Polaris Ranger RZR User Manual

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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.

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational 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 (MSD) Technician.

Your Polaris dealer knows your vehicle best 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.com. Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2007 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 inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2008 RANGER RZR Owner’s Manual P/N 9921181

TABLE OF CONTENTS

Vehicle Identification Numbers. . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 32

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Emission Control Systems . . . . . . . . . . . . . . . 74

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 126

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 128

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 129

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 137

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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 Identification

Key

Number

####

Number

Engine Serial Number

Vehicle Model Number: ___________________________________________________

Vehicle Identification Number: ______________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

SAFETY

Rider Safety

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, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

SAFETY

Safety Decals and Locations

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

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

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)

Tire Pressure/Cargo Overload Warning

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 CAPACITY

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.

Cargo Box Warning

Tire Pressure/Cargo Overload

Warning

Safety Decals 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. The cab frame is not designed or intended to provide rollover protection.

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

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.

Age

Warning

Cab Frame/Seat

Belt Warning

SAFETY

Overturn

Warning

Shift

Caution

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.

SAFETY

Safety Decals and Locations

Discretionary

Warning

Passenger Safety

Warning

Passenger Safety Warning

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.

SAFETY

Safety Decals and Locations

Discretionary Warning

WARNING ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR FOR OPERATOR AND PASSENGER

NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL 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.

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

SAFETY

Rider Safety

WARNING

Failure to follow the warnings 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 and understand your owner's manual and all warnings before operating the vehicle. Always heed the following instructions and procedures, which are outlined in further detail within your owner's manual.

• Read this manual and all labels carefully. Follow the operating procedures described.

• 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 60-61.

• 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 any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor.

• Riders should wear seat belts at all times. Seat belts reduce the severity of injury in the event of a sudden stop or accident.

• Always use the cab nets while operating the vehicle.

• Helmets and eye protection are required for both operator and passenger at all times.

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

• Never allow a passenger to ride in the cargo box. Never carry more than one passenger.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels, and has completed the New Operator Driving Procedures outlined on pages 60-61.

• To reduce tipover risk, be especially careful when encountering obstacles and slopes and when braking on hills or during turns.

• Never operate with accessories not approved by Polaris for use on this vehicle. Non-approved accessories may seriously affect vehicle stability and could cause the vehicle to overturn.

SAFETY

Rider Safety

• This vehicle handles differently than cars, trucks or other off-road

vehicles. Turning improperly can result in an overturn. 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.

• Never operate at excessive speeds. Always travel at a speed appropri-

ate for your skills, your passenger's skills, and operating conditions.

• This vehicle is for off road use only. Never operate on public roads.

Always avoid paved surfaces.

• Never consume alcohol or drugs before or while operating this vehi-

cle.

• Always inspect your vehicle each time you use it to make sure it's in

safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

• Always keep both hands on the steering wheel during operation. A

passenger should always be seated in the passenger seat with both feet on the floor and with both hands securely grasping the hand holds.

• Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain.

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper procedures for turning as described in this

manual. Practice turning at slow speeds before attempting to turn at faster speeds.

• Always have this vehicle checked by an authorized Polaris dealer if it

has been involved in an accident.

• Never operate this vehicle on hills too steep for the vehicle or for your

abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

SAFETY

Rider Safety

• Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

• Avoid crossing the side of a hill.

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

• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

• Never operate in fast-flowing water or in water that exceeds the recommended maximum depth. See page 68. Wet brakes may have reduced stopping ability. To dry out the pads, apply the brakes lightly several times while driving slowly.

• Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid making sharp turns in reverse.

• Always use the proper size and type of tires specified for your vehicle. Always maintain proper tire pressure.

• Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

• 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. See page 31 for fuel safety warnings.

• Remove flammable material containers from the box before filling.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800342-3764.

SAFETY

Rider Safety

WARNING

Modifications to your vehicle may negatively impact vehicle stability and result in serious injury or death. 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.

Your Polaris vehicle is designed to provide safe operation when used as directed.

• Do not make any modifications to this Polaris vehicle.

