POLARIS RANGER RZR 800 ATV Service Repair Manual 2008

2008 RANGER RZR SERVICE MANUAL FOREWORD This 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 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 the text 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. Comments or suggestions about this manual may be directed to: Se rvice Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340. 2008 Service Manual PN 9921278

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION

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

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

1.2 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH076OLE021 ..................................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification Engine Serial Number Location Whenever corresponding about an engine, be sure to refer 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 Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 0 8 V H 7 6 A D } 4 X A V H 7 6 A * 8 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier } Check Digit Model Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions

1.3 GENERAL INFORMATION 1 Unit Serial Number (VIN) Location The machine model number and 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 sticker under the hood (B) or on the lower frame rail in front of the LH rear tire (C). A A B C

1.4 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER RZR MODEL NUMBER: R08VH76AD, AG ENGINE MODEL: EH076OLE021 Category Dimension / Capacity Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 cm Wheel 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 56cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 336.4 kg (Includes rider(s), cargo, and accessories) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg FRONT REAR TOP SIDE

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)

1.6 GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Paint Codes Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe 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 supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Model Model No. Owner’s Manual PN Parts Manual PN 2008 RANGER RZR, Red R08VH76AD 9921181 9921207 2008 RANGER RZR, Green R08VH76AG 9921181 9921207 Painted Part Color Description Polaris Number Frame / Bumpers / Racks Gloss Black P-067 Frame / Bumpers / Racks Matte Black P-458 Plastic - Hood / Dash / Fenders Indy Red P-293 Plastic - Hood / Dash / Fenders Sage Brush Green Metallic P-498 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

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

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POLARIS RANGER RZR 800 ATV Service Repair Manual 2008

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