Polaris Utility Vehicle RZR XP 4 900 User Manual

RANGER

RZR XP 900

RANGER

RZR XP 4 900

Owner's Manual

for Maintenance and Safety

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The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

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WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:

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

• without first viewing safety video and quick start guide.

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

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

• on hills steeper than 15 degrees.

• on public roads.

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

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

ALWAYS:

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

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

• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and

over-the-anke boots.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

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

• Make sure passengers read and understand all safety labels.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR

OPERATOR AND PASSENGERS. NEVER USE ON PUBLIC ROADS.

NEVER USE WITH DRUGS OR ALCOHOL.

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

For your nearest Polaris dealer,

call 1-800-POLARIS

or visit www.polarisindustries.com

Polaris Sales Inc.,

2100 Hwy. 55

Medina, MN 55340

Phone 1-888-704-5290

Part No. 9924107 Rev 01

Printed in USA

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WELCOME

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

world-wide family of POLARIS owners. We proudly produce an excit-

ing line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

• Low Emission Vehicles (LEVs)

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

recreational vehicles manufactured in the world today. Many years of

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

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

duced.

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

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the POLARIS Service Manual and should be

performed only by a factory certified Master Service Dealer® (MSD)

Technician.

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

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

vice needs during, and after, the warranty period.

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POLARIS, RANGER, RANGER RZR and RANGER RZR XP 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 discrep-

ancies may result between the actual vehicle and the information presented in this publi-

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

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

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

translations of the original instructions.

Printed in U.S.A.

2013 RANGER RZR XP 900 / RANGER RZR XP 4 900 Owner’s Manual

P/N 9924107

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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INTRODUCTION

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. Understand all safety warnings, precautions and

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

vehicle.

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

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

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

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

and over-the-ankle boots.

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

• Visit the Recreational Off-Highway Vehicle Association web site (rohva.org)

and take the free on-line training course.

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

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

New Operator Driving Procedures.

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration lev-

els 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 con-

trolled 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

Vehicle Identification

Number

####

Engine Serial

Number

Vehicle Model Number: ___________________________________________________

Vehicle Identification Number: ______________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

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SAFETY

Equipment Modifications

Your POLARIS vehicle is designed to provide safe operation when used

as directed. Modifications to your vehicle may negatively impact vehi-

cle stability. Failure of critical machine components may result from

operation with any modifications, especially those that increase speed or

power. This vehicle may become less stable at speeds higher than those

for which it is designed. Loss of control may occur at higher speeds.

Do not install on a POLARIS vehicle any equipment that may increase

the speed or power of the vehicle, or make any other modifications to

the vehicle for these purposes. Any modifications to the original equip-

ment of the vehicle create a substantial safety hazard and increase the

risk of bodily injury.

The warranty on your POLARIS vehicle is terminated if any equipment

has been added to the vehicle, or if any modifications have been made to

the vehicle, that increase its speed or power.

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

ers, blades, tires, sprayers, or large racks, may change the handling char-

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

familiarize yourself with their function and effect on the vehicle.

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SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding a POLARIS vehicle.

Wear protective clothing for comfort and to reduce the chance of injury.

Long

Eye

Sleeves

Protection

Long

Pants

Sturdy

Footwear

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 a POLARIS vehicle, always wear shatterproof goggles or

use a shatterproof helmet face shield. POLARIS recommends wearing

approved Personal Protective Equipment (PPE) bearing markings such

as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept

clean.

Gloves

Wear gloves for comfort and for protection from sun, cold weather and

other elements.

Boots

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

bare feet.

Clothing

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

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SAFETY

Safety Warnings

WARNING

Failure to operate this vehicle properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Heed all safety

warnings outlined in this section of the owner’s manual. See the OPERATION

section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction

increases the risk of an accident. The operator

must understand how to operate the vehicle

properly in different situations and on different

types of terrain. Take a training course and

complete the New Operator Driving Procedures

outlined on pages 56-57.

All operators must read and understand the

owner's manual and all warning and instruction

labels before operating the vehicle. Never allow a

guest to operate this vehicle until the guest has

completed the New Operator Driving Procedures

outlined on pages 56-57.

Operator Restrictions/Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age or anyone without a valid driver’s license. Never operate

with a passenger under the age of 12. Make sure all passengers are tall enough

to comfortably and safely reach the hand holds and place both feet on the floor.

Accessories

Non-approved accessories may seriously affect vehicle stability. Using

accessories not approved by POLARIS for use on this vehicle could cause loss

of control or an accident. Never operate with accessories not approved by

POLARIS for use on this vehicle.

Using Alcohol or Drugs

Riding in this vehicle after consuming alcohol or

drugs could adversely affect operator judgment,

reaction time, balance and perception.

Never consume alcohol or drugs before or while

operating or riding in this vehicle.

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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 inspect the vehicle before each use

to make sure it's in safe operating

condition.

Always follow the inspection and

maintenance procedures and schedules

described in the owner's manual.

Protective Apparel

Riding in this vehicle without wearing an

approved helmet and protective eyewear

increases the risk of a serious injuries in the

event of an accident.

Operator and all passengers must always

wear a helmet, eye protection, gloves, 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 an accident or sudden stop. Riders must wear seat belts at

all times. Seat belts reduce the severity of injury in the event of a sudden stop or

accident. Always make sure the seat belts are secured for both the operator and

all passengers before riding.

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious

injury or death in the event of an accident or overturn. Always use the cab nets

while riding in this vehicle.

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

Carrying Passengers (RZR XP 4)

Never carry a passenger until you have operated this

vehicle for at least two hours and have completed

the New Operator Driving Procedures outlined on

pages 56-57.

A passenger must always be seated in a passenger

seat with seat belt secured.

Never carry more than three passengers in a 4-seat

vehicle.

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SAFETY

Safety Warnings

Carrying Multiple Passengers (RZR XP)

Never carry a passenger until you have operated this

vehicle for at least two hours and have completed the New

Operator Driving Procedures outlined on pages 56-57.

A passenger must always be seated in a passenger seat

with seat belt secured. Carrying more than one passenger

in a 2-seat vehicle can affect the operator’s ability to steer

and operate the controls, which increases the risk of loss of

control and accident or overturn. Never carry more than

one passenger in a 2-seat vehicle.

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation. For your

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

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

loading, tire pressure, gear selection and speed.

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

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

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

be reduced accordingly.

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

manual and on a label on the vehicle.

Always follow these guidelines:

Under ANY of these conditions:

Do ALL of these steps:

Passenger and/or cargo exceeds half the 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.

Operating on Pavement

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

lots, and driveways) may seriously affect handling and control of the vehicle,

and may cause the vehicle to go out of control. This vehicle's tires are designed

for off-road use only, not for use on pavement.

Avoid operating the vehicle on pavement. If you must operate on a paved

surface, travel slowly and do not make sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads

or highways could result in a collision with

another vehicle.

Never operate this vehicle on any public

street, road or highway, including dirt and

gravel roads.

In many areas it's illegal to operate vehicles

of this type on public streets, roads and

highways.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds

increases the operator's risk of losing

control.

Always operate at a speed that's

appropriate for the terrain, the visibility and

operating conditions, your skills and your

passenger’s skills.

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SAFETY

Safety Warnings

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or

overturn. Always follow proper procedures for turning as described in the

owner's manual.

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

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

faster speeds.

Physical Control of the Vehicle

Removing hands from the steering wheel or hand hold or removing feet from the

floor while riding increases the risk of loss of control and accident or overturn.

The operator should always keep both hands on the steering wheel during

operation. Passengers should always be seated in a passenger seat with seat

belt secured, with both feet on the floor and with both hands securely grasping

the passenger hand hold or grab bar.

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

Jumps and Stunts

Exhibition driving increases the risk of an

accident or overturn. DO NOT do power

slides, “donuts”, jumps or other driving

stunts. Avoid exhibition driving.

Descending Hills Improperly

Improperly descending a hill could cause

loss of control or overturn. Always follow

proper procedures for traveling down hills

as described in the owner's manual.

• Always descend a hill with the transmis-

sion in forward gear. Never descend a

hill with the transmission in neutral.

• Always check the terrain carefully before

descending a hill.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle,

which would cause the vehicle to lean

+15°

sharply to one side. Travel straight

downhill.

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SAFETY

Safety Warnings

Improper Hill Climbing

Improper hill climbing could cause loss of

control or overturn. Use extreme caution

when operating on hills. Always follow

proper procedures for hill climbing as

described in the owner's manual. See

page 60.

+15°

Crossing Hillsides

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

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

necessary.

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

described in the owner's manual. See page 61.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a

hill could cause an overturn. Maintain a

steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is

fully stopped. Place the transmission in

reverse and slowly allow the vehicle to roll

straight downhill while applying light brake

pressure to control speed.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on

unfamiliar terrain could result in an accident or

overturn.

Unfamiliar terrain may contain hidden rocks,

bumps, or holes that could cause loss of

control or overturn.

Travel slowly and use extra caution when

operating on unfamiliar terrain. Always be

alert to changing terrain conditions.

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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 64.

Before shifting into reverse gear, always check

for obstacles or people behind the vehicle.

When it's safe to proceed, back slowly.

Improper Tire Maintenance

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

pressure could cause loss of control, accident or overturn.

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

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

Operating on Slippery Terrain

Operating on excessively rough, slippery or

loose terrain could cause loss of traction, loss

of control, accident or overturn.

Do not operate on excessively rough, slippery

or loose terrain. Always use extra caution on

rough, slippery or loose terrain.

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SAFETY

Safety Warnings

Operating Over Obstacles

Improperly operating over obstacles

could cause loss of control or overturn.

Before operating in a new area, check

for obstacles. Never attempt to operate

over large obstacles such as rocks or

fallen trees. Always follow the proper

procedures outlined in this manual

when operating over obstacles.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction

unexpectedly). Always follow proper procedures for operating on slippery

surfaces as described in the owner's manual.

When operating on slippery surfaces such as ice or loose gravel, reduce speed

and use extra caution to reduce the chance of skidding or sliding.

Do not operate on excessively slippery surfaces.

Operating Through Water

Operating through deep or fast-flowing

water can cause loss of traction, loss of

control, overturn or accident. Never operate

in fast-flowing water or in water that

exceeds the recommended maximum

depth.

Always follow proper procedures for

operating in water as described in the

owner's manual.

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

brakes. Apply them lightly several times while driving slowly. The friction will

help dry out the pads.

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SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the vehicle or carrying cargo

improperly may cause changes in stability

and handling, which could cause loss of

control or an accident.

• Always follow the instructions in the

owner's manual for carrying cargo.