• Never operate with accessories not approved by Polaris for use on this vehicle.

• The operator must check all safety components before each ride.

• Make sure your vehicle is in excellent operating condition at all times.

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we design accessories for your vehicle that take into consideration safe vehicle handling and stability. Never operate with accessories not approved by Polaris for use on this vehicle. Nonapproved accessories may seriously affect vehicle stability and could cause the vehicle to overturn.

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.

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, 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.

SAFETY

Safe Riding Gear

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

Eye

Protection

Sleeves

Gloves

Long

Sturdy

Footwear

Helmet

Long

Pants

SAFETY

Safe Riding Gear

Helmet

Wearing 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.

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.

051039

0006.31

SAFETY

Rider Safety

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 any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

SAFETY

Rider Safety

Know Your Riding Area/Tread Lightly

Your Polaris vehicle is an off-road vehicle. 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. Tread 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.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control and accident resulting in serious

injury or death HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the

operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle.

WARNING

POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Loss of control, accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD 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. Practice turning at slow speeds before attempting to turn at faster speeds.

WARNING

POTENTIAL HAZARD Riding in this vehicle without wearing the seat belt WHAT CAN HAPPEN Serious injury or death in the event of an accident or sudden stop HOW TO AVOID THE HAZARD Always make sure the seat belts are secured for both the operator and

passenger before riding.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Riding in this vehicle without using the cab nets WHAT CAN HAPPEN Serious injury or death in the event of an accident or overturn HOW TO AVOID THE HAZARD Always use the cab nets while operating the vehicle.

WARNING

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD 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 any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor.

WARNING

POTENTIAL HAZARD Riding this vehicle without wearing an

approved helmet and eye protection WHAT CAN HAPPEN Head injury, eye injury or death in the

event of an accident HOW TO AVOID THE HAZARD Operator and passenger: Always wear an approved helmet that

fits properly. Always wear eye protection (goggles or face shield).

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Riding this vehicle after consuming alcohol or

drugs WHAT CAN HAPPEN Accident resulting in serious injury or death due

to affected judgment, balance and perception and slower reaction time

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while

riding this vehicle.

WARNING

POTENTIAL HAZARD Removing hands from the steering wheel or hand holds or removing feet

from the floor while riding WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD The operator should always keep both hands on the steering wheel during

operation. A passenger should securely grasp the hand holds and plant both feet firmly on the floor.

WARNING

POTENTIAL HAZARD Failure to inspect the vehicle before operating

Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your 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.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Using accessories not approved by Polaris for use on this vehicle WHAT CAN HAPPEN Loss of control, accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Never operate with accessories not approved by Polaris for use on this

vehicle. Non-approved accessories may seriously affect vehicle stability.

WARNING

POTENTIAL HAZARD Operating this vehicle on paved surfaces, including sidewalks, paths, parking

lots, and driveways WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD This vehicle's tires are designed for off-road use only, not for use on

pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.

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

POTENTIAL HAZARD Operating this vehicle on public

streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any

public street, road or highway, including dirt or gravel.

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

WARNING

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Improperly operating over

obstacles WHAT CAN HAPPEN Loss of control or overturn

resulting in serious injury or death HOW TO AVOID THE HAZARD Before operating in a new area,

check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and operate slowly.

WARNING

POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Loss of control, accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD 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 out of control.

Do not operate on excessively slippery surfaces.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating through deep or fast-flowing

water WHAT CAN HAPPEN Loss of traction, loss of control, overturn

or accident resulting in serious injury or death

HOW TO AVOID THE HAZARD Always follow proper procedures for

operating in water as described in the owner's manual.

Never operate in fast-flowing water or in water that exceeds the recommended maximum depth.

WARNING

POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN Collision with an obstacle or person,

resulting in severe injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for

operating in reverse as described in the owner's manual.

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

Avoid making sharp turns in reverse.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Overloading the vehicle or

carrying/towing cargo improperly WHAT CAN HAPPEN Loss of control, accident due to

instability and changes in vehicle handling

HOW TO AVOID THE HAZARD 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.

WARNING

POTENTIAL HAZARD Operating this vehicle with improper tires

or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control, accident or overturn

resulting in serious injury or death HOW TO AVOID THE HAZARD Always use the size and type of tires

specified for your vehicle. Always maintain proper tire pressure.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Loss of control or overturn resulting in

serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for

climbing hills as described in the owner's manual.

Always check the terrain carefully before ascending a hill.

Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating

procedures outlined in the owner's manual. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. 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 other side of the hill.

WARNING

+15°

POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Loss of control or overturn resulting in

serious injury or death HOW TO AVOID THE HAZARD 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.

+15°

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Crossing hills and turning on hills WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Avoid operating on steep hills (15° maximum). Avoid crossing the side of a hill.

WARNING

POTENTIAL HAZARD Stalling, rolling backwards while climbing

a hill WHAT CAN HAPPEN Loss of control or overturn resulting in

serious injury or death HOW TO AVOID THE HAZARD 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.

Rider Safety

WARNING

POTENTIAL HAZARD Operating on excessively rough, slippery

or loose terrain WHAT CAN HAPPEN Loss of traction, loss of control, accident or

overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Do not operate on excessively rough,

slippery or loose terrain.

WARNING

POTENTIAL HAZARD Operating this vehicle at

excessive speeds WHAT CAN HAPPEN Loss of control and accident

resulting in serious injury or death HOW TO AVOID THE HAZARD Operate at speeds appropriate for

your skills, the conditions and the terrain.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident or overturn

resulting in serious injury or death HOW TO AVOID THE HAZARD Never attempt jumps and other stunts.

Avoid exhibition driving.

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death if the vehicle

and/or riders fall through the ice HOW TO AVOID THE HAZARD Never operate this vehicle on a

frozen body of water.

Rider Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating this vehicle on unfamiliar terrain

WHAT CAN HAPPEN Loss of control or overturn resulting in

serious injury or death HOW TO AVOID THE HAZARD Travel slowly and use extra caution

when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

WARNING

POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN Serious injury or death due to a fall from

the vehicle or contact with moving components

HOW TO AVOID THE HAZARD Never allow a passenger to ride in the

cargo box.

SAFETY

WARNING

POTENTIAL HAZARD Operating with more than one passenger WHAT CAN HAPPEN Loss of control and accident resulting in

serious injury or death HOW TO AVOID THE HAZARD Never carry more than one passenger.

Additional passengers can affect the operator’s ability to steer and operate the controls.

SAFETY

Rider Safety

WARNING

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.

WARNING

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious 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.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

SAFETY

Fuel Safety

WARNING

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 before 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. Never start the engine or let it run in an enclosed area. Gasoline powered

engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

FEATURES AND CONTROLS

Component Locations

Your vehicle is equipped with upper and lower cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger at all times. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized Polaris dealer.

NOTE: The vehicle illustrated below is shown without cab nets only to allow

component identification.

Seat Belts

Cargo Box

Hip Bar

Cab Frame

Shifter

Fuel Tank

Cap

Cab Nets

Dash

Passenger Hand Hold

Seat

FEATURES AND CONTROLS

Component Locations

Headlights

Storage Compartment

(under hood)

Steering

Wheel

Radiator

Brush Guard

FEATURES AND CONTROLS

Component Locations

Taillights

Muffler

(Spark Arrestor)

Receiver

Hitch

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 72-73.

FEATURES AND CONTROLS

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 both 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.

Reverse this procedure to reinstall the seat. Make sure the front edge of the seat is properly installed to the seat retainer bar. Press down firmly at the rear of the seat to engage the rear latch.

Front Seat

Retainer

Seat Latch

FEATURES AND CONTROLS

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 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.

Adjustment Lever

Retainer

Adjustment

Mounting

Bracket Holes

FEATURES AND CONTROLS

Storage Compartment

Remove the hood to access the front storage compartment. Refer to the specifications section beginning on page 126 for storage compartment capacity.

