2008 ranger rzr service manual

By Robert Stutesman Find their other files. Share More sharing options Followers 1. Released June 23, No changelog available for this version.

Previous File Polaris Ranger Service manual. By Larry Fox , September 10, rzr. Manufacturer Logos. Newbie advice! Hi crazy people. Sign In Sign Up. Remove the E-clips F , washers G , and the clutch rollers H. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly, replace it.

Install puller adapter Item 10 onto puller. Install adapter reducer Item 9. Install adapter Item 9 onto puller. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Put Install a new bearing onto the output shaft using a press. Install the spring over the shaft.

The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. Install the clutch rollers D onto each side of the outside Flat Side Down spider. Install the cam helix assembly over the shaft. Line up the Engine RPM below specified operating -Drive clutch shift weight too heavy.

Situation Probable Cause Remedy -Plugged air intake or outlet. Clean , repair or replace as necessary. Seal PVT system ducts. PVT cover -Clutches or weight being applied to cover while in -Remove weight. The tire should rotate smoothly without binding or rough spots. Use wire to hang caliper to prevent damage to the brake line.

Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. Support the bottom of the bearing carrier housing. Tighten nut slightly if necessary to align cotter pin holes.

Front Caliper Mounting Bolt Torque: 80 ft. Drive Shaft Removal Pinch Bolt Elevate front of vehicle and safely support machine under the frame area. Be sure machine is secure before beginning this service procedure. Care should be exercised during drive shaft removal or when Retaining Ring servicing CV joints. Drive shaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.

Install new spring ring on drive shaft. Apply an anti-seize Position large end of boot on CV joint, purge excess air by compound to splines. Lift one edge of boot to let out excess air. NOTE: Front wheel can be removed to gain better access to the propshaft roll pin. Using a suitable arbor, fully seat the bearing cap in one side. Support U-joint in vise as shown and drive inner yoke down Continually check for free movement of bearing cross as to remove remaining bearing caps.

Front Gearcase Engagement: The AWD switch may be This magnetic field attracts an armature plate keyed to a roller turned on or off while the vehicle is moving. The U-shaped insert controls the pole gap. Stop engine and place gear selector in Park. No adjustment is required unless the and remove the assembly from the gearcase housing.

Remove the roll cage assembly and rollers from the clutch Inspect both output hub assemblies. Inspect the bearings housing. Use a shop towel to cover the housing in order to and replace if needed. RH Hub Clutch Housing While holding the hub in the clutch housing, flip the clutch housing over and install the armature plate.

Line up the gearcase housing with the cover plate assembly. Set the gearcase housing on top of the assembled cover NOTE: Ring gear backlash is set from the factory.

Take care not to damage the new seal when installing No adjustment is required unless the cover plate, the gearcase housing. Install the vent line. Install Back the adjustment screw out while rotating the pinion Vent Line shaft. The pinion shaft should rotate freely during four Connect complete rotations. The four pinion shaft rotations ensures Harness that the ring gear completes one full rotation. While rotating bearings by outer race on the new bearing. Be sure that all oil residue hand, inspect for rough spots, discoloration, or has been removed from each surface.

Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. Torque wheel nuts to Remove the two brake caliper attaching bolts. Wheel Nut Torque: Steel Wheels: 27 ft. Clamp Pliers PN A. Take care not to damage threads on fingers.

While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw Install new spring ring on drive shaft. Apply anti-seize driver between the small end of the boot and the shaft. This compound to splines. Torque fastener to 37 ft. Rear Caliper Mounting Bolt Torque: 18 ft. New bolts have a pre-applied locking agent 50 Nm which is destroyed upon removal.

Gearcase Removal Drain the fluid from the rear gearcase. Remove the rear drive shafts from each side of the rear gearcase. Pinion and ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears. If damaged, replace the ring gear and pinion gear as suitable method.

Inspect Inspect the input shaft by rotating the assembly in the NOTE: In the event damage to the gears or housing gearcase housing while checking for any looseness or requires replacement, the entire assembly must be Install a new input shaft seal using a standard seal installer or other suitable method. Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method. Page Gearcase Installation Install the gearcase cover.

Verify the o-ring is in position. Install the cover screws onto the rear gearcase. Torque to specification.

Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification.

Pry the shift lever cover using a suitable tool and remove the screw. Pull knob off the shifter. Removal of the transmission is not possible without removing the engine and differential.

The shift housing cannot be removed without first disassembling the transfer case. Remove the intermediate pinion shaft assembly from the bearing cup and shims from the cover. Bearing cup is a housing. Check bearings and gear teeth for wear or damage slip-fit. Note and record the number and thickness of shims and replace as needed. Remove the front output pinion shaft assembly. The shaft Remove the lower snap ring from under the gear.

Remove the intermediate shaft seal using a seal puller or other suitable method. Install the intermediate shaft seal circled flush or slightly below the case.

Install circlips and gear onto the input intermediate shaft as shown. Install a new output shaft seal flush with the case. Torque the screws evenly to specification in sequence as shown. Read and understand all instructions before beginning disassembly. Inspect the Remove the input shaft seal and clutch intermediate shaft park flange dogs for wear or damage. Replace as required. Inspect the shaft bearing. Use a standard bearing puller to Remove the 2 screws that attach the shift switch to the remove the shaft bearing if required.

Remove the park flange sleeve from the clutch shaft. Replace any worn or damaged components. Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke. Remove the sliding shoes from the clutch yoke. From the back side of the high gear assembly, separate the high and low gear assemblies by tapping the gear retaining plate from the roll pins using a brass punch.

Note the order of disassembly on the entire gear assembly plate, thrust washer, bearing, thrust washer. Remove the clutch yoke from the gear selector shaft and Remove the screw from the end of the gear selector shaft spring. Note the clips, spring and plate orientation.

Install a new shift lever seal flush with the case. Apply lubricant to the seal lip. Press new bearings if required into the housing. Install clutch yoke into the gear selector shaft and spring. Align the pivot pin holes and install clutch yoke pivot pin. Install the clutch shaft into the housing. Note that the Complete the assembly by aligning the roll pin holes and forward gear assembly is loose in the housing and that tapping the roll pins through the retaining plate and into the alignment of the shaft, gear assembly, thrust washer and high gear using a brass punch.

Install the outer sleeve screws and inner shift detent screws, With the transmission in neutral, lubricate and install the thrust washer, drum gear, plate, springs, pins and the shift position springs, and balls from each side of the shift housing. Install the reverse idler lower washer, needle bearing, gear, Place the transmission shift housing onto a flat surface as Install the 2 shift housing case screws to the backside as shown. Apply a bead of crankcase sealant onto the mating shown.

Align the dowels and install the transmission case NOTE: Shift cable bracket installation is required. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

Locate the master cylinder above the LH front tire in the Do not allow brake fluid to come in contact wheel well area. Check brake system for fluid leaks. Add brake fluid to the indicated MAX level of reservoir. Then remove inner pad. Pad Removal Elevate and support front of vehicle. Severe injury may occur if machine tips or falls. Socket Set Screw B. Bleeder Screw C. Caliper Assy. Boot E. Square O-ring thick F. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassembly the caliper.

Caliper Disassembly Use low pressure compressed air to remove the pistons Push brake pad retainer pin inward and slip brake pads past Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. All Season Grease PN , and install the rubber Torque the banjo bolt brake line s to the proper torque dust seal boots. Disc Inspection 4 Bolts Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident.

Pad Removal Elevate and support rear of vehicle. Apply Polaris All Purpose 5. Brake Pad B. Mount Bracket C. Piston D. Square Ring thick F. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage Push upper pad retainer pin inward and slip brake pads past is evident or if worn beyond service limit. Page Caliper Assembly 18 ft. Install piston D with a twisting motion while pushing inward.

Piston should slide in and out of bore smoothly with light resistance. Do not pull on the wiring. This Polaris Ranger RZR Service Repair Workshop Manual will easily pay for itself on the first oil change, spark plug change, or air filter change that you perform! Just imagine how much you can save by doing simple repairs yourself. Many people buy this manual just to have it around for when the inevitable happens.

Sooner or later, maintenance will need to be performed. This manual is in pdf format so they can be viewed on your PC or Mac, as well as a number of devices including many phones and ebook readers like the amazon kindle. You can print out individual pages as needed which avoids the possibility of the original becoming obscured and unreadable by oil stains. You must be logged in to post a review. Purchased manual was received quickly, and though while the original download link was for the incorrect manual, it was quickly replaced and resent with the right one without hassle.

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