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1. 105 B Battery eee 110 115 Charging Conventional 114 Charging Sealed 114 115 Fluid Replenishment 113 112 Removal 111 SIOTABE ergs 113 Before 52 Belt 127 Belt Dife ta teed 67 Belts Seats cg 35 e ei te eck sackets VUES 9 Brake Fluid 2 0 cece eee eens 100 Brake Inspection 101 Brake 109 Brake Pedal wees e 39 Brake System Break in 51 Brakes 280 hoy ced ede coe eee ane 99 101 Braking vou dK ae eve dow eters 54 Break In Period 50 51 Netsi iiy 34 Cap dere 34 Cargo scie neater 66 67 Chart Periodic Maintenance 69 73 Check Engine Indicator 49 Chrome Wheel 118 Cleaning and Storage 116 121 Cleaning the Air 95 Cleaning the Exhaust System 96 Cleaning the Spark Arrestor 96 Clothing oe soe e cup ES 9 Clutching RZR RZR S 123 Clutching 4 125 Component Locations 28 30 142 Coolant 92 Coolant Level Radiator 91 Coolant Adding or Changing 90 Cooling
2. 67 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 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 15 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 d
3. es 50 Emission Control Systems 68 Maintenance 69 122 POLARIS Products 126 Troubleshooting 127 Declaration of Conformity 131 eris 132 Maintenance Log 139 Ind X veneSeescub e ki eI t hee Va EXE 142 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 A 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 INTRODUCTION 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 vehi
4. 139 141 Maintenance Periodic 69 73 Metric 45 Mode Button 41 Nets oe ce ue 34 New Operator Driving Procedure 56 57 Obstacles onas ioco Pix es Ae ES 63 Oil Demand Drive 84 Engine p renes 76 79 Front 84 Main Gearcase 82 83 Rear 85 Transfer 80 81 Transmission 82 83 Oil and Filter Care During Storage 119 Oil Recommendations 76 143 INDEX P Parking 65 Parking the Vehicle 55 Passenger Hand Hold Adjustment 32 Periodic Maintenance Chart 69 73 Plug 87 Plug Gap 86 Plug T otque lee 86 Plug 36 Plugs Spark cocer v pI S 86 87 Polaris 126 Polishing the Vehicle 117 Power Steering 04 36 Pre Ride Inspection 52 PVT 51 Dtyllg bey RUNE eng 94 PVT System Operation 93 94 R Radiator ies stow yas Salas 91 Radiator Coolant Level 91 Rear Gearcase Fluid Change 85 Receiver Hitch 30 Re
5. 9 Fan Cooling scene 91 Filling the 113 Filter Care During Storage 119 Filter Cleaning 95 Filter 95 Filter ER 95 Fluid Demand 84 Front Gearcase 84 Main 82 83 Rear Gearcase 85 Transfer 80 81 Transmission 82 83 Fluid Levels During Storage 119 Fluid Recommendations 86 Fluid Battery 113 Fluid Brake sane fees ood ees 100 Fogging the Engine 120 Fouled Plugs i aeneo P Rs 87 Freeplay Adjustment Throttle 98 Freeplay Steering Wheel 101 Fuel Caps zc cess e IER REY ET 34 Fuel Safety 2 2 22 50 cece eee ee 19 Fuel 119 Fuel Tank Filler 34 FUSES e 88 89 G Gap Spark Plug 86 Gasoline Handling 19 Gear 38 Gearcase Capacities 86 Gearcase Oil Demand 84 Sb plos Shales 84 Main zio ee KA 82 83 JOE Qood d AUR Un TA 85 Transfer 80 81 Gearcase Specifications 86 GearcaseS oie rever ERR 80 86 Demand
6. Factory Preload Settings a MT RZR S Premium Front 3 50 88 9 mm RZR S Premium Rear 5 38 136 6 mm Preload Setting RZR 4 Front 4 76 120 9 mm Measurement RZR 4 Rear 5 44 138 2 mm 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 e 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 Ze 2 Loosen the jam nut and back it away from the adjusting ring ss 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 ee ing WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments 4 Tighten the jam nut firmly against the adjuster ring 103 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 cl
7. 84 Front 84 Main 82 83 Rear Gearcase 85 Specification Chart 86 Transfer 80 81 Transmission 82 83 Gears Shifting 38 H Hand Hold 32 Hauling 66 67 Headlight High Beam Adjustment 108 Headlight Lamp Replacement 107 Headlight 37 Helmet 225551 Cel Ns TA ULT 8 oat uvae x RECEPIT 30 Hitch Weight uec teer rep rh 67 Hood Removal 33 l Idle Speed reni he AE E R 98 Ignition Switch 37 Indicator 42 Inspection Axle Nuts 105 Inspection 101 Inspection Pre Ride 52 Inspection Steering Wheel 101 Inspection Throttle Freeplay 97 Inspection Wheel Nuts 105 Instrument Cluster 41 49 K Key Periodic Maintenance Chart 70 L Lights Brake 109 Headlight Lamp Replacement 107 Headlight Switch 37 High Beam Adjustment 108 Loads 67 Lubricant Part Numbers 126 Lubrication for Storage 120 Lubrication Recommendations 74 75 Maintenance Log
8. Vehicle handling may change with passengers and or cargo on board Allow more time and distance for braking Always follow all operating guidelines as outlined on safety labels and in this manual OPERATION Driving on Slippery Surfaces A 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 Sideways Turn in skid eed of ski C OC Co5ec 5 AT ANY d ELAS La O BS BS CC Qy 59 OPERATION Driving Uphill Whenever traveling uphill follow these precaution
9. 7 Check for leaks Discard used fluid properly 85 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 Drain Plug Torque Level Check Plug Torque Transmission Premium AGL 24 oz 40 50 ft Ibs 30 45 in Ibs Main Gearcase Synthetic 710 ml 54 68 Nm 3 5 Nm Gearcase Fluid Transmission Premium AGL 14 oz 40 50 ft Ibs 30 45 in Ibs Transfer Case Synthetic 414 ml 54 68 Nm 3 5 Nm Gearcase Fluid Demand Drive Unit Demand Drive 6 75 oz 8 10 ft Ibs 11 ft Ibs Front Gearcase Plus Fluid 200 ml 11 13 6 Nm 15 Nm Rear Gearcase Premium ATV 26 oz 40 50 ft Ibs 30 45 lbs Angle Drive Fluid 769 ml 54 68 Nm 3 5 Nm Spark Plugs Spark Plug Gap Torque Electrode Gap New Plug Torque Used Plug Torque 035 9 mm 18 ft Ibs 18 ft Ibs 24 Nm 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 syst
10. Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer 130 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 EN 55012 2007 CAN CSA C108 4 M92 EN 61000 6 2 2005 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL YEARS KA05 KA09 OUTLAW 50 90 2008 2009 2010 2011 FA00 SPORTSMAN 90 2008 2009 2010 2011 __VAI7__ RZR 170 2009 2010 2011 PB20 PHOENIX 200 2008 2009 2010 2011 BA32 NA22 TRAIL BLAZER 330 2008 2009 2010 2011 CA32 EA32 TRAIL BOSS 330 2008 2009 2010 2011 BAS0 BG50 SCRAMBLER 500 2008 20
11. Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride Air filter pre filter Daily Inspect clean often replace as E needed Coolant Daily Check level daily change cool if applicable ant every 2 years gt Power steering unit Daily Inspect daily clean often if equipped Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly 100 160 Inspect periodically n Battery 25H Monthly 250 400 Check terminals clean test gt Demand drive fluid 25H Monthly 250 400 Inspect level change yearly gt Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly gt Main gearcase oil 25H Monthly 250 400 Inspect level change yearly gt Transfer case oil 25H Monthly 250 400 Inspect level change yearly gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Have an authorized POLARIS dealer perform these services n 71 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine breather 25H Monthly 150 250 _ Inspect replace if necessary E filter if equipped gt Engine oil change 25H 1M Perform a break in oil and filter break
12. 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 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 Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds estab lishe
13. Coolant test strength fill 119 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 Ar
14. This indicator illuminates when the 4X4 system 1s engaged switch is on 4X4 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options Display Units Standard Metric The display can be changed to show either standard or metric units of measurement for each of the following settings 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 MODE Button units Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius 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 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 fla
15. 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 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 sli
16. mum marks on the bottle when the fluid is cool Position the vehicle on a level surface 2 Remove the hood See page 33 3 View the coolant level Radiator Cap Peri in the overflow bottle 4 Ifthe 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 MAINTENANCE POLARIS Variable Transmission PVT System A 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 ins
17. 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 OPERATION Driving Through Water Your vehicle can operate through water with a maximum d ccr recommended depth equal to pF floor level Follow these precautions when operating through water 1 Determine water depth and current before entering water 2 Choosea crossing where the water level is lowest and where both banks have grad ual inclines Never operate in water that exceeds the maximum recommended depth WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast flowing water which could result in loss of traction loss of control overturn or accident 3 Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads NOTICE Major eng
18. 77 Brake Fluid DOT 4 Maintain level between fill lines See page 100 Transmission Oil Premium AGL Synthetic See page 82 Main Gearcase Gearcase Lube Transmission Oil Premium AGL Synthetic See page 80 Transfer Case Gearcase Lube Demand Drive Fluid Demand Drive Plus Fluid See page 84 Front Gearcase Rear Gearcase Oil Premium ATV Angle Drive See page 85 Prop Shaft POLARIS Premium U Joint Lube Locate fittings and grease 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 conforming to NLGI No 2 Locate fittings and grease Prop Shaft Grease Fitting 74 MAINTENANCE Lubrication Recommendations p RZR RZR S RZR 4 lt Stabilizer Bar Control Arm Pivot Y Zp Bushings Bushings nd 75 Control Arm Pivot Bushings RZR S RZR 4 Control Arm Pivot Bushings 75 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
19. 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 perf
20. FOR OPERATOR AND PASSENGERS NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Ke For your nearest Polaris dealer POLARIS call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922973 Rev 02 Printed in USA 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 e Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles e 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 f
21. Fan ee eee 91 Cooling 91 92 Cooling System Operation 90 Crankcase Emission Control System 68 D Demand Drive Fluid 84 Display Units Standard Metric 45 Drive Belt 127 Drivetrain 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 60 Driving with Passengers 58 Driving After Driving in Water 94 Drying the Transmission 94 E Electronic Power Steering 36 Emission Control System 68 Engaging AWD 40 Engine 51 Engine 120 Engine Idle 98 Engine Oil biz ewe mme 76 79 Engine 54 Engine 54 Equipment Modifications 7 Error Codes 49 Etiquette Trail Riding 55 Exhaust Cleaning 96 Exhaust Emission Control System 68 Exhaust System Warning 96 Eye
22. NA i NI IAN VANTIN ANI 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2 Tip 44 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 If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Information Display Area This area displays odometer trip meter engine hour meter and programmable service hour interval 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 Clock The clock displays time in a 12 hour or 24 hour format See page 46 for resetting instructions 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 4X4 Indicator
23. 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 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 14 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
24. Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 126 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range See warnings on page 60 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently 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 ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low rang
25. 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 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 Aa overturns s 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 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
26. accessories trailer tongue weight Receiver Hitch Tongue Capacity 150 16 68 kg Receiver Hitch Towing Capacity 1500 Ibs 680 kg Fuel Capacity 7 gal 26 51 Engine Oil Capacity 2 qts 1 91 Coolant Capacity 5 5 qts 5 21 Rear Gearcase Oil Capacity 26 oz 769 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Overall Length Width Height 130 60 5 75 in 330 154 190 5 cm Wheelbase 103 in 262 cm Ground Clearance 11 5 in 29 cm Engine 4 valve 4 stroke twin cylinder with counterbalance Displacement 760 cc Bore x Stroke 80mm x 76mm Alternator Output 500 W 3000 RPM Compression Ratio 10 1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark Plug Gap RC7YC 035 in 0 9 mm Front Suspension Independent double a arm with 12 in 30 5 cm of travel Rear Suspension Independent double a arm with 12 in 30 5 cm of travel 124 SPECIFICATIONS RANGER RZR 4 Lubrication System Wet Sump Engine Oil 2W 50 Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 82
27. 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 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 proper installation Item Remarks Page Brake system pedal travel Ensure proper operation 38 Brake fluid Ensure proper level 100 Front suspension Inspect lubricate if necessary 74 Rear suspension Inspect lubricate if necessary 74 Steering Ensure free operation 101 Tires Inspect condition and pressure 10s Wheels fasteners Inspect ensure fastener tightness 105 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels ix Coolant level Ensure proper level Coolant hoses Inspect for leaks Throttle Ensure proper operation 97 Indicator lights switches Ensure proper operation 37 Air filter pre filter Inspect clean 95 Headlamp Check operation apply POLARIS 107 dielectric grease when lamp is replaced Brake light tail lamp Check operation apply POLARIS 109 dielectric grease when lamp is replaced Seat Latches Push down on both seat backs to 31 ensure the
28. are properly routed Reinstall the driver s seat 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 Lower Upper deteriorate rapidly Check the bat Mark Mark tery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 113 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 bat
29. clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel filter See your POLARIS dealer Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Mechanical failure Recharge the battery to 12 8 VDC See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 128 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace p
30. drain hole in the skid plate 1 OUR spo 8 9 Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Allow the fluid to drain completely Clean the drain plug Reinstall the drain plug with a new o ring Torque to specification Remove the level check plug Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole Reinstall the level check plug Torque to specification Reinstall the fill plug Torque to specification 10 Check for leaks Discard used fluid properly 81 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 recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification Fill Plug 82 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 plat
31. driving slowly The friction will help dry out the pads 17 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
32. 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 24 Discretionary Warning 2 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
33. 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 SAFETY Safety Warnings Operating on Publi
34. 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 39 FEATURES AND CONTROLS Wheel Drive AWD System The Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the vehi cle 15 in two wheel drive at all times When the AWD T switch is on AWD the vehicle is in all wheel drive Ha and the 4X4 indicator in the instrument cluster will be on ET When in AWD the demand drive unit will auto matically engage any time the rear wheels lose 2WD 3 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 switc
35. repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use 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 defectiv
36. throttle and steering systems 18 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 f 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 t
37. 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 Pulleach 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 Toclean 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 FEATURES AND CONTROLS Switches Ignition Instrument Switch Cluster Light AWD Switch 12V Accessory Outlet Switch Auxiliary Outlet The vehicle is equipped with one or more 12 volt accessory outlets One outlet is on the dash a second outlet if equipped is in the rear passen ger area Use the outlets to power an auxiliary light or other optional accessories or lights For service the dash outlet connection is under the dash The rear outlet connection is under the rear passenger seats E
38. 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 MAINTENANCE Battery 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 l 2 5 Remove the driver s seat See page 31 On conventional batteries remove the battery vent tube Disconnect the bl
39. 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 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
40. 000 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 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
41. 04 5290 Canada 1 204 925 7100 136 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 Ignition system Fuelsystem Exhaust gas rec
42. 09 2010 2011 GM5 OUTLAW 450 2008 2009 2010 2011 GJ532 GP52 OUTLAW 525 525 S 2008 2009 2010 2011 LH46 SPORTSMAN 400 2008 2009 2010 2011 MH50 SPORTSMAN 500 HO 2008 2009 2010 2011 DH50 SPORTSMAN 500 HO TOURING 2010 2011 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 2011 TN55 TX55 SPORTSMAN 550 X2 2010 201 DN55 DX55 SPORTSMAN 550 TOURING 2010 201 MN76 SPORTSMAN 800 2008 2009 2010 2011 CF76__ SPORTSMAN 800 6X6 2009 2010 2011 ZN85 ZX85 __ SPORTSMAN 850 EFI 2009 2010 2011 TN85 TX85 SPORTSMAN 850 X2 2010 201 DNS85 DX85 SPORTSMAN 850 TOURING 2010 201 RH45 RANGER 400 2010 201 WH45 RANGER 400 CREW 2011 RH50 RANGER 500 4X4 2010 2011 TH76 RANGER 800 EFI 4X4 2010 2011 ___WH76__ RANGER 800 EFI CREW 2010 201 ___HR76__ RANGER 800 6X6 2010 201 HY76 TY 76 RANGER HD 800 4X4 2010 2011 TH90 RANGER DIESEL 2011 WH90 RANGER DIESEL CREW 2011 VH76 VY76 RANGER RZR RZR S 2008 2009 2010 2011 XH76 RANGER RZR 4 2011 European Community Person Authorized Manufacturer Signatory Authorized to Compile the Technical File Empowered to Draw up the EC Declaration of Conformity Ross Clifford General Manager Lawrence E Keller Product Compliance Manager Polaris Britain Ltd 7290 East Viking Blvd Forge Mills Park Station Road Wyoming MN 55092 Coleshill Warwickshire B46 IHT 131 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55