Hood

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

1. If your model is equipped with removable fasteners at the upper hood edge, remove the fasteners.

2. Grasp the upper hood

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

3. Continue pulling the

hood upward to disengage the lower hood fasteners.

4. Lift the hood away

from the vehicle.

Storage

Compartment

Upper

Fasteners

Lower

Fasteners

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 E-85 fuel.

Remove flammable material containers from the box before filling.

Fuel Cap

FEATURES AND CONTROLS

Cab Nets

WARNING

Riding in this vehicle without using the cab nets can result in serious injury or death in the event of an accident or overturn. Always use the cab nets while operating the vehicle.

Your vehicle is equipped with upper and lower cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger 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.

Latches

Upper Cab NetLower Cab Net

Upper Cab Net Interference (Driver)

The upper cab net on the driver’s side may interfere with vehicle operation for some operators due to operator body type, driving style or riding apparel. Each operator must check for upper cab net interference before operating the vehicle.

1. Complete the New Operator Driving Procedures outlined on pages 60-61.

2. Test for upper cab net interference by making slow speed turns to

the left and right. If the net interferes with operation, it should be removed from the vehicle for this operator only. All other cab nets must remain on the vehicle during operation. See page 39.

FEATURES AND CONTROLS

Cab Nets

Upper Cab Net Removal (Driver)

The upper cab net on the driver’s side may be removed only if it interferes with operation of the vehicle. All other cab nets must remain

installed.

1. Using a T-25 torx bit and 7/16" open end wrench, remove the mounting screw and washers securing the upper and lower cab nets to the floor of the vehicle on the driver’s side.

2. Reinstall the lower net with the

screw and all washers. Tighten the screw securely.

3. Unclip the four latches that secure

the upper net to the chassis and lower net. See the photo on the previous page.

4. Clip the free upper latch of the

lower cab net to the free latch on the shoulder net, adjusting strap length as needed. Tighten the strap.

5. Reverse all steps to reinstall the cab

net.

NOTE: Always reinstall the upper cab net for any other operator of the vehicle.

Step 1

Screw

and

Washers

Step 2

FEATURES AND CONTROLS

Seat Belts

This Polaris vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger.

WARNING

Riding in this vehicle without wearing the seat belt can result in serious injury or death in the event of an accident or sudden stop. Always make sure the seat belts are secured for both the operator and passenger 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.

NOTE: Press the red release latch on

the buckle to release the seat belt.

Seat Belt

Latches

Seat Belt

Buckles

FEATURES AND CONTROLS

Seat Belts

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, dirt, debris or stiffness. If any damage is found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

FEATURES AND CONTROLS

Switches

Ignition

Switch

Light

Switch

Instrument

Cluster

Mode Switch

Work Light Switch

12V Accessory

Outlet

AWD

Switch

Mode Switch

The yellow switch located near the instrument gauge is used to toggle through mode options available such as odometer, trip meter, hour meter, tachometer and clock. See page 49 for operation of the modes.

Work Light Switch

Use the work light switch to turn the work light on or off. The work light is located at the rear of the vehicle. Turn the light on while loading and unloading cargo in low light situations. Turn the work light off when driving.

FEATURES AND CONTROLS

Switches

Ignition Switch

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

The ignition switch is a three-position, key-operated switch. Use the ignition switch to start the engine. See page 57 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.

Light Switch

Use the headlight switch to turn the lights on and off.

NOTE: The ignition switch must be in the ON position

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 46 for AWD operating instructions.

The key returns to the ON position when released.

to operate the headlights.

OFF

AWD

Auxiliary Outlet

The 12-volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are under the dash.

2WD

FEATURES AND CONTROLS

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.

NOTE: Maintaining shift linkage adjustment is important to assure proper

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

CAUTION

Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

Using Low Range and High Range

Gear

Selector

Condition Range to Use

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

FEATURES AND CONTROLS

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 104 for throttle pedal adjustment procedures.

Brake Pedal

Throttle

Pedal

FEATURES AND CONTROLS

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 AWD, the vehicle is in all wheel drive and the AWD indicator light 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.

