PMS 419
RANGER RZR
RANGER RZR S
RANGER RZR 4
Owner's Manual
for Maintenance and Safety
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WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
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The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
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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.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
1
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POLARIS, THE WAY OUT, RANGER and RANGER RZR are registered trademarks of
POLARIS Industries Inc.
Copyright 2010 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.
2011 RANGER RZR / RANGER RZR S / RANGER RZR 4 Owner’s Manual
P/N 9922973
2
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TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . . . . . 28
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Emission Control Systems . . . . . . . . . . . . . . . . . . . . 68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
POLARIS Products . . . . . . . . . . . . . . . . . . . . . . . . 126
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Declaration of Conformity. . . . . . . . . . . . . . . . . . . 131
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3
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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.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may 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.
4
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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.
• 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.
• 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.
5
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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.
Vehicle Identification Num-
ber
Key
Number
Engine Serial Number
####
Vehicle Model Number: __________________________________________________________
Vehicle Identification Number: _____________________________________________________
Engine Serial Number: ___________________________________________________________
Key Number ____________________________________________________________________
6
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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.
7
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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 Sleeves
Eye Protection
Long
Pants
Sturdy
Footwear
Gloves
Helmet
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds 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
8
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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 footwear. Do not ride a POLARIS vehicle with bare feet.
Clothing
Wear long sleeves and long pants to protect arms and legs.
9
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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. 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.
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 an approved helmet that fits properly
and eye protection (goggles or face shield).
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.
11
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SAFETY
Safety Warnings
Carrying Passengers (RZR 4)
Never carry a passenger until you have operated
this vehicle for at least two hours and have
completed the New Operator Driving Procedures
outlined on pages 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.
Carrying Multiple Passengers (RZR)
Never carry a passenger until you have operated this
vehicle for at least two hours and have completed the
New Operator Driving Procedures outlined on pages
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.
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.
12
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SAFETY
Safety Warnings
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.
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.
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.
13
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SAFETY
Safety Warnings
Physical Control of the Vehicle
Removing hands from the steering wheel or hand holds 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.
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 transmission in
forward gear. Never descend a hill with the
transmission in neutral.
+15°
• 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
sharply to one side. Travel straight downhill.
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°
14
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SAFETY
Safety Warnings
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/towing
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 or pull-
ing a trailer.
• Never exceed the stated load capacity for
this vehicle.
• Cargo should be properly distributed and
securely attached.
• Reduce speed when carrying cargo or pulling a trailer. 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.
Cargo Box Warning
WARNING
• Passengers can be thrown off. This can cause serious injury or death.
• Never carry passengers in cargo box.
• Maximum 4X4 Box Load is 300 lbs. (136.4 kg)
Cargo Box Warning
Tire Pressure/Cargo
Overload Warning
20
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SAFETY
Safety Labels and Locations
Tire Pressure/Cargo Overload Warning (RZR)
WARNING
IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
4X4 - FRONT 8 (55.2) REAR 8 (55.2)
MAXIMUM WEIGHT CAPACITY INCLUDING DRIVER, PASSENGER, CARGO
AND ACCESSORIES: 4X4 is 740 LBS. (336.4 kg)
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.
Read Owner’s Manual for more detailed loading information.
7175103
Tire Pressure/Cargo Overload Warning (RZR 4)
WARNING
IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
4x4 FRONT 10 (68.9) REAR 12 (82.7)
MAXIMUM WEIGHT CAPACITY
INCLUDING DRIVER, PASSENGERS, CARGO AND ACCESSORIES:
4x4 is 900 LBS. (408.2 kg)
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.
Read Owner’s Manual for more detailed loading information.
7176606
21
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SAFETY
Safety Labels and Locations
Age
Warning
Overturn
Warning
Cab Frame/Seat Belt
Warning
Discretionary
Warning
Shift
Caution
Cab Frame/Seat Belt Warning
WARNING
• ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat
belt.
• ALWAYS SECURE CAB NETS.
• VEHICLE OVERTURN could cause severe injury or death.
22
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SAFETY
Safety Labels and Locations
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
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
23
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SAFETY
Safety Labels and Locations
Discretionary Warning (RZR)
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.
• reduce speed and use extra caution when carrying a
passenger.
• operate slowly in reverse - avoid sharp turns or sud-
den braking.
• make sure passenger reads and understands all
safety labels.
• watch for branches or other hazards that could enter
vehicle.
ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR FOR OPERATOR AND
PASSENGER
NEVER USE ON PUBLIC ROADS
NEVER USE WITH DRUGS OR ALCOHOL
LOCATE AND READ OWNER’S MANUAL. FOLLOW
ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S
MANUAL IS MISSING, CONTACT A POLARIS
DEALER FOR A REPLACEMENT.
7175104
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SAFETY
Safety Labels and Locations
Discretionary Warning (RZR 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
25
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SAFETY
Safety Labels and Locations
Passenger
Safety Warn-
ing
Passenger Safety Warning (RZR)
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 holds.
THE PASSENGER MUST ALWAYS:
• wear seat belt.
• use an approved helmet 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.
• watch for branches, brush, and other hazards that could
enter vehicle.
7175102
26
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SAFETY
Safety Labels and Locations
Passenger Safety Warning (RZR 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
Rear Passenger Cab Frame Warn-
Passenger Cab Frame
Warning (both sides)
ing (RZR 4)
WARNING
Do NOT hold onto this bar. Hands and arms
could be crushed or seriously injured in
event of rollover.
ALWAYS keep hands on passenger grab bar.
7176700
Rear Passenger Grab Bar
Warning (RZR 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
27
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FEATURES AND CONTROLS
Component Locations
Rear Passenger Grab
Bar
Cab Nets
Front
Passenger
Hand Hold
Cargo
Box
Shifter
Fuel Tank
Hip Bars
Cap
Tie-Down
Points
Rack Extenders (RZR/
RZR EPS only)
28
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FEATURES AND CONTROLS
Component Locations
Cab Frame
Storage
Compartment
(under hood)
Steering
Wheel
Headlights
Radiator
Brush Guard
29
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FEATURES AND CONTROLS
Component Locations
Taillights
Receiver
Hitch
Trailer Receiver Hitch Bracket
This vehicle is equipped with a receiver hitch bracket for a trailer hitch.
Trailer towing equipment is not supplied with this vehicle.
To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 66-67.
30
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FEATURES AND CONTROLS
Rear Service Panel
The rear service panel is located behind the seats on the frame of the
vehicle. Remove the seats to access the service panel. Remove the ser-
vice panel to access serviceable engine components and clutches.
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
Seat
Latch
Front Seat
Retainer
under the seat retainer bar.
5. Press down firmly at the
rear of the seat to engage
the rear latch.
31
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FEATURES AND CONTROLS
Steering Wheel
The steering wheel can be
tilted upward or downward
for rider preference.
Lift and hold the steering
wheel adjustment lever
while moving the steering
wheel upward or down-
ward. Release the lever
when the steering wheel is
at the desired position.
Adjustment Lever
Passenger Hand Hold
Always adjust the hand hold to a comfortable position for your front-
seat passenger before operating. Make sure the adjustment pin and
retainer are securely installed after making adjustments.
1. Remove the retainer from the end of the adjustment pin.
2. Remove the pin from the post.
3. Slide the post inward or outward to the desired position.
4. Reinstall the pin through the mounting bracket hole, through both
post adjustment holes, and through the remaining bracket hole.
5. Reinstall the retainer to the pin.
Pin
Retainer
Adjustment
Mounting
Bracket Holes
Pin
32
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FEATURES AND CONTROLS
Hood
Remove the hood to access the front storage compartment, the radiator
cap and the coolant overflow bottle.
1. Turn the hood fasteners
1/4 turn.
Storage Compartment
2. Grasp the upper hood
edge and pull upward to
disengage the hood
from the vehicle.
3. Pivot the hood forward
and lift upward to disen-
gage the lower hood
hooks.
4. Lift the hood away from
the vehicle.
Overflow
Bottle
Radiator Cap
33
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FEATURES AND CONTROLS
Fuel Cap
The fuel tank filler cap is located
on the right-hand side of the
vehicle near the passenger seat.
When refueling, always use
either leaded or unleaded gaso-
line with a minimum pump
octane number of 87 R+M/2
octane. Do not use fuel with eth-
anol content greater than 10
percent, such as E-85 fuel.
Remove flammable material
containers from the box before
filling.
Fuel Cap
Cab Nets
All RZR models are equipped
Rear Cab Net
Latches
Front Cab Net
Latches
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 over-
turn. 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.
34
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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.
35
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FEATURES AND CONTROLS
Switches
Instrument
Cluster
Ignition
Switch
12V Accessory
Light
Switch
AWD Switch
Outlet
Auxiliary Outlet
The vehicle is equipped with one or more 12-volt accessory outlets. One
outlet is on the dash, a second outlet (if equipped) is in the rear passen-
ger area. Use the outlets to power an auxiliary light or other optional
accessories or lights. For service, the dash outlet connection is under the
dash. The rear outlet connection is under the rear passenger seats.
Electronic Power Steering (EPS)
Electronic power steering (if
equipped) engages when the ignition
key is turned to the ON position. EPS
remains engaged whether the vehicle
is moving or idle.
The EPS warning indicator briefly
illuminates when the key is turned to
the ON position. See page 42.
If the light remains on after starting
the engine, the EPS system is
Power Steering Unit
inoperative. See your authorized
(under cover)
POLARIS dealer for service.
36
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FEATURES AND CONTROLS
Switches
Ignition Switch
The ignition switch is a three-position, key-operated switch. Use the
ignition switch to start the engine. See page 54 for starting procedures.
The key can be removed from the switch when it is in the OFF position.
OFF
The engine is off. Electrical circuits are off, except accessory 12V.
Electrical circuits are on. Electrical equipment can be used.
ON
START
Turn the key to the START position to engage the electric starter. The key
returns to the ON position when released.
Headlight Switch
Use the headlight switch to turn the lights on and
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.
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 and High Range
Condition
Range to Use
Operating at speeds less than 7 MPH (11 km/h)
Operating in rough terrain or over obstacles
Loading the vehicle onto a trailer
Low
Low
Low
Low
High
Towing heavy loads
Operating at speeds greater than 7 MPH (11 km/h)
38
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FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to
slow or stop the vehicle.
Apply the brakes while start-
ing 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 start-
ing the engine. Make sure
there's adequate throttle
pedal freeplay. See page 98
for throttle pedal adjustment
procedures.
Brake Pedal
Throttle
Pedal
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.
AWD
2WD
When in AWD, the demand drive unit will auto-
matically engage any time the rear wheels lose
traction. When the rear wheels regain traction, the
demand drive unit will automatically disengage.
There is no limit to the length of time the vehicle
may remain in AWD.
Engaging AWD
The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the demand drive unit is moving, it will not disengage until the
rear wheels regain traction.
Engage the AWD switch before getting into conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.
NOTICE: Switching to AWD while the rear wheels are spinning or slipping may
cause severe drive shaft and gearcase damage. Always switch to
AWD while the rear wheels have traction or are at rest.
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
Over
When metric mode is selected, speed displays in
kilometers per hour.
This lamp illuminates to indicate an overheated
Temperature engine. If the indicator flashes, the overheating
condition remains, and the system will automatically
reduce engine power.
EPS Warning This indicator illuminates briefly when the key is
turned to the ON position. If the light remains on, the
EPS system is inoperative. See your authorized
POLARIS dealer for service.
Neutral
This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam
This lamp illuminates when the headlamp switch is
set to high beam.
Helmet/Seat This lamp flashes for several seconds when the key is
Belt
turned to the ON position. The lamp is a reminder to
the operator to ensure all riders are wearing helmets
and seat belts before operating.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.
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)
MODE
Button
The display can be changed to show either
standard or metric units of measurement for
each of the following settings.
Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key
on. The gauge display the mode that was displayed prior to setting the
units.
Standard Display
Miles
Metric Display
Kilometers
Distance
Fuel
U.S. Gallons
Fahrenheit
Liters, Imperial Gallons
Celsius
Temperature
Time
12-Hour Clock
24-Hour Clock
1. Turn the key to the OFF position.
2. Press and hold the MODE button while turning the key to the ON
position.
3. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting.
4. Press and hold the MODE button to save the setting and advance to
the next display option.
5. Repeat the procedure to change remaining display settings.
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
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.
Number (0-9)
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 34. 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. Pull only light loads.
8. During the break-in period, change both the oil and the filter at 25
hours or one month.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive or
overly forceful braking when the brake system is new could damage
brake pads and rotors.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur-
ing the break-in period.
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
Inspect, lubricate if necessary
Inspect, lubricate if necessary
Ensure free operation
74
101
Tires
Inspect condition and pressure
21
105
Wheels/fasteners
Inspect, ensure fastener tightness
105
-
Frame nuts, bolts, fasteners Inspect, ensure tightness
Fuel and oil
Ensure proper levels
44
77
Coolant level
Ensure proper level
92
91
Coolant hoses
Throttle
Inspect for leaks
-
Ensure proper operation
Ensure proper operation
Inspect, clean
97
37
95
107
Indicator lights/switches
Air filter, pre-filter
Headlamp
Check operation, apply POLARIS
dielectric grease when lamp is
replaced
Brake light/tail lamp
Check operation, apply POLARIS
dielectric grease when lamp is
replaced
109
Seat Latches
Seat Belts
Cab Nets
Push down on both seat backs to
ensure the latches are secure
31
35
34
Check length of belt for damage,
check latches for proper operation
Check for wear or damage, ensure
proper installation
52
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OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle.
2. Do not allow anyone under 16 years of age or without a valid
driver’s license to operate this vehicle.
3. Never operate with a passenger under the age of 12. Never carry
more one passenger in a 2-seat vehicle. Never carry more than three
passengers in a 4-seat vehicle. Never allow a passenger to ride in
the cargo box.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Never operate with accessories not approved by POLARIS for use
on this vehicle.
6. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
7. Drive in a manner appropriate for your skills and operating condi-
tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Keep both hands on the steering wheel dur-
ing operation.
8. Never consume alcohol or drugs before or while operating this vehi-
cle.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged vehicle. After any 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.
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. Perform the pre-ride inspection. See page 52.
3. Wear an approved helmet that fits properly and eye protection (gog-
gles or face shield).
4. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
5. Do not tow or carry cargo during this period.
6. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.
7. Sit in the driver's seat and fasten the seat belt.
8. Always use the cab nets while riding in this vehicle.
9. Place the transmission in PARK.
10. Start the engine.
56
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OPERATION
New Operator Driving Procedures
11. Apply the brakes and shift into low gear.
12. Check your surroundings and determine your path of travel.
13. Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving.
14. 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.
15. Increase speed only after mastering all maneuvers at a slow speed.
16. 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 passengers in a
4-seat vehicle. Additional
passengers can affect the
operator’s ability to steer
and operate the controls.
4. Make sure all passengers
are at least 12 years of age
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. Make sure all passengers are wearing appropriate riding gear,
including an approved helmet and eye protection. 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
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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
water level is lowest and
Floor Level
where both banks have grad-
ual inclines. Never operate
in water that exceeds the
maximum recommended depth.
WARNING! The large tires on your vehicle may cause the vehicle to float in
deep or fast-flowing water, which could result in loss of traction, loss of control,
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 or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:
Never exceed the stated load capacity for this vehicle.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, passengers, accessories, loads in the rack or box and the load on the
trailer tongue. The combined weight of these items must not exceed the
maximum weight capacity.
Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.
Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
Carrying a passenger in the cargo box could
result in a fall from the vehicle or contact with
moving components. Never allow a
passenger to ride in the cargo box. A
passenger must always be seated in a
passenger seat with seat belt secured.
66
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OPERATION
Hauling Cargo
Your POLARIS vehicle has been designed to carry or tow specific
capacities. Reduce speed and allow a greater distance for braking when
carrying cargo.
Loads should be centered and carried as low as possible in the box. For
stability on rough or hilly terrain, reduce both speed and cargo. Exercise
caution if the cargo load extends over the side of the box.
Always read and understand the load distribution warnings listed on
warning labels and in this manual. Never exceed the maximum capaci-
ties specified for your vehicle. See page 122.
Belt Life
To extend belt life, use low gear when hauling or towing heavy cargo.
Towing Loads
WARNING
Towing improperly can alter vehicle handling and may cause loss of control or
brake instability.
Always follow these precautions when towing:
1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow-
ing bracket.
2. Do not operate the vehicle faster than 10 mph (16 km/h) when tow-
ing. Towing a trailer increases braking distance.
3. Do not tow more than the recommended weight for the vehicle.
4. Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location, which could result in loss of control of
the vehicle.
5. The total load (operator, passengers, accessories, cargo and weight
on hitch) must not exceed the maximum weight capacity of the
vehicle.
Total Towed
Load Weight
(Level Ground)
Total Towed
Load Weight
(15° grade)
Total Hitch
Vertical
Weight
Maximum
Towing
Speed
1500 lbs.
(681 kg)
850 lbs.
(386 kg)
150 lbs.
(68.1 kg)
10 mph
(16 kph)
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 arrestor that was tested and quali-
fied to be in accordance with the USFS standard 5100-1C. Federal law
requires that this spark arrestor be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI com-
ponents are set at the factory for optimal performance and are not
adjustable.
The emissions label is located on the lower frame behind the driver’s
seat.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-
tives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the lim-
itations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.
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MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.
Record maintenance and service in the Maintenance Log beginning on
page 139.
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
riding conditions and an average vehicle speed of approximately ten
(10) miles per hour. Vehicles subjected to severe use must be inspected
and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank-
case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
69
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MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
X
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.)
n
Have an authorized POLARIS dealer perform these services.
WARNING! Improperly performing the procedures marked with a n 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)
n
Steering
-
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
-
-
-
-
-
Make adjustments as need ed.
See Pre-Ride Checklist on page
52.
X Front suspension
X Rear suspension
Tires
X Brake fluid level
X Brake pedal travel
Brake system
-
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Daily
-
-
-
-
-
Wheels/fasteners
Frame fasteners
X Engine oil level
X Air filter, pre-filter
E
Inspect; clean often; replace as
needed
Coolant
-
Daily
Daily
-
-
-
-
Check level daily, change cool-
ant every 2 years
(if applicable)
X Power steering unit
-
Inspect daily; clean often
(if equipped)
Headlamp/tail lamp
-
-
Daily
Check operation; apply
dielectric grease if replacing
X Air filter,
Weekly
Monthly
Inspect; replace as needed
E
main element
X Brake pad wear
10 H
100 (160) Inspect periodically
n
Battery
25 H
25 H
25 H
25 H
25 H
Monthly
Monthly
Monthly
Monthly
Monthly
250 (400) Check terminals; clean; test
250 (400) Inspect level; change yearly
250 (400) Inspect level; change yearly
250 (400) Inspect level; change yearly
250 (400) Inspect level; change yearly
X Demand drive fluid
X Rear gearcase oil
X Main gearcase oil
X Transfer case oil
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
n
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)
X Engine breather
25 H
25 H
50 H
50 H
50 H
Monthly
1 M
150 (250) Inspect; replace if necessary
E
filter (if equipped)
X Engine oil change
-
Perform a break-in oil and filter
change at one month
(break-in)
nE Throttle cable/ ETC
6 M
300 (500) Inspect; adjust; lubricate;
replace if necessary
switch
E
Throttle body air
intake ducts/flange
6 M
300 (500) Inspect duct for proper sealing/
air leaks
X General
lubrication
3 M
500 (800) Lubricate all fittings, pivots,
cables, etc.
Shift Linkage
Steering
50 H
50 H
50 H
50 H
50 H
6 M
6 M
6 M
6 M
6 M
500 (800)
Inspect, lubricate, adjust
n
500 (800) Lubricate
500 (800) Lubricate
500 (800) Lubricate
X Front Suspension
X Rear Suspension
Cooling system
(if applicable)
500 (800) Inspect coolant strength
seasonally; pressure test
system yearly
nE Fuel system
100 H
12 M
600 (1000) Check for leaks at tank cap,
lines, filter, pump, throttle body;
replace lines every two years
X Spark plug
100 H
100 H
100 H
12M
6 M
6 M
600 (1000) Inspect; replace as needed
E
X Engine oil change
1000 (1600) Perform a break-in oil change at
one month
X Oil filter change
1000 (1600) Replace with oil change
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
n
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)
X Radiator
100 H
12 M
1000 (1600) Inspect; clean external
surfaces
(if equipped)
X Cooling Hoses
X Engine mounts
100 H
100 H
12 M
12 M
12 M
12 M
12 M
1000 (1600) Inspect for leaks
1000 (1600) Inspect
Exhaust muffler/pipe 100 H
1000 (1600) Inspect
n
Ignition timing
X Wiring
100 H
100 H
1000 (1600) Inspect
1000 (1600) Inspect for wear, routing,
security; apply dielectric grease
to connectors
subjected to water, mud, etc.
n
Clutches (drive and
driven)
100 H
12 M
1000 (1600) Inspect; clean; replace worn
parts
Drive belt
100 H
100 H
12 M
12 M
1000 (1600) Inspect; replace as needed
1000 (1600) Inspect; replace as needed
n
n
Front wheel
bearings
Brake fluid
200 H
300 H
24 M
36 M
2000 (3200) Change every two years
3000 (4800) Clean out
Adjust as needed
Spark arrestor
Idle speed
-
n
Toe adjustment
-
Inspect periodically; adjust
when parts are replaced
Headlight aim
-
Adjust as needed
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
n
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
Lube
Method
Engine Oil
PS-4 PLUS Synthetic
Engine Oil
Add to proper level on dipstick.
See page 77.
Brake Fluid
DOT 4
Maintain level between fill lines.
See page 100.
Transmission Oil
(Main Gearcase)
Premium AGL Synthetic
Gearcase Lube
See page 82.
See page 80.
See page 84.
See page 85.
Transmission Oil
(Transfer Case)
Premium AGL Synthetic
Gearcase Lube
Demand Drive Fluid
(Front Gearcase)
Demand Drive Plus Fluid
Rear Gearcase Oil
Premium ATV Angle Drive
Fluid
Prop Shaft
POLARIS Premium U-Joint Locate fittings and grease.
Lube
Control Arm Pivot
Bushings, Front/Rear
POLARIS Premium all
Season Grease or grease
conforming to NLGI No. 2
Locate fittings and grease.
Stabilizer Bar Bushings POLARIS Premium all
Season Grease or grease
Locate fittings and grease.
conforming to NLGI No. 2
Prop Shaft
Grease Fitting
74
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MAINTENANCE
Lubrication Recommendations
RZR S/RZR 4
Control Arm Pivot
Bushings
RZR
Stabilizer Bar
Bushings
RZR 4
Stabilizer Bar Bushings
RZR
Control Arm Pivot
Bushings
RZR S/RZR 4
Control Arm Pivot
Bushings
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MAINTENANCE
Engine Oil
Oil Recommendations
POLARIS recommends the use of POLARIS PS-4 PLUS Synthetic
engine oil.
WARNING! Vehicle operation with insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and may result in engine seizure,
accident, and injury. Always perform the maintenance procedures as outlined in
the Periodic Maintenance Chart.
Oil may need to be changed more frequently if POLARIS PS-4 PLUS
Synthetic engine oil is not used. Follow the manufacturer's recommen-
dations for ambient temperature operation. See page 126 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
The oil dipstick and fill tube is
located on the engine, behind
the passenger seat (behind the
right rear passenger seat on
RZR 4 models).
1. Position the vehicle on a
level surface.
2. Place the transmission in
PARK.
3. Remove both seats. Remove
the rear service panel. See
page 31.
4. Lift the lever lock to remove
the dipstick. Wipe it dry with
a clean cloth.
Dipstick
5. Reinstall the dipstick com-
pletely, but do not lock it. The
dipstick must be inserted com-
pletely in to keep the angle
and depth of the stick consis-
tent.
Safe
6. Remove the dipstick and
check the oil level. Maintain
the oil level in the safe range.
Do not overfill.
Safe
Range
Tip: Due to the dipstick entry angle
into the crankcase, the oil level
will read higher on the bottom
side of the dipstick. Always read
the level on the upper surface of
the dipstick.
Check Level
on Top Side
7. Reinstall the dipstick. Seat the
lever lock.
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.
The engine drain plug is located on
the bottom of the crankcase.
1. Position the vehicle on a level
surface. Place the transmission
in PARK. Apply the brakes.
2. Start the engine. Allow it to idle
for two to three minutes. Stop
the engine.
3. Clean the area around the drain
plug.
CAUTION! Hot oil can cause burns to
skin. Do not allow hot oil to contact skin.
Drain Plug
4. Place a drain pan beneath engine
crankcase and remove the drain plug.
5. Allow the oil to drain completely.
6. Reinstall the sealing washer on the drain plug.
Tip: The sealing surfaces on drain plug and crankcase should be clean and free
of burrs, nicks or scratches.
7. Reinstall the drain plug. Torque to 16 ft. lbs. (22 Nm).
78
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MAINTENANCE
Engine Oil
Oil and Filter Change
8. Using a cap-style oil filter wrench, turn the filter counter-clockwise
to remove it.
9. Using a clean dry cloth, clean the filter sealing surface on the crank-
case.
10. Lubricate the o-ring on the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition.
11. Install the new filter and turn by hand until the filter gasket contacts
the sealing surface, then turn and additional 1/2 turn.
12. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec-
ommended oil.
13. Place the transmission in PARK. Apply the brakes.
14. Start the engine. Allow it to idle for one to two minutes.
15. Stop the engine. Inspect for leaks.
16. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.
17. Dispose of used filter and oil properly.
79
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MAINTENANCE
Gearcases
Transfer Case
Always check and change the fluid at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.
Fill Plug
Level
Check Plug
Drain Plug
Fluid Check
The fill plug and level check plug are located on the left side of the
transfer case. The fluid level is sufficient when fluid flows out of the
check plug hole at step 4.
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Remove the level check plug.
4. Add the recommended fluid to the fill plug hole until it begins to
flow out of the check plug hole.
5. Reinstall the level check plug. Torque to specification.
6. Reinstall the fill plug. Torque to specification.
80
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MAINTENANCE
Gearcases
Transfer Case
Fluid Change
The drain plug is located on the bottom of the transfer case. Access the
drain plug through the drain hole in the skid plate.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring. Torque to specification.
6. Remove the level check plug.
7. Add the recommended fluid to the fill plug hole until it begins to
flow out of the check plug hole.
8. Reinstall the level check plug. Torque to specification.
9. Reinstall the fill plug. Torque to specification.
10. Check for leaks. Discard used fluid properly.
81
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MAINTENANCE
Gearcases
Transmission (Main Gearcase)
Always check and change the fluid at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.
Fluid Check
The fill plug is located on the left side
of the gearcase. Maintain the fluid
level at the bottom of the fill plug
hole.
1. Position the vehicle on a level
surface.
2. Remove the fill plug.
3. Check the fluid level.
4. Add the recommended fluid to
the bottom of the fill plug hole.
Do not overfill.
5. Reinstall the fill plug. Torque to
specification.
Fill Plug
82
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MAINTENANCE
Gearcases
Transmission (Main Gearcase)
Fluid Change
The drain plug is located on the bottom of the gearcase. Access the drain
plug through the drain hole in the skid plate.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring. Torque to specification.
6. Add the recommended fluid to the bottom of the fill plug hole. Do
not overfill.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Discard used fluid properly.
Transfer Case
Main Gearcase Drain
Drain Plug
Plug
Rear Gearcase
Drain Plug
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MAINTENANCE
Gearcases
Demand Drive Unit (Front Gearcase)
Always check and change the fluid at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.
Fluid Check
The fill plug is located on the
bottom right side of the demand
Drain Plug
drive unit. Maintain the fluid
level even with the bottom
thread of the fill plug hole.
1. Position the vehicle on a
level surface.
2. Remove the fill plug. Check
the fluid level.
View of Bot-
3. Add the recommended fluid
tom
to the bottom thread of the
fill plug hole.
Fill Plug
4. Reinstall the fill plug.
Torque to specification.
Fluid Change
The drain plug is located on the bottom of the gearcase.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug. If the o-ring is damaged, install a new o-ring.
5. Reinstall the drain plug. Torque to specification.
6. Add the recommended fluid to the bottom thread of the fill plug
hole.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Discard used fluid properly.
84
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MAINTENANCE
Gearcases
Rear Gearcase
Always check and change the fluid at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 69. Refer to the Gearcase
Specifications Chart on page 86 for recommended lubricants, capacities
and torque specifications.
Fluid Check
The fill plug is located on the right
side of the rear gearcase. Maintain
the fluid level even with the bot-
tom thread of the fill plug hole.
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check
the fluid level.
3. Add the recommended fluid to
the bottom thread of the fill
plug hole.
Drain Plug
Fill Plug
4. Reinstall the fill plug. Torque
to specification.
Fluid Change
The drain plug is located on the bottom right side of the rear gearcase.
1. Remove the fill plug.
2. Place a drain pan under the drain plug. Remove the drain plug.
3. Allow the fluid to drain completely.
4. Clean the drain plug. Reinstall the drain plug with a new o-ring.
Torque to specification.
5. Add the recommended fluid to the bottom thread of the fill plug
hole.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks. Discard used fluid properly.
85
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MAINTENANCE
Gearcases
Gearcase Specification Chart
Use of other fluids may result in improper operation of components. See
page 126 for the part numbers of POLARIS products.
Gearcase
Lubricant
Capacity
Fill Plug
Torque
Drain Plug/
Level Check
Plug Torque
Transmission
(Main Gearcase)
Premium AGL
Synthetic
Gearcase Fluid
24 oz.
(710 ml)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
Transmission
(Transfer Case)
Premium AGL
Synthetic
Gearcase Fluid
14 oz.
(414 ml)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
Demand Drive Unit
(Front Gearcase)
Demand Drive
Plus Fluid
6.75 oz.
(200 ml)
8-10 ft. lbs.
(11-13.6 Nm)
11 ft. lbs.
(15 Nm)
Rear Gearcase
Premium ATV
Angle Drive Fluid
26 oz.
(769 ml)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
Spark Plugs
Spark Plug Gap/Torque
Electrode Gap
New Plug Torque
Used Plug Torque
.035" (.9 mm)
18 ft. lbs.
(24 Nm)
18 ft. lbs.
(24 Nm)
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs. Refer to
the specifications section beginning on page 122.
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 87.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
86
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MAINTENANCE
Spark Plugs
Spark Plug Removal and Replacement
1. Remove both seats.
2. Remove the rear service
panel. See page 31.
Spark Plugs
3. Remove the spark plug cap.
4. Using the spark plug wrench
provided in the tool kit,
remove the plug by rotating
it counter-clockwise.
5. Reverse the procedure for
spark plug installation.
Torque to specification. See
page 86.
Spark Plug Condition
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi-
cates the proper type and heat range for the engine and the service.
Tip: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body adjust-
ments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended injection oil or incorrect throttle body adjust-
ments.
87
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MAINTENANCE
Fuses
If the engine stops or will not start, if the power steering stops working
(if equipped), or if you experience other electrical failures, a fuse may
need replacement. Locate and correct any short circuits that may have
caused the blown fuse, then replace the fuse.
Fuse
Feature Supported
Lights: Headlights, Taillights
20A
10A
20A
10A
20A
Drive: AWD
Accessory: Winch Switch, 12V Power Receptacle
Fuel Pump
Electronic Engine Control, Starting
Power Fuse
20A
Feature Supported
Engine Control
30A
30A
Lights, Drive, Accessories
Power Steering (if equipped)
88
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MAINTENANCE
Fuses
The fuse box is located above the power
steering unit. Spare fuses are provided in the
fuse box.
Fuse Label
1. From the left side of the vehicle, reach in
and lift up on the two fuse box tabs.
2. Slide the fuse box slightly toward the
right side of the vehicle to disengage it
from the mount.
3. Remove the fuse box cover.
4. Remove the suspect fuse from the fuse
panel. If the fuse is blown, install a new
fuse with the same amperage rating.
5. Reinstall the fuse box cover. Reinstall the
fuse box over the mount and slide it
toward the left to engage the tabs. Be
sure the fuse box is securely mounted.
Step 1 - Lift tabs
Step 3 - Cover removed
89
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MAINTENANCE
Cooling System
Operation
The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the overflow bottle, radia-
tor filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the overflow bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.
Tip: Some coolant level drop on new vehicles is normal as the system is purging
itself of trapped air. Observe coolant levels and maintain as recommended
by adding coolant to the overflow bottle.
Adding or Changing Coolant
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added. POLARIS recommends the
use of POLARIS 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 126 for the part numbers of
POLARIS products.
Tip: Always follow the manufacturer's mixing recommendations for the freeze
protection required in your area.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.
90
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MAINTENANCE
Cooling System
Radiator and Cooling Fan
Always check and clean the screen and radiator fins at the intervals out-
lined in the Periodic Maintenance Chart beginning on page 69. Do not
obstruct or deflect air flow through the radiator by installing unautho-
rized accessories in front of the radiator or behind the cooling fan. Inter-
ference with the radiator air flow can lead to overheating and
consequent engine damage.
NOTICE: Washing the vehicle with a high-pressure hose could damage the
radiator fins and impair the radiator's effectiveness. Using a high-
pressure system is not recommended.
Radiator Coolant Level
This procedure is required only if the cooling system has been drained
for maintenance and/or repair. But if the overflow bottle has run dry, the
level in the radiator should also be inspected.
CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.
1. Remove the hood. See page 33.
2. Slowly remove the radiator cap.
3. View the coolant level through the opening.
4. Use a funnel and slowly add coolant as needed.
Tip: Use of a non-standard pressure cap will not allow the recovery system to
function properly. See your dealer for the correct replacement part.
91
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MAINTENANCE
Cooling System
Coolant Level
Always check and change
the coolant at the intervals
outlined in the Periodic
Maintenance Chart begin-
ning on page 69. Maintain
the coolant level between
the minimum and maxi-
mum marks on the bottle
(when the fluid is cool).
1. Position the vehicle on a
level surface.
2. Remove the hood. See
page 33.
Overflow
Bottle
Radiator Cap
3. View the coolant level
in the overflow bottle.
4. If the coolant level is
below the safe operating
range, remove the cap and use a funnel to add coolant through the
opening. Reinstall the cap.
Tip: If coolant must be added often, or if the overflow bottle runs completely dry,
there may be a leak in the system. Have the cooling system inspected by
your POLARIS dealer.
92
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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. See your dealer as
outlined in the owner's manual.
• This PVT system is intended for use on POLARIS products only. Do not install
it in any other product.
• Always make sure the PVT housing is securely in place during operation.
Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch
to low range while operating at slower speeds to extend the life of the
PVT components (belt, cover, etc.).
93
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MAINTENANCE
POLARIS Variable Transmission (PVT) System
PVT Drying
Before washing the vehicle, locate the PVT outlet duct under the right
rear wheel well. Avoid spraying water directly toward the duct when
washing the vehicle from the rear. See page 116.
There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before operat-
ing.
1. Remove both seats. Remove the rear service panel. See page 31.
2. Loosen the lower screws that secure the clutch cover.
3. Allow the water to drain.
4. Tighten the screws.
5. Place the transmission in PARK. Apply the brakes.
6. Start the engine.
7. 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.
8. Allow the engine RPM to settle to idle speed. Apply the brakes.
Shift the transmission to the lowest available range.
9. Test for belt slippage. If the belt slips, repeat the process.
10. Take the vehicle to your dealer for service as soon as possible.
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. Access the air box from
Air Box Cover
behind the left rear wheel.
2. Remove the air box cover
and inspect the gasket. It
should adhere tightly to the
cover around the entire
edge.
Gasket
3. Remove the air filter.
4. Install a new filter if
needed. Do not attempt to
clean the air filter. Apply a
small amount of general
purpose grease to the seal-
ing edges of the filter
Air Filter
before installing.
5. Inspect the air box for oil or water deposits. If present, drain them
into a suitable container.
95
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MAINTENANCE
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark arrestor 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.
Periodically clean the spark arrestor to remove accumulated carbon.
1. Remove the retaining
screw and washer.
Remove the arrestor from
the end of the muffler.
Arrestor
Screen
2. Use a non-synthetic brush
to clean the arrestor
screen. A synthetic brush
may melt if components
are warm. If necessary,
blow debris from the
screen with compressed
air.
Muffler
Retaining
Screw and
Washer
3. Inspect the screen for
wear and damage.
Replace a worn or dam-
aged screen.
4. Reinstall the arrestor.
Torque screws to 5-7 ft. lbs. (7-9 Nm).
96
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MAINTENANCE
Throttle System
WARNING
Failure to check or maintain proper operation of the throttle system can result in
an accident and lead to serious injury or death if the throttle pedal sticks during
operation.
Never start or operate this vehicle if it has a sticking or improperly operating
throttle pedal.
Immediately contact your dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the engine
and occasionally during operation.
Throttle Freeplay
If the throttle pedal has excessive
play due to cable stretch or mis-
adjustment, it will cause a delay
in throttle response, especially at
low engine speed. The throttle
may also not open fully. If the
throttle pedal has no freeplay, the
throttle may be hard to control,
and the idle speed may be erratic.
Check the throttle pedal freeplay
at the intervals outlined in the
Periodic Maintenance Chart
beginning on page 69. Adjust the
freeplay if necessary.
Throttle
Pedal
Throttle Freeplay Inspection
1. Place the transmission in PARK.
2. Apply the brakes. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.5-
3 mm).
97
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MAINTENANCE
Throttle System
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer for adjustment.
Throttle Freeplay Adjustment
1. Remove both seats. Remove the
rear service panel. See page 31.
Jam Nut
Adjuster
2. Locate the throttle cable adjuster
at the throttle body.
3. Slide the cable adjuster boot off
the cable adjuster.
4. Using a 10 mm open-end wrench,
loosen the adjustment jam nut.
Boot
5. Using an 8 mm open-end wrench,
move the cable adjuster until 1/16"
to 1/8" (1.5-3 mm) of freeplay is
achieved at the throttle pedal. See page 97. While adjusting, lightly
flip the throttle pedal up and down.
6. Tighten the jam nut.
7. Apply a small amount of grease to the inside of the boot and slide it
over the cable adjuster to its original position.
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.
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 126 for the part num-
bers of POLARIS products.
WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or severe injury.
Change the brake fluid every two
Brake Fluid
Reservoir
years and any time the fluid
Maximum
Minimum
becomes contaminated, the fluid
level is below the minimum, or if
the type and brand of the fluid in
the reservoir are unknown.
Access the brake fluid reservoir
through the left front wheel well.
1. Position the vehicle on a
level surface.
2. Place the transmission in
PARK.
3. View the brake fluid level in
the reservoir. The level
should be between the maxi-
mum and minimum level
lines.
4. If the fluid level is lower
than the lower level line, add
brake fluid to the upper line.
5. Apply the brake forcefully for a few seconds and check for fluid
leakage around the fittings.
100
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MAINTENANCE
Brakes
Brake Inspection
1. Check the brake system for
fluid leaks.
2. Check the brake pedal for
excessive travel or a spongy
feel.
3. Check the friction pads for
wear, damage and looseness.
4. Inspect the brake pad wear
surface for excessive wear.
5. Change pads when worn to
3/64" (1 mm).
3/64" (1mm)
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 the steering feels
rough or “catchy,” have the steering system inspected by an autho-
rized POLARIS dealer.
101
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MAINTENANCE
Suspension Settings
(RZR and RZR S Base Models)
The front and rear suspensions are preload adjustable, with five settings
on each axle.
The suspensions are set on the lowest (softest) setting at the factory.
This setting is appropriate for nearly all riding conditions. Since the
vehicle is equipped with full skid plates, suspension adjustment is not
necessary.
If desired, the suspension may be adjusted to maintain vehicle clearance
height when carrying loads. Please see your POLARIS dealer for the
tool required to make suspension adjustments. Elevate the vehicle
slightly for easier adjustment.
Always heed the following rules if you make adjustments to this suspen-
sion.
• Always return the suspension to the lowest (softest) setting after the
load is removed from the vehicle. The increased suspension height
will negatively impact vehicle stability when operating without a
load.
• Always apply the same adjustment setting to all four wheels.
• Never operate the vehicle on the highest (stiffest) or second highest
preload settings without a total combined payload in the vehicle of
450 lbs. (204 kg) or more. Payload includes the driver, passenger,
POLARIS-approved accessories and cargo. Never exceed the stated
load capacity for this vehicle. See page 122.
Adjustment
Cam
Lowest
(Softest)
Setting
Highest
(Stiffest)
Setting
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MAINTENANCE
Suspension Settings
(RZR S Premium Models and RZR 4)
Front/Rear Spring Preload
The factory setting is appropriate for nearly all
riding conditions. Since the vehicle is equipped
with full skid plates, adjustment is not necessary.
If desired, the suspension may be adjusted to
maintain vehicle clearance height when carrying
loads. Please see your POLARIS dealer for the
tool required to make suspension adjustments.
Elevate the vehicle slightly for easier adjustment.
Factory Preload Settings
RZR S Premium Front
RZR S Premium Rear
RZR 4 Front
3.50” (88.9 mm)
5.38” (136.6 mm)
4.76” (120.9 mm)
5.44” (138.2 mm)
Preload Setting
Measurement
RZR 4 Rear
Follow these guidelines if you make adjustments to this suspension.
• Always return the suspension to the factory setting after the load is removed
from the vehicle. The increased suspension height will negatively impact vehi-
cle stability when operating without a load.
• Always apply the same adjustment setting to all four wheels.
• Do not increase the spring preload by more than one inch (25.4 mm) over the
factory setting.
1. Elevate the vehicle to allow the suspension
to fully extend.
2. Loosen the jam nut and back it away from
1
2
the adjusting ring.
3. Turn the adjusting ring to the left (1) to
increase preload for a stiffer ride. Turn the
adjusting ring to the right (2) to decrease
preload for a softer ride.
WARNING! Uneven adjustment may cause poor
handling of the vehicle, which could result in an
accident. Always adjust both the left and right spring
preloads equally or have your POLARIS dealer
perform the adjustments.
Adjusting
Ring
4. Tighten the jam nut firmly against the
adjuster ring.
103
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MAINTENANCE
Suspension Settings
(RZR S Premium Models and RZR 4)
Front/Rear Shock Compression
Use a flat-blade screwdriver to make damping
adjustments. The compression damping clicker is
located on top of the shock reservoir, under the
rear fender. When the adjuster screw is turned
clockwise until it stops, the damping is in the
fully closed position.
Clicker
2
1
1. Turn the clicker clockwise (1) to increase
compression damping.
2. Turn the clicker counter-clockwise (2) to
decrease compression damping.
Setting
Compression Damping
Softest
Factory
Firmest
20 clicks from closed
7 clicks from closed
2 clicks 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
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
1/8" (3 mm)
Axle and Wheel Nut Torque Specifications
Inspect the following items occasionally for tightness, and if they've
been loosened for maintenance service. Do not lubricate the stud or the
lug nut.
Lug Nut
(Aluminum
Wheels)
Front and Rear
30 ft. lbs. (41 Nm)
PLUS 1/4 TURN
2-Piece Flange
Nut (Steel
Front and Rear
Front and Rear
27 ft. lbs. (37 Nm)
80 ft. lbs. (108 Nm)
Wheels)
Hub Retaining Nut
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
in PARK.
2. Place the wheel in the
correct position on the
wheel hub. Be sure the
valve stem is toward the
outside and rotation
arrows on the tire point
toward forward 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.
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
Poor lighting while driving can result in severe injury or death. Head-
light and taillight lenses become dirty during normal operation. Wash
the headlights frequently to maintain lighting quality.
When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.
Headlight Lamp Replacement
Do not service the headlamps until they've cooled sufficiently.
1. Unplug the headlamp from
the wiring harness. Be sure
to pull on the connector, not
on the wiring.
2. Turn the lamp counter-clock-
wise to remove it.
3. Install the new lamp. Make
sure the tab on the lamp
locates properly in the hous-
ing.
4. Reinstall the harness assem-
bly into the headlight assem-
bly.
Wiring
Harness
107
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MAINTENANCE
Lights
Headlight High Beam Adjustment
25 ft.
(7.6 m)
X
X
8" (20 cm)
1. Place the vehicle on a level surface with the headlight approxi-
mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Apply the brakes. Start the engine. Turn the headlights to high
beam.
4. Observe the headlight aim. The most intense part of the headlight
beam should be aimed 8" (20 cm) below the mark placed on the
wall in step 2. Include the weight of a rider on the seat while per-
forming this step.
5. If adjustment is necessary, turn the headlight adjustment screw to
adjust the beam.
6. Repeat steps 4-5 until the beam is properly adjusted.
108
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MAINTENANCE
Lights
Brake Lights
When the brake pedal is depressed, the brake light comes on. Check the
brake light before each ride.
1. Turn the ignition switch to the ON position.
2. Apply the brakes. The brake light should come on after about 10
mm (0.4 in.) of pedal travel. If the light doesn't come on, check the
bulb.
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result
if the machine is not thoroughly inspected. Take the vehicle to your
dealer before starting the engine.
If it's impossible to take your vehicle to a dealer before starting it, 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. Thoroughly dry the air pre-filter. See page
95.
3. Remove the spark plugs.
4. Turn the engine over several times.
5. Dry the spark plugs and reinstall them, or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying proce-
dure.
7. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
8. If water has been ingested into the PVT follow the procedure on
page 94 for drying.
109
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MAINTENANCE
Battery
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be identi-
fied by its flat covers on the top of the battery. A conventional battery
has six filler caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into a conventional battery.
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.
Battery Removal
1. Remove the driver’s seat. See
page 31.
2. On conventional batteries,
remove the battery vent tube.
3. Disconnect the black (negative)
battery cable first.
4. Disconnect the red (positive)
battery cable last.
5. Lift the battery out of the vehicle. Be careful not to tip a conven-
tional battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
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 114 before installing
the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. On conventional batteries, install the battery vent tube (sealed bat-
teries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.
4. Coat the terminals with dielectric grease or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed.
8. Reinstall the driver’s seat.
112
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MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
See page 114.
Tip: Battery charge can be maintained by using a POLARIS Battery Tender
charger or by charging about once a month to make up for normal self-dis-
charge. Battery Tender can be left connected during the storage period, and
will automatically charge the battery if the voltage drops below a pre-deter-
mined point. See page 126 for the part numbers of POLARIS products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the bat-
tery fluid level often. Maintain the
fluid level between the upper and
lower level marks.
Upper
Mark
Lower
Mark
Add only distilled water. Tap water
contains minerals that are harmful
to a battery.
113
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MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 111.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific grav-
ity to 1.270 or greater.
3. Reinstall the battery. See page 112. Make sure the positive terminal
is toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
Tip: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
guidelines on the next page for recharging.
114
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MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
(Using constant current
Voltage
Action
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None, check at 3
mos. from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no
3-6 hours
charge given,
check in 3 months
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
Needs charge
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
115
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MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle
clean will not only improve its
appearance but it can also extend the
life of various components.
Before washing the vehicle, locate
the PVT outlet duct under the right
rear wheel well. Avoid spraying
water directly toward the duct when
washing the vehicle from the rear.
NOTICE: Water in the PVT system
could cause the drive belt to
become wet and slip in the clutches. Always avoid spraying water
directly toward the PVT outlet duct when washing the vehicle from
the rear.
High water pressure may damage 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.
116
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MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the follow-
ing items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
If warning and safety labels are damaged, contact your POLARIS dealer
for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
117
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MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, pre-
serve wheel life and ensure a “like new” appearance for many years.
Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are
more susceptible to corrosion if not properly cleaned. Clean chrome wheels
more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as out-
lined above.
118
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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 116.
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
Inspect and clean or replace the pre-filter and 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
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
119
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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 87.
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 113-115 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.
120
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MAINTENANCE
Cleaning and Storage
Removal from Storage
1. Check the battery electrolyte level and charge the battery if neces-
sary. Install it in the vehicle. Make sure the battery vent hose is
routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 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.
121
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SPECIFICATIONS
RANGER RZR / RZR S
Gross Vehicle Weight
Dry Weight
1727 lbs. (783 kg) (RZR)
1782 lbs. (808 kg) (RZR S)
945 lbs. (429 kg) (RZR)
961 lbs. (436 kg) (RZR EPS)
1000 lbs. (454 kg) (RZR S)
Rear Cargo Box Capacity
300 lbs. (136 kg)
Maximum Weight Capacity
(Payload)
740 lbs. (336.4 kg) (riders/cargo/accessories/
trailer tongue weight)
Receiver Hitch Tongue Capacity 150 lbs. (68 kg)
Receiver Hitch Towing Capacity 1500 lbs. (680 kg
Fuel Capacity
Engine Oil Capacity
7 gal. (26.5 l)
2 qts. (1.9 l)
Coolant Capacity
4.8 qts. (4.5 l)
26 oz. (769 ml)
6.75 oz. (200 ml)
24 oz. (710 ml)
14 oz. (414 ml)
Rear Gearcase Oil Capacity
Demand Drive Fluid Capacity
Transmission Oil Capacity
Transfer Case Oil Capacity
Overall Length/Width/Height
102/50/68.5 in. (259/127/174 cm) (RZR)
106/60.5/70.5 in. (269/154/179 cm) (RZR S)
Wheelbase
77 in. (196 cm)
Ground Clearance
10 in. (25.4 cm) (RZR)
12 in. (30.5 cm) (RZR S)
Engine
4 valve 4 stroke twin cylinder with
counterbalance
Displacement
760 cc
Bore x Stroke
80mm x 76mm
500 W @ 3000 RPM
10:1
Electric
Electronic fuel injection
ECU
Alternator Output
Compression Ratio
Starting System
Fuel System
Ignition System
Spark Plug / Gap
Front Suspension
RC7YC /.035 in. (0.9 mm)
Independent double a-arm with travel:
9 in. (23 cm) (RZR)
12 in. (30.5 cm) (RZR S)
Rear Suspension
Independent double a-arm with travel:
9.5 in. (24 cm) (RZR)
12 in. (30.5 cm) (RZR S)
122
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SPECIFICATIONS
RANGER RZR / RZR S
Lubrication System
Engine Oil
Wet Sump
2W-50
Driving System Type
Shift Type
Automatic POLARIS Variable Transmission
Dual Range P/R/N/L/H
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Drive Ratio - Front
Drive Ratio - Final
Tire Size - Front
8.71:1
5.94:1
3.14:1
3.82:1
3.70:1
25x8-12 (RZR)
26x9-12 (RZR S)
Tire Size - Rear
25x10-12 (RZR)
26x12-12 (RZR S)
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Headlights
Taillights
Brake Lights
8 psi (55 KPa)
8 psi (55 KPa)
Foot Activated, 4-wheel hydraulic disc
2 dual beam, 60W/55W halogen
2 single beam, 5W
2 single beam, 5W
LCD
Instrument Cluster
Auxiliary DC Outlet
12V
Clutching
Altitude
Shift
Weight
Drive Clutch
Spring
Driven Clutch
Spring
Meters
(Feet)
0-1500
(0-5000)
23-62
Black
Black/Almond
PN 7043167
PN 5632337 PN 7043594
1500-3700
(5000-12000)
23-58
Black
Black/Almond
PN 7043167
PN 5632218 PN 7043594
123
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SPECIFICATIONS
RANGER RZR 4
Gross Vehicle Weight
Dry Weight
2206 lbs. (1000 kg)
1255 lbs. (569 kg) (RZR 4)
1271 lbs. (576.5 kg) (RZR 4 EPS)
Rear Cargo Box Capacity
300 lbs. (136 kg)
Maximum Weight Capacity
(Payload)
900 lbs. (408.2 kg) (riders/cargo/accessories/
trailer tongue weight)
Receiver Hitch Tongue Capacity 150 lbs. (68 kg)
Receiver Hitch Towing Capacity 1500 lbs. (680 kg
Fuel Capacity
7 gal. (26.5 l)
Engine Oil Capacity
Coolant Capacity
2 qts. (1.9 l)
5.5 qts. (5.2 l)
Rear Gearcase Oil Capacity
Demand Drive Fluid Capacity
Transmission Oil Capacity
Transfer Case Oil Capacity
Overall Length/Width/Height
Wheelbase
26 oz. (769 ml)
6.75 oz. (200 ml)
24 oz. (710 ml)
14 oz. (414 ml)
130/60.5/75 in. (330/154/190.5 cm)
103 in. (262 cm)
11.5 in. (29 cm)
Ground Clearance
Engine
4 valve 4 stroke twin cylinder with
counterbalance
Displacement
760 cc
Bore x Stroke
80mm x 76mm
500 W @ 3000 RPM
10:1
Electric
Electronic fuel injection
ECU
RC7YC /.035 in. (0.9 mm)
Independent double a-arm with 12 in. (30.5 cm)
of travel
Alternator Output
Compression Ratio
Starting System
Fuel System
Ignition System
Spark Plug / Gap
Front Suspension
Rear Suspension
Independent double a-arm with 12 in. (30.5 cm)
of travel
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SPECIFICATIONS
RANGER RZR 4
Lubrication System
Engine Oil
Wet Sump
2W-50
Driving System Type
Shift Type
Automatic POLARIS Variable Transmission
Dual Range P/R/N/L/H
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Drive Ratio - Front
Drive Ratio - Final
Tire Size - Front
Tire Size - Rear
8.71:1
5.94:1
3.14:1
3.82:1
3.70:1
26x9-12
26x12-12
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Headlights
Taillights
Brake Lights
10 psi (68.9 KPa)
12 psi (82.7 KPa)
Foot Activated, 4-wheel hydraulic disc
2 dual beam, 60W/55W halogen
2 single beam, 5W
2 single beam, 5W
LCD
Instrument Cluster
Auxiliary DC Outlets
2 12-Volt
Clutching
Altitude
Shift
Weight
Drive Clutch
Spring
Driven Clutch
Spring
Meters
(Feet)
0-1500
(0-5000)
23-62
Black
Black/Almond
PN 7043167
PN 5632337 PN 7043594
1500-3700
(5000-12000)
23-58
Black
Black/Almond
PN 7043167
PN 5632218 PN 7043594
125
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POLARIS PRODUCTS
Part
Description
Number
Engine Lubricant
2870791
2876244
2876245
Fogging Oil (12 oz./355 ml Aerosol)
PS-4 PLUS Synthetic Engine Oil (qt./.95 l)
PS-4 PLUS Synthetic Engine 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
2871312
2871322
2871423
2871460
2871515
2871551
2871329
Premium U-Joint Lube (3 oz./89 ml cartridge)
Premium U-Joint Lube (14 oz./414 ml cartridge)
Dielectric Grease (NyogelTM
Additives / Miscellaneous
Carbon Clean Plus
)
2871326
2870652
2872189
2871956
2859044
Fuel Stabilizer
DOT 4 Brake Fluid
LoctiteTM 565 Thread Sealant
POLARIS Battery TenderTM Charger
126
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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.
Driving at low RPM or
Drive at a higher speed or use low range more frequently.
ground speed (3-7 MPH) See page 38.
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
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing
Use low range only.
Stuck in mud or snow
Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle 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 94). Prevent water from enter-
or snow ingestion into the ing the PVT outlet duct (see page 116). Inspect clutch
PVT system
seals for damage if repeated leaking occurs.
Clutch malfunction
See your POLARIS dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt
Improper break-in
Install the recommended belt.
Always break in a new belt and/or clutch. See pages 50
and 38.
127
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TROUBLESHOOTING
Engine Doesn't Turn Over
Possible Cause
Solution
Low battery voltage
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Loose battery connections
Loose solenoid connections
Loose electronic control box connections Inspect, clean, reinstall connectors
Engine Turns Over, Fails to Start
Possible Cause
Solution
Out of fuel
Refuel
Clogged fuel filter
See your POLARIS dealer
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plugs
No spark to spark plug
Water or fuel in crankcase
Low battery voltage
Drain the fuel system and refuel
Replace with fresh recommended fuel
Inspect plugs and replace if necessary
Inspect plugs and replace if necessary
Immediately see your POLARIS dealer
Recharge the battery to 12.8 VDC
See your dealer
Mechanical failure
Engine Backfires
Possible Cause
Solution
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
Mechanical failure
See your dealer
Loose ignition connections
Water present in fuel
Check all connections and tighten
Replace with fresh recommended fuel
128
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TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Solution
Poor quality or low octane fuel
Incorrect ignition timing
Replace with recommended fuel
See your dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Solution
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Inspect, clean and/or replace spark plugs
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Low battery voltage
Recharge battery to 12.8 VDC
Inspect and replace
Kinked or plugged fuel tank vent line
Incorrect fuel
Replace with recommended fuel
Inspect and clean or replace
See your dealer
Clogged air filter
Other mechanical failure
Possible Lean Fuel Cause
Solution
Low or contaminated fuel
Low octane fuel
Add or change fuel, clean the fuel system
Replace with recommended fuel
See your POLARIS dealer
Clogged fuel filter
Possible Rich Fuel Cause
Solution
Fuel is very high octane
Replace with lower octane fuel
129
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TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Solution
Out of fuel
Refuel
Kinked or plugged fuel vent line
Water is present in fuel
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Inspect and replace
Replace with new fuel
Inspect, clean and/or replace spark plug
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
Incorrect fuel
Clogged air filter
Other mechanical failure
Overheated engine
Clean radiator screen and core, clean
engine exterior, see your dealer
130
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DECLARATION OF CONFORMITY
Polaris Industries Inc.,
2100 Hwy 55, Medina, MN 55340 U.S.A.
Telephone 763-542-0500
April 22, 2010
We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health
and safety requirements applicable to off-road all-terrain vehicles.
APPLICABLE EUROPEAN DIRECTIVES
TEST / EVALUATION METHODS
2006/42/EC as amended (Machinery Directive)
EN 1050 hazard analysis
prEN 15997 driver-perceived noise level
prEN 15997 vibration
2004/108/EC as amended (EMC Directive)
CISPR 12:2009
CAN/CSA-C108.4-M92
EN 55012:2007
EN 61000-6-2:2005
PRODUCT IDENTIFICATION
VEHICLE SERIES
TRADE NAME
OUTLAW 50 / 90
SPORTSMAN 90
RZR 170
PHOENIX 200
TRAIL BLAZER 330
TRAIL BOSS 330
SCRAMBLER 500
OUTLAW 450
OUTLAW 525 / 525 S
SPORTSMAN 400
SPORTSMAN 500 HO
SPORTSMAN 500 HO TOURING
SPORTSMAN 550 EFI
SPORTSMAN 550 X2
SPORTSMAN 550 TOURING
SPORTSMAN 800
SPORTSMAN 800 6X6
SPORTSMAN 850 EFI
SPORTSMAN 850 X2
SPORTSMAN 850 TOURING
RANGER 400
MODEL YEARS
___KA05__ / ___KA09__
___FA09__
___VA17__
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2010, 2011
2009, 2010, 2011
2010, 2011
2010, 2011
2008, 2009, 2010, 2011
2009, 2010, 2011
2009, 2010, 2011
2010, 2011
___PB20__
___BA32__, ___NA32__
___CA32__, ___EA32__
___BA50__, ___BG50__
___GJ45__
___GJ52__, ___GP52__
___LH46__
___MH50__
___DH50__
___ZN55__ ___ZX55__
___TN55__, ___TX55__
___DN55__, ___DX55__
___MN76__
___CL76__, ___CF76__
___ZN85__, ___ZX85__
___TN85__, ___TX85__
___DN85__, ___DX85__
___RH45__
2010, 2011
2010, 2011
___WH45__
___RH50__
RANGER 400 CREW
RANGER 500 4X4
2011
2010, 2011
___TH76__
___WH76__
___HR76__
RANGER 800 EFI 4X4
RANGER 800 EFI CREW
RANGER 800 6X6
2010, 2011
2010, 2011
2010, 2011
___HY76__, ___TY76__
___TH90__
RANGER HD 800 4X4
RANGER DIESEL
2010, 2011
2011
___WH90__
___VH76__, ___VY76__
___XH76__
RANGER DIESEL CREW
RANGER RZR / RZR S
RANGER RZR 4
2011
2008, 2009, 2010, 2011
2011
European Community Person
Authorized to Compile the Technical File:
Authorized Manufacturer Signatory
Empowered to Draw up the EC Declaration of
Conformity:
Ross Clifford, General Manager
Polaris Britain Ltd
Forge Mills Park, Station Road
Coleshill, Warwickshire B46 1HT
Lawrence E. Keller, Product Compliance Manager
7290 East Viking Blvd.
Wyoming, MN 55092
131
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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.
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
Clutches and components
Steering components
Batteries
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Light bulbs/Sealed beam lamps
132
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WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
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
Fuel
Sealants
Hotel fees
Towing charges
Mileage
Rentals/Loss of product use
•
•
•
•
•
•
•
•
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Meals
Shipping/ handling fees
Product pick-up/delivery
Loss of vacation/personal time
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.
133
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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 ARRESTOR
POLARIS warrants that the spark arrestor 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.
134
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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.
135
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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
136
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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
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
137
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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.
138
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MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
OR HOURS
139
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
OR HOURS
140
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
OR HOURS
141
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INDEX
A
C
Accessory Outlet . . . . . . . . . . . . . . . . . . . 36
Adjustment
Coolant Level . . . . . . . . . . . . . . . . . . . . . . 92
Coolant Level, Radiator . . . . . . . . . . . . . . 91
Coolant, Adding or Changing. . . . . . . . . . 90
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . 91
Cooling System. . . . . . . . . . . . . . . . . . 91-92
Cooling System Operation . . . . . . . . . . . . 90
Crankcase Emission Control System . . . . 68
Hand Hold . . . . . . . . . . . . . . . . . . . . 32
Seat . . . . . . . . . . . . . . . . . . . . . . . . . 31
Steering Wheel . . . . . . . . . . . . . . . . 32
Adjustment, Headlight Beam . . . . . . . . . 108
Adjustment, Throttle Freeplay . . . . . . . . . 98
Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . 95
All Wheel Drive Switch . . . . . . . . . . . . . . 37
All Wheel Drive System . . . . . . . . . . . . . 40
Auxiliary Outlet . . . . . . . . . . . . . . . . . . . . 36
Axle Nut Torque. . . . . . . . . . . . . . . . . . . 105
D
Demand Drive Fluid . . . . . . . . . . . . . . . . . 84
Display Units, Standard/Metric . . . . . . . . 45
Drive Belt Wear . . . . . . . . . . . . . . . . . . . 127
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 . . . . . . . . 94
Drying the Transmission. . . . . . . . . . . . . . 94
B
Battery. . . . . . . . . . . . . . . . . . . . . . . 110-115
Charging (Conventional). . . . . . . . 114
Charging (Sealed) . . . . . . . . . . 114-115
Fluid Replenishment . . . . . . . . . . . 113
Installation. . . . . . . . . . . . . . . . . . . 112
Removal . . . . . . . . . . . . . . . . . . . . 111
Storage. . . . . . . . . . . . . . . . . . . . . . 113
Before Riding . . . . . . . . . . . . . . . . . . . . . . 52
Belt Burning/Wear . . . . . . . . . . . . . . . . . 127
Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Belts, Seat. . . . . . . . . . . . . . . . . . . . . . . . . 35
Boots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Fluid. . . . . . . . . . . . . . . . . . . . . . . 100
Brake Inspection. . . . . . . . . . . . . . . . . . . 101
Brake Lights . . . . . . . . . . . . . . . . . . . . . . 109
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . 39
Brake System Break-in. . . . . . . . . . . . . . . 51
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . 99-101
Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Break-In Period . . . . . . . . . . . . . . . . . . 50-51
E
Electronic Power Steering . . . . . . . . . . . . 36
Emission Control System . . . . . . . . . . . . . 68
Engaging AWD . . . . . . . . . . . . . . . . . . . . 40
Engine Break-In . . . . . . . . . . . . . . . . . . . . 51
Engine Fogging. . . . . . . . . . . . . . . . . . . . 120
Engine Idle Speed. . . . . . . . . . . . . . . . . . . 98
Engine Oil. . . . . . . . . . . . . . . . . . . . . . 76-79
Engine Starting . . . . . . . . . . . . . . . . . . . . . 54
Engine Stopping . . . . . . . . . . . . . . . . . . . . 54
Equipment Modifications . . . . . . . . . . . . . . 7
Error Codes, Engine . . . . . . . . . . . . . . . . . 49
Etiquette, Trail Riding . . . . . . . . . . . . . . . 55
Exhaust Cleaning . . . . . . . . . . . . . . . . . . . 96
Exhaust Emission Control System . . . . . . 68
Exhaust System Warning . . . . . . . . . . . . . 96
Eye Protection. . . . . . . . . . . . . . . . . . . . . . . 9
C
Cab Nets . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cap, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . 66-67
Chart, Periodic Maintenance . . . . . . . . 69-73
Check Engine Indicator . . . . . . . . . . . . . . 49
Chrome Wheel Care. . . . . . . . . . . . . . . . 118
Cleaning and Storage . . . . . . . . . . . . 116-121
Cleaning the Air Filter . . . . . . . . . . . . . . . 95
Cleaning the Exhaust System. . . . . . . . . . 96
Cleaning the Spark Arrestor. . . . . . . . . . . 96
Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching, RZR/RZR S . . . . . . . . . . . . . 123
Clutching, RZR 4 . . . . . . . . . . . . . . . . . . 125
Component Locations . . . . . . . . . . . . . 28-30
F
Fan, Cooling . . . . . . . . . . . . . . . . . . . . . . . 91
Filling the Battery. . . . . . . . . . . . . . . . . . 113
Filter Care During Storage . . . . . . . . . . . 119
Filter Cleaning, Air. . . . . . . . . . . . . . . . . . 95
Filter Systems . . . . . . . . . . . . . . . . . . . . . . 95
Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . 95
142
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INDEX
F
I
Fluid
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . 98
Ignition Switch . . . . . . . . . . . . . . . . . . . . . 37
Indicator Lamps. . . . . . . . . . . . . . . . . . . . . 42
Inspection, Axle Nuts . . . . . . . . . . . . . . . 105
Inspection, Brakes . . . . . . . . . . . . . . . . . . 101
Inspection, Pre-Ride . . . . . . . . . . . . . . . . . 52
Inspection, Steering Wheel . . . . . . . . . . . 101
Inspection, Throttle Freeplay . . . . . . . . . . 97
Inspection, Wheel Nuts . . . . . . . . . . . . . . 105
Instrument Cluster. . . . . . . . . . . . . . . . 41-49
Demand Drive . . . . . . . . . . . . . . . . . 84
Front Gearcase . . . . . . . . . . . . . . . . . 84
Main Gearcase . . . . . . . . . . . . . . 82-83
Rear Gearcase . . . . . . . . . . . . . . . . . 85
Transfer Case . . . . . . . . . . . . . . . 80-81
Transmission . . . . . . . . . . . . . . . 82-83
Fluid Levels During Storage. . . . . . . . . . 119
Fluid Recommendations, Gearcase. . . . . . 86
Fluid, Battery . . . . . . . . . . . . . . . . . . . . . 113
Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . 100
Fogging the Engine. . . . . . . . . . . . . . . . . 120
Fouled Plugs . . . . . . . . . . . . . . . . . . . . . . . 87
Freeplay Adjustment, Throttle . . . . . . . . . 98
Freeplay, Steering Wheel . . . . . . . . . . . . 101
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . 119
Fuel Tank Filler Cap. . . . . . . . . . . . . . . . . 34
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 88-89
K
Key, Periodic Maintenance Chart . . . . . . . 70
L
Lights
Brake Lights . . . . . . . . . . . . . . . . . . 109
Headlight Lamp Replacement . . . . 107
Headlight Switch . . . . . . . . . . . . . . . 37
High Beam Adjustment . . . . . . . . . 108
Loads, Towing. . . . . . . . . . . . . . . . . . . . . . 67
Lubricant Part Numbers . . . . . . . . . . . . . 126
Lubrication for Storage . . . . . . . . . . . . . . 120
Lubrication Recommendations . . . . . . 74-75
G
Gap, Spark Plug . . . . . . . . . . . . . . . . . . . . 86
Gasoline Handling . . . . . . . . . . . . . . . . . . 19
Gear Selector. . . . . . . . . . . . . . . . . . . . . . . 38
Gearcase Capacities . . . . . . . . . . . . . . . . . 86
Gearcase Oil
M
Maintenance Log. . . . . . . . . . . . . . . 139-141
Maintenance, Periodic. . . . . . . . . . . . . 69-73
Metric Display. . . . . . . . . . . . . . . . . . . . . . 45
Mode Button . . . . . . . . . . . . . . . . . . . . . . . 41
Demand Drive . . . . . . . . . . . . . . . . . 84
Front. . . . . . . . . . . . . . . . . . . . . . . . . 84
Main. . . . . . . . . . . . . . . . . . . . . . 82-83
Rear . . . . . . . . . . . . . . . . . . . . . . . . . 85
Transfer Case . . . . . . . . . . . . . . . 80-81
Gearcase Specifications . . . . . . . . . . . . . . 86
Gearcases . . . . . . . . . . . . . . . . . . . . . . 80-86
Demand Drive . . . . . . . . . . . . . . . . . 84
Front Gearcase . . . . . . . . . . . . . . . . . 84
Main Gearcase . . . . . . . . . . . . . . 82-83
Rear Gearcase . . . . . . . . . . . . . . . . . 85
Specification Chart . . . . . . . . . . . . . 86
Transfer Case . . . . . . . . . . . . . . . 80-81
Transmission . . . . . . . . . . . . . . . 82-83
Gears, Shifting . . . . . . . . . . . . . . . . . . . . . 38
N
Nets, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 34
New Operator Driving Procedure . . . . 56-57
O
Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Oil
Demand Drive . . . . . . . . . . . . . . . . . 84
Engine. . . . . . . . . . . . . . . . . . . . . 76-79
Front Gearcase . . . . . . . . . . . . . . . . . 84
Main Gearcase . . . . . . . . . . . . . . 82-83
Rear Gearcase. . . . . . . . . . . . . . . . . . 85
Transfer Case . . . . . . . . . . . . . . . 80-81
Transmission . . . . . . . . . . . . . . . 82-83
Oil and Filter Care During Storage . . . . . 119
Oil Recommendations. . . . . . . . . . . . . . . . 76
H
Hand Hold, Passenger. . . . . . . . . . . . . . . . 32
Hauling Cargo. . . . . . . . . . . . . . . . . . . 66-67
Headlight High Beam Adjustment . . . . . 108
Headlight Lamp Replacement . . . . . . . . 107
Headlight Switch. . . . . . . . . . . . . . . . . . . . 37
Helmet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hitch Weight. . . . . . . . . . . . . . . . . . . . . . . 67
Hood Removal . . . . . . . . . . . . . . . . . . . . . 33
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INDEX
P
S
Parking on an Incline . . . . . . . . . . . . . . . . 65
Parking the Vehicle . . . . . . . . . . . . . . . . . 55
Passenger Hand Hold Adjustment . . . . . . 32
Periodic Maintenance Chart. . . . . . . . . 69-73
Plug Condition . . . . . . . . . . . . . . . . . . . . . 87
Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . 86
Plug Torque . . . . . . . . . . . . . . . . . . . . . . . 86
Plug, Accessory . . . . . . . . . . . . . . . . . . . . 36
Plugs, Spark . . . . . . . . . . . . . . . . . . . . . 86-87
Polaris Products . . . . . . . . . . . . . . . . . . . 126
Polishing the Vehicle . . . . . . . . . . . . . . . 117
Power Steering . . . . . . . . . . . . . . . . . . . . . 36
Pre-Ride Inspection . . . . . . . . . . . . . . . . . 52
PVT Break-In . . . . . . . . . . . . . . . . . . . . . . 51
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . 94
PVT System Operation. . . . . . . . . . . . . 93-94
Speedometer . . . . . . . . . . . . . . . . . . . . . . . 41
Spring Preload . . . . . . . . . . . . . . . . 102-103
Stabilizing the Fuel. . . . . . . . . . . . . . . . . 119
Starting the Engine . . . . . . . . . . . . . . . . . . 54
Steering Wheel Adjustment . . . . . . . . . . . 32
Steering Wheel Inspection . . . . . . . . . . . 101
Stopping the Engine . . . . . . . . . . . . . . . . . 54
Storage . . . . . . . . . . . . . . . . . . . . . . 116-121
Storage Area . . . . . . . . . . . . . . . . . . . . . . 120
Storage, Battery . . . . . . . . . . . . . . . . . . . 113
Storage, Fluid Levels . . . . . . . . . . . . . . . 119
Storage, Oil and Filter. . . . . . . . . . . . . . . 119
Suspension Settings . . . . . . . . . . . . 102-104
Switches
AWD Switch . . . . . . . . . . . . . . . 37, 40
Ignition Switch. . . . . . . . . . . . . . . . . 37
Mode Button . . . . . . . . . . . . . . . . . . 41
R
T
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Radiator Coolant Level . . . . . . . . . . . . . . 91
Rear Gearcase Fluid Change . . . . . . . . . . 85
Receiver Hitch . . . . . . . . . . . . . . . . . . . . . 30
Removing the Vehicle from Storage . . . 121
Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Rider Information Center . . . . . . . . . . . 43-49
Riding Area . . . . . . . . . . . . . . . . . . . . . . . 55
Riding Gear . . . . . . . . . . . . . . . . . . . . . . . 8-9
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . 47
Throttle Freeplay Adjustment. . . . . . . . . . 98
Throttle Freeplay Inspection. . . . . . . . . . . 97
Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . 39
Throttle System. . . . . . . . . . . . . . . . . . . . . 97
Tire Tread Depth. . . . . . . . . . . . . . . . . . . 105
Tires . . . . . . . . . . . . . . . . . . . . . . . . 105-106
Torque, Axle Nuts . . . . . . . . . . . . . . . . . 105
Torque, Spark Plug . . . . . . . . . . . . . . . . . . 86
Torque, Wheel Nut . . . . . . . . . . . . . . . . . 105
Towing Loads . . . . . . . . . . . . . . . . . . . . . . 67
Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . 55
Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . 30
Transfer Case Oil . . . . . . . . . . . . . . . . 80-81
Transmission Oil. . . . . . . . . . . . . . . . . 82-83
Transmission Operation . . . . . . . . . . . 93-94
Transmission, Drying . . . . . . . . . . . . . . . . 94
Transporting the Vehicle . . . . . . . . . . . . 121
Tread Depth, Tire . . . . . . . . . . . . . . . . . . 105
S
Safe Operation Practices . . . . . . . . . . . . . 53
Safety Labels . . . . . . . . . . . . . . . . . . . . 20-27
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . 4
Safety Warnings . . . . . . . . . . . . . . . . . . 10-19
Seat Adjustment . . . . . . . . . . . . . . . . . . . . 31
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . 35
Seat Removal . . . . . . . . . . . . . . . . . . . . . . 31
Service Panel, Rear . . . . . . . . . . . . . . . . . 31
Severe Use Definition . . . . . . . . . . . . . . . 69
Shifting Gears. . . . . . . . . . . . . . . . . . . . . . 38
Shock Compression . . . . . . . . . . . . . . . . 104
Signal Words . . . . . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor Cleaning. . . . . . . . . . . . . . 96
Spark Arrestor Warning . . . . . . . . . . . . . . 96
Spark Plug Condition . . . . . . . . . . . . . . . . 87
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . 86
Spark Plug Removal. . . . . . . . . . . . . . . . . 87
Spark Plug Torque . . . . . . . . . . . . . . . . . . 86
Spark Plugs. . . . . . . . . . . . . . . . . . . . . . 86-87
Spark Plugs, Fouled . . . . . . . . . . . . . . . . . 87
Specifications . . . . . . . . . . . . . . . . . . 122-125
Specifications, Gearcase. . . . . . . . . . . . . . 86
V
Vehicle Identification Numbers . . . . . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . . . . 109
Vehicle Transport . . . . . . . . . . . . . . . . . . 121
W
Warning Symbols . . . . . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . . . . . 116-117
Wear, Drive Belt. . . . . . . . . . . . . . . . . . . 127
Wheel Installation. . . . . . . . . . . . . . . . . . 106
Wheel Nut Torque . . . . . . . . . . . . . . . . . 105
Wheel Removal . . . . . . . . . . . . . . . . . . . 106
144
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