Polaris 2014 RZR 9002014 RZR 4 900 Owner'S Manual Download

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SPECIFICATIONS

Clutching

RZR 900

Lubrication System

Wet Sump

Driving System Type

Automatic POLARIS Variable Transmission

Shift Type

Dual Range P/R/N/L/H

Gear Reduction - Low

6.45:1

Gear Reduction - Reverse

5.776:1

Gear Reduction - High

3.037:1

Drive Ratio - Front

3.82:1

Drive Ratio - Final

3.53:1

Tire Size - Front

27x9-12

Tire Size - 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, 6-LED cluster, 40w High / 27w Low

Taillights

2 single beam, 6w

Brake Lights

2 single beam, 27w

Instrument Cluster

LCD

Auxiliary DC Outlet

12V

Altitude

Shift

Weight

Drive

Spring

Driven
Spring

Meters

(Feet)

0-1500

(0-5000)

26-59

PN 1322981

Blue/Yellow

PN 7043766

Red

PN 3234452

1500-3700

(5000-12000)

26-55

PN 1322982

Blue/Yellow

PN 7043766

Red

PN 3234452

Summary of Contents for 2014 RZR 9002014 RZR 4 900

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RZR 900 RZR 4 900...

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: ...one 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 instruct...

Page 4: ...ween 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 omissio...

Page 5: ...ntroduction 4 Safety 7 Features and Controls 25 Operation 46 Winch Guide 65 Emission Control Systems 76 Maintenance 77 Specifications 128 POLARIS Products 132 Troubleshooting 133 Warranty 137 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: ...umber and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identifica...

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: ...prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow...

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: ...t all times 7176701 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle When vehicle is stopped place shift in the parked position APPLY BRAKE TO START...

Page 15: ...cured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load e...

Page 16: ...2 53 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has compl...

Page 17: ...risk of serious injury 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...

Page 18: ...afely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is lis...

Page 19: ...nt 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 Public Roads Operating this vehicle on publ...

Page 20: ...turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Practice turning at slow speeds before attempting to turn at faster speeds Improper Hill Climbing Improper hill clim...

Page 21: ...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...

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: ...ne 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 well v...

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: ...ent Locations Hip Bars Fuel Tank Cap Cargo Box Front Passenger Hand Hold Cab Nets ROPS Frame Radiator Steering Wheel Gear Selector Throttle Pedal Brake Pedal Fuel Tank Cap Shifter Rear Passenger Hand...

Page 28: ...nder the rear pas senger seats Ignition Switch The ignition switch is a three position key operated switch Use the ignition switch to start the engine See page 50 for starting procedures The key can b...

Page 29: ...of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive See page 36 for AWD operating instructions Electronic Power Steering EPS Electronic power st...

Page 30: ...of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure the seat tabs at the front edge of the seat slide unde...

Page 31: ...Remove the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole adap...

Page 32: ...oolant overflow bottle 1 Turn the hood fasteners 1 4 turn 2 Grasp the upper hood edge and pull upward to disengage the fasteners 3 Pivot the hood forward and lift upward to dis engage the lower hood h...

Page 33: ...d behind the seats on the frame of the vehicle Remove the seats and remove the access panel to reach serviceable engine components Cargo Box Access Panel The cargo box access panel is located on the f...

Page 34: ...e from those 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 b...

Page 35: ...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 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: ...engine speed will be limited and power to the rear wheels will be reduced Rollover Protective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performa...

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: ...only light loads 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...

Page 50: ...3 Wheels fasteners Inspect ensure fastener tightness 113 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 40 85 Coolant level Ensure proper level 97 98 Coolant hos...

Page 51: ...y 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 han...

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: ...rry a passenger until you have at least two hours of driving experience with this vehicle 5 Do not carry cargo during this period 6 Select an open area that allows room to familiarize yourself with ve...

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: ...iving 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 times See page 8 6 Make...

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: ...hicle can result in serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precau tions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine o...

Page 64: ...rive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STAB...

Page 65: ...ugh or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels...

Page 66: ...increases braking distance Do not operate the vehicle 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: ...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 desig...

Page 79: ...liar with safe service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently Seve...

Page 80: ...d service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the...

Page 81: ...Pre Ride Engine oil level Pre Ride E Engine intake pre filter Daily Inspect clean often PVT intake pre filter Daily Inspect clean often Coolant Daily Check coolant level Power steering unit if equippe...

Page 82: ...M 1000 1600 Perform a break in oil change at one month Oil filter change 50 H 6 M 1000 1600 Replace with oil change Oil lines fasteners 50 H 6 M 1000 1600 Inspect for leaks and loose fittings Shift Li...

Page 83: ...uting security apply dielectric grease to connectors subjected to water mud etc D Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 H 12 M 1000 1600 Inspec...

Page 84: ...en fill lines See page 108 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 88 Front Gearcase Fluid Demand Drive Demand Drive Fluid See page 90 Prop Shaft U Joint Grea...

Page 85: ...83 MAINTENANCE Lubrication Recommendations Grease Stabilizer Bar Bushings one on each side of vehicle Front Control Arm Pivot Bushings 3 per side View of Driver s Side From Bottom of Vehicle...

Page 86: ...be changed more frequently if POLARIS oil is not used Do not use automotive oil Follow the manufacturer s recommen dations for ambient temperature operation See page 132 for the part numbers of POLARI...

Page 87: ...through the service access panel on the floor of the cargo box 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine and allow it to idle for 30 seconds 4 Stop...

Page 88: ...se drain plug is located on the bottom of the crankcase Access the drain plug through the access hole under the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK 2 Cle...

Page 89: ...lbs 16 Nm 9 Remove the oil fill cap and add 2 5 quarts 2 4 l of recommended oil Reinstall the fill cap 10 Start the engine and allow it to idle for 30 seconds 11 Stop the engine and wait 15 seconds be...

Page 90: ...recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the rear of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position th...

Page 91: ...ug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specifica tion 6 A...

Page 92: ...ed lubricants capacities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fi...

Page 93: ...plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug If the o ring is damaged install a new o ring 5 Reinstall the drain plug Torque to specification 6 Add the reco...

Page 94: ...lug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 93 CAUTION A hot exhaust sy...

Page 95: ...sulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service Tip T...

Page 96: ...er the dash above the brake and throt tle pedals Spare fuses are provided in the fuse box The power fuse box is located under the driver s seat Remove the engine access panel to access the fuse box Ma...

Page 97: ...rom the mount 3 Remove the fuse box cover 4 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rat ing 5 Reinstall the fuse box cover Reinstall...

Page 98: ...d water added See page 97 for changing procedure POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled...

Page 99: ...pressure cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed 5 Before reinstalling the pres sure cap bleed the system of trapped air Remove the engine acc...

Page 100: ...run dry the level in the radi ator should also be inspected 1 Position the vehicle on a level surface 2 Remove the hood See page 30 3 View the coolant level in the overflow bottle 4 Remove the cap an...

Page 101: ...s on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of ot...

Page 102: ...ore performing this procedure 2 Remove the engine access cover and thoroughly clean all debris from the aluminum debris basket and from the engine compartment 3 Remove the clutch cover screws and open...

Page 103: ...c PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Remove the clutch cover drain plug 2 All...

Page 104: ...ove the filter and install the new filter Make sure the direction of the arrow is the same as noted before fil ter removal 3 Reinstall the access panel and seats Intake Pre Filters The engine intake p...

Page 105: ...the cover rearward far enough to remove the air filter 5 Inspect the air box for oil or water deposits and any dust or debris that may have fallen off the soiled filter Wipe away any deposits with a...

Page 106: ...en run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves...

Page 107: ...from the end of the muffler 3 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 4 In...

Page 108: ...starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or misad justment it will cause a delay in throttle response espe...

Page 109: ...icle with a spongy brake pedal can result in loss of braking which could cause an accident resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal Brake Inspect...

Page 110: ...fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes con taminated the fluid level is below the minimum or if the type and brand...

Page 111: ...ion may be adjusted to maintain vehicle clearance height when carrying loads Factory Preload Settings RZR 900 Premium Front 7 625 193 7 mm RZR 900 Premium Rear 3 625 92 1 mm RZR 4 900 Front 6 560 166...

Page 112: ...m over the factory setting 1 Use the shock clutch tool from the tool kit to aid in making suspension adjustments 2 Elevate the vehicle to allow the suspension to fully extend 3 Loosen the jam nut and...

Page 113: ...t increase the spring preload by more than one inch 25 4 mm over the factory setting 1 Use the shock clutch tool from the tool kit to aid in making suspension adjustments 2 Elevate the vehicle to allo...

Page 114: ...kwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damp ing FOX Shocks Walker Evans Shocks Setting Compression Damping Setting Compression Damping Softe...

Page 115: ...ult in vehicle damage or personal 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 t...

Page 116: ...b 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 wh...

Page 117: ...t properly working headlights Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Apply the b...

Page 118: ...the headlight and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn the headlights to high beam 5 Include the weight of a rider on the seat while performing this step...

Page 119: ...heck the air box See page 103 If water is present dry the air box and replace the filter with a new filter 3 Dry the spark plug wells with a clean cloth then remove the spark plugs 4 Turn the engine o...

Page 120: ...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 ex...

Page 121: ...ays keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water...

Page 122: ...itive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 8 Reinstall the driver s seat Battery Storage Whenever the vehicle is not used for a peri...

Page 123: ...An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming cha...

Page 124: ...ps 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 hou...

Page 125: ...in 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...

Page 126: ...amaged contact your POLARIS dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine o...

Page 127: ...moves water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse...

Page 128: ...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 93 4 Apply dielectric grease to the inside of each spark plug cap Do...

Page 129: ...r death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Remove the key to prev...

Page 130: ...l Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 108 4 64 73 in 275 162 5 185 4 cm Wheelbase 81 4 in 206 8 cm Ground Clearance 13 in 33...

Page 131: ...2 Tire Size 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 6 LED cluster 40w High 27w L...

Page 132: ...Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 134 4 64 77 in 341 4 162 5 195 6 cm Wheelbase 107 4 in 272 8 cm Ground Clearance 12 5 in...

Page 133: ...7x9 12 Tire Size Rear 27x12 12 Tire Pressure Front 20 psi 138 KPa Tire Pressure Rear 20 psi 138 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 6 LED cluster 40w Hig...

Page 134: ...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 135: ...le rollover 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 thro...

Page 136: ...nspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your dealer Low battery voltage Recharge the battery to 1...

Page 137: ...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 p...

Page 138: ...ive 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 t...

Page 139: ...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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...144 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 147: ...145 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 148: ...32 Cargo 62 64 Cargo Box Access Panel 31 Changing Gears 34 Chart Periodic Maintenance 77 81 Check Engine Indicator 45 Cleaning and Storage 123 127 Cleaning the Air Filter 103 Cleaning the Exhaust Sys...

Page 149: ...ing Air 103 Filter Systems 102 103 Fluid Demand Drive 90 91 Front Gearcase 90 91 Main Gearcase 88 89 Transmission 88 89 Fluid Change Demand Drive 91 Front Gearcase 91 Main Gearcase 89 Transmission 89...

Page 150: ...ads Towing 64 Low Beam Adjustment 116 Lubricant Part Numbers 132 Lubrication for Storage 126 Lubrication Recommendations 82 83 M Maintenance Periodic 77 81 Metric Display 41 Mode Button 37 N Nets Cab...

Page 151: ...51 Riding Gear 8 9 Rollover 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 RO...

Page 152: ...ransmission Oil 88 89 Transmission Operation 99 101 Transmission Drying 101 Transporting the Vehicle 127 Tread Depth Tire 113 Tread Lightly 51 V Vehicle Identification Numbers 6 Vehicle Immersion 117...

Page 153: ...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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