CAUTION

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

FEATURES AND CONTROLS

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM.

Speedometer

Needle

Rider

Information

Center

NOTE: In addition to showing vehicle speed, the speedometer needle flashes

when the fuel level is low.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may

1. Gear Indicator - This

2. AWD Indicator - This

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates

6. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

7. Fuel Gauge - The segments of the fuel gauge show the level of fuel

8. Check Engine Warning Indicator - This indicator serves two pur-

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.

indicator displays gear

345

shifter position. P = Park

R = Reverse N = Neutral L = Low Gear H = High Gear

indicator illuminates when the AWD switch

is in the AWD position.

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.

in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.

poses. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the yellow mode switch located near the instrument gauge to toggle through the mode options. See page 42.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode switch until the total changes to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

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

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page

50.

mal point, but the odometer displays without a decimal point.

of changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Place the transmission in neutral.

3. Hold the mode switch and turn the key switch on. Release the switch as soon as the display is activated.

4. Use the mode switch to toggle through the diagnostic screens.

Clock Screen

To reset the clock:

1. Enter the diagnostic mode. Toggle to the clock screen.

2. Press and hold the mode switch until the hour display flashes. Release the switch.

3. Press and release the mode switch once to advance the setting by one hour. Press and hold the mode switch to advance the hours quickly.

4. When the desired hour is displayed, wait approximately four seconds, until the minute display flashes.

5. Use the same procedure to reset the minutes.

6. When the display stops flashing, the mode has been set.

NOTE: Do not turn the key switch off until the display stops flashing or

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

the new setting will not be locked into the memory.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

AWD Diagnostic Screen

The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs.

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. To enable or disable the service interval:

1. Enter the diagnostic mode. Toggle to the service interval screen.

2. Press and hold the mode switch for about seven (7) seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode. Toggle to the service interval screen.

2. Press and hold the mode switch for 2-3 seconds, until the wrench icon flashes. Release the switch.

3. Press and release the mode switch once to advance the setting by one hour. Press and hold the mode switch to advance the hours quickly.

NOTE: If you scroll past the intended number, press and hold the switch until

4. When the desired setting is displayed, wait until the wrench icon

the hours cycle back to zero.

stops flashing. The new service interval is now programmed.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Miles/Kilometers Toggle

The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles (MP).

3. Press and hold the mode switch until the letters flash, then press and release the switch once. When the display stops flashing, the mode has been set.

Downloading Codes

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

See page 53 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in PARK.

2. Stop the engine.

3. Turn the key switch to the ON position.

4. Turn the key switch off and on three times in less than five seconds, then leave the switch on. Any blink code numbers stored in the EFI module will display, one at a time, on the screen. The number “61” and the word “END” displays after all codes have been transmitted.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink

Failure Description

Code

-- No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to Ground 22 TPS: Short Circuit to Battery 23 RAM Error: Defective ECU 42 Engine Temp Sensor Circuit: Short to Ground 42 Engine Temp Sensor Circuit: Open or Short to Battery 51 Injector 1: Open Load 51 Injector 1: Short Circuit to Ground 51 Injector 1: Short Circuit to Battery 52 Injector 2: Open Load 52 Injector 2: Short Circuit to Ground 52 Injector 2: Short Circuit to Battery 54 Engine Temp Lamp: Open Load 54 Engine Temp Lamp: Short Circuit to Ground 54 Engine Temp Lamp: Short Circuit to Battery 55 Diag Lamp: Open Load 55 Diag Lamp: Short Circuit to Ground 55 Diag Lamp: Short Circuit to Battery 56 Pump Relay: Open Load 56 Pump Relay: Short Circuit to Ground 56 Pump Relay: Short Circuit to Battery 58 Cooling Fan: Open Load 58 Cooling Fan: Short Circuit to Ground 58 Cooling Fan: Short Circuit to Battery 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage 41 Intake Air Temp Sensor: Short Circuit to Ground 61 END

OPERATION

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.

CAUTION

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.

OPERATION

Vehicle Break-In Period

The break-in period for your vehicle is defined on the previous page. Please read the information carefully.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 37.

