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The model and VIN numbers are also located on a sticker under the hood B. 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 Ownners are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. Distance between center of crankshaft and rze of driven clutch shaft.

Distance between chain link pins No. Polaris measures chain length in number of pitches. See information provided above.

RZR Manuals

Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. Engine Oil Change 25 H Perform a break-in oil change at one month Break-In Period Perform these procedures more often for vehicles subjected to severe use.

Clean out Inspect periodically; adjust when parts are Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. Each item can be purchased separately at your local Polaris dealer. Make sure line is not kinked or pinched. Replace fuel line every two years. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed.

Also, the throttle may not open fully. Installation Inspect the main air filter element and replace if necessary.

Polaris 2008 RZR Service Manual

Clean the air box thoroughly. Do not clean the main filter, the filter should be replaced.

Install a new or clean pre-filter over the main air filter NOTE: If the filter has been soaked with fuel or oil it element. To check the oil level follow the procedure listed below. Remove dipstick and fill sump with 2 quarts 1. Crankcase Drain Plug Torque: Drain plug is accessed through the skid plate. Low engine compression is rarely a factor in running condition The engine is equipped with a breather hose. Inspect the problems above idle speed.

The hose is form fit- A cylinder leakdown test is the best indication of engine ted for a proper fit. The fill plug is located on the side of the gearcase just below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole. Position vehicle on a level surface. Remove the fill plug. The front gearcase lubricant level should be checked and Remove the fill plug and check the fluid level.


Add the recommended fluid as needed. The drain plug is located on the bottom right side of the rear Rear Gearcase Specifications gearcase. Remove recovery bottle cap and add coolant using a funnel. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Wheel, Hub, and Spindle Torque Table Remove manuual upper engine outlet hose and recovery hose from the top of the radiator.

Operating a RANGER with worn tires will increase the possibility of the vehicle skidding If hub iwners was removed, install maual new cotter pin after the easily with possible loss of control. Battery Maintenance Keep battery terminals and connections free of corrosion. If Battery cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.

Battery charge can be maintained by using a A hot exhaust system and engine can cause serious Polaris battery tender charger or by charging about burns. Allow engine to cool or rsr protective once a month to make up for normal self-discharge.

Install spark plug and torque to specification. Due to the critical nature of the procedures outlined in Recommended Spark Plug: Set steering wheel in a straight ahead position and secure the steering wheel in this position. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod Stop the engine.

Raise and safely support the front or rear of the vehicle off NOTE: Be sure steering wheel is straight ahead the ground to allow the suspension to fully extend. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear.

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Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage.

Park machine on a level surface. Place the vehicle in of air. Place the vehicle in neutral and set the parking brake. Block the rear wheels. Capacity – Approximately 2 U. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.


Engine Removal Remove the 2 push rivets from the rear of the center console. Because of its design configuration, Polaris recommends removing the engine, transmission, and rear gearcase as one assembly.

Use the following procedure when engine removal is required. Elevate the rear of the vehicle off the ground using a Remove the 6 fasteners retaining the upper bolt-in frame suitable ATV lift and remove both rear wheels.

Loosen the hose clamp between the throttle body and intake Remove the airbox and throttle body from the vehicle as polarus adaptor. Take care in not allowing the throttle cable to bend excessively or kink.

Carefully place the assembly on the floor next to the vehicle. Mark the upper jam nut and loosen the lower jam nut. Disconnect the transmission speed sensor harness. If the upper jam nut is moved, shift cable adjustment will Remove the through-bolt that attaches the upper A-arm to Disconnect the engine coolant temperature ECT sensor the rear hub on both sides of the vehicle.

Pivot the A-arms upward and rear hub carriers downward Remove RH engine mount fastener. Remove LH transmission mount fastener. Remove propshaft from the transmission output shaft. Remove only the 4 outer fasteners retaining the engine to the transmission bracket. Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame.

Remove the valve cover. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all zrr cylinder head bolts. The following procedure is only for servicing Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. Carefully remove the cylinder components.

Polagis is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

Mark the valves with a white pen. Check valve face for runout, pitting, and burnt spots. Combustion Area Install pilot into valve guide. Valve Seat Reconditioning Apply cutting oil to valve seat and cutter. Place 46 cutter on the pilot and make a light cut. When using an interference angle, the seat Inspect the cut area of the seat: