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Polaris 2015 RZR 900 XC Edition, Owner'S Manual, Page: 108 / 160

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Polaris 2015 RZR 900 XC Edition Owner'S Manual Download Page 108

106

MAINTENANCE

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

If a belt fails, always clean any debris 
from the duct and from the clutch and 
engine compartments when replacing 
the belt.

WARNING!

Failure to remove ALL debris 

when replacing the belt could result in 
vehicle damage, loss of control and 
severe injury or death.

1. Allow hot components to cool 

before performing this 
procedure.

2. Remove the engine access cover 

and thoroughly clean all debris 
from the aluminum debris 
bracket and from the engine 
compartment.

3. Remove the clutch cover screws 

and open the clutch cover. (It 
does not have to be removed 
from the vehicle.) Remove all 
debris wrapped in and around the 
PVT system. 

Tip:

Use the shock/clutch tool from the 
tool kit to slightly open the sheaves 
to aid in debris removal and belt 
installation. 

(Continued on next page)

Debris Bracket

Remove ALL Debris

Insert hooked end of tool.

Apply force to opposite end of 

tool to spread sheaves.

(Non-EBS Clutch Shown)

Summary of Contents for 2015 RZR 900 XC Edition

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RZR 900 RZR 900 EPS TRAIL RZR 900 XC Edition RZR S 900 RZR S 900 EPS RZR 4 900 EPS RZR S 1000 EPS ...

Page 2: ...he 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 For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone ...

Page 3: ...ecommendations in this owner s manual Review the safety DVD that came with your vehicle Polaris also recommends that all drivers take the ROHVA safety e course and a ROHVA hands on safety training course www rohva org Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Mast...

Page 4: ...tion Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instru...

Page 5: ...Introduction 4 Safety 7 Features and Controls 25 Operation 49 Winch Guide 69 Emission Control Systems 80 Maintenance 81 Specifications 132 POLARIS Products 140 Troubleshooting 141 Warranty 145 Maintenance Log 152 Index 154 ...

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 avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that ...

Page 7: ...d 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 seat belt when riding in this vehicle Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judgment and reduce operator r...

Page 8: ... 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 VIN _________________________________________ Engine Serial Number ___________________________________________________ Key Number ________________________________________________________...

Page 9: ...Your 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 the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at...

Page 10: ... a helmet that meets or exceeds 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...

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 by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at l...

Page 12: ...fety labels are provided by POLARIS at no charge The part number is printed on the label Proper Use Warning WARNING Require Proper Use of Your Vehicle Do your part to 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 operation on public roads unless d...

Page 13: ...duce your risk of injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason 7179762 Seat Belt Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use cab nets and or doors Each rider must be able to sit wi...

Page 14: ...sk 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 7182922 RZR RZR XC RZR S RZR 4 MAXIMUM CARGO BOX LOAD 300 lbs 136 kg 300 lbs 136 kg 300 lbs 136 kg 300 lbs 136 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 REAR 12 83 FRONT 10 69 REAR 12 83 FRONT 10 69 REAR 14 97 FRONT 16 110 REAR 20 138 MAXIMUM WEIGHT CAPAC...

Page 15: ... no dirt or debris in the clean side of the intake tube The air filter must be properly seated before the lid is reinstalled Please reference your owner s manual for additional information regarding air filter service 7181111 Intake Duct Caution CAUTION Air intake tube must be fully seated on air box and throttle body Inspect full perimeter if serviced Clamps at air box and throttle body must be t...

Page 16: ...55 56 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 55 56 Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age ...

Page 17: ...event of an accident Operator and all passengers must always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All rider...

Page 18: ... more than three passengers in a 4 seat vehicle Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation and stability For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicl...

Page 19: ...ncrease 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 Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including di...

Page 20: ...nd 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 climbing could cause loss of control or rollover Use extreme caution when operating on hills Always follow proper procedures for hill climbing as described in this owner s manual See page 59 Descending H...

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 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 22: ...kidding 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 excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regai...

Page 23: ...hicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passenger and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over y...

Page 24: ...ine 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 ventilated area free of any source of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to ele...

Page 25: ...t components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 1...

Page 26: ... 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 bodily injury The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The a...

Page 27: ...S AND CONTROLS Component Locations Cab Doors Fuel Tank Cap Cargo Box Passenger Hand Hold ROPS Frame Radiator Steering Wheel Gear Selector Throttle Pedal Brake Pedal Cargo Box Tie Down Points 4 corners RZR 4 Shown ...

Page 28: ...r passenger seats Ignition Switch The ignition switch is a three position key operated switch Use the ignition switch to start the engine See page 53 for starting procedures The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except accessory 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to ...

Page 29: ...WD Switch has either two or three positions depending on your model s features All Wheel Drive AWD Two Wheel Drive 2WD Turf Mode Differential Unlocked 1WD See page 38 for AWD operating instructions Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle The EPS warning i...

Page 30: ...e 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 under the seat retainer bar 5 Press down firmly at the rear of the seat to engage the rear latch Steering Wheel The steering wheel can be tilted upward or downward for rider preference Lift and hold the...

Page 31: ...e the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole adapter bushing hole both post adjustment holes and lastly through the remaining bushing hole and post mounting hole 5 Reinstall the retainer to the pin Adjustment Position Holes Post Mounting Holes Adjustment...

Page 32: ... coolant 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 disengage the lower hood hooks 4 Lift the hood away from the vehicle Hood Fasteners Pressure Cap Overflow Bottle ...

Page 33: ...pped with a receiver hitch bracket for a trailer hitch To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 66 68 Service Access Panels Engine Access Panel The engine access panel is located behind the seats on the frame of the vehicle Remove the seats and remove the access panel to reach serviceable engine components Cargo Box Access Panel The cargo...

Page 34: ... 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 Pull up on the strap to tighten 3 Press the red release latch on the buckle to release the seat belt Seat Belt Height Adjuster if equipped A breakthrough in comfort the seat belt height adjuster reduces neck ru...

Page 35: ...inuing to stretch the seat belt height adjuster slide the adjuster up or down rocking it side to side if necessary until you reach the desired height This may require both hands Do not attempt to adjust while vehicle is in motion NOTE Adjustment becomes easier with repeated use CLEANING INSTRUCTIONS The seat belt height adjuster can be cleaned with water STEP 1 STEP 2 ...

Page 36: ...s 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 belts sponge the straps with mild soap and water Do not use bleach dye or house...

Page 37: ...ear H High Gear To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmission function Your POLARIS dealer can assist in resolving any shifting problems NOTICE Do not attempt to shift the trans...

Page 38: ...Throttle 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 starting the engine Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited Throttle Pedal Brake Pedal ...

Page 39: ...d in any way No device can assure occupant protection in the event of a rollover When used with seat belts and cab nets or doors the ROPS helps prevent occupants from being ejected from the vehicle Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could res...

Page 40: ... is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not dise...

Page 41: ...ow gear and drive forward 5 If the front gearcase remains locked after following these instructions see your dealer for service Locking Unlocking the Differential if equipped NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential Locking the ...

Page 42: ...surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 44 Mode Button Use the MODE button to toggle through mode options See page 44 for operation of the mo...

Page 43: ...ht remains on the EPS system is inoperative Your POLARIS dealer can assist Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating The driver...

Page 44: ...trument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs your POLARIS dealer can provide proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 45 1 2 6 5 4 7 3 8...

Page 45: ...meter and programmable service hour interval 4 Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 5 Clock The clock displays time in a 12 hour or ...

Page 46: ...mode 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 setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining dis...

Page 47: ...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 button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit...

Page 48: ...ets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Engine Temperature Mode This mode displays current temperature of the coolant Battery Voltage Mode This mode displays current system voltage level Tachometer Mode The engine RPM ...

Page 49: ...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 Display Mode The EFI diagnostic display mode is for informational purposes only Your POLARIS dealer can provide for all major repairs The diagnostic mode is accessible only when the check engine warnin...

Page 50: ...s 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 button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and hold the ...

Page 51: ...carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any improper oils may cause serious engine damage POLARIS Premium 4 Synthetic Oil is specifically formulated for your 4 cycle engine Engine and Drivetrain Break in 1 Fi...

Page 52: ...d rotors PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance If a belt fails always clean any debris from the duct and from the engine compartment Standard Break In Drive at slower speeds for the first 50 miles 80 km of operation Carry only light loads Avoid aggressive acceleration high speed operation and prolonged operation...

Page 53: ...e free operation 122 Tires Inspect condition and pressure 12 117 Wheels fasteners Inspect ensure fastener tightness 117 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 43 91 Coolant level Ensure proper level 103 104 Coolant hoses Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure proper operation 26 27 PVT intake Inspect clean ...

Page 54: ...ghway including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both hands on the steering wheel during operation 8 Never consume alcohol or drugs before or while operating this vehicle 9 Always use the size and type of tires specified for your vehicle Always maintain ...

Page 55: ... and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmissi...

Page 56: ...icle in your area Respect the environment in which you ride your vehicle Find out where the designated riding areas are by contacting 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 f...

Page 57: ... Do not carry 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 vehicle operation and handling 7 The driver and passenger must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times 8 Always make sure...

Page 58: ...ng 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 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 heavy throttle Never make ab...

Page 59: ...on the floor and both hands on the steering wheel if driving or on a passenger hand hold 6 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 7 Always make sure all cab doors are closed and latched when riding in this vehicle 8 Allow a passenger to ride only in a passenger seat 9 Slow down Alw...

Page 60: ...ntain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 4 Correct a skid by turning the steering wheel in the direction of the s...

Page 61: ...before ascending 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 hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 7 If the vehicle stalls while climbing a hill apply the brakes Place the tra...

Page 62: ... Engage all wheel drive 2 Drive slowly and use extreme caution 3 If the vehicle begins to roll over or if it feels as if it may roll over immediately turn downhill 4 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 5 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuve...

Page 63: ...ain carefully before descending a hill Never drive on hills with excessively slippery or loose surfaces 4 Always descend a hill with the transmission in forward gear Never descend a hill with the transmission in neutral 5 Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill 6 Apply the brakes lightly to aid in slowing ...

Page 64: ...ter leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Avoid applying brake and throttle at the same time 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 81 Give special attention to engine oil transmissio...

Page 65: ...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 large 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...

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: ...n an incline If parking on an incline is unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 4 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 5 Block the rear wheels on the downhill side ...

Page 68: ...esult in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid te...

Page 69: ...ator passengers non factory installed accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle See page 132 Belt Life To extend belt life use low gear in the following conditions when hauling or towing heavy cargo when consistently operating at speeds less than 35 MPH 56 km h in hard pulling terrain such as mud rocks or sand dune environments Towing a RZR To...

Page 70: ...Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 66 Towing a trailer increases braking distance 4 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 132 5 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of th...

Page 71: ...er 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 when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 78 7 Always keep the area around the vehicle winch winch cable and ...

Page 72: ... 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 76 to feed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s...

Page 73: ...er Your dealer can provide service on your winch 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 components 24 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons 25 Never grease or oil the winch cable This wil...

Page 74: ...g 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 help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 75: ...cable 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 available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load ...

Page 76: ... 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 you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid po...

Page 77: ...slack 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 vehicle throttle and winch together to free the vehicle I Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the...

Page 78: ...cross 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 Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook strap E Slowly winch the cable in while your assistant moves the end of the winch cable back and fort...

Page 79: ... 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 right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in...

Page 80: ...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 with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and poss...

Page 81: ...ctivation 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 use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be ...

Page 82: ...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 electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustab...

Page 83: ...an lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent parts may be used for emissions related service Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can perform these ope...

Page 84: ... Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Checklist on page 51 Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level Daily Air filter pre filter Daily Inspect clean often replace as needed Air box sediment tube Daily ...

Page 85: ...needed Throttle body air intake ducts flange 50 H 6 M 500 800 Inspect duct for proper sealing air leaks Shift Linkage 50 H 6 M 500 800 Inspect adjust Ź Front Suspension 50 H 6 M 500 800 Lubricate and inspect bushings Ź Rear Suspension 50 H 6 M 500 800 Lubricate and inspect bushings Cooling system if applicable 50 H 6 M 1000 1600 Inspect coolant strength seasonally pressure test system yearly Ź Oil...

Page 86: ...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 Ź Shock Seals 100 H Inspect shock seals Ź D Shocks 12 M 1500 2400 See your dealer for oil change seal inspection D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24 M 2000 3200 Change every two years Suspension b...

Page 87: ...d level Pre Ride Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level Daily Air filter pre filter Daily Inspect clean often replace as needed Air box sediment tube Daily Drain deposits when visible Coolant Daily Check coolant level PVT intake Daily Inspect clean often Ź Power steering unit if equipped Daily Inspect daily clean often Headlight...

Page 88: ...l 50 H 6 M 500 800 Inspect for free movement replace pedal as needed Throttle body air intake ducts flange 50 H 6 M 500 800 Inspect duct for proper sealing air leaks Shift Linkage 50 H 6 M 500 800 Inspect adjust Ź Front Suspension 50 H 6 M 500 800 Lubricate and inspect bushings Ź Rear Suspension 50 H 6 M 500 800 Lubricate and inspect bushings Cooling system if applicable 50 H 6 M 1000 1600 Inspect...

Page 89: ...g 100 H 12 M 1000 1600 Inspect for wear routing 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 Ź Shock Seals 100 H Inspect shock seals Ź D Shocks 12 M 1500 2400 See your dealer for oil change seal inspection D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake fluid...

Page 90: ... 50 4 Cycle Oil See page 90 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 112 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 94 Front Gearcase Fluid Demand Drive Demand Drive Fluid See page 96 Prop Shaft U Joint Grease Grease middle and rear fittings Control Arm Bushings All Season Grease or grease conforming to NLGI No 2 Grease fitting...

Page 91: ...89 MAINTENANCE Lubrication Recommendations Front Stabilizer Bar RZR 900 RZR 900 EPS Trail RZR 900 EPS XC Rear Stabilizer Bar All Models ...

Page 92: ... be changed more frequently if POLARIS oil is not used Do not use automotive oil Follow the manufacturer s recommendations for ambient temperature operation See page 140 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Ambient Temperature Range Recommended O...

Page 93: ... panel located behind the seats 1 Position the vehicle on a level surface 2 Place the transmission in PARK NOTE Always check the oil when the engine is cold 3 Remove the seats and remove the engine access panel 4 Remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick completely Remove the dipstick and check the oil level 6 Remove the oil fill cap to add the recommended oil as ...

Page 94: ...cess the drain plug through the access hole under the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK 2 Clean the area around the crankcase drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 3 Place a drain pan under the engine crankcase and remove the drain plug Allow the oil to drain completely 4 Remove the seats and remove ...

Page 95: ...o 12 ft lbs 16 Nm 10 Remove the oil fill cap and add 2 5 quarts 2 4 l of recommended oil Reinstall the fill cap 11 Start the engine and check for leaks 12 Stop the engine and wait 15 seconds before removing the dipstick 13 Remove the dipstick Wipe it dry with a clean cloth 14 Reinstall the dipstick completely Remove the dipstick and check the oil level 15 Add oil as necessary to bring the level to...

Page 96: ... recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the rear of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specific...

Page 97: ...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 Torque to specification 6 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly Demand Drive Drain Plug Transmission Drain Plug ...

Page 98: ...ded lubricants capacities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug To...

Page 99: ...r the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the recommended fluid to the bottom thread of the fill plug hole 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly Demand Drive Drain Plug Transmission Drain Plug ...

Page 100: ...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 99 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Level Check Plug Torque Transmission Main Gearcase AGL Gea...

Page 101: ...insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is b...

Page 102: ... the driver s seat RZR RZR S or under the left rear passenger seat RZR 4 Label Value Function FAN 20A Circuit Breaker Fan EFI 10A Fuse EFI Relay Injectors Coil ECM Chassis Relay Coil Fan Relay Coil Fuel Pump Relay Coil KEY 10A Fuse Gauge EFI Relay Coil EPS Relay Coil Key Switch TERM 10A Fuse Under Hood Terminal Block Interior LED EPS 20A Fuse Power Steering optional LIGHTS 15A Fuse Headlights Tail...

Page 103: ...evel drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50 50 Premix This antifreeze is already premixed and ready to use Do not dilute with water See page 140 for the part numbers of POLARIS products To e...

Page 104: ...truct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference 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 recommende...

Page 105: ...essure cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed 5 Before reinstalling the pressure cap bleed the system of trapped air Remove the engine access panel behind the seats and use a flat blade screwdriver to turn the bleed screw slightly allowing the air to escape Slowly add additional coolant to the radiator until air no longer escapes and only c...

Page 106: ...e has run dry the level in the radiator 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 and use a funnel to add coolant as needed to maintain the level between the two marks 5 Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may b...

Page 107: ...ds 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 others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as recommended in the ...

Page 108: ...ming this procedure 2 Remove the engine access cover and thoroughly clean all debris from the aluminum debris bracket and from the engine compartment 3 Remove the clutch cover screws and open the clutch cover It does not have to be removed from the vehicle Remove all debris wrapped in and around the PVT system Tip Use the shock clutch tool from the tool kit to slightly open the sheaves to aid in d...

Page 109: ...cover etc 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 operating 1 Remove the clutch cover drain plug 2 Allow the water to drain Reinstall the drain plug 3 Place the transmission in PARK Apply the brakes 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry ...

Page 110: ...ll with a clean dry cloth NOTICE Dirt or debris in the intake tube could result in severe engine damage Always clean all dirt and debris from the intake tube before installing the filter 7 Reinstall the air filter if clean or install a new air filter if soiled Do not attempt to clean the air filter NOTICE Use of a non POLARIS approved air filter may cause engine damage Always use a POLARIS approve...

Page 111: ...e gas that can cause loss of consciousness or death in a very short time Periodically clean the spark arrester to remove accumulated carbon A plugged spark arrester will affect engine performance Clean daily when driving in mud and water Replace a cracked or damaged arrester before operating 1 Remove the arrester retaining bolt and nut 2 Remove the arrester from the end of the muffler 3 Use a non ...

Page 112: ...dicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 112 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 resu...

Page 113: ...s 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 types of products are flammable and may also reduce the friction between the brake pad and caliper 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 03 0 ...

Page 114: ... fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown Access the brake fluid reservoir through the left front wheel well 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 View the brake...

Page 115: ...ys heed the following rules if you make adjustments to this suspension Always return the suspension to the lowest setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting to all four wheels Never operate the vehicle on the highest or second highest preload setti...

Page 116: ...e slightly for easier adjustment Follow these guidelines if you make adjustments to this suspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting to all four wheels Do not increase the spring preload by more...

Page 117: ...ng 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 nut firmly against the adjuster...

Page 118: ...ir 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 clockwise to decrease compression damping Setting Compression Damping Softest 20 clicks from closed Factory 12 clicks from closed Firmest 2 clicks from closed Decrease Increase ...

Page 119: ...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 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 st...

Page 120: ... 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 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 Your POLARIS dealer can assist 3 Attach t...

Page 121: ... for a few days to allow the moisture to clear out Taillight Brake Light Replacement The taillight assembly is not serviceable If the taillight or brake light fails to operate properly replace the entire taillight assembly Headlight Replacement If a headlight becomes damaged or inoperable the entire headlight assembly must be replaced Do not operate this vehicle at night or in low light conditions...

Page 122: ...t 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 Observe the headlight aim As a starting point the most intense part of the headlight beam should be 2 inches 5 cm below the mark on the wall Adjust to operator preference 6 Tighten or loosen the three 3 headligh...

Page 123: ...t dry the air box and replace the filter with a new filter 3 Remove the fuse relay center cover See page 100 Allow any moisture to dry then reinstall the cover 4 Dry the spark plug wells with a clean cloth then remove the spark plugs 5 Turn the engine over several times 6 Dry the spark plugs and reinstall them or install new plugs 7 Attempt to start the engine If necessary repeat the drying proced...

Page 124: ...e Periodic Maintenance Chart beginning on page 81 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 if the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer ...

Page 125: ...y terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Battery Removal 1 Remove the driver s seat RZR RZR S or the left rear passenger seat RZR 4 Se...

Page 126: ...sitive 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 period of three months or more recharge the battery about once a month to make up for normal self discharge see page 125 or use a POLARIS Battery Tender which can be left connected during the storage per...

Page 127: ...G An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the battery voltage with ...

Page 128: ...mps 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 least 20 ...

Page 129: ...ect 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 lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent ...

Page 130: ...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 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...

Page 131: ... recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 92 Air Filter Air Box Replace the air filter See page 108 Clean the air box...

Page 132: ...plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 99 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 ...

Page 133: ...osed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 3 Remove the key to prevent loss during transporting 4 Secure the hood doors access panels fuel cap and seats Ensure that the seats are attached correctly and a...

Page 134: ... Fluid Capacity 7 5 oz 222 ml Transmission Oil Capacity 44 oz 1300 ml Turf Models 40 5 oz 1200 ml Overall Length Width Height RZR 900 107 50 69 5 in 271 8 127 176 5 cm EPS TRAIL 107 50 69 5 in 271 8 127 176 5 cm XC 108 59 70 5 in 274 3 149 9 179 cm Wheelbase 79 in 200 cm Ground Clearance RZR 900 10 in 25 4 cm EPS TRAIL 10 in 25 4 cm EPS XC 11 in 28 cm Engine 4 Stroke DOHC Twin Cylinder Displacemen...

Page 135: ...nder 27x9 14 10 psi 69 kPa Tires Tire Pressure Rear RZR 900 EPS TRAIL PXT 26x9 12 12 psi 83 kPa EPS XC Dirt Commander 27x11 14 12 psi 83 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 Dual Beam Halogen or LED Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V Output Gear Ratios Rear High Gear 10 73 Low Gear 18 77 ...

Page 136: ...l Coolant Capacity 5 qts 4 7 l Demand Drive Fluid Capacity 7 5 oz 222 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 108 60 72 in 274 3 152 4 182 9 cm Wheelbase 79 in 200 cm Ground Clearance 12 5 in 31 75 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93 mm x 64 4 mm Alternator Output 560 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric ...

Page 137: ...mander 27x9 12 10 psi 69 kPa Tires Tire Pressure Rear Dirt Commander 27x11 12 14 psi 97 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 Dual Beam Halogen or LED Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V Output Gear Ratios Rear High Gear 10 73 Low Gear 18 77 Reverse 20 41 Front including front drive Non EPS...

Page 138: ...lant Capacity 5 7 qts 5 4 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 138 60 72 in 350 5 152 4 182 9 cm Wheelbase 106 5 in 271 cm Ground Clearance 12 5 in 31 75 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93 mm x 64 4 mm Alternator Output 560 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric ...

Page 139: ...Front Dirt Commander 27x9 12 16 psi 110 kPa Tires Tire Pressure Rear Dirt Commander 27x11 12 20 psi 138 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 Dual Beam Halogen Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 2 12V Output Gear Ratios Rear High Gear 12 05 Low Gear 18 79 Reverse 22 92 Front including front dr...

Page 140: ...mand Drive Fluid Capacity 7 5 oz 222 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 108 60 72 in 274 3 152 4 182 9 cm Wheelbase 79 in 200 cm Ground Clearance 12 5 in 31 75 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 999 cc Bore x Stroke 93mm x 73 5mm Alternator Output 560 W 3000 RPM Compression Ratio 11 0 1 Starting System Electric Fuel System Electronic fuel injecti...

Page 141: ...r 27x9 12 10 psi 69 kPa Tires Tire Pressure Rear Dirt Commander 27x11 12 14 psi 97 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 Dual Beam Halogen or LED Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V Output Gear Ratios Rear High Gear 10 73 Low Gear 18 77 Reverse 20 41 Front including front drive Non EPS EPS ...

Page 142: ...luid gal 3 8 l 2877922 Demand Drive Fluid qt 95 l 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle Driv...

Page 143: ...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 rollover Belt slippage from water or snow ingestion into the PVT system Dry out the PVT see page 107 Prevent water from entering the PVT outlet duct see page 127 Inspect...

Page 144: ...d replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Your POLARIS dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Loose ignition connections Check all connections and tighten Mechanical failure Your POLARIS dealer can assist Possible Cause Solution Out of fuel Refuel Weak spark from spark plug Inspect clean and or re...

Page 145: ...et 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 or filter Inspect and replace Kinked idle air control lines Inspect rotate lines to remove kink Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and rep...

Page 146: ...ark plug wires Your POLARIS dealer can assist 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 replace Other mechanical failure Your POLARIS dealer can assist Overheated engine Clea...

Page 147: ...ginal registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage And...

Page 148: ...ES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE ...

Page 149: ...es vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue...

Page 150: ...chased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void bec...

Page 151: ...dar 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 whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related p...

Page 152: ...ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY 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 not allow limitations on how long an implied warranty lasts so the above limitation may not apply i...

Page 153: ...pplied 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 POLARIS Off Road Vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified ...

Page 154: ...152 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 155: ...153 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 156: ... 37 Cap Fuel 31 Cargo 66 67 Cargo Box Access Panel 31 Changing Gears 35 Chart Periodic Maintenance 81 87 Check Engine Indicator 48 Cleaning and Storage 127 131 Cleaning the Air Filter 108 Cleaning the Exhaust System 109 Cleaning the Spark Arrestor 109 Clothing 9 Clutching 133 135 137 139 Component Locations 25 Condition Spark Plugs 99 Coolant Level Overflow Bottle 104 Coolant Level Radiator 103 Co...

Page 157: ...ain Gearcase 94 Transmission 94 Fluid Levels During Storage 129 Fluid Recommendations Gearcase 98 Fluid Brake 112 Fogging the Engine 130 Fouled Plugs 99 Freeplay Steering Wheel 122 F Fuel Cap 31 Fuel Safety 22 Fuel Stabilizer 129 Fuel Tank Filler Cap 31 Fuse Relay Center 100 G Gap Spark Plug 98 Gasoline Handling 22 Gear Selector 35 Gearcase Capacities 98 Gearcase Oil Demand Drive 96 97 Front 96 97...

Page 158: ...tion on Public Lands 80 Operation Cooling System 101 102 O Operation Transmission 105 107 Operator Restrictions 14 Outlets Auxiliary 26 Overflow Bottle Coolant Level 104 P Parking on an Incline 65 Parking the Vehicle 54 Passenger Hand Hold Adjustment 29 Periodic Maintenance Chart 81 87 Plug Condition 99 Plug Gap 98 Plug Torque 98 Plugs Fouled 99 Plugs Spark 98 99 Polaris Products 140 Polishing the...

Page 159: ...0 Storage Battery 124 Storage Covers 130 Storage Fluid Levels 129 Storage Oil and Filter 129 Storage Removal 131 Suspension Settings RZR 900 113 Suspension Settings S XC 4 114 116 Switches AWD Switch 27 38 Headlight Switch 27 Ignition 26 Mode Button 40 T Tachometer 46 Taillight 119 Throttle Pedal 36 Tire Tread Depth 117 Tires 117 118 Torque Axle Nuts 117 Torque Spark Plug 98 Torque Wheel Nut 117 T...

Page 160: ... Wear 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 passengers read and understand all safety labels Operate slowly in reverse avoid sharp turns or sudden braking On paved surfaces pavement may seriously affect handling and control With non Polaris appro...

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