Polaris RZR XP 900, RZR XP 4 900 User Manual

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RANGER

RZR XP

900

RANGER

RZR XP

Owner's Manual

for Maintenance and Safety

4 900

WARNING

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

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

WARNING

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

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

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:

• If you are under age 16 and without a valid driver’s license.

• without first viewing safety video and quick start guide.

• with more than one passenger in a 2-seat vehicle.

• with more than three passengers in a 4-seat vehicle.

• 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:

• Wear your seat belt. Vehicle rollover can cause severe injury or death.

• Secure cab nets and keep hands and feet inside vehicle at all times.

• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-anke boots.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

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

• Make sure passengers read and understand all safety labels.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGERS. NEVER USE ON PUBLIC ROADS. NEVER USE WITH DRUGS OR ALCOHOL.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924107 Rev 01 Printed in USA

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

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

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

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

POLARIS, RANGER, RANGER RZR and RANGER RZR XP are registered trademarks of POLARIS Industries Inc.

Copyright 2012 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.

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

Printed in U.S.A. 2013 RANGER RZR XP 900 / RANGER RZR XP 4 900 Owner’s Manual P/N 9924107

TABLE OF CONTENTS

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

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

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

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

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

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 120

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 124

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 125

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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

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

INTRODUCTION

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

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

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

CAUTION

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

NOTICE

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

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

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

INTRODUCTION

WARNING

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

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

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s license to operate this vehicle.

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

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

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

• Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course.

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

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

INTRODUCTION

Engine Serial

Number

Vehicle Identification Numbers

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

Vehicle Identification

Number

Vehicle Model Number: ___________________________________________________

Vehicle Identification Number: ______________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

####

Key

Number

SAFETY

Equipment Modifications

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

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

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

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

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.

Long

Sleeves

Long

Pants

Sturdy

Footwear

Gloves

Helmet

Eye

Protection

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

051039

0006.31

number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

Wear sturdy over-the-ankle boots. Do not ride a POLARIS vehicle with bare feet.

Clothing

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

SAFETY

WARNING

Safety Warnings

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

Operating Without Instruction

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

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

Operator Restrictions/Age Restrictions

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

Accessories

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

Using Alcohol or Drugs

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

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

SAFETY

Safety Warnings

Failure to Inspect Before Operating

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

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

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

Protective Apparel

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

Operator and all passengers must always wear a helmet, eye protection, gloves, longsleeve shirt, long pants and over-the-ankle boots.

Seat Belts

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

Cab Nets

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

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

Carrying Passengers (RZR XP 4)

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

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

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

SAFETY

Safety Warnings

Carrying Multiple Passengers (RZR XP)

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

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

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight

capacity is listed in the specifications section of this manual and on a label on the vehicle. When more passenger weight is added, cargo weight may need to be reduced accordingly.

• The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle.

Always follow these guidelines:

Under ANY of these conditions: Do ALL of these steps:

Passenger and/or cargo exceeds half the maximum weight capacity

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

SAFETY

Safety Warnings

Passengers in the Cargo Box

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

Operating on Pavement

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

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

Operating on Public Roads

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

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

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

Operating at Excessive Speeds

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

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

SAFETY

Safety Warnings

Turning Improperly

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

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

Physical Control of the Vehicle

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

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

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

Jumps and Stunts

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

Descending Hills Improperly

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

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

• Always check the terrain carefully before descending a hill.

• Never travel down a hill at high speed.

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

+15°

SAFETY

Safety Warnings

Improper Hill Climbing

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

Crossing Hillsides

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

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

Stalling While Climbing a Hill

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

If you lose all forward speed:

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

+15°

Operating in Unfamiliar Terrain

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

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

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

SAFETY

Safety Warnings

Operating Improperly in Reverse

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

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

Improper Tire Maintenance

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

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

Operating on Slippery Terrain

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

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

SAFETY

Safety Warnings

Operating Over Obstacles

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

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

Skidding or Sliding

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

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

Do not operate on excessively slippery surfaces.

