification Chart, Maintenance
Specification Balance Shaft Gear Bolt Torque
Specification Cam Lobe Height
Specification, Cam Thrust Plate Fastener Torque
Specification Camshaft Gear Bolt Torque
Specification, Coolant Sensor Resistance
Specification, Cylinder Head Warp
Specification, Cylinder Taper Limit
Specification, Cylinder Warp Limit
Specification, Oil Pump Bolt Torque
Specification, Oil Pump Rotor Clearance
Specification, Timing Gear Alignment
Specification, Valve Seat Contact Width
Specification, Valve Spring Free Length
Specification, Valve Stem Diameter
Specification, Valve Stem Guide ID
Specification, Wheel ToeOut
Specifications, Cam Shaft
Specifications, Cooling System
Specifications, Crankcase Fastener Torque
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Specifications, General
Specifications, Oil Baffle Bolt Torque
Specifications, Oil Pickup Bolt Torque
Speed Sensor
Speedometer
Speedometer Installation
Speedometer Removal
Speedometer Troubleshooting Tests
Starter Armature Testing
Starter Assembly Exploded View
Starter Brush Inspection / Replacement
Starter Drive
Starter Drive Removal
Starter Motor, Removal
Starter Reassembly / Installation
Starter Solenoid, Test
Starter System Flow Chart
Starter System, Troubleshooting
Stator, Removal
Steering Inspection
Steering Wheel Freeplay
Steering, Alignment
Steering, Exploded View
Steering, Toe Adjustment
Steering, Wheel Toe Alignment
Suspension, Spring Preload Adjustment
Sway Bar Linkage Removal
Switch, AWD
Switch, Brake Light
Switch, Headlamp
T
Tachometer
Tail Lights
Tap/Drill Sizes
Temperature / Barometric Air Pressure Sensor (TBAP)
Throttlc Freeplay Adjustment
Throttle Pedal Inspection
Throttle Position Sensor (TPS)
Throttle Position Sensor Initialization
Throttle Position Sensor Replacement
Timing Gear Mark Alignment
Tire Inspection
Tire Pressure
Toe Alignment
Torque Chart
Torque Specifications Engine
Torque Specifications, Body/Steering/Suspension
Torque Specifications, Brakes
Torque Specifications, Clutching
Torque Specifications, Final Drive
Torque Specifications, Transmission
Torque Specifications, Wheel, Hub, and Spindle
Transfer Case, Disassembly
Transfer Case, Reassembly
Transmission Lubrication
Transmission, Exploded View
Transmission, Removal
Transmission, Shift Housing Disassembly
Transmission, Shift Housing Reassembly
Trip Meter
Troubleshooting, Brake Noise
Troubleshooting, Brake System
Troubleshooting, Clutching
Troubleshooting, No AWT)
Troubleshooting, No AWT) Hub Safety Limiter
Troubleshooting, No Fuel Gauge Display
Troubleshooting, No Gear Indicator Display
Troubleshooting, No Instrument Display
Troubleshooting, Transmission
Troubleshooting, Vehicle Speed Sensor
V
Valve Scalf’Spring Service
Valve Scaling Test
Valve Scat Reconditioning
Vent Lines
VIN Identification
VIN Location
Voltage Drop Test
W
Wheel Hubs
Wheel, Installation
Wheel, Removal