2. Check the oil level. See page 83. 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 60-61.

NOTE: Avoid aggressive use of the brakes. See Brake System Break-in.

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

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 56.

6. Pull only light loads.

7. 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.

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition.

Item Remarks Page

Brake system/pedal travel Ensure proper operation 45

Brake fluid Ensure proper level 106

Front suspension Inspect, lubricate if necessary 80

Rear suspension Inspect, lubricate if necessary 80

Steering Ensure free operation 107

Tires Inspect condition and pressure 6

Wheels/fasteners Inspect, ensure fastener tightness 109

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels

Coolant level Ensure proper level 97

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 103

Indicator lights/switches Ensure proper operation 43

Air filter, pre-filter Inspect, clean 101

Headlamp Check operation, apply Polaris dielec-

Brake light/tail lamp Check operation, apply Polaris dielec-

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

tric grease when lamp is replaced

ensure the latches are secure

check latches for proper operation

proper installation

105

109

48 83

111

113

OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

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

2. Place the transmission in PARK.

3. Apply the brakes.

NOTE: Do not press the throttle pedal while starting the engine.

4. 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.

5. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 4 and 5 until the engine starts.

6. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.

CAUTION

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

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.

WARNING

A rolling vehicle can cause property damage and serious injury. Always place the transmission in PARK when stopping the engine.

OPERATION

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.

NOTE: When the throttle pedal is released completely and engine speed

Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury. Always slow down and allow additional braking distance when towing or hauling cargo.

slows to near idle, the vehicle has no engine braking.

WARNING

OPERATION

Parking the Vehicle

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. 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.

WARNING

A rolling vehicle can cause property damage and serious injury. Always place the transmission in PARK when stopping the engine.

1. Stop the vehicle on a level surface. Place the transmission in PARK.

2. Turn the engine off.

3. Remove the ignition switch key to prevent unauthorized use.

OPERATION

New Operator Driving Procedures

WARNING

Operating improperly can cause an accident or overturn which could result in severe injury or death. This vehicle handles differently than cars, trucks or other off-road vehicles. Operators of this vehicle must become familiar with vehicle handling at slow speeds before operating at faster speeds.

Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

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

experience with this vehicle.

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

3. Select an open area that allows room to familiarize yourself with vehicle operation and handling. Check your surroundings and determine your path of travel.

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

OPERATION

New Operator Driving Procedures

5. 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.

6. Check for upper cab net interference. See page 39.

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

8. 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 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.

OPERATION

Driving with a Passenger

1. Complete the New Operator Driving Procedures outlined on pages 60-61.

2. Perform the pre-ride inspection. See page 56.

3. Make sure the passenger is at least 12 years of age and is tall enough

to comfortably and safely sit in the passenger seat with the seat belt secured, put both feet on the floor and grasp the hand holds.

4. Make sure the passenger is wearing appropriate riding gear, includ-

ing an approved helmet and eye protection. See page 14.

5. Make sure the passenger secures the seat belt.

6. Make sure all cab nets are properly secured.

OPERATION

Driving with a Passenger

7. Allow a passenger to ride only in the passenger seat.

8. Do not carry more than one passenger. Additional passengers can affect the operator’s ability to steer and operate the controls.

9. Slow down. Always travel at a speed appropriate for your skills, your passenger's skills, and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger.

10. Vehicle handling may change with a passenger 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.

OPERATION

Driving on Slippery Surfaces

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

low these precautions:

1. Slow down when 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.

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

skid.

CAUTION

Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution when operating on slippery

surfaces.

OPERATION

Driving Uphill

Whenever traveling uphill, follow these

precautions:

1. Drive straight uphill.

2. Proceed at a steady

rate of speed and throttle opening. Avoid unnecessary changes in speed or direction.

3. Avoid steep hills

(15° maximum).

NOTE: If ascending a steeper grade is unavoidable, engage all-wheel drive

before ascending.

4. 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.

Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill.

Braking and handling are greatly affected when operating in hilly terrain. Improper operating procedures could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating

another vehicle or person could be on the other side of the hill.

