PMS 419 FOUR STROKE 2014 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.
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POLARIS® and RZR® are registered trademarks of POLARIS Industries Inc. Copyright 2013 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.
WELCOME Dear Parents: We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We encourage you to teach your children to ride safely, and to help ensure the future of recreational sports, please teach them to show respect for our environment and for the rights of others while operating the vehicle. This vehicle is not a toy and can be hazardous to operate.
WELCOME Dear Young Operators: Before you ride your new POLARIS vehicle, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you're riding. Your parents and POLARIS want you to be safe while you enjoy riding your new vehicle, and that's why it’s very important that you read this owner’s manual and watch the instructional video. Make sure you understand and follow all of the instructions and warnings in this owner’s manual and video.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Features and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Emission Control Systems . . . . . . . . . . . . . . . 52 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 92 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 follow 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. • Never operate this vehicle without proper instruction.
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. WARNING! Modifying this vehicle in any way can change the top speed, stability and handling performance of this vehicle. Modifications that increase speed, decrease stability or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death. Use only POLARIS-approved accessories to modify this vehicle.
SAFETY Safe Riding Gear The driver and passenger must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Eye Protection Long Sleeves Helmet Gloves Over-the-Ankle Boots Long Pants 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.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this 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.
SAFETY Safety Warnings WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your child's safety.
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. See page 38. Always follow the inspection and maintenance procedures and schedules described in this owner’s manual. See page 53.
SAFETY Safety Warnings 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. Carrying a Passenger Never carry a passenger until you have operated this vehicle for at least four hours and have completed the New Operator Driving Procedures outlined on pages 42-43.
SAFETY Safety Warnings 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 experience and your passengers’ skills and experience. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual.
SAFETY Safety Warnings Driving Downhill Improperly Driving down a hill improperly could cause loss of control or rollover. Always follow proper procedures for driving down a hill as described in this owner’s manual. See page 47. +15° Improper Hill Climbing Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner’s manual. See page 46.
SAFETY Safety Warnings Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover. 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. Crossing Hillsides Driving on a sidehill is not recommended.
SAFETY Safety Warnings Operating on Sand or Slippery Terrain Operating on sand or on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Always use extra caution when operating on sand or on rough, slippery or loose terrain. Do not operate on excessively rough, slippery or loose terrain. Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person.
SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Never attempt to operate over large obstacles such as large rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See page 49. Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident.
SAFETY Safety Warnings Overloading the Vehicle Overloading the vehicle or carrying/towing loads may cause changes in stability and handling, which could cause loss of control or an accident. • Never tow objects or carry loads with this vehicle. • Never exceed the maximum weight capacity for this vehicle. See page 23. Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident.
SAFETY Safety Warnings Refueling Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. • Never allow a child to refuel or handle gasoline. • Always stop the engine when refueling. • Always refuel outdoors or in a well ventilated area. • 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.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown 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.
SAFETY Safety Labels and Locations Rear Warning Label WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be operated: • without adult supervision. • by anyone under age 10. • with a passenger under age 10. • with a passenger whose feet cannot touch the floor. • without all occupants first viewing and understanding safety video and warning labels. • with more than one passenger. • on hills steeper than 15 degrees 15°.
FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger at all times. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized POLARIS dealer. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets.
FEATURES AND CONTROLS Component Locations Cab Frame Steering Wheel Running Lights Brush Guard Taillight/Brake Light Muffler (Spark Arrester) 25
FEATURES AND CONTROLS Seats Driver’s Seat Adjustment 1. Lift the seat latch lever located under the right front edge of the driver’s seat. 2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever. 3. Slide the seat forward and rearward to ensure the latch is engaged. Before operating the vehicle, always make sure both seats are securely installed. Seat Latch Lever Seat Removal 1. To remove the driver’s seat, lift the seat latch lever. 2.
FEATURES AND CONTROLS Steering Wheel The steering wheel can be adjusted upward or downward for rider preference. 1. Loosen the steering wheel adjustment bolt. 2. Move the steering wheel upward or downward to the desired position. 3. Tighten the bolt to 10 ft. lbs. (13.5 Nm). Adjustment Bolt Passenger Hand Hold Always adjust the hand hold to a comfortable position for your passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments. 1.
FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding. To wear the seat belt properly, follow Seat Belt this procedure: Buckles Seat Belt Latches 1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat.
FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness.
FEATURES AND CONTROLS 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 rollover. Adjusters/Latches Screw Cab nets must be used by both operator and passenger at all times. Make sure all latches are secure before operating the vehicle. Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS Fuel Cap Never allow a child to refuel or handle gasoline. The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. Use POLARIS Carbon Clean fuel treatment at each fill. Follow the Fuel Cap mixing directions on the container. Fuel Valve See page 94 for the part numbers of POLARIS products. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Non-ethanol fuel is recommended.
FEATURES AND CONTROLS Ignition Switch The ignition switch is a three-position, key-operated switch. Use the ignition switch to start the engine. See page 40 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.
FEATURES AND CONTROLS Gear Selector F: Forward N: Neutral R: Reverse The gear selector is located between the seats. 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 check that the throttle pedal returns norThrottle Brake mally before starting the engine. Pedal Pedal Make sure there's adequate throttle pedal freeplay. See page 70 for throttle pedal adjustment procedures.
FEATURES AND CONTROLS Speed Control System The speed of this vehicle is restricted to under 15 MPH (24 km/h) at manufacture. The speed limiting device may be adjusted by supervising adults when they determine that their child is capable of handling additional speed. The unrestricted top speed for this model is approximately 25 MPH (40 km/h). The adjustable throttle limiting screw is located behind the throttle pedal. Use the following procedure to control how far the throttle opens. 1. Loosen the jam nut.
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, 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 defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle gasoline. 2. Check the oil level. See page 59. 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 42-43. 4. Avoid aggressive use of the brakes. See Brake System Break-in below. 5. Vary throttle positions.
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. Complete the New Operator Driving Procedures outlined on pages 42-43. 2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that are designed for driving in these conditions. 3. Never tow objects or carry loads with this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never allow a child to handle gasoline. 5.
OPERATION Starting the Engine 1. 2. 3. 4. 5. 6. 7. Turn the fuel valve on. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. Place the transmission in neutral. Set the parking brake. Apply the brakes. Do not press the throttle pedal while starting the engine. 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.
OPERATION Stopping the Engine 1. 2. 3. 4. 5. Release the throttle pedal completely and brake to a complete stop. Place the transmission in neutral. Set the parking brake. Stop the engine. Turn the fuel valve off. 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.
OPERATION New Operator Driving Procedures 1. Read and understand this owner's manual and all warning and instruction labels before operating this vehicle. 2. Watch the instructional video with the supervising adult. 3. Review the section of this owner’s manual about starting the engine, stopping the engine, braking and parking (pages 40-41). 4. Perform the pre-ride inspection (page 38). 5.
OPERATION New Operator Driving Procedures 7. Select a level open area to practice driving. Make sure you have adult supervision and permission to drive in this area. 8. Sit in the driver's seat and fasten the seat belt. 9. Make sure all passengers secure their seat belts. 10. Make sure all cab nets are properly secured. 11. Do not carry a passenger until you have at least four hours of driving experience with this vehicle. See page 44. 12. Set the parking brake. 13. Place the transmission in neutral. 14.
OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on pages 42-43. 2. Perform the pre-ride inspection. See page 38. 3. Do not carry a passenger until you have at least four hours of driving experience with this vehicle. 4. Never operate with a passenger under age 10. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold. 5.