Operating Through Water

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

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

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

SAFETY

Safety Warnings

Improper Cargo Loading

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

• Always follow the instructions in the owner's manual for carrying cargo.

• Never exceed the stated load capacity for this vehicle.

• Cargo should be properly distributed and securely attached.

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

Operating on Frozen Bodies of Water

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

Operating a Damaged Vehicle

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

SAFETY

Safety Warnings

Handling Gasoline

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

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box 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.

Refueling

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

Remove flammable material containers from the box before filling.

Exposure to Exhaust

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

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

Hot Exhaust Systems

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

Unauthorized Use of the Vehicle

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

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

SAFETY

Load/Passenger/Tire Pressure

Warning (in cargo box)

Safety Labels and Locations

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

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

Load/Passenger/Tire Pressure Warning

WARNING

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

• Never carry passengers in cargo box.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• 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.

RANGER RZR RZR 4 RZR XP RZR XP 4

MAXIMUM CARGO BOX LOAD 300 lbs.

TIRE PRESSURE IN PSI (KPa) FRONT 8 (55)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

(136 kg)

REAR 8 (55)

740 lbs. (336 kg)

300 lbs. (136 kg)

FRONT 10 (69)

REAR 12 (83)

900 lbs. (408 kg)

300 lbs. (136 kg)

FRONT 12 (83)

REAR 14 (97)

740 lbs. (336 kg)

FRONT 14 (97) REAR 16 (110)

300 lbs. (136 kg)

900 lbs. (408 kg)

Safety Labels and Locations

Passenger

Safety

Warning

Passenger Safety Warning (RZR XP)

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 hold.

THE PASSENGER MUST ALWAYS:

• wear seat belt.

• use an approved helmet and protective gear.

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

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

• keep hands and feet inside vehicle at all times.

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

7175102

SAFETY

PASSENGERS

UNDER

Safety Labels and Locations

Passenger Safety Warning (RZR XP 4)

WARNING

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

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

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

THE PASSENGERS MUST ALWAYS:

• wear seat belts.

• use approved helmets and protective gear.

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

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

• keep hands and feet inside vehicle at all times.

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

7176608

Safety Labels and Locations

Passenger Grab Bar

Warning

Passenger Cab Frame

Warning (both sides)

Rear Passenger Cab Frame Warning (RZR XP 4)

WARNING Do NOT hold onto this bar. Hands and arms

could be crushed or seriously injured in event of rollover.

ALWAYS keep hands on passenger grab bar.

7176700

Rear Passenger Grab Bar Warning (RZR XP 4)

Always use seat belt, helmet and eye protection.

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

7176701

SAFETY

Shift

Caution

Cab Frame/Seat

Belt Warning

Age

Warning

Overturn

Warning

Discretionary

Warning

Safety Labels and Locations

Cab Frame/Seat Belt Warning

WARNING

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

• ALWAYS SECURE CAB NETS.

• VEHICLE OVERTURN could cause severe injury or death.

Shift Caution

CAUTION

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

APPLY BRAKE TO START

7174843

SAFETY

Safety Labels and Locations

Age Warning

WARNING

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

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

Overturn Warning

WARNING

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

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

• avoid sharp turns.

• never turn while applying heavy throttle.

• never make abrupt steering maneuvers.

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

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

7175105

Belt Debris Warning

WARNING

Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH.

Always look for and remove debris inside and around the clutch and vent system when replacing the belt.

Read owner’s manual or see authorized POLARIS dealer.

7177469

SAFETY

Safety Labels and Locations

Discretionary Warning (RZR XP)

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER operate:

• without first viewing safety video and quick start guide.

• with more than one passenger.

• on hills steeper than 15 degrees.

• on public roads.

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

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

ALWAYS:

• keep hands and feet inside vehicle. Use the cab nets.

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

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

• make sure passenger reads and understands all safety labels.

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

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

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

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

7175104

Discretionary

Warning

SAFETY

Safety Labels and Locations

Discretionary Warning (RZR XP 4)

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER operate:

• without first viewing safety video and quick start guide.

