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.  
Copyright 2012 POLARIS Sales Inc. All information contained within this publication  
is based on the latest product information at the time of publication. Due to constant  
improvements in the design and quality of production components, some minor 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  
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  
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  
4
E
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.  
10  
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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.  
11  
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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.  
12  
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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.  
13  
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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.  
14  
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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.  
15  
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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.  
16  
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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.  
17  
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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.  
18  
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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.  
19  
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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.  
300 lbs.  
300 lbs.  
300 lbs.  
(136 kg)  
(136 kg)  
(136 kg)  
(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.  
20  
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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  
21  
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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  
12  
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  
22  
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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  
23  
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SAFETY  
Safety Labels and Locations  
Age  
Overturn  
Warning  
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  
24  
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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  
25  
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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  
26  
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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  
27  
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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  
28  
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FEATURES AND CONTROLS  
Component Locations  
Rear Passenger  
Grab Bar  
Shifter  
Fuel Tank  
Cap  
Cargo Box  
Tie-Down  
Points  
29  
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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  
ON  
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.  
30  
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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.  
31  
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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  
32  
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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  
Pin  
Retainer  
Post Mounting  
Adjustment  
Holes  
Pin  
33  
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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.  
34  
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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.  
35  
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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  
36  
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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.  
37  
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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  
38  
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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  
39  
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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.  
40  
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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.  
41  
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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.  
42  
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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.  
2
E
F
Trip 1  
RPM  
1
3
km  
mi  
4
:
8888  
5
6
7
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)  
43  
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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).  
44  
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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.  
45  
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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.  
46  
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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.  
47  
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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.  
48  
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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.  
49  
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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.  
50  
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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.  
51  
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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  
39  
99  
Brake fluid  
Front suspension  
Rear suspension  
Steering  
Ensure proper level  
100  
74  
74  
Inspect, lubricate if necessary  
Inspect, lubricate if necessary  
Ensure free operation  
110  
Tires  
Inspect condition and pressure  
20  
105  
Wheels/fasteners  
Frame nuts, bolts, fasteners Inspect, ensure tightness  
Inspect, ensure fastener tightness  
105  
-
Fuel and oil  
Ensure proper levels  
44  
77  
Coolant level  
Coolant hoses  
Ensure proper level  
Inspect for leaks  
89-90  
-
Throttle  
Ensure proper operation  
Ensure proper operation  
Inspect, clean  
Inspect, clean  
Check operation  
98  
30-31  
94  
94  
-
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  
32  
37  
36  
52  
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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.  
53  
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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.  
54  
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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.  
55  
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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.  
56  
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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.  
57  
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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.  
58  
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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  
59  
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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  
60  
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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.  
61  
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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.  
62  
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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.  
63  
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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.  
64  
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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.  
65  
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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.  
66  
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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.  
67  
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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.  
68  
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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.  
69  
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MAINTENANCE  
Periodic Maintenance Chart  
Maintenance Chart Key  
M Perform these operations more often for vehicles subjected to severe  
use.  
E
Emission-related service (Failure to conduct this maintenance will  
not void the emissions warranty but may affect emissions.)  
D Have an authorized POLARIS dealer perform these services.  
WARNING! Improperly performing the procedures marked with a “D” could  
result in component failure and lead to serious injury or death. Have an  
authorized POLARIS dealer perform these services.  
70  
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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  
Pre-Ride  
Pre-Ride  
Pre-Ride  
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  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Daily  
Daily  
Daily  
Daily  
-
-
-
-
-
-
-
-
Wheels/fasteners  
Frame fasteners  
Engine oil level  
E Engine intake pre-filter  
PVT intake pre-filter  
Coolant  
Inspect; clean often  
Inspect; clean often  
Check coolant level  
Check operation; apply  
dielectric grease if  
replacing  
Headlight/taillight  
M Engine oil change  
25 H  
25 H  
25 H  
25 H  
10 H  
25 H  
25 H  
1 M  
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  
E
M Brake pad wear  
Monthly 100 (160) Inspect periodically  
D
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.  
71  
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MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
Remarks  
(whichever comes first)  
Hours Calendar  
Miles  
(Km)  
M General  
50 H  
50 H  
50 H  
50 H  
3 M  
6 M  
6 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
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  
50 H  
50 H  
50 H  
50 H  
6 M  
6 M  
6 M  
6 M  
6 M  
1000 (1600) Replace with oil change  
500 (800) Inspect, adjust  
500 (800) Lubricate  
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  
100 H  
12 M  
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  
E
M Spark plugs  
100 H  
12 M  
1000 (1600) Inspect; replace as needed,  
torque to specification  
E
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.  
72  
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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  
100 H  
100 H  
12 M  
12 M  
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  
100 H  
-
12 M  
-
12 M  
1000 (1600) Inspect; replace as needed  
-
Inspect shock seals  
1500 (2400) See your dealer for oil  
change/seal inspection.  
D
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  
24 M  
24 M  
-
-
Replace coolant  
200 H  
200 H  
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  
E
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.  
73  
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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  
74  
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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)  
75  
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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.  
76  
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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.  
77  
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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  
78  
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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.  
79  
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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.  
80  
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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.  
81  
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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.  
82  
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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.  
83  
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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.  
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.  
84  
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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.  
85  
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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  
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  
86  
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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  
87  
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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.  
88  
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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  
89  
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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.  
90  
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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.  
91  
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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.  
92  
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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.  
93  
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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.  
94  
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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  
95  
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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.  
96  
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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  
97  
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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.  
98  
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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).  
99  
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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  
1
2
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.  
1
2
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  
Increase  
Decrease  
Rear  
HARD  
SOFT  
Front  
FOX Shocks  
Walker Evans Shocks  
Setting Compression Damping  
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)  
X
X
2 in. (5 cm)  
2. Place the transmission in PARK.  
3. Measure the distance from the floor to the center of the headlight  
and make a mark on the wall at the same height.  
4. Apply the brakes. Start the  
engine. Turn the headlights to  
high beam.  
5. 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  
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.  
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  
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  
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  
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  
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  
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MAINTENANCE LOG  
DATE  
MILES (KM)  
OR HOURS  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
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INDEX  
A
C
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  
B
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  
D
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  
140  
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INDEX  
E
F
Electromagnetic Interference . . . . . . 68  
Emission Control, Crankcase . . . . . . 68  
Emission Control, Exhaust . . . . . . . . 68  
Emission Control, Noise. . . . . . . . . . 68  
Emissions Limited Warranty . 135-136  
Engaging AWD. . . . . . . . . . . . . . . . . 40  
Engine Access Panel. . . . . . . . . . . . . 35  
Engine Break-In . . . . . . . . . . . . . . . . 51  
Engine Fogging. . . . . . . . . . . . . . . . 118  
Engine Idle Speed . . . . . . . . . . . . . . . 98  
Engine Intake Pre-Filter . . . . . . . . . . 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  
G
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  
F
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  
H
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  
141  
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INDEX  
I
O
Idle Speed . . . . . . . . . . . . . . . . . . . . 98  
Ignition Switch. . . . . . . . . . . . . . . . . 30  
Indicator Lamps. . . . . . . . . . . . . . . . 42  
Inspection, Axle Nuts . . . . . . . . . . 105  
Inspection, Brakes . . . . . . . . . . . . . . 99  
Inspection, Pre-Ride . . . . . . . . . . . . 52  
Inspection, Steering Wheel . . . . . . 110  
Inspection, Wheel Nuts . . . . . . . . . 105  
Installation, Battery . . . . . . . . . . . . 112  
Installation, Wheels . . . . . . . . . . . . 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  
K
Key, Periodic Maintenance Chart . . 70  
L
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  
P
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  
M
Maintenance, Periodic . . . . . . . . . 69-73  
Metric Display . . . . . . . . . . . . . . . . . 45  
Mode Button . . . . . . . . . . . . . . . . . . 41  
N
Nets, Cab . . . . . . . . . . . . . . . . . . . . . 36  
New Operator Procedures . . . . . . 56-57  
Noise Emission Control System . . . 68  
O
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  
R
S
Radiator. . . . . . . . . . . . . . . . . . . . . . . 88  
Radiator Coolant Level. . . . . . . . . . . 89  
Removing Vehicle from Storage . . 119  
Restrictions, Age. . . . . . . . . . . . . . . . 10  
Reverse . . . . . . . . . . . . . . . . . . . . . . . 64  
Rider Information Center . . . . . . 43-49  
Riding Area. . . . . . . . . . . . . . . . . . . . 55  
Riding Gear. . . . . . . . . . . . . . . . . . . 8-9  
Rollover Protective Structure . . . . . . 39  
ROPS Cab Frame . . . . . . . . . . . . . . . 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  
S
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  
T
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  
V
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  
W
Warning Symbols . . . . . . . . . . . . . . . . 4  
Washing the Vehicle. . . . . . . . 115-116  
Wheel Installation. . . . . . . . . . . . . . 106  
Wheel Nut Torque . . . . . . . . . . . . . 105  
Wheel Removal . . . . . . . . . . . . . . . 106  
143  
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