OPERATION Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding. Follow these precautions when driving in slippery conditions: 1. Slow down before entering slippery areas. 2. Be alert, watch the path ahead and avoid quick turns, which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. Never drive on hills with excessively slippery or loose surfaces. 2. Avoid excessively 15° maximum steep hills (15° maximum). 3. Drive straight uphill. 4. Drive at a steady rate of speed. Never press the throttle suddenly. 5. Avoid unnecessary changes in speed or direction. 6. Never go over the crest of a hill at a high speed.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or rollover. If crossing a hill is unavoidable, follow these precautions: 1. Drive slowly and use extreme caution. 2. If the vehicle begins to roll over, or if it feels as if it may roll over, immediately turn downhill. 3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide. 4.
OPERATION Driving Through Water Your vehicle can drive through shallow water. Make sure the water is no deeper than the floor of the vehicle. Follow these precautions when driving through water: 1. Check water depth. Never drive through water that is deeper than the floor level. 2. After driving through water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
OPERATION Driving Over Obstacles Follow these precautions when driving over obstacles: 1. Always check for obstacles before driving in a new area. 2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches. 3. Drive slowly and use extra caution when driving on unfamiliar terrain. Obstacles are not always clearly visible. 4. Do not drive over large obstacles such as large rocks and fallen trees. If it’s unavoidable, use extreme caution and drive slowly. 5.
OPERATION Driving in Reverse Follow these precautions when driving in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply 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 neutral. 2. Set the parking brake. 3. Stop the engine. 4. Turn the fuel valve off. 5. Always block the rear wheels on the downhill side.
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 106.
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Ź 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 Miles (Km) Steering - - Front suspension - - Rear suspension - - Tires - Brake fluid level - Daily - Brake pedal travel - - Brake system - - Wheels/fasteners - - Frame fasteners - - Engine oil level - - Ź Air filter E Remarks Check each day before driving the vehicle. Make adjustments as needed.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Ź Engine breather E filter (if equipped) 25 Monthly 150 (250) Inspect; replace if necessary Ź Engine oil change 30 6M 300 (480) Perform a break-in oil change at one month Ź General lubrication 50 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Hours Calendar Ź Engine mounts Exhaust muffler/ pipe Remarks (whichever comes first) Miles (Km) 100 12 M 1000 (1600) Inspect 100 12 M 1000 (1600) Inspect D Ignition timing 100 12 M 1000 (1600) Inspect Ź Wiring 100 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 53, 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.
MAINTENANCE Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. POLARIS recommends the use of POLARIS PS-4 Extreme Duty 10W-50 4-Cycle Oil for this vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. See page 94 for the part numbers of POLARIS products. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage.
MAINTENANCE Engine Oil Oil Change 1. 2. 3. 4. Position the vehicle on a level surface. Set the parking brake. Clean the area around the pre-filter plug. Start the engine. Allow it to idle for two to three minutes. Stop the engine. Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 5. Place a drain pan under the engine crankcase. 6. Remove the pre-filter plug. Allow the oil to drain completely. 7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry.
MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. POLARIS recommends the use of AGL Gearcase Lubricant & Transmission Fluid for this vehicle. Fluid Check Fill Plug The fill plug is located on the rear of the gearcase. Access the fill plug through the left rear wheel well. Maintain the fluid level at the bottom of the fill plug hole. 1. Position the vehicle on a level surface. 2.
MAINTENANCE Drive Chain Lubrication Lubricate the drive chain with POLARIS chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 53. Lubricate more often under severe use, such as in dirty or wet conditions. See page 94 for the part numbers of POLARIS products. NOTICE: Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure.
MAINTENANCE Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts (two on each side). 2. Loosen the chain adjuster lock nuts. 3. Turn the chain adjusters clockwise to 1/4"-1/2" (6-12 mm) deflection. 4. Tighten the chain adjuster lock nuts to 18 ft. lbs. (25 Nm). Hold the adjuster stud securely while tightening the nut to avoid breaking the stud. 5. Tighten the four rear housing mount bolts to 43 ft. lbs. (60 Nm).
MAINTENANCE Parking Brake Cable Freeplay Adjustment 1. Inspect and perform any needed service on the brake pads before adjusting parking brake cable freeplay. 2. Make sure the parking brake is NOT set (lever is DOWN). 3. Pull the brake cable back to inspect freeplay between the cable end and the caliper bracket. Freeplay should be 1/16" - 1/8" (1.5-3 mm). 4. To adjust freeplay, loosen the jam nut. Turn the in-line adjuster nut outward to decrease freeplay. Turn the adjuster nut inward to increase freeplay.
MAINTENANCE Spark Plugs Spark Plug Gap/Torque Electrode Gap 0.6-0.7 mm New Plug Torque 9-11 ft. lbs. (12-15 Nm) Used Plug Torque 17-20 ft. lbs. (23-27 Nm) NOTICE: Using non-recommended spark plugs can result in serious engine damage. Use POLARIS-recommended spark plugs. See page 92. 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.
MAINTENANCE Constant Variable Transmission (CVT) 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 CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Access the air box through the access cover on the forward surface of the rear body panel. 1. Move or remove the storage bag. Remove the four (4) access cover fasteners to remove the access cover. 2. Release the air box cover spring clips and remove the cover. 3. Loosen the air filter clamp. Remove the air filter. 4.
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 service on the spark arrester while the system is hot. Allow components to cool sufficiently before proceeding. • Wear eye protection and gloves. • Never operate without the spark arrestor. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
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 Throttle System Throttle Freeplay Adjustment Access the throttle cable adjuster through the right front wheel well. 1. Slide the cable adjuster boot off the cable adjuster. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Move the cable adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the throttle pedal. See page 69. While adjusting, lightly flip the throttle pedal up and down. 5.
MAINTENANCE Carburetor Your POLARIS vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 8,000 feet (2400 m) and temperatures above 0° F (-18° C). Refer to the specifications section beginning on page 92 for carburetor and jetting specifications. Any jetting changes must be made only by an authorized POLARIS dealer. Always see your dealer if jetting changes are needed.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 34. 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 73 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 94 for the part numbers of POLARIS products. 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 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 53. 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 the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer.
MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer. 1. Position the vehicle on a level surface. 2. Set the handlebars in a straight-ahead position and secure them in this position. 2 3.
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 Installation 1. Place the transmission in neutral. 2. Set the parking brake. 3. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 4. Attach the wheel nuts and finger tighten. 5. Carefully lower the vehicle to the ground. 6. Torque the wheel nuts to specification. Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death.
MAINTENANCE Lights Daytime Running Lights Lamp Replacement If the daytime running lights do not operate, replace the lamps. POLARIS recommends that you install replacement lamps obtained from your authorized POLARIS dealer. 1. Disconnect the lights from the harness. 2. Remove the rubber cover from the back of the light assembly. 3. Press the lamp retainer inward and turn it counter-clockwise to remove it. Note the position of the lamp positioning tab, then carefully pull the lamp out. 4.
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. Turn the fuel valve off. 3. Check the air box. If water is present, dry the air box and replace the filter with a new filter. Thoroughly dry the air pre-filter.
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. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
MAINTENANCE Battery Battery Removal 1. Remove the driver’s seat. See page 26. 2. On conventional batteries, remove the battery vent tube (sealed batteries do not have a vent tube). 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
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 84 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. On conventional batteries, install the battery vent tube. The vent tube must be free of obstructions and securely installed.
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 84. Tip: Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 81. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 82. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) 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.
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. Before washing the vehicle, locate the CVT inlet and outlet ducts. The ducts are located under the rear wheel wells. Avoid spraying water directly toward the ducts when washing the vehicle from the rear. NOTICE: Water in the CVT system could cause the drive belt to become wet and slip in the clutches.
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 Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
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 86. 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 53. Fog the Engine Use POLARIS Engine Fogging Oil. Follow label directions carefully. Battery Maintenance See pages 83-85 for storage and charging procedures. Storage Area/Covers Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials.
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Place the transmission in neutral. Set the parking brake. 2. Stop the engine. 3. Turn the fuel valve off. 4. Remove the key to prevent loss during transporting. 5. Secure the fuel cap and seats. Ensure that the seats are attached correctly and are not loose. NOTICE: Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope.