• with more than three passengers.

• on hills steeper than 15 degrees.

• on public roads.

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

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

• keep hands and feet inside vehicle.

• reduce speed and use extra caution when carrying passengers.

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

• make sure passengers read and understand all safety labels.

• avoid branches or other hazards that could enter vehicle.

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

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

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

7176607

FEATURES AND CONTROLS

Component Locations

ROPS Frame

Cargo

Box

Brake Pedal

Fuel Tank

Cap

Cab

Nets

Steering

Wheel

Radiator

Hip

Bars

Front Passenger

Hand Hold

Throttle Pedal

Gear Selector

FEATURES AND CONTROLS

Component Locations

Rear Passenger

Grab Bar

Fuel Tank

Cap

Shifter

Cargo Box

Tie-Down

Points

FEATURES AND CONTROLS

Light

Switch

AWD

Switch

12V Accessory

Outlet

Ignition

Switch

Instrument

Cluster

Switches

Auxiliary Outlets

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

Ignition Switch

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

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

OFF The engine is off. Electrical circuits are off, except accessory 12V.

ON Electrical circuits are on. Electrical equipment can be used.

START Turn the key to the START position to engage the electric starter.

The key returns to the ON position when released.

FEATURES AND CONTROLS

Switches

Headlight Switch

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

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

All Wheel Drive (AWD) Switch

The AWD Switch has two positions:

• All Wheel Drive (AWD)

• Two Wheel Drive (2WD).

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

See page 40 for AWD operating instructions.

HIGH

LOW

AWD

2WD

FEATURES AND CONTROLS

Adjustment Lever

Seats

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

Seat Adjustments

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

Seat Removal

1. Pull up on the seat latch lever located under the rear edge of the seat.

2. Tilt the seat forward.

3. Lift the seat upward to

remove it from the vehicle.

4. Reverse this procedure to

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

5. Press down firmly at the

rear of the seat to engage the rear latch.

Front Seat

Retainer

Seat

Latch

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.

FEATURES AND CONTROLS

Passenger Hand Hold

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

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

2. Remove the pin from the post.

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

4. Reinstall the pin through the post mounting hole, adapter bushing hole, both post adjustment holes and lastly through the remaining bushing hole and post mounting hole.

5. Reinstall the retainer to the pin.

Adapter Bushing

Retainer

Adjustment

Post Mounting

Holes

FEATURES AND CONTROLS

Pressure

Cap

Overflow

Bottle

Hood Fasteners

Hood

Remove the hood to access the radiator pressure cap and coolant overflow bottle.

1. Turn the hood fasteners 1/4 turn.

2. Grasp the upper hood

edge and pull upward to disengage the fasteners.

3. Pivot the hood forward

and lift upward to disengage the lower hood hooks.

4. Lift the hood away from

the vehicle.

FEATURES AND CONTROLS

Service Access Panels

Engine Access Panel

The engine access panel is located behind the seats on the frame of the vehicle. Remove the seats and remove the access panel to reach serviceable engine components.

Cargo Box Access Panel

The cargo box access panel is located on the floor of the cargo box. Remove the panel to access the engine oil fill cap, spark plugs and air filter.

FEATURES AND CONTROLS

Fuel Cap

The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane.

Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

Remove flammable material containers from the box before filling.

Cab Nets

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

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

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

Fuel Cap

Cab Net Latches

FEATURES AND CONTROLS

Seat Belts

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

To wear the seat belt properly, follow this procedure:

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

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

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

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

Seat Belt Inspection

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

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

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

releases freely.

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

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

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

mild soap and water. Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden hose to flush out the retractor and latch housings regularly.

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.

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

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

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

Using Low Range

Always shift into low gear for any of the following conditions.

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

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

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.

This vehicle is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle pedal, engine speed will be limited, and power to the rear wheels will be reduced.

Brake Pedal

Rollover Protective Structure (ROPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OSHA

1928.53 rollover performance requirements. Always have your autho-

rized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover.

Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in vehicle rollover.

