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1. 34 Throttle System 91 Tire Tread Depth 97 Tires ueste erect rubr hU nen tied 977 98 Torque Axle Nuts 97 Torque Spark Plug 78 Torque Wheel Nut 97 Towing Loads 63 Towing Speed 63 Trail Etiquette 51 Trailer Hitch 25 Transmission Oil 77 Transmission Operation 85 87 Transmission Drying 87 Transporting the Vehicle 113 Tread Depth Tire 97 Tread Lightly lusus 51 TUREMod no Rem 38 INDEX V Vehicle Identification Numbers 6 Vehicle Immersion 101 Vehicle Transport 113 Ww Warning Symbols 4 Washing the Vehicle 108 109 Water Immersion of Vehicle 101 Wear Drive Belt 117 Weight Hitch 63 Wheel Installation 98 Wheel Nut Torque 97 Wheel Removal 98 133
2. 78 Gasoline Handling 19 Gear Selectot sub lm Reo 33 Gearcase Capacities 78 Gearcase Oil Demand Drive 76 Frnt 1o eoe eR ees 76 Mant 3 5 EE SE RFEA ae TI G Gearcase Specifications 78 Gearcases ce cee ee eees 76 78 Demand Drive 76 Front Gearcase 76 Main Gearcase 77 Specification Chart 78 Transmission 77 Gears shifting 33 GOV OS ne cete pe omen oe 9 Grill Removal usse 25 H Hand Hold Passenger 26 Hauling a Load 62 63 Hauling Cargo 62 63 Headlight Beam Adjustment 100 Headlight Lamp Replacement 99 Helm t rem itm eeics 8 lords 25 Hitch Weight 63 Hood Removal 27 l Idle Speed css ces secies iisa 92 Ignition Switch 31 Indicator Lamps 39 Inspection Axle Nuts 97 Inspection Brakes 95 Inspection Pre Ride 48 Inspection Steering Wheel 95 Inspection Throttle Freeplay 91 Inspection Wheel Nuts 97 Installation Battery 104 Installation Wheels 98 Instrument Cluster 39 45 Interference Electromagnetic 64 K Key Periodic Maintenance Chart 66 L Light Switch 31 Lights ier eg ntn 99 101 Beam Adjustment
3. Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines See your POLARIS 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 page 46 117 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 clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Refuel Clogged fuel filter See your POLARIS dealer Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your POLARIS dealer Engine Backfires Possible Cause Solution Weak spark from sp
4. 100 Brake Lights 101 Headlight Lamp Replacement 99 Loads Towing luus 63 Lubricant Part Numbers 116 Lubrication for Storage 112 Lubrication Recommendations 70 71 M Maintenance Log 128 Maintenance Periodic 65 69 Metric Display 42 Mode Button 4 39 N Nets Cab esaet etes 27 New Operator Procedures 52 53 Noise Emission Control System 64 Oo Obstacles 00000 e eee 59 Oil Demand Drive 76 Engine 72 75 Front Gearcase 76 Main Gearcase 77 Transmission 77 Oil and Filter Care During Storage 111 Oil Change Demand Drive 76 Engine Sain hws wots 75 Engine Oil 74 Front Gearcase 76 Main Gearcase 77 Transmission 71 Oil Check Demand Drive 76 Engine Oil eere rr ane d 73 Front Gearcase 76 Main Gearcase 77 Transmission TI 131 INDEX 0 Oil Recommendations 72 Operation on Public Lands 64 Operation Cooling System 82 Operation Transmission 85 87 P Parking on an Incline 61 Parking the Vehicle 51 Passenger Hand Hold Adjustment 26 Periodic Maintenance Chart 65 69 Plug Condition 79 Pl g Gap 5 eurer ener 78 Plug Torqu
5. Never carry passengers in cargo box WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo e 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 Becareful if load extends over the side of the box Load Passenger Tire Pressure Warning RANGER RZR RZR 570 RZR RZR 4 RZR XP MAXIMUM CARGO BOX LOAD 300 Ibs 300 Ibs 300 Ibs 300 Ibs 136 kg 136 kg 136 kg 136 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 FRONT 8 55 FRONT 10 69 FRONT 12 83 REAR 12 83 REAR 8 55 REAR 12 83 REAR 14 97 MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF 740 Ibs 740 lbs 900 Ibs 740 lbs OPERATOR PASSENGER 336 kg 336 kg 408 kg 336 kg CARGO AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information 20 SAFETY Safety Labels and Locations Overturn Passenger Safety Age Warning Warning Warning Discretionary Shift Warning Cab Frame Seat Caution Belt Warning Cab Frame Seat Belt Warning WARNING ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat belt ALWAYS SECURE CAB NETS VEHICLE OVERTURN could
6. 13 Reinstall and tighten the dipstick 14 Make sure the transmission is in PARK Apply the brakes 15 Start the engine Allow it to idle for one to two minutes 16 Stop the engine Inspect for leaks 17 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 18 Dispose of used filter and oil properly 75 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 65 Refer to the Gearcase Specifications Chart on page 78 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase Drain Plug Fill Plug 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 If the o ring is damaged install a new o ring Reinstall the drain plug Torque to specification Add the recommended fluid to th
7. toward forward rotation 4 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 3 Attach the wheel nuts and washers and finger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 97 98 MAINTENANCE Lights Poor lighting while driving can result in severe injury or death Head light and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp LED Headlamps if equipped If a headlight becomes damaged or inoperable the entire headlight assembly must be replaced Headlight Lamp Replacement Do not service the headlamps until they ve cooled sufficiently 1 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp Make sure the tab on the lamp locates properly in the housing 4 Reinstall the harness assembly into the headlight assembly Wiring Harness 99 MAINTENANCE Lights Headlight
8. FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 7175104 23 FEATURES AND CONTROLS Component Locations Cab aoe Nets rame Storage Compartment under hood Cargo Box Taillights Hip Bars Passenger Steering Hand Hold Wheel Brake Throttle Pedal Pedal Shifter 24 FEATURES AND CONTROLS Component Locations Receiver Hitch Guard Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 62 63 Radiator Access Grill Removal The front grill can be removed to clean debris from the radiator Push down on the two tabs and pivot the grill outward to remove it Service Access Panels The engine access panel is located behind the seats on the frame of the vehicle Remove the seats and remove the access panel to reach some serviceable engine components The rear access panel is located in the bed of the cargo box Remove this access panel to access the air box and spark plug 25 FEATURES AND CONTROLS Steering Wheel The steering wheel can be P tilted upward or downward for rider preference Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or down ward Release the lever when th
9. dry the air box and replace the filter with a new filter Thoroughly dry the air pre filter See pages 88 89 Remove the spark plug Turn the engine over several times Dry the spark plug and reinstall it or install a new plug Attempt to start the engine If necessary repeat the drying proce dure Take the vehicle to your POLARIS 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 87 for drying 101 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 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
10. major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer amp MSD Technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period POLARIS POLARIS RANGER and RANGER RZR are registered trademarks of POLARIS Indus tries Inc Copyright 2012 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2013 RANGER RZR 570 Owner s Manual P N 9924102 2 TABLE OF CONTENTS Introduce tre ee mmm Ek Re 4 Safety 25 2x cdi a demde PE SESS dE 7 Features and Controls 24 Operation 2 22ex terrx Rx 46 Emission Contr
11. 1 Remove the retaining nut Remove the arrester from the end of the muffler 2 Use anon synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect the screen for wear and damage Replace a worn or dam aged screen 4 Reinstall the arrester Torque the nut to 7 9 ft lbs 10 12 Nm Screen Arrester c Retaining Muffler Nut 90 MAINTENANCE Throttle System A 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 POLARIS 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 misadjust ment 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 free play the throttle may be hard to con trol and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Throttle Maintenance Chart beginning on page Pedal 65 Adjust the freeplay
12. All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 52 53 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 any passenger is tall enough to comfortably and safely reach the hand hold 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 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
13. Differential Switch has three positions l AWD e All Wheel Drive AWD e Differential Lock 2WD Differential Unlock TURF mode Press the top of the rocker switch to Differential Unlock engage All Wheel Drive AWD See page 38 for operating instructions Move the rocker switch to the center position to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the two rear drive wheels to operate indepen dently See page 38 for differential lock operating instructions WARNING Never operate in TURF mode if equipped while operating on a hill or other irregular terrain Always move the AWD switch to AWD before ascending or descending a hill See page 38 Differential Lock 32 FEATURES AND CONTROLS Gear Selector P Park R Reverse N Neutral L Low Gear H High Gear To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmis sion function See your POLARIS 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 id
14. Make sure passengers read and understand all safety labels ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS n For your nearest Polaris dealer PELARIS 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 9924102 Rev 01 Printed in USA WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polarisindustries com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles Victory Motorcycles Low Emission Vehicles LEVs We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about
15. RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to per form warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTER POLARIS warrants that the spark arrester in this vehicle will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to nor mal use and when maintenance and installation are in accordance with POLARIS rec ommendations 123 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from POLARIS Industries Dealers may not give authorization for export You should
16. Travel straight downhill 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 57 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed 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 60 Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control accident or 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 in Unfamilia
17. a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 72 Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Always use the recommended engine oil NOTICE Allowing dirt or debris to enter the engine can result in serious engine damage Always clean away all dirt and debris from the dipstick area before removing the dipstick Oil Check The oil dipstick and fill tube is located on the engine behind the passenger seat Access the dipstick through the right rear wheel well 1 2 3 Position the vehicle on a level surface Place the transmission in PARK Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick Wipe it dry with a clean cloth Reinstall and tighten the dipstick Remove the dipstick and check the oil level Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL and ADD marks Do not overfill Reinstall and tighten the dipstick MAINTENANCE Full Add PULL TE wo A 73 MAINTENANCE Engine Oil Oil and Filter Change Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Always change the oil filter whenever changing oil The engi
18. area Respect the environment in which you ride your vehicle Find out where the designated riding areas are by con tacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 51 OPERATION New Operator Driving Procedures 52 Read and understand the owner s manual and all warning and instruction labels before operating this vehicle Perform the pre ride inspection See page 48 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 The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Always use the cab net
19. consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your vehicle was purchased War ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importa tion rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries
20. day may be normal because of changes in humidity temperature and elevation 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is pro grammed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the deter mination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit 44 F
21. following chart are based upon average rid ing 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 Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your POLARIS dealer 65 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description 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 D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 66 Periodic Maintenance Chart Perform all services at whichever maintenance interval is
22. illuminates to indicate an overheated ee Temperature engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power Dh EPS Warning This indicator illuminates briefly when the key is if equippe urned to the position e light remains on the if equipped t d to the ON ition If the light i th EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in IN neutral and the ignition key is in the ON position High Beam if This lamp illuminates when the headlamp switch is ZD equipped set to high beam Helmet Seat This lamp flashes for several seconds when the key is A Belt turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating Check Engine This indicator appears if an EFI related fault occurs JY Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for one second at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the vehicle to yo
23. or when operating on uneven loose or slippery terrain such as sand gravel ice gt snow obstacles and water crossings Always operate in AWD on these types of terrain WARNING Operating in TURF mode if equipped when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to turf driving or whenever aggressive traction is not required 38 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components Wash the vehicle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Speedometer Indicator Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 42 Mode Button Use the MODE button to toggle through mode options See page 42 Rider Information Center for operation of the modes 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 E Over This lamp
24. reached first MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Inspect and make Brake fluid level Pre Ride adjustments as need ed See Pre Ride Checklist on Brake pedal travel page 48 Brake system Wheels fasteners Frame fasteners Engine oil level Intake pre filters Coolant Daily Check level daily change coolant every 2 years gt Power steering unit Daily Inspect daily clean often if equipped Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly 100 160 Inspect periodically D gt Engine breather 25H Monthly 150 250 Inspect replace if necessary E Battery 25H Monthly 250 400 Check terminals clean test gt Engine oil change 25H 1M Break in oil and filter change gt Demand drive fluid 25 H 1M Break in oil level check gt Transmission oil 25H 1M Break in oil level check main gearcase gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 67 MAINTENANCE Periodic Maintenance Chart main ge
25. the rear latch 28 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 passenger before riding To wear the seat belt properly follow this procedure l 2 3 4 Pull the seat belt latch downward and across your chest toward the buckle at the inner edge ofthe seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted Push the latch plate into the buckle until it clicks Release the strap it will self tighten 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 l 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 Push the red release latch in the middle of the buckle to make sure it releases freely Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household deter
26. 0 1500 25 52 Black Red Feet 0 5000 PN 5632409 PN 7043594 PN 3234452 1500 3700 25 48 Black Red 5000 12000 PN 5632408 PN 7043594 PN 3234452 115 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 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 I 2878069 AGL PLUS Transmission Fluid gal 3 8 1 2870465 Pump for Gallon 3 8 I Jug 2877922 Demand Drive Plus Fluid qt 95 I 2877923 Demand Drive Plus Fluid gal 3 8 1 Coolant 2871323 60 40 Coolant gal 3 8 I 2871534 60 40 Coolant qt 95 I Grease 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 116 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in
27. BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehi cle
28. Beam Adjustment 100 y 8 20 cm Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Apply the brakes Turn the ignition switch to the LIGHTS ON posi tion 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 If adjustment is necessary turn the headlight adjustment screw to adjust the beam Repeat steps 4 5 until the beam is properly adjusted MAINTENANCE Lights Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 2 Turn the ignition switch to the LIGHTS 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 If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your POLARIS 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
29. EATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter The error screen displays Error Code Number SPN only when the CHECK Number 0 9 umber SER ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and mes sage is lost but will reap pear if the fault reoccurs after restarting the engine If the CHECK ENGINE 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 Press the MODE button to advance to the next error code 5 Press and hold the MODE button to exit the diagnostics code menu See an authorized POLARIS dealer for code details and diagnosis 45 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 t
30. 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 122 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR
31. JURY or DEATH NEVER carry a passenger under age 12 or too small to firmly plant feet on the floor and securely grasp hand hold THE PASSENGER MUST ALWAYS wear seat belt use an approved helmet and protective gear securely grasp hand 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 22 SAFETY Safety Labels and Locations Discretionary Warning 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 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
32. 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 27 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed Tip Use of a non standard pressure cap will not allow the recovery system to function properly See your POLARIS dealer for the correct replacement part 83 MAINTENANCE Cooling System Coolant Level Always check and change LE Model Shown the coolant at the intervals outlined in the Periodic Maintenance Chart begin ning on page 65 Maintain the coolant level between the minimum and maxi mum marks on the bottle when the fluid is cool l 2 Tip 84 Position the vehicle on a level surface Remove the hood See page 27 View the coolant level Radiator Overflow in the overflow bottle Cap Bottle If the coolant level is below the safe operating range remove the cap and use a funnel to add coolant through the opening Reinstall the cap 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 in
33. Low fuel pressure See your POLARIS dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your POLARIS dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Possible Rich Fuel Cause Fuel is very high octane See your POLARIS dealer Solution Replace with lower octane fuel 119 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 plug Inspect clean and or replace spark plug Worn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten 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 POLARIS dealer Overheated engine Clean radiator screen and core clean engine exterior see your POLARIS dealer 120 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against de
34. 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 127 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 128 A Access Panels cercei ec oh tance 25 Accessory Outlet 30 Adding Coolant 82 Adjustment Hand Hold 26 ND 28 Steering Wheel 26 Adjustment Headlight Beam 100 Adjustment Throttle Freeplay 92 Air Filter 88 89 Air Filter Cleaning 88 89 All Wheel Drive Disengaging AWD 3T Engaging AWD 36 Locking the Differential 38 Unlocking the Differential 38 All Wheel Drive Switch 32 All Wheel Drive System 35 AWD Rear Differential System 36 38 Arrester Spark Warning 90 Auxiliary Outlet llus 30 AWD Switch 32 35 AWD System 0 32 Axle Nut Torque 97 B Battery c
35. RANGER RZR 570 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 ON ie The text is printed on 10096 recycled with 4096 post consumer waste PCW AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license Without first viewing safety video and quick start guide With more than one passenger On hills steeper than 15 degrees On public roads On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover can cause severe injury or death Secure cab nets and keep hands and feet inside vehicle at all times Wear a helmet eye protection gloves long sleeve shirt long pants and over the anke boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking
36. Seon conte ater Sdn 30 Equipment Modifications 7 Error Codes Engine 45 Etiquette Trail Riding 51 Exhaust Cleaning 90 Exhaust Emission Control System 64 Exhaust System Warning 90 Eye Protection 9 130 F Fan Cooling 5 83 Filling the Battery 105 Filter Care During Storage 111 Filter Cleaning Air 88 89 Filter Air sees 88 89 Fluid Demand Drive 76 Front Gearcase 76 Main Gearcase 71 Transmission Ls TI Fluid Change Demand Drive 76 Front Gearcase 76 Main Gearcase TI Transmission TI Fluid Check Coolant Bottle 84 Demand Drive 76 Front Gearcase 76 Main Gearcase TI Radiator Coolant 83 Transmission TI Fluid Levels During Storage 111 Fluid Recommendations Gearcase 78 Fluid Battery 105 Fluid Brake suus 94 Fogging the Engine 112 Fouled Plugs 005 05 79 Freeplay Adjustment Throttle 92 Freeplay Steering Wheel 95 BUC Cap secs setteiers pen enti cha Paes 28 Fuel Safety siente be RR UTR 19 Fuel Stabilizer 111 Fuel Tank Filler Cap 28 EUSeS c soe voee eie ret ees 80 81 G Gap Spark Plug
37. Transmission PVT System Belt Replacement Debris Removal If a belt fails always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death 1 Remove the clutch cover screws and open the clutch cover Remove all debris wrapped in and around the PVT system 2 Remove all debris from the entire clutch air duct passage 3 Check for signs of damage to seals on the transmission and engine See your POLARIS dealer promptly for service if any seals appear to be damaged Tip Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc 86 MAINTENANCE POLARIS Variable Transmission PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing NOTICE When washing the vehicle always avoid spraying water directly toward the PVT intake duct See page 108 for recommended washing procedures 1 Remove the drain plug from the bottom of the clutch box Allow the water to drain Reinstall the drain plug securely 2 Place the transmission in PARK Apply the brak
38. aining display settings 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip The clock must be reset any time the battery has been disconnected or dis charged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position 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
39. 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 Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Seat belts reduce the severity of injury in the event of a sudden stop or accident Always make sure the seat belts are secured for both the operator and passenger 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 Multiple Passengers Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 52 53 A passenger must always be seated in a passenger seat with seat belt secured Carrying more than one passenger in a 2 seat vehicle can affect the operator s ability to steer and operate the controls which increases the risk of loss of control and accident or overturn N
40. ar suspensions are preload adjustable with five settings on each axle The suspensions are set on the lowest softest setting at the factory This setting is appropriate for nearly all riding conditions Since the vehicle is equipped with full skid plates suspension adjustment is not necessary If desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads Please see your POLARIS dealer for the tool required to make suspension adjustments Elevate the vehicle slightly for easier adjustment Always heed the following rules if you make adjustments to this suspen sion Always return the suspension to the lowest softest setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting to all four wheels Never operate the vehicle on the highest stiffest or second highest preload settings without a total combined payload in the vehicle of 450 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 114 Adjustment Cam Highest Softest Stiffest Setting Setting 96 MAINTENANCE Tires A WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serio
41. arcase Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Throttle cable 50 H 6M 300 500 Inspect adjust lubricate E replace if necessary E Throttle body air 50 H 6M 300 500 Inspect duct for proper seal intake ducts flange ing air leaks gt General lubrication 50 H 3M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 6M 500 800 Inspect lubricate adjust D Steering 50H 6M 500 800 Lubricate gt Front Suspension 50 H 6M 500 800 Lubricate gt Rear Suspension 50H 6M 500 800 Lubricate Cooling system 50 H 6M 500 800 Inspect coolant strength seasonally pressure test system yearly D Fuel system 100 H 12M 600 1000 Check for leaks at tank cap E lines filter pump throttle body replace lines every two years gt Spark plug 100 H 12M 600 1000 Inspect replace as needed E gt Engine oil change 100 H 6M Change the oil and filter gt Demand drive fluid 100 H 12M Change fluid gt Transmission oil 100 H 12M Change fluid gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 68 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Radiator 100 H 12M 1000 1600 Insp
42. ark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your POLARIS dealer Incorrect ignition timing See your POLARIS dealer Mechanical failure See your POLARIS dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 118 Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspect clean and or replace spark plug Worn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug 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
43. ashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your POLARIS dealer for scheduled maintenance See page 43 for resetting instructions 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on 4X4 Turf Mode Indicator if equipped This indicator illuminates when the operator unlocks the differential See page 38 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the S 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 rem
44. cause severe injury or death Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle When vehicle is stopped place shift in the parked position APPLY BRAKE TO START 7174843 CAUTION N Failure to follow these storage instructions could result in injury or property damage Temperatures in this storage box can exceed 150 F 65 C Items such as lighters sealed gasses and electronics are heat sensitive NEVER store such items in this box SAFETY Safety Labels and Locations Age Warning WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 or without a valid driver s license Overturn Warning WARNING Improper operation can cause this vehicle to overturn and lead to serious injury or death This vehicle handles differently than cars trucks or other off road vehicles In order to avoid overturns avoid sharp turns never turn while applying heavy throttle never make abrupt steering maneuvers operate at speeds appropriate for your skills the con ditions and the terrain DO NOT do power slides donuts jumps or other driving stunts 7175105 Passenger Safety Warning 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 IN
45. ccessories 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 Towin Level Ground 15 grade Weight Spee 1500 Ibs 850 Ibs 150 Ibs 10 MPH 681 kg 386 kg 68 1 kg 16 km h 63 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1C Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system AII 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 compo nen
46. 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 102 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 1 2 Remove the driver s seat See page 28 On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the vehicle Be not to tip a conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 103 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 106 before installing the batt
47. creases the risk of an accident or overturn DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving 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 A passenger should always be seated in the passenger seat with seat belt secured with both feet on the floor and with both hands securely grasping the passenger hand hold Always keep hands and feet inside the vehicle at all times 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 56 14 SAFETY Safety Warnings Descending Hills Improperly N Improperly descending a hill could cause loss Ss 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
48. d 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 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 110 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 108 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 74 Air Filter Air Box Inspect and clean or replace th
49. d 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 rz zu REL NN a L KER NS NN NES gt E Se aed a Y CN p IN SQ SS fq N We 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 Never operate in TURF mode if equipped while operating on a hill or other irregular terrain Always move the AWD switch to AWD before ascending or descending a hill See page 38 3 Drive slowly and use extreme caution 4 Ifthe vehicle begins to overturn or if it feels as if it may overturn immediately turn downhill 5 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 6 Ifthe vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and care ful
50. dents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems 18 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
51. differently than cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Always use the cab nets while riding in this vehicle Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Always keep hands and feet inside the vehicle at all times Complete the New Operator Driving Procedures outlined on pages 52 53 Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was con trolled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent o
52. e 78 Plug Accessory sssssss 30 Plug Spark 78 79 Plugs Fouled 2 eor ae ceed 79 Polaris Products 116 Polishing the Vehicle 109 Power Steering 30 Pre Filters Intake 89 Pre Ride Inspection 48 Public Lands 2 0 44 ore 64 PVT Break In 47 PVT Dtying scat Rr REI 87 PVT Intake Pre Filter 89 PVT System Operation 85 87 PVT Cleaning Debris 86 R Radiator cec eee 83 Radiator Access lusus 25 Radiator Coolant Level 83 Receiver Hitch 25 Removal Battery 103 Removal Seat 28 Removal Wheels 98 Removal from Storage 113 Reverse a s ccc ee etn pA ere 60 Rider Information Center 40 45 Riding Area 0 51 Riding Gear 2 2 9 v Bw 8 9 Rollover Protective Structure 34 ROPS Cab Frame 34 RPM Idle Throttle Body 92 132 S Safe Operation Practices 49 Safety Labels 20 23 Safety Symbols 4 Safety Warnings 10 19 Seat Adjustment 28 Seat Belts 2 e ante ane ow ae 29 Seat Removals 22 2 scgaeg aes ee 28 selector Gea ouesse corr oes daewees 33 Service Panels 25 Severe Use Definition 65 Shifting Gears ses due ee edness 33 Signal Word
53. e air filter Install the air filter with the pleats facing upward 7 Reinstall the air box cover and secure the cover clips Do not allow the air box cover to contact the air filter during installation 8 Reinstall the intake hose and tighten the clamp securely 9 Reinstall the access panel Intake Pre Filters The engine and PVT intake pre filters are located on the left side of the cargo box Inspect both pre filters before each use of the vehicle to ensure ade quate air flow If necessary remove the pre filters and clean with soapy water Dry with low pressure compressed air NOTICE When washing the vehicle always avoid spraying water directly toward the PVT intake duct See page 108 for recommended washing PVT Intake Pre Filter procedures Engine Intake Pre Filter 89 MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Periodically clean the spark arrester to remove accumulated carbon
54. e before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning or slipping may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 35 FEATURES AND CONTROLS All Wheel Drive Rear Differential System Engaging AWD Press the top of the switch to engage All Wheel Drive AWD The 4X4 indicator illuminates in AWD the rider information center to indicate that the vehicle is in Differential Lock AWD See page 41 When the AWD switch is on the Differential Unlock front wheels will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front wheels will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The AWD switch may be turned on or off while the vehicle is moving Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest 36 FEATURES AND CONTROLS All Wheel Drive Rear Differential System Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off whi
55. e bottom thread of the fill plug hole Reinstall the fill plug Torque to specification OY Un cde T 8 Check for leaks Discard used fluid properly 76 MAINTENANCE Gearcases Transmission Main Gearcase Always check and change the fluid at the intervals outlined in the Peri odic Maintenance Chart beginning on page 65 Refer to the Gearcase Specifications Chart on page 78 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the rear of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase Access the drain plug through the drain hole in the skid plate 1 Qv a a a 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 Add the recommended fluid to the bottom of the fill plug hole Do not overfill Reinstall the fill plug Torque to specification Check for leaks Discard used fluid properly 77 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fl
56. e pre filter and air filter Clean the air box See pages 88 89 Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 65 Demand drive fluid front gearcase Rear gearcase fluid if equipped Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill 111 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 65 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 plug 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 plug Torque to specification See page 79 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the cap onto the plug at this step 5 Turn the engine over several times Oil will be
57. e 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 106 MAINTENANCE Battery Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Charge Tune 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 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfa
58. e steering wheel is at the desired position Passenger Hand Hold Always adjust the hand hold to a comfortable position for your passen ger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments Adjustment Lever 1 Remove the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole adapter bushing hole both post adjustment holes and lastly through the remaining bushing hole and post mounting hole 5 Reinstall the retainer to the pin Adapter Bushing Pin Retainer Adjustment f i e Pin oles 26 FEATURES AND CONTROLS Hood Sealed Storage Box LE Only Remove the hood to access the radiator cap coolant overflow bottle and sealed storage box LE model 1 Turn the hood fasteners 1 4 turn 2 Grasp the upper hood edge and pull upward to disengage the hood from the vehicle 3 Pivot the hood forward and lift upward to disen gage the lower hood hooks Radiator Overflow 4 Lift the hood away from Cap Bottle the vehicle Cab Nets All RZR models are equipped with cab nets which may differ slightly in appearance from those shown Cab Net Latches 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 u
59. e the battery if the voltage drops below a pre deter mined point See page 116 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 105 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 103 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 104 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 b
60. earings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring If warning and safety labels are damaged contact your POLARIS dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 109 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 an
61. ect clean external surfaces gt Cooling Hoses 100 H 12M 1000 1600 Inspect for leaks gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts Drive belt 100 H 12M 1000 1600 Inspect replace as needed D Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 300 H 36M 3000 4800 Clean out gt Valve clearance 500 H 5000 8000 Inspect adjust as needed E D Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 69 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 65 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 Front Gearcase Item Lube Method Engine Oil PS 4 PLUS Synthetic Add to prop
62. edures outlined on pages 52 53 Perform the pre ride inspection See page 48 fi Do not carry more than one Wr D N passenger in a 2 seat vehicle gu Additional passengers can affect the operator s ability to steer and operate the con trols Make sure the passenger is at least 12 years of age and is tall enough to comfortably and safely sit in the passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times See page 8 Make sure all cab nets are properly secured Allow a passenger to ride only in the passenger seat Slow down Always travel at a speed appropriate for your skills your passenger s skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger Vehicle handling may change with a passenger 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 o
63. ehicle before operating over an obstacle that could cause an overturn 59 OPERATION Driving in Reverse VN g rT T fa M mr eg i yiii A P S M 7 Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Apply the throttle ightly Never open the throttle suddenly Back slowly Apply the brakes ightly for stopping Sho Eo P2 Avoid making sharp turns 60 OPERATION Parking on an Incline bs V TZ a N w 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 6l OPERATION Hauling Cargo AWARNING 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 passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these item
64. er level on dipstick Engine Oil See page 73 Brake Fluid DOT 4 Maintain level between fill lines See page 94 Transmission Oil Premium AGL Synthetic See page 77 Main Gearcase Gearcase Lube Demand Drive Fluid Demand Drive Plus Fluid See page 76 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 70 MAINTENANCE Lubrication Recommendations Rear Control Arm Pivot Bushings Front Stabilizer Bar Bushings Front Control Arm Pivot Bushings 71 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS 4 PLUS Synthetic engine oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil may need to be changed more frequently if POLARIS PS 4 PLUS Synthetic engine oil is not used Follow the manufacturer s recommen dations for ambient temperature operation See page 116 for the part numbers of POLARIS products NOTICE Mixing brands or using
65. er the driver s seat Remove the engine access panel to access the fuse box 80 Power Fuse Box Fuses Main Fuse Box 1 From the left side of the vehicle reach in and lift up on the two fuse box tabs Slide the fuse box slightly toward the right side of the vehicle to disengage it from the mount Remove the fuse box cover Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating MAINTENANCE Release Tabs Slide right to disengage 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 81 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radia tor filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Tip Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding
66. ery 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 QoS Oy vc ors 104 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 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 106 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 charg
67. es Start the engine 3 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 4 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 5 Test for belt slippage If the belt slips repeat the process 6 Take the vehicle to your POLARIS dealer for service as soon as possible 87 MAINTENANCE Air Filter Always clean all dirt and debris away from the air box area before servicing the air filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 l 2 Remove the rear access panel in the cargo box Clean all dirt and debris from the air box area Loosen the hose clamp and remove the intake hose from the air box cover before unlatching the cover clips Unlatch the cover clips and carefully remove the air box cover Do not allow the air box cover to contact the air filter during removal NOTICE Dirt or debris in the air box 88 could result in severe engine damage Always clean all dirt and debris from the air box before installing the filter Inspect the air box for dirt debris oil or water Clean the air box thoroughly and wipe it well with a clean dry cloth Hose Clamp Air Filter MAINTENANCE Air Filter 6 Install a new filter if needed Do not attempt to clean th
68. ever carry more than one passenger in a 2 seat vehicle Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the 1 Slow down maximum weight capacity 2 Verify tire pressure Operating in rough terrain 3 Use extra caution when operating Operating over obstacles Climbing an incline Towing 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 12 SAFETY Safety Warnings Operating on Pavement Operating this ve
69. fects in material or workmanship Warranty period will vary regionally This warranty covers the parts and labor charges for repair or replacement of defective parts which are cov ered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle tha
70. 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 cap to the spark plug Battery Maintenance See pages 105 107 for storage and charging procedures Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a gen uine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 112 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 48 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when tran
71. g Fan 4 re chee ees 83 Cooling System 83 84 Cooling System Operation 82 Corrosion Removal Chrome 110 Cover for Storage 112 Crankcase Emission Control System 64 129 INDEX D Demand Drive Fluid 76 Differential Locking se esee eae aiis 38 Unlocking Lse 38 Differential Lock Switch 32 Disengaging AWD 37 Display Units Standard Metric 42 Drive Belt Wear 117 Drivetrain Break In 47 Driving Downhill 57 Driving in Reverse 60 Driving on a Sidehill 57 Driving on Slippery Surfaces 325 Driving Over Obstacles 59 Driving Procedures 52 53 Driving Through Water 58 Driving Uphill 56 Driving with a Passenger 54 Driving After Driving in Water 87 Drying the Transmission 87 E Electromagnetic Interference 64 Electronic Power Steering 30 Emission Control Crankcase 64 Emission Control Exhaust 64 Emission Control Noise 64 Emissions Limited Warranty 126 127 Engaging AWD 35 36 Engine Break In 47 Engine Fogging 112 Engine Idle Speed 92 Engine Intake Pre Filter 89 Engine Oil 72 75 Engine Starting 50 Engine Stopping 50 BBS eie cues aisha
72. gents 29 FEATURES AND CONTROLS Switches Ignition Switch Light Switch Base Model Instrument Cluster Light Switch AWD 12V Accessory LE Model Switch Outlet Auxiliary Outlet The vehicle is equipped with a 12 volt accessory outlet on the dash Use the outlet to power an auxiliary light or other optional accessories or lights For service the dash outlet connection is under the dash Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle The EPS warning indicator briefly illuminates when the key is turned to the ON position See page 39 To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will Power Steering Unit illuminate to indicate the EPS has shut under cover down If the light remains on after starting the engine the EPS system is inop erative See your authorized POLARIS dealer for service 30 FEATURES AND CONTROLS Switches Ignition Switch Light Switch Base Model Use the ignition switch to start the engine and to turn the lights on or off The key can be removed from the switch when it is in the OFF position OFF Turn the key to the OFF position to stop the engine Electrical circuits are off LIGHTS ON Electrical circuits are on Electrica
73. hicle on paved surfaces including sidewalks paths parking lots and driveways may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control This vehicle s tires are designed for off road use only not for use on pavement Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads In many areas it s illegal to operate vehicles of this type on public streets roads and highways Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and your passenger s skills 13 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Exhibition driving in
74. high range Solution Use low range during loading Starting out going up a steep incline Use low range See warnings on page 56 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently Insufficient warm up at low ambient 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 range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT see page 87 Prevent water from enter ing the PVT intake duct see page 89 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer
75. htness 97 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 2 Coolant level Ensure proper level T Coolant hoses Inspect for leaks Throttle Ensure proper operation 91 Indicator lights switches Ensure proper operation 31 Air filter pre filter Inspect clean 88 89 Intake pre filters Inspect clean 89 Headlamp Check operation apply POLARIS 99 dielectric grease when lamp is replaced Brake light tail lamp Check operation apply POLARIS 101 dielectric grease when lamp is replaced Seat Latches Push down on both seat backs to 28 ensure the latches are secure Seat Belts Check length of belt for damage 29 check latches for proper operation Cab Nets Check for wear or damage ensure 27 48 OPERATION Safe Operation Practices 1 2 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 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 di
76. if necessary Throttle Freeplay Inspection 1 Place the transmission in PARK 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 5 3 mm 91 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 l 92 Remove both seats Remove the engine access panel See page 28 Locate the throttle cable adjuster at the throttle body Slide the cable adjuster boot off the cable adjuster Using a 10 mm open end wrench loosen the adjust ment jam nut ster 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 91 While adjusting lightly flip the throttle pedal up and down Boot Tighten the jam nut Jam Nut Adjuster 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 34 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 spongi
77. 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 124 WARRANTY How to Get Service If Purchased From A Private Party If you purchase a POLARIS product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic war ranty For questions call POLARIS Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 125 WARRANTY U S A EPA Emi
78. 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 defective materi als or components or products THE REMEDIES SET FORTH
79. ission 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 Fuel Line Control Linkages Fuel Line Fittings e 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 126 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR POSE ALL IMPLIED WARRANTIES INCLUDING
80. l _ 3 Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 65 Give special attention to engine oil transmission oil demand drive fluid rear gearcase oil if equipped and all grease fittings If your vehicle becomes immersed or is operated in water that exceeds the floor level take it to your POLARIS 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 101 and take the vehicle to your dealer at the first opportunity 58 OPERATION Driving Over Obstacles x qu i aii 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 a passenger dismount and move away from the v
81. l equipment can be used LIGHTS OFF Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter See page 50 for starting procedures Ignition Switch LE Model The ignition switch is a three position key operated switch 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 Acc 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 Light Switch LE Model The ignition switch key must be in the HIGH ON RUN position to operate the head lights Press the top of the rocker switch toward the dash to place the headlights on LOW high beam Move the rocker switch to the center position to place the headlights on OFF low beam Press the bottom of the rocker switch to turn off the headlights 31 FEATURES AND CONTROLS Switches All Wheel Drive AWD Switch if equipped The AWD Switch has two positions All Wheel Drive AWD AWD a Two Wheel Drive 2WD e Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to O operate in two wheel drive 2WD gts See page 35 for AWD operating instructions AWD Differential Lock Switch if equipped The AWD
82. le Gear Selector Using Low Range Always shift into low gear for any of the following conditions Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads 33 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while start ing the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when Throttle released Always check that Pedal the throttle pedal returns nor mally before starting the engine Make sure there s adequate throttle pedal freeplay See page 92 for throttle pedal adjustment procedures This vehicle is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle pedal engine speed will be limited and power to the rear wheels will be reduced Rollover Protective Structure ROPS The Rollover Protective Struc ROPS Label ture ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way Brake Pedal No device can assure occupant protection in the event of a roll over Always follow all safe operating practices outlined in this manual to avoid vehicle r
83. le the front hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following proce dure to unlock the front gearcase 1 2 3 4 5 Stop the vehicle Operate in reverse for at least 10 feet 3 m Stop completely Shift into low gear and drive forward If the front gearcase remains locked after following these instruc tions see your dealer for service 37 FEATURES AND CONTROLS All Wheel Drive Rear Differential System Locking the Differential NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive See illustration below Unlocking the Differential TURF Mode When operating in TURF mode the inside rear wheel will rotate e i independently from the outside wheel during turns Operate in TURF mode T only as needed to protect smooth level surfaces from tire damage DO NOT operate in TURF mode when climbing or descending hills when sidehilling
84. ls of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period If a belt fails always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt 47 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 us Brake fluid Ensure proper level 94 Front suspension Inspect lubricate if necessary 70 Rear suspension Inspect lubricate if necessary 70 Steering Ensure free operation 95 Tires Inspect condition and pressure A Wheels fasteners Inspect ensure fastener tig
85. ly until the vehicle can be driven straight downhill Driving Downhill Whenever descending a hill follow these precautions 1 Avoid steep hills 15 maximum 2 Never operate in TURF mode if equipped while operating on a hill or other irregular terrain Always move the AWD switch to AWD before ascending or descending a hill See page 38 3 Slow down Never travel down a hill at high speed 4 Always check the terrain carefully before descending a hill 5 Always descend a hill with the transmission in forward gear Never descend a hill with the transmission in neutral 6 Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill 7 Apply the brakes ightly to aid in slowing 57 OPERATION Driving Through Water Your vehicle can operate through g SR water with a maximum AR E E recommended depth equal to A be floor level Follow these j precautions when operating ki through water Ke 1 Determine water depth and eee a a current before entering GA L5 water Ve 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 Floor Leve
86. n many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Abihty of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Key Number HH Vehicle Identification Number Stamp Left Front Frame Engine Serial Number Manufacturing Data Label Right Front Fender Area 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 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 equi
87. ne drain plug is located on the bottom of the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK Apply the brakes 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 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 12 ft lbs 16 Nm Drain Plug Access 74 MAINTENANCE Engine Oil Oil and Filter Change 8 Using a cap style oil filter wrench turn the filter coun ter clockwise to remove it 9 Using a clean dry cloth clean the filter sealing sur face on the crankcase Make sure the old filter o ring is completely removed 10 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in Oil Filter good condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick and fill the sump with two quarts 1 9 I of recommended oil
88. ness would indicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 94 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your POLARIS dealer for proper diagno sis 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 93 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 116 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 transmi
89. ngine starts Aw 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 speed slows to near idle the vehicle has no engine braking 2 Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls 50 OPERATION Parking the Vehicle 1 Stop the vehicle on a level surface When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 2 Place the transmission in PARK 3 Turn the engine off 4 Remove the ignition key to prevent unauthorized use Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this vehicle in your
90. nic fuel injection Ignition System ECU Spark Plug Gap RG4YCX 0 7 0 8 mm Front Suspension Independent double a arm with 9 in 23 cm travel Rear Suspension Independent double a arm with 9 5 in 24 cm travel 114 SPECIFICATIONS RANGER RZR 570 Lubrication System Wet Sump Engine Oil PS 4 PLUS Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Gear Reduction Low 25 59 1 Gear Reduction Reverse 22 92 1 Gear Reduction High 12 05 1 Drive Ratio Front 3 818 1 Tire Size Front 25x8 12 Tire Size Rear 25x10 12 Tire Pressure Front 10 psi 69 KPa Tire Pressure Rear 12 psi 83 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights Base Model 2 single beam 55W halogen Headlights LE Model 2 dual beam 6 LED cluster 40w High 27w Low Taillights 2 single beam 6W Brake Lights 2 single beam 27W Instrument Cluster LCD Auxiliary DC Outlet 12V Clutching Base Model Altitude Shift Drive Clutch Driven Clutch Weight Spring Spring Meters 0 1500 25 52 Black Black Almond Feet 0 5000 PN 5632409 PN 7043594 PN 3235088 1500 3700 25 48 Black Black Almond 5000 12000 PN 5632408 PN 7043594 PN 3235088 Clutching LE Model Altitude Shift Drive Clutch Driven Clutch Weight Spring Spring Meters
91. of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust System Use caution when traveling through tall grass especially dry grass Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 19 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 abels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Load Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death
92. ol Systems 64 Maintenance soo eee x ERRORI CR I e 65 Specifications oe xy ee wae cee AR Re 114 POLARIS Products 116 Troubleshooting 117 Warranty oec d e Robe ee RR RUN ate amp See Re 121 Maintenance Log sssss 128 lude pt nm 129 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 DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard 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 vehicle handles
93. ollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover 34 FEATURES AND CONTROLS All Wheel Drive AWD System For models equipped with a rear differential refer to the All Wheel Drive Rear Differential section beginning on page 36 On models not equipped with a rear differential the All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the vehi AWD i cle is in two wheel drive at all times When the switch is on AWD the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will K x be on 2WD gle When in AWD the demand drive unit will auto matically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttl
94. 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 116 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 82 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 65 Do not obstruct or deflect air flow through the radiator by installing unauthor ized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended Radiator Coolant
95. oser er Rs 102 107 Charging 106 Charging Sealed Battery 106 107 Battery Fluid Replenishment 105 Battery Installation 104 Battery Removal 103 Battery Storage 105 Before Riding 48 Belt Buttng 5e 117 Belt Lite 2i Rer REY eS 63 Belt Replacement 86 Belt Weat i4 echec s 117 Belts Seat sese ees 29 Bo tis eece he eR REPE 9 B Brake Fluid lee cca seas 94 Brake Inspection 95 Brake Tights 2 2see cee aes 101 Brake Pedali dicen a een ieadias he 34 Brake System Break in 47 Brakes ise leer eere 93 95 Braking 4 ed adig del PE SES 50 Break In Period 46 47 Burning Belts 117 C Cab Frame ROPS 34 CAD Nets eere hte eto dete n 27 Cap Fuel eee mee ee 28 CIBO ceca xy o E eR 62 63 Changing Coolant 82 Changing Gears 33 Chart Periodic Maintenance 65 69 Check Engine Indicator 45 Chrome Wheel Care 110 Cleaning and Storage 108 113 Cleaning the Air Filter 88 89 Cleaning the Exhaust System 90 Cleaning the Spark Arrestor 90 Clothing 55s sese eee e 9 Clutching 000 115 Component Locations 24 25 Condition Spark Plugs 79 Coolant Level 4 84 Coolant Level Radiator 83 Coolant Adding or Changing 82 Coolin
96. perate 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 direction of skid C OC D C 2e D LA ONE L4 DS lt gt L Co C CC BS S Coe Q4 55 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 2 56 Always check the terrain carefully before ascending a hill Never operate in TURF mode if equipped while operating on a hill or other irregular terrain Always move the AWD switch to AWD before ascending or descending a hill See page 38 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 an
97. pment 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 The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Wear protective clothing for comfort and to reduce the chance of injury Long Long Pants Over the Ankle Boots Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the disting
98. r Operating through deep or fast flowing water can cause loss of traction loss of control overturn or accident Never operate in fast flowing water or in water that exceeds the recommended maximum depth Always follow proper procedures for operating in water as described in the owner s manual Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 17 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 passenger and your cargo together with any other vehicles in your party Always check with local authorities and resi
99. r 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 Operating on Slippery Terrain Operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain 16 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 Mf m 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 Wate
100. r 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 62 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities Reduce speed and allow a greater distance for braking when carrying cargo Loads should be centered and carried as low as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the maximum capaci ties specified for your vehicle See page 114 Belt Life To extend belt life use low gear when hauling or towing heavy cargo Towing Loads AWARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when towing 1 Never load more than 150 lbs 68 1 kg tongue weight on the tow ing bracket 2 Do not operate the vehicle faster than 10 MPH 16 km h when tow ing Towing a trailer increases braking distance 3 Do not tow more than the recommended weight for the vehicle 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location which could result in loss of control of the vehicle 5 The total load operator passenger a
101. rt 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 machine for possi ble damage Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passenger and your cargo together with any other vehicles in your party 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 49 OPERATION Starting the Engine 1 Position the vehicle on a level surface outdoors or in a well venti lated area Sit in the driver s seat and fasten the seat belt Secure the cab nets Place the transmission in PARK Apply the brakes Do not press the throttle pedal while starting the engine 5 Turn the ignition key to the START position Engage the starter for a maximum of five seconds Release the key when the e
102. s 00 4 Spark Arrester Warning 90 Spark Arrestor Cleaning 90 Spatk Pl g eer 78 79 Spark Plug Condition 79 Spark Plug Gap 78 Spark Plug Removal 79 Spark Plug Torque rr 78 Spark Plugs Fouled 79 Specifications 114 115 Specifications Gearcase 78 Speed Idle asso n ke 92 Speed Towing 63 Speedometer 04 39 Spring Preload 96 Stabilizing the Fuel 111 Starting the Engine 50 Steering Wheel Adjustment 26 Steering Wheel Inspection 95 Stopping the Engine 50 Storage i nra A e etree sates 108 113 Storage and Inspection 112 Storage and Lubrication 112 Storage Area woes cee er ern 112 Storage Battery 105 Storage Covers 05 112 Storage Fluid Levels 111 Storage Oil and Filter 111 Storage Removal 113 Suspension Settings 96 S Switches AWD Switch 32 35 Differential Lock Switch 32 Ignition iio Re 31 LAght 1s rece s tertie teen 31 Light Switch 31 Mode Button 39 T Tachometer 00 43 Throttle Freeplay Adjustment 92 Throttle Freeplay Inspection 91 Throttle Freeplay Freeplay Throttle 91 Throttle Pedal
103. s must not exceed the maximum weight capacity Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill Carrying a passenger in the cargo box could result in a fall from the vehicle o
104. s while riding in this vehi cle Sit in the driver s seat and fasten the seat belt Place the transmission in PARK Start the engine OPERATION New Operator Driving Procedures 10 Apply the brakes and shift into low gear 11 Check your surroundings and determine your path of travel 12 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 13 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 WARNING Operating in TURF mode if equipped when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again 14 Increase speed only after mastering all maneuvers at a slow speed 15 After you become skilled at making turns and begin to operate at faster speeds follow these precautions Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts 53 OPERATION Driving with a Passenger l 10 54 Complete the New Operator Driving Proc
105. sed by operator and passenger 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 27 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right side of the vehicle near the passenger seat When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Remove flammable material containers from the box before filling 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 Seat Latch under the rear edge of the seat Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure the seat tabs at the front edge of the seat slide under the seat retainer bar 5 Press down firmly at the rear of the seat to engage
106. spected by your POLARIS dealer 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 Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your POLARIS dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install 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 85 MAINTENANCE POLARIS Variable
107. sporting the vehicle Ww 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 113 SPECIFICATIONS RANGER RZR 570 Gross Vehicle Weight 1719 Ibs 780 kg Dry Weight 962 Ibs 436 kg Base Model 999 Ibs 453 kg LE Model Rear Cargo Box Capacity 300 Ibs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg riders cargo accessories trailer tongue weight Receiver Hitch Tongue Capacity 150 Ibs 68 kg Receiver Hitch Towing Capacity 1500 Ibs 680 kg Fuel Capacity 7 gal 26 5 1 Engine Oil Capacity 2 qts 1 9 1 Coolant System Capacity 4 qts 3 76 1 excluding coolant bottle Coolant Bottle Capacity 8 oz 237 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Overall Length Width Height 107 5 50 69 in 273 127 175 3 cm Wheelbase 77 in 196 cm Ground Clearance 10 in 25 4 cm Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73 6mm Alternator Output 650 W 7000 RPM Compression Ratio 10 1 Starting System Electric Fuel System Electro
108. ssion in PARK 3 View the brake fluid level in the reservoir The level should be between the maxi mum and minimum level lines 4 If the fluid level is lower than the lower level line add brake fluid to the upper line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings 94 Brakes Brake Inspection 1 2 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corro sion warping or other dam age Clean any grease using an approved brake cleaner or alcohol MAINTENANCE NOTICE Do not apply WD 40 or any petroleum product to brake discs Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm 5 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 65 l 2 3 4 Position the vehicle on level ground Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay 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 95 MAINTENANCE Suspension Settings The front and re
109. ssions 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 recirculation systems The following parts are also considered em
110. t 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 121 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage
111. ting charger 107 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use aprofessional 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 108 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 b
112. ts are set at the factory for optimal Emissions Label performance and are not adjustable on inside of frame tube The emissions label 1s located on the inside of the lower left frame tube below driver s foot area Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the lim itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 64 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 128 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
113. uids may result in improper operation of components See page 116 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 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 Spark Plug Spark Plug Gap Torque Electrode Gap New Plug Torque Used Plug Torque 0 7 0 8 mm 7 5 ft Ibs 10 Nm 7 5 ft lbs 10 Nm NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Refer to the specifications section beginning on page 114 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 79 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 78 MAINTENANCE Spark Plug Spark Plug Removal and Replacement 1 Remove the rear access panel in the cargo box Spark Plug Remove the spark plug cap 3 Using the spark plug wrench provided in the tool kit remove the plug by rotating it co
114. uishing 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 over the ankle boots Do not ride a POLARIS vehicle with bare feet Clothing Wear long sleeves and long pants to protect arms and legs SAFETY Safety Warnings A WARNING Failure to operate this vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain Complete the New Operator Driving Procedures outlined on pages 52 53
115. unter clockwise 4 Reverse the procedure for spark plug installation Torque to specification See page 78 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 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 79 MAINTENANCE Fuses If the engine stops or will not start if the power steering stops working if equipped or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Main 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 30A Engine Control 30A Lights Drive Accessories 30A Power Steering if equipped The main fuse box is located under the dash above the brake and throt tle pedals Spare fuses are provided in the fuse box The power fuse box is located und
116. ur 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 43 yet NWA i Trip 1 RPM NA WANA NANA NA IAN VN N N YANN AN 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 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2 Tip 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 POLARIS 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 43 for resetting instructions Service Indicator A fl
117. us 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 t 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 Ibs 41 Nm Aluminum PLUS 1 4 TURN or Wheels 90 degrees 2 Piece Flange A Front and Rear 27 ft Ibs 37 Nm Nut Steel O Wheels Hub Retaining Nut Front and Rear 80 ft Ibs 108 Nm 97 MAINTENANCE Tires Wheel Removal 1 2 3 4 5 Position the vehicle on a level surface Place the transmission in PARK Stop the engine Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Remove the wheel nuts and washers Remove the wheel Wheel Installation l 2 Place the transmission in PARK Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point
118. wo tanks full of gaso line No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these compo nents Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any oils other than those recommended by POLARIS may cause serious engine damage We recommend the use of POLARIS Premium 4 Synthetic Oil for your 4 cycle engine 46 OPERATION Vehicle Break in Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 28 Always exercise extreme caution whenever handling gasoline 2 Check the oil level See page 73 Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Complete the New Operator Driving Procedures outlined on pages 52 53 4 Avoid aggressive use of the brakes See Brake System Break in on page 47 5 Vary throttle positions Do not operate at sustained idle Pull only light loads 7 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 48 8 During the break in period change both the oil and the filter at 25 hours or one month 9 Check fluid leve

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