Polaris Offroad Vehicle RZR 4 800 User Manual

PMS 419

RZR

800

RZR

S 800

4 800

RZR

Owner's Manual

for Maintenance and Safety

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WARNING

Read, understand, and follow all of the instructions and safety precautions in

this manual and on all product labels.

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

WARNING

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

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

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WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our

world-wide family of POLARIS enthusiasts. Be sure to visit us online at

www.polaris.com for the latest news, new product introductions,

upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and

recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

• GEM® electric vehicles

We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your POLARIS vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Review the

safety DVD that came with your vehicle. Polaris also recommends that

all drivers take the ROHVA safety e-course and a ROHVA hands-on

safety training course (www.rohva.org).

Your manual contains instructions for minor maintenance, but informa-

tion about major repairs is outlined in the POLARIS Service Manual

and should be performed only by a factory certified Master Service

Dealer® (MSD) Technician.

Your POLARIS dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser-

vice needs during, and after, the warranty period.

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POLARIS® and RZR® are registered trademarks of POLARIS Industries Inc.

is based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor

discrepancies may result between the actual vehicle and the information presented in

this publication. Depictions and/or procedures in this publication are intended for

reference use only. No liability can be accepted for omissions or inaccuracies. Any

reprinting or reuse of the depictions and/or procedures contained within, whether whole

or in part, is expressly prohibited.

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

translations of the original instructions.

Printed in U.S.A.

2014 RZR 800 / RZR S 800 / RZR 4 800 Owner’s Manual

P/N 9924707

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TABLE OF CONTENTS

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

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

Features and Controls. . . . . . . . . . . . . . . . . . . 25

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Emission Control Systems . . . . . . . . . . . . . . . 76

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 132

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 136

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 137

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 148

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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INTRODUCTION

The RZR is an off-road vehicle. Familiarize yourself with all laws and

regulations concerning the operation of this vehicle in your area.

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and sym-

bols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in

death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in

minor or moderate injury.

NOTICE

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

The Prohibition Safety Sign indicates an action NOT to take in order

to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be

taken to avoid a hazard.

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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 and review the safety DVD that came with your

vehicle. A free extra copy of the DVD can be obtained by contacting your local

POLARIS dealer. Understand all safety warnings, precautions and operating

procedures before operating the vehicle. Keep this manual with the vehicle.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and

have a valid driver’s license to operate this vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. All rid-

ers 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.

• Always use the cab nets (or doors) while riding in this vehicle. Always keep

hands, feet and all other body parts inside the vehicle at all times.

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants

and over-the-ankle boots.

• Never use this vehicle with drugs or alcohol, as these conditions impair judg-

ment and reduce operator reaction time.

• Complete the New Operator Driving Procedures outlined on pages 52-53.

Never allow a guest to operate this vehicle until the guest has completed the

New Operator Driving Procedures.

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this

machinery is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as

indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many

factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

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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.

Key

Number

####

Engine Serial Number

Vehicle Identification Number Stamp

(Left Rear Fender Area Near Air Box)

Manufacturing Data Label

(Right Front Fender Area)

Vehicle Model Number: ___________________________________________________

Vehicle Identification Number: ______________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

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SAFETY

Safety Training

Safety training is a top priority for POLARIS. POLARIS strongly

encourages you and any family members who will be riding this vehicle

to take a training course.

ROHVA (Recreational Off-Highway Vehicle Association) provides both

an online safety e-course and a hands-on safety course. To access this

valuable training, visit www.rohva.org.

Your POLARIS vehicle is considered an off-road vehicle. Familiarize

yourself with all laws and regulations concerning the operation of this

vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance

program outlined in your owner's manual. This preventive maintenance

program is designed to ensure that all critical components on your

vehicle are thoroughly inspected at specific intervals.

For more information about recreational off-road vehicle safety in

the United States, visit www.rohva.org or call POLARIS at 1-800-

342-3764.

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SAFETY

Safe Riding Gear

The driver and all passengers must wear helmet, eye protection, gloves,

long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all

times. Protective gear reduces the chance of injury.

Long

Sleeves

Eye

Protection

Long

Pants

Over-the-Ankle

Boots

Gloves

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding this

POLARIS vehicle, always wear a helmet that meets or exceeds estab-

lished safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

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SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever 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.

Boots

Wear sturdy over-the-ankle boots for support and protection. Never ride

a POLARIS vehicle with bare feet or sandals.

Clothing

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

Rider Comfort

Under certain operating conditions, heat generated by the engine and

exhaust system can elevate temperatures in the driver and passenger cab

area. The condition occurs most frequently when a vehicle is being

operated in high ambient temperatures at low speeds and/or high load

conditions for an extended period of time. The use of certain wind-

shield, roof and/or cab systems may contribute to this condition by

restricting airflow. Any discomfort due to heat buildup in this area can

be minimized by wearing proper riding apparel and by varying speeds to

increase airflow.

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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, con-

tact your POLARIS dealer to purchase a replacement. Replacement

safety labels are provided by POLARIS at no charge. The part number is

printed on the label.

Load/Passenger/Tire Pressure Warning

WARNING

• Passengers can be thrown off. This can

cause serious injury or death.

Load/Passenger/Tire Pressure

Warning

• Never carry passengers in cargo box.

WARNING

IMPROPER TIRE PRESSURE OR

OVERLOADING CAN CAUSE LOSS OF

CONTROL RESULTING IN SERIOUS

INJURY OR DEATH.

• Reduce speed and allow greater

distance for braking when carrying

cargo.

• Overloading or carrying tall, off-center,

or unsecured loads will increase your

risk of losing control. Loads should be centered and carried as low as

possible in box.

• For stability on rough or hilly terrain, reduce speed and cargo.

• Be careful if load extends over the side of the box.

RZR

RZR S

RZR 4

MAXIMUM CARGO BOX LOAD

TIRE PRESSURE IN PSI (KPa)

300 lbs.

(136 kg)

300 lbs.

(136 kg)

300 lbs.

(136 kg)

1 RIDER

FRONT 8 (55)

REAR 10 (69)

FRONT 10 (69)

REAR 10 (69)

FRONT 12 (83)

REAR 14 (97)

2 RIDERS

FRONT 10 (69)

REAR 12 (83)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR,

PASSENGER, CARGO AND

ACCESSORIES

740 lbs.

(336 kg)

740 lbs.

(336 kg)

900 lbs.

(408 kg)

Read Operation and Maintenance Manual for more detailed loading information.

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SAFETY

Safety Labels and Locations

Seat Belt/Drive Responsibly Warning

WARNING

Improper vehicle use can result in SEVERE

INJURY or DEATH

Be Prepared

• Fasten seat belts.

• Wear an approved helmet and protective

gear.

• ALWAYS use cab nets and/or doors.

Seat Belt/Drive

Responsibly

Warning

• Each rider must be able to sit with back

against seat, feet flat on the floor, and hands

on steering wheel or hand holds. Stay com-

pletely inside the vehicle.

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding,

skidding or fishtailing, and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even

from a stop.

• Plan for hills, rough terrain, ruts and other

changes in traction and terrain.

Rollovers have caused

severe injuries and death,

even on flat, open areas.

• Avoid paved surfaces.

• Avoid sidehilling (riding across slopes).

Be Sure Riders Pay Attention and Plan Ahead

If you think or feel the vehicle may tip or roll, reduce your risk of injury:

• Keep a firm grip on the steering wheel or hand holds and brace yourself.

• Do not put any part of your body outside of the vehicle for any reason.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA

TRAINING (rohva.org).

7179988

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SAFETY

Safety Labels and Locations

Proper Use

Warning

Shift Caution

Proper Use Warning (RZR)

WARNING

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s

license.

• Do not let people drive or ride after using alcohol or drugs.

• Do not allow operation on public roads (unless designated

for off-highway vehicle access) - collisions with cars and trucks can occur.

• Do not exceed seating capacity: 2 occupants.

7179978

Proper Use Warning (RZR 4)

WARNING

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s

license.

• Do not let people drive or ride after using alcohol or drugs.

• Do not allow operation on public roads (unless designated

for off-highway vehicle access) - collisions with cars and trucks can occur.

Do not exceed seating capacity: 4 occupants.

7179980

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SAFETY

Safety Labels and Locations

Rear Passenger Cab Frame

Warning (RZR 4)

WARNING

Passenger Cab Frame

Warning (both sides)

Do NOT hold onto this bar. Hands and arms

could be crushed or seriously injured in

event of rollover.

ALWAYS keep hands on passenger hand

hold.

7176700

Rear Passenger Hand Hold

Warning (RZR 4)

Always use seat belt, helmet and eye

protection.

Always use this passenger hand hold and

side nets to keep hands and feet in vehicle at

all times.

7176701

Passenger Grab Bar

Warning

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle.

When vehicle is stopped, place shift in the parked position.

APPLY BRAKE TO START

7174843

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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. See the OPERATION section of the owner’s manual

for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction

increases the risk of an accident. The operator

must understand how to operate the vehicle

properly in different situations and on different

types of terrain. Complete the New Operator

Driving Procedures outlined on pages 52-53.

All operators must read and understand the

owner's manual and all warning and instruction

labels before operating the vehicle. Never allow a

guest to operate this vehicle until the guest has

completed the New Operator Driving Procedures

outlined on pages 52-53.

Operator Restrictions/Age Restrictions

This vehicle is an ADULT VEHICLE ONLY.

Operation is prohibited for anyone under 16 years

of age or anyone without a valid driver’s license.

Never operate with a passenger under the age of

12. 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.

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.

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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 perform the pre-ride inspection before each

use of your vehicle to make sure it's in safe operating

condition. See page 48.

Always follow the inspection and maintenance

procedures and schedules described in this owner’s

manual. See page 77.

Protective Apparel

Riding in this vehicle without wearing an approved

helmet and protective eyewear increases the risk

of a serious injuries in the event of an accident.

Always wear a helmet, eye protection, gloves,

long-sleeve shirt, long pants and over-the-ankle

boots.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of serious

injury in the event of rollover, loss of control, other accident or sudden stop. Seat

belts may reduce the severity of injury in these circumstances.

All riders must wear seat belts at all times.

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases

the risk of serious injury or death in the event of an accident or rollover. Always

use the cab nets (or doors) while riding in this vehicle. Always keep hands and

feet inside the vehicle at all times.

Carrying Multiple Passengers (RZR)

Never carry a passenger until you have operated this

vehicle for at least two hours and have completed the New

Operator Driving Procedures outlined on pages 52-53.

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 rollover. Never carry more than

one passenger in a 2-seat vehicle.

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SAFETY

Safety Warnings

Carrying Multiple Passengers (RZR 4)

Never carry a passenger until you have operated this

vehicle for at least two hours and have completed

the New Operator Driving Procedures outlined on

pages 52-53.

A passenger must always be seated in a passenger

seat with seat belt secured.

Never carry more than three passengers in a 4-seat

vehicle.

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation and

stability. The weight of both cargo and passengers impacts vehicle operation.

For your safety and the safety of others, carefully consider how your vehicle is

loaded and how to safely operate the vehicle. Follow the instructions in this

manual for loading, tire pressure, gear selection and speed.

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

capacity is listed in the specifications section of this manual and on a label on

the vehicle. When more passenger weight is added, cargo weight may need to

be reduced accordingly.

• The recommended tire pressures are listed in the specifications section of this

manual and on a label on the vehicle.

Always follow these guidelines:

Under ANY of these conditions:

Do ALL of these steps:

Passenger and/or cargo exceeds half the 1. Slow down.

maximum weight capacity

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

2. Verify tire pressure.

3. Use extra caution when

operating.

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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. A

passenger must always be seated in a passenger

seat with seat belt secured.

Operating on Pavement

This vehicle's tires are designed for off-road use only, not for use on pavement.

Operating this vehicle on paved surfaces (including sidewalks, paths, parking

lots and driveways) may adversely affect the handling of the vehicle and may

increase the risk of loss of control and accident or rollover. Avoid operating the

vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and

avoid sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads

or highways could result in a collision with

another vehicle. Never operate this vehicle on

any public street, road or highway, including

dirt and gravel roads (unless designated for

off-highway use). In some areas it's unlawful

to operate this vehicle on public streets, roads

and highways.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds

increases the operator's risk of losing control.

Always operate at a speed that's appropriate

for the terrain, the visibility and operating

conditions, your skills and experience and

your passengers’ skills and experience.

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SAFETY

Safety Warnings

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.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt

steering maneuvers. Practice turning at slow speeds before attempting to turn at

faster speeds.

Jumps and Stunts

Exhibition driving increases the risk of an

accident or rollover. DO NOT do power slides,

“donuts”, jumps or other driving stunts. Avoid

exhibition driving.

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 56.

Descending Hills Improperly

Improperly descending a hill could cause loss

of control or rollover. Always follow proper

procedures for traveling down hills as

described in this owner’s manual. See page

57.

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SAFETY

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss

of control or rollover. Avoid crossing the side of any hill unless absolutely

necessary.

If crossing a hillside is unavoidable, always follow proper procedures as

described in this owner's manual. See page 57.

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.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating

on unfamiliar terrain could result in an

accident or rollover.

Unfamiliar terrain may contain hidden rocks,

bumps, or holes that could cause loss of

control or rollover.

Travel slowly and use extra caution when

operating on unfamiliar terrain. Always be

alert to changing terrain conditions.

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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 60.

Before shifting into reverse gear, always check

for obstacles or people behind the vehicle.

When it's safe to proceed, back slowly.

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire

pressure could cause loss of control, accident or rollover.

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

proper tire pressure as described in this owner's manual and on safety labels.

Skidding or Sliding

Failure to use extra caution when operating on

excessively rough, slippery or loose terrain

could cause loss of traction, loss of control,

accident or rollover. Do not operate on

excessively slippery surfaces. Always slow

down and use additional caution when

operating on slippery surfaces.

Skidding or sliding due to loss of traction can

cause loss of control or rollover (if tires regain

traction unexpectedly). Always follow proper

procedures for operating on slippery surfaces

as described in this owner's manual. See page 55.

Operating Over Obstacles

Improperly operating over obstacles

could cause loss of control or rollover.

Before operating in a new area, check

for obstacles. Avoid operating over

large obstacles such as large rocks and

fallen trees. Always follow the proper

procedures outlined in this manual

when operating over obstacles. See

page 59.

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SAFETY

Safety Warnings

Operating Through Water

Operating through deep or fast-flowing

water can cause loss of traction, loss of

control, rollover or accident. Never operate

in fast-flowing water or in water that

exceeds the floor level of the vehicle.

Always follow proper procedures for

operating in water as described in this

owner’s manual. See page 58.

Wet brakes may have reduced stopping

ability. After leaving water, test the brakes. Apply them lightly several times while

driving slowly. The friction will help dry out the pads.

Operating on Frozen Bodies of Water

Severe injury or death can result if the

vehicle and/or the operator fall through the

ice. Never operate the vehicle on a frozen

body of water unless you have first verified

that the ice is sufficiently thick to support the

weight and moving force of the vehicle, you

and your passengers, and your cargo,

together with any other vehicles in your party.

Always check with local authorities and

residents to confirm ice conditions and

thickness over your entire route. Vehicle

operators assume all risk associated with ice

conditions on frozen bodies of water.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any rollover or

other accident, have a qualified service dealer inspect the entire machine for

possible damage, including (but not limited to) seat belts, rollover protection

devices, brakes, throttle and steering systems.

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SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the vehicle or carrying/towing

cargo improperly may cause changes in

stability and handling, which could cause

loss of control or an accident.

• Always follow the instructions in this

owner’s manual for carrying cargo. See

page 62.

• Never exceed the stated load capacity for

this vehicle. See page 10.

• Cargo should be properly distributed and

securely attached. See page 62.

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

Refueling

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame

or sparks.

• Always use an approved gasoline container to store fuel and remove the

container from the vehicle before filling to avoid fuel ignition due to electrical

static discharge.

• Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where gasoline is stored.

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

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

water and change clothing.

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SAFETY

Safety Warnings

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or

death in a short time. Never start the engine or let it run in an enclosed area.

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

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause burns and fire. Do not touch hot exhaust system

components. Always keep combustible materials away from the exhaust

system. Use caution when traveling through tall grass, especially dry grass, to

avoid debris build-up around the exhaust system.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by

someone under the age of 16, without a drivers license, or without proper

training. This could result in an accident or rollover. Always remove the ignition

key when the vehicle is not in use.

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SAFETY

Safety Warnings

Equipment Modifications

Your POLARIS vehicle is designed to provide safe operation when used as

directed. Modifications to your vehicle may negatively impact vehicle stability.

Failure of critical machine components may result from operation with any

modifications, especially those that increase speed or power. This vehicle may

become less stable at speeds higher than those for which it is designed. Loss of

control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for

the purpose of increasing speed or power. Any modifications or installation of

non-POLARIS-approved accessories could create a substantial safety hazard

and increase the risk of bodily injury.

The warranty on your POLARIS vehicle will be terminated if any non-POLARIS-

approved equipment and/or modifications have been added to the vehicle that

increase speed or power.

The addition of certain accessories, including (but not limited to) mowers,

blades, tires, sprayers, or large racks, may change the handling characteristics

of the vehicle. Use only POLARIS-approved accessories, and familiarize

yourself with their function and effect on the vehicle.

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

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FEATURES AND CONTROLS

Component Locations

Rear Passenger

Hand Hold

Cab Nets

Front

Passenger

Hand Hold

Cargo

Box

Shifter

Fuel Tank

Hip Bars

Cap

Tie-Down

Points

Rack Extenders

(RZR/RZR EPS only)

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FEATURES AND CONTROLS

Component Locations

Cab Frame

Under Hood

Steering

Wheel

Storage

Compartment

(LE models)

Headlights

Radiator

Brush Guard

Taillights

Receiver

Hitch

Trailer Receiver Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch.

Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and

towing capacities outlined on pages 62-64.

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FEATURES AND CONTROLS

Rear Service Panel

The rear service panel is located behind the seats on the frame of the

vehicle. Remove the seats to access the service panel. Remove the ser-

vice panel to access serviceable engine components and clutches.

Radiator Access/Grill Removal

The front grill can be removed to clean debris from the radiator. Push

down on the two tabs and pivot the grill outward to remove it.

Seats

Before operating the vehicle, always push down on all seat backs to

ensure the latches are secure.

Seat Adjustments

On seats equipped with an adjustment lever, pull upward on the release

lever located under the front edge of the seat. Slide the seat forward or

rearward to the desired position. Release the lever. The seat will lock

into the new position.

For other seat styles, loosen (do not remove) the four screws located on

the seat bottom. Slide the seat forward or rearward to the desired posi-

tion. Tighten the screws to 4 ft. lbs. (5.4 Nm). Do not overtighten.

Seat Removal

1. Pull up on the seat latch

lever located under the rear

edge of the seat.

2. Tilt the seat forward.

3. Lift the seat upward to

remove it from the vehicle.

4. Reverse this procedure to

reinstall the seat. Make

sure the seat tabs at the

front edge of the seat slide

Seat

Latch

Front Seat

Retainer

under the seat retainer bar.

5. Press down firmly at the

rear of the seat to engage

the rear latch.

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FEATURES AND CONTROLS

Steering Wheel

The steering wheel can be

tilted upward or downward

for rider preference.

Lift and hold the steering

wheel adjustment lever

while moving the steering

wheel upward or down-

ward. Release the lever

when the steering wheel is

at the desired position.

Adjustment Lever

Passenger Hand Hold

Always adjust the hand hold to a comfortable position for your front-

seat passenger before operating. Make sure the adjustment pin and

retainer are securely installed after making adjustments.

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

2. Remove the pin from the post.

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

4. Reinstall the pin through the post mounting hole, adapter bushing

hole, both post adjustment holes and lastly through the remaining

bushing hole and post mounting hole.

5. Reinstall the retainer to the pin.

Adapter

Bushing

Retainer

Post Mounting

Adjustment

Holes

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FEATURES AND CONTROLS

Hood

Remove the hood to access the front storage compartment (if equipped),

the radiator cap and the coolant overflow bottle.

1. Turn the hood fasteners

1/4 turn.

Storage Compartment

(LE models)

2. Grasp the upper hood

edge and pull upward to

disengage the hood

from the vehicle.

3. Pivot the hood forward

and lift upward to disen-

gage the lower hood

hooks.

4. Lift the hood away from

the vehicle.

Overflow

Bottle

Radiator

Cap

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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 gaso-

line with a minimum pump

octane number of 87 R+M/2

octane. Do not use fuel with eth-

anol content greater than 10

percent, such as E-85 fuel.

Fuel Cap

Cab Nets

All RZR models are equipped

with cab nets, which may differ

slightly in appearance from

Rear Cab Net

Latches

Front Cab Net

Latches

those shown.

Riding in this vehicle without

using the cab nets (or doors, if

equipped) increases the risk of

serious injury or death in the

event of an accident or rollover.

Cab nets (or doors) must be

used by both operator and

passengers at all times. Make

sure all latches are secure

before operating the vehicle.

Always inspect cab nets and

latches for tightness, wear and damage before each use of the vehicle.

Use the strap adjusters to tighten any loose straps. Promptly replace

worn or damaged cab nets and latches with new cab nets and latches.

Please see your authorized POLARIS dealer.

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FEATURES AND CONTROLS

Seat Belts

This POLARIS vehicle is equipped with three-point lap and diagonal

seat belts for all riders. Always make sure the seat belts are secured for

the operator and all passengers before riding.

To wear the seat belt properly, follow this procedure:

1. Pull the seat belt latch downward and across your chest toward the

buckle at the inner edge of the seat. The belt should fit snugly across

your hips and diagonally across your chest. Make sure the belt is not

twisted.

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

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

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

Seat Belt Inspection

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

1. Push the latch plate into the buckle until it clicks. The latch plate

must slide smoothly into the buckle. A click indicates that it's

securely latched.

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

releases freely.

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

damage, including cuts, wear, fraying or stiffness. If any damage is

found, or if the seat belt does not operate properly, have the seat belt

system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from

the seat belts, sponge the

straps with mild soap and

water. Do not use bleach,

dye or household

detergents. Rinse the entire

length of the belt webbing.

Use a garden hose to flush

out the retractor and latch

housings regularly.

Retractor

Housing

Latch Housings

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FEATURES AND CONTROLS

Switches

Ignition Switch

Instrument Cluster

Light Switch

12V Accessory Outlet

AWD Switch

Auxiliary Outlet

The vehicle is equipped with one or more 12-volt accessory outlets. One

outlet is on the dash, a second outlet (if equipped) is in the rear passen-

ger area. Use the outlets to power an auxiliary light or other optional

accessories or lights. For service, the dash outlet connection is under the

dash. The rear outlet connection is under the rear passenger seats.

Electronic Power Steering (EPS)

Electronic power steering (if

equipped) engages when the ignition

key is turned to the ON position. EPS

remains engaged whether the vehicle

is moving or idle.

The EPS warning indicator briefly

illuminates when the key is turned to

the ON position. See page 38.

To conserve battery power, the EPS

will shut down 5 minutes after the

Power Steering Unit

engine is stopped if the key remains

(under cover)

in the ON position. The EPS warning

indicator will illuminate to indicate

the EPS has shut down.

If the light remains on after starting the engine, the EPS system is

inoperative. See your authorized POLARIS dealer for service.

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FEATURES AND CONTROLS

Switches

Ignition Switch

The ignition switch is a three-position, key-operated switch. Use the

ignition switch to start the engine. See page 50 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.

Electrical circuits are on. Electrical equipment can be used.

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

The key returns to the ON position when released.

Headlight Switch

Use the headlight switch to turn the lights on and

HIGH

LOW

off and to change the lights from high beam to low

beam. The ignition switch must be in the ON posi-

tion to operate the headlights.

Press the top of the rocker switch toward the dash

to place the headlights on high beam. Move the

rocker switch to the center position to place the

headlights on low beam. Press the bottom of the

rocker switch to turn off the headlights.

All Wheel Drive (AWD) Switch

The AWD Switch has two positions:

• All Wheel Drive (AWD)

AWD

2WD

• Two Wheel Drive (2WD).

Press the top of the rocker switch to engage All

Wheel Drive. Press the bottom of the switch to

operate in two wheel drive.

See page 36 for AWD operating instructions.

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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 transmis-

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

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

damage to the transmission could result. Always shift when the

vehicle is stationary and the engine is at idle.

Using Low Range

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

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

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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

Brake

Pedal

Throttle

Pedal

normally before starting the engine. Make sure there's adequate throttle

pedal freeplay. See page 106 for throttle pedal adjustment procedures.

This vehicle is equipped with a throttle release switch, which is

designed to reduce the risk of a frozen or stuck throttle. If the throttle

cable should stick in an open position when the operator releases the

throttle pedal, engine speed will be limited, and power to the rear wheels

will be reduced.

Rollover Protective Structure (ROPS)

The Rollover Protective

Structure (ROPS) on this

vehicle meets OSHA 1928.53

rollover performance

ROPS Label

requirements. Always have your

authorized POLARIS dealer

thoroughly inspect the ROPS if

it ever becomes damaged in any

way.

No device can assure occupant

protection in the event of a

rollover. When used with seat

belts and cab nets, the ROPS

helps prevent occupants from being ejected from the vehicle. Always

follow all safe operating practices outlined in this manual to avoid

vehicle rollover.

WARNING! Vehicle rollover could cause severe injury or death. Always avoid

operating in a manner that could result in vehicle rollover.

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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 vehi-

cle 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.

AWD

2WD

When in AWD, the demand drive unit will auto-

matically engage any time the rear wheels lose

traction. When the rear wheels regain traction, the

demand drive unit will automatically disengage.

There is no limit to the length of time the vehicle

may remain in AWD.

Engaging AWD

The AWD switch may be turned on or off while the vehicle is moving.

Initially, the vehicle's electronic system will not enable the AWD until

the engine RPM is below 3100. Once enabled, the AWD remains

enabled until the AWD switch is turned off. If the switch is turned off

while the demand drive unit is moving, it will not disengage until the

rear wheels regain traction.

Engage the AWD switch before getting into conditions where front

wheel drive may be needed. If the rear wheels are spinning, release the

throttle before switching to AWD.

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

cause severe drive shaft and gearcase damage. Always switch to

AWD while the rear wheels have traction or are at rest.

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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.

Indicator Lamps

Speedometer

MODE

Button

Rider Information

Center

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH)

or kilometers per hour (km/h). See page 41.

Mode Button

Use the MODE button to toggle through mode options. See page 41 for

operation of the modes.

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FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp

Indicates

Condition

When standard mode is selected, speed displays in

miles per hour.

Vehicle

Speed

Over

When metric mode is selected, speed displays in

kilometers per hour.

This lamp illuminates to indicate an overheated

Temperature engine. If the indicator flashes, the overheating

condition remains, and the system will automatically

reduce engine power.

EPS Warning This indicator illuminates briefly when the key is

turned to the ON position. If the light remains on, the

EPS system is inoperative. See your authorized

POLARIS dealer for service.

Neutral

This lamp illuminates when the transmission is in

neutral and the ignition key is in the ON position.

High Beam

This lamp illuminates when the headlamp switch is

set to high beam.

Helmet/Seat This lamp flashes for several seconds when the key is

Belt

turned to the ON position. The lamp is a reminder to

the operator to ensure all riders are wearing helmets

and seat belts before operating.

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

Do not operate the vehicle if this warning appears.

Serious engine damage could result. See your dealer.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All seg-

ments 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 speedome-

ter. If this occurs, take the vehicle to your POLARIS dealer for proper

diagnosis.

The information center is set to display standard units of measurement

and a 12-hour clock at the factory. To change to metric and/or a 24-hour

clock, see page 42.

Trip 1

RPM

8888

1. Gear Indicator - This indicator displays gear shifter position.

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

P = Park

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

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

in the fuel tank. When the last segment clears, a low fuel warning is

activated. All segments including the fuel icon will flash. Refuel

immediately.

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

fuel sensor circuit. See your dealer.

3. Information Display Area - This area displays odometer, trip

meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the

vehicle is operating at an RPM too low to keep the battery charged.

It may also occur when the engine is at idle and high electrical load

(lights, cooling fan, accessories) is applied. Drive at a higher RPM

or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See

page 42 for resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator

that the preset service interval has been reached. The vehicle should

be brought to your dealer for scheduled maintenance. See page 42

for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is

engaged (switch is on 4X4).

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the

information area options.

Display Units (Standard/Metric)

MODE

Button

The display can be changed to show either

standard or metric units of measurement for

each of the following settings.

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

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

units.

Standard Display

Miles

Metric Display

Kilometers

Distance

Fuel

U.S. Gallons

Fahrenheit

Liters, Imperial Gallons

Celsius

Temperature

Time

12-Hour Clock

24-Hour Clock

1. Turn the key to the OFF position.

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

position.

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

to advance to the desired setting.

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

the next display option.

5. Repeat the procedure to change remaining display settings.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

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

charged.

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

the odometer display.

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

Release the button.

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

desired setting.

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

Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.

After completing the 1-minute segment, step 4 will save the new

settings and exit the clock mode.

6. Turn the key to the OFF position.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

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

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before

each trip. To reset, select the trip meter mode. Press and hold the MODE

button until the meter resets to zero. In the Rider Information Center, the

trip meter display contains a decimal point, but the odometer displays

without a decimal point.

Hour Meter Mode

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

Engine Temperature Mode

This mode displays current temperature of the coolant.

Tachometer Mode

The engine RPM is displayed digitally.

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

changes in humidity, temperature and elevation.

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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 pro-

grammed at 50 hours at the factory. Use the following procedure to

change the service interval.

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

2. Press and hold the MODE button.

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

advance the hours to the desired setting (including OFF). Press and

hold the MODE button to set the new service hour interval.

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only.

Please see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning

indicator activates after the key has been turned on. Leave the key on if

you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and

on and the warning indicator is no longer active. This allows the deter-

mination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Engine Error Codes

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

The error screen displays

only when the CHECK

ENGINE light is on or

when it goes on and off

during one ignition cycle.

Error codes are not stored.

When the key is turned

OFF, the code and mes-

sage is lost, but will reap-

pear if the fault reoccurs

after restarting the engine.

If the CHECK ENGINE

light illuminates, retrieve

the error codes from the

display.

Failure Mode Indicator (FMI)

1. If the error codes are not displayed, use the MODE button to toggle

until “Ck ENG” displays on the main line of the display.

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

menu.

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

odometer displays.

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

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

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

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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 the first 25 hours

of operation, or the time it takes to use the first two tanks full of gaso-

line. No single action on your part is as important as a proper break-in

period. Careful treatment of a new engine and drive components will

result in more efficient performance and longer life for these compo-

nents. Perform the following procedures carefully.

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

damage close-fitted engine parts and drive components. Do not

operate at full throttle or high speeds during the first three hours of

use.

Use of any oils other than those recommended by POLARIS may

cause serious engine damage. We recommend the use of POLARIS

PS-4 oils for your 4-cycle engine.

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OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 30. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level. See page 85. 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

52-53.

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

page 47.

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

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

on the daily pre-ride inspection checklist. See page 48.

7. Pull only light loads.

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

hours or one month.

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

hours of operation and every 100 hours thereafter.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or

overly forceful braking when the brake system is new could damage

brake pads and rotors.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life

and better performance. Break in the clutches and belt by operating at

slower speeds during the break-in period as recommended. Pull only

light loads. Avoid aggressive acceleration and high speed operation dur-

ing the break-in period.

If a belt fails, always clean any debris from the duct and from the clutch

and engine compartments when replacing the belt.

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OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condi-

tion before operating increases the risk of an accident. Always inspect

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

Item

Remarks

Page

Brake system/pedal travel

Ensure proper operation

107

Brake fluid

Front suspension

Rear suspension

Steering

Ensure proper level

108

Inspect, lubricate if necessary

Ensure free operation

110

Tires

Inspect condition and pressure

115

Wheels/fasteners

Inspect, ensure fastener tightness

115

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level

Ensure proper level

100

Coolant hoses

Throttle

Inspect for leaks

Ensure proper operation

Inspect, clean

105

Indicator lights/switches

Air filter, pre-filter

Headlamp

103

117

Check operation, apply POLARIS

dielectric grease when lamp is

replaced

Brake light/tail lamp

Check operation, apply POLARIS

dielectric grease when lamp is

replaced

119

Seat Latches

Seat Belts

Cab Nets

Push down on both seat backs to

ensure the latches are secure

Check length of belt for damage,

check latches for proper operation

Check for wear or damage, ensure

proper installation

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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

recommended safety training before operating this vehicle.

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

driver’s license to operate this vehicle.

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

more one passenger in a 2-seat vehicle. Never carry more than three

passengers in a 4-seat vehicle. Never allow a passenger to ride in

the cargo box.

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

run in an enclosed area.

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

on this vehicle.

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

pavement or on any public street, road or highway, including dirt

and gravel roads.

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

tions. Never operate at excessive speeds. Never attempt wheelies,

jumps, or other stunts. Keep both hands on the steering wheel dur-

ing operation.

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

cle.

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

Always maintain proper tire pressure.

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

have a qualified service dealer inspect the entire machine for possi-

ble damage.

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

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

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OPERATION

Starting the Engine

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

lated area.

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

3. Place the transmission in PARK.

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

engine.

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

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

engine starts.

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

switch to the OFF position and wait five seconds. Repeat steps 5

and 6 until the engine starts.

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

until the engine idles smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

operating the vehicle.

Stopping the Engine

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

2. Place the transmission in PARK.

3. Turn the engine off.

Braking

1. Release the throttle pedal completely. (When the throttle pedal is

released completely and engine speed slows to near idle, the vehicle

has no engine braking.)

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

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

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OPERATION

Parking the Vehicle

1. Stop the vehicle on a level surface. When parking inside a garage or

other structure, be sure that the structure is well ventilated and that

the vehicle is not close to any source of flame or sparks, including

any appliance with pilot lights.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Remove the ignition key to prevent unauthorized use.

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera-

tion of this vehicle in your area. Respect the environment in which you

ride your vehicle. Find out where the designated riding areas are by con-

tacting your POLARIS dealer, a local riding club, or local officials.

Help keep our trails open for recreational vehicle use. As an off-road

enthusiast, you represent the sport and can set a good example (or a poor

example) for others to follow. Tread lightly. Operate with respect for the

terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance

between your vehicle and other vehicles operating in the same area.

Communicate to oncoming operators by signaling the number of vehi-

cles in your group. When stopping, move your vehicle to the edge of the

trail as far as possible to allow others to pass safely.

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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. Hands-on

training is also available through ROHVA.

3. Perform the pre-ride inspection. See page 48.

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

experience with this vehicle.

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

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

vehicle operation and handling.

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

gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat

belt at all times.

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. Place the transmission in PARK.

12. Start the engine.

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OPERATION

New Operator Driving Procedures

13. Apply the brakes and shift into low gear.

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

15. Keeping both hands on the steering wheel, slowly release the brakes

and depress the throttle with your right foot to begin driving.

16. Drive slowly at first. On level surfaces, practice starting, stopping,

turning, maneuvering, using the throttle and brakes and driving in

reverse. Learn how the vehicle handles when making both left and

right turns at a slow speed.

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

18. After you become skilled at making turns and begin to operate at

faster speeds, follow these precautions:

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

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

the terrain.

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

stunts.

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OPERATION

Driving with Passengers

1. Complete the New

Operator Driving

Procedures outlined on

pages 52-53.

2. Perform the pre-ride

inspection. See page 48.

3. Do not carry more than

one passenger in a 2-seat

vehicle. Do not carry more

than three passengers in a

4-seat vehicle. Additional

passengers can affect the

operator’s ability to steer

and operate the controls.

4. Make sure all passengers

are at least 12 years of

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

gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat

belt at all times. See page 8.

6. Make sure all cab nets are properly secured.

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

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

your passengers’ skills and operating conditions. Avoid unexpected

or aggressive maneuvers that could cause discomfort or injury to a

passenger.

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

board. Allow more time and distance for braking.

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

and in this manual.

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OPERATION

Driving on Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, or

ice, be alert for the possibility of skidding and sliding.

Follow these precautions when encountering slippery conditions:

1. Slow down before entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

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

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

while the wheels are spinning. Always allow the wheels to stop

spinning before engaging AWD.

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

skid. Never apply the brakes during a skid.

Turn in

direction of

skid

Sideways

skid

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OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always check the terrain carefully before ascending any hill. Never

drive on hills with excessively slippery or loose surfaces.

2. Avoid excessively steep hills. If ascending a steeper grade is

unavoidable, engage all-wheel drive before ascending.

3. Drive straight uphill.

4. Proceed at a steady rate of speed and throttle opening. Never open

the throttle suddenly.

5. Avoid unnecessary changes in speed or direction.

6. Never go over the crest of a hill at high speed. An obstacle, a sharp

drop, or another vehicle or person could be on the other side of the

hill.

7. If the vehicle stalls while climbing a hill, apply the brakes. Place the

transmission in reverse and slowly allow the vehicle to roll straight

downhill while applying light brake pressure to control speed.

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OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could

cause loss of control or rollover. Avoid crossing the side of any hill

unless absolutely necessary.

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

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

immediately turn downhill.

4. Avoid obstacles and changes in terrain that may lower or raise one

side of the vehicle or cause the vehicle to slide.

5. If the vehicle begins to slide downhill, immediately turn downhill to

stop the slide, or stop the vehicle and maneuver slowly and care-

fully until the vehicle can be driven straight downhill.

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid excessively steep hills.

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

3. Always check the terrain carefully before descending a hill. Never

drive on hills with excessively slippery or loose surfaces.

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

descend a hill with the transmission in neutral.

5. Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight downhill.

6. Apply the brakes lightly to aid in slowing.

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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

Floor Level

where both banks have grad-

ual inclines. Never operate

in water that exceeds the

maximum recommended depth.

WARNING! The large tires on your vehicle may cause the vehicle to float in

deep or fast-flowing water, which could result in loss of traction, loss of control,

rollover or accident.

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

test the brakes. Apply them lightly several times while driving

slowly. The friction will help dry out the pads.

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

inspected after operation in water. Perform the services outlined in

the maintenance chart. See page 77. Give special attention to engine

oil, transmission oil, demand drive fluid, rear gearcase oil, and all

grease fittings.

If your vehicle becomes immersed or is operated in water that

exceeds the floor level, take it to your dealer for service before

starting the engine. If it's impossible to bring the vehicle to your

dealer before starting the engine, perform the service outlined on

page 119, and take the vehicle to your dealer at the first opportunity.

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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 large rocks and fallen

trees. If unavoidable, use extreme caution and operate slowly.

5. Always have all passengers dismount and move away from the

vehicle before operating over an obstacle that could cause a

rollover.

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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.

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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 precau-

tions:

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.

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OPERATION

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle

handling and may cause loss of control or brake instability. Always follow these

precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of the

operator, passengers, accessories, loads in the rack or box and the load on the

trailer tongue. The combined weight of these items must not exceed the

maximum weight capacity.

Always load the cargo box with the load as far forward and as low as possible.

When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions.

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

Slow down and drive in the lowest gear available.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load

and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain or

situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack

sides. Stability and maneuverability may be adversely affected, causing vehicle

rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 MPH (16 km/h) while towing a load on a level grass

surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads

in rough terrain, while cornering, or while ascending or descending a hill.

Carrying a passenger in the cargo box could

result in a fall from the vehicle or contact with

moving components. Never allow a

passenger to ride in the cargo box. A

passenger must always be seated in a

passenger seat with seat belt secured.

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OPERATION

Hauling Cargo

Your POLARIS vehicle has been designed to carry or tow specific

capacities. Reduce speed and allow a greater distance for braking when

carrying cargo.

Loads should be centered and carried as low as possible in the box. For

stability on rough or hilly terrain, reduce both speed and cargo. Exercise

caution if the cargo load extends over the side of the box.

Always read and understand the load distribution warnings listed on

warning labels and in this manual. Never exceed the maximum capaci-

ties specified for your vehicle. See page 132.

Belt Life

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

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OPERATION

Hauling Cargo

Towing Loads

WARNING

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

brake instability.

Always follow these precautions when towing:

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

ing bracket.

2. When towing a disabled RZR vehicle, place the disabled vehicle’s

transmission in neutral. Do not operate the vehicle faster than 10

MPH (16 km/h) when towing.

3. Towing a trailer increases braking distance. Do not operate the vehi-

cle faster than 10 MPH (16 km/h) when towing.

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

5. Attach a trailer to the trailer hitch bracket only. Do not attach a

trailer to any other location, which could result in loss of control of

the vehicle.

6. The total load (operator, passengers, accessories, cargo and weight

on hitch) must not exceed the maximum weight capacity of the

vehicle.

Total Towed

Load Weight

(Level Ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 MPH

(16 km/h)

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WINCH GUIDE

These safety warnings and instructions apply if your vehicle came

equipped with a winch or if you choose to add an accessory winch to

your vehicle.

WARNING

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all

winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially

designed synthetic rope. The term “winch cable” will be used for either

unless noted otherwise.

Winch Safety Precautions

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the

winch.

5. Always keep body, hair, clothing and jewelry clear of the winch

cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving

vehicle. See the Shock Loading section on page 74.

7. Always keep the area around the vehicle, winch, winch cable and

load clear of people (especially children) and distractions while

operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch

are not being used.

9. Always be sure that at least five (5) full turns of winch cable are

wrapped around the winch drum at all times. The friction provided

by this wrapped cable allows the drum to pull on the winch cable

and move the load.

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WINCH GUIDE

Winch Safety Precautions

10. Always apply your vehicle’s park brake and/or park mechanism to

hold the vehicle in place during winching. Use wheel chocks if

needed.

11. Always align the vehicle and winch with the load directly in front of

the vehicle as much as possible. Avoid winching with the winch

cable at an angle to the winching vehicle’s centerline whenever

possible.

12. If winching at an angle is unavoidable, follow these precautions:

A. Look at the winch drum occasionally. Never let the winch cable “stack”

or accumulate at one end of the winch drum. Too much winch cable at

one end of the winch drum can damage the winch and the winch cable.

B. If stacking occurs, stop winching. Follow step 15 on page 72 to feed

and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the

winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s

rated capacity.

15. The winch motor may become hot during winch use. If you winch

for more than 45 seconds, or if the winch stalls during operation,

stop winching and permit the winch to cool down for 10 minutes

before using it again.

16. Never touch, push, pull or straddle the

winch cable while winching a load.

17. Never let the winch cable run through

your hands, even if wearing heavy

gloves.

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WINCH GUIDE

Winch Safety Precautions

18. Never release the clutch on the winch when the winch cable is under

load.

19. Never use the winch for lifting or transporting people.

20. Never use the winch to hoist or suspend a vertical load.

21. Never immerse or submerse your winch in water. Take your winch

to your dealer for service if this occurs.

22. Always inspect your winch and winch cable before each use.

23. Never winch the hook fully into the winch. This can cause damage

to winch components.

24. Unplug the remote control from the vehicle when the winch is not in

use to prevent inadvertent activation and use by unauthorized

persons.

25. Never grease or oil the winch cable. This will cause the winch cable

to collect debris that will shorten the life of the cable.

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WINCH GUIDE

Winch Operation

Read the Winch Safety Precautions in the preceding pages before using

your winch.

Tip: Consider practicing the operation and use of your winch before you actually

need to use it in the field.

WARNING

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all

winch instructions and warnings in this manual.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able

to deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls

for any signs of damage or parts in need of repair or replacement

before each use. Pay particular attention to the first 3 feet (1 meter)

of winch cable if the winch is being used (or has been used) for lift-

ing an accessory plow assembly. Promptly replace any worn or

damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your

vehicle’s park brake and/

or park mechanism to hold

the vehicle in place during

Hook Strap

winching. Use wheel

chocks if needed.

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WINCH GUIDE

Winch Operation

4. Always use the hook strap when

handling the hook.

WARNING! Never put your fingers into

the hook. This could lead to SEVERE

INJURY.

A. Attach the hook itself onto the

load or use a tow strap or chain

to secure the load to the winch

cable.

YES

Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to

stretch.

WARNING! Never use a recovery strap when winching due to the excessive

energy that can be released if the winch cable breaks. This can result in

SEVERE INJURY or DEATH. See the Shock Loading section on page 74.

B. Never hook the winch cable back onto itself. This will damage the

winch cable and may result in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent

SEVERE INJURY or DEATH in the event of failure. For your safety, always

replace POLARIS winch parts (including the cable) with genuine POLARIS

replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the

winching vehicle. This will help the spooling of the winch cable and

reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a

tow strap to avoid damaging the tree during winch operation. Sharp

cables and chains can damage and even kill trees. Please remember

to TreadLightly® (treadlightly.org).

E. Before operating the winch, be sure

that the safety latch on the winch

cable hook is fully seated when the

load is attached.

F. Never operate your winch with a

damaged hook or latch. Always

replace damaged parts before using

the winch.

YES

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WINCH GUIDE

Winch Operation

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’s pulling

capacity. Always be sure that at least five (5) full turns of winch

cable are wrapped around the winch drum at all times. The friction

provided by this wrapped cable allows the drum to pull on the

winch cable and move the load.

8. Read and adhere to the following information for winch damping to

ensure safe winch use.

A. In order to absorb energy that could be released by a winch cable

failure, always place a “damper” on the winch cable. A damper can be

a heavy jacket, tarp, or other soft, dense object. A damper can absorb

much of the energy released if a winch cable breaks when winching.

Even a tree limb can help as a damper if no other items are available to

you.

B. Lay the damper on top of the mid-point of the winch cable length that is

spooled out.

C. On a long pull, it may be necessary to stop winching so that the

damper can be repositioned to the new mid-point of the winch cable.

Always release the tension on the winch cable before repositioning the

damper.

D. Avoid being directly in line with the winch cable whenever possible.

Also, never permit others to stand near or in line with the winch cable

during winch operation.

9. Never hook the winch cable back onto itself. This will damage the

winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or

worn.

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WINCH GUIDE

Winch Operation

11. The ONLY time a winch-equipped vehicle should be moving when

using the winch is when that vehicle itself is stuck. The winch-

equipped vehicle should NEVER be in motion to “shock” load the

winch cable in an attempt to move a second stuck vehicle. See the

Shock Loading section on page 74. For your safety, always follow

these guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch

cable.

B. Align the winch cable as close as possible to the winching vehicle’s

centerline.

C. Attach the winch cable hook to the anchor point or the stuck vehicle’s

frame following instructions in this manual.

D. Re-engage the clutch on the winch.

E. Slowly winch in the slack in the winch cable.

F. Select the proper vehicle gear to propel the stuck vehicle in the

direction of winching.

G. Shift to the lowest gear available on the stuck vehicle.

H. Slowly and carefully apply vehicle throttle and winch together to free

the vehicle.

I. Stop winching as soon as the stuck vehicle is able to propel itself

without the help of the winch.

J. Detach the winch cable hook.

K. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual.

12. Never attempt to winch another stuck vehicle by attaching the

winch cable to a suspension component, brush guard, bumper or

cargo rack. Vehicle damage may result. Instead, attach the winch to

a strong portion of the vehicle frame or hitch.

13. Extensive winching will run down the battery on the winching

vehicle. Let the winching vehicle’s engine run while operating the

winch to prevent the battery from running low if winching for long

periods.

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WINCH GUIDE

Winch Operation

14. The winch motor may become hot during winch use. If you winch

for more than 45 seconds, or if the winch stalls during operation,

stop winching and permit the winch to cool down for 10 minutes

before using it again.

15. After winching is complete, especially if winching at an angle, it

may be necessary to re-distribute the winch cable across the winch

drum. You will need an assistant to perform this task.

A. Release the clutch on the winch.

B. Feed out the winch cable that is unevenly bunched up in one area.

C. Re-engage the winch clutch.

D. Have an assistant pull the winch cable tightly with about 100 lbs. (45

kg) of tension using the hook strap.

E. Slowly winch the cable in while your assistant moves the end of the

winch cable back and forth horizontally to evenly distribute the winch

cable on the drum.

F. Doing this reduces the chances of the winch cable “wedging” itself

between lower layers of winch cable.

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WINCH GUIDE

Winch Cable Care

For your safety, always replace POLARIS winch parts (including the

cable) with genuine POLARIS replacement parts available at your

authorized POLARIS dealer.

WARNING! Use of worn or damaged cable could lead to sudden failure and

SEVERE INJURY.

1. Always inspect your winch before each use. Inspect for worn or

loose parts including mounting hardware. Never use the winch if

any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn

or kinked winch cable.

A. A kinked winch cable made of

wire rope is shown at right. Even

after being “straightened out,”

this cable has already been

permanently and severely

damaged. Promptly discontinue

use of a winch cable in this

condition.

B. A kinked winch cable made of

wire rope that has been

“straightened out” is shown at

right. Even though it may look

usable, the cable has been

permanently and severely damaged. It can no longer transmit the load

that it could prior to kinking. Promptly discontinue use of a winch cable

in this condition.

C. A winch cable made of

synthetic rope should be

inspected for signs of fraying.

Replace the cable if fraying is

observed (shown at right).

Promptly discontinue use of a

winch cable in this condition.

D. Also replace the winch cable if there are fused or melted fibers. Such

an area of the synthetic rope will be stiff and appear smooth or glazed.

Promptly discontinue use of a winch cable in this condition.

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WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic,

or “shock” loading. Shock loading may tension a winch cable beyond its strength

and cause the cable to break. The end of a broken winch cable under such high

loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both

wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never

take up slack in the winch cable by moving the winching vehicle in

an attempt to move an object. This is a dangerous practice. It gener-

ates high winch cable loads that may exceed the strength of the

cable. Even a slowly moving vehicle can create large shock loads in

a winch cable.

WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).

This puts extra load on the winch, winch cable, and generates

excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an

object with a winch produces shock loading of the cable even when

towing at slow speeds. Towing from a winch also positions the

towing force high on the vehicle. This can cause instability of the

vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are

designed to stretch and can store energy. This stored energy in the

recovery strap is released if a winch cable fails making the event

even more hazardous. Similarly, never use elastic “bungie” cords

for winching.

5. Never use the winch to tie down a vehicle to a trailer or other

transportation vehicle. This type of use also causes shock loading

that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads

produced by the winch motor when operated from a stationary

vehicle. Always remember that the winch and winch cable are NOT

designed for shock loading.

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WINCH GUIDE

Winch Maintenance and Service Safety

WARNING! Improper or lack of winch maintenance and service could lead to

SEVERE INJURY or DEATH. Always follow all winch instructions and warnings

in this manual.

1. Always inspect your winch before each use. Inspect for worn or

kinked winch cable. Also inspect for worn or loose parts including

mounting hardware.

2. Permit your winch motor to cool down prior to servicing your

winch.

3. Never work on your winch without first disconnecting the battery

connections to prevent accidental activation of the winch

4. For your safety, always replace POLARIS winch parts (including

the cable) with genuine POLARIS replacement parts available at

your authorized POLARIS dealer.

5. Some winch models use wire rope as the winch cable. Other

winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade

polymer rope such as can be purchased in a hardware store.

Although they may look similar, they are NOT alike. A polymer

rope not designed for winch use will stretch and store excessive

energy when winching.

WARNING! Failure of a stretched rope under winching conditions will release

all of the stored energy. This will increase the chances of SEVERE INJURY or

DEATH.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compli-

ance 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 accor-

dance with the USFS standard 5100-1C. Federal law requires that this spark arrester be

installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420.

Violations are subject to monetary penalties. Federal regulations can be viewed online at

www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back

to the combustion chamber by the intake system. All exhaust gases exit through the

exhaust system.

Exhaust Emission Control System

Exhaust emissions are controlled by engine

design. An electronic fuel injection (EFI) sys-

tem controls fuel delivery. The engine and EFI

components are set at the factory for optimal

performance and are not adjustable.

Emissions Label

(on inside of frame tube)

The emissions label is located on the inside of

the lower left frame tube (below driver’s foot

area).

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with

active or non-active implantable medical devices (such as heart monitoring or control-

ling devices) should review the limitations of their device and the applicable electro-

magnetic standards and directives that apply to this vehicle.

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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 148.

Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have a

qualified dealer perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and

serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or crank-

case. Change oil immediately if the oil level begins to rise. Monitor the

oil level, and if it continues to rise, discontinue use and determine the

cause or see your dealer.

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MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Symbol

Description

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

Emission-related service (failure to conduct this maintenance will not void

the emissions warranty but may affect emissions)

Have an authorized POLARIS dealer perform these services.

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

result in component failure and lead to serious injury or death. Have an

authorized POLARIS dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Steering

Front suspension

Rear suspension

Tires

Brake fluid level

Brake pedal travel

Brake system

Pre-Ride

Make adjustments as need ed.

See Pre-Ride Checklist on

page 48.

Wheels/fasteners

Frame fasteners

Engine oil level

Ź Air filter, pre-filter

Daily

Inspect; clean often; replace as

needed

Coolant (if

applicable)

Check level daily, change

coolant every 2 years

Ź Power steeringunit

Daily

Inspect daily; clean often

(if equipped)

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

Ź Air filter, main

E element

Weekly

Inspect; replace as needed

Ź Brake pad wear

10 H

Monthly 100 (160) Inspect periodically

Battery

25 H

Monthly 250 (400) Check terminals; clean; test

Monthly 150 (250) Inspect; replace if necessary

Ź Engine breather

E filter (if equipped)

Ź Engine oil change

25 H

1 M

Break-in oil and filter change

Break-in oil level check

Ź Demand drive fluid 25 H

Ź Rear gearcase oil

Ź Main gearcase oil

Ź Transfer case oil

25 H

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

E Emission-Related Service

D Have an authorized POLARIS dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Ź Throttle cable/

E Throttle Release

Switch

50 H

6 M

300 (500) Inspect; adjust; lubricate;

replace if necessary

E Throttle body air

6 M

3 M

6 M

300 (500) Inspect duct for proper

sealing/air leaks

intake ducts/flange

Ź General lubrication 50 H

500 (800) Lubricate all fittings, pivots,

cables, etc.

Ź Oil lines, fasteners 50 H

1000 (1600) Inspect for leaks and loose

fittings

Shift Linkage

D Steering

50 H

6 M

500 (800)

Inspect, lubricate, adjust

500 (800) Lubricate

Ź Front Suspension

Ź Rear Suspension

Cooling system (if

applicable)

500 (800) Inspect coolant strength

seasonally; pressure test

system yearly

Ź Engine oil change 100 H

6 M

Change the oil and filter

Change fluid

Ź Demand drive fluid 100 H

12 M

Ź Rear gearcase oil

Ź Main gearcase oil

Ź Transfer case oil

100 H

Change fluid

D Fuel system

600 (1000) Check for leaks at tank cap,

lines, filter, pump, throttle

body; replace lines every two

years

Ź Spark plug

100 H

12M

600 (1000) Inspect; replace as needed

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

E Emission-Related Service

D Have an authorized POLARIS dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Ź Radiator (if

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

equipped)

Ź Cooling Hoses

100 H

12 M

1000 (1600) Inspect for leaks

1000 (1600) Inspect

Ź Engine mounts

Exhaust muffler/

pipe

1000 (1600) Inspect

D Ignition timing

100 H

12 M

1000 (1600) Inspect

Ź Wiring

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

D Clutches (drive

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

and driven)

Drive belt

100 H

12 M

1000 (1600) Inspect; replace as needed

D Front wheel

bearings

D Brake fluid

Spark arrester

Idle speed

200 H

300 H

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Adjust as needed

D Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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

E Emission-Related Service

D Have an authorized POLARIS dealer perform these services.

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MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 77, 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 5W-50 4-Cycle Oil

Add to proper level on dipstick.

See page 85.

Brake Fluid

DOT 4 Brake Fluid

Maintain level between fill lines.

See page 108.

Transmission Oil

(Main Gearcase)

AGL Gearcase Lubricant & See page 90.

Transmission Fluid

Transmission Oil

(Transfer Case)

AGL Gearcase Lubricant & See page 88.

Transmission Fluid

Demand Drive Fluid

(Front Gearcase)

Demand Drive Fluid

See page 92.

Rear Gearcase Oil

Prop Shaft

Angle Drive Fluid

U-Joint Grease

See page 93.

Locate fittings and grease.

Control Arm Pivot

Bushings, Front/Rear

All Season Grease or grease Locate fittings and grease.

conforming to NLGI No. 2

Stabilizer Bar Bushings All Season Grease or grease Locate fittings and grease.

conforming to NLGI No. 2

Prop Shaft

Grease Fitting

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MAINTENANCE

Lubrication Recommendations

RZR S/RZR 4

Control Arm

Pivot Bushings

RZR

Stabilizer Bar

Bushings

RZR 4

Stabilizer Bar Bushings

RZR

Control Arm

Pivot Bushings

RZR S/RZR 4

Control Arm

Pivot Bushings

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MAINTENANCE

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-

50 4-cycle oil or a similar oil for this engine. Oil may need to be

changed more frequently if POLARIS oil is not used. Always use 5W-

50 oil.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated

engine oil will cause accelerated wear and may result in engine seizure,

accident, and injury. Always perform the maintenance procedures as outlined in

the Periodic Maintenance Chart.

Oil may need to be changed more frequently if POLARIS PS-4 oil is not

used. Follow the manufacturer's recommendations for ambient tempera-

ture operation. See page 136 for the part numbers of POLARIS prod-

ucts.

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

engine damage. Always use the recommended oil. Never substitute

or mix oil brands.

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MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 77. Always use the recommended

engine oil.

Oil Check

The oil dipstick and fill tube is

located on the engine, behind

the passenger seat (behind the

right rear passenger seat on

RZR 4 models).

1. Position the vehicle on a

level surface.

2. Place the transmission in

PARK.

3. Remove both seats. Remove the

rear service panel. See page 27.

4. Lift the lever lock to remove the

dipstick. Wipe it dry with a clean

cloth.

Dipstick

5. Reinstall the dipstick completely,

but do not lock it. The dipstick

must be inserted completely in to

keep the angle and depth of the

stick consistent.

6. Remove the dipstick and check the

oil level. Maintain the oil level in

the safe range. Do not overfill.

Safe

Tip: Due to the dipstick entry angle into the

crankcase, the oil level will read higher

on the bottom side of the dipstick.

Always read the level on the upper

surface of the dipstick.

Safe

Range

Check Level

on Top Side

7. Reinstall the dipstick. Seat the

lever lock.

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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 77. Always change the oil filter

whenever changing oil.

The engine drain plug is located on

the bottom of the crankcase.

1. Position the vehicle on a level

surface. Place the transmission

in PARK. Apply the brakes.

2. Start the engine. Allow it to idle

for two to three minutes. Stop

the engine.

3. Clean the area around the drain

plug.

CAUTION! Hot oil can cause burns to

skin. Do not allow hot oil to contact skin.

Drain Plug

4. Place a drain pan beneath engine

crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

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

of burrs, nicks or scratches.

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

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MAINTENANCE

Engine Oil

Oil and Filter Change

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

to remove it.

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

case.

10. Lubricate the o-ring on the new filter with a film of fresh engine oil.

Check to make sure the o-ring is in good condition.

11. Install the new filter and turn by hand until the filter gasket contacts

the sealing surface, then turn and additional 1/2 turn.

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

ommended oil.

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

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

15. Stop the engine. Inspect for leaks.

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

bring the level to the upper mark on the dipstick.

17. Dispose of used filter and oil properly.

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MAINTENANCE

Gearcases

Transfer Case

Always check and change the fluid at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 77. Refer to the Gearcase

Specifications Chart on page 94 for recommended lubricants, capacities

and torque specifications.

Fill Plug

Level

Check

Plug

Drain Plug

Fluid Check

The fill plug and level check plug are located on the left side of the

transfer case. The fluid level is sufficient when fluid flows out of the

check plug hole at step 4.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Remove the level check plug.

4. Add the recommended fluid to the fill plug hole until it begins to

flow out of the check plug hole.

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

6. Reinstall the fill plug. Torque to specification.

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MAINTENANCE

Gearcases

Transfer Case

Fluid Change

The drain plug is located on the bottom of the transfer case. Access the

drain plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

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

6. Remove the level check plug.

7. Add the recommended fluid to the fill plug hole until it begins to

flow out of the check plug hole.

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

9. Reinstall the fill plug. Torque to specification.

10. Check for leaks. Discard used fluid properly.

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MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Always check and change the fluid at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 77. Refer to the Gearcase

Specifications Chart on page 94 for recommended lubricants, capacities

and torque specifications.

Fluid Check

The fill plug is located on the left side

of the gearcase. Maintain the fluid

level at the bottom of the fill plug

hole.

1. Position the vehicle on a level

surface.

2. Remove the fill plug.

3. Check the fluid level.

4. Add the recommended fluid to

the bottom of the fill plug hole.

Do not overfill.

5. Reinstall the fill plug. Torque to

specification.

Fill Plug

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MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Fluid Change

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

plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

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

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

not overfill.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

Transfer Case

Main Gearcase

Drain Plug

Rear Gearcase

Drain Plug

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MAINTENANCE

Gearcases

Demand Drive Unit (Front Gearcase)

Always check and change the fluid at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 77. Refer to the Gearcase

Specifications Chart on page 94 for recommended lubricants, capacities

and torque specifications.

Fluid Check

The fill plug is located on the

bottom right side of the demand

Drain Plug

drive unit. Maintain the fluid

level even with the bottom

thread of the fill plug hole.

1. Position the vehicle on a

level surface.

2. Remove the fill plug. Check

the fluid level.

View of

Bottom

3. Add the recommended fluid

to the bottom thread of the

fill plug hole.

Fill Plug

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

5. Reinstall the drain plug. Torque to specification.

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

hole.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

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MAINTENANCE

Gearcases

Rear Gearcase

Always check and change the fluid at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 77. Refer to the Gearcase

Specifications Chart on page 94 for recommended lubricants, capacities

and torque specifications.

Fluid Check

The fill plug is located on the right

side of the rear gearcase. Maintain

the fluid level even with the bot-

tom thread of the fill plug hole.

1. Position the vehicle on a level

surface.

2. Remove the fill plug. Check

the fluid level.

3. Add the recommended fluid to

the bottom thread of the fill

plug hole.

Drain Plug

Fill Plug

4. Reinstall the fill plug. Torque

to specification.

Fluid Change

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

1. Remove the fill plug.

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

3. Allow the fluid to drain completely.

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

Torque to specification.

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

hole.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

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MAINTENANCE

Gearcases

Gearcase Specification Chart

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

page 136 for the part numbers of POLARIS products.

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug/

Level Check

Plug Torque

Transmission

AGL Gearcase

Lubricant &

Transmission Fluid

24 oz.

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

(Main Gearcase)

(710 ml)

Transmission

(Transfer Case)

14 oz.

(414 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

Demand Drive Unit

(Front Gearcase)

Demand Drive

Fluid

6.75 oz.

(200 ml)

8-10 ft. lbs.

(11-13.6 Nm)

11 ft. lbs.

(15 Nm)

Rear Gearcase

Angle Drive Fluid

26 oz.

(769 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

Spark Plugs

Spark Plug Gap/Torque

Electrode Gap

New Plug Torque

Used Plug Torque

.035" (.9 mm)

18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

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

damage. Always use POLARIS-recommended spark plugs. Refer to

the specifications section beginning on page 132.

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine is warmed up and

the vehicle is driven at higher speeds. Immediately check the spark plug

for correct color. See page 95.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

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MAINTENANCE

Spark Plugs

Spark Plug Removal and Replacement

1. Remove both seats.

2. Remove the rear service

panel. See page 27.

Spark Plugs

3. Remove the spark plug cap.

4. Using the spark plug wrench

provided in the tool kit,

remove the plug by rotating

it counter-clockwise.

5. Reverse the procedure for

spark plug installation.

Torque to specification. See

page 94.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This indi-

cates the proper type and heat range for the engine and the service.

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

caused by use of an improper spark plug or incorrect throttle body adjust-

ments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil, use

of non-recommended injection oil or incorrect throttle body adjust-

ments.

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MAINTENANCE

Fuses

If the engine stops or will not start, if the power steering stops working

(if equipped), or if you experience other electrical failures, a fuse may

need replacement. Locate and correct any short circuits that may have

caused the blown fuse, then replace the fuse.

Fuse

Feature Supported

Lights: Headlights, Taillights

Drive: AWD

Accessory: Winch Switch, 12V Power Receptacle

Fuel Pump

Electronic Engine Control, Starting

20A

10A

20A

10A

20A

Power Fuse

Feature Supported

20A

30A

Engine Control

Lights, Drive, Accessories

Power Steering (if equipped)

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MAINTENANCE

Fuses

The fuse box is located above the power

steering unit. Spare fuses are provided in the

fuse box.

Fuse Label

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

and lift up on the two fuse box tabs.

2. Slide the fuse box slightly toward the

right side of the vehicle to disengage it

from the mount.

3. Remove the fuse box cover.

4. Remove the suspect fuse from the fuse

panel. If the fuse is blown, install a new

fuse with the same amperage rating.

5. Reinstall the fuse box cover. Reinstall the

fuse box over the mount and slide it

toward the left to engage the tabs. Be

sure the fuse box is securely mounted.

Step 1 - Lift tabs

Step 3 - Cover removed

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MAINTENANCE

Cooling System

Operation

The engine coolant level is controlled or maintained by the recovery

system. The recovery system components are the overflow bottle, radia-

tor filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated)

excess coolant is forced out of the radiator, past the pressure cap, and

into the overflow bottle. As engine coolant temperature decreases, the

contracting (cooled) coolant is drawn back up from the tank, past the

pressure cap, and into the radiator.

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

itself of trapped air. Observe coolant levels and maintain as recommended

by adding coolant to the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we

recommend that the system be completely drained every two years and a

fresh mixture of antifreeze and water added.

POLARIS recommends the use of POLARIS Antifreeze 60/40 premix

or a 50/50 mixture of high quality aluminum compatible anti-freeze/

coolant and distilled water. POLARIS Antifreeze is already premixed

and ready to use. Do not dilute with water. See page 136 for the part

numbers of POLARIS products.

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

protection required in your area.

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

replace the coolant. If the recovery bottle has run dry, the level in the

radiator should be inspected. Add coolant as needed.

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MAINTENANCE

Cooling System

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals out-

lined in the Periodic Maintenance Chart beginning on page 77. Do not

obstruct or deflect air flow through the radiator by installing unauthor-

ized accessories in front of the radiator or behind the cooling fan. Inter-

ference with the radiator air flow can lead to overheating and

consequent engine damage.

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

radiator fins and impair the radiator's effectiveness. Using a high-

pressure system is not recommended.

Radiator Coolant Level

This procedure is required only if the cooling system has been drained

for maintenance and/or repair. But 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 29.

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

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

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

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

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MAINTENANCE

Cooling System

Coolant Level

Always check and change

the coolant at the intervals

outlined in the Periodic

Maintenance Chart begin-

ning on page 77. Maintain

the coolant level between the

minimum and maximum

marks on the bottle (when

the fluid is cool).

LE Model Shown

1. Position the vehicle on a

level surface.

Radiator

Cap

Overflow

Bottle

2. Remove the hood. See

page 29.

3. View the coolant level in the overflow bottle.

4. If the coolant level is below the safe operating range, remove the

cap and use a funnel to add coolant through the opening. Reinstall

the cap.

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

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

your POLARIS dealer.

100

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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.

The PVT system rotates at high speeds, creating large amounts of force on

clutch components. As the owner, you have the following responsibilities for

your own safety and the safety of others:

• Always follow all recommended maintenance procedures. Always look for and

remove debris inside and around the clutch and vent system when replacing

the belt.

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

• This PVT system is intended for use on POLARIS products only. Do not install

it in any other product.

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

Belt slip is responsible for creating excessive heat that destroys belts,

wears clutch components and causes outer clutch covers to fail. Switch

to low range while operating at slower speeds to extend the life of the

PVT components (belt, cover, etc.).

101

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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, loss of control and severe injury or death.

1. Allow hot components to cool before performing this procedure.

2. Remove the seat and the under-seat storage box.

3. Remove the clutch cover screws and open the clutch cover. Remove

all debris wrapped in and around the PVT system.

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

5. Check for signs of damage to seals on the transmission and engine.

See your dealer promptly for service if any seals appear to be dam-

aged.

Tip: Belt slip is responsible for creating excessive heat that destroys belts,

wears clutch components and causes outer clutch covers to fail. Switch to

low range while operating at slower speeds to extend the life of the PVT

components (belt, cover, etc.).

PVT Drying

Before washing the vehicle, locate the PVT outlet duct under the right

rear wheel well. Avoid spraying water directly toward the duct when

washing the vehicle from the rear. See page 126.

There may be some instances when water is accidently ingested into the

PVT system. Use the following instructions to dry it out before operat-

ing.

1. Remove both seats. Remove the rear service panel. See page 27.

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

water to drain. Tighten the screws.

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

4. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for

more than 10 seconds.

5. Allow the engine RPM to settle to idle speed. Apply the brakes.

Shift the transmission to the lowest available range.

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

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

102

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MAINTENANCE

Air Filter

Always change the air filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 77.

1. Access the air box from

Air Box Cover

behind the left rear wheel.

2. Remove the air box cover

and inspect the gasket. It

should adhere tightly to the

cover around the entire

edge.

Gasket

3. Remove the air filter.

4. Install a new filter if

needed. Do not attempt to

clean the air filter. Apply a

small amount of general

purpose grease to the seal-

ing edges of the filter

Air Filter

before installing.

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

into a suitable container.

103

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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 operate without the spark arrestor.

• Never run the engine in an enclosed area. Exhaust contains poisonous carbon

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

time.

Periodically clean the spark arrester to remove accumulated carbon.

1. Remove the retaining nut. Remove the arrester from the end of the

muffler.

2. 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.

3. Inspect the screen for wear and damage. Replace a worn or dam-

aged screen.

4. Reinstall the arrester. Torque the nut to 5-7 ft. lbs. (7-9 Nm).

Muffler

Screen

Retaining

Nut

Arrester

104

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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.

Throttle Freeplay

If the throttle pedal has excessive

play due to cable stretch or mis-

adjustment, it will cause a delay

in throttle response, especially at

low engine speed. The throttle

may also not open fully. If the

throttle pedal has no freeplay, the

throttle may be hard to control,

and the idle speed may be erratic.

Check the throttle pedal freeplay

at the intervals outlined in the

Periodic Maintenance Chart

beginning on page 77. Adjust the

freeplay if necessary.

Throttle

Pedal

Throttle Freeplay Inspection

1. Place the transmission in PARK.

2. Apply the brakes. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.5-

3 mm).

105

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MAINTENANCE

Throttle System

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not

satisfactory, please see your POLARIS dealer for adjustment.

Throttle Freeplay Adjustment

1. Remove both seats. Remove the

rear service panel. See page 27.

Jam Nut

Adjuster

Boot

2. Locate the throttle cable adjuster

at the throttle body.

3. Slide the cable adjuster boot off

the cable adjuster.

4. Using a 10 mm open-end wrench,

loosen the adjustment jam nut.

5. Using an 8 mm open-end wrench,

move the cable adjuster until 1/16"

to 1/8" (1.5-3 mm) of freeplay is

achieved at the throttle pedal. See page 105. While adjusting, lightly

flip the throttle pedal up and down.

6. Tighten the jam nut.

7. Apply a small amount of grease to the inside of the boot and slide it

over the cable adjuster to its original position.

106

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MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the

brake pedal. See page 35.

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 108

for brake fluid information.

If you discover any irregularities in brake system operation, including

excessive pedal travel, contact your dealer for proper diagnosis and

repairs.

WARNING! Operating the vehicle with a spongy brake pedal can result in loss

of braking, which could cause an accident resulting in severe injury or death.

Never operate the vehicle with a spongy-feeling brake pedal.

107

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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 136 for the part num-

bers 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. The moisture causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and

the possibility of accident or severe injury.

Change the brake fluid every two

Brake Fluid

Reservoir

years and any time the fluid

Maximum

Minimum

becomes contaminated, the fluid

level is below the minimum, or if

the type and brand of the fluid in

the reservoir are unknown.

Access the brake fluid reservoir

through the left front wheel well.

1. Position the vehicle on a

level surface.

2. Place the transmission in

PARK.

3. View the brake fluid level in

the reservoir. The level

should be between the maxi-

mum and minimum level

lines.

4. If the fluid level is lower

than the lower level line, add

brake fluid to the upper line.

5. Apply the brake forcefully for a few seconds and check for fluid

leakage around the fittings.

108

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MAINTENANCE

Brakes

Brake Inspection

1. Check the brake system for

fluid leaks.

2. Check the brake pedal for

excessive travel or a spongy

feel.

3. Check the friction pads for

wear, damage and looseness.

4. Check brake discs for signs

of cracks, excessive

corrosion, warping or other

damage. Clean any grease

using an approved brake

cleaner or alcohol.

3/64" (1mm)

WARNING! Do not apply WD-40 or any petroleum product to brake discs.

These types of products are flammable and may also reduce the friction

between the brake pad and caliper.

5. Inspect the brake disc spline and pad wear surface for excessive

wear. Change pads when worn to 3/64" (1 mm).

109

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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 77.

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 autho-

rized POLARIS dealer.

110

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MAINTENANCE

Suspension Settings

(RZR and RZR S Base Models)

The front and rear suspensions are preload adjustable, with five settings

on each axle.

The suspensions are set on the lowest (softest) setting at the factory.

This setting is appropriate for nearly all riding conditions. Since the

vehicle is equipped with full skid plates, suspension adjustment is not

necessary.

If desired, the suspension may be adjusted to maintain vehicle clearance

height when carrying loads. Please see your POLARIS dealer for the

tool required to make suspension adjustments. Elevate the vehicle

slightly for easier adjustment.

Always heed the following rules if you make adjustments to this suspen-

sion.

• Always return the suspension to the lowest (softest) 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.

• Never operate the vehicle on the highest (stiffest) or second highest

preload settings without a total combined payload in the vehicle of

450 lbs. (204 kg) or more. Payload includes the driver, passenger,

POLARIS-approved accessories and cargo. Never exceed the stated

load capacity for this vehicle. See page 132.

Adjustment

Cam

Lowest

(Softest)

Setting

Highest

(Stiffest)

Setting

111

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MAINTENANCE

Suspension Settings

(RZR S Premium Models and RZR 4)

Front/Rear Spring Preload

The factory setting is appropriate

for nearly all riding conditions.

Since the vehicle is equipped with

full skid plates, adjustment is not

necessary.

If desired, the suspension may be

adjusted to maintain vehicle

clearance height when carrying

loads. Please see your POLARIS

dealer for the tool required to make

suspension adjustments. Elevate the

vehicle slightly for easier

adjustment.

Preload Setting

Measurement

Factory Preload Settings

4.34” (110.2 mm)

RZR S Premium Front

RZR S Premium Rear

RZR 4 Base Front

5.15” (130.8 mm)

4.5” (114.3 mm)

5.29” (134.4 mm)

4.31” (109.5 mm)

4.99” (126.7 mm)

RZR 4 Base Rear

RZR 4 Premium Front

RZR 4 Premium Rear

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 vehi-

cle 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 (25.4 mm) over the

factory setting.

112

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MAINTENANCE

Suspension Settings

(RZR S Premium Models and RZR 4)

Front/Rear Spring Preload

1. Elevate the vehicle to allow the sus-

pension to fully extend.

2. Loosen the jam nut and back it away

from the adjusting ring.

3. Turn the adjusting ring to the left (1)

to increase preload for a stiffer ride.

Turn the adjusting ring to the right (2)

Adjusting

Ring

to decrease preload for a softer ride.

WARNING! Uneven adjustment may cause

poor handling of the vehicle, which could result

in an accident. Always adjust both the left and

right spring preloads equally or have your

POLARIS dealer perform the adjustments.

4. Tighten the jam nut firmly against the

adjuster ring.

113

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MAINTENANCE

Suspension Settings

(RZR S Premium and RZR 4 Premium Models)

Increase

Front/Rear Shock Compression

Decrease

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.

Setting

Compression Damping

Softest

Factory

Firmest

20 clicks from closed

10 clicks from closed

2 clicks from closed

114

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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. Always use POLARIS-

approved size and type of tires for this vehicle when replacing tires.

Tire Tread Depth

Always replace tires

when tread depth is

worn to 1/8" (3 mm)

or less.

1/8" (3 mm)

Axle and Wheel Nut Torque Specifications

Inspect the following items occasionally for tightness, and if they've

been loosened for maintenance service. Do not lubricate the stud or the

lug nut.

Lug Nut

(Aluminum

Wheels)

Front and Rear

30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

2-Piece Flange

Nut (Steel

Front and Rear

27 ft. lbs. (37 Nm)

80 ft. lbs. (108 Nm)

Wheels)

Hub Retaining Nut

115

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MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK. Stop the engine.

3. Loosen the wheel nuts slightly.

4. 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. Be sure the

valve stem is toward the

outside and rotation

arrows on the tire point

toward forward rotation.

WARNING! Improperly installed wheels can adversely affect tire wear and

vehicle handling, which can result in serious injury or death. Always ensure that

all nuts are torqued to specification. Do not service axle nuts that have a cotter

pin installed. See your POLARIS dealer.

3. Attach the wheel nuts and washers and finger tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification. See page 115.

116

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MAINTENANCE

Lights

Do not operate the vehicle at night or in low light conditions without

properly working headlights. Always make sure lights are adjusted

properly for best visibility.

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. Do not operate the vehicle at night or in low light conditions without

properly working headlights.

Poor lighting while driving can result in severe injury or death. Head-

light and taillight lenses become dirty during normal operation. Wash

the headlights frequently to maintain lighting quality.

Headlight Replacement (LED)

If an LED headlight becomes damaged or inoperable, the entire head-

light assembly must be replaced.

Tip: This type of headlight may have a short jumper cable between the wiring

harness and headlight assembly.

Headlight Lamp Replacement (Halogen)

Do not service the headlamps until

they've cooled sufficiently. When ser-

vicing a halogen lamp, don't touch the

lamp with bare fingers. Oil from your

skin leaves a residue, causing a hot

spot that will shorten the life of the

lamp.

1. Unplug the headlamp from the

wiring harness. Be sure to pull on

the connector, not on the wiring.

2. Turn the lamp counter-clockwise

to remove it.

3. Install the new lamp. Make sure

the tab on the lamp locates prop-

erly in the housing.

4. Reinstall the harness assembly

Wiring Harness

into the headlight assembly.

117

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MAINTENANCE

Lights

Headlight High Beam Adjustment

25 ft.

(7.6 m)

8" (20 cm)

1. Place the vehicle on a level surface with the headlight approxi-

mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

3. Apply the brakes. Start the engine. Turn the headlights to high

beam.

4. Observe the headlight aim. The most intense part of the headlight

beam should be aimed 8" (20 cm) below the mark placed on the

wall in step 2. Include the weight of a rider on the seat while per-

forming this step.

5. If adjustment is necessary, turn the headlight adjustment screw to

adjust the beam.

6. Repeat steps 4-5 until the beam is properly adjusted.

118

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MAINTENANCE

Lights

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.

2. Apply the brakes. The brake light should come on after about 10

mm (0.4 in.) of pedal travel. If the light doesn't come on, check the

bulb.

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. Thoroughly dry the air pre-filter. See page

103.

3. Remove the spark plugs.

4. Turn the engine over several times.

5. Dry the spark plugs and reinstall them, or install new plugs.

6. Attempt to start the engine. If necessary, repeat the drying proce-

dure.

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

whether you succeed in starting it or not.

8. If water has been ingested into the PVT follow the procedure on

page 102 for drying.

119

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MAINTENANCE

Battery

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.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Your vehicle may have either a sealed battery, which requires little

maintenance, or a conventional battery. A sealed battery can be identi-

fied by its flat covers on the top of the battery. A conventional battery

has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If

cleaning is necessary, remove the corrosion with a stiff wire brush.

Wash with a solution of one tablespoon baking soda and one cup water.

Rinse well with tap water and dry off with clean shop towels. Coat the

terminals with dielectric grease or petroleum jelly. Be careful not to

allow cleaning solution or tap water into a conventional battery.

120

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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.

Battery Removal

1. Remove the driver’s seat. See

page 27.

2. On conventional batteries,

remove the battery 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 conven-

tional battery sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the

vehicle.

121

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MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 124 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 (sealed bat-

teries do not have a vent tube). The vent tube must be free of

obstructions and securely installed. Route the tube away from the

frame and vehicle body to prevent contact with electrolyte.

WARNING! Battery gases could accumulate in an improperly installed vent tube

and cause an explosion, resulting in serious injury or death. Always ensure that

the vent tube is free of obstructions and is securely installed as recommended.

4. Coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed.

8. Reinstall the driver’s seat.

122

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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 124.

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-dis-

charge. Battery Tender can be left connected during the storage period, and

will automatically charge the battery if the voltage drops below a pre-deter-

mined point. See page 136 for the part numbers of POLARIS products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will

deteriorate rapidly. Check the bat-

tery fluid level often. Maintain the

fluid level between the upper and

lower level marks.

Upper

Mark

Lower

Mark

Add only distilled water. Tap water

contains minerals that are harmful

to a battery.

123

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MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 121.

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 grav-

ity to 1.270 or greater.

3. Reinstall the battery. See page 122. Make sure the positive terminal

is toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installa-

tion 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.

The single most important thing about maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

WARNING! An overheated battery may explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if the battery

becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until battery voltage is 12.8 or greater.

Tip: When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the

guidelines on the next page for recharging.

124

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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

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

125

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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 PVT outlet duct under the right

rear wheel well. Avoid spraying

water directly toward the duct when

washing the vehicle from the rear.

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

the PVT outlet duct when washing the vehicle from the rear.

High water pressure may damage the radiator fins and impair the

radiator’s effectiveness. High pressure may also damage other

vehicle components. POLARIS recommends washing the vehicle by

hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will

damage plastic surfaces. Do not allow these types of products to

contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a gar-

den hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first

and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

126

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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. Avoid directing the water stream at the follow-

ing items:

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Electrical components and wiring

If warning and safety labels are damaged, contact your POLARIS dealer

for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to

run for a while to evaporate any water that may have entered the engine

or exhaust system.

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture

polish for polishing the finish on your POLARIS vehicle. Follow the

instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the

finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

127

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MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre-

serve 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. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes.

Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT

grade) to remove it. Gently rub the affected areas with the steel wool

until the corrosion has been removed. Clean and polish the wheel as out-

lined above.

128

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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 126.

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 recom-

mended amount. Carbon Clean removes water from fuel systems,

stabilizes fuel and removes carbon deposits from pistons, rings,

valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

disperse through the entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 86.

Air Filter / Air Box

Inspect and clean or replace the pre-filter and air filter. See page 103.

Clean the air box. Drain the sediment tube.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the

Periodic Maintenance Chart beginning on page 77.

• Demand drive fluid (front gearcase)

• Rear gearcase fluid

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength/fill)

129

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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 77.

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. To

access the plug holes, use a section of clear 1/4" hose and a small

plastic squeeze bottle filled with the pre-measured amount of oil.

Do this carefully! If you miss the plug holes, oil will drain from the

spark plug cavities into the hole at the front of the cylinder head,

and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 95.

4. Apply dielectric grease to the inside of each spark plug cap. Do not

reinstall the caps onto the plugs at this step.

5. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protec-

tive film of fresh oil.

6. If POLARIS fuel system additive is not used, fuel tank, fuel lines,

and injectors should be completely drained of gasoline.

7. Reinstall the spark plug caps to the spark plugs.

Battery Maintenance

See pages 123-125 for storage and charging procedures.

Storage Area/Covers

Be sure the storage area is well ventilated. Cover the vehicle with a gen-

uine POLARIS cover. Do not use plastic or coated materials. They do

not allow enough ventilation to prevent condensation, and may promote

corrosion and oxidation.

130

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MAINTENANCE

Cleaning and Storage

Removal from Storage

1. Check the battery electrolyte level and charge the battery if neces-

sary. Install it in the vehicle. Make sure the battery vent hose is

routed properly and that it's not pinched or restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection section

on page 48. 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 77.

WARNING! Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness or death. Never run an engine in an enclosed area.

Transporting the Vehicle

Follow these procedures when transporting the vehicle.

1. Place the transmission in PARK. Stop the engine.

2. Remove the key to prevent loss during transporting.

3. Secure the fuel cap and seats. Ensure that the seats are attached cor-

rectly and are not loose.

WARNING! Cargo and other loose vehicle parts may fly off while transporting

this vehicle. Secure or remove all cargo, and inspect the unit for loose parts prior

to transport.

4. Always tie the frame of the POLARIS vehicle to the transporting

unit securely with suitable straps or rope. Do not attach tie straps to

the front control arm bolt pockets.

131

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SPECIFICATIONS

RZR / RZR S

Gross Vehicle Weight Rating

Dry Weight

RZR: 1727 lbs. (783 kg)

RZR S: 1782 lbs. (808 kg)

RZR: 993 lbs. (450 kg)

RZR EPS: 1041 lbs. (472 kg)

RZR S: 1029 lbs. (467 kg)

RZR S EPS: 1055 lbs. (479 kg)

Test GVW - Rollover Protection RZR: 1745 lbs. (791.5 kg) per OSHA 29 CFR

System (ROPS)

1928.53

RZR S: 1795 lbs. (814 kg) per OSHA 29 CFR

1928.53

Rear Cargo Box Capacity

300 lbs. (136 kg)

Maximum Weight Capacity

(Payload)

740 lbs. (336.4 kg) (riders/cargo/accessories/

trailer tongue weight)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg)

Receiver Hitch Towing Capacity 1500 lbs. (680 kg

Fuel Capacity

Engine Oil Capacity

7 gal. (26.5 l)

2 qts. (1.9 l)

Coolant Capacity

4.8 qts. (4.5 l)

26 oz. (769 ml)

6.75 oz. (200 ml)

24 oz. (710 ml)

14 oz. (414 ml)

Rear Gearcase Oil Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Transfer Case Oil Capacity

Overall Length/Width/Height

RZR: 102/50/68.5 in. (259/127/174 cm)

RZR S: 106/60.5/70.5 in. (269/154/179 cm)

Wheelbase

77 in. (196 cm)

Ground Clearance

Engine

RZR: 10 in. (25.4 cm) / RZR S: 12 in. (30.5 cm)

4 valve 4 stroke twin cylinder with

counterbalance

Displacement

760 cc

Bore x Stroke

80mm x 76mm

500 W @ 3000 RPM

10:1

Electric

Electronic fuel injection

ECU

RC7YC /.035 in. (0.9 mm)

Independent double a-arm with travel:

RZR: 9 in. (23 cm) / RZR S: 12 in. (30.5 cm)

Alternator Output

Compression Ratio

Starting System

Fuel System

Ignition System

Spark Plug / Gap

Front Suspension

Rear Suspension

Independent double a-arm with travel:

RZR: 9.5 in. (24 cm) / RZR S: 12 in. (30.5 cm)

132

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SPECIFICATIONS

RZR / RZR S

Lubrication System

Driving System Type

Shift Type

Wet Sump

Automatic POLARIS Variable Transmission

Dual Range P/R/N/L/H

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front

Drive Ratio - Final

Tire Size - Front

8.71:1

5.94:1

3.14:1

3.82:1

3.70:1

RZR: 25x8-12

RZR S: 27x9-12

Tire Size - Rear

Tire Pressure

RZR: 25x10-12

RZR S: 27x12-12

RZR - ONE RIDER

Front: 8 psi (55 KPa)

Rear: 10 psi (69 KPa)

RZR - TWO RIDERS

Front: 10 psi (69 KPa)

Rear: 12 psi (83 KPa)

RZR S

Front: 10 psi (69 KPa)

Rear: 10 psi (69 KPa)

Brakes, Front/Rear

Headlights

Foot Activated, 4-wheel hydraulic disc

2 dual beam, 60W/55W halogen

Taillights

Brake Lights

Instrument Cluster

Auxiliary DC Outlet

2 single beam, 5W

LCD

12V

Clutching (Standard Model)

Altitude

Shift

Weight

Drive Clutch

Spring

Driven Clutch

Spring

Meters

(Feet)

0-1500

(0-5000)

23-62

Green

Black/Almond

PN 7043167

PN 5632337 PN 7043789

1500-3700

(5000-12000)

23-58

Green

Black/Almond

PN 7043167

PN 5632218 PN 7043789

Clutching (EBS Model)

Altitude

Shift

Weight

Drive Clutch

Spring

Driven Clutch

Spring

Meters

(Feet)

0-1500

(0-5000)

23-66

Green

Red

PN 3234452

PN 5632763 PN 7043789

1500-3700

(5000-12000)

23-62

Green

Red

PN 3234452

PN 5632337 PN 7043789

133

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SPECIFICATIONS

RZR 4

Gross Vehicle Weight Rating

Dry Weight

2206 lbs. (1000 kg)

1255 lbs. (569 kg) (RZR 4)

1271 lbs. (576.5 kg) (RZR 4 EPS)

Test GVW - Rollover Protection 2250 lbs. (1021 kg) per OSHA 29 CFR 1928.53

System (ROPS)

Rear Cargo Box Capacity

300 lbs. (136 kg)

Maximum Weight Capacity

(Payload)

900 lbs. (408.2 kg) (riders/cargo/accessories/

trailer tongue weight)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg)

Receiver Hitch Towing Capacity 1500 lbs. (680 kg

Fuel Capacity

7 gal. (26.5 l)

Engine Oil Capacity

Coolant Capacity

2 qts. (1.9 l)

5.5 qts. (5.2 l)

Rear Gearcase Oil Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Transfer Case Oil Capacity

Overall Length/Width/Height

Wheelbase

26 oz. (769 ml)

6.75 oz. (200 ml)

24 oz. (710 ml)

14 oz. (414 ml)

130/60.5/75 in. (330/154/190.5 cm)

103 in. (262 cm)

12 in. (30.5 cm)

Ground Clearance

Engine

4 valve 4 stroke twin cylinder with

counterbalance

Displacement

760 cc

Bore x Stroke

80mm x 76mm

500 W @ 3000 RPM

10:1

Electric

Electronic fuel injection

ECU

RC7YC /.035 in. (0.9 mm)

Independent double a-arm with 12 in. (30.5 cm)

of travel

Alternator Output

Compression Ratio

Starting System

Fuel System

Ignition System

Spark Plug / Gap

Front Suspension

Rear Suspension

Independent double a-arm with 12 in. (30.5 cm)

of travel

134

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SPECIFICATIONS

RZR 4

Lubrication System

Driving System Type

Shift Type

Wet Sump

Automatic POLARIS Variable Transmission

Dual Range P/R/N/L/H

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front

Drive Ratio - Final

Tire Size - Front

Tire Size - Rear

8.71:1

5.94:1

3.14:1

3.82:1

3.70:1

27x9-12

27x12-12

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Headlights

Taillights

Brake Lights

12 psi (83 KPa)

14 psi (97 KPa)

Foot Activated, 4-wheel hydraulic disc

2 dual beam, 60W/55W halogen

2 single beam, 5W

LCD

Instrument Cluster

Auxiliary DC Outlets

2 12-Volt

Clutching

Altitude

Shift

Weight

Drive Clutch

Spring

Driven Clutch

Spring

Meters

(Feet)

0-1500

(0-5000)

23-62

Black

Black/Almond

PN 7043167

PN 5632337 PN 7043594

1500-3700

(5000-12000)

23-58

Black

Black/Almond

PN 7043167

PN 5632218 PN 7043594

135

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POLARIS PRODUCTS

Part

Description

Number

Engine Lubricant

2870791

2876244

2876245

2878920

2878919

Fogging Oil (12 oz./355 ml Aerosol)

PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)

PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)

PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)

PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068

2878069

AGL Full Synthetic Gearcase Lubricant & Transmission Fluid

(qt./.95 l)

AGL Full Synthetic Gearcase Lubricant & Transmission Fluid

(gal./3.8 l)

2877922

2877923

2870465

Demand Drive Fluid (qt./.95 l)

Demand Drive Fluid (gal./3.8 l)

Pump for Gallon (3.8 l) Jug

Coolant

2871534

2871323

Polaris Antifreeze 60/40 Premix (qt./.95 l)

Polaris Antifreeze 60/40 Premix (gal./3.8 l)

Grease / Specialized Lubricants

Grease Gun Kit, All Season Grease

All Season Grease (3 oz./89 ml cartridge)

All Season Grease (14 oz./414 ml cartridge)

ATV Angle Drive Fluid (qt./.95 l)

ATV Angle Drive Fluid (2.5 gal./9.5 l)

Premium Starter Grease

2871312

2871322

2871423

2876160

2872276

2871460

2871515

2871551

2871329

U-Joint Grease (3 oz./89 ml cartridge)

U-Joint Grease (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel™)

Additives / Miscellaneous

2871326

2870652

2872189

2871956

2859044

Carbon Clean

Fuel Stabilizer

DOT 4 Brake Fluid

Loctite™ 565 Thread Sealant

POLARIS Battery Tender™ Charger

136

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TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or Use low range during loading.

tall trailer in high range

Starting out going up a

steep incline

Use low range. See warnings on page 56.

Driving at low RPM or

ground speed (3-7 MPH)

Drive at a higher speed or use low range more frequently.

Insufficient warm-up at

low ambient

temperatures

Warm the engine at least 5 minutes. With the transmission

in neutral, advance the throttle to about 1/8 throttle in

short bursts, 5 to 7 times. The belt will become more

flexible and prevent belt burning.

Slow/easy clutch

engagement

Use the throttle quickly and effectively.

Towing/pushing at low

RPM/low ground speed

Use low range only.

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range and carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle rollover.

Climbing over large

objects from a stopped

position

Shift the transmission to low range and carefully use fast,

brief, aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle rollover.

Belt slippage from water Dry out the PVT (see page 102). Prevent water from

or snow ingestion into the entering the PVT outlet duct (see page 126). Inspect

PVT system

clutch seals for damage if repeated leaking occurs.

Clutch malfunction

See your POLARIS dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or

fuel lines. See your dealer.

Slippage from failure to

warm up belt

Always warm up the belt by operating below 30 MPH for

one mile (5 miles or more when temperature is below

freezing).

Wrong or missing belt

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 46.

137

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Loose electronic control box connections Inspect, clean, reinstall connectors

Engine Turns Over, Fails to Start

Possible Cause

Out of fuel

Solution

Refuel

Clogged fuel filter

See your POLARIS dealer

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plugs

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Immediately see your POLARIS dealer

Recharge the battery to 12.8 VDC

See your dealer

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

Loose ignition connections

Water present in fuel

Check all connections and tighten

Replace with fresh recommended fuel

138

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TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

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

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Other mechanical failure

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

See your POLARIS dealer

Clogged fuel filter

Possible Rich Fuel Cause

Solution

Fuel is very high octane

Replace with lower octane fuel

139

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel

Inspect and replace

Kinked or plugged fuel vent line

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

Replace with new fuel

Inspect, clean and/or replace spark plug

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Other mechanical failure

Overheated engine

Clean radiator screen and core, clean

engine exterior, see your dealer

140

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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.

This warranty covers parts and labor charges for repair or replacement of defective parts

and begins on the date of purchase by the original retail purchaser. This warranty is

transferable to another owner during the warranty period through a POLARIS dealer,

but any such transfer will not extend the original term of the warranty. The duration of

this warranty may vary by international region based upon local laws and regulations.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to POLARIS within ten days of purchase. Upon receipt of this

registration, POLARIS will record the registration for warranty. No verification of

registration will be sent to the purchaser as the copy of the Warranty Registration Form

will be your proof of warranty coverage. If you have not signed the original registration

and received the customer copy, please contact your dealer immediately. NO

WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS

REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is

very important in ensuring trouble-free operation. Purchasing a machine in the crate or

without proper dealer set-up will void your warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

This POLARIS limited warranty excludes any failures that are not caused by a defect in

material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF

DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental

damage, normal wear and tear, abuse or improper handling. This warranty also does not

cover any vehicle, component, or part that has been altered structurally, modified,

neglected, improperly maintained, or used for purposes other than for which it was

designed.

This warranty excludes damages or 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; snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket or unapproved components, accessories, or attachments; unauthorized

repairs; or repairs made after the warranty period expires or by an unauthorized repair

center.

141

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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 components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Light bulbs/Sealed beam lamps

Filter

Lubricants

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components and fluids

Circuit breakers/Fuses

Electronic components

Spark plugs

Sealants

Coolants

Bearings

Bushings

Lubricants and Fluids

1. Mixing oil brands or using non-recommended oil may cause engine damage. We

recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is

not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage,

transportation costs, hotels, meals, shipping or handling fees, product pick-up or

delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or

personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,

AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE

MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN

THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON

FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY

TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL

DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR

IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR

OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL,

INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL

SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS

ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS

EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED

WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE

ABOVE SIX MONTH WARRANTY PERIOD. P0LARIS DISCLAIMS ALL

EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO

NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR

CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION

OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY

TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

142

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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.

In the country where your product was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If

you move or are traveling within the country where your product was purchased,

Warranty and Service Bulletin repairs may be requested from any authorized POLARIS

dealer that sells the same line as your product.

Outside the country where your product was purchased:

If you are traveling temporarily outside the country where your product was purchased,

you should take your product to an authorized POLARIS dealer. You must show the

dealer photo identification from the country of the selling dealer’s authorized location as

proof of residence. Upon residence verification, the servicing dealer will be authorized

to perform the warranty repair.

If you move:

If you move to another country, be sure to contact POLARIS Customer Assistance and

the customs department of the destination country before you move. Product

importation rules vary considerably from country to country. You may be required to

present documentation of your move to POLARIS in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS in order to

a local POLARIS dealer in your new country immediately after you move to continue

your warranty coverage and to ensure that you receive information and notices regarding

your vehicle.

If you purchase from a private party:

If you purchase a POLARIS product from a private party, to be kept and used outside of

the country in which the product was originally purchased, all warranty coverage will be

denied. You must nonetheless register your product under your name and address with a

local POLARIS dealer in your country to ensure that you receive safety information and

notices regarding your product.

143

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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. This policy does not apply to products registered to government

officials or military personnel on assignment outside the country of the selling dealer’s

authorized location. This policy does not apply to Safety Bulletins.

NOTICE

If your product is registered outside of the country where it was purchased and you have

not followed the procedure set above, your product will no longer be eligible for

warranty or service bulletin coverage of any kind, other than safety bulletins. Products

registered to Government officials or military personnel on assignment outside of the

country where the product was purchased will continue to be covered by the Limited

Warranty.

Please work with your dealer to resolve any warranty issues. Should your dealer require

any additional assistance, they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state or in different countries. If any of the above terms are void

because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

144

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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.

POLARIS warrants that the vehicle is free from defects in materials and workmanship

that would cause it to fail to meet these regulations.

The warranty period for off-road vehicles 100cc or greater emissions-certified vehicles

starts on the date of purchase by original retail purchaser and continues for a period of

500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30

calendar months from the date of purchase, whichever comes first. The warranty period

for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by

original retail purchaser and continues for a period of 250 hours of engine operation,

2500 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of

purchase, whichever comes first. This EPA emissions warranty period is extended for at

least as long as the standard factory warranty that Polaris provides on the vehicle as a

whole. The EPA emissions warranty period does not further extend if you purchase

additional warranty coverage in the form of a service contract or other paid warranty

extension, but emission-related parts may be covered subject to the terms of any such

paid service contract or paid warranty extension.

This emissions limited warranty covers components whose failure increases the

vehicle’s regulated emissions, and it covers components of systems whose only purpose

is to control emissions. Repairing or replacing other components not covered by this

warranty is the responsibility of the vehicle owner. This emissions limited warranty does

not cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust

emissions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

145

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

The following parts are considered emission-related components for evaporative

emissions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

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. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND

SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL

PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow

limitations on how long an implied warranty lasts, so the above limitation may not apply

if it is inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or

workmanship. This limited warranty does not cover damage due to accidents, abuse or

improper handling, maintenance or use. This limited warranty also does not cover any

engine that has been structurally altered, or when the vehicle has been used in racing

competition. This limited warranty also does not cover physical damage, corrosion or

defects caused by fire, explosions or other similar causes beyond the control of

POLARIS.

146

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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. POLARIS recommends that you contact an

authorized POLARIS dealer to perform any service that may be necessary for your

vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a

potential violation of the Clean Air Act if a part supplied by an aftermarket parts

manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering

with emission controls is prohibited by federal law.

California Residents

Certain POLARIS off-road vehicles are available in 49-state and 50-state versions. Only

the 50-state models are certified for sale in California. The 50-state models available for

sale in California are identified by the letter “C” in the model name (e.g.,

R13UH88A_C). The POLARIS 50-state models are designed and built with features

such as a reduced cargo box capacity. Any modifications to these features may be a

violation of the applicable California regulations and may void this limited emissions

warranty offered by the manufacturer.

If you have any questions regarding your warranty rights and responsibilities, please

contact POLARIS Customer Assistance.

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

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MAINTENANCE LOG

Use the following chart to record periodic maintenance.

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

149

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INDEX

Accessory Outlet . . . . . . . . . . . . . . . 32

Adding Coolant . . . . . . . . . . . . . . . . 98

Adjustment

Cab Frame, ROPS . . . . . . . . . . . . . . . 35

Cab Nets . . . . . . . . . . . . . . . . . . . . . . 30

Cap, Fuel . . . . . . . . . . . . . . . . . . . . . . 30

Cargo . . . . . . . . . . . . . . . . . . . . . . 62-64

Changing Coolant . . . . . . . . . . . . . . . 98

Changing Gears . . . . . . . . . . . . . . . . . 34

Chart, Periodic Maintenance . . . . 77-81

Check Engine Indicator . . . . . . . . . . . 45

Chrome Wheel Care . . . . . . . . . . . . 128

Cleaning and Storage. . . . . . . . 126-131

Cleaning the Air Filter. . . . . . . . . . . 103

Cleaning the Exhaust System . . . . . 104

Cleaning the Spark Arrestor . . . . . . 104

Clothing . . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching . . . . . . . . . . . . . . . . . 133, 135

Component Locations . . . . . . . . . 25-26

Condition, Spark Plugs . . . . . . . . . . . 95

Coolant Level . . . . . . . . . . . . . . . . . 100

Coolant Level, Radiator. . . . . . . . . . . 99

Coolant, Adding or Changing . . . . . . 98

Cooling Fan . . . . . . . . . . . . . . . . . . . . 99

Cooling System . . . . . . . . . . . . . 99-100

Cooling System Operation. . . . . . . . . 98

Corrosion Removal, Chrome. . . . . . 128

Cover for Storage. . . . . . . . . . . . . . . 130

Crankcase Emission Control System. 76

Hand Hold. . . . . . . . . . . . . . . . . . 28

Seat . . . . . . . . . . . . . . . . . . . . . . . 27

Steering Wheel . . . . . . . . . . . . . . 28

Adjustment, Headlight Beam. . . . . 118

Adjustment, Throttle Freeplay. . . . 106

Age Restrictions. . . . . . . . . . . . . . . . 14

Air Filter . . . . . . . . . . . . . . . . . . . . 103

Air Filter Cleaning. . . . . . . . . . . . . 103

All Wheel Drive Switch. . . . . . . . . . 33

All Wheel Drive System . . . . . . . . . 36

Arrester, Spark, Warning. . . . . . . . 104

Auxiliary Outlet. . . . . . . . . . . . . . . . 32

AWD Switch . . . . . . . . . . . . . . . 33, 36

AWD System. . . . . . . . . . . . . . . . . . 36

Axle Nut Torque . . . . . . . . . . . . . . 115

Battery . . . . . . . . . . . . . . . . . . . 120-125

Battery Charging . . . . . . . . . . . 124-125

Battery Fluid Replenishment. . . . . 123

Battery Installation. . . . . . . . . . . . . 122

Battery Removal . . . . . . . . . . . . . . 121

Battery Storage . . . . . . . . . . . . . . . 123

Before Riding. . . . . . . . . . . . . . . . . . 48

Belt Burning. . . . . . . . . . . . . . . . . . 137

Belt Life. . . . . . . . . . . . . . . . . . . . . . 63

Belt Replacement. . . . . . . . . . . . . . 102

Belt Wear. . . . . . . . . . . . . . . . . . . . 137

Belts, Seat . . . . . . . . . . . . . . . . . . . . 31

Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake Fluid . . . . . . . . . . . . . . . . . . 108

Brake Inspection . . . . . . . . . . . . . . 109

Brake Lights. . . . . . . . . . . . . . . . . . 119

Brake Pedal . . . . . . . . . . . . . . . . . . . 35

Brake System Break-in . . . . . . . . . . 47

Brakes . . . . . . . . . . . . . . . . . . . 107-109

Braking . . . . . . . . . . . . . . . . . . . . . . 50

Break-In Period . . . . . . . . . . . . . . 46-47

Burning Belts. . . . . . . . . . . . . . . . . 137

Demand Drive Fluid . . . . . . . . . . . . . 92

Display Units, Standard/Metric. . . . . 41

Drive Belt Wear. . . . . . . . . . . . . . . . 137

Drivetrain Break-In . . . . . . . . . . . . . . 47

Driving Downhill. . . . . . . . . . . . . . . . 57

Driving in Reverse. . . . . . . . . . . . . . . 60

Driving on a Sidehill . . . . . . . . . . . . . 57

Driving on Slippery Surfaces . . . . . . 55

Driving Over Obstacles . . . . . . . . . . . 59

Driving Procedures . . . . . . . . . . . 52-53

Driving Through Water . . . . . . . . . . . 58

Driving Uphill . . . . . . . . . . . . . . . . . . 56

Driving with Passengers . . . . . . . . . . 54

Driving, After Driving in Water . . . 102

Drying the Transmission . . . . . . . . . 102

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INDEX

Electromagnetic Interference . . . . . . 76

Electronic Power Steering . . . . . . . . 32

Emission Control, Crankcase . . . . . . 76

Emission Control, Exhaust . . . . . . . . 76

Emission Control, Noise. . . . . . . . . . 76

Emissions Limited Warranty . 145-147

Engaging AWD. . . . . . . . . . . . . . . . . 36

Engine Break-In . . . . . . . . . . . . . . . . 47

Engine Fogging. . . . . . . . . . . . . . . . 130

Engine Idle Speed . . . . . . . . . . . . . . 106

Engine Oil. . . . . . . . . . . . . . . . . . 84-87

Engine Starting . . . . . . . . . . . . . . . . . 50

Engine Stopping . . . . . . . . . . . . . . . . 50

EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Equipment Modifications . . . . . . . . . 24

Error Codes, Engine . . . . . . . . . . . . . 45

Etiquette, Trail Riding . . . . . . . . . . . 51

Exhaust Cleaning . . . . . . . . . . . . . . 104

Exhaust Emission Control System . . 76

Exhaust System Warning . . . . . . . . 104

Eye Protection. . . . . . . . . . . . . . . . . . . 9

Fluid Check

Demand Drive . . . . . . . . . . . . . . . 92

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . . . . 90

Transfer Case . . . . . . . . . . . . . . . . 88

Transmission . . . . . . . . . . . . . . . . 90

Fluid Levels During Storage. . . . . . 129

Fluid Recommendations, Gearcase . 94

Fluid, Battery . . . . . . . . . . . . . . . . . 123

Fluid, Brake . . . . . . . . . . . . . . . . . . 108

Fogging the Engine. . . . . . . . . . . . . 130

Fouled Plugs . . . . . . . . . . . . . . . . . . . 95

Freeplay Adjustment, Throttle . . . . 106

Freeplay, Steering Wheel . . . . . . . . 110

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 30

Fuel Safety . . . . . . . . . . . . . . . . . . . . 22

Fuel Stabilizer. . . . . . . . . . . . . . . . . 129

Fuel Tank Filler Cap. . . . . . . . . . . . . 30

Fuses . . . . . . . . . . . . . . . . . . . . . . 96-97

Gap, Spark Plug . . . . . . . . . . . . . . . . 94

Gasoline Handling . . . . . . . . . . . . . . 22

Gear Selector . . . . . . . . . . . . . . . . . . 34

Gearcase Capacities . . . . . . . . . . . . . 94

Gearcase Oil

Fan, Cooling . . . . . . . . . . . . . . . . . . . 99

Filling the Battery . . . . . . . . . . . . . . 123

Filter Care During Storage . . . . . . . 129

Filter Cleaning, Air. . . . . . . . . . . . . 103

Filter, Air . . . . . . . . . . . . . . . . . . . . 103

Fluid

Demand Drive . . . . . . . . . . . . . . . 92

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . 90-91

Rear Gearcase . . . . . . . . . . . . . . . 93

Transfer Case . . . . . . . . . . . . . 88-89

Transmission . . . . . . . . . . . . . 90-91

Fluid Change

Demand Drive . . . . . . . . . . . . . . . 92

Front. . . . . . . . . . . . . . . . . . . . . . . 92

Main . . . . . . . . . . . . . . . . . . . . 90-91

Rear . . . . . . . . . . . . . . . . . . . . . . . 93

Transfer Case . . . . . . . . . . . . . 88-89

Gearcase Specifications . . . . . . . . . . 94

Gearcases. . . . . . . . . . . . . . . . . . 88-94

Demand Drive . . . . . . . . . . . . . . . 92

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . 90-91

Rear Gearcase . . . . . . . . . . . . . . . 93

Specification Chart. . . . . . . . . . . . 94

Transfer Case . . . . . . . . . . . . . 88-89

Transmission . . . . . . . . . . . . . 90-91

Gears, shifting. . . . . . . . . . . . . . . . . . 34

Gloves. . . . . . . . . . . . . . . . . . . . . . . . . 9

Grill Removal . . . . . . . . . . . . . . . . . . 27

Demand Drive . . . . . . . . . . . . . . . 92

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . . . . 91

Rear Gearcase . . . . . . . . . . . . . . . 93

Transfer Case . . . . . . . . . . . . . . . . 89

Transmission . . . . . . . . . . . . . . . . 91

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INDEX

Hand Hold, Passenger . . . . . . . . . . . 28

Hauling a Load . . . . . . . . . . . . . . 62-64

Hauling Cargo . . . . . . . . . . . . . . . 62-64

Headlight High Beam Adjustment. 118

Headlight Lamp Replacement . . . . 117

Headlight Replacement (LED) . . . 117

Headlight Switch . . . . . . . . . . . . . . . 33

Helmet . . . . . . . . . . . . . . . . . . . . . . . . 8

Hitch . . . . . . . . . . . . . . . . . . . . . . . . 26

Hitch Weight . . . . . . . . . . . . . . . . . . 64

Hood Removal. . . . . . . . . . . . . . . . . 29

Maintenance Log. . . . . . . . . . . 148-149

Maintenance, Periodic . . . . . . . . . 77-81

Metric Display. . . . . . . . . . . . . . . . . . 41

Mode Button . . . . . . . . . . . . . . . . . . . 37

Nets, Cab . . . . . . . . . . . . . . . . . . . . . . 30

New Operator Procedures . . . . . . 52-53

Noise Emission Control System . . . . 76

Obstacles . . . . . . . . . . . . . . . . . . . . . . 59

Oil

Idle Speed . . . . . . . . . . . . . . . . . . . 106

Ignition Switch. . . . . . . . . . . . . . . . . 33

Indicator Lamps. . . . . . . . . . . . . . . . 38

Inspection, Axle Nuts . . . . . . . . . . 115

Inspection, Brakes . . . . . . . . . . . . . 109

Inspection, Pre-Ride . . . . . . . . . . . . 48

Inspection, Steering Wheel . . . . . . 110

Inspection, Throttle Freeplay. . . . . 105

Inspection, Wheel Nuts . . . . . . . . . 115

Installation, Battery . . . . . . . . . . . . 122

Installation, Wheels . . . . . . . . . . . . 116

Instrument Cluster . . . . . . . . . . . . 37-45

Interference, Electromagnetic . . . . . 76

Demand Drive. . . . . . . . . . . . . . . . 92

Engine. . . . . . . . . . . . . . . . . . . 84-87

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . 90-91

Rear Gearcase . . . . . . . . . . . . . . . . 93

Transfer Case . . . . . . . . . . . . . 88-89

Transmission. . . . . . . . . . . . . . 90-91

Oil and Filter Care During Storage . 129

Oil Change

Demand Drive. . . . . . . . . . . . . . . . 92

Engine. . . . . . . . . . . . . . . . . . . . . . 87

Engine Oil. . . . . . . . . . . . . . . . . . . 86

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . . . . 91

Rear Gearcase . . . . . . . . . . . . . . . . 93

Transfer Case . . . . . . . . . . . . . . . . 89

Transmission. . . . . . . . . . . . . . . . . 91

Oil Check

Key, Periodic Maintenance Chart . . 78

Demand Drive. . . . . . . . . . . . . . . . 92

Engine Oil. . . . . . . . . . . . . . . . . . . 85

Front Gearcase . . . . . . . . . . . . . . . 92

Main Gearcase . . . . . . . . . . . . . . . 90

Transfer Case . . . . . . . . . . . . . . . . 88

Transmission. . . . . . . . . . . . . . . . . 90

Oil Recommendations . . . . . . . . . . . . 84

Operation on Public Lands . . . . . . . . 76

Operation, Cooling System . . . . . . . . 98

Operation, Transmission . . . . . 101-102

Operator Restrictions. . . . . . . . . . . . . 14

Level, Coolant . . . . . . . . . . . . . . 99-100

Lights . . . . . . . . . . . . . . . . . . . 117-119

Brake Lights . . . . . . . . . . . . . . . 119

Headlight Lamp Replacement . 117

Headlight Replacement (LED) . 117

Headlight Switch. . . . . . . . . . . . . 33

High Beam Adjustment . . . . . . 118

Loads, Towing. . . . . . . . . . . . . . . . . 64

Lubricant Part Numbers. . . . . . . . . 136

Lubrication for Storage . . . . . . . . . 130

Lubrication Recommendations . . 82-83

152

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INDEX

Parking on an Incline . . . . . . . . . . . . 61

Parking the Vehicle. . . . . . . . . . . . . . 51

Passenger Hand Hold Adjustment . . 28

Periodic Maintenance Chart . . . . 77-81

Plug Condition . . . . . . . . . . . . . . . . . 95

Plug Gap . . . . . . . . . . . . . . . . . . . . . . 94

Plug Torque. . . . . . . . . . . . . . . . . . . . 94

Plug, Accessory . . . . . . . . . . . . . . . . 32

Plugs, Fouled . . . . . . . . . . . . . . . . . . 95

Plugs, Spark . . . . . . . . . . . . . . . . 94-95

Polaris Products . . . . . . . . . . . . . . . 136

Polishing the Vehicle . . . . . . . . . . . 127

Power Steering . . . . . . . . . . . . . . . . . 32

Pre-Ride Inspection. . . . . . . . . . . . . . 48

Public Lands . . . . . . . . . . . . . . . . . . . 76

PVT Break-In . . . . . . . . . . . . . . . . . . 47

PVT Drying. . . . . . . . . . . . . . . . . . . 102

PVT System Operation . . . . . . 101-102

PVT, Cleaning Debris. . . . . . . . . . . 102

Safe Operation Practices. . . . . . . . . . 49

Safety Labels . . . . . . . . . . . . . . . 10-13

Safety Symbols . . . . . . . . . . . . . . . . . . 4

Safety Training . . . . . . . . . . . . . . . . . . 7

Safety Training, ROHVA . . . . . . 49, 52

Safety Warnings . . . . . . . . . . . . . 14-24

Safety, Winch Maintenance . . . . . . . 75

Seat Adjustment . . . . . . . . . . . . . . . . 27

Seat Belts . . . . . . . . . . . . . . . . . . . . . 31

Seat Removal . . . . . . . . . . . . . . . . . . 27

Selector, Gear . . . . . . . . . . . . . . . . . . 34

Service Panel, Rear. . . . . . . . . . . . . . 27

Severe Use Definition. . . . . . . . . . . . 77

Shifting Gears . . . . . . . . . . . . . . . . . . 34

Shock Compression . . . . . . . . . . . . 114

Shock Loading the Winch . . . . . . . . 74

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Arrester Warning . . . . . . . . . 104

Spark Arrestor Cleaning . . . . . . . . . 104

Spark Plug Condition . . . . . . . . . . . . 95

Spark Plug Gap. . . . . . . . . . . . . . . . . 94

Spark Plug Removal . . . . . . . . . . . . . 95

Spark Plug Torque . . . . . . . . . . . . . . 94

Spark Plugs . . . . . . . . . . . . . . . . . 94-95

Spark Plugs, Fouled . . . . . . . . . . . . . 95

Specifications . . . . . . . . . . . . . 132-135

Specifications, Gearcase. . . . . . . . . . 94

Speed, Idle . . . . . . . . . . . . . . . . . . . 106

Speed, Towing . . . . . . . . . . . . . . . . . 64

Speedometer . . . . . . . . . . . . . . . . . . . 37

Spring Preload . . . . . . . . . . . . 112-113

Spring Preload (RZR). . . . . . . . . . . 111

Stabilizing the Fuel. . . . . . . . . . . . . 129

Starting the Engine . . . . . . . . . . . . . . 50

Steering Wheel Adjustment . . . . . . . 28

Steering Wheel Inspection . . . . . . . 110

Stopping the Engine . . . . . . . . . . . . . 50

Storage . . . . . . . . . . . . . . . . . . 126-131

Storage and Inspection . . . . . . . . . . 130

Storage and Lubrication . . . . . . . . . 130

Radiator. . . . . . . . . . . . . . . . . . . . . . . 99

Radiator Access . . . . . . . . . . . . . . . . 27

Radiator Coolant Level. . . . . . . . . . . 99

Rear Gearcase Fluid Change. . . . . . . 93

Rear Gearcase Oil Change . . . . . . . . 93

Receiver Hitch . . . . . . . . . . . . . . . . . 26

Refueling Safety . . . . . . . . . . . . . . . . 22

Removal, Battery . . . . . . . . . . . . . . 121

Removal, Seat . . . . . . . . . . . . . . . . . . 27

Removal, Wheels . . . . . . . . . . . . . . 116

Removing the Vehicle from Storage 131

Restrictions, Age. . . . . . . . . . . . . . . . 14

Reverse . . . . . . . . . . . . . . . . . . . . . . . 60

Rider Information Center . . . . . . 39-45

Riding Area. . . . . . . . . . . . . . . . . . . . 51

Riding Gear. . . . . . . . . . . . . . . . . . . 8-9

Rollover Protective Structure . . . . . . 35

ROPS Cab Frame . . . . . . . . . . . . . . . 35

RPM, Idle, Throttle Body . . . . . . . . 106

153

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INDEX

Storage Area . . . . . . . . . . . . . . . . . 130

Storage, Battery . . . . . . . . . . . . . . . 123

Storage, Covers . . . . . . . . . . . . . . . 130

Storage, Fluid Levels. . . . . . . . . . . 129

Storage, Oil and Filter . . . . . . . . . . 129

Storage, Removal. . . . . . . . . . . . . . 131

Suspension Settings . . . . . . . . . 111-114

Switches

Vehicle Identification Numbers. . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . 119

Vehicle Transport . . . . . . . . . . . . . . 131

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . 126-127

Water, Immersion of Vehicle . . . . . 119

Wear, Drive Belt . . . . . . . . . . . . . . . 137

Weight, Hitch. . . . . . . . . . . . . . . . . . . 64

Wheel Installation . . . . . . . . . . . . . . 116

Wheel Nut Torque . . . . . . . . . . . . . . 115

Wheel Removal . . . . . . . . . . . . . . . . 116

Winch Cable Care . . . . . . . . . . . . . . . 73

Winch Maintenance/Service Safety. . 75

Winch Operation . . . . . . . . . . . . . 68-72

Winch Safety Precautions . . . . . . 65-67

Winch Shock Loading . . . . . . . . . . . . 74

AWD Switch. . . . . . . . . . . . . 33, 36

Ignition . . . . . . . . . . . . . . . . . . . . 33

Mode Button . . . . . . . . . . . . . . . . 37

Tachometer . . . . . . . . . . . . . . . . . . . 43

Throttle Freeplay Adjustment . . . . 106

Throttle Freeplay Inspection . . . . . 105

Throttle Freeplay . . . . . . . . . . . . . . 105

Throttle Pedal. . . . . . . . . . . . . . . . . . 35

Throttle System . . . . . . . . . . . . . . . 105

Tire Tread Depth . . . . . . . . . . . . . . 115

Tires. . . . . . . . . . . . . . . . . . . . . 115-116

Torque, Axle Nuts . . . . . . . . . . . . . 115

Torque, Spark Plug . . . . . . . . . . . . . 94

Torque, Wheel Nut . . . . . . . . . . . . 115

Towing Loads . . . . . . . . . . . . . . . . . 64

Towing Speed . . . . . . . . . . . . . . . . . 64

Trail Etiquette . . . . . . . . . . . . . . . . . 51

Trailer Hitch. . . . . . . . . . . . . . . . . . . 26

Training . . . . . . . . . . . . . . . . . . . . . . . 7

Transfer Case Oil. . . . . . . . . . . . . 88-89

Transmission Oil . . . . . . . . . . . . . 90-91

Transmission Operation. . . . . . 101-102

Transmission, Drying . . . . . . . . . . 102

Transporting the Vehicle . . . . . . . . 131

Tread Depth, Tire. . . . . . . . . . . . . . 115

Tread Lightly . . . . . . . . . . . . . . . . . . 51

154

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