SPECIFICATIONS RZR 170 Maximum Rider Weight Maximum Weight Capacity Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Engine Type Displacement Cooling Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Air Screw Jet Needle Starting System Ignition System Spark Plug / Gap Front Suspension Rear Suspension Lubrication System Driving System Type Final Drive Shift Type 92
SPECIFICATIONS RZR 170 Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Parking Brake Daytime Running Lights Brake Light 19x7-8 20x10-9 3 psi (20.7 kPa) 3 psi (20.7 kPa) Foot Activated, 4-wheel hydraulic disc Mechanical, Rear (Lever) Dual, Standard Standard Jetting Chart Carburetor Jetting *Shaded cells indicate factory settings.
POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving at low RPM or ground speed Drive at a higher speed. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes. With the transmission in neutral, apply small amount of throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Slow/easy clutch engage- Use the throttle quickly and effectively.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections 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 vent line Overuse of choke 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 Electronic throttle control malfunction Other mechanical failure 98 Solution Refuel Inspect and replace Inspect, clean and/or replace spark plugs Replace with new fuel Inspect,
WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • • • • • • • • • • • Wheels and tires Suspension
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 From 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 PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
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.
WARRANTY U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 107
INDEX A C Air Filter . . . . . . . . . . . . . . . . . . . . . 67 Arrester, Spark, Warning. . . . . . . . . 68 Constant Variable Transmission . . . . 66 Corrosion Removal, Chrome. . . . . . . 88 Cover for Storage. . . . . . . . . . . . . . . . 90 Crankcase Emission Control System. 52 CVT Break-In . . . . . . . . . . . . . . . . . . 37 CVT Drying. . . . . . . . . . . . . . . . . . . . 66 CVT System . . . . . . . . . . . . . . . . . . . 66 B Battery . . . . . . . . . . . . . . . . . . . .
INDEX F Filling the Battery . . . . . . . . . . . . . . . Filter Care During Storage . . . . . . . . Filter Cleaning, Air . . . . . . . . . . . . . . Filter Systems . . . . . . . . . . . . . . . . . . Filter, Air . . . . . . . . . . . . . . . . . . . . . Fluid, Main Gearcase . . . . . . . . . . . . Fluid, Transmission . . . . . . . . . . . . . Fluid Levels During Storage. . . . . . . Fluid, Battery . . . . . . . . . . . . . . . . . . Fluid, Brake . . . . . . . . . . . . . . . . . . . Fogging the Engine . .
INDEX P S Parking Brake Adjustment. . . . . . . . 64 Parking on an Incline . . . . . . . . . . . . 51 Parking the Vehicle . . . . . . . . . . . . . 41 Passenger Hand Hold Adjustment . . 27 Periodic Maintenance Chart . . . . 53-57 Plug Condition . . . . . . . . . . . . . . . . . 65 Plug Gap . . . . . . . . . . . . . . . . . . . . . 65 Plug Torque . . . . . . . . . . . . . . . . . . . 65 Plugs, Fouled . . . . . . . . . . . . . . . . . . 65 Plugs, Spark . . . . . . . . . . . . . . . . . . .
INDEX S V Storage . . . . . . . . . . . . . . . . . . . . 86-90 Storage and Inspection . . . . . . . . . . . 90 Storage and Lubrication . . . . . . . . . . 90 Storage Area . . . . . . . . . . . . . . . . . . . 90 Storage, Battery . . . . . . . . . . . . . . . . 83 Storage, Covers . . . . . . . . . . . . . . . . . 90 Storage, Fluid Levels . . . . . . . . . . . . 89 Storage, Oil Change . . . . . . . . . . . . . 89 Storage, Removal . . . . . . . . . . . . . . . 90 Vehicle Identification Numbers . . . . .
PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be operated: • without all occupants first viewing and understanding safety video and warning labels. • with more than one passenger. • on hills steeper than 15 degrees 15 . • on paved surfaces - pavement may seriously affect handling and control. • with non-Polaris approved accessories - they may seriously affect stability.