15° maximum

WARNING

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid driving across the side of a hill. Control becomes difficult and there is an increased chance of vehicle overturn when driving on a hillside.

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.

WARNING

Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill. Avoid operating on steep hills (15° maximum).

OPERATION

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Slow down.

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

3. Travel straight downhill.

4. Apply the brakes lightly to aid in slowing.

WARNING

Traveling downhill improperly could cause loss of control or vehicle overturn. Always check the terrain carefully before descending a hill.

Never descend a hill at high speed. Excessive speed may result in loss of vehicle control and lead to serious injury or death. Always operate slowly when traveling downhill.

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

OPERATION

Driving Through Water

WARNING

The large tires on your vehicle may cause the vehicle to float in deep or fastflowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your vehicle.

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

1. Determine water depths and current before crossing.

2. Never operate in water

that exceeds the maximum recommended depth.

3. Choose a crossing where both banks have gradual inclines.

4. Proceed slowly, avoiding rocks and obstacles.

5. Wet brakes may have reduced stopping ability. To dry out the pads,

apply the brakes lightly several times while driving slowly.

NOTE: After running your vehicle in water, it's critical that you perform the ser-

vices outlined in the Periodic Maintenance Chart beginning on page

75. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil, and all grease fittings.

Floor Level

CAUTION

Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer for service. Do not start the engine.

If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 113, and take the vehicle to your dealer at the first opportunity.

OPERATION

Driving Over Obstacles

1. Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches.

2. Before operating in a new area, check for obstacles.

3. Avoid operating over large obstacles such as rocks and fallen trees.

If unavoidable, use extreme caution and operate slowly.

4. Always have a passenger dismount and move away from the vehicle

before operating over an obstacle that could cause an overturn.

WARNING

Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Reduce speed and travel with caution in unfamiliar terrain.

OPERATION

Driving in Reverse

Follow these guidelines 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.

WARNING

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly. Avoid making sharp turns.

OPERATION

Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Place the transmission in PARK.

2. Turn the engine off.

3. Block the rear wheels on the downhill side.

WARNING

A rolling vehicle can cause property damage and serious injury. Always place the transmission in PARK when stopping the engine. Always block the downhill side of the wheels if leaving the vehicle on a hill, or park the vehicle in a sidehill position instead.

OPERATION

Hauling Cargo

WARNING

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. 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.

WARNING

Driving with passengers in the cargo box can result in severe injury or death.

Never allow a passenger to ride in the cargo box. A passenger must always ride in the passenger seat with the seat belt fastened securely.

OPERATION

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 cargo. 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 126.

Belt Life

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

Towing Loads

WARNING

Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing:

Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. Towing

a trailer increases braking distance. Do not tow more than the recommended weight for the vehicle. 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.

Model Total Towed

RANGER

RZR

Load Weight

(Level Ground)

1500 lbs.

(681 kg)

Total Towed

Load Weight

(15° grade)

850 lbs. (386 kg)

To t al Hi t c h

Vertical

Weight

150 lbs.

(68.1 kg)

Maximum

To w in g

Speed

10 mph

(16 kph)

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 USDA Forest Service 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 8343. 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 European directives 97/24/EC and 89/336/

EEC.

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 137.

NOTE: Service and adjustments are important for proper vehicle operation. If

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.

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

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.)

Q Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Q Steering - Pre-Ride - Make adjustments as need

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

Coolant (if applicable)

Headlamp/tail lamp

XEAir filter,

main element

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

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

X Demand drive fluid 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

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Check level daily, change

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

(Km)

ed. See Pre-Ride Checklist on page 56.

as needed

coolant every 2 years

dielectric grease if replacing

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

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

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)

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

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

Q 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

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

50 H 6 M 300 (500) Inspect duct for proper seal-

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

50 H 6 M 500 (800) Inspect coolant strength

(Km)

filter change at one month

replace if necessary

ing/air leaks

cables, etc.

seasonally; pressure test system yearly

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

at one month

Remarks

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

Q Ignition timing 100 H 12 M 1000 (1600) Inspect

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

Q Clutches (drive

and driven)

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

Q Front wheel

bearings

Q 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

Q 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

Q 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

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

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 75, 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 Polaris Premium 4 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, Front/Rear

0W40

Premium AGL Synthetic Gearcase Lube

Demand Drive LT Premium Fluid

Fluid

Lube

Polaris Premium all Season Grease or grease conforming to NLGI No. 2

Add to proper level on dipstick. See page 83.

