Polaris PMS 419 User Manual

PMS 419

RANGER RZR
RANGER RZR S
RANGER RZR 4

Owner's Manual

for Maintenance and Safety

WARNING

Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit­ing line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

• Victory Motorcycles

• Low Emission Vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle, making it the finest machine we’ve ever pro­duced.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the POLARIS Service Manual and should be
performed only by a factory certified Master Service Dealer
Technician.

Your POLARIS dealer knows your vehicle b est and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces­sories, available through our online store at www .purepolaris.co m. Have
your accessories and clothing delivered right to your door!

®

utility vehicles

®

®

(MSD)

1

POLARIS, THE WAY OUT, RANGER and RANGER RZR are registered trademarks of
POLARIS Industries Inc.

Copyright 2010 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or in acc uracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.

Printed in U.S.A.
2011 RANGER RZR / RANGER RZR S / RANGER RZR 4 Owner’s Manual
P/N 9922973

2

TABLE OF CONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . 28

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Emission Control Systems . . . . . . . . . . . . . . . . . . . . 68

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

POLARIS Products . . . . . . . . . . . . . . . . . . . . . . . . 126

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Declaration of Conformity. . . . . . . . . . . . . . . . . . . 131

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3

INTRODUCTION

The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym­bols are used. Become familiar with their meanings before reading the
manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

4

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.

• Read this owner ’s manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the
vehicle.

• Complete the New Operator Driving Procedures outlined on pages 56-57.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age or anyone without a valid driver’s license.

5

INTRODUCTION

Engine Serial Number

Key

Number

Vehicle Identification Num­ber

####

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: __________________________________________________________

Vehicle Identification Number: _____________________________________________________

Engine Serial Number: ___________________________________________________________

Key Number____________________________________________________________________

6

SAFETY

Equipment Modifications

Your POLARIS vehicle is designed to provide safe operation when used
as directed. Modifications to your vehicle may negatively impact vehi­cle stability. Failure of critical machine components may result from
operation with any modifications, especially those that increase speed or
power. This vehicle may become less stable at speeds higher than those
for which it is designed. Loss of control may occur at higher speeds.

Do not install on a POLARIS vehicle any equipment that may increase
the speed or power of the vehicle, or make any other modifications to
the vehicle for these purposes. Any modifications to the original equip­ment of the vehicle create a substantial safety hazard and increase the
risk of bodily injury.

The warranty on your POLARIS vehicle is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.

The addition of certain accessories, including (but not limited to) mow­ers, blades, tires, sprayers, or large racks, may change the handling char­acteristics of the vehicle. Use only POLARIS-approved accessories, and
familiarize yourself with their function and effect on the vehicle.

7

SAFETY

Helmet

Eye Protection

Gloves

Sturdy

Footwear

Long
Pants

Long Sleeves

E

4

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding a POLARIS vehicle.
Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

W earing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds estab­lished safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.

8

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When­ever riding a POLARIS vehicle, always wear shatterproof goggles or
use a shatterproof helmet face shield. POLARIS recommends wearing
approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.

Gloves

Wear gloves for comfort and for protection from sun, cold weather and
other elements.

Boots

Wear sturdy footwear. Do not ride a POLARIS vehicle with bare feet.

Clothing

Wear long sleeves and long pants to protect arms and legs.

9

SAFETY

WARNING

Safety Warnings

Failure to operate this vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain. Complete the New Operator
Driving Procedures outlined on pages 56-57.

All operators must read and understand the
owner's manual and all warning and instruction
labels before operating the vehicle. Never allow a
guest to operate this vehicle until the guest has
completed the New Operator Driving Procedures
outlined on pages 56-57.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age or anyone without a valid driver’s license. Never operate
with a passenger under the age of 12. Make sure all passengers are tall enough
to comfortably and safely reach the hand holds and place both feet on the floor.

Accessories

Non-approved accessories may seriously affect vehicle stability. Using
accessories not approved by POLARIS for use on this vehicle could cause loss
of control or an accident. Never operate with accessories not approved by
POLARIS for use on this vehicle.

Using Alcohol or Drugs

Riding in this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.

Never consume alcohol or drugs before or while
operating or riding in this vehicle.

10

SAFETY

Safety Warnings

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle
is in safe operating condition before
operating increases the risk of an accident.

Always inspect the vehicle before each use
to make sure it's in safe operating
condition.

Always follow the inspection and
maintenance procedures and schedules
described in the owner's manual.

Protective Apparel

Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.

Operator and all passengers must always
wear an approved helmet that fits properly
and eye protection (goggles or face shield).

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of an accident or sudden stop. Riders must wear seat belts at
all times. Seat belts reduce the severity of injury in the event of a sudden stop or
accident. Always make sure the seat belts are secured for both the operator and
all passengers before riding.

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious
injury or death in the event of an accident or overturn. Always use the cab nets
while riding in this vehicle.

Always keep hands and feet inside the vehicle at all times.

11

SAFETY

Safety Warnings

Carrying Passengers (RZR 4)

Never carry a passenger until you have operated
this vehicle for at least two hours and have
completed the New Operator Driving Procedures
outlined on pages 56-57.

A passenger must always be seated in a passenger
seat with seat belt secured.

Never carry more than three passengers in a 4-seat
vehicle.

Carrying Multiple Passengers (RZR)

Never carry a passenger until you have operated this
vehicle for at least two hours and have completed the
New Operator Driving Procedures outlined on pages
56-57.

A passenger must always be seated in a passenger
seat with seat belt secured. Carrying more than one
passenger in a 2-seat vehicle can affect the
operator’s ability to steer and operate the controls,
which increases the risk of loss of control and
accident or overturn. Never carry more than one
passenger in a 2-seat vehicle.

Passengers in the Cargo Box

Carrying a passenger in the cargo box could result
in a fall from the vehicle or contact with moving
components. Never allow a passenger to ride in the
cargo box. A passenger must always be seated in
the passenger seat with seat belt secured.

Operating on Pavement

Operating this vehicle on paved surfaces (including
sidewalks, paths, parking lots, and driveways) may
seriously affect handling and control of the vehicle,
and may cause the vehicle to go out of control. This
vehicle's tires are designed for off-road use only, not
for use on pavement.

Avoid operating the vehicle on pavement. If you must operate on a paved
surface, travel slowly and do not make sudden turns or stops.

12

SAFETY

Safety Warnings

Operating on Public Roads

Operating this vehicle on public streets, roads
or highways could result in a collision with
another vehicle.

Never operate this vehicle on any public
street, road or highway, including dirt and
gravel roads.

In many areas it's illegal to operate vehicles
of this type on public streets, roads and
highways.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds
increases the operator's risk of losing
control.

Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, your skills and your
passenger’s skills.

Turning Improperly

Turning improperly could cause loss of
traction, loss of control, accident or
overturn. Always follow proper procedures
for turning as described in the owner's manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.

Jumps and Stunts

Exhibition driving increases the risk of an
accident or overturn. DO NOT do power
slides, “donuts”, jumps or other driving
stunts. Avoid exhibition driving.

13

SAFETY

+15°

+15°

Safety Warnings

Physical Control of the Vehicle

Removing hands from the steering wheel or hand holds or removing feet from
the floor while riding increases the risk of loss of control and accident or
overturn.

The operator should always keep both hands on the steering wheel during
operation. Passengers should always be seated in a passenger seat with seat
belt secured, with both feet on the floor and with both hands securely grasping
the passenger hand hold or grab bar.

Always keep hands and feet inside the vehicle at all times.

Descending Hills Improperly

Improperly descending a hill could cause loss
of control or overturn. Always follow proper
procedures for traveling down hills as
described in the owner's manual.

• Always descend a hill with the transmission in
forward gear. Never descend a hill with the
transmission in neutral.

• Always check the terrain carefully before
descending a hill.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight downhill.

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Use extreme caution when
operating on hills. Always follow proper
procedures for hill climbing as described in the
owner's manual. See page 60.

14

SAFETY

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.

If crossing a hillside is unavoidable, always
follow proper procedures as described in the
owner's manual. See page 61.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill
could cause an overturn. Maintain a steady
speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped. Place the
transmission in reverse and slowly allow the vehicle to roll straight downhill while
applying light brake pressure to control speed.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating
on unfamiliar terrain could result in an
accident or overturn.

Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of
control or overturn.

Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions.

15

SAFETY

Safety Warnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a
collision with an obstacle or person. Always
follow proper operating procedures as outlined
in this manual. See page 64.

Before shifting into reverse gear, always check
for obstacles or people behind the vehicle.
When it's safe to proceed, back slowly.

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire
pressure could cause loss of control, accident or overturn.

Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in the owner's manual and on safety labels.

Operating on Slippery Terrain

Operating on excessively rough, slippery or
loose terrain could cause loss of traction, loss
of control, accident or overturn.

Do not operate on excessively rough, slippery
or loose terrain. Always use extra caution on
rough, slippery or loose terrain.

16

SAFETY

Safety Warnings

Operating Over Obstacles

Improperly operating over obstacles
could cause loss of control or overturn.

Before operating in a new area, check
for obstacles. Never attempt to operate
over large obstacles such as rocks or
fallen trees. Always follow the proper
procedures outlined in this manual
when operating over obstacles.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly). Always follow proper procedures for operating on slippery
surfaces as described in the owner's manual.

When operating on slippery surfaces such as ice or loose gravel, reduce speed
and use extra caution to reduce the chance of skidding or sliding.

Do not operate on excessively slippery surfaces.

Operating Through Water

Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, overturn or accident. Never operate
in fast-flowing water or in water that
exceeds the recommended maximum
depth.

Always follow proper procedures for
operating in water as described in the
owner's manual.

Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.

17

SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the vehicle or carrying/towing
cargo improperly may cause changes in
stability and handling, which could cause
loss of control or an accident.

• Always follow the instructions in the
owner's manual for carrying cargo or pull­ing a trailer.

• Never exceed the stated load capacity for
this vehicle.

• Cargo should be properly distributed and
securely attached.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance
for braking.

Operating on Frozen Bodies of Water

Severe injury or death can result if the
vehicle and/or the operator fall through the
ice. Never operate the vehicle on a frozen
body of water unless you have first verified
that the ice is sufficiently thick to support
the weight and moving force of the vehicle,
you and your passengers, and your cargo,
together with any other vehicles in your
party. Always check with local authorities
and residents to confirm ice conditions and
thickness over your entire route. Vehicle
operators assume all risk associated with
ice conditions on frozen bodies of water.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident with serious injury or
death. After any overturn or accident, have a qualified service dealer inspect the
entire vehicle for possible damage, including (but not limited to) brakes, throttle
and steering systems.

18

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and is explosive under certain conditions. Always
exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box be fore filling.

• Do not smoke or allow open flames or sparks in or near the refueling area or
where gasoline is stored.

• Never refuel while a person is in the vehicle.

• Do not over fill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and
water and change clothing.

Refueling

Always turn off the engine before refueling. Make sure the refueling area is well
ventilated and free of any source of flame or sparks. Gasoline is extremely
flammable.

Remove flammable material containers from the box before filling.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.

Operate this vehicle only outdoors or in well-ventilated areas.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

19

SAFETY

Cargo Box Warning
Tire Pressure/Cargo

Overload Warning

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.

If an informational or graphic label becomes illegible or comes off, con­tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.

Cargo Box Warning

WARNING

• Passengers can be thrown off. This can cause serious injury or death.

• Never carry passengers in cargo box.

• Maximum 4X4 Box Load is 300 lbs. (136.4 kg)

20

SAFETY

Safety Labels and Locations

Tire Pressure/Cargo Overload Warning (RZR)

WARNING

IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa):
4X4 - FRONT 8 (55.2) REAR 8 (55.2)
MAXIMUM WEIGHT CAP ACITY INCLUDING DRIVER, PASSENGER, CARGO

AND ACCESSORIES: 4X4 is 740 LBS. (336.4 kg)
Reduce speed and allow greater distance for braking when carrying cargo.

Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.

Read Owner’s Manual for more detailed loading information.

7175103

Tire Pressure/Cargo Overload Warning (RZR 4)

WARNING

IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa):

4x4 FRONT 10 (68.9) REAR 12 (82.7)

MAXIMUM WEIGHT CAPACITY

INCLUDING DRIVER, PASSENGERS, CARGO AND ACCESSORIES:
4x4 is 900 LBS. (408.2 kg)
Reduce speed and allow greater distance for braking when carrying cargo.

Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.

Read Owner’s Manual for more detailed loading information.

7176606

21

SAFETY

Shift

Caution

Cab Frame/Seat Belt

Warning

Age

Warning

Overturn

Warning

Discretionary

Warning

Safety Labels and Locations

Cab Frame/Seat Belt Warning

WARNING

• ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat
belt.

• ALWAYS SECURE CAB NETS.

• VEHICLE OVERTURN could cause severe injury or death.

22

SAFETY

Safety Labels and Locations

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle.
When vehicle is stopped, place shift in the parked position.

APPLY BRAKE TO START

7174843

Age Warning

WARNING

Operating this vehicle if you are under the age
of 16 increases your chance of severe injury or
death.

NEVER operate this vehicle if you are under
age 16 or without a valid driver’s license.

Overturn Warning

WARNING

Improper operation can cause this vehicle to overturn and lead to serious injury
or death.

This vehicle handles differently than cars, trucks
or other off-road vehicles. In order to avoid
overturns:

• avoid sharp turns.

• never turn while applying heavy throttle.

• never make abrupt steering maneuvers.

• operate at speeds appropriate for your skills,
the conditions and the terrain.

• DO NOT do power slides, “donuts”, jumps or
other driving stunts.

7175105

23

SAFETY

Discretionary

Warning

Safety Labels and Locations

Discretionary Warning (RZR)

WARNING

Improper vehicle use can result in SEVERE
INJURY or DEATH

NEVER operate:

• without first viewing safety video and quick
start guide.

• with more than one passenger.

• on hills steeper than 15 degrees.

• on public roads.

• on paved surfaces - pavement may seriously
affect handling and control.

• with non-POLARIS approved accessories ­they may seriously affect stability.

ALWAYS:

• keep hands and feet inside vehicle.

• reduce speed and use extra caution when carrying a
passenger.

• operate slowly in reverse - avoid sharp turns or sud­den braking.

• make sure passenger reads and understands all
safety labels.

• watch for branches or other hazards that could enter
vehicle.

ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR FOR OPERATOR AND
PASSENGER

NEVER USE ON PUBLIC ROADS
NEVER USE WITH DRUGS OR ALCOHOL
LOCATE AND READ OWNER’S MANUAL. FOLLOW

ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S
MANUAL IS MISSING, CONTACT A POLARIS
DEALER FOR A REPLACEMENT.

7175104

24

SAFETY

Safety Labels and Locations

Discretionary Warning (RZR 4)

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER operate:

• without first viewing safety video and quick start guide.

• with more than three passengers.

• on hills steeper than 15 degrees.

• on public roads.

• on paved surfaces - pavement may seriously affect handling and control.

• with non-POLARIS approved accessories - they may seriously affect stability.
ALWAYS:

• keep hands and feet inside vehicle.

• reduce speed and use extra caution when carrying
passengers.

• operate slowly in reverse - avoid sharp turns or sud­den braking.

• make sure passengers read and understand all
safety labels.

• avoid branches or other hazards that could enter
vehicle.

ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR FOR OPERATOR AND
PASSENGERS

NEVER USE ON PUBLIC ROADS
NEVER USE WITH DRUGS OR ALCOHOL
LOCATE AND READ OWNER’S MANUAL. FOLLOW

ALL INSTRUCTIONS AND WARNINGS. IF
OWNER’S MANUAL IS MISSING, CONTACT A
POLARIS DEALER FOR A REPLACEMENT.

7176607

25

SAFETY

Passenger

Safety Warn-

ing

Safety Labels and Locations

Passenger Safety Warning (RZR)

WARNING

NEVER CARRY A PASSENGER UNDER AGE 12
NEVER CARRY MORE THAN ONE PASSENGER
NEVER RIDE AFTER USING DRUGS OR ALCOHOL

To reduce the risk of SEVERE INJURY or DEATH,
NEVER carry a passenger under age 12 or too small to
firmly plant feet on the floor and securely grasp hand holds.

THE PASSENGER MUST ALWAYS:

• wear seat belt.

• use an approved helmet and protective gear.

• securely grasp hand holds and plant feet firmly on the
floor.

• tell operator to slow down or stop if uncomfortable - get off
and walk if conditions require.

• keep hands and feet inside vehicle at all times.

• watch for branches, brush, and other hazards that could
enter vehicle.

7175102

26

Safety Labels and Locations

12

PASSENGERS

UNDER

Passenger Grab Bar

Warning

Passenger Cab Frame

Warning (both sides)

Passenger Safety Warning (RZR 4)

WARNING

NEVER CARRY PASSENGERS UNDER AGE 12
NEVER CARRY MORE THAN THREE PASSENGERS

NEVER RIDE AFTER USING DRUGS OR ALCOHOL
To reduce the risk of SEVERE INJURY or DEATH,

NEVER carry passengers under age 12 or too small to
firmly plant feet on the floor and securely grasp hand holds.

THE PASSENGERS MUST ALWAYS:

• wear seat belts.

• use approved helmets and protective gear.

• securely grasp hand holds and plant feet firmly on the
floor.

• tell operator to slow down or stop if uncomfortable - get off
and walk if conditions require.

• keep hands and feet inside vehicle at all times.

• avoid branches, brush and other hazards that could enter
vehicle.

7176608

Rear Passenger Cab Frame Warn­ing (RZR 4)

WARNING
Do NOT hold onto this bar. Hands and arms

could be crushed or seriously injured in
event of rollover.

AL W AYS keep hands on passenger grab bar .

7176700

SAFETY

Rear Passenger Grab Bar
Warning (RZR 4)

Always use seat belt, helmet and eye
protection.

Always use passenger grab bar and side
nets to keep hands and feet in vehicle at all
times.

7176701

27

FEATURES AND CONTROLS

Hip Bars

Fuel Tank

Cap

Cargo

Box

Shifter

Front

Passenger

Hand Hold

Cab Nets

Rear Passenger Grab

Bar

Rack Extenders (RZR/

RZR EPS only)

Tie-Down

Points

Component Locations

28

Component Locations

Headlights

Brush Guard

Radiator

Steering

Wheel

Storage

Compartment

(under hood)

Cab Frame

FEATURES AND CONTROLS

29

FEATURES AND CONTROLS

Taillights

Receiver

Hitch

Component Locations

Trailer Receiver Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch.
Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 66-67.

30

FEATURES AND CONTROLS

Front Seat

Retainer

Seat

Latch

Rear Service Panel

The rear service panel is located behind the seats on the frame of the
vehicle. Remove the seats to access the service panel. Remove the ser­vice panel to access serviceable engine components and clutches.

Seats

Before operating the vehicle, always push down on all seat backs to
ensure the latches are secure.

Seat Adjustments

Loosen (do not remove) the four screws located on the seat bottom.
Slide the seat forward or rearward to the desired position. Tighten the
screws to 4 ft. lbs. (5.4 Nm). Do not overtighten.

Seat Removal

1. Pull up on the seat latch

lever located under the rear
edge of the seat.

2. Tilt the seat forward.

3. Lift the seat upward to

remove it from the vehicle.

4. Reverse this procedure to

reinstall the seat. Make
sure the seat tabs at the
front edge of the seat slide
under the seat retainer bar.

5. Press down firmly at the

rear of the seat to engage
the rear latch.

31

FEATURES AND CONTROLS

Adjustment Lever

A

d

j

u

s

t

m

e

n

t

P

o

s

i

-

t

i

o

n

H

o

l

e

s

Mounting

Bracket Holes

Adjustment

Pin

Pin

Retainer

Steering Wheel

The steering wheel can be
tilted upward or downward
for rider preference.

Lift and hold the steering
wheel adjustment lever
while moving the steering
wheel upward or down­ward. Release the lever
when the steering wheel is
at the desired position.

Passenger Hand Hold

Always adjust the hand hold to a comfortable position for your front­seat passenger before operating. Make sure the adjustment pin and
retainer are securely installed after making adjustments.

1. Remove the retainer from the end of the adjustment pin.

2. Remove the pin from the post.

3. Slide the post inward or outward to the desired position.

4. Reinstall the pin through the mounting bracket hole, through both
post adjustment holes, and through the remaining bracket hole.

5. Reinstall the retainer to the pin.

32

FEATURES AND CONTROLS

Storage Compartment

Radiator Cap

Overflow

Bottle

Hood

Remove the hood to access the front storage compartment, the radiator
cap and the coolant overflow bottle.

1. Turn the hood fasteners
1/4 turn.

2. Grasp the upper hood

edge and pull upward to
disengage the hood
from the vehicle.

3. Pivot the hood forward

and lift upward to disen­gage the lower hood
hooks.

4. Lift the hood away from

the vehicle.

33

FEATURES AND CONTROLS

Fuel Cap

Front Cab Net

Latches

Rear Cab Net

Latches

Fuel Cap

The fuel tank filler cap is located
on the right-hand side of the
vehicle near the passenger seat.
When refueling, always use
either leaded or unleaded gaso­line with a minimum pump
octane number of 87 R+M/2
octane. Do not use fuel with eth-

anol content greater than 10
percent, such as E-85 fuel.

Remove flammable material
containers from the box before
filling.

Cab Nets

All RZR models are equipped
with cab nets, which may differ
slightly in appearance from
those shown.

Riding in this vehicle without
using the cab nets increases the
risk of serious injury or death in
the event of an accident or over­turn. Cab nets must be used by
operator and passengers at all
times. Make sure all latches are
secure before operating the
vehicle.

Always inspect cab nets for tightness, wear and damage before each use
of the vehicle. Use the strap adjusters to tighten any loose straps.
Promptly replace worn or damaged cab nets with new cab nets, avail­able from your authorized POLARIS dealer.

34

FEATURES AND CONTROLS

Seat Belts

This POLARIS vehicle is equipped with three-point lap and diagonal
seat belts for all riders. Always make sure the seat belts are secured for
the operator and all passengers before riding.

To wear the seat belt properly, follow this procedure:

1. Pull the seat belt latch downward and across your chest toward the
buckle at the inner edge of the seat. The belt should fit snugly across
your hips and diagonally across your chest. Make sure the belt is not
twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self-tighten.

4. Press the red release latch on the buckle to release the seat belt.

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's
securely latched.

2. Push the red release latch in the middle of the buckle to make sure it

releases freely.

3. Pull each seat belt completely out and inspect the full length for any

damage, including cuts, wear, fraying or stiffness. If any damage is
found, or if the seat belt does not operate properly, have the seat belt
system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with

mild soap and water. Do not use bleach, dye or household deter­gents.

35

FEATURES AND CONTROLS

Light

Switch

AWD Switch

12V Accessory

Outlet

Ignition

Switch

Instrument

Cluster

Power Steering Unit

(under cover)

Switches

Auxiliary Outlet

The vehicle is equipped with one or more 12-volt accessory outlets. One
outlet is on the dash, a second outlet (if equipped) is in the rear passen­ger area. Use the outlets to power an auxiliary light or other optional
accessories or lights. For service, the dash outlet connection is under the
dash. The rear outlet connection is under the rear passenger seats.

Electronic Power Steering (EPS)

Electronic power steering (if
equipped) engages when the ignition
key is turned to the ON position. EPS
remains engaged whether the vehicle
is moving or idle.

The EPS warning indicator briefly
illuminates when the key is turned to
the ON position. See page 42.

If the light remains on after starting
the engine, the EPS system is
inoperative. See your authorized
POLARIS dealer for service.

36

FEATURES AND CONTROLS

HIGH

LOW

AWD

2WD

Switches

Ignition Switch

The ignition switch is a three-position, key-operated switch. Use the
ignition switch to start the engine. See page 54 for starting procedures.

The key can be removed from the switch when it is in the OFF position.

OFF The engine is off. Electrical circuits are off, except accessory 12V.
ON Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter. The key

Headlight Switch

Use the headlight switch to turn the lights on and
off and to change the lights from high beam to low
beam. The ignition switch must be in the ON posi­tion to operate the headlights.

Press the top of the rocker switch toward the dash
to place the headlights on high beam. Move the
rocker switch to the center position to place the
headlights on low beam. Press the bottom of the
rocker switch to turn off the headlights.

All Wheel Drive (AWD) Switch

The AWD Switch has two positions:

• All Wheel Drive (AWD)

• Two Wheel Drive (2WD).

Press the top of the rocker switch to engage All
Wheel Drive. Press the bottom of the switch to
operate in two wheel drive.

See page 40 for AWD operating instructions.

returns to the ON position when released.

37

FEATURES AND CONTROLS

Gear Selector

Gear Selector

P: Park
R: Reverse
N: Neutral
L: Low Gear
H: High Gear
To change gears, stop the vehicle,

and with the engine idling, move the
lever to the desired gear. Do not
attempt to shift gears with engine
speed above idle or while the vehicle
is moving.

Tip: Maintaining shift linkage adjustment is important to assure proper transmis-

sion function. See your dealer if you experience any shifting problems.

NOTICE: Do not attempt to shift the transmission while the vehicle is moving or

Using Low Range and High Range

Operating at speeds less than 7 MPH (11 km/h) Low
Operating in rough terrain or over obstacles Low
Loading the vehicle onto a trailer Low
Towing heavy loads Low
Operating at speeds greater than 7 MPH (11 km/h) High

damage to the transmission could result. Always shift when the
vehicle is stationary and the engine is at idle.

Condition Range to Use

38

FEATURES AND CONTROLS

Throttle

Pedal

Brake Pedal

Brake Pedal

Depress the brake pedal to
slow or stop the vehicle.
Apply the brakes while start­ing the engine.

Throttle Pedal

Push the pedal down to
increase engine speed.
Spring pressure returns the
pedal to the rest position
when released. Always
check that the throttle pedal
returns normally before start­ing the engine. Make sure
there's adequate throttle
pedal freeplay. See page 98
for throttle pedal adjustment
procedures.

39

FEATURES AND CONTROLS

AWD

2WD

All Wheel Drive (AWD) System

The All Wheel Drive system is controlled by the
AWD switch. When the switch is on 2X4, the vehi­cle is in two-wheel drive at all times. When the
switch is on A WD, the vehicle is in all wheel drive
and the 4X4 indicator in the instrument cluster will
be on.

When in AWD, the demand drive unit will auto­matically engage any time the rear wheels lose
traction. When the rear wheels regain traction, the
demand drive unit will automatically disengage.

There is no limit to the length of time the vehicle
may remain in AWD.

Engaging AWD

The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the demand drive unit is moving, it will not disengage until the
rear wheels regain traction.

Engage the AWD switch before getting into conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.

NOTICE: Switching to AWD while the rear wheels are spinning or slipping may

cause severe drive shaft and gearcase damage. Always switch to
AWD while the rear wheels have traction or are at rest.

40

FEATURES AND CONTROLS

Rider Information

Center

Speedometer

Indicator Lamps

MODE

Button

Instrument Cluster

NOTICE: High water pressure may damage components. Wash the vehicle by

hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will

damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on

the instrument cluster.

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH)
or kilometers per hour (km/h). See page 45.

Mode Button

Use the MODE button to toggle through mode options. See page 45 for
operation of the modes.

41

FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

Vehicle
Speed

Over
Temperature

EPS Warning This indicator illuminates briefly when the key is

Neutral This lamp illuminates when the transmission is in

High Beam This lamp illuminates when the headlamp switch is

Helmet/Seat
Belt

Check Engine This indicator appears if an EFI-related fault occurs.

When standard mode is selected, speed displays in
miles per hour.

When metric mode is selected, speed displays in
kilometers per hour.

This lamp illuminates to indicate an overheated
engine. If the indicator flashes, the overheating
condition remains, and the system will automatically
reduce engine power.

turned to the ON position. If the light remains on, the
EPS system is inoperative. See your authorized
POLARIS dealer for service.

neutral and the ignition key is in the ON position.

set to high beam.
This lamp flashes for several seconds when the key is

turned to the ON position. The lamp is a reminder to
the operator to ensure all riders are wearing helmets
and seat belts before operating.

Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.

42

FEATURES AND CONTROLS

1

2

6

5

4

7

3

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster . All seg­ments will light up for one second at start-up. If the instrument cluster
fails to illuminate, a battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the electronic speedome­ter. If this occurs, take the vehicle to your POLARIS dealer for proper
diagnosis.

The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 46.

EF

Trip 1

RPM

km

:

88

1. Gear Indicator - This indicator displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park

-- = Gear Signal Error (or shifter between gears)

88

mi

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

3. Information Display Area - This area displays odometer, trip
meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the
vehicle is operating at an RPM too low to keep the battery charged.
It may also occur when the engine is at idle and high electrical load
(lights, cooling fan, accessories) is applied. Drive at a higher RPM
or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See
page 46 for resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator
that the preset service interval has been reached. The vehicle should
be brought to your dealer for scheduled maintenance. See page 46
for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is
engaged (switch is on 4X4).

44

FEATURES AND CONTROLS

MODE

Button

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the
information area options.

Display Units (Standard/Metric)

The display can be changed to show either
standard or metric units of measurement for
each of the following settings.

Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key

on. The gauge display the mode that was displayed prior to setting the
units.

Standard Display Metric Display

Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to the ON
position.

3. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting.

4. Press and hold the MODE button to save the setting and advance to
the next display option.

5. Repeat the procedure to change remaining display settings.

45

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or dis-

charged.

1. Turn the key to the ON position. Use the MODE button to toggle to
the odometer display.

2. Press and hold the MODE button until the hour segment flashes.
Release the button.

3. With the segment flashing, tap the MODE button to advance to the
desired setting.

4. Press and hold the MODE button until the next segment flashes.
Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.

6. Turn the key to the OFF position.

46

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before
each trip. T o reset, select the trip meter mode. Press and hold the MODE
button until the meter resets to zero. In the Rider Information Center, the
trip meter display contains a decimal point, but the odometer displays
without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Engine Temperature Mode

This mode displays current temperature of the coolant.

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of

changes in humidity, temperature and elevation.

47

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Programmable Service Interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is pro­grammed at 50 hours at the factory. Use the following procedure to
change the service interval.

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to

advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only.
Please see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if
you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and
on and the warning indicator is no longer active. This allows the deter­mination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

48

FEATURES AND CONTROLS

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

Instrument Cluster

Rider Information Center

Engine Error Codes

The error screen displays
only when the CHECK
ENGINE light is on or
when it goes on and off
during one ignition cycle.
Error codes are not stored.
When the key is turned
OFF, the code and mes­sage is lost, but will reap­pear if the fault reoccurs
after restarting the engine.

If the CHECK ENGINE
light illuminates, retrieve
the error codes from the
display.

1. If the error codes are not displayed, use the MODE button to toggle
until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code
menu.

3. Record the three numbers displayed in the gear position, clock and
odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See an authorized POLARIS dealer for code details and diagnosis.

49

OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.

Vehicle Break-in Period

The break-in period for your new POLARIS vehicle is the first 25 hours
of operation, or the time it takes to use the first two tanks full of gaso­line. No single action on your part is as important as a proper break-in
period. Careful treatment of a new engine and drive components will
result in more efficient performance and longer life for these compo­nents. Perform the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.

Use of any oils other than those recommended by POLARIS may
cause serious engine damage. We recommend the use of POLARIS
Premium 4 Synthetic Oil for your 4-cycle engine.

50

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 34. Always exercise
extreme caution whenever handling gasoline.

2. Check the oil level. See page 77. Add the recommended oil as

needed to maintain the oil level in the safe operating range.

3. Complete the New Operator Driving Procedures outlined on pages

56-57.

4. Avoid aggressive use of the brakes. See Brake System Break-in on

page 51.

5. Vary throttle positions. Do not operate at sustained idle.

6. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 52.

7. Pull only light loads.

8. During the break-in period, change both the oil and the filter at 25

hours or one month.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or
overly forceful braking when the brake system is new could damage
brake pads and rotors.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur­ing the break-in period.

51

OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condi­tion before operating increases the risk of an accident. Always inspect
the vehicle before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/pedal travel Ensure proper operation 39
Brake fluid Ensure prop er level 100

Front suspension Inspect, lubricate if necessary 74
Rear suspension Inspect, lubricate if necessary 74
Steering Ensure free operation 101
Tires Inspect condition and pressure 21

Wheels/fasteners Inspect, ensure fastener tightness 105
Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 44

Coolant level Ensure proper level 92
Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 97
Indicator lights/switches Ensure proper operation 37
Air filter, pre-filter Inspect, clean 95
Headlamp Check operation, apply POLARIS

Brake light/tail lamp Check operation, apply POLARIS

Seat Latches Push down on both seat backs to
Seat Belts Check length of belt for damage,
Cab Nets Check for wear or damage, ensure

dielectric grease when lamp is
replaced

dielectric grease when lamp is
replaced

ensure the latches are secure
check latches for proper operation
proper installation

99

105

77
91

107

109

31
35
34

52

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this
vehicle.

2. Do not allow anyone under 16 years of age or without a valid

driver’s license to operate this vehicle.

3. Never operate with a passenger under the age of 12. Never carry

more one passenger in a 2-seat vehicle. Never carry more than three
passengers in a 4-seat vehicle. Never allow a passenger to ride in
the cargo box.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Never operate with accessories not approved by POLARIS for use

on this vehicle.

6. Operate this vehicle off-road only. Never operate the vehicle on

pavement or on any public street, road or highway, including dirt
and gravel roads.

7. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Keep both hands on the steering wheel dur­ing operation.

8. Never consume alcohol or drugs before or while operating this vehi-

cle.

9. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

10. Never operate a damaged vehicle. After any overturn or accident,

have a qualified service dealer inspect the entire machine for possi­ble damage.

11. Never operate the vehicle on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use.

53

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti­lated area.

2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the

engine.

5. Turn the ignition key past the ON/RUN position to START. Engage

the starter for a maximum of five seconds. Release the key when the
engine starts.

6. If the engine does not start within five seconds, return the ignition

switch to the OFF position and wait five seconds. Repeat steps 5
and 6 until the engine starts.

7. Vary the engine RPM slightly with the throttle to aid in warm up

until the engine idles smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

damage. Allow the engine to warm up for several minutes before
operating the vehicle.

Braking

1. Release the throttle pedal completely. (When the throttle pedal is
released completely and engine speed slows to near idle, the vehicle
has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and

stopping (using the brakes) until you're familiar with the controls.

54

OPERATION

Parking the Vehicle

1. Stop the vehicle on a level surface. When parking inside a garage or
other structure, be sure that the structure is well ventilated and that
the vehicle is not close to any source of flame or sparks, including
any appliance with pilot lights.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Remove the ignition key to prevent unauthorized use.

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera­tion of this vehicle in your area. Respect the environment in which you
ride your vehicle. Find out where the designated riding areas are by con­tacting your POLARIS dealer, a local riding club, or local officials.

Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow . T read lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

55

OPERATION

New Operator Driving Procedures

1. Read and understand the owner's manual and all warning and
instruction labels before operating this vehicle.

2. Perform the pre-ride inspection. See page 52.

3. Wear an approved helmet that fits properly and eye protection (gog-

gles or face shield).

4. Do not carry a passenger until you have at least two hours of driving

experience with this vehicle.

5. Do not tow or carry cargo during this period.

6. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

7. Sit in the driver's seat and fasten the seat belt.

8. Always use the cab nets while riding in this vehicle.

9. Place the transmission in PARK.

10. Start the engine.

56

OPERATION

New Operator Driving Procedures

11. Apply the brakes and shift into low gear.

12. Check your surroundings and determine your path of travel.

13. Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving.

14. Drive slowly at first. On level surfaces, practice starting, stopping,
turning, maneuvering, using the throttle and brakes and driving in
reverse. Learn how the vehicle handles when making both left and
right turns at a slow speed.

15. Increase speed only after mastering all maneuvers at a slow speed.

16. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions:

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt stee ring maneuvers.

• Operate at speeds appropriate for your skills, the conditions and
the terrain.

• DO NOT do power slides, “donuts”, jumps or other driving
stunts.

57

OPERATION

Driving with Passengers

1. Complete the New
Operator Driving
Procedures outlined on
pages 56-57.

2. Perform the pre-ride

inspection. See page 52.

3. Do not carry more than

one passenger in a 2-seat
vehicle. Do not carry more
than three passengers in a
4-seat vehicle. Additional
passengers can affect the
operator’s ability to steer
and operate the controls.

4. Make sure all passengers

are at least 12 years of age
and are tall enough to
comfortably and safely sit
in a passenger seat, put
both feet on the floor and
grasp the passenger hand hold or grab bar.

5. Make sure all passengers are wearing appropriate riding gear,

including an approved helmet and eye protection. See page 8.

6. Make sure all passengers secure their seat belts.

7. Make sure all cab nets are properly secured.

8. Allow a passenger to ride only in a passenger seat.

9. Slow down. Always travel at a speed appropriate for your skills,

your passengers’ skills and operating conditions. Avoid unexpected
or aggressive maneuvers that could cause discomfort or injury to a
passenger.

10. Vehicle handling may change with passengers and/or cargo on

board. Allow more time and distance for braking.

11. Always follow all operating guidelines as outlined on safety labels

and in this manual.

58

OPERATION

WARNING

Sideways

skid

Tur n in

direction of

skid

Driving on Slippery Surfaces

Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly). When operating on slippery surfaces such as ice or loose gravel,
reduce speed and use extra caution to reduce the chance of skidding or sliding
out of control. Do not operate on excessively slippery surfaces.

When driving on slippery surfaces such as wet trails, loose gravel, or
ice, be alert for the possibility of skidding and sliding.

Follow these precautions when encountering slippery conditions:

1. Slow down before entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.

3. Engage all-wheel drive before wheels begin to lose traction.

NOTICE: Severe damage to the drive train may occur if the AWD is engaged

4. Correct a skid by turning the steering wheel in the direction of the

while the wheels are spinning. Always allow the wheels to stop
spinning before engaging AWD.

skid. Never apply the brakes during a skid.

59

OPERATION

15° maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always check the terrain carefully before ascending a hill.

2. Avoid steep hills (15° maximum). If ascending a steeper grade is
unavoidable, engage all-wheel drive before ascending.

3. Drive straight uphill.

4. Never climb hills with excessively slippery or loose surfaces.

5. Proceed at a steady rate of speed and throttle opening. Never open
the throttle suddenly.

6. Avoid unnecessary changes in speed or direction.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the ot her side of the
hill.

8. If the vehicle stalls while climbing a hill, apply the brakes. Place the
transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to control speed.

60

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

3. If the vehicle begins to overturn, or if it feels as if it may overturn,
immediately turn downhill.

4. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide.

5. If the vehicle begins to slide downhill, immediately turn downhill to
stop the slide, or stop the vehicle and maneuver slowly and care­fully until the vehicle can be driven straight downhill.

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Slow down. Never travel down a hill at high speed.

3. Always check the terrain carefully before descending a hill.

4. Always descend a hill with the transmission in forward gear. Never
descend a hill with the transmission in neutral.

5. Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight downhill.

6. Apply the brakes lightly to aid in slowing.

61

OPERATION

Floor Level

Driving Through Water

Y our vehicle can operate through
water with a maximum
recommended depth equal to
floor level. Follow these
precautions when operating
through water:

1. Determine water depth and
current before entering
water.

2. Choose a crossing where the

water level is lowest and
where both banks have grad­ual inclines. Never operate
in water that exceeds the
maximum recommended depth.

WARNING! The large tires on your vehicle may cause the vehicle to float in
deep or fast-flowing water, which could result in loss of traction, loss of control,
overturn or accident.

3. Wet brakes may have reduced stopping ability. After leaving water,

test the brakes. Apply them lightly several times while driving
slowly. The friction will help dry out the pads.

NOTICE: Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 69. Give special attention to engine
oil, transmission oil, demand drive fluid, rear gearcase oil, and all
grease fittings.

If your vehicle becomes immersed or is operated in water that
exceeds the floor level, take it to your dealer for service before
starting the engine. If it's impossible to bring the vehicle to your
dealer before starting the engine, perform the service outlined on
page 109, and take the vehicle to your dealer at the first opportunity.

62

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for haz­ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.

4. Avoid operating over large obstacles such as rocks and fallen trees.
If unavoidable, use extreme caution and operate slowly.

5. Always have all passengers dismount and move away from the
vehicle before operating over an obstacle that could cause an over­turn.

63

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Apply the throttle lightly. Never open the throttle suddenly.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

64

OPERATION

Parking on an Incline

A rolling vehicle can result in serious injury. Avoid parking on an
incline. If parking on an incline is unavoidable, follow these precau­tions:

1. Place the transmission in PARK.

2. Turn the engine off.

3. Block the rear wheels on the downhill side, or park the vehicle in a
sidehill position instead.

65

OPERATION

WARNING

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of the
operator, passengers, accessories, loads in the rack or box and the load on the
trailer tongue. The combined weight of these items must not exceed the
maximum weight capacity .

Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.

Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.

Carrying a passenger in the cargo box could
result in a fall from the vehicle or contact with
moving components. Never allow a
passenger to ride in the cargo box. A
passenger must always be seated in a
passenger seat with seat belt secured.

66

OPERATION

WARNING

Hauling Cargo

Your POLARIS vehicle has been designed to carry or tow specific
capacities. Reduce speed and allow a greater distance for braking when
carrying cargo.

Loads should be centered and carried as low as possible in the box. For
stability on rough or hilly terrain, reduce both speed and car go. Exercise
caution if the cargo load extends over the side of the box.

Always read and understand the load distribution warnings listed on
warning labels and in this manual. Never exceed the maximum capaci­ties specified for your vehicle. See page 122.

Belt Life

To extend belt life, use low gear when hauling or towing heavy cargo.

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or
brake instability.

Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow-

ing bracket.

2. Do not operate the vehicle faster than 10 mph (16 km/h) when tow­ing. Towing a trailer increases braking distance.

3. Do not tow more than the recommended weight for the vehicle.

4. Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location, which could result in loss of control of
the vehicle.

5. The total load (operator, passengers, accessories, cargo and weight
on hitch) must not exceed the maximum weight capacity of the
vehicle.

Load Weight

(Level Ground)

Total Towed

1500 lbs.

(681 kg)

Total Towed

Load Weight

(15° grade)

850 lbs.

(386 kg)

Total Hitch

Vertical

Weight

150 lbs.

(68.1 kg)

Maximum

Towing

Speed

10 mph

(16 kph)

67

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrestor that was tested and quali­fied to be in accordance with the USFS standard 5100-1C. Federal law
requires that this spark arrestor be installed and functional when the
vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI com­ponents are set at the factory for optimal performance and are not
adjustable.

The emissions label is located on the lower frame behind the driver’s
seat.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic

energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the lim­itations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.

68

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log beginning on
page 139.

Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately ten
(10) miles per hour. Vehicles subjected to severe use must be inspected
and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank­case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.

69

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to
severe use.

E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)

n Have an authorized POLARIS dealer perform these services.

WARNING! Improperly perform in g th e procedures marked with a n could result
in component failure and lead to serious injury or death. Have an authorized
POLARIS dealer perform these services.

70

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

n

Steering - Pre-Ride - Make adjustments as need ed.

X Front suspension - Pre-Ride -
X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride -
X Brake pedal travel

Brake system - Pre-Ride ­Wheels/fasteners - Pre-Ride ­Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride -
XEAir filter, pre-filter - Daily - Inspect; clean often; replace as

Coolant
(if applicable)

X Power steering unit

(if equipped)
Headlamp/tail lamp - Daily - Check operation; apply

XEAir filter,

main element
Brake pad wear 10 H Monthly 100 (160) Inspect periodically

X

n

Battery 25 H Monthly 250 (400) Check terminals; clean; test

X Demand drive flui d 25 H Monthly 250 (400) Inspect level; change yearly
X Rear gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly
X Main gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly
X Transfer case oil 25 H Monthly 250 (400) Inspect level; change yearly

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

E Emission-Related Service

n Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Check level daily, change cool-

- Daily - Inspect daily; clean often

- Weekly - Inspect; replace as needed

(Km)

See Pre-Ride Checklist on page

52.

needed

ant every 2 years

dielectric grease if replacing

Remarks

71

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

nE Throttle cable/ ETC

switch

E Throttle body air

intake ducts/flange

X General

lubrication
Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

n

Steering 50 H 6 M 500 (800) Lubricate

X Front Suspension 50 H 6 M 500 (800) Lubricate
X Rear Suspension 50 H 6 M 500 (800) Lubricate

Cooling system
(if applicable)

nE Fuel system 100 H 12 M 600 (1000) Check for leaks at tank cap,

XESpark plug 100 H 12M 600 (1000) Inspect; replace as needed

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change at

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

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

E Emission-Related Service

n Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

25 H Monthly 150 (250) Inspect; replace if necessary

25 H 1 M - Perform a break-in oil and filter

50 H 6 M 300 (500) Inspect; adjust; lubricate;

50 H 6 M 300 (500) Inspect duct for proper sealing/

50 H 3 M 500 (800) Lubricate all fittings, pivots,

50 H 6 M 500 (800) Inspect coolant strength

(Km)

change at one month

replace if necessary

air leaks

cables, etc.

seasonally; pressure test
system yearly

lines, filter, pump, throttle body;
replace lines every two years

one month

Remarks

72

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

X Radiator

(if equipped)

X Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
X Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/pipe 100 H 12 M 1000 (1600) Inspect

n

Ignition timing 100 H 12 M 1000 (1600) Inspect

X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

n

Clutches (drive and
driven)

Drive belt 100 H 12 M 1000 (1600) Inspect; replace as needed

n

Front wheel
bearings

n

Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrestor 300 H 36 M 3000 (4800) Clean out
Idle speed - Adjust as needed

n

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service

n Have an authorized POLARIS dealer perform these services

(whichever comes first)

Hours Calendar Miles

100 H 12 M 1000 (1600) Inspect; clean external

100 H 12 M 1000 (1600) Inspect; clean; replace worn

100 H 12 M 1000 (1600) Inspect; replace as needed

(Km)

surfaces

security; apply dielectric grease
to connectors
subjected to water, mud, etc.

parts

when parts are replaced

Remarks

73

MAINTENANCE

Prop Shaft

Grease Fitting

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 69, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS Synthetic

Brake Fluid DOT 4 Maintain level between fill lines.

Transmission Oil
(Main Gearcase)

Transmission Oil
(Transfer Case)

Demand Drive Fluid
(Front Gearcase)

Rear Gearcase Oil Premium ATV Angle Drive

Prop Shaft POLARIS Premium U-Joint

Control Arm Pivot
Bushings, Front/Rear

Stabilizer Bar Bushings POLARIS Premium all

Engine Oil

Premium AGL Synthetic
Gearcase Lube

Premium AGL Synthetic
Gearcase Lube

Demand Drive Plus Fluid See page 84.

Fluid

Lube
POLARIS Premium all

Season Grease or grease
conforming to NLGI No. 2

Season Grease or grease
conforming to NLGI No. 2

Add to proper level on dipstick.
See page 77.

See page 100.
See page 82.

See page 80.

See page 85.

Locate fittings and grease.

Locate fittings and grease.

Locate fittings and grease.

74

Lubrication Recommendations

RZR S/RZR 4

Control Arm Pivot

Bushings

RZR S/RZR 4

Control Arm Pivot

Bushings

RZR 4

Stabilizer Bar Bushings

RZR

Stabilizer Bar

Bushings

RZR

Control Arm Pivot

Bushings

MAINTENANCE

75

MAINTENANCE

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 PLUS Synthetic
engine oil.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and may result in engine seizure,
accident, and injury. Always perform the maintenance procedures as outlined in
the Periodic Maintenance Chart.

Oil may need to be changed more frequently if POLARIS PS-4 PLUS
Synthetic engine oil is not used. Follow the manufacturer's recommen­dations for ambient temperature operation. See page 126 for the part
numbers of POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. Always use the recommended oil. Never substitute
or mix oil brands.

76

MAINTENANCE

Dipstick

Safe

{

Safe

Range

Check Level

on Top Side

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 69. Always use the recommended
engine oil.

Oil Check

The oil dipstick and fill tube is
located on the engine, behind
the passenger seat (behind the
right rear passenger seat on
RZR 4 models).

1. Position the vehicle on a

level surface.

2. Place the transmission in
PAR K.

3. Remove both seats. Remove
the rear service panel. See
page 31.

4. Lift the lever lock to remove
the dipstick. Wipe it dry with
a clean cloth.

5. Reinstall the dipstick com­pletely, but do not lock it. The
dipstick must be inserted com­pletely in to keep the angle
and depth of the stick consis­tent.

6. Remove the dipstick and
check the oil level. Maintain
the oil level in the safe range.
Do not overfill.

Tip: Due to the dipstick entry angle

into the crankcase, the oil level
will read higher on the bottom
side of the dipstick. Always read
the level on the upper surface of
the dipstick.

7. Reinstall the dipstick. Seat the
lever lock.

77

MAINTENANCE

Drain Plug

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 69. Always change the oil filter
whenever changing oil.

The engine drain plug is located on
the bottom of the crankcase.

1. Position the vehicle on a level
surface. Place the transmission
in PARK. Apply the brakes.

2. Start the engine. Allow it to idle

for two to three minutes. Stop
the engine.

3. Clean the area around the drain

plug.

CAUTION! Hot oil can cause burns to
skin. Do not allow hot oil to contact skin.

4. Place a drain pan beneath engine

crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

Tip: The sealing surfaces on drain plug and crankcase should be clean and free

of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 16 ft. lbs. (22 Nm).

78

MAINTENANCE

Engine Oil

Oil and Filter Change

8. Using a cap-style oil filter wrench, turn the filter counter-clockwise
to remove it.

9. Using a clean dry cloth, clean the filter sealing surface on the crank­case.

10. Lubricate the o-ring on the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition.

11. Install the new filter and turn by hand until the filter gasket contacts
the sealing surface, then turn and additional 1/2 turn.

12. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec­ommended oil.

13. Place the transmission in PARK. Apply the brakes.

14. Start the engine. Allow it to idle for one to two minutes.

15. Stop the engine. Inspect for leaks.

16. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.

17. Dispose of used filter and oil properly.

79

MAINTENANCE

Fill Plug

Level

Check Plug

Drain Plug

Gearcases

Transfer Case

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug and level check plug are located on the left side of the
transfer case. The fluid level is sufficient when fluid flows out of the
check plug hole at step 4.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Remove the level check plug.

4. Add the recommended fluid to the fill plug hole until it begins to
flow out of the check plug hole.

5. Reinstall the level check plug. Torque to specification.

6. Reinstall the fill plug. Torque to specification.

80

MAINTENANCE

Gearcases

Transfer Case

Fluid Change

The drain plug is located on the bottom of the transfer case. Access the
drain plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Allow the fluid to drain completely.

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring. Torque to specification.

6. Remove the level check plug.

7. Add the recommended fluid to the fill plug hole until it begins to
flow out of the check plug hole.

8. Reinstall the level check plug. Torque to specification.

9. Reinstall the fill plug. Torque to specification.

10. Check for leaks. Discard used fluid properly.

81

MAINTENANCE

Fill Plug

Gearcases

Transmission (Main Gearcase)

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug is located on the left side
of the gearcase. Maintain the fluid
level at the bottom of the fill plug
hole.

1. Position the vehicle on a level
surface.

2. Remove the fill plug.

3. Check the fluid level.

4. Add the recommended fluid to

the bottom of the fill plug hole.
Do not overfill.

5. Reinstall the fill plug. Torque to

specification.

82

MAINTENANCE

Transfer Case

Drain Plug

Rear Gearcase

Drain Plug

Main Gearcase Drain

Plug

Gearcases

Transmission (Main Gearcase)

Fluid Change

The drain plug is located on the bottom of the gearcase. Access the drain
plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Allow the fluid to drain completely.

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring. Torque to specification.

6. Add the recommended fluid to the bottom of the fill plug hole. Do
not overfill.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

83

MAINTENANCE

Drain Plug

Fill Plug

View of Bot-

tom

Gearcases

Demand Drive Unit (Front Gearcase)

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug is located on the
bottom right side of the demand
drive unit. Maintain the fluid
level even with the bottom
thread of the fill plug hole.

1. Position the vehicle on a
level surface.

2. Remove the fill plug. Check

the fluid level.

3. Add the recommended fluid

to the bottom thread of the
fill plug hole.

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

The drain plug is located on the bottom of the gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Allow the fluid to drain completely.

4. Clean the drain plug. If the o-ring is damaged, install a new o-ring.

5. Reinstall the drain plug. Torque to specification.

6. Add the recommended fluid to the bottom thread of the fill plug

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

hole.

84

MAINTENANCE

Fill Plug

Drain Plug

Gearcases

Rear Gearcase

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug is located on the right
side of the rear gearcase. Maintain
the fluid level even with the bot­tom thread of the fill plug hole.

1. Position the vehicle on a level
surface.

2. Remove the fill plug. Check

the fluid level.

3. Add the recommended fluid to

the bottom thread of the fill
plug hole.

4. Reinstall the fill plug. Torque

to specification.

Fluid Change

The drain plug is located on the bottom right side of the rear gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug. Remove the drain plug.

3. Allow the fluid to drain completely.

4. Clean the drain plug. Reinstall the drain plug with a new o-ring.

Torque to specification.

5. Add the recommended fluid to the bottom thread of the fill plug

hole.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

85

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See
page 126 for the part numbers of POLARIS products.

Gearcase Lubricant Capacity Fill Plug

Transmission

(Main Gearcase)

Transmission

(Transfer Case)

Demand Drive Unit

(Front Gearcase)

Rear Gearcase Premium ATV

Premium AGL

Synthetic

Gearcase Fluid

Premium AGL

Synthetic

Gearcase Fluid

Demand Drive

Plus Fluid

Angle Drive Fluid

24 oz.

(710 ml)

14 oz.

(414 ml)

6.75 oz.

(200 ml)

26 oz.

(769 ml)

40-50 ft. lbs.

(54-68 Nm)

40-50 ft. lbs.

(54-68 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

40-50 ft. lbs.

(54-68 Nm)

Torque

Drain Plug/
Level Check
Plug Torque

30-45 in. lbs.

(3-5 Nm)

30-45 in. lbs.

(3-5 Nm)

11 ft. lbs.

(15 Nm)

30-45 in. lbs.

(3-5 Nm)

Spark Plugs

Spark Plug Gap/Torque

Electrode Gap New Plug Torque Used Plug Torque

.035" (.9 mm) 18 ft. lbs.

(24 Nm)

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. Always use POLARIS-recommended spark plugs. Refer to
the specifications section beginning on page 122.

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 87.

CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.

18 ft. lbs.

(24 Nm)

86

MAINTENANCE

Spark Plugs

Spark Plugs

Spark Plug Removal and Replacement

1. Remove both seats.

2. Remove the rear service
panel. See page 31.

3. Remove the spark plug cap.

4. Using the spark plug wrench
provided in the tool kit,
remove the plug by rotating
it counter-clockwise.

5. Reverse the procedure for
spark plug installation.
Torque to specification. See
page 86.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi­cates the proper type and heat range for the engine and the service.

Tip: The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect throttle body adjust­ments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended injection oil or incorrect throttle body adjust­ments.

87

MAINTENANCE

Fuses

If the engine stops or will not start, if the power steering stops working
(if equipped), or if you experience other electrical failures, a fuse may
need replacement. Locate and correct any short circuits that may have
caused the blown fuse, then replace the fuse.

Fuse Feature Supported

20A Lights: Headlights, Taillights
10A Drive: AWD
20A Accessory: Winch Switch, 12V Power Receptacle
10A Fuel Pump
20A Electronic Engine Control, Starting

Power Fuse Feature Supported

20A Engine Control
30A Lights, Drive, Accessories
30A Power Steering (if equipped)

88

Fuses

Step 3 - Cover removed

Step 1 - Lift tabs

Fuse Label

The fuse box is located above the power
steering unit. Spare fuses are provided in the
fuse box.

1. From the left side of the vehicle, reach in

and lift up on the two fuse box tabs.

2. Slide the fuse box slightly toward the
right side of the vehicle to disengage it
from the mount.

3. Remove the fuse box cover.

4. Remove the suspect fuse from the fuse
panel. If the fuse is blown, install a new
fuse with the same amperage rating.

5. Reinstall the fuse box cover. Reinstall the
fuse box over the mount and slide it
toward the left to engage the tabs. Be
sure the fuse box is securely mounted.

MAINTENANCE

89

MAINTENANCE

Cooling System

Operation

The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the overflow bottle, radia­tor filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the overflow bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.

Tip: Some coolant level drop on new vehicles is normal as the system is purging

itself of trapped air. Observe coolant levels and maintain as recommended
by adding coolant to the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added. POLARIS recommends the
use of POLARIS Premium 60/40 anti-freeze/coolant or a 50/50 mixture
of high quality aluminum compatible anti-freeze/coolant and distilled
water. POLARIS Premium 60/40 is already premixed and ready to use.
Do not dilute with water. See page 126 for the part numbers of
POLARIS products.

Tip: Always follow the manufacturer's mixing recommendations for the freeze

protection required in your area.

Any time the cooling system has been drained for maintenance or repair,
replace the coolant. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.

90

MAINTENANCE

Cooling System

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals out­lined in the Periodic Maintenance Chart beginning on page 69. Do not
obstruct or deflect air flow through the radiator by installing unautho­rized accessories in front of the radiator or behind the cooling fan. Inter­ference with the radiator air flow can lead to overheating and
consequent engine damage.

NOTICE: Washing the vehicle with a high-pressure hose could damage the

Radiator Coolant Level

This procedure is required only if the cooling system has been drained
for maintenance and/or repair. But i f the overflow bottle has run dry, the
level in the radiator should also be inspected.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.

1. Remove the hood. See page 33.

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

Tip: Use of a non-standard pressure cap will not allow the recovery system to

radiator fins and impair the radiator's effectiveness. Using a high­pressure system is not recommended.

function properly. See your dealer for the correct replacement part.

91

MAINTENANCE

Radiator Cap

Overflow

Bottle

Cooling System

Coolant Level

Always check and change
the coolant at the intervals
outlined in the Periodic
Maintenance Chart begin­ning on page 69. Maintain
the coolant level between
the minimum and maxi­mum marks on the bottle
(when the fluid is cool).

1. Position the vehicle on a
level surface.

2. Remove the hood. See

page 33.

3. View the coolant level

in the overflow bottle.

4. If the coolant level is

below the safe operating
range, remove the cap and use a funnel to add coolant through the
opening. Reinstall the cap.

Tip: If coolant must be added often, or if the overflow bottle runs completely dry,

there may be a leak in the system. Have the cooling system inspected by
your POLARIS dealer.

92

MAINTENANCE

WARNING

POLARIS Variable Transmission (PVT) System

Failure to comply with the instructions in this warning can result in severe injury
or death.

Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your de aler as
outlined in the owner's manual.

• This PVT system is intended for use on POLARIS products only . Do not inst all
it in any other product.

• Always make sure the PVT housing is securely in place during operation.

Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch
to low range while operating at slower speeds to extend the life of the
PVT components (belt, cover, etc.).

93

MAINTENANCE

POLARIS Variable Transmission (PVT) System

PVT Drying

Before washing the vehicle, locate the PVT outlet duct under the right
rear wheel well. Avoid spraying water directly toward the duct when
washing the vehicle from the rear. See page 116.

There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before operat­ing.

1. Remove both seats. Remove the rear service panel. See page 31.

2. Loosen the lower screws that secure the clutch cover.

3. Allow the water to drain.

4. Tighten the screws.

5. Place the transmission in PARK. Apply the brakes.

6. Start the engine.

7. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.

8. Allow the engine RPM to settle to idle speed. Apply the brakes.
Shift the transmission to the lowest available range.

9. Test for belt slippage. If the belt slips, repeat the process.

10. Take the vehicle to your dealer for service as soon as possible.

94

MAINTENANCE

Air Box Cover

Air Filter

Gasket

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 69.

1. Access the air box from
behind the left rear wheel.

2. Remove the air box cover

and inspect the gasket. It
should adhere tightly to the
cover around the entire
edge.

3. Remove the air filter.

4. Install a new filter if

needed. Do not attempt to
clean the air filter . Apply a
small amount of general
purpose grease to the seal­ing edges of the filter
before installing.

5. Inspect the air box for oil or water deposits. If present, drain them

into a suitable container.

95

MAINTENANCE

WARNING

Arrestor

Retaining

Screw and

Washer

Screen

Muffler

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death.

Do not perform clean-out immediately after the engine has been run, as the
exhaust system becomes very hot. Serious burns could result from contact with
the exhaust components. Allow components to cool sufficiently before
proceeding.

Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust contains poisonous carbon

monoxide gas that can cause loss of consciousness or death in a very short
time.

Periodically clean the spark arrestor to remove accumulated carbon.

1. Remove the retaining
screw and washer.
Remove the arrestor from
the end of the muffler.

2. Use a non-synthetic brush
to clean the arrestor
screen. A synthetic brush
may melt if components
are warm. If necessary,
blow debris from the
screen with compressed
air.

3. Inspect the screen for

wear and damage.
Replace a worn or dam­aged screen.

4. Reinstall the arrestor.

Torque screws to 5-7 ft. lbs. (7-9 Nm).

96