Throttle

Pedal

ROPS Label

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 4X4 indicator in the instrument cluster will be on.

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

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

Engaging AWD

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

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

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

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

AWD

2WD

FEATURES AND CONTROLS

Rider Information

Center

Speedometer

Indicator Lamps

MODE Button

Instrument Cluster

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

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

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

the instrument cluster.

Speedometer

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

Mode Button

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

FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

Over Temperature

Neutral This lamp illuminates when the transmission is in

High Beam This lamp illuminates when the headlamp switch is

Helmet/Seat Belt

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

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

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

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

neutral and the ignition key is in the ON position.

set to high beam.

This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating.

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

FEATURES AND CONTROLS

Trip 1

RPM

Instrument Cluster

Rider Information Center

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

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

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

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

fuel sensor circuit. See your dealer.

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

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

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

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

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

FEATURES AND CONTROLS

MODE Button

Instrument Cluster

Rider Information Center

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

Display Units (Standard/Metric)

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

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

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

Standard Display Metric Display Distance Miles Kilometers Fuel U.S. Gallons Liters, Imperial Gallons Tem per atur e Fahrenheit Celsius Time 12-Hour Clock 24-Hour Clock

1. Turn the key to the OFF position.

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

position.

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

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

5. Repeat the procedure to change remaining display settings.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

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

charged.

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

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

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

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

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

6. Turn the key to the OFF position.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

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

Trip Meter Mode

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

Hour Meter Mode

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

Engine Temperature Mode

This mode displays current temperature of the coolant.

Tachometer Mode

The engine RPM is displayed digitally.

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

changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Programmable Service Interval

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

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

2. Press and hold the MODE button.

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

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

Diagnostic Display Mode

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

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

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

Inactive codes are stored in the history of the unit.

FEATURES AND CONTROLS

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

Instrument Cluster

Rider Information Center

Engine Error Codes

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

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

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

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

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

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

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

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

OPERATION

WARNING

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

Vehicle Break-in Period

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

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

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

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

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 36. Always exercise extreme caution whenever handling gasoline.

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

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

3. Complete the New Operator Driving Procedures outlined on pages

56-57.

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

page 51.

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

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

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

7. Carry only light loads.

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

hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 25

hours of operation and every 100 hours thereafter.

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. Carry only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

If a belt fails, always clean any debris from the duct and from the engine compartment.

OPERATION

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 39

Brake fluid Ensure proper level 100

Front suspension Inspect, lubricate if necessary 74

Rear suspension Inspect, lubricate if necessary 74

Steering Ensure free operation 110

Tires Inspect condition and pressure 20

Wheels/fasteners Inspect, ensure fastener tightness 105

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 44

Coolant level Ensure proper level 89-90

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 98

Indicator lights/switches Ensure proper operation 30-31

Engine intake pre-filter Inspect, clean 94

PVT intake pre-filter Inspect, clean 94

Headlamp Check operation -

Brake light/tail lamp Check operation, apply POLARIS

Seat Latches Push down on both seat backs to

Seat Belts Check length of belt for damage,

Cab Nets Check for wear or damage, ensure

dielectric grease when lamp is replaced

ensure the latches are secure

check latches for proper operation

proper installation

105

107

OPERATION

Safe Operation Practices

1. Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course. Complete the New Operator Driving Procedures outlined on pages 56-57.

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

driver’s license to operate this vehicle.

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

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

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

run in an enclosed area.

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

on this vehicle.

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

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

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

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

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

cle.

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

Always maintain proper tire pressure.

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

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

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

first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your passenger, and your cargo, together with any other vehicles in your party.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

OPERATION

Starting the Engine

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

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

3. Place the transmission in PARK.

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

engine.

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

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

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

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

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

until the engine idles smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine

Stopping the Engine

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

2. Place the transmission in PARK.

3. Turn the engine off.

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

Braking

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

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

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

OPERATION

Parking the Vehicle

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

2. Place the transmission in PARK.

3. Turn the engine off.

4. Remove the ignition key to prevent unauthorized use.

Know Your Riding Area/Tread Lightly

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

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. 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.

OPERATION

New Operator Driving Procedures

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

2. Visit the Recreational Off-Highway Vehicle Association web site

(rohva.org) and take the free on-line training course.

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

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

experience with this vehicle.

5. Do not carry cargo during this period.

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

vehicle operation and handling.

7. The driver and all passengers must wear helmet, eye protection,

gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Always use the cab nets while riding in this vehicle.

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

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

10. Place the transmission in PARK.

11. Start the engine.

OPERATION

New Operator Driving Procedures

12. Apply the brakes and shift into low gear.

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

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

15. 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.

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

17. 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 Passengers

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

2. Perform the pre-ride

inspection. See page 52.

3. Do not carry more than

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

4. Make sure all passengers

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

5. The driver and all passengers must wear helmet, eye protection,

gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. See page 8.

6. Make sure all passengers secure their seat belts.

7. Make sure all cab nets are properly secured.

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

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

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

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

board. Allow more time and distance for braking.

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

and in this manual.

OPERATION

WARNING

Driving on Slippery Surfaces

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

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

Follow these precautions when encountering slippery conditions:

1. Slow down before entering slippery areas.

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

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

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

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

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

skid. Never apply the brakes during a skid.

Sideways

skid

Turn in

direction of

skid

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

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

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

3. Drive straight uphill.

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

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

6. Avoid unnecessary changes in speed or direction.

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

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

15° maximum

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

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

immediately turn downhill.

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

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

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid steep hills (15° maximum).

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

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

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

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

6. Apply the brakes lightly to aid in slowing.

OPERATION

Driving Through Water

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

1. Determine water depth and current before entering water.

2. Choose a crossing where the

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

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

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

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

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

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

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

Floor Level

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

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

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

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

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

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

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

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

OPERATION

Parking on an Incline

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

1. Place the transmission in PARK.

2. Turn the engine off.

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

OPERATION

WARNING

Hauling Cargo

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

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

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

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

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

stable driving conditions. Always operate the vehicle with extreme care when hauling cargo. 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. \

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 km/h) while cornering or while ascending or descending a hill.

OPERATION

Hauling Cargo

Your POLARIS vehicle has been designed to carry a specific capacity. 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 120.

Belt Life

To extend belt life, use low gear when hauling a heavy load at less than 7 MPH (11 km/h) for extended periods and when operating uphill at a slow speed.

EMISSION CONTROL SYSTEMS

Emissions Label

(on inside of frame tube)

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

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

Crankcase Emission Control System

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

Exhaust Emission Control System

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

The emissions label is located on the inside of the lower right frame tube (below front passenger foot area).

Electromagnetic Interference

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

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

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

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.

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

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 MPH (16 km/h). 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

• Frequent short trip operation in cold weather (engine frequently does

not operate long enough to reach full operating temperature)

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.

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

 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.)

D Have an authorized POLARIS dealer perform these services.

WARNING! Improperly performing the procedures marked with a “D” 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

Steering - Pre-Ride - Make adjustments as need

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake pedal travel

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

Engine oil level - Pre-Ride -

E Engine intake pre-filter - Daily - Inspect; clean often

PVT intake pre-filter - Daily - Inspect; clean often

Coolant - Daily - Check coolant level

Headlight/taillight - Daily - Check operation; apply

 Engine oil change

(break-in)

 Front gearcase

(demand drive) fluid

 Transmission (main

gearcase) oil

EAir filter 25 H Monthly - Inspect; replace as needed

(whichever comes first)

Hours Calendar Miles

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

25 H 1 M - Perform a break-in oil level

(Km)

ed. See Pre-Ride Checklist on page 52.

dielectric grease if replacing

filter change at one month

check

Remarks

DBrake pad wear 10 H Monthly 100 (160) Inspect periodically

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

EEngine breather filter

(if equipped)

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

25 H Monthly 150 (250) Inspect; replace if

test

necessary

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

 General

lubrication

DEThrottle cable 50 H 6 M 300 (500) Inspect; see dealer for

E Throttle body air

intake ducts/flange

 Engine oil change 50 H 6 M 1000 (1600) Perform a break-in oil change

 Oil filter change 50 H 6 M 1000 (1600) Replace with oil change

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

 Front Suspension 50 H 6 M 500 (800) Lubricate

 Rear Suspension 50 H 6 M 500 (800) Lubricate

Cooling system (if applicable)

 Front gearcase

(demand drive) fluid

 Transmission

(main gearcase) oil

DEFuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,

ESpark plugs 100 H 12 M 1000 (1600) Inspect; replace as needed,

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

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

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

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

50 H 6 M 500 (800) Inspect coolant strength

100 H 12 M 1000 (1600) Change fluid

(Km)

cables, etc.

service

sealing/air leaks

at one month

seasonally; pressure test system yearly

lines, filter, pump, throttle body

torque to specification

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

 Radiator

(if equipped)

 Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks

 Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

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

D Clutches (drive

and driven)

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

 Shock Seals 100 H - - Inspect shock seals

DShocks - 12 M 1500 (2400) See your dealer for oil

D Front wheel

bearings

 Coolant - 24 M - Replace coolant

D Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrester 200 H 24 M 2000 (3200) Clean out

Valve lash 200 H - 2000 (3200) Check; adjust as needed

ESpark plugs 500 H 36 M 5000 (8000) Replace, torque to

D Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

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

E Emission-Related Service D 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

change/seal inspection.

specification

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 69, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS and PS-4

Brake Fluid DOT 4 Maintain level between fill lines.

Transmission Oil (Main Gearcase)

Front Gearcase Fluid (Demand Drive)

Prop Shaft POLARIS Premium U-Joint

Front Control Arm Pivot Bushings

Stabilizer Bar Bushings POLARIS Premium all

Extreme Duty synthetic oils

Premium AGL Synthetic Gearcase Lube

Demand Drive Plus Fluid See page 82.

Lube

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

Season Grease or grease conforming to NLGI No. 2

Middle Prop Shaft

Grease Fitting

See page 76.

See page 100.

See page 80.

Grease middle and rear fittings.

Grease 3 fittings on each side of the vehicle.

Grease 2 fittings through the skid plate access holes located directly below the seat backs.

Fitting Access

(as viewed from top with

center floor panel removed)

Rear Prop Shaft

Grease Fitting

Lubrication Recommendations

Grease Stabilizer Bar Bushings

(one on each side of vehicle)

Front Control Arm Pivot

Bushings (3 per side)

View of Driver’s Side From Bottom of Vehicle

MAINTENANCE

Engine Oil

Oil Recommendations

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.

Ambient Temperature Range Recommended Oil

° F to +100° F

-35

(-37° C to +38° C)

° F to 120° F

(-18

° C to +49° C)

Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 124 for the part numbers of POLARIS products.

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

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

PS-4 PLUS Synthetic

4-Cycle Engine Oil

PS-4 Extreme Duty Synthetic

4-Cycle Engine Oil

MAINTENANCE

Oil Check

Oil Fill

Engine Oil

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

Oil Check

Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull.

Access the oil check dipstick through the service access panel behind the seats. Access the oil fill cap through the service access panel on the floor of the cargo box.

1. Position the vehicle on a level

surface.

2. Place the transmission in PAR K.

3. Start the engine and allow it to idle for 30 seconds.

4. Stop the engine and wait 15 seconds before removing the dipstick.

5. Remove the dipstick. Wipe it dry with a clean cloth.

6. Reinstall the dipstick completely. Remove the dipstick and check the oil level.

7. Remove the oil fill cap to add the recommended oil as needed. Maintain the oil level between the minimum and maximum marks on the dipstick. Do not overfill.

8. Reinstall the fill cap. Reinstall the dipstick.

MAINTENANCE

Oil Filter

Engine Oil

Oil and Filter Change

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

Access the oil check dipstick through the service access panel behind the seats. Access the oil fill cap through the service access panel on the floor of the cargo box.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole under the crankcase.

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

2. Clean the area around the crankcase drain plug.

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

3. Place a drain pan under the

engine crankcase and remove the drain plug. Allow the oil to drain completely.

4. Using an oil filter wrench,

turn the filter counter-clockwise to remove it.

5. Using a clean dry cloth, clean

the filter sealing surface on the crankcase.

MAINTENANCE

Engine Oil

Oil and Filter Change

6. 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.

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

8. Reinstall the crankcase drain plug. Torque to 12 ft. lbs. (16 Nm).

9. Remove the oil fill cap and add 2.5 quarts (2.4 l) of recommended oil. Reinstall the fill cap.

10. Start the engine and allow it to idle for 30 seconds.

11. Stop the engine and wait 15 seconds before removing the dipstick.

12. Remove the dipstick. Wipe it dry with a clean cloth.

13. Reinstall the dipstick completely. Remove the dipstick and check the oil level.

14. Add oil as necessary to bring the level to the upper mark on the dipstick. Do not overfill.

15. Reinstall the dipstick.

16. Reinstall the oil fill cap.

17. Dispose of used filter and oil properly.

MAINTENANCE

Transmission (Main Gearcase)

Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications.

Fluid Check

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

Fill Plug

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the fluid level.

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

5. Reinstall the fill plug. Torque to specification.

Transmission (Main Gearcase)

Drain Plug

(bottom view)

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

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

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

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

MAINTENANCE

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

to the bottom thread of the fill plug hole.

4. Reinstall the fill plug.

Torque to specification.

Fill Plug

MAINTENANCE

Drain Plug

(bottom view)

Demand Drive Unit (Front Gearcase)

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 oring is damaged, install a new oring.

5. Reinstall the drain plug. Torque to specification.

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

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See page 124 for the part numbers of POLARIS products.

Gearcase Lubricant Capacity Fill Plug

Transmission

(Main Gearcase)

Demand Drive

Unit (Front Gearcase)

Premium AGL

Synthetic

Gearcase Fluid

Demand Drive

Plus Fluid

44 oz.

(1300 ml)

6.75 oz.

(200 ml)

10-14 ft. lbs.

(14-19 Nm)

8-10 ft. lbs. (11-14 Nm)

Torq ue

Drain Plug

Torq ue

10-14 ft. lbs.

(14-19 Nm)

8-10 ft. lbs. (11-14 Nm)

Spark Plugs

Spark Plug Gap/Torque

Electrode Gap Spark Plug Torque

0.7-0.8 mm 7 ft. lbs. (10 Nm)

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

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 85.

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

damage. Always use POLARIS-recommended spark plugs. Refer to the specifications section beginning on page 120.

MAINTENANCE

Spark Plugs

Spark Plug Removal and Replacement

1. Remove the cargo box

access panel.

2. Clean the area around the spark plugs before removing the plugs.

3. Remove the spark plug caps.

4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counterclockwise.

5. Reverse the procedure for spark plug installation. Torque to specification. See page 84.

Spark Plug Condition

Normal Plug

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

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

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

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather.

MAINTENANCE

Fuses

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

Main Fuse Feature Supported

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

Power Fuse Feature Supported

30A Engine Control 30A Lights, Drive, Accessories

The main fuse box is located under the dash, above the brake and throttle pedals. Spare fuses are provided in the fuse box.

The power fuse box is located under the driver’s seat. Remove the engine access panel to access the fuse box.

Main

Fuse Box

Power

Fuse Box

Fuses

Step 3 - Cover removed

Step 1 - Lift tabs

Main Fuse Box

1. Lift up on the two fuse box tabs.

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

3. Remove the fuse box cover.

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

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

MAINTENANCE

Cooling System

The engine coolant level is maintained by the recovery system. The recovery system components are the overflow bottle, radiator vent fitting, radiator pressure cap and connecting hose.

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

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

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

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. See page 89 for changing procedure.

POLARIS recommends the use of POLARIS Premium 60/40 antifreeze/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 124 for the part numbers of POLARIS products.