See page 106.

See page 88.

See page 86.

See page 90.

See page 91.

Locate fittings and grease.

Prop Shaft

Grease Fitting

Lubrication Recommendations

MAINTENANCE

Stabilizer Bar

Bushings

Control Arm

Pivot Bushings

MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always change the oil filter whenever changing oil.

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 128 for the part numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° to +120° F. (-40° to +49° C.). Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W-

40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified "SH" oil, 0W-40. Never substitute or mix oil brands. Use only 0W-40.

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.

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always use the recommended engine oil.

Oil Check

The oil dipstick and fill tube is located on the engine, behind the passenger seat.

1. Position the vehicle on a level surface.

2. Place the transmission in

PARK. Apply the brakes.

3. Start the engine. Allow it to idle

for 20-30 seconds. Stop the engine.

4. Remove both seats. Remove the

rear service panel. See page 35.

5. Lift the lever lock to remove the

dipstick. Wipe it dry with a clean cloth.

6. 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.

7. Remove the dipstick and check the

oil level. Maintain the oil level in the safe range. Do not overfill.

NOTE: 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.

8. Reinstall the dipstick. Seat the

lever lock.

Safe

Range

Dipstick

Safe

{

Check Level on Top Side

MAINTENANCE

Engine Oil

Oil and Filter Change

CAUTION

Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin.

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. 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.

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.

NOTE: 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).

Drain Plug

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.

MAINTENANCE

Gearcases

Transfer Case

Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications.

Fill Plug

Level

Check

Plug

Drain Plug

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.

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.

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

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 as

needed.

5. Reinstall the fill plug. Torque to

specification.

Fill Plug

MAINTENANCE

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 fill hole. Maintain the fluid level at 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.

Rear Gearcase

Drain Plug

Transfer Case

Drain Plug

Main Gearcase

Drain Plug

MAINTENANCE

Gearcases

Demand Drive Unit (Front Gearcase)

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

as needed.

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. Maintain the fluid level even with the

bottom thread of the fill plug hole.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

Fill Plug

Drain Plug

MAINTENANCE

Gearcases

Rear Gearcase

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 as needed.

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. Maintain the fluid level even with the

bottom thread of the fill plug hole.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

Fill Plug

Drain Plug

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See page 128 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 LT

Premium Fluid

Angle Drive Fluid

24 oz.

(710 ml)

14 oz.

(414 ml)

6.75 oz. (200 ml)

18 oz.

(532 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)

To r q u e

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)

MAINTENANCE

Spark Plugs

CAUTION

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 126.

Spark Plug Gap/Torque

Model Electrode Gap New Plug Torque Used Plug Torque

RANGER

RZR

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 94.

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

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

(24 Nm)

WARNING

18 ft. lbs.

(24 Nm)

MAINTENANCE

Spark Plugs

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.

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

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.

Spark Plug Removal and Replacement

1. Remove both seats.

2. Remove the rear service

3. Remove the spark plug cap.

4. Using the spark plug wrench

5. Reverse the procedure for

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

panel. See page 35.

provided in the tool kit, remove the plug by rotating it counterclockwise.

spark plug installation. Torque to specification. See page 93.

Spark Plugs

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.

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

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 128 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer's mixing recommendations for the

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.

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

freeze protection required in your area.

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 75. 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.

CAUTION

Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator's effectiveness. Using a high-pressure system is not recommended.

MAINTENANCE

Cooling System

Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart begin-

Radiator

Cap

ning on page 75. 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 37.

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.

NOTE: 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.

Coolant

Overflow

Bottle

Polaris Ranger RZR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual