RANGER RZR XP® 900 RANGER RZR XP® 4 900 Owner's Manual for Maintenance and Safety
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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.
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.
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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 28 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Emission Control Systems . . . . . . . . . . . . . . . 68 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 120 POLARIS Products.
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.
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.
INTRODUCTION 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.
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.
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 Eye Protection Long Pants Sturdy Footwear Gloves Helmet 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.
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.
SAFETY Safety Warnings WARNING 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.
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.
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.
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.
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.
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. +15° 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.
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.
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).
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.
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.
SAFETY 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.
SAFETY 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.
SAFETY 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.
SAFETY Safety Labels and Locations 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. Passenger Cab Frame Warning (both sides) 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.
SAFETY Safety Labels and Locations Age Warning Overturn Warning Discretionary Warning Cab Frame/Seat Belt Warning Shift Caution 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.
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.
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.
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.
FEATURES AND CONTROLS Component Locations ROPS Frame Cab Nets Cargo Box Steering Wheel Radiator Fuel Tank Cap Hip Bars Front Passenger Hand Hold Brake Pedal Throttle Pedal 28 Gear Selector
FEATURES AND CONTROLS Component Locations Rear Passenger Grab Bar Fuel Tank Cap Shifter Cargo Box Tie-Down Points 29
FEATURES AND CONTROLS Switches Ignition Switch Light Switch Instrument Cluster AWD Switch 12V Accessory Outlet 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.
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.
FEATURES AND CONTROLS 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.
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.
FEATURES AND CONTROLS 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.
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.
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. Gear Selector Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.
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 Throttle Brake check that the throttle pedal Pedal 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.
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.
FEATURES AND CONTROLS 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.
FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Vehicle Speed Condition When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. Over Temperature This lamp illuminates to indicate an overheated engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.
FEATURES AND CONTROLS 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.
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.
FEATURES AND CONTROLS 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. MODE Button 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.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 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.
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.
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.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays Number (SPN) Number (0-9) 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
OPERATION Driving on Slippery Surfaces WARNING 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.
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.
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.
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.
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.
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 Hauling Cargo WARNING 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.
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.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.
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.
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.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Remarks Miles (Km) Steering - Pre-Ride - Front suspension - Pre-Ride - Rear suspension - Pre-Ride - Tires - Pre-Ride - Brake fluid level - Pre-Ride - Make adjustments as need ed. See Pre-Ride Checklist on page 52.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) General lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Hours Calendar Radiator (if equipped) Remarks (whichever comes first) 100 H 12 M Miles (Km) 1000 (1600) Inspect; clean external surfaces Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks Engine mounts 100 H 12 M 1000 (1600) Inspect 100 H 12 M 1000 (1600) Inspect Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
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 Extreme Duty synthetic oils See page 76. Brake Fluid DOT 4 Maintain level between fill lines. See page 100.
MAINTENANCE Lubrication Recommendations View of Driver’s Side From Bottom of Vehicle Grease Stabilizer Bar Bushings (one on each side of vehicle) Front Control Arm Pivot Bushings (3 per side) 75
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.
MAINTENANCE 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.
MAINTENANCE 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.
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.
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. 2. 3. 4. Position the vehicle on a level surface. Remove the fill plug.
MAINTENANCE Transmission (Main Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean the drain plug. 5. Reinstall the drain plug with a new o-ring. Torque to specification. 6. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill. 7.
MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the demand drive unit. Maintain the fluid level even with the bottom thread of the fill plug hole. 1. Position the vehicle on a level surface. 2.
MAINTENANCE 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.
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 Transmission (Main Gearcase) Premium AGL Synthetic Gearcase Fluid Demand Drive Plus Fluid Demand Drive Unit (Front Gearcase) 44 oz. (1300 ml) Fill Plug Torque 10-14 ft. lbs. (14-19 Nm) Drain Plug Torque 10-14 ft. lbs. (14-19 Nm) 6.75 oz. (200 ml) 8-10 ft. lbs. (11-14 Nm) 8-10 ft. lbs.
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 Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown.
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.
MAINTENANCE Fuses 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.
MAINTENANCE 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.
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 Overflow level surface. Pressure Bottle Cap 2. Remove the hood. See page 34. 3.
MAINTENANCE POLARIS Variable Transmission (PVT) System WARNING 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.
MAINTENANCE 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. Debris Basket 2.
MAINTENANCE 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.
MAINTENANCE 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 Fuel Tank Vent Filter the direction of the arrow is the same as noted before filter removal. 3.
MAINTENANCE 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 Wing Nuts/Bolts 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. Cover Latches 6.
MAINTENANCE Spark Arrester WARNING 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.
MAINTENANCE Spark Arrester Periodically clean the spark arrester to remove accumulated carbon. 1. Remove the arrester retaining bolt and nut. 2. Remove the arrester from the end of the muffler. 3. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 4. Inspect the screen for wear and damage. Replace a worn or damaged screen. 5. Reinstall the arrester. Torque bolt to 9-11 ft. lbs. (12-15 Nm).
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 39. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 100 for brake fluid information.
MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 124 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE Suspension Settings Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. Fox Shock Preload Measurement Walker Evans Front Shock Preload Measurement Walker Evans Rear Shock Preload Measurement Factory Preload Settings RZR XP Premium Front RZR XP Premium Rear RZR XP 4 Front RZR XP 4 Rear 7.625” (193.7 mm) 3.625” (92.1 mm) 6.560” (166.6 mm) 0.940” (23.
MAINTENANCE Suspension Settings Front/Rear Spring Preload Fox Shock Preload Adjustment Follow these guidelines if you make adjustments to this suspension. • Always return the suspension to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. • Always apply the same adjustment setting to all four wheels. • Do not increase the spring preload by more than one inch (25.
MAINTENANCE Suspension Settings Front/Rear Spring Preload Walker Evans Shock Preload Adjustment Follow these guidelines if you make adjustments to this suspension. • Always return the suspension to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. • Always apply the same adjustment setting to all four wheels. • Do not increase the spring preload by more than one inch (25.
MAINTENANCE Suspension Settings Front/Rear Shock Compression The compression damping clicker knob is located on top of the shock reservoir. When the knob is turned clockwise until it stops, the damping is in the fully closed position. 1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression damping.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel in the correct position on the wheel hub.
MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out. Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position.
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward and to the left or right. 1. Position the vehicle on a level surface. The headlight should be approximately 25 ft. (7.6 m) from a wall. 25 ft. (7.6 m) X X 2 in. (5 cm) 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 4. Apply the brakes. Start the engine. Turn the headlights to high beam. 5.
MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land. 2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. 3.
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or if the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer.
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Your vehicle has a sealed battery, which requires little maintenance. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 113 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Coat the terminals with dielectric grease or petroleum jelly. 4. Secure the battery hold-down strap. 5.
MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. A sealed battery must always be maintained with a full charge.
MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos. from date of manufacture May need slight charge, if no charge given, check in 3 months Needs charge Needs charge 0%-25% 11.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: Water in the PVT system could cause the drive belt to become wet and slip in the clutches. Always avoid spraying water directly toward any intake prefilters. PVT Intake Pre-Filter High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 115. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 69. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of engine oil.
MAINTENANCE Cleaning and Storage Removal from Storage 1. 2. 3. 4. Charge the battery if necessary. Make sure the spark plug is tight. Fill the fuel tank with fuel. Check all the points listed in the Daily Pre-Ride Inspection section on page 52. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 69.
SPECIFICATIONS RANGER RZR XP 900 Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 120 1930 lbs. (875 kg) 1190 lbs. (540 kg) 300 lbs.
SPECIFICATIONS RANGER RZR XP 900 Lubrication System Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump Automatic POLARIS Variable Transmission Dual Range P/R/N/L/H 6.45:1 5.776:1 3.037:1 3.82:1 3.53:1 27x9-12 27x11-12 12 psi (82.
SPECIFICATIONS RANGER RZR XP 4 900 Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 122 2375 lbs. (1077 kg) 1390 lbs. (630.5 kg) 300 lbs.
SPECIFICATIONS RANGER RZR XP 4 900 Lubrication System Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump Automatic POLARIS Variable Transmission Dual Range P/R/N/L/H 6.45:1 5.776:1 3.037:1 3.82:1 3.53:1 27x9-12 27x11-12 14 psi (96.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878920 2878922 2878919 2878068 2878069 2871653 2872276 2870465 2877922 2877923 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 124 Description Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 PLUS Synthetic 4-Cycle Engine Oil (qt./.95 l) PS-4 PLUS Synthetic 4-Cycle Engine Oil (gal./3.8 l) PS-4 Extreme Duty Synthetic 4-Cycle Oil (qt./.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH/ 5-11 km/h) Insufficient warm-up at low ambient temperatures Solution Use low range during loading. Use low range. See warnings on page 60. Drive at a higher speed or use low range more frequently. See page 38. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Mechanical failure Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent lin
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel tank vent line or filter Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Overheated engine 128 Solution Refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plug See your dealer Set gap to specs
WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a POLARIS dealer.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in f
WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
WARRANTY How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE 138 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 139
INDEX A C Access Panel Cargo Box . . . . . . . . . . . . . . . . 35 Engine . . . . . . . . . . . . . . . . . . . 35 Oil Tank . . . . . . . . . . . . . . . . . . 35 Accessory Outlets . . . . . . . . . . . . . . 30 Adjustments Hand Hold . . . . . . . . . . . . . . . . 33 Seat . . . . . . . . . . . . . . . . . . . . . 32 Steering Wheel. . . . . . . . . . . . . 32 Age Restrictions. . . . . . . . . . . . . . . . 10 Air Filter . . . . . . . . . . . . . . . . . . . . . 95 Air Filter Cleaning. . . . . . . . . . .
INDEX E F Electromagnetic Interference . . . . . . 68 Emission Control, Crankcase . . . . . . 68 Emission Control, Exhaust . . . . . . . . 68 Emission Control, Noise . . . . . . . . . . 68 Emissions Limited Warranty . 135-136 Engaging AWD. . . . . . . . . . . . . . . . . 40 Engine Access Panel . . . . . . . . . . . . . 35 Engine Break-In . . . . . . . . . . . . . . . . 51 Engine Fogging. . . . . . . . . . . . . . . . 118 Engine Idle Speed . . . . . . . . . . . . . . . 98 Engine Intake Pre-Filter . . . . .
INDEX I O Idle Speed . . . . . . . . . . . . . . . . . . . . 98 Ignition Switch. . . . . . . . . . . . . . . . . 30 Indicator Lamps . . . . . . . . . . . . . . . . 42 Inspection, Axle Nuts . . . . . . . . . . 105 Inspection, Brakes . . . . . . . . . . . . . . 99 Inspection, Pre-Ride . . . . . . . . . . . . 52 Inspection, Steering Wheel . . . . . . 110 Inspection, Wheel Nuts . . . . . . . . . 105 Installation, Battery . . . . . . . . . . . . 112 Installation, Wheels . . . . . . . . . . . .
INDEX R S Radiator. . . . . . . . . . . . . . . . . . . . . . . 88 Radiator Coolant Level . . . . . . . . . . . 89 Removing Vehicle from Storage . . 119 Restrictions, Age. . . . . . . . . . . . . . . . 10 Reverse . . . . . . . . . . . . . . . . . . . . . . . 64 Rider Information Center . . . . . . 43-49 Riding Area. . . . . . . . . . . . . . . . . . . . 55 Riding Gear. . . . . . . . . . . . . . . . . . . 8-9 Rollover Protective Structure . . . . . . 39 ROPS Cab Frame . . . . . . . . . . . . . . .