• Never exceed the stated load capacity for

this vehicle.

• Cargo should be properly distributed and

securely attached.

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

Operating on Frozen Bodies of Water

Severe injury or death can result if the

vehicle and/or the operator fall through the

ice. Never operate the vehicle on a frozen

body of water unless you have first verified

that the ice is sufficiently thick to support

the weight and moving force of the vehicle,

you and your passengers, and your cargo,

together with any other vehicles in your

party. Always check with local authorities

and residents to confirm ice conditions and

thickness over your entire route. Vehicle

operators assume all risk associated with

ice conditions on frozen bodies of water.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident with serious injury or

death. After any overturn or accident, have a qualified service dealer inspect the

entire vehicle for possible damage, including (but not limited to) brakes, throttle

and steering systems.

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SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and is explosive under certain conditions. Always

exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box before filling.

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

where gasoline is stored.

• Never refuel while a person is in the vehicle.

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

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

water and change clothing.

Refueling

Always turn off the engine before refueling. Make sure the refueling area is well

ventilated and free of any source of flame or sparks. Gasoline is extremely

flammable.

Remove flammable material containers from the box before filling.

Exposure to Exhaust

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

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

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

Hot Exhaust Systems

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

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

components. Always keep combustible materials away from the exhaust

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

Unauthorized Use of the Vehicle

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

which could result in an accident or overturn. Always remove the ignition key

when the vehicle is not in use.

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

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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

Load/Passenger/Tire Pressure

• Passengers can be thrown off. This

Warning (in cargo box)

can cause serious injury or death.

• Never carry passengers in cargo

box.

WARNING

IMPROPER TIRE PRESSURE OR

OVERLOADING CAN CAUSE LOSS

OF CONTROL RESULTING IN

SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance for braking when carrying cargo.

• Overloading or carrying tall, off-center, or unsecured loads will increase your

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

possible in box.

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

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

RANGER

RZR

RZR 4

RZR XP

RZR XP 4

MAXIMUM CARGO BOX LOAD

300 lbs.

(136 kg)

TIRE PRESSURE IN PSI (KPa) FRONT 8 (55) FRONT 10 (69) FRONT 12 (83) FRONT 14 (97)

REAR 8 (55)

REAR 12 (83)

REAR 14 (97)

REAR 16 (110)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF

740 lbs.

(336 kg)

900 lbs.

(408 kg)

740 lbs.

(336 kg)

900 lbs.

(408 kg)

OPERATOR, PASSENGER,

CARGO AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

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SAFETY

Safety Labels and Locations

Passenger

Safety

Warning

Passenger Safety Warning (RZR XP)

WARNING

NEVER CARRY A PASSENGER UNDER AGE 12

NEVER CARRY MORE THAN ONE PASSENGER

NEVER RIDE AFTER USING DRUGS OR ALCOHOL

To reduce the risk of SEVERE INJURY or DEATH,

NEVER carry a passenger under age 12 or too small to

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

THE PASSENGER MUST ALWAYS:

• wear seat belt.

• use an approved helmet and protective gear.

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

• tell operator to slow down or stop if uncomfortable - get off

and walk if conditions require.

• keep hands and feet inside vehicle at all times.

• watch for branches, brush, and other hazards that could

enter vehicle.

7175102

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SAFETY

Safety Labels and Locations

Passenger Safety Warning (RZR XP 4)

WARNING

NEVER CARRY PASSENGERS UNDER AGE 12

NEVER CARRY MORE THAN THREE PASSENGERS

NEVER RIDE AFTER USING DRUGS OR ALCOHOL

To reduce the risk of SEVERE INJURY or DEATH,

NEVER carry passengers under age 12 or too small to

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

PASSENGERS

UNDER

THE PASSENGERS MUST ALWAYS:

• wear seat belts.

• use approved helmets and protective gear.

• securely grasp hand holds and plant feet firmly on the

floor.

• tell operator to slow down or stop if uncomfortable - get off

and walk if conditions require.

• keep hands and feet inside vehicle at all times.

• avoid branches, brush and other hazards that could enter

vehicle.

7176608

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SAFETY

Safety Labels and Locations

Rear Passenger Cab Frame

Warning (RZR XP 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 grab bar.

7176700

Rear Passenger Grab Bar

Warning (RZR XP 4)

Always use seat belt, helmet and eye

protection.

Always use passenger grab bar and side

nets to keep hands and feet in vehicle at all

times.

7176701

Passenger Grab Bar

Warning

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SAFETY

Safety Labels and Locations

Age

Overturn

Warning

Cab Frame/Seat

Belt Warning

Discretionary

Warning

Shift

Caution

Cab Frame/Seat Belt Warning

WARNING

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

belt.

• ALWAYS SECURE CAB NETS.

• VEHICLE OVERTURN could cause severe injury or death.

Shift Caution

CAUTION

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

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

APPLY BRAKE TO START

7174843

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SAFETY

Safety Labels and Locations

Age Warning

WARNING

Operating this vehicle if you are under the age

of 16 increases your chance of severe injury or

death.

NEVER operate this vehicle if you are under

age 16 or without a valid driver’s license.

Overturn Warning

WARNING

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

or death.

This vehicle handles differently than cars, trucks

or other off-road vehicles. In order to avoid

overturns:

• avoid sharp turns.

• never turn while applying heavy throttle.

• never make abrupt steering maneuvers.

• operate at speeds appropriate for your skills,

the conditions and the terrain.

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

other driving stunts.

7175105

Belt Debris Warning

WARNING

Improper service or maintenance of this PVT system can result in vehicle

damage, SEVERE INJURY or DEATH.

Always look for and remove debris inside and around the clutch and vent

system when replacing the belt.

Read owner’s manual or see authorized POLARIS dealer.

7177469

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SAFETY

Safety Labels and Locations

Discretionary Warning (RZR XP)

WARNING

Improper vehicle use can result in SEVERE

INJURY or DEATH

NEVER operate:

• without first viewing safety video and quick

start guide.

• with more than one passenger.

• on hills steeper than 15 degrees.

• on public roads.

Discretionary

Warning

• on paved surfaces - pavement may seriously

affect handling and control.

• with non-POLARIS approved accessories -

they may seriously affect stability.

ALWAYS:

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

• reduce speed and use extra caution when carrying a

passenger.

• operate slowly in reverse - avoid sharp turns or sud-

den braking.

• make sure passenger reads and understands all

safety labels.

• watch for branches or other hazards that could enter

vehicle.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR FOR OPERATOR AND

PASSENGER

NEVER USE ON PUBLIC ROADS

NEVER USE WITH DRUGS OR ALCOHOL

LOCATE AND READ OWNER’S MANUAL. FOLLOW

ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S

MANUAL IS MISSING, CONTACT A POLARIS

DEALER FOR A REPLACEMENT.

7175104

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SAFETY

Safety Labels and Locations

Discretionary Warning (RZR XP 4)

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER operate:

• without first viewing safety video and quick start guide.

• with more than three passengers.

• on hills steeper than 15 degrees.

• on public roads.

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

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

ALWAYS:

• keep hands and feet inside vehicle.

• reduce speed and use extra caution when carrying

passengers.

• operate slowly in reverse - avoid sharp turns or sud-

den braking.

• make sure passengers read and understand all

safety labels.

• avoid branches or other hazards that could enter

vehicle.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR FOR OPERATOR AND

PASSENGERS

NEVER USE ON PUBLIC ROADS

NEVER USE WITH DRUGS OR ALCOHOL

LOCATE AND READ OWNER’S MANUAL. FOLLOW

ALL INSTRUCTIONS AND WARNINGS. IF

OWNER’S MANUAL IS MISSING, CONTACT A

POLARIS DEALER FOR A REPLACEMENT.

7176607

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FEATURES AND CONTROLS

Component Locations

ROPS Frame

Cab

Nets

Cargo

Box

Steering

Wheel

Radiator

Hip

FuelTank

Cap

Bars

Front Passenger

Hand Hold

Brake

Pedal

Throttle Pedal

Gear Selector

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FEATURES AND CONTROLS

Component Locations

Rear Passenger

Grab Bar

Shifter

Fuel Tank

Cap

Cargo Box

Tie-Down

Points

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FEATURES AND CONTROLS

Switches

Instrument

Cluster

Ignition

Switch

12V Accessory

Outlet

Light

Switch

AWD

Switch

Auxiliary Outlets

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

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

Ignition Switch

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

ignition switch to start the engine. See page 54 for starting procedures.

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

OFF

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

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.

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FEATURES AND CONTROLS

Switches

Headlight Switch

Use the headlight switch to turn the lights on and

off and to change the lights from high beam to low

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

tion to operate the headlights.

HIGH

LOW

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 40 for AWD operating instructions.

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FEATURES AND CONTROLS

Seats

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

ensure the latches are secure.

Seat Adjustments

Loosen (do not remove) the four screws located on the seat bottom.

Slide the seat forward or rearward to the desired position. Tighten the

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

Seat Removal

1. Pull up on the seat latch

lever located under the rear

edge of the seat.

2. Tilt the seat forward.

3. Lift the seat upward to

remove it from the vehicle.

4. Reverse this procedure to

reinstall the seat. Make

sure the seat tabs at the

front edge of the seat slide

under the seat retainer bar.

5. Press down firmly at the

rear of the seat to engage

the rear latch.

Seat

Front Seat

Retainer

Latch

Steering Wheel

The steering wheel can be

tilted upward or downward

for rider preference.

Lift and hold the steering

wheel adjustment lever

while moving the steering

wheel upward or down-

ward. Release the lever

when the steering wheel is

at the desired position.

Adjustment Lever

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FEATURES AND CONTROLS

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

Hood Fasteners

Remove the hood to access

the radiator pressure cap

and coolant overflow bottle.

1. Turn the hood fasteners

1/4 turn.

2. Grasp the upper hood

edge and pull upward to

disengage the fasteners.

3. Pivot the hood forward

and lift upward to dis-

engage the lower hood

hooks.

Overflow

Bottle

Pressure

Cap

4. Lift the hood away from

the vehicle.

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FEATURES AND CONTROLS

Service Access Panels

Engine Access Panel

The engine access panel

is located behind the

seats on the frame of the

vehicle. Remove the

seats and remove the

access panel to reach

serviceable engine

components.

Cargo Box Access Panel

The cargo box access panel

is located on the floor of

the cargo box. Remove the

panel to access the engine

oil fill cap, spark plugs and

air filter.

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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

gasoline with a minimum pump

octane number of 87 R+M/2 octane.

Do not use fuel with ethanol content

greater than 10 percent, such as E-85

fuel.

Fuel Cap

Remove flammable material contain-

ers from the box before filling.

Cab Nets

All RZR models are equipped with cab nets, which may differ slightly

in appearance from those shown.

Riding in this vehicle without using the cab nets increases the risk of

serious injury or death in the event of an accident or overturn. Cab nets

must be used by operator and passengers at all times. Make sure all

latches are secure before operating the vehicle.

Always inspect cab nets for tightness, wear and damage before each use

of the vehicle. Use the strap adjusters to tighten any loose straps.

Promptly replace worn or damaged cab nets with new cab nets, avail-

able from your authorized POLARIS dealer.

Cab Net Latches

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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 deter-

gents. Rinse the entire length of the belt webbing. Use a garden

hose to flush out the retractor and latch housings regularly.

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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 normally before

starting the engine.

Throttle

Pedal

Brake

Pedal

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 requirements. Always have your autho-

rized POLARIS dealer thoroughly inspect the ROPS if it ever becomes

damaged in any way.

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

Always follow all safe operating practices outlined in this manual to

avoid vehicle rollover.

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

operating in a manner that could result in vehicle rollover.

ROPS Label

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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.

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.

AWD

2WD

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 45.

Mode Button

Use the MODE button to toggle through mode options. See page 45 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

When metric mode is selected, speed displays in

kilometers per hour.

Over

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.

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 46.

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 46 for resetting instructions.

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

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

be brought to your dealer for scheduled maintenance. See page 46

for resetting instructions.

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

engaged (switch is on 4X4).

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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)

The display can be changed to show either

standard or metric units of measurement for

each of the following settings.

MODE

Button

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

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

units.

Standard Display

Miles

U.S. Gallons

Fahrenheit

Metric Display

Kilometers

Liters, Imperial Gallons

Celsius

Distance

Fuel

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 overturn, which may result in serious injury or death. Read and

understand all safety warnings outlined in the safety section of this owner’s

manual.

Vehicle Break-in Period

The break-in period for your new POLARIS vehicle is the first 25 hours

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

Premium 4 Synthetic Oil 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 36. Always exercise

extreme caution whenever handling gasoline.

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

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

3. Complete the New Operator Driving Procedures outlined on pages

56-57.

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

page 51.

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

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

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

7. Carry only light loads.

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

hours or one month.

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

hours of operation and every 100 hours thereafter.

Brake System Break-in

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

overly forceful braking when the brake system is new could damage

brake pads and rotors.

PVT Break-in (Clutches/Belt)

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

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

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

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

ing the break-in period.

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

compartment.

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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

Brake fluid

Front suspension

Rear suspension

Steering

Ensure proper level

100

Inspect, lubricate if necessary

Ensure free operation

110

Tires

Inspect condition and pressure

105

Wheels/fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Inspect, ensure fastener tightness

105

Fuel and oil

Ensure proper levels

Coolant level

Coolant hoses

Ensure proper level

Inspect for leaks

89-90

Throttle

Ensure proper operation

Inspect, clean

Check operation

30-31

Indicator lights/switches

Engine intake pre-filter

PVT intake pre-filter

Headlamp

Brake light/tail lamp

Check operation, apply POLARIS

dielectric grease when lamp is

replaced

107

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

New Operator Driving Procedures outlined on pages 56-57.

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

driver’s license to operate this vehicle.

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

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

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

the cargo box.

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

run in an enclosed area.

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

on this vehicle.

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

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

and gravel roads.

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

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

jumps, or other stunts. Keep both hands on the steering wheel 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 overturn 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 unless you have

first verified that the ice is sufficiently thick to support the weight

and moving force of the vehicle, you and your passenger, and your

cargo, together with any other vehicles in your party.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

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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.

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

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

experience with this vehicle.

5. Do not carry cargo during this period.

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

vehicle operation and handling.

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

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

belt at all times. Always use the cab nets while riding in this vehi-

cle.

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

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

10. Place the transmission in PARK.

11. Start the engine.

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OPERATION

New Operator Driving Procedures

12. Apply the brakes and shift into low gear.

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

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

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

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

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

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

right turns at a slow speed.

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

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

faster speeds, follow these precautions:

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

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

the terrain.

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

stunts.

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OPERATION

Driving with Passengers

1. Complete the New

Operator Driving

Procedures outlined on

pages 56-57.

2. Perform the pre-ride

inspection. See page 52.

3. Do not carry more than

one passenger in a 2-seat

vehicle. Do not carry

more than three passen-

gers in a 4-seat vehicle.

Additional passengers

can affect the operator’s

ability to steer and oper-

ate the controls

4. Make sure all passengers

are at least 12 years of

age and are tall enough

to comfortably and

safely sit in a passenger

seat, put both feet on the

floor and grasp the passenger hand hold or grab bar.

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

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

belt at all times. See page 8.

6. Make sure all passengers secure their seat belts.

7. Make sure all cab nets are properly secured.

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

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

your passengers’ skills and operating conditions. Avoid unexpected

or aggressive maneuvers that could cause discomfort or injury to a

passenger.

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

board. Allow more time and distance for braking.

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

and in this manual.

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OPERATION

Driving on Slippery Surfaces

WARNING

Skidding or sliding can cause loss of control or overturn (if tires regain traction

unexpectedly). When operating on slippery surfaces such as ice or loose gravel,

reduce speed and use extra caution to reduce the chance of skidding or sliding

out of control. Do not operate on excessively slippery surfaces.

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

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

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 a hill.

2. Avoid steep hills (15° maximum). If ascending a steeper grade is

unavoidable, engage all-wheel drive before ascending.

3. Drive straight uphill.

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

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

the throttle suddenly.

6. Avoid unnecessary changes in speed or direction.

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

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

hill.

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

transmission in reverse and slowly allow the vehicle to roll straight

downhill while applying light brake pressure to control speed.

15° maximum

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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 overturn. Avoid crossing the side of any hill

unless absolutely necessary.

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

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

immediately turn downhill.

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

side of the vehicle or cause the vehicle to slide.

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

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

fully until the vehicle can be driven straight downhill.

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid steep hills (15° maximum).

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

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

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

descend a hill with the transmission in neutral.

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

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

6. Apply the brakes lightly to aid in slowing.

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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

Floor Level

water level is lowest and

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,

overturn or accident.

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

test the brakes. Apply them lightly several times while driving

slowly. The friction will help dry out the pads.

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

inspected after operation in water. Perform the services outlined in

the maintenance chart. See page 69. Give special attention to engine

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

grease fittings.

If your vehicle becomes immersed or is operated in water that

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

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

dealer before starting the engine, perform the service outlined on

page 109, and take the vehicle to your dealer at the first opportunity.

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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 haz-

ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

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

If unavoidable, use extreme caution and operate slowly.

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

vehicle before operating over an obstacle that could cause an over-

turn.

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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 cargo improperly can alter vehicle handling

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

precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

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

operator, passengers, accessories and loads in the rack or box. The combined

weight of these items must not exceed the maximum weight capacity.

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

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

stable driving conditions.

Always operate the vehicle with extreme care when hauling cargo. Slow down

and drive in the lowest gear available.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

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

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

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

and operate with extra caution. \

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

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

situations that may require backing downhill.

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

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

vehicle to overturn.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 MPH (16 km/h) while cornering or while ascending or

descending a hill.

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 a specific capacity.

Reduce speed and allow a greater distance for braking when carrying

cargo.

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

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

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

Always read and understand the load distribution warnings listed on

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

ties specified for your vehicle. See page 120.

Belt Life

To extend belt life, use low gear when hauling a heavy load at less than

7 MPH (11 km/h) for extended periods and when operating uphill at a

slow speed.

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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 compliance with U.S.A. EPA noise control requirements (40

CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrester that was tested and qualified

to be in accordance with the USFS standard 5100-1C. Federal law

requires that this spark arrester be installed and functional when the

vehicle is operated on public lands.

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

by 43 CFR 420. Violations are subject to monetary penalties. Federal

regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

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

are forced back to the combustion chamber by the intake system. All

exhaust gases exit through the exhaust system.

Exhaust Emission Control System

Exhaust emissions are controlled by

engine design. An electronic fuel injec-

tion (EFI) system controls fuel delivery.

The engine and EFI components are set

at the factory for optimal performance

Emissions Label

and are not adjustable.

(on inside of frame tube)

The emissions label is located on the

inside of the lower right frame tube (below front passenger foot area).

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic

energy. People with active or non-active implantable medical devices

(such as heart monitoring or controlling devices) should review the lim-

itations of their device and the applicable electromagnetic 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 137.

Service and adjustments are important for proper vehicle operation. If

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

qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average rid-

ing conditions and an average vehicle speed of approximately 10 MPH

(16 km/h). Vehicles subjected to severe use must be inspected and ser-

viced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

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

not operate long enough to reach full operating temperature)

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

weather can indicate contaminants collecting in the oil sump or 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

M 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.)

D Have an authorized POLARIS dealer perform these services.

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

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

authorized POLARIS dealer perform these services.

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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

Pre-Ride

Make adjustments as need

ed. See Pre-Ride Checklist

on page 52.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake pedal travel

Brake system

Pre-Ride

Daily

Wheels/fasteners

Frame fasteners

Engine oil level

E Engine intake pre-filter

PVT intake pre-filter

Coolant

Inspect; clean often

Check coolant level

Check operation; apply

dielectric grease if

replacing

Headlight/taillight

M Engine oil change

25 H

10 H

25 H

1 M

Perform a break-in oil and

filter change at one month

Perform a break-in oil level

check

Perform a break-in oil level

check

Inspect; replace as needed

(break-in)

M Front gearcase

(demand drive) fluid

M Transmission (main

1 M

gearcase) oil

M Air filter

Monthly

M Brake pad wear

Monthly 100 (160) Inspect periodically

Battery

Monthly 250 (400) Check terminals; clean;

test

Monthly 150 (250) Inspect; replace if

necessary

M Engine breather filter

E (if equipped)

M 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)

M General

50 H

3 M

6 M

500 (800) Lubricate all fittings, pivots,

cables, etc.

300 (500) Inspect; see dealer for

service

300 (500) Inspect duct for proper

sealing/air leaks

1000 (1600) Perform a break-in oil change

at one month

lubrication

D Throttle cable

E Throttle body air

intake ducts/flange

M Engine oil change

M Oil filter change

Shift Linkage

M Front Suspension

M Rear Suspension

50 H

6 M

1000 (1600) Replace with oil change

500 (800) Inspect, adjust

500 (800) Lubricate

Cooling system

500 (800) Inspect coolant strength

seasonally; pressure test

system yearly

(if applicable)

M Front gearcase

(demand drive)

fluid

100 H

12 M

1000 (1600) Change fluid

M Transmission

100 H

12 M

1000 (1600) Change fluid

(main gearcase) oil

D Fuel system

1000 (1600) Check for leaks at tank cap,

lines, filter, pump, throttle

body

M Spark plugs

100 H

12 M

1000 (1600) Inspect; replace as needed,

torque to specification

M 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)

M Radiator

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

1000 (1600) Inspect for leaks

1000 (1600) Inspect

(if equipped)

M Cooling Hoses

M Engine mounts

100 H

12 M

Exhaust muffler/

1000 (1600) Inspect

pipe

M Wiring

100 H

12 M

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

M Shock Seals

M Shocks

100 H

12 M

1000 (1600) Inspect; replace as needed

Inspect shock seals

1500 (2400) See your dealer for oil

change/seal inspection.

D Front wheel

100 H

12 M

1000 (1600) Inspect; replace as needed

bearings

M Coolant

D Brake fluid

Spark arrester

Valve lash

24 M

Replace coolant

200 H

500 H

2000 (3200) Change every two years

2000 (3200) Clean out

2000 (3200) Check; adjust as needed

5000 (8000) Replace, torque to

specification

M Spark plugs

36 M

D Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

M 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 69, or more often under

severe use, such as wet or dusty conditions. Items not listed in the chart

should be lubricated at the general lubrication interval.

Item

Engine Oil

Lube

Method

See page 76.

PS-4 PLUS and PS-4

Extreme Duty synthetic oils

Brake Fluid

DOT 4

Maintain level between fill lines.

See page 100.

Transmission Oil

(Main Gearcase)

Premium AGL Synthetic

Gearcase Lube

See page 80.

Front Gearcase Fluid

(Demand Drive)

Demand Drive Plus Fluid

See page 82.

Prop Shaft

POLARIS Premium U-Joint Grease middle and rear fittings.

Lube

Front Control Arm Pivot POLARIS Premium all

Grease 3 fittings on each side of

the vehicle.

Bushings

Season Grease or grease

conforming to NLGI No. 2

Stabilizer Bar Bushings POLARIS Premium all

Season Grease or grease

Grease 2 fittings through the

skid plate access holes located

directly below the seat backs.

conforming to NLGI No. 2

Middle Prop Shaft

Grease Fitting

Fitting Access

(as viewed from top with

center floor panel removed)

Rear Prop Shaft

Grease Fitting

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MAINTENANCE

Lubrication Recommendations

View of Driver’s Side From Bottom of Vehicle

Grease Stabilizer Bar Bushings

(one on each side of vehicle)

Front Control Arm Pivot

Bushings (3 per side)

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MAINTENANCE

Engine Oil

Oil Recommendations

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated

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

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

the Periodic Maintenance Chart.

Ambient Temperature Range

Recommended Oil

PS-4 PLUS Synthetic

-35° F to +100° F

4-Cycle Engine Oil

(-37° C to +38° C)

PS-4 Extreme Duty Synthetic

4-Cycle Engine Oil

0° F to 120° F

(-18° C to +49° C)

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

used. Do not use automotive oil. Follow the manufacturer's recommen-

dations for ambient temperature operation. See page 124 for the part

numbers of POLARIS products.

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

engine damage. Always use the recommended oil. Never substitute

or mix oil brands.

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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 69. Always use the recommended

engine oil.

Oil Check

Always check the oil when the engine is cold. If the engine is hot when

the oil is checked, the level will appear to be overfull.

Access the oil check dipstick through the service access panel behind

the seats. Access the oil fill cap through the service access panel on the

floor of the cargo box.

1. Position the vehicle on a level

surface.

2. Place the transmission in

PARK.

3. Start the engine and allow it to

idle for 30 seconds.

4. Stop the engine and wait 15

seconds before removing the

dipstick.

5. Remove the dipstick. Wipe it

dry with a clean cloth.

Oil Check

Oil Fill

6. Reinstall the dipstick com-

pletely. Remove the dipstick

and check the oil level.

7. Remove the oil fill cap to add

the recommended oil as

needed. Maintain the oil level

between the minimum and

maximum marks on the dip-

stick. Do not overfill.

8. Reinstall the fill cap. Reinstall

the dipstick.

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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 69. Always change the oil filter

whenever changing oil.

Access the oil check dipstick through the service access panel behind

the seats. Access the oil fill cap through the service access panel on the

floor of the cargo box.

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

Access the drain plug through the access hole under the crankcase.

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

PARK.

2. Clean the area around the crankcase drain plug.

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

3. Place a drain pan under the

engine crankcase and remove

the drain plug. Allow the oil

to drain completely.

4. Using an oil filter wrench,

turn the filter counter-clock-

wise to remove it.

5. Using a clean dry cloth, clean

the filter sealing surface on

the crankcase.

Oil Filter

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MAINTENANCE

Engine Oil

Oil and Filter Change

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

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

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

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

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

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

oil. Reinstall the fill cap.

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

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

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

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

the oil level.

14. Add oil as necessary to bring the level to the upper mark on the dip-

stick. Do not overfill.

15. Reinstall the dipstick.

16. Reinstall the oil fill cap.

17. Dispose of used filter and oil properly.

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MAINTENANCE

Transmission (Main Gearcase)

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

odic Maintenance Chart beginning on page 69. Refer to the Gearcase

Specifications Chart on page 84 for recommended lubricants, capacities

and torque specifications.

Fluid Check

The fill plug is located on the rear of the gearcase. Maintain the fluid

level at the bottom of the fill plug hole.

Fill Plug

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the fluid level.

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

not overfill.

5. Reinstall the fill plug. Torque to specification.

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MAINTENANCE

Transmission (Main Gearcase)

Fluid Change

The drain plug is located on the bot-

tom 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 specifica-

tion.

6. Add the recommended fluid to

the bottom of the fill plug hole.

Do not overfill.

7. Reinstall the fill plug. Torque to

specification.

Drain Plug

(bottom view)

8. Check for leaks. Discard used

fluid properly.

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MAINTENANCE

Demand Drive Unit (Front Gearcase)

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

odic Maintenance Chart beginning on page 69. Refer to the Gearcase

Specifications Chart on page 84 for recommended lubricants, capacities

and torque specifications.

Fluid Check

The fill plug is located on the

bottom right side of the demand

drive unit. Maintain the fluid

level even with the bottom

thread of the fill plug hole.

1. Position the vehicle on a

level surface.

2. Remove the fill plug. Check

the fluid level.

3. Add the recommended fluid

to the bottom thread of the

fill plug hole.

Fill Plug

4. Reinstall the fill plug.

Torque to specification.

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MAINTENANCE

Demand Drive Unit (Front Gearcase)

Fluid Change

The drain plug is located on the bot-

tom 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.

Drain Plug

7. Reinstall the fill plug. Torque to

(bottom view)

specification.

8. 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 124 for the part numbers of POLARIS products.

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Transmission

Premium AGL

Synthetic

44 oz.

10-14 ft. lbs.

(Main Gearcase)

(1300 ml) (14-19 Nm)

(14-19 Nm)

Gearcase Fluid

Demand Drive

Unit (Front

Demand Drive

6.75 oz.

(200 ml)

8-10 ft. lbs.

(11-14 Nm)

8-10 ft. lbs.

(11-14 Nm)

Plus Fluid

Gearcase)

Spark Plugs

Spark Plug Gap/Torque

Electrode Gap

Spark Plug Torque

0.7-0.8 mm

7 ft. lbs. (10 Nm)

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

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

the specifications section beginning on page 120.

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

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

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

for correct color. See page 85.

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

protective gloves when removing a spark plug for inspection.

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MAINTENANCE

Spark Plugs

Spark Plug Removal and Replacement

1. Remove the cargo box

Spark Plugs

access panel.

2. Clean the area around the

spark plugs before remov-

ing the plugs.

3. Remove the spark plug

caps.

4. Using the spark plug

wrench provided in the tool

kit, remove the plugs by

rotating them counter-

clockwise.

5. Reverse the procedure for

spark plug installation.

Torque to specification. See

page 84.

Spark Plug Condition

Normal Plug

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

combustion deposits. The electrodes are not burned or eroded. This 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. Fouling may be caused by excessive oil or by

frequent short trips, especially in cold weather.

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MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical

failures, a fuse may need replacement. Locate and correct any short cir-

cuits that may have caused the blown fuse, then replace the fuse.

Main 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

30A

Engine Control

Lights, Drive, Accessories

The main fuse box is located under the dash, above the brake and throt-

tle pedals. Spare fuses are provided in the fuse box.

The power fuse box is located under the driver’s seat. Remove the

engine access panel to access the fuse box.

Main

Fuse Box

Power

Fuse Box

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MAINTENANCE

Fuses

Main Fuse Box

1. Lift up on the two fuse box tabs.

2. Slide the fuse box slightly toward the

right side of the vehicle to disengage it

from the mount.

3. Remove the fuse box cover.

4. Remove the suspect fuse from the fuse

panel. If the fuse is blown, install a

new fuse with the same amperage rat-

ing.

Step 1 - Lift tabs

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 3 - Cover removed

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MAINTENANCE

Cooling System

The engine coolant level is maintained by the recovery system. The

recovery system components are the overflow bottle, radiator vent fit-

ting, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated)

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

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

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

pressure cap, and into the radiator.

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

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

by adding coolant to the overflow bottle.

Adding or Changing Coolant

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

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

fresh mixture of antifreeze and water added. See page 89 for changing

procedure.

POLARIS recommends the use of POLARIS Premium 60/40 anti-

freeze/coolant or a 50/50 mixture of high quality aluminum compatible

anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is

already premixed and ready to use. Do not dilute with water. See page

124 for the part numbers of POLARIS products.

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

protection required in your area.

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

replace the coolant.

Radiator and Cooling Fan

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

lined in the Periodic Maintenance Chart beginning on page 69. 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.

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MAINTENANCE

Cooling System

Radiator Coolant Level/Changing Coolant

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

for maintenance and/or repair. If the overflow bottle has run dry, the

level in the radiator should also be inspected.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap

while the engine is warm or hot. Always allow the engine to cool before

removing the pressure cap.

1. Remove the hood. See page

Overflow

Pressure

Cap

34.

Bottle

2. Slowly remove the radiator

pressure cap.

3. View the coolant level

through the opening.

4. Use a funnel and slowly

add coolant as needed.

5. Before reinstalling the pres-

sure cap, bleed the system

of trapped air. Remove the

engine access panel behind

the seats and use a flat-

blade screwdriver to turn

the bleed screw slightly,

allowing the air to escape.

Slowly add additional cool-

ant to the radiator until air

no longer escapes and only

coolant flows from the

bleed hole, then tighten the

bleed screw.

6. Reinstall the pressure cap.

Tip: Use of a non-standard pres-

sure cap will not allow the

recovery system to function

properly. See your dealer for

the correct replacement part.

Bleed Screw

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MAINTENANCE

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the

Periodic Maintenance Chart beginning on page 69. Maintain the coolant

level between the minimum and maximum marks on the bottle (when

the fluid is cool). If the overflow bottle has run dry, the level in the radi-

ator should also be inspected.

1. Position the vehicle on a

Overflow

Bottle

level surface.

Pressure

Cap

2. Remove the hood. See page

34.

3. View the coolant level in

the overflow bottle.

4. Remove the cap and use a

funnel to add coolant as

needed to maintain the

level between the two

marks.

5. Reinstall the cap.

Tip: If coolant must be added

often, or if the overflow bottle

runs completely dry, there may

be a leak in the system. Have

the cooling system inspected

by your POLARIS dealer.

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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. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

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

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

the belt.

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

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

it in any other product.

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

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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 and severe

injury or death.

1. Remove the engine access

cover and thoroughly clean all

debris from the aluminum

debris basket and from the

engine compartment.

Debris Basket

2. Remove the clutch cover

screws and open the clutch

cover. (It does not have to be

removed from the vehicle.)

Remove all debris wrapped in

and around the PVT system.

Tip: Use the shock/clutch tool from the

tool kit to slightly open the

sheaves to aid in debris removal

and belt installation.

Remove ALL Debris

(Continued on next page)

Insert hooked end of tool.

Apply force to opposite end of

tool to spread sheaves.

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MAINTENANCE

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

3. Remove all debris from the

entire clutch air duct passage.

4. Check for signs of damage to

seals on the transmission and

engine. See your dealer

promptly for service if any

seals appear to be damaged.

Tip: Belt slip is responsible for

creating excessive heat that

destroys belts, wears clutch

components and causes outer

Clutch Air Duct

clutch covers to fail. Switch to low

range while operating at slower

speeds to extend the life of the

PVT components (belt, cover, etc.).

PVT Drying

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

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

ing.

1. Remove the clutch cover drain plug.

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

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

4. Start the engine.

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

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

more than 10 seconds.

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

Shift the transmission to the lowest available range.

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

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

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MAINTENANCE

Filter Systems

Fuel Tank Vent Filter

If the engine sputters, the inline

fuel tank vent filter may be

clogged. Do not attempt to clean

the filter. Replace the filter with

a new filter.

1. Remove the seats and

remove the engine access

panel.

Tip: Note the direction of the arrow

on the filter before removing it.

2. Remove the filter and install

the new filter. Make sure

the direction of the arrow is

the same as noted before fil-

ter removal.

Fuel Tank Vent Filter

PVT Intake Pre-Filter

3. Reinstall the access panel and seats.

Intake Pre-Filters

The engine intake pre-filter is

located on the left side of the

cargo box. The PVT intake

pre-filter is located on the

right side of the cargo box.

Inspect the pre-filters before

each use of the vehicle.

Remove the pre-filters and

use compressed air to clean

them frequently to ensure

adequate air flow.

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MAINTENANCE

Filter Systems

Air Filter

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

Maintenance Chart beginning on page 69.

1. Remove the cargo box

access panel.

Wing Nuts/Bolts

2. Loosen the air box cover

wing nuts and rotate the

bolts away from the cover.

3. Release the cover latches.

4. Pull the cover rearward far

enough to remove the air

filter.

5. Inspect the air box for oil

or water deposits. Wipe

away any deposits with a

clean cloth.

6. Install a new filter if

needed. Do not attempt to

clean the air filter.

Cover Latches

7. Close the air box cover and

tighten the wing nuts

securely.

Air Filter

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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 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.

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MAINTENANCE

Spark Arrester

Periodically clean the spark arrester to remove accumulated carbon.

1. Remove the arrester retaining bolt and nut.

2. Remove the arrester from the end of the muffler.

3. Use a non-synthetic brush to clean the arrester screen. A synthetic

brush may melt if components are warm. If necessary, blow debris

from the screen with compressed air.

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

aged screen.

5. Reinstall the arrester. Torque bolt to 9-11 ft. lbs. (12-15 Nm).

Muffler

Bolt

Arrester Screen

Nut

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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 misad-

justment, 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. If

engine idle speed is not satisfactory,

please see your POLARIS dealer for

Throttle Pedal

adjustment.

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.

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MAINTENANCE

Brakes

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

brake pedal. See page 39.

Always check brake pedal travel and the brake fluid reservoir level

before each use of the vehicle. When applied, the brake pedal should

feel firm. Any sponginess would indicate a possible fluid leak or low

brake fluid level, which must be corrected before riding. See page 100

for brake fluid information.

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.

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

3/64" (1mm)

damage. Clean any grease

using an approved brake

cleaner or alcohol.

NOTICE: Do not apply WD-40 or any petroleum product to brake discs.

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

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

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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 124 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 years and any

time the fluid becomes con-

taminated, the fluid level is

below the minimum, or if

Maximum

Minimum

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 maximum

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.

100

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MAINTENANCE

Suspension Settings

Front/Rear Spring Preload

The factory setting is appropriate for nearly all riding conditions. If

desired, the suspension may be adjusted to maintain vehicle clearance

height when carrying loads.

Fox Shock Preload

Measurement

Walker Evans Front

Shock Preload

Measurement

Walker Evans Rear

Shock Preload

Measurement

Factory Preload Settings

RZR XP Premium Front

RZR XP Premium Rear

RZR XP 4 Front

7.625” (193.7 mm)

3.625” (92.1 mm)

6.560” (166.6 mm)

0.940” (23.9 mm)

RZR XP 4 Rear

101

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MAINTENANCE

Suspension Settings

Front/Rear Spring Preload

Fox Shock Preload Adjustment

Follow these guidelines if you make adjustments to this suspension.

• Always return the suspension to the factory setting after the load is removed

from the vehicle. The increased suspension height will negatively impact 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.

1. Use the shock/clutch tool from the tool kit to

aid in making suspension adjustments.

2. Elevate the vehicle to allow the suspension

to fully extend.

3. Loosen the jam nut and back it away from

the adjusting ring.

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

increase preload for a stiffer ride. Turn the

adjusting ring to the right (2) to decrease

preload for a softer ride.

Adjusting

Ring

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.

5. Tighten the jam nut firmly against the adjuster ring.

102

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MAINTENANCE

Suspension Settings

Front/Rear Spring Preload

Walker Evans Shock Preload Adjustment

Follow these guidelines if you make adjustments to this suspension.

• Always return the suspension to the factory setting after the load is removed

from the vehicle. The increased suspension height will negatively impact 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.

1. Use the shock/clutch tool from

the tool kit to aid in making

suspension adjustments.

Adjusting

Ring

2. Elevate the vehicle to allow the

suspension to fully extend.

3. Turn the adjusting ring to the

left (1) to increase preload for a

stiffer ride. Turn the adjusting

ring to the right (2) 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.

Front

Rear

103

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MAINTENANCE

Suspension Settings

Front/Rear Shock Compression

The compression damping clicker knob is located on top of the shock

reservoir. When the knob is turned clockwise until it stops, the damping

is in the fully closed position.

1. Turn the clicker clockwise to increase compression damping.

2. Turn the clicker counter-clockwise to decrease compression damp-

ing.

Decrease

Increase

Decrease

Rear

HARD

SOFT

Front

FOX Shocks

Walker Evans Shocks

Setting Compression Damping

Softest

20 clicks from closed

Softest

16 clicks from closed

Factory 10 clicks from closed

Factory Front: 6 clicks from closed

Rear: 7 clicks from closed

Firmest 2 clicks from closed

Firmest 1 click from closed

104

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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. When replacing tires,

always use original equipment size and type.

Tire Tread Depth

1/8" (3 mm)

Always replace tires

when tread depth is

worn to 1/8" (3 mm)

or less.

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

Front and Rear

30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

(Aluminum

Wheels)

Hub Retaining Nut

Front and Rear

80 ft. lbs. (108 Nm)

105

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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

Right Rear Wheel

in PARK.

(type varies by model)

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 rota-

tion.

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.

Forward

Rotation

Valve Stem

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification. See page 105.

106

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MAINTENANCE

Lights

Headlight and taillight lenses become dirty during normal operation.

Clean all lights frequently to ensure a clear field of vision as well as vis-

ibility to other vehicles.

Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring

harness from the headlamp(s) for a few days to allow the moisture to clear

out.

Brake Lights

When the brake pedal is depressed, the brake light comes on. Check the

brake light before each ride.

1. Turn the ignition switch to the ON position.

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.

Headlight Replacement

If a headlight becomes damaged or

inoperable, the entire headlight

assembly must be replaced.

Headlight Rear View

107

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MAINTENANCE

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward and

to the left or right.

1. Position the vehicle on a level surface. The headlight should be

approximately 25 ft. (7.6 m) from a wall.

25 ft.

(7.6 m)

2 in. (5 cm)

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

4. Apply the brakes. Start the

engine. Turn the headlights to

high beam.

5. Include the weight of a rider on

the seat while performing this

step. Observe the headlight

aim. As a starting point, the

most intense part of the head-

light beam should be 2 inches

(5 cm) below the mark on the

wall. Adjust to operator prefer-

ence.

Adjustment

6. Tighten or loosen the three (3)

headlight screws to adjust the

beam upward or downward or

to the left or right.

Screws

108

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MAINTENANCE

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result

if the machine is not thoroughly inspected. Take the vehicle to your

dealer before starting the engine.

If it's impossible to take your vehicle to a dealer before starting it, fol-

low the steps outlined below.

1. Move the vehicle to dry land.

2. Check the air box. If water is present, dry the air box and replace the

filter with a new filter.

3. Dry the spark plug wells with a clean cloth, then 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 93 for drying.

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 69.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8-1.0" (20-25 mm) of freeplay.

4. If there is excessive freeplay or strange noises, or if the steering

feels rough or “catchy,” have the steering system inspected by an

authorized POLARIS dealer.

110

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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.

Your vehicle has a sealed battery, which requires little maintenance.

Always keep battery terminals and connections free of corrosion. If

cleaning is necessary, remove the corrosion with a stiff wire brush.

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.

Battery Removal

1. Remove the driver’s seat. See page 32.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle.

111

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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 113 before installing

the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Secure the battery hold-down strap.

5. 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.

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

recharge the battery about once a month to make up for normal self-dis-

charge (see page 113), or use a POLARIS Battery Tender, which can be

left connected during the storage period. Battery Tender will automati-

cally charge the battery if voltage drops below a pre-determined point.

See page 124 for the part numbers of POLARIS products.

During the storage period, park the vehicle out of the sun in a cool, dry

place or remove the battery and store it in a cool, dry place.

112

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MAINTENANCE

Battery

Battery Charging

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.

A sealed battery must always be maintained with a full charge. 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. The battery should be disconnected from a load or charger for at

least two hours before checking voltage. 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.

3. When using an automatic charger, refer to the charger manufac-

turer's instructions for recharging. When using a constant current

charger, use the guidelines on the next page for recharging.

113

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MAINTENANCE

Battery

Battery Charging

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

3-6 hours

charge, if no

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

114

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appear-

ance but it can also extend the life of various components.

NOTICE: Water in the PVT system

PVT Intake Pre-Filter

could cause the drive belt

to become wet and slip in

the clutches. Always avoid

spraying water directly

toward any intake pre-

filters.

High water pressure may

damage 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.

115

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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

• Air intake components

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.

116

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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 115.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel

Stabilizer. Follow the instructions on the container for the 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 78.

Air Filter / Air Box

Replace the air filter. See page 95. 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 69.

• Demand drive fluid (front gearcase)

• Rear gearcase fluid (if equipped)

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength/fill)

117

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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 69.

Fog the Engine

1. Treat the fuel system with POLARIS Carbon Clean. Follow the

instructions on the container. Start the engine. Allow it to idle for

several minutes so the Carbon Clean reaches the injectors. Stop the

engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil. 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 85.

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 112-114 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.

118

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MAINTENANCE

Cleaning and Storage

Removal from Storage

1. Charge the battery if necessary.

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 52. Tightness of the bolts, nuts and other fasteners should

be checked by an authorized POLARIS dealer.

5. Lubricate at the intervals outlined in the Periodic Maintenance

Chart beginning on page 69.

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.

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.

Front Tie-Down Points

(one on each side)

Rear Tie-Down Points

119

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SPECIFICATIONS

RANGER RZR XP 900

Gross Vehicle Weight

Dry Weight

Rear Cargo Box Capacity

1930 lbs. (875 kg)

1190 lbs. (540 kg)

300 lbs. (136 kg)

Maximum Weight Capacity

740 lbs. (336.4 kg) (including riders, cargo and

(Payload)

accessories)

Fuel Capacity

7.25 gal. (27.4 l)

2.5 qts. (2.4 l)

4.9 qts. (4.6 l)

6.75 oz. (200 ml)

44 oz. (1300 ml)

108.4/64/73 in. (275/162.5/185.4 cm)

81.4 in. (206.8 cm)

13 in. (33 cm)

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Overall Length/Width/Height

Wheelbase

Ground Clearance

Engine

Displacement

4-Stroke DOHC Twin Cylinder

875 cc

Bore x Stroke

93mm x 64.4mm

560 W @ 3000 RPM

10.5:1

Alternator Output

Compression Ratio

Starting System

Electric

Fuel System

Ignition System

Electronic fuel injection

ECU

Spark Plug / Gap

Front Suspension

RG4YCX / 0.7-0.8 mm

Independent double a-arm with 13.5 in. (34.3 cm)

travel

Rear Suspension

Independent trailing arms with 14 in. (35.5 cm)

travel

120

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SPECIFICATIONS

RANGER RZR XP 900

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

6.45:1

5.776:1

3.037:1

3.82:1

3.53:1

27x9-12

27x11-12

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Headlights

12 psi (82.7 KPa)

14 psi (96.5 KPa)

Foot Activated, 4-wheel hydraulic disc

2 dual beam, 6-LED cluster, 40w High / 27w Low

Taillights

Brake Lights

Instrument Cluster

Auxiliary DC Outlet

2 single beam, 6w

2 single beam, 27w

LCD

12V

Clutching

Please see your POLARIS dealer for clutching specifications.

121

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SPECIFICATIONS

RANGER RZR XP 4 900

Gross Vehicle Weight

Dry Weight

2375 lbs. (1077 kg)

1390 lbs. (630.5 kg)

300 lbs. (136 kg)

Rear Cargo Box Capacity

Maximum Weight Capacity

900 lbs. (408 kg) (including riders, cargo and

(Payload)

accessories)

Fuel Capacity

7.25 gal. (27.4 l)

2.5 qts. (2.4 l)

9.7 qts. (9.2 l)

6.75 oz. (200 ml)

44 oz. (1300 ml)

134.4/64/77 in. (341.4/162.5/195.6 cm)

107.4 in. (272.8 cm)

12.5 in. (31.7 cm)

4-Stroke DOHC Twin Cylinder

875 cc

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Overall Length/Width/Height

Wheelbase

Ground Clearance

Engine

Displacement

Bore x Stroke

93mm x 64.4mm

560 W @ 3000 RPM

10.5:1

Alternator Output

Compression Ratio

Starting System

Electric

Fuel System

Ignition System

Electronic fuel injection

ECU

Spark Plug / Gap

Front Suspension

RG4YCX / 0.7-0.8 mm

Independent double a-arm with 13.5 in. (34.3 cm)

travel

Rear Suspension

Independent trailing arms with 14 in. (35.5 cm)

travel

122

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SPECIFICATIONS

RANGER RZR XP 4 900

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

6.45:1

5.776:1

3.037:1

3.82:1

3.53:1

27x9-12

27x11-12

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Headlights

14 psi (96.5 KPa)

16 psi (110.3 KPa)

Foot Activated, 4-wheel hydraulic disc

2 dual beam, 6-LED cluster, 40w High / 27w Low

Taillights

Brake Lights

Instrument Cluster

Auxiliary DC Outlet

2 single beam, 6w

2 single beam, 27w

LCD

12V

Clutching

Please see your POLARIS dealer for clutching specifications.

123

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POLARIS PRODUCTS

Part

Description

Number

Engine Lubricant

2870791

2876244

2876245

2878920

2878922

2878919

Fogging Oil (12 oz./355 ml Aerosol)

PS-4 PLUS Synthetic 4-Cycle Engine Oil (qt./.95 l)

PS-4 PLUS Synthetic 4-Cycle Engine Oil (gal./3.8 l)

PS-4 Extreme Duty Synthetic 4-Cycle Oil (qt./.95 l)

PS-4 Extreme Duty Synthetic 4-Cycle Oil (2 qt./1.9 l)

PS-4 Extreme Duty Synthetic 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

AGL PLUS Transmission Fluid (qt./.95 l)

AGL PLUS Transmission Fluid (gal./3.8 l)

Premium ATV Angle Drive Fluid (8 oz./237 ml)

Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

Pump for Gallon (3.8 l) Jug

2878068

2878069

2871653

2872276

2870465

2877922

2877923

Demand Drive Plus Fluid (qt./.95 l)

Demand Drive Plus Fluid (gal./3.8 l)

Coolant

2871323

2871534

60/40 Coolant (gal./3.8 l)

60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season

Premium All Season Grease (3 oz./89 ml cartridge)

Premium All Season Grease (14 oz./414 ml cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz./89 ml cartridge)

Premium U-Joint Lube (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel™)

2871312

2871322

2871423

2871460

2871515

2871551

2871329

Additives / Miscellaneous

2871326

2870652

2872189

2871956

2859044

Carbon Clean Plus

Fuel Stabilizer

DOT 4 Brake Fluid

Loctite™ 565 Thread Sealant

POLARIS Battery Tender™ Charger

124

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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 60.

Drive at a higher speed or use low range more frequently.

Driving at low RPM or

ground speed (3-7 MPH/ See page 38.

5-11 km/h)

Insufficient warm-up at

low ambient tempera-

tures

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 flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

Hauling heavy cargo/

pushing at low RPM/low

ground speed

Use low range only.

Utility use/plowing

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 overturn.

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 overturn.

Belt slippage from water Dry out the PVT (see page 93). Prevent water from enter-

or snow ingestion into the ing the PVT outlet duct (see page 115). Inspect clutch

PVT system

Clutch malfunction

seals for damage if repeated leaking occurs.

See your 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 (48

km/h) for one mile (1.5 km) and for 5 miles (8 km) or

more when temperature is below freezing.

Wrong or missing belt

Improper break-in

Failed belt

Install the recommended belt.

Always break in a new belt and/or clutch. See page 50.

Remove the belt and clean away any debris from the

clutch box, clutch duct and engine compartment. Install a

new belt. WARNING! Failure to remove ALL debris

when replacing the belt could result in vehicle damage

and severe injury or death. See page 92.

125

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Loose battery connections

Loose solenoid connections

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose electronic control box connections Inspect, clean, reinstall connectors

Mechanical failure See your dealer

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel

Clogged fuel filter

See your 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 dealer

Recharge the battery to 12.8 VDC

Check all connections and tighten

See your dealer

Loose ignition connections

Mechanical failure

Engine Backfires

Possible Cause

Solution

Out of fuel

Refuel

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

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Check all connections and tighten

Replace with fresh recommended fuel

Check all connections

Exhaust leak

Mechanical failure

See your dealer

126

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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 or

filter

Kinked idle air control lines

Incorrect fuel

Clogged air filter

Inspect; rotate lines to remove kink

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Other mechanical failure

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Low octane fuel

Clogged fuel filter

Low fuel pressure

Add or change fuel, clean the fuel system

Replace with recommended fuel

See your dealer

127

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel

Inspect and replace

Kinked or plugged fuel tank vent line or

filter

Water is present in fuel

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Incorrect fuel

Clogged air filter

Other mechanical failure

Overheated engine

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

Clean radiator screen and core, clean

engine exterior, check coolant level, see

your dealer if condition persists

128

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WARRANTY

LIMITED WARRANTY

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH

LIMITED WARRANTY on all components of your POLARIS vehicle against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts which are covered by this warranty. This warranty begins

on the date of purchase. This warranty is transferable to another consumer during the

warranty period through a POLARIS dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to POLARIS within ten days. 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 the warranty entitle-

ment. 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 trou-

ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will

void your warranty coverage.

129

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The POLARIS limited warranty excludes any failures that are not caused by a defect in

material or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any vehicle that

has been altered structurally, modified, neglected, improperly maintained, used for rac-

ing, or used for purposes other than for which it was manufactured, or for any damages

which occur during trailer transit or as a result of unauthorized service or the use of

unauthorized parts. In addition, this warranty does not cover physical damage to paint or

finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in

parts, components or the vehicle due to fire, explosions or any other cause beyond

POLARIS' control.

Warranty does not apply to 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

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Suspension components

Brake components

Seat components

Drive belts

Clutches and components

Steering components

Batteries

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered “consumable,” meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

•

Spark Plugs

Filters

•

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Fuel

Sealants

Hotel fees

Towing charges

Mileage

Rentals/Loss of product use

Meals

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

130

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WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the vehicle. The exclusive remedy for breach of this warranty

shall be, at POLARIS' exclusive option, repair or replacement of any defective materi-

als, or 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 WAR-

RANTY 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 PUR-

POSE. Some states do not permit the exclusion or limitation of incidental or consequen-

tial damages or implied warranties, so the above limitations or exclusions may not apply

to you if inconsistent with controlling state law.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX

MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-

tations on how long an implied warranty lasts, so the above limitation may not apply to

you if inconsistent with controlling state law.

131

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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 form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM

THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your

original selling dealer; however, you may use any POLARIS Servicing Dealer to per-

form warranty service.

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.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

Lubricants

1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-

ommend the use of POLARIS engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

SPARK ARRESTER

POLARIS warrants that the spark arrester in this vehicle will meet the efficiency

requirements of USFS standard 5100-1C for at least 1000 hours when subjected to nor-

mal use and when maintenance and installation are in accordance with POLARIS rec-

ommendations.

132

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

POLARIS Industries. Dealers may not give authorization for export. You should consult

an authorized dealer to determine this vehicle's warranty or service bulletin coverage if

you have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer's authorized location.

This policy does not apply to Safety Bulletins.

How to Get Service

In the Country where your vehicle 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 vehicle was purchased, War-

ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer

who sells the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle 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. Vehicles importa-

tion rules vary considerably from country to country. You may be required to present

documentation of your move to POLARIS Industries in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS Industries

in order to register your vehicle in your new country. You should warranty register your

vehicle at a local POLARIS dealer in your new country immediately after you move to

continue your warranty coverage and to ensure that you receive safety information and

notices regarding your vehicle.

133

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WARRANTY

How to Get Service

If Purchased From A Private Party:

If you purchase a POLARIS product from a private citizen, to be kept and used outside

of the country in which the vehicle was originally purchased, all warranty coverage will

be denied. You must nonetheless warranty register your vehicle under your name and

address with a local POLARIS dealer in your country to ensure that you receive safety

information and notices regarding your vehicle.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles reg-

istered to Government officials or military personnel on assignment outside of the

country where the vehicle was purchased will continue to be covered by the basic war-

ranty.)

For questions call POLARIS Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited war-

ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur-

chased, 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 this emissions-certified vehicle starts on the date the vehicle is

first purchased and continues for a period of 500 hours of engine operation, 5000 kilo-

meters (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase,

whichever comes first.

This emissions limited warranty covers components whose failure increases the vehi-

cle’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 war-

ranty 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 emis-

sions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative emis-

sions:

•

Fuel Tank

•

Vacuum Control Diaphragms*

Control Cables*

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

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.

135

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of POLARIS, repair or replacement of any defective materials, components or

products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY 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 PUR-

POSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES 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 incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.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.

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 con-

trol 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 vehi-

cle. 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.

If you have any questions regarding your warranty rights and responsibilities, please

contact the POLARIS Warranty Department at 1-888-704-5290.

136

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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

138

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

139

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INDEX

Access Panel

Cab Frame, ROPS . . . . . . . . . . . . . . . 39

Cab Nets . . . . . . . . . . . . . . . . . . . . . . 36

Cap, Fuel . . . . . . . . . . . . . . . . . . . . . . 36

Cargo . . . . . . . . . . . . . . . . . . . . . . 66-67

Cargo Box Access Panel . . . . . . . . . . 35

Changing Gears . . . . . . . . . . . . . . . . . 38

Chart, Periodic Maintenance . . . . 69-73

Check Engine Indicator . . . . . . . . . . . 49

Cleaning and Storage. . . . . . . . 115-119

Cleaning the Air Filter. . . . . . . . . . . . 95

Cleaning the Exhaust System . . . . . . 97

Cleaning the Spark Arrestor . . . . . . . 97

Clothing . . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching . . . . . . . . . . . . . . . . . 121, 123

Component Locations . . . . . . . . . 28-29

Condition, Spark Plugs . . . . . . . . . . . 85

Coolant

Cargo Box . . . . . . . . . . . . . . . . 35

Engine . . . . . . . . . . . . . . . . . . . 35

Oil Tank. . . . . . . . . . . . . . . . . . 35

Accessory Outlets . . . . . . . . . . . . . . 30

Adjustments

Hand Hold . . . . . . . . . . . . . . . . 33

Seat . . . . . . . . . . . . . . . . . . . . . 32

Steering Wheel. . . . . . . . . . . . . 32

Age Restrictions. . . . . . . . . . . . . . . . 10

Air Filter . . . . . . . . . . . . . . . . . . . . . 95

Air Filter Cleaning. . . . . . . . . . . . . . 95

All Wheel Drive Switch. . . . . . . . . . 31

All Wheel Drive System . . . . . . . . . 40

Arrester, Spark, Warning. . . . . . . 96-97

Auxiliary Outlets . . . . . . . . . . . . . . . 30

AWD Switch . . . . . . . . . . . . . . . 31, 40

AWD System. . . . . . . . . . . . . . . . . . 40

Axle Nut Torque . . . . . . . . . . . . . . 105

Level, Overflow Bottle . . . . . . . 90

Level, Radiator . . . . . . . . . . . . . 89

Adding . . . . . . . . . . . . . . . . . . . . 88

Changing . . . . . . . . . . . . . . . 88-89

Replacing. . . . . . . . . . . . . . . . . . 89

Cooling Fan . . . . . . . . . . . . . . . . . . . . 88

Cooling System . . . . . . . . . . . . . . 89-90

Cooling System Operation. . . . . . . . . 88

Cover for Storage. . . . . . . . . . . . . . . 118

Crankcase Emission Control System. 68

Battery . . . . . . . . . . . . . . . . . . 111-114

Charging . . . . . . . . . . . . . 113-114

Installation . . . . . . . . . . . . . . . 112

Removal. . . . . . . . . . . . . . . . . 111

Storage. . . . . . . . . . . . . . . . . . 112

Before Riding. . . . . . . . . . . . . . . . . . 52

Belt Burning. . . . . . . . . . . . . . . . . . 125

Belt Life. . . . . . . . . . . . . . . . . . . . . . 67

Belt Replacement. . . . . . . . . . . . . 92-93

Belt Wear. . . . . . . . . . . . . . . . . . . . 125

Belts, Seat . . . . . . . . . . . . . . . . . . . . 37

Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake Fluid . . . . . . . . . . . . . . . . . . 100

Brake Inspection . . . . . . . . . . . . . . . 99

Brake Lights. . . . . . . . . . . . . . . . . . 107

Brake Pedal . . . . . . . . . . . . . . . . . . . 39

Brake System Break-in . . . . . . . . . . 51

Brakes . . . . . . . . . . . . . . . . . . . . 99-100

Braking . . . . . . . . . . . . . . . . . . . . . . 54

Break-In Period . . . . . . . . . . . . . . 50-51

Burning Belts. . . . . . . . . . . . . . . . . 125

Demand Drive Fluid . . . . . . . . . . 82-83

Display Units, Standard/Metric. . . . . 45

Drive Belt Wear. . . . . . . . . . . . . . . . 125

Drivetrain Break-In . . . . . . . . . . . . . . 51

Driving Downhill. . . . . . . . . . . . . . . . 61

Driving in Reverse. . . . . . . . . . . . . . . 64

Driving on a Sidehill . . . . . . . . . . . . . 61

Driving on Slippery Surfaces . . . . . . 59

Driving Over Obstacles . . . . . . . . . . . 63

Driving Procedures . . . . . . . . . . . 56-57

Driving Through Water . . . . . . . . . . . 62

Driving Uphill . . . . . . . . . . . . . . . . . . 60

Driving with Passengers . . . . . . . . . . 58

Driving, After Driving in Water . . . . 93

Drying the Transmission . . . . . . . . . . 93

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INDEX

Electromagnetic Interference . . . . . . 68

Emission Control, Crankcase . . . . . . 68

Emission Control, Exhaust . . . . . . . . 68

Emission Control, Noise. . . . . . . . . . 68

Emissions Limited Warranty . 135-136

Engaging AWD. . . . . . . . . . . . . . . . . 40

Engine Access Panel. . . . . . . . . . . . . 35

Engine Break-In . . . . . . . . . . . . . . . . 51

Engine Fogging. . . . . . . . . . . . . . . . 118

Engine Idle Speed . . . . . . . . . . . . . . . 98

Engine Intake Pre-Filter . . . . . . . . . . 94

Engine Oil. . . . . . . . . . . . . . . . . . 76-79

Engine Starting . . . . . . . . . . . . . . . . . 54

Engine Stopping . . . . . . . . . . . . . . . . 54

Equipment Modifications . . . . . . . . . . 7

Error Codes, Engine . . . . . . . . . . . . . 49

Etiquette, Trail Riding . . . . . . . . . . . 55

Exhaust Cleaning . . . . . . . . . . . . . . . 97

Exhaust Emission Control System . . 68

Exhaust System Warning . . . . . . 96-97

Eye Protection. . . . . . . . . . . . . . . . . . . 9

Fluid Levels During Storage. . . . . . 117

Fluid Recommendations, Gearcase . 84

Fluid, Brake . . . . . . . . . . . . . . . . . . 100

Fogging the Engine. . . . . . . . . . . . . 118

Fouled Plugs . . . . . . . . . . . . . . . . . . . 85

Freeplay, Steering Wheel . . . . . . . . 110

Freeplay, Throttle . . . . . . . . . . . . . . . 98

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 36

Fuel Safety . . . . . . . . . . . . . . . . . . . . 19

Fuel Stabilizer. . . . . . . . . . . . . . . . . 117

Fuel Tank Filler Cap. . . . . . . . . . . . . 36

Fuel Tank Vent Filter . . . . . . . . . . . . 94

Fuses . . . . . . . . . . . . . . . . . . . . . . 86-87

Gap, Spark Plug . . . . . . . . . . . . . . . . 84

Gasoline Handling . . . . . . . . . . . . . . 19

Gear Selector . . . . . . . . . . . . . . . . . . 38

Gearcase Capacities . . . . . . . . . . . . . 84

Gearcase Oil

Demand Drive. . . . . . . . . . . 82-83

Front . . . . . . . . . . . . . . . . . . 82-83

Main . . . . . . . . . . . . . . . . . . 80-81

Gearcase Specifications . . . . . . . . . . 84

Gearcases. . . . . . . . . . . . . . . . . . 80-84

Demand Drive. . . . . . . . . . . 82-83

Front Gearcase . . . . . . . . . . 82-83

Main Gearcase . . . . . . . . . . 80-81

Specification Chart . . . . . . . . . . 84

Transmission. . . . . . . . . . . . 80-81

Gears, shifting. . . . . . . . . . . . . . . . . . 38

Gloves. . . . . . . . . . . . . . . . . . . . . . . . . 9

Fan, Cooling . . . . . . . . . . . . . . . . . . . 88

Filter

Air Filter . . . . . . . . . . . . . . . . . . 95

Care During Storage . . . . . . . . 117

Cleaning, Air. . . . . . . . . . . . . . . 95

Fuel Tank Vent Filter . . . . . . . . 94

Systems . . . . . . . . . . . . . . . . 94-95

Fluid

Demand Drive. . . . . . . . . . . 82-83

Front Gearcase . . . . . . . . . . 82-83

Main Gearcase . . . . . . . . . . 80-81

Transmission. . . . . . . . . . . . 80-81

Fluid Change

Hand Hold, Passenger. . . . . . . . . . . . 33

Hauling a Load . . . . . . . . . . . . . . 66-67

Hauling Cargo. . . . . . . . . . . . . . . 66-67

Headlight Replacement. . . . . . . . . . 107

Headlight Switch . . . . . . . . . . . . . . . 31

Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8

Hood Removal . . . . . . . . . . . . . . . . . 34

Demand Drive. . . . . . . . . . . . . . 83

Front Gearcase . . . . . . . . . . . . . 83

Main Gearcase . . . . . . . . . . . . . 81

Transmission. . . . . . . . . . . . . . . 81

Fluid Check

Demand Drive. . . . . . . . . . . . . . 82

Front Gearcase . . . . . . . . . . . . . 82

Main Gearcase . . . . . . . . . . . . . 80

Transmission. . . . . . . . . . . . . . . 80

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INDEX

Idle Speed . . . . . . . . . . . . . . . . . . . . 98

Ignition Switch. . . . . . . . . . . . . . . . . 30

Indicator Lamps. . . . . . . . . . . . . . . . 42

Inspection, Axle Nuts . . . . . . . . . . 105

Inspection, Brakes . . . . . . . . . . . . . . 99

Inspection, Pre-Ride . . . . . . . . . . . . 52

Inspection, Steering Wheel . . . . . . 110

Inspection, Wheel Nuts . . . . . . . . . 105

Installation, Battery . . . . . . . . . . . . 112

Installation, Wheels . . . . . . . . . . . . 106

Instrument Cluster . . . . . . . . . . . . 41-49

Interference, Electromagnetic . . . . . 68

Oil and Filter Care During Storage . 117

Oil Change

Demand Drive . . . . . . . . . . . . . . 83

Engine . . . . . . . . . . . . . . . . . . . . 79

Engine Oil . . . . . . . . . . . . . . . . . 78

Front Gearcase. . . . . . . . . . . . . . 83

Main Gearcase. . . . . . . . . . . . . . 81

Transmission . . . . . . . . . . . . . . . 81

Oil Check

Demand Drive . . . . . . . . . . . . . . 82

Engine Oil . . . . . . . . . . . . . . . . . 77

Front Gearcase. . . . . . . . . . . . . . 82

Main Gearcase. . . . . . . . . . . . . . 80

Transmission . . . . . . . . . . . . . . . 80

Oil Recommendations . . . . . . . . . . . . 76

Oil Tank Access Panel. . . . . . . . . . . . 35

Operation on Public Lands . . . . . . . . 68

Operation, Cooling System . . . . . . . . 88

Operation, Transmission . . . . . . . 91-93

Operator Restrictions. . . . . . . . . . . . . 10

Outlets, Auxiliary . . . . . . . . . . . . . . . 30

Overflow Bottle Coolant Level . . . . . 90

Key, Periodic Maintenance Chart . . 70

Lights

Brake Lights . . . . . . . . . . . . . 107

Headlight Beam Adjustment . 108

Headlight Replacement . . . . . 107

Headlight Switch . . . . . . . . . . . 31

Low Beam Adjustment . . . . . . . . . 108

Lubricant Part Numbers. . . . . . . . . 124

Lubrication for Storage . . . . . . . . . 118

Lubrication Recommendations . . 74-75

Parking on an Incline. . . . . . . . . . . . . 65

Parking the Vehicle . . . . . . . . . . . . . . 55

Passenger Hand Hold Adjustment. . . 33

Periodic Maintenance Chart . . . . 69-73

Plug Condition. . . . . . . . . . . . . . . . . . 85

Plug Gap . . . . . . . . . . . . . . . . . . . . . . 84

Plug Torque . . . . . . . . . . . . . . . . . . . . 84

Plugs, Fouled . . . . . . . . . . . . . . . . . . . 85

Plugs, Spark. . . . . . . . . . . . . . . . . 84-85

Polaris Products. . . . . . . . . . . . . . . . 124

Polishing the Vehicle. . . . . . . . . . . . 116

Pre-Filters, Intake . . . . . . . . . . . . . . . 94

Pre-Ride Inspection . . . . . . . . . . . . . . 52

Public Lands . . . . . . . . . . . . . . . . . . . 68

PVT Break-In . . . . . . . . . . . . . . . . . . 51

PVT Drying . . . . . . . . . . . . . . . . . . . . 93

PVT Intake Pre-Filter . . . . . . . . . . . . 94

PVT System Operation . . . . . . . . 91-93

PVT, Cleaning Debris . . . . . . . . . 92-93

Maintenance, Periodic . . . . . . . . . 69-73

Metric Display . . . . . . . . . . . . . . . . . 45

Mode Button . . . . . . . . . . . . . . . . . . 41

Nets, Cab . . . . . . . . . . . . . . . . . . . . . 36

New Operator Procedures . . . . . . 56-57

Noise Emission Control System . . . 68

Obstacles . . . . . . . . . . . . . . . . . . . . . 63

Oil

Demand Drive . . . . . . . . . . . 82-83

Engine . . . . . . . . . . . . . . . . . 76-79

Front Gearcase. . . . . . . . . . . 82-83

Main Gearcase . . . . . . . . . . . 80-81

Transmission . . . . . . . . . . . . 80-81

142

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INDEX

Radiator. . . . . . . . . . . . . . . . . . . . . . . 88

Radiator Coolant Level. . . . . . . . . . . 89

Removing Vehicle from Storage . . 119

Restrictions, Age. . . . . . . . . . . . . . . . 10

Reverse . . . . . . . . . . . . . . . . . . . . . . . 64

Rider Information Center . . . . . . 43-49

Riding Area. . . . . . . . . . . . . . . . . . . . 55

Riding Gear. . . . . . . . . . . . . . . . . . . 8-9

Rollover Protective Structure . . . . . . 39

ROPS Cab Frame . . . . . . . . . . . . . . . 39

RPM, Idle, Throttle Body . . . . . . . . . 98

Stopping the Engine . . . . . . . . . . . . . 54

Storage . . . . . . . . . . . . . . . . . . 115-119

Inspection . . . . . . . . . . . . . . . . 118

Lubrication . . . . . . . . . . . . . . . 118

Area. . . . . . . . . . . . . . . . . . . . . 118

Battery. . . . . . . . . . . . . . . . . . . 112

Covers. . . . . . . . . . . . . . . . . . . 118

Fluid Levels . . . . . . . . . . . . . . 117

Oil and Filter. . . . . . . . . . . . . . 117

Removal . . . . . . . . . . . . . . . . . 119

Suspension Settings . . . . . . . . 101-104

Switches

AWD Switch. . . . . . . . . . . . 31, 40

Ignition Switch . . . . . . . . . . . . . 30

Mode Button . . . . . . . . . . . . . . . 41

Safe Operation Practices. . . . . . . . . . 53

Safety Labels. . . . . . . . . . . . . . . . 20-27

Safety Symbols . . . . . . . . . . . . . . . . . . 4

Safety Training, ROHVA . . 1, 5, 53, 56

Safety Warnings . . . . . . . . . . . . . 10-19

Seat Adjustment . . . . . . . . . . . . . . . . 32

Seat Belts . . . . . . . . . . . . . . . . . . . . . 37

Seat Removal . . . . . . . . . . . . . . . . . . 32

Severe Use Definition. . . . . . . . . . . . 69

Shifting Gears . . . . . . . . . . . . . . . . . . 38

Shock Compression . . . . . . . . . . . . 104

Signal Words. . . . . . . . . . . . . . . . . . . . 4

Spark Arrester Warning . . . . . . . 96-97

Spark Arrestor Cleaning . . . . . . . . . . 97

Spark Plugs . . . . . . . . . . . . . . . . 84-85

Condition . . . . . . . . . . . . . . . . . 85

Tachometer . . . . . . . . . . . . . . . . . . . . 47

Throttle Freeplay . . . . . . . . . . . . . . . 98

Throttle Pedal . . . . . . . . . . . . . . . . . . 39

Throttle System. . . . . . . . . . . . . . . . . 98

Tire Tread Depth. . . . . . . . . . . . . . . 105

Tires . . . . . . . . . . . . . . . . . . . . 105-106

Trail Etiquette . . . . . . . . . . . . . . . . . . 55

Transmission Oil. . . . . . . . . . . . . 80-81

Transmission Operation . . . . . . . 91-93

Transmission, Drying . . . . . . . . . . . . 93

Transporting the Vehicle . . . . . . . . 119

Tread Depth, Tire . . . . . . . . . . . . . . 105

Tread Lightly . . . . . . . . . . . . . . . . . . 55

Gap . . . . . . . . . . . . . . . . . . . . . . 84

Removal . . . . . . . . . . . . . . . . . . 85

Torque. . . . . . . . . . . . . . . . . . . . 84

Fouled . . . . . . . . . . . . . . . . . . . . 85

Vehicle Identification Numbers . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . 109

Vehicle Transport . . . . . . . . . . . . . . 119

Specifications . . . . . . . . . . . . . 120-123

Specifications, Gearcase . . . . . . . . . . 84

Speed, Idle . . . . . . . . . . . . . . . . . . . . 98

Speedometer . . . . . . . . . . . . . . . . . . . 41

Spring Preload. . . . . . . . . . . . . 101-103

Stabilizing the Fuel . . . . . . . . . . . . . 117

Starting the Engine . . . . . . . . . . . . . . 54

Steering Wheel Adjustment . . . . . . . 32

Steering Wheel Inspection . . . . . . . 110

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle. . . . . . . . 115-116

Wheel Installation. . . . . . . . . . . . . . 106

Wheel Nut Torque . . . . . . . . . . . . . 105

Wheel Removal . . . . . . . . . . . . . . . 106

143

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