Polaris 2014 RZR 800 Owner'S Manual Download Page 124 | Manualshive

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122

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 124 before installing
the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. On conventional batteries, install the battery vent tube (sealed bat-

teries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.

WARNING!

Battery gases could accumulate in an improperly installed vent tube

and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.

4. Coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed.

8. Reinstall the driver’s seat.

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Summary of Contents for 2014 RZR 800

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RZR 800 RZR S 800 RZR 4 800...

Page 2: ...ns 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 th...

Page 3: ...ne into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructi...

Page 4: ...the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or...

Page 5: ...ntroduction 4 Safety 7 Features and Controls 25 Operation 46 Winch Guide 65 Emission Control Systems 76 Maintenance 77 Specifications 132 POLARIS Products 136 Troubleshooting 137 Warranty 141 Maintena...

Page 6: ...ntial 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 av...

Page 7: ...ing or on a passenger hand hold Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a helmet eye p...

Page 8: ...keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number _________________________________...

Page 9: ...our POLARIS vehicle is considered an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow...

Page 10: ...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 t...

Page 11: ...and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated...

Page 12: ...IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying ta...

Page 13: ...nuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sideh...

Page 14: ...e access collisions with cars and trucks can occur Do not exceed seating capacity 2 occupants 7179978 Proper Use Warning RZR 4 WARNING Require Proper Use of Your Vehicle Do your part to prevent injuri...

Page 15: ...assenger Hand Hold Warning RZR 4 Always use seat belt helmet and eye protection Always use this passenger hand hold and side nets to keep hands and feet in vehicle at all times 7176701 Shift Caution C...

Page 16: ...tors 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 O...

Page 17: ...njury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Cab Nets R...

Page 18: ...ur 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...

Page 19: ...e the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops Operating on Pub...

Page 20: ...d Stunts Exhibition driving increases the risk of an accident or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving Improper Hill Climbing Improper hill clim...

Page 21: ...tain 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 r...

Page 22: ...s Skidding or Sliding Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on exc...

Page 23: ...cle 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 forc...

Page 24: ...soline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a we...

Page 25: ...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...

Page 26: ...ify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bod...

Page 27: ...25 FEATURES AND CONTROLS Component Locations Hip Bars Fuel Tank Cap Cargo Box Shifter Front Passenger Hand Hold Cab Nets Rear Passenger Hand Hold Rack Extenders RZR RZR EPS only Tie Down Points...

Page 28: ...ch 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 64 Hea...

Page 29: ...on the release lever located under the front edge of the seat Slide the seat forward or rearward to the desired position Release the lever The seat will lock into the new position For other seat styl...

Page 30: ...t passenger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments 1 Remove the retainer from the end of the adjustment pin 2 Remove the pin from th...

Page 31: ...the coolant overflow bottle 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...

Page 32: ...shown Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Cab nets or doors must be used by bo...

Page 33: ...on Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicat...

Page 34: ...quipped 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...

Page 35: ...dash to place the headlights on high beam Move the rocker switch to the center position to place the headlights on low beam Press the bottom of the rocker switch to turn off the headlights All Wheel D...

Page 36: ...e adjustment is important to assure proper transmis sion function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or...

Page 37: ...sition when the operator releases the throttle pedal engine speed will be limited and power to the rear wheels will be reduced Rollover Protective Structure ROPS The Rollover Protective Structure ROPS...

Page 38: ...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 enable...

Page 39: ...urfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Speedometer The spe...

Page 40: ...to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignit...

Page 41: ...ter may have shut off to protect the electronic speedome ter If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set to display standard units of meas...

Page 42: ...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 lig...

Page 43: ...ode that was displayed prior to setting the units 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 s...

Page 44: ...lay 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 butto...

Page 45: ...he 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 mod...

Page 46: ...hen 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 D...

Page 47: ...ates retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE butt...

Page 48: ...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 com...

Page 49: ...8 During the break in period change both the oil and the filter at 25 hours or one month 9 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hour...

Page 50: ...ls fasteners Inspect ensure fastener tightness 115 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 40 85 Coolant level Ensure proper level 100 99 Coolant hoses In...

Page 51: ...this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating...

Page 52: ...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...

Page 53: ...u 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 a...

Page 54: ...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...

Page 55: ...g 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 17 Increase speed only after mastering all maneuv...

Page 56: ...the steering wheel if driving or on a passenger hand hold 5 The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all...

Page 57: ...tain 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 tr...

Page 58: ...nding 3 Drive straight uphill 4 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 5 Avoid unnecessary changes in speed or direction 6 Never go over the crest of a...

Page 59: ...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 Dow...

Page 60: ...y 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...

Page 61: ...s 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 obstacle...

Page 62: ...se 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 lightl...

Page 63: ...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 d...

Page 64: ...cured 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 canno...

Page 65: ...w 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 dis...

Page 66: ...increases braking distance Do not operate the vehi cle faster than 10 MPH 16 km h when towing 4 Do not tow more than the recommended weight for the vehicle 5 Attach a trailer to the trailer hitch brac...

Page 67: ...r 16 years of age to operate the winch 4 Always wear eye protection and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook wh...

Page 68: ...at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 72 to feed and rewind the cable evenly before continuing the winch opera...

Page 69: ...er Take your winch to your dealer for service if this occurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch co...

Page 70: ...strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to...

Page 71: ...able at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts...

Page 72: ...jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to yo...

Page 73: ...lack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply...

Page 74: ...ross the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D...

Page 75: ...cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at...

Page 76: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object wit...

Page 77: ...tivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models us...

Page 78: ...ow 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...

Page 79: ...for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns mus...

Page 80: ...ead to serious injury or death Have an authorized POLARIS dealer perform these services Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related s...

Page 81: ...ter Daily Inspect clean often replace as needed Coolant if applicable Daily Check level daily change coolant every 2 years Power steering unit if equipped Daily Inspect daily clean often Headlamp tail...

Page 82: ...nes fasteners 50 H 6 M 1000 1600 Inspect for leaks and loose fittings Shift Linkage 50 H 6 M 500 800 Inspect lubricate adjust D Steering 50 H 6 M 500 800 Lubricate Front Suspension 50 H 6 M 500 800 Lu...

Page 83: ...muffler pipe 100 H 12 M 1000 1600 Inspect D Ignition timing 100 H 12 M 1000 1600 Inspect Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected...

Page 84: ...id Maintain level between fill lines See page 108 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 90 Transmission Oil Transfer Case AGL Gearcase Lubricant Transmissio...

Page 85: ...INTENANCE Lubrication Recommendations RZR S RZR 4 Control Arm Pivot Bushings RZR S RZR 4 Control Arm Pivot Bushings RZR 4 Stabilizer Bar Bushings RZR Stabilizer Bar Bushings RZR Control Arm Pivot Bush...

Page 86: ...l 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 mo...

Page 87: ...r service panel See page 27 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...

Page 88: ...n 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...

Page 89: ...ition 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 o...

Page 90: ...g 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...

Page 91: ...g 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 recomm...

Page 92: ...or 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 Posi...

Page 93: ...n under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Add the recommended flu...

Page 94: ...urface 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...

Page 95: ...urface 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...

Page 96: ...speeds Immediately check the spark plug for correct color See page 95 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Gearcase...

Page 97: ...own There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service Tip The tip should not be white A white...

Page 98: ...ent Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Fuse Feature Supported 20A Lights Headlights Taillights 10A Drive AWD 20A Accessory Winch Switch 12V...

Page 99: ...htly toward the right side of the vehicle to disengage it from the mount 3 Remove the fuse box cover 4 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same...

Page 100: ...intain 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 complet...

Page 101: ...effectiveness Using a high pressure system is not recommended Radiator Coolant Level This procedure is required only if the cooling system has been drained for maintenance and or repair But if the ove...

Page 102: ...tion the vehicle on a level surface 2 Remove the hood See page 29 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 funn...

Page 103: ...u have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch a...

Page 104: ...covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc PVT Drying Before washing the vehicle locate the PVT outlet duct under the...

Page 105: ...ver 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 am...

Page 106: ...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 remo...

Page 107: ...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 h...

Page 108: ...ter 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 un...

Page 109: ...icate a possible fluid leak or low brake fluid level which must be corrected before riding See page 108 for brake fluid information If you discover any irregularities in brake system operation includi...

Page 110: ...e 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...

Page 111: ...scs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These...

Page 112: ...e Periodic Maintenance Chart beginning on page 77 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 e...

Page 113: ...vate 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...

Page 114: ...tment Follow these guidelines if you make adjustments to this suspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height...

Page 115: ...djusting 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...

Page 116: ...k reservoir When the knob is turned clockwise until it stops the damping is in the fully closed position 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwi...

Page 117: ...l injury Always maintain proper tire pressure Always use POLARIS approved size and type of tires for this vehicle when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to...

Page 118: ...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 rotation WARNING Improperly installed wheels can adversely affect...

Page 119: ...lighting quality Headlight Replacement LED If an LED headlight becomes damaged or inoperable the entire head light assembly must be replaced Tip This type of headlight may have a short jumper cable b...

Page 120: ...the wall at the same height 3 Apply the brakes Start the engine Turn the headlights to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below t...

Page 121: ...tarting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the...

Page 122: ...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...

Page 123: ...ttery Removal 1 Remove the driver s seat See page 27 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery...

Page 124: ...ave 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 ac...

Page 125: ...ery 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 t...

Page 126: ...e 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 st...

Page 127: ...ndard 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...

Page 128: ...ther vehicle 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...

Page 129: ...act 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 s...

Page 130: ...t 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 periodic...

Page 131: ...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...

Page 132: ...he 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 95 4 Apply dielectric grease to the inside of each spark plug cap Do...

Page 133: ...ginning on page 77 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...

Page 134: ...ant Capacity 4 8 qts 4 5 l Rear Gearcase Oil Capacity 26 oz 769 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Overall Len...

Page 135: ...69 KPa Rear 12 psi 83 KPa RZR S Front 10 psi 69 KPa Rear 10 psi 69 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 60W 55W halogen Taillights 2 single beam 5W Brake...

Page 136: ...ty 5 5 qts 5 2 l Rear Gearcase Oil Capacity 26 oz 769 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Overall Length Width...

Page 137: ...ize Rear 27x12 12 Tire Pressure Front 12 psi 83 KPa Tire Pressure Rear 14 psi 97 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 60W 55W halogen Taillights 2 single...

Page 138: ...5 l 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Grease Specialized...

Page 139: ...use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the trans...

Page 140: ...d 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 deal...

Page 141: ...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 Kinke...

Page 142: ...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 volt...

Page 143: ...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 prepa...

Page 144: ...NY 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 WARRANT...

Page 145: ...he 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 coun...

Page 146: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Page 147: ...ar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a...

Page 148: ...ERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do...

Page 149: ...upplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POL...

Page 150: ...148 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 151: ...149 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 152: ...Frame ROPS 35 Cab Nets 30 Cap Fuel 30 Cargo 62 64 Changing Coolant 98 Changing Gears 34 Chart Periodic Maintenance 77 81 Check Engine Indicator 45 Chrome Wheel Care 128 Cleaning and Storage 126 131 C...

Page 153: ...Case 88 89 Transmission 90 91 Fluid Change Demand Drive 92 Front Gearcase 92 Main Gearcase 91 Rear Gearcase 93 Transfer Case 89 Transmission 91 F Fluid Check Demand Drive 92 Front Gearcase 92 Main Gea...

Page 154: ...Replacement LED 117 Headlight Switch 33 High Beam Adjustment 118 Loads Towing 64 Lubricant Part Numbers 136 Lubrication for Storage 130 Lubrication Recommendations 82 83 M Maintenance Log 148 149 Main...

Page 155: ...lover Protective Structure 35 ROPS Cab Frame 35 RPM Idle Throttle Body 106 S Safe Operation Practices 49 Safety Labels 10 13 Safety Symbols 4 Safety Training 7 Safety Training ROHVA 49 52 Safety Warni...

Page 156: ...heel Nut 115 Towing Loads 64 Towing Speed 64 Trail Etiquette 51 Trailer Hitch 26 Training 7 Transfer Case Oil 88 89 Transmission Oil 90 91 Transmission Operation 101 102 Transmission Drying 102 Transp...

Page 157: ...ar your seat belt Vehicle rollover can cause severe injury or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passe...

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