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Polaris 2009 Ranger RZR, Owner'S Manual, Page: 6 / 146

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Polaris 2009 Ranger RZR Owner'S Manual Download Page 6

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POLARIS, POLARIS THE WAY OUT, RANGER and RANGER RZR are registered 

trademarks of Polaris Industries Inc.
Copyright 2010 Polaris Sales Inc. All information contained within this publication is 

based on the latest product information at the time of publication. Due to constant 

improvements in the design and quality of production components, some minor discrep-

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

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

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

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

expressly prohibited. 
Printed in U.S.A.
2010 

RANGER 

RZR/RZR EPS Owner’s Manual

P/N 9922955

Summary of Contents for 2009 Ranger RZR

Page 1: ...Pantone 426C Owner s Manual for Maintenance and Safety RANGER RZR RANGER RZR EPS TM TM ...

Page 2: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...affect handling and control 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 sudden braking watch for branches or other hazards that could enter vehicle make sure passenger reads and understands all safety labels ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE...

Page 5: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 6: ...esign 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 p...

Page 7: ...tion 4 Safety 7 Features and Controls 26 Operation 48 Emission Control Systems 66 Maintenance 67 Specifications 120 Polaris Products 122 Troubleshooting 123 Declaration of Conformity 127 Warranty 128 Maintenance Log 135 Index 138 ...

Page 8: ...al injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The ...

Page 9: ... or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle Complete the New Operator Driving Procedures outlined on pages 54 55 Never allow a guest to operate this vehicle until the guest has completed the New Operator Drivin...

Page 10: ...number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number ______________________________________________ Engine Serial Number ___________________________________________________ Key Number ________________________________________________________...

Page 11: ... 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 equipment 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 t...

Page 12: ...xceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the...

Page 13: ...ace shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy footwear Do not ride a Polaris vehicle with bare feet Clothing Wear long sleeves and long pants to protect arms and le...

Page 14: ... allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 54 55 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 ...

Page 15: ...ssenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Seat belts reduce the severity of injury in the event of a sudden stop or accident Always make sure the seat b...

Page 16: ...n the cargo box A passenger must always be seated in the passenger seat with seat belt secured Operating on Pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control This vehicle s tires are designed for off road use only not for use on pavement Avoid...

Page 17: ... abrupt steering maneuvers Practice turning at slow speeds before attempting to turn at faster speeds Physical Control of the Vehicle Removing hands from the steering wheel or hand 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 alwa...

Page 18: ... hill with the transmission in neutral Always check the terrain carefully before descending a hill Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Use extreme caution when operating on hills Always fo...

Page 19: ...ntain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an acciden...

Page 20: ...esult in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 62 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 accid...

Page 21: ...rfaces as described in the owner s manual When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Water Operating through deep or fast flowing water can cause loss of traction loss of control overturn or accident Never operate in fast flowing wate...

Page 22: ...and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Operating on Frozen Bodies of Water Operating on frozen bodies of water can result in the vehicle and or riders falling through the ice Never operate this vehicle on a frozen body of water Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident with serious inj...

Page 23: ...any source of flame or sparks Gasoline is extremely flammable Remove flammable material containers from the box before filling Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas Hot Exhaust Systems Exhaust system co...

Page 24: ...ed in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label Cargo Box Warning Tire Pressure Cargo Overload W...

Page 25: ...E PRESSURE IN PSI KPa 4X4 FRONT 8 55 2 REAR 8 55 2 MAXIMUM WEIGHT CAPACITY INCLUDING DRIVER PASSENGER CARGO AND ACCESSORIES 4X4 is 740 LBS 336 4 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on...

Page 26: ...AR YOUR SEAT BELT and make sure passenger wears seat belt ALWAYS SECURE CAB NETS VEHICLE OVERTURN could cause severe injury or death The cab frame is not designed or intended to provide rollover protection 7175100 Shift Caution Cab Frame Seat Belt Warning Age Warning Overturn Warning ...

Page 27: ...VER operate this vehicle if you are under age 16 or without a valid driver s license 7175101 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 m...

Page 28: ...mall to firmly plant feet on the floor and securely grasp hand holds THE PASSENGER MUST ALWAYS wear seat belt use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on the floor tell operator to slow down or stop if uncomfortable get off and walk if conditions require keep hands and feet inside vehicle at all times watch for branches brush and other hazards that...

Page 29: ...eriously 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 sudden 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 O...

Page 30: ...r and passenger at all times Promptly replace worn or dam aged cab nets with new cab nets available from your authorized Polaris dealer The vehicle illustrated below is shown without cab nets only to allow component identification Always use the cab nets and side guards Dash Hip Bar Fuel Tank Cap Seat Belts Cargo Box Seat storage under driver s seat Shifter Passenger Hand Hold Cab Nets Side Guard ...

Page 31: ...27 FEATURES AND CONTROLS Component Locations Headlights Brush Guard Radiator Steering Wheel Storage Compartment under hood Cab Frame ...

Page 32: ...ehicle 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 64 65 Taillights Receiver Hitch Muffler Spark Arrestor ...

Page 33: ...en do not remove the four screws located on the seat bottom Slide the seat forward or rearward to the desired position Tighten the screws to 4 ft lbs 5 4 Nm Do not overtighten Seat Removal 1 Pull up on the seat latch lever located under the rear edge of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure the...

Page 34: ...table position for your passen ger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments 1 Remove the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the mounting bracket hole through both post adjustment holes and through the remain...

Page 35: ...y from the vehicle Storage Compartments Remove the hood to access the front storage compartment Remove the driver s seat to access the under seat storage compartment See page 29 Fuel Cap The fuel tank filler cap is located on the right hand side of the vehi cle near the passenger seat When refueling always use either leaded or unleaded gasoline with a mini mum pump octane number of 87 R M 2 octane...

Page 36: ... cab nets with new cab nets available from your authorized Polaris dealer Upper Cab Net Interference Driver The upper cab net on the driver s side may interfere with vehicle opera tion for some operators due to operator body type driving style or riding apparel Each operator must check for upper cab net interference before operating the vehicle 1 Complete the New Operator Driving Procedures outlin...

Page 37: ... of the vehicle on the driver s side 2 Reinstall the lower net with the screw and all washers Tighten the screw securely 3 Unclip the latches that secure the upper net to the chassis and lower net See the photo on the previous page 4 Loop the free upper latch of the lower cab net through the gap at the front of the side guard and secure the latch adjusting strap length as needed Tighten the strap ...

Page 38: ...t belt properly follow this procedure 1 Pull the seat belt latch down ward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten 4 Press the red release latch on the buckle to r...

Page 39: ...h the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized Polaris dealer 4 To clean dirt or debris from the seat belt...

Page 40: ... or lights The connections are under the dash Electronic Power Steering EPS The EPS warning indicator briefly illuminates when the key is turned to the ON position If the light remains on after starting the engine the EPS system is inoperative See your authorized Polaris dealer for service Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains ...

Page 41: ...osition to operate the headlights All Wheel Drive AWD Switch The AWD Switch has two positions All Wheel Drive AWD Two Wheel Drive 2WD Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive See page 40 for AWD operating instructions OFF The engine is off Electrical circuits are off except accessory 12V ON Electrical circuits are on ...

Page 42: ...transmis sion function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Using Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Operating in rough terrain or ...

Page 43: ...ottle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before start ing the engine Make sure there s adequate throttle pedal freeplay See page 96 for throttle pedal adjustment procedures Throttle Pedal Brake Pedal ...

Page 44: ...WD 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 swi...

Page 45: ...that senses vehicle speed from the transmission The instrument cluster measures distance in miles as well as time hours of operation and engine RPM In addition to showing vehicle speed the speedometer needle flashes when the fuel level is low Rider Information Center Speedometer Speedometer Needle ...

Page 46: ...ostic Mode Indicator 5 Low Battery and 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 elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The s...

Page 47: ...ach trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode switch until the total changes to 0 Tip 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 Tachometer Mode The engine RPM is d...

Page 48: ...ause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Place the transmission in neutral 3 Hold the mode switch and turn the key switch on Release the switch as soon as the display is activated 4 Use the mode switch to toggle through the diagnostic screens Battery Voltage Screen View this screen to check battery voltage level Tachom...

Page 49: ... it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory To enable or disable the service interval 1 Enter the diagnostic mode Toggle to the service interval screen 2 Press and hold the mode switch for about seven 7 seconds until either ON or OFF appears in the Rider Information Center depend ing on your preference To reset the...

Page 50: ...ng the mode has been set Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 47 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in PARK 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the ke...

Page 51: ...ircuit to Ground 51 Injector 1 Short Circuit to Battery 52 Injector 2 Open Load 52 Injector 2 Short Circuit to Ground 52 Injector 2 Short Circuit to Battery 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Battery 56 Pump Relay Open Load 56...

Page 52: ...le 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 components Per form 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 ...

Page 53: ... on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 50 7 Pull only light loads 8 During the break in period change both the oil and the filter at 25 hours or one month Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors PVT Br...

Page 54: ...ls fasteners Inspect ensure fastener tightness 103 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 42 75 Coolant level Ensure proper level 89 90 Coolant hoses Inspect for leaks Throttle Ensure proper operation 95 Indicator lights switches Ensure proper operation 37 Air filter pre filter Inspect clean 93 Headlamp Check operation apply Polaris dielec tric grease...

Page 55: ...eet road or highway including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both hands on the steering wheel dur ing operation 8 Never consume alcohol or drugs before or while operating this vehi cle 9 Always use the size and type of tires specified for your vehicle...

Page 56: ...e 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 sto...

Page 57: ...ou 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 t...

Page 58: ...rotection gog gles or face shield 4 Do not carry a passenger until you have at least two hours of driving experience with this vehicle 5 Do not tow or carry cargo during this period 6 Select an open area that allows room to familiarize yourself with vehicle operation and handling 7 Sit in the driver s seat and fasten the seat belt 8 Always use the cab nets and side guards while riding in this vehi...

Page 59: ...hrottle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed 15 Check for upper cab net interference See page 33 16 Increase speed only after mastering all maneuvers at a slow speed 17 After you become skilled at making turns and begin to operate at faster speeds follow these precautions Avoid sharp turns Never turn while applying he...

Page 60: ...e the passenger secures the seat belt 6 Make sure all cab nets and side guards are properly secured 7 Allow a passenger to ride only in the passenger seat 8 Do not carry more than one passenger Additional passengers can affect the operator s ability to steer and operate the controls 9 Slow down Always travel at a speed appropriate for your skills your passenger s skills and operating conditions Av...

Page 61: ...e be alert for the possibility of skidding and sliding Follow these precautions when encountering slip pery 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 trac tion NOTICE Severe damage to the drive train may occur if the AWD is eng...

Page 62: ...ppery or loose surfaces 5 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 6 Avoid unnecessary changes in speed or direction 7 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 8 If the vehicle stalls while climbing a hill apply the brakes Place the transmission in reve...

Page 63: ...e or cause the vehicle to slide 5 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and care fully until the vehicle can be driven straight downhill Driving Downhill Whenever descending a hill follow these precautions 1 Avoid steep hills 15 maximum 2 Slow down Never travel down a hill at high speed 3 Always check the terrain...

Page 64: ...ay 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 67 Give special attention to engine oil transmission oil demand dri...

Page 65: ...az 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 vehicle before operating over an obstacle that co...

Page 66: ...ese precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns ...

Page 67: ...t 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 ...

Page 68: ...ed 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 extr...

Page 69: ...g 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 tra...

Page 70: ...subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An el...

Page 71: ...ice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high...

Page 72: ...ted service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 73: ...em Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed Coolant if applicable Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly Inspect replace as needed X Q Brake pad wear 10 H M...

Page 74: ...ke ducts flange 50 H 6 M 300 500 Inspect duct for proper seal ing air leaks X General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 6 M 500 800 Inspect lubricate adjust Q Steering 50 H 6 M 500 800 Lubricate X Front Suspension 50 H 6 M 500 800 Lubricate X Rear Suspension 50 H 6 M 500 800 Lubricate Cooling system if applicable 50 H 6 M 500 800 Inspect coola...

Page 75: ...aust muffler pipe 100 H 12 M 1000 1600 Inspect Q Ignition timing 100 H 12 M 1000 1600 Inspect X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 H 12 M 1000 1600 Inspect replace as needed Q Front wheel bearings 100 H 12 M 100...

Page 76: ...nes See page 98 Transmission Oil Main Gearcase Premium AGL Synthetic Gearcase Lube See page 80 Transmission Oil Transfer Case Premium AGL Synthetic Gearcase Lube See page 78 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid See page 82 Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 83 Prop Shaft Polaris Premium U Joint Lube Locate fittings and grease Control Arm Pivot Bushi...

Page 77: ...73 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Control Arm Pivot Bushings ...

Page 78: ...ce and protection See page 122 for the part num bers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambi ent temperatures from 40 to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power out put and lower fuel consumption Although Polaris Pre...

Page 79: ...9 4 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick completely but do not lock it The dipstick must be inserted completely in to keep the angle and depth of the stick consistent 6 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level...

Page 80: ...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 o...

Page 81: ...dition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Remove the dipstick and fill the sump with two quarts 1 9 l of rec ommended oil 13 Place the transmission in PARK Apply the brakes 14 Start the engine Allow it to idle for one to two minutes 15 Stop the engine Inspect for leaks 16 Re check the oil level on the...

Page 82: ...ug and level check plug are located on the left side of the transfer case The fluid level is sufficient when fluid flows out of the check plug hole at step 4 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Remove the level check plug 4 Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole 5 Reinstall the level check plug Torque to spe...

Page 83: ...ug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Remove the level check plug 7 Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole 8 Reinstall the level check plug Torque to specification 9 Reinstall the fill plug Torque to specification 10 Chec...

Page 84: ...ons Chart on page 84 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the left side of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid as needed 5 Reinstall the fill plug Torque to specification Fill Pl...

Page 85: ...ug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Add the recommended fluid to the fill hole Maintain the fluid level at the bottom of the fill plug hole Do not overfill 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly Transfer Case Drain Plug Re...

Page 86: ...a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug If the o ring is damaged install a ...

Page 87: ...surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom right side of the rear gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug 3 Allow the fluid to drain completely 4 Clean the drain plug Reinstall the drain plug wi...

Page 88: ...e Transmission Main Gearcase Premium AGL Synthetic Gearcase Fluid 24 oz 710 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Transmission Transfer Case Premium AGL Synthetic Gearcase Fluid 14 oz 414 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Demand Drive Unit Front Gearcase Demand Drive LT Premium Fluid 6 75 oz 200 ml 8 10 ft lbs 11 13 6 Nm 11 ft lbs 15 Nm Rear Gearcase Premium ATV Angle Drive Fluid...

Page 89: ...ark Plugs Spark Plug Gap Torque NOTICE Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 120 Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately...

Page 90: ...t 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 Spark Plug Removal and Replacement 1 Remove both seats 2 Remove the rear service panel See page 29 3 R...

Page 91: ... as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible a...

Page 92: ...ruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommend...

Page 93: ...Position the vehicle on a level surface 2 Remove the hood See page 31 3 View the coolant level in the overflow bottle 4 If the coolant level is below the safe operating range remove the cap and use a funnel to add coolant through the opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system i...

Page 94: ...caping 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 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 1 Remove the hood See page 31 2 Slowly remove the rad...

Page 95: ...ts Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Alway...

Page 96: ...ove the seats See page 29 2 Loosen the lower screws that secure the clutch cover 3 Allow the water to drain 4 Tighten the screws 5 Place the transmission in PARK Apply the brakes 6 Start the engine 7 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 8 Allow the engine RPM to settle to idle sp...

Page 97: ...r box cover and inspect the gasket It should adhere tightly to the cover around the entire edge 3 Remove the air filter 4 Install a new filter if needed Do not attempt to clean the air filter Apply a small amount of general purpose grease to the seal ing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container Air Box Cov...

Page 98: ...an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Periodically clean the spark arrestor to remove accumulated carbon 1 Remove the retaining screw and remove the arrestor from the end of the muffler 2 Use a non synthetic brush to clean the arrestor screen A syn thetic brush may melt if components are warm If necessary ...

Page 99: ...e pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 67 ...

Page 100: ... at the throttle body 3 Slide the cable adjuster boot off the cable adjuster 4 Using a 10 mm open end wrench loosen the adjustment jam nut 5 Using an 8 mm open end wrench move the cable adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page 95 While adjusting lightly flip the throttle pedal up and down 6 Tighten the jam nut 7 Apply a small amount of grease to th...

Page 101: ...dicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 98 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs WARNING Operating the vehicle with a spongy brake pedal can result in loss of braking which could cause an accident resul...

Page 102: ...he 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 2 Place the transmission in PARK 3 View the brake fluid leve...

Page 103: ...64 1 mm 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 67 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or...

Page 104: ... 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 v...

Page 105: ...servoir under the rear fender When the adjuster screw is turned clockwise until it stops the damping is in the fully closed position 1 Turn the clicker clockwise 1 to increase compression damping 2 Turn the clicker counter clockwise 2 to decrease compression damping Setting Compression Damping Softest 20 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed Clicker 1 2 ...

Page 106: ...justing ring 3 Turn the adjusting ring to the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease preload for a softer ride WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments 4 Tighten the jam ...

Page 107: ... proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less 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 Wheel Type Nut Type Location Nut Torque ...

Page 108: ...e correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your ...

Page 109: ... from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement Do not service the headlamps until they ve cooled sufficiently 1 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp Make sure the tab on the lamp locates properly in th...

Page 110: ... on the wall at the same height 3 Apply the brakes Start the engine Turn on the headlights 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall in step 2 Include the weight of a rider on the seat while per forming this step 5 If adjustment is necessary turn the headlight adjustment screw to adjust the beam 6 Repeat steps ...

Page 111: ... starting the engine If it s impossible to take your vehicle to a dealer before starting it fol low the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the air box and replace the filter with a new filter Thoroughly dry the air pre filter See page 93 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall the...

Page 112: ...s when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is neces...

Page 113: ...attery Removal 1 Remove the driver s seat See page 29 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable last 5 Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solut...

Page 114: ...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 recomme...

Page 115: ...tery Tender charger or by charging about once a month to make up for normal self dis charge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre deter mined point See page 122 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the ...

Page 116: ...he sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop ...

Page 117: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 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 desulfating charger At l...

Page 118: ...g 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 garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lowe...

Page 119: ...tact 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...

Page 120: ...nt Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pro...

Page 121: ... 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 76 Air Filter Air Box Inspect and clean or replace the pre filter and air filter See page 93 Clean the air box Drain the ...

Page 122: ...cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 86 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a pro...

Page 123: ...d be checked by an authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 67 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop th...

Page 124: ... Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Overall Length Width Height 102 50 68 5 in 259 127 174 cm RZR 106 60 5 70 5 in 269 154 179 cm RZR S Wheelbase 77 in 196 cm Ground Clearance 10 in 25 4 cm RZR 12 in 30 5 cm RZR S Engine 4 valve 4 stroke twin cylinder with counterbalance Displacement 760 cc Bore x Stroke 80mm x 76mm Alternat...

Page 125: ... Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Tire Size Front 25x8 12 RZR 26x9 12 RZR S Tire Size Rear 25x10 12 RZR 26x12 12 RZR S Tire Pressure Front 8 psi 55 KPa Tire Pressure Rear 8 psi 55 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 single beam 55W quartz halogen Taillights 2 single beam 5W Brake Lights 2...

Page 126: ...465 Pump for Gallon Jug 2876251 Demand Drive LT Premium Fluid 8 oz 237 ml Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint...

Page 127: ...fully 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 wat...

Page 128: ...ed fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark ...

Page 129: ...t range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Possible Lea...

Page 130: ... Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clea...

Page 131: ...2009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH27__ SPORTSMAN 300 2008 2009 2010 81 1 ___LH46__ SPORTSMAN 400 2008 2009 2010 80 2 ___MN50__ SPORTSMAN 500 EFI 2008 2009 2010 80 4 ___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009 2010 80 8 ___TN55__ ___DN...

Page 132: ...egistration 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 ple...

Page 133: ...y 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 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 effe...

Page 134: ...e The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER A...

Page 135: ...y 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 o...

Page 136: ...o 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 per form 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 coun...

Page 137: ...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 followin...

Page 138: ...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 perform...

Page 139: ...135 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 140: ...136 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 141: ...137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 142: ...ging Coolant 87 Changing Gears 38 Chart Periodic Maintenance 67 71 Chrome Wheel Care 116 Cleaning and Storage 114 119 Cleaning the Air Filter 93 Cleaning the Exhaust System 94 Cleaning the Spark Arrestor 94 Clock Setting 44 Clothing 9 Clutching 121 Component Locations 26 28 Condition Spark Plugs 86 Coolant Level Overflow Bottle 89 Coolant Level Radiator 90 Coolant Adding or Changing 87 Cooling Fan...

Page 143: ... Gearcase 81 Rear Gearcase 83 Transfer Case 79 Transmission 81 Fluid Check Demand Drive 82 Front Gearcase 82 Main Gearcase 80 Transfer Case 78 Transmission 80 F Fluid Levels During Storage 117 Fluid Recommendations Gearcase 84 Fluid Battery 111 Fluid Brake 98 Fogging the Engine 118 Fouled Plugs 86 Freeplay Adjustment Throttle 96 Freeplay Steering Wheel 99 Fuel Cap 31 Fuel Safety 19 Fuel Stabilizer...

Page 144: ...es 54 55 Noise Emission Control System 66 O Obstacles 61 Odometer 43 O Oil Demand Drive 82 Engine 74 77 Front Gearcase 82 Main Gearcase 80 81 Rear Gearcase 83 Transfer Case 78 79 Transmission 80 81 Oil and Filter Care During Storage 117 Oil Change Demand Drive 82 Engine 77 Engine Oil 76 Front Gearcase 82 Main Gearcase 81 Rear Gearcase 83 Transfer Case 79 Transmission 81 Oil Check Demand Drive 82 E...

Page 145: ...icle 18 Operating Through Water 17 Passengers in the Cargo Box 12 Pavement 12 Physical Control 13 Protective Apparel 11 Public Roads 12 S Safety Warnings 10 19 Refueling 19 Reverse 16 Seat Belts 11 Skidding or Sliding 17 Slippery Terrain 16 Stalling on a Hill 15 Turning Improperly 13 Unauthorized Vehicle Use 19 Unfamiliar Terrain 15 Using Alcohol or Drugs 10 Seat Adjustment 29 Seat Belt Cleaning 3...

Page 146: ...95 Throttle Pedal 39 Throttle System 95 Tire Tread Depth 103 Tires 103 104 Torque Axle Nuts 103 Torque Spark Plug 85 Torque Wheel Nut 103 T Towing Loads 65 Towing Speed 65 Trail Etiquette 53 Trailer Hitch 28 Transfer Case Oil 78 79 Transmission Oil 80 81 Transmission Operation 91 92 Transmission Drying 92 Transporting the Vehicle 119 Tread Depth Tire 103 Tread Lightly 53 Trip Meter 43 V Vehicle Id...

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