43. 1 Drive Ratio Final 3 70 1 Tire Size Front 26x9 12 Tire Size Rear 26x12 12 Tire Pressure Front 10 psi 68 9 KPa Tire Pressure Rear 12 psi 82 7 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 60W 55W halogen Taillights 2 single beam 5W Brake Lights 2 single beam 5W Instrument Cluster LCD Auxiliary DC Outlets 2 12 Volt Clutching Altitude Shift Drive Clutch Driven Clutch Weight Spring Spring Meters 0 1500 23 62 Black Black Almond Feet 0 5000 PN 5632337 PN 7043594 PN 7043167 1500 3700 23 58 Black Black Almond 5000 12000 PN 5632218 PN 7043594 PN 7043167 125 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 02 355 ml Aerosol 2876244 PS 4 PLUS Synthetic Engine Oil qt 95 1 2876245 PS 4 PLUS Synthetic Engine Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid qt 95 1 2878069 AGL PLUS Transmission Fluid gal 3 8 1 2871653 Premium ATV Angle Drive Fluid 8 02 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 1 2870465 Pump for Gallon 3 8 I Jug 2877922 Demand Drive Plus Fluid qt 95 1 2877923 Demand Drive Plus Fluid gal 3 8 1 Coolant 2871323 60 40 Coolant gal 3 8 1 2871534 60 40 Coolant qt 95 I Grease
44. Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75956 10096 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50926 7596 12 0 12 5 volts 25976 5096 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0926 2596 11 5 volts or less Needs charge with desulfating charger At least 20 hours 115 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 rep
45. EVER carry passengers under age 12 or too small to firmly plant feet on the floor and securely grasp hand holds 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 Y 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 ing RZR 4 Passenger Cab Frame 8 Warning both sides 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 FEATURES AND CONTROLS Component Locations Rear Passenger Grab Bar Cab Nets Front Passenger Hand Hold Fuel Tank Cap Hip Bars Tie Down Rack Extenders RZR RZR EPS only 28 Component Locations Cab Frame E Steering N AN Wheel Headlights PALARAN 5 Radiator Brush Guard FEATURES AND CONTROLS Storage Compartment under hood 29 FEA
46. IGHT 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 SAFETY Safety Labels and Locations Age Overturn Warning Warning Discretionary Cab Frame Seat Belt Shift Warning Warning Caution Cab Frame Seat Belt Warning
47. 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 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 Drain Pl skin Do not allow hot oil to contact skin ram Flug 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 165 22 Nm 78 MAINTENANCE Engine Oil Oil and Filter Change 8 9 10 11 12 13 14 15 16 17 Using a cap style oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crank case 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 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and a
48. 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 im
49. S Gross Vehicle Weight 1727 lbs 783 kg RZR 1782 Ibs 808 kg RZR S Dry Weight 945 Ibs 429 kg RZR 961 Ibs 436 kg RZR EPS 1000 Ibs 454 kg RZR S Rear Cargo Box Capacity 300 Ibs 136 kg Maximum Weight Capacity Payload 740 Ibs 336 4 kg riders cargo accessories trailer tongue weight Receiver Hitch Tongue Capacity 150 Ibs 68 kg Receiver Hitch Towing Capacity 1500 165 680 kg Fuel Capacity 7 gal 26 51 Engine Oil Capacity 2 qts 1 91 Coolant Capacity 4 8 qts 4 5 D Rear Gearcase Oil Capacity 26 oz 769 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml 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 Alternator Output 500 W 3000 RPM Compression Ratio 10 1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark Plug Gap RC7YC 035 in 0 9 mm Front Suspension Independent double a arm with travel 9 in 23 cm RZR 12 in 30 5 cm RZR S Rear Su
50. TURES AND CONTROLS Component Locations EEL STRYIES 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 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 Tiltthe seat forward 3 Liftthe seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure the seat tabs at the front edge of the seat slide under the seat retainer bar Front Seat Seat Retainer Latch 5 Press down firmly at the rear of the seat to engage the rear latch 31 FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upwar
51. ack negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE f 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 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 2 3 Ensure that the battery is fully charged Place the battery in the battery holder 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 9o DW OA 112 Coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Verify that cables
52. ange A Front and Rear 27 ft Ibs 37 Nm Nut Steel KP Wheels Hub Retaining Nut Front and Rear 80 ft 165 108 Nm 105 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 Place the transmission in PARK AOR 2 Place the wheel in the ae correct position on the er wheel hub Be sure the f WARNING Improperly installed wheels can adversely valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion affect tire wear and vehicle d 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 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 ba
53. c 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 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
54. cle 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 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 Key bet Engine Serial Number mmm Number Vehicle Model Number Vehicle Identification Number Engine Serial Number Key Number SAFETY Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed Modifications to your vehicle may negatively impact vehi
55. d 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 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the scre
56. d 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 xj Z Adjustment Pin Mounting Bracket Holes 32 FEATURES AND CONTROLS Hood Remove the hood to access the front storage compartment the radiator cap and the coolant overflow bottle l 2 3 4 Turn the hood fasteners Storage Compartment 1 4 turn Grasp the upper hood edge and pull upward to disengage the hood from the vehicle Pivot the hood forward and lift upward to disen gage the lower hood hooks Lift the hood away from the vehicle Radiator Cap MN ottle 33 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 re
57. d safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 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 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 wi
58. d slows to near idle the vehicle has no engine braking 2 Presson the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls 54 OPERATION Parking the Vehicle 1 Stop the vehicle on a level surface When parking inside a garage 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 stoppin
59. dditional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of rec ommended oil Place the transmission in PARK Apply the brakes Start the engine Allow it to idle for one to two minutes Stop the engine Inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 79 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 t grs Ts 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 Reinstall the level check plug Torque to specification en 6 Reinstall the fill plug Torque to specification 80 MAINTENANCE Gearcases Transfer Case Fluid Change The drain plug is located on the bottom of the transfer case Access the drain plug through the
60. e 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 Drain Plug Main Gearcase Drain Plug Rear Gearcase Drain Plug 83 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 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 Removethe fill plug Check the fluid level RSS TZ 3 Add the recommended fluid PRA LAX 2 View of Bot to the bottom thread of the A tom fill plug hole 4 Reinstall the fill plug Torque to specification Drain Plug Fill Plug 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 Allo
61. e 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 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 25 98 Remove both seats Remove the rear service panel See page 31 Jam Nut Locate the throttle cable adjuster at the throttle body Slide the cable adjuster boot off the cable adjuster Adjuster gt Using a 10 mm open end wrench loosen the adjustment jam nut Boot 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 Tighten the jam nut Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position 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 fo
62. e caused the blown fuse then replace the fuse Fuse Feature Supported 20A Lights Headlights Taillights 10A Drive AWD 20A Accessory Winch Switch 12V Power Receptacle 10A Fuel Pump 20A Electronic Engine Control Starting Power Fuse Feature Supported 20A Engine Control 30A Lights Drive Accessories 30A Power Steering if equipped 88 MAINTENANCE Fuses The fuse box is located above the power steering unit Spare fuses are provided in the fuse box 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 93 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 EPS EFI FAN FUEL PUMP amp RELAY RELAY RELAY RELAY LIGHTS DRIVE CHASSIS 20 10A RELAY FUEL PUMP EH 20 717691 Step 3 Cover removed 89 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 an
63. e 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 or snow ingestion into the PVT system Dry out the PVT see page 94 Prevent water from enter ing the PVT outlet duct see page 116 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 50 and 38 127 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect
64. e 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 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 d
65. ea 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 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 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 d 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 SPECIFICATIONS RANGER RZR RZR
66. ealer 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 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 Ind
67. ellents 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 Usea 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 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 e 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 Po
68. em and engine can cause burns Wear protective gloves when removing a spark plug for inspection 86 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 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 hav
69. en 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 Usea 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 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
70. 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 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 Cil 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 l 2 Position the vehicle level surface Place the transmission in PARK Remove both seats Remove the rear service panel See page 31 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 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 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Range Due to the dipstick entry angle into the crankcase the oil level Check Level will read higher on the bottom on Top Side side of the dipstick Always read the level on the upper surface of the dipstick Reinstall the dipstick Seat the lever lock 77
71. epressed the brake light comes on Check the brake light before each ride 1 2 Turn the ignition switch to the ON position 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 f 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 Move the vehicle to dry land 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 Remove the spark plugs Turn the engine over several times Dry the spark plugs and reinstall them or install new plugs Attempt to start the engine If necessary repeat the drying proce dure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 94 for drying 109 MAINTENANCE Battery A 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
72. er 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 A 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 16 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 Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towing Level Ground 15 grade Weight Speed 1500 lbs 850 lbs 150 165 10 mph 681 kg 386 kg 68 1 kg 16 kph
73. for leaks gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler pipe 100 H 12M 1000 1600 Inspect n Ignition timing 100 H 12M 1000 1600 Inspect gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc n Clutches drive and 100 H 12M 1000 1600 Inspect clean replace worn driven parts Drive belt 100 H 12M 1000 1600 Inspect replace as needed Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings n Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36M 3000 4800 Clean out Idle speed Adjust as needed n adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed V 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 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 Fluid Item Lube Method Engine Oil PS 4 PLUS Synthetic Add to proper level on dipstick Engine See page
74. fueling always use either leaded or unleaded gaso line with a minimum pump octane number of 87 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 Puer eap filling Cab Nets RZR models are equipped Front Cab Net Rear Cab Net with cab nets which may differ Latches Latches 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 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
75. g move your vehicle to the edge of the trail as far as possible to allow others to pass safely 55 OPERATION New Operator Driving Procedures 8 9 Read and understand the owner s manual and all warning and instruction labels before operating this vehicle Perform the pre ride inspection See page 52 Wear an approved helmet that fits properly and eye protection gog gles or face shield Do not carry a passenger until you have at least two hours of driving experience with this vehicle Do not tow or carry cargo during this period Select an open area that allows room to familiarize yourself with vehicle operation and handling Sit in the driver s seat and fasten the seat belt Always use the cab nets while riding in this vehicle Place the transmission in PARK 10 Start the engine 56 OPERATION New Operator Driving Procedures 11 12 13 14 15 16 Apply the brakes and shift into low gear Check your surroundings and determine your path of travel Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 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 Increase speed only after mastering all maneuvers at a slow speed After you bec
76. he vehicle Apply the throttle lightly Never open the throttle suddenly Back slowly Apply the brakes lightly for stopping Avoid making sharp turns 64 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 OPERATION Hauling Cargo A 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 to
77. hing 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 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 FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected speed displays in Vehicle miles per hour Speed When metric mode is selected speed displays in kilometers per hour Over This lamp illuminates to indicate an overheated Temperature engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine po
78. icker 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 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 20 clicks from closed Factory 7 clicks from closed Firmest 2 clicks from closed 104 Clicker 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 1 8 3 mm Y when tread depth is worn to 1 8 3 mm or less 22 WS Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Lug Nut Front and Rear 30 ft lbs 41 Nm Aluminum S LA PLUS 1 4 TURN Wheels NI 2 Piece Fl
79. 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter The error screen displays Error Code only when the CHECK Number 0 9 NICE SEN ENGINE light is on or when it goes on and off during one ignition cycle Er
80. in change at one month nE Throttle cable ETC 50H 6M 300 500 Inspect adjust lubricate switch replace if necessary E Throttle body air 50H 6M 300 500 nspect duct for proper sealing intake ducts flange air leaks gt General 50H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Shift Linkage 50H 6M 500 800 Inspect lubricate adjust n Steering 50H 6M 500 800 Lubricate gt Front Suspension 50H 6M 500 800 Lubricate gt Rear Suspension 50H 6M 500 800 Lubricate Cooling system 50H 6M 500 800 Inspect coolant strength if applicable seasonally pressure test system yearly nE Fuel system 100H 12M 600 1000 Check for leaks at tank cap lines filter pump throttle body replace lines every two years gt Spark plug 100H 12M 600 1000 Inspect replace as needed E gt Engine oil change 100H 6M 1000 1600 Perform a break in oil change at one month gt Oil filter change 100H 6M 1000 1600 Replace with oil change gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service n 72 Have an authorized POLARIS dealer perform these services MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Radiator 100 H 12M 1000 1600 Inspect clean external if equipped surfaces gt Cooling Hoses 100 H 12M 1000 1600 Inspect
81. ine 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 OPERATION Driving Over Obstacles qas Y 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 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind t
82. irculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables FuelLine Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 137 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
83. irec tives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the lim itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 68 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 id
84. ired 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 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 7
85. latches are secure Seat Belts Check ru of belt for damage 35 check latches for proper operation Cab Nets Check for wear or damage ensure 34 52 OPERATION Safe Operation Practices l 25 10 11 12 13 Complete the recommended safety training before operating this vehicle Do not allow anyone under 16 years of age or without a valid driver s license to operate this vehicle 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 Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Never operate with accessories not approved by POLARIS for use on this vehicle 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 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 Never consume alcohol or drugs before or while operating this vehi cle Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged vehicle After any overturn or accident have a qualified service dealer inspect the entire
86. le 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 oll level and if it continues to rise discontinue use and determine the cause or see your dealer 69 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt 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 Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km n Steering Pre Ride Make adjustments as need ed gt Front suspension Pre Ride d Pre Ride Checklist on page gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake pedal travel Brake system Pre Ride Wheels fasteners
87. lectronic 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 inoperative See your authorized Power Steering Unit POLARIS dealer for service under cover 36 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 ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low HIGH beam The ignition switch must be in the ON posi tion to operate the headlights 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 tu
88. lishing 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 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 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion Polish the clean chrome wheels periodically Use an automotive grade chrome polish 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 0
89. lter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 69 1 2 Access the air box from behind the left rear wheel Remove the air box cover and inspect the gasket It should adhere tightly to the cover around the entire edge Remove the air filter 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 before installing MAINTENANCE Air Box Cover Gasket Air Filter Inspect the air box for oil or water deposits If present drain them into a suitable container 95 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 Arrestor Remove the arrestor from the end of the muffler 2 Use anon synthe
90. lugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter See your POLARIS dealer Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel 129 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten
91. ly 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 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 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
92. machine for possi ble damage Never operate the vehicle on a frozen body of water Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 53 OPERATION Starting the Engine Position the vehicle on a level surface outdoors or in a well venti lated area 2 Sitin 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 Ifthe 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 spee
93. moving the Vehicle from Storage 121 Reversen siehe Mi tere be aan 64 Rider Information Center 43 49 Riding Area 55 Riding 8 9 S Safe Operation Practices 53 Safety Labels 20 27 Safety 4 Safety 10 19 Seat 31 Sedt Belts E xe 35 Seat 1 31 Service Panel Rear 31 Severe Use Definition 69 shifting Geats 2 arenai io sake sagan 38 Shock Compression 104 Signal Words 4 Spark Arrestor Cleaning 96 Spark Arrestor Warning 96 Spark Plug Condition 87 Spark Plug 86 Spark Plug 87 Spark Plug 86 Spark Pl gs 2 2 etos y noy obs 86 87 Spark Plugs 87 5 122 125 Specifications 86 144 Speedometer cud 41 Spring Preload 102 103 Stabilizing the Fuel LLL 119 Starting the 54 Steering Wheel Adjustment 32 Steering Wheel Inspection 101 Stopping the 54 S
94. nes 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 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 A 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 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 adju
95. ome 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 OPERATION Driving with Passengers 1 S o HOO 10 11 58 Complete the New Operator Driving Procedures outlined on pages 56 57 Perform the pre ride inspection See page 52 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 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 Make sure all passengers are wearing appropriate riding gear including an approved helmet and eye protection See page 8 Make sure all passengers secure their seat belts Make sure all cab nets are properly secured Allow a passenger to ride only in a passenger seat 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
96. or 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 POLARIS The Way Out 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 TABLE OF CONTENTS 4 Sal ty osi wos bare Sa Sates ote cee 7 Features and Controls 28 Operations 9 ES dE EE
97. orm 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 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 139 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 140 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 141 INDEX A Accessory Outlet 36 Adjustment Hand 32 Sedi 31 Steering Wheel 32 Adjustment Headlight Beam 108 Adjustment Throttle Freeplay 98 Air Filter oct e ee dee wee ee EUM 95 All Wheel Drive Switch 37 All Wheel Drive System 40 Auxiliary 36 Axle Nut
98. 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 SAFETY Safety Labels and Locations 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 Passenger ll Safety Warn ing 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 N
99. ppery or loose terrain could cause loss of traction loss of control accident or overturn ne Do not operate on excessively rough slippery 4 or loose terrain Always use extra caution amp rough slippery or loose terrain 16 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
100. proper 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 Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps 132 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
101. que 105 Wheel Removal 106
102. r 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 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 years and any time the fluid 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 Brake Fluid Reservoir Maximum Minimum 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 li
103. raveling 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 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 Ibs 136 4 kg Cargo Box Warning Tire Pressure Cargo Overload Warning 815 20 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 WE
104. re 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 l Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring Turn the lamp counter clock wise to remove it Install the new lamp Make sure the tab on the lamp locates properly in the hous ing Reinstall the harness assem bly into the headlight assem bly Wiring Harness 107 MAINTENANCE Lights Headlight High Beam Adjustment A AN A v 25 ft ie M 7 6 m A I BEC Wi 1 Place the vehicle 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 Ifadjustment is necessary turn the headlight adjustment screw to adjust the beam 6 Repeat steps 4 5 until the beam is properly adjusted 108 MAINTENANCE Lights Brake Lights When the brake pedal is d
105. rn off the headlights All Wheel Drive AWD Switch The AWD Switch has two positions AWD All Wheel Drive AWD Two Wheel Drive 2WD Press the top of the rocker switch to engage AII Wheel Drive Press the bottom of the switch to 2WD operate in two wheel drive See page 40 for AWD operating instructions 37 FEATURES AND CONTROLS Gear Selector P Park 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 Gear Selector is moving 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 Low Operating in rough terrain or over obstacles Low Loading the vehicle onto a trailer Low Towing heavy loads Low Operating at speeds greater than 7 MPH 11 km h High 38 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
106. ror codes are not stored When the key is turned OFF the code and mes sage is lost but will reap pear if the fault reoccurs after restarting the engine If the CHECK ENGINE Failure Mode Indicator FMI light illuminates retrieve the error codes from the display 1 Ifthe 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 OPERATION 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 careful
107. s l 2 60 Always check the terrain carefully before ascending a hill Avoid steep hills 15 maximum If ascending a steeper grade is unavoidable engage all wheel drive before ascending Drive straight uphill Never climb hills with excessively slippery or loose surfaces Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly Avoid unnecessary changes in speed or direction 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 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 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 Ifthe 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 Ifthe vehicle begins to slide downhill immediately turn downhill to stop the slide
108. shes 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 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 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
109. spension Independent double a arm with travel 9 5 in 24 cm RZR 12 in 30 5 cm RZR S 122 SPECIFICATIONS RANGER RZR RZRS Lubrication System Wet Sump Engine Oil 2W 50 Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Tire Size Front 25x8 12 RZR 26x9 12 RZR S Tire Size Rear 25x10 12 RZR 26x12 12 RZR S Tire Pressure Front 8 psi 55 KPa Tire Pressure Rear 8 psi 55 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 60W 55W halogen Taillights 2 single beam 5W Brake Lights 2 single beam 5W Instrument Cluster LCD Auxiliary DC Outlet 12V Clutching Altitude Shift Drive Clutch Driven Clutch Weight Spring Spring Meters 0 1500 23 62 Black Black Almond Feet 0 5000 PN 5632337 PN 7043594 PN 7043167 1500 3700 23 58 Black Black Almond 5000 12000 PN 5632218 PN 7043594 PN 7043167 123 SPECIFICATIONS RANGER RZR 4 Gross Vehicle Weight 2206 165 1000 kg Dry Weight 1255 Ibs 569 kg RZR 4 1271 Ibs 576 5 kg RZR 4 EPS Rear Cargo Box Capacity 300 Ibs 136 kg Maximum Weight Capacity Payload 900 Ibs 408 2 kg riders cargo
110. sted 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 Ibs 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 c Cam P Lowest Highest Softest Stiffest Setting Setting 102 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
111. tall itin 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 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 Remove both seats Remove the rear service panel See page 31 Loosen the lower screws that secure the clutch cover Allow the water to drain Tighten the screws Place the transmission in PARK Apply the brakes Start the engine c 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 Fi
112. tery 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 Ifthe 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 MAINTENANCE
113. thout 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 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and
114. tic 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 Retaining Screw and 3 Inspect the screen for Washer wear and damage Replace a worn or dam aged screen 4 Reinstall the arrestor Torque screws to 5 7 ft 165 7 9 Nm 96 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 Pedal beginning on page 69 Adjust the freeplay if necessary Throttle Throttle Freeplay Inspection 1 Place the transmission in PARK 2 Apply the brakes Start the engin
115. torage saber eee dl Lieb dd be 116 121 Storage 120 Storage Battery 113 Storage Fluid Levels 119 Storage Oil and Filter 119 Suspension Settings 102 104 Switches AWD 37 40 Ignition Switch 37 Mode Button 41 T T choinetet 2o bee bei ees 47 Throttle Freeplay Adjustment 98 Throttle Freeplay Inspection 97 Throttle 39 Throttle System 97 Tire Tread 105 er pU Ute 105 106 Torque Axle Nuts 105 Torque Spark 86 Torque Wheel 105 Towing Loads 67 Trail 55 Trailer 30 Transfer Case 80 81 Transmission Oil 82 83 Transmission Operation 93 94 Transmission Drying 94 Transporting the Vehicle 121 Tread Depth 105 V Vehicle Identification Numbers 6 Vehicle Immersion 109 Vehicle 121 W Warning 4 Washing the Vehicle 116 117 Wear Drive 127 Wheel 106 Wheel Nut Tor
116. u PMS 419 B RANGER RZR RANGER RZR S RANGER RZR 4 Owner s Manual for Maintenance and Safety A 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 100 RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW PMS 419 AWARNING 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 in a 2 seat vehicle With more than three passengers in a 4 seat vehicle on hills steeper than 15 degrees on public roads on paved surfaces pavement may seriously affect handling and control with non Polaris approved accessories they may seriously affect stability ALWAYS keep hands and feet inside vehicle Use the cab nets reduce speed and use extra caution when carrying passengers operate slowly in reverse avoid sharp turns or sudden 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
117. ustries 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 requ
118. w 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 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 Addthe recommended fluid to the bottom thread of the fill N plug hole Drain Plug 4 Reinstall the fill plug Torque mus 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
119. wer D 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 89 Helmet Seat Belt This lamp flashes for several seconds when the key is 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 amp 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster 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 ag rip 1
120. wing 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 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities Reduce speed and allow a great

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