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

protection required in your area.

Any time the cooling system has been drained for maintenance or repair, replace the coolant.

Radiator and Cooling Fan

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

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

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

MAINTENANCE

Bleed Screw

Pressure

Cap

Overflow

Bottle

Cooling System

Radiator Coolant Level/Changing Coolant

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

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

1. Remove the hood. See page

34.

2. Slowly remove the radiator pressure cap.

3. View the coolant level through the opening.

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

5. Before reinstalling the pressure cap, bleed the system of trapped air. Remove the engine access panel behind the seats and use a flatblade screwdriver to turn the bleed screw slightly, allowing the air to escape. Slowly add additional coolant to the radiator until air no longer escapes and only coolant flows from the bleed hole, then tighten the bleed screw.

6. Reinstall the pressure cap.

Tip: Use of a non-standard pres-

sure cap will not allow the recovery system to function properly. See your dealer for the correct replacement part.

MAINTENANCE

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). If the overflow bottle has run dry, the level in the radiator should also be inspected.

1. Position the vehicle on a level surface.

2. Remove the hood. See page

34.

3. View the coolant level in

the overflow bottle.

4. Remove the cap and use a

funnel to add coolant as needed to maintain the level between the two marks.

5. Reinstall the cap.

Tip: If coolant must be added

often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer.

Pressure

Cap

Overflow

Bottle

MAINTENANCE

WARNING

POLARIS Variable Transmission (PVT) System

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

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

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

• Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.

• See your dealer as recommended in the owner’s manual and on safety labels.

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

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

MAINTENANCE

Debris Basket

Remove ALL Debris

Insert hooked end of tool. Apply force to opposite end of

tool to spread sheaves.

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt.

WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death.

1. Remove the engine access cover and thoroughly clean all debris from the aluminum debris basket and from the engine compartment.

2. Remove the clutch cover

screws and open the clutch cover. (It does not have to be removed from the vehicle.) Remove all debris wrapped in and around the PVT system.

Tip: Use the shock/clutch tool from the

tool kit to slightly open the sheaves to aid in debris removal and belt installation.

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MAINTENANCE

Clutch Air Duct

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

3. Remove all debris from the entire clutch air duct passage.

4. Check for signs of damage to seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged.

Tip: Belt slip is responsible for

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

PVT Drying

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

1. Remove the clutch cover drain plug.

2. Allow the water to drain. Reinstall the drain plug.

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

4. Start the engine.

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

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

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

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

MAINTENANCE

PVT Intake Pre-Filter

Filter Systems

Fuel Tank Vent Filter

If the engine sputters, the inline fuel tank vent filter may be clogged. Do not attempt to clean the filter. Replace the filter with a new filter.

1. Remove the seats and remove the engine access panel.

Tip: Note the direction of the arrow

on the filter before removing it.

2. Remove the filter and install

the new filter. Make sure the direction of the arrow is the same as noted before filter removal.

3. Reinstall the access panel and seats.

Intake Pre-Filters

The engine intake pre-filter is located on the left side of the cargo box. The PVT intake pre-filter is located on the right side of the cargo box.

Inspect the pre-filters before each use of the vehicle. Remove the pre-filters and use compressed air to clean them frequently to ensure adequate air flow.

Fuel Tank Vent Filter

MAINTENANCE

Wing Nuts/Bolts

Air Filter

Cover Latches

Filter Systems

Air Filter

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

1. Remove the cargo box access panel.

2. Loosen the air box cover

wing nuts and rotate the bolts away from the cover.

3. Release the cover latches.

4. Pull the cover rearward far

enough to remove the air filter.

5. Inspect the air box for oil

or water deposits. Wipe away any deposits with a clean cloth.

6. Install a new filter if

needed. Do not attempt to clean the air filter.

7. Close the air box cover and

tighten the wing nuts securely.

MAINTENANCE

WARNING

Spark Arrester

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

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

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

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

Polaris RZR XP 900, RZR XP 4 900 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual