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Polaris 2015 RZR XP 1000 EPS, Owner'S Manual

The Polaris 2015 RZR XP 1000 EPS is a high-performance off-road vehicle built for adventure seekers. Enhance your riding experience by downloading the Owner's Manual for free from our website. This comprehensive manual provides essential information, maintenance tips, and safety guidelines to ensure an exciting and worry-free journey through rough terrains.

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147

INDEX

S

Service Access Panels. . . . . . . . . . . .  31
Severe Use Definition . . . . . . . . . . . .  77
Shifting Gears . . . . . . . . . . . . . . . . . .  34
Shock Compression  . . . . . . . . . . . .  112
Shock Loading the Winch. . . . . . . . .  74
Signal Words. . . . . . . . . . . . . . . . . . . .  4
Spark Arrester Warning  . . . . .   104-105
Spark Arrestor Cleaning . . . . . . . . .  105
Spark Plug Condition . . . . . . . . . . . .  93
Spark Plug Gap . . . . . . . . . . . . . . . . .  92
Spark Plug Removal . . . . . . . . . . . . .  93
Spark Plug Torque  . . . . . . . . . . . . . .  92
Spark Plugs . . . . . . . . . . . . . . . . .   92-93
Spark Plugs, Fouled  . . . . . . . . . . . . .  93
Specifications, Gearcase . . . . . . . . . .  92
Speedometer . . . . . . . . . . . . . . . . . . .  37
Spring Preload. . . . . . . . . . . . .   109-111
Stabilizing the Fuel . . . . . . . . . . . . .  125
Starting the Engine . . . . . . . . . . . . . .  50
Steering Wheel Adjustment  . . . . . . .  28
Steering Wheel Inspection  . . . . . . .  118
Stopping the Engine . . . . . . . . . . . . .  50
Storage  . . . . . . . . . . . . . . . . . .   123-127
Storage and Inspection . . . . . . . . . .  126
Storage and Lubrication . . . . . . . . .  126
Storage Area . . . . . . . . . . . . . . . . . .  126
Storage, Battery  . . . . . . . . . . . . . . .  120
Storage, Covers . . . . . . . . . . . . . . . .  126
Storage, Fluid Levels  . . . . . . . . . . .  125
Storage, Oil and Filter. . . . . . . . . . .  125
Storage, Removal . . . . . . . . . . . . . .  127
Suspension Settings  . . . . . . . .   109-112

Switches

AWD Switch  . . . . . . . . . . . . .  27, 36
Headlight Switch . . . . . . . . . . . . .  27
Ignition . . . . . . . . . . . . . . . . . . . . .  26
Mode Button  . . . . . . . . . . . . . . . .  37
Remote Winch Switch . . . . . . . . .  27
Winch Switch . . . . . . . . . . . . . . . .  27

T

Tachometer . . . . . . . . . . . . . . . . . . . .  43
Taillight. . . . . . . . . . . . . . . . . . . . . .  115
Throttle Pedal . . . . . . . . . . . . . . . . . .  35
Tire Tread Depth. . . . . . . . . . . . . . .  113
Tires  . . . . . . . . . . . . . . . . . . . .   113-114
Torque, Axle Nuts  . . . . . . . . . . . . .  113
Torque, Spark Plug . . . . . . . . . . . . . .  92
Torque, Wheel Nut . . . . . . . . . . . . .  113
Towing Loads . . . . . . . . . . . . . . . . . .  64
Trail Etiquette . . . . . . . . . . . . . . . . . .  51
Training. . . . . . . . . . . . . . . . . . . . . . . .  7
Transmission 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
Vehicle Transport . . . . . . . . . . . . . .  127

W

Warning Symbols . . . . . . . . . . . . . . . .  4
Washing the Vehicle. . . . . . . .   123-124
Water, Immersion of Vehicle . . . . .  117
Wear, Drive Belt . . . . . . . . . . . . . . .  131
Wheel Installation . . . . . . . . . . . . . .  114
Wheel Nut Torque  . . . . . . . . . . . . .  113
Wheel Removal  . . . . . . . . . . . . . . .  114
Winch Cable Care. . . . . . . . . . . . . . .  73
Winch Maintenance/Service Safety .  75
Winch Operation. . . . . . . . . . . . .   68-72
Winch Safety Precautions. . . . . .   65-67
Winch Shock Loading  . . . . . . . . . . .  74
Winch Switch . . . . . . . . . . . . . . . . . .  27
Winch Switch, Remote . . . . . . . . . . .  27

Summary of Contents for 2015 RZR XP 1000 EPS

Page 1: ...Owner s Manual for Maintenance and Safety RZR XP 1000 EPS High Lifter Edition ...

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: ...gone 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 instructions and recommendations 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 t...

Page 4: ...lication 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 in...

Page 5: ...Introduction 4 Safety 7 Features and Controls 25 Operation 46 Winch Guide 65 Emission Control Systems 76 Maintenance 77 Specifications 128 POLARIS Products 130 Troubleshooting 131 Warranty 135 Maintenance Log 142 Index 144 ...

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 judg ment and reduce operator ...

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 ______________________________________________ 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: ...placement Replacement safety 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 ...

Page 13: ...ep 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 with back against seat feet f...

Page 14: ... tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box RZR XP 1000 High Lifter MAXIMUM CARGO BOX LOAD 300 lbs 136 kg TIRE PRESSURE IN PSI KPa FRONT 18 124 REAR 18 124 MAXIMUM WEIGHT CAPACITY INCLUDES...

Page 15: ... owner s manual or see authorized POLARIS dealer 7177469 Air Box Caution CAUTION Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing filter ensure there is 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...

Page 16: ...52 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 completed the New Operator Driving Procedures outlined on pages 52 53 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: ...your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight...

Page 19: ...ent 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 dirt and gravel roads unless designated for off...

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 56 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: ...icle 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 passengers 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: ...dify 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 bodily injury The 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 addition ...

Page 27: ...EATURES AND CONTROLS Component Locations Cab Doors Fuel Tank Cap Cargo Box Passenger Hand Hold ROPS Frame Gear Selector Throttle Pedal Brake Pedal Cargo Box Tie Down Points 4 corners Winch Tow Loop Snorkels ...

Page 28: ...ed switch Use the ignition switch to start the engine See page 50 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 the START position to engage the electric starter The key returns to the ON position...

Page 29: ... Switch Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive See page 36 for AWD operating instructions Winch Switch Press the top of the rocker switch to spool line out from the winch Press the bottom of the rocker switch to spool line in to the winch Move the rocker switch to the center position to stop spooling Remote Winch Sw...

Page 30: ... screws to 4 ft lbs 5 4 Nm Do not overtighten Seat Removal 1 Pull up on the seat latch lever located under the rear edge of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure the 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 t...

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: ...use fuel with ethanol content greater than 10 percent such as E 85 fuel 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 box access panel is located on the floor of the cargo box Remove the panel to access the ...

Page 34: ...equipped with seat belts for all riders Always make sure the seat belts are secured for the operator and all passengers before riding The driver s seat belt is equipped with a seat belt interlock Vehicle speed will be limited to 15 MPH 24 km h if the seat belt is not secured 3 Point Seat Belt To wear the 3 point seat belt properly follow this procedure 1 Pull the seat belt latch downward and acros...

Page 35: ...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 36: ...ays shift into low gear for any of the following conditions Operating in rough terrain or over obstacles Operating in mud or other high load conditions Towing heavy loads Loading the vehicle onto a trailer 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 w...

Page 37: ...r Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way 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 fo...

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 enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AW...

Page 39: ...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 41 Mode Button Use the MODE button to toggle through mode options See page 41 for operation of the mo...

Page 40: ...ht 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 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 oper...

Page 41: ...instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 42 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N ...

Page 42: ...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 24 hour format See page 42 for resetting inst...

Page 43: ...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 44: ...play 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 exi...

Page 45: ...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 46: ...When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warnin...

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 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 t...

Page 48: ...ly NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any oils other than those recommended by POLARIS may cause serious engine damage We recommend the use of POLARIS PS 4 oils for your 4 cycle engine Engine and Drivetrain Break ...

Page 49: ...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 a...

Page 50: ...re free operation 118 Tires Inspect condition and pressure 12 113 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 hoses Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure proper operation 26 27 Headlights Check operation...

Page 51: ...l 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 proper tire pressure 10 Never ...

Page 52: ...e OFF position and wait five seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely ...

Page 53: ...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 for the terrain avoid littering and always stay on t...

Page 54: ...o 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 all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times 8 Always make s...

Page 55: ...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 56: ... 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 Always make sure all cab doors are closed and latched when riding in this vehicle 7 Allow a passenger to ride only in a passenger seat 8 Slow down Always travel at a speed appropriate for your skills your passengers skills and o...

Page 57: ...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 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 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 transmission i...

Page 59: ... 5 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill Driving Downhill Whenever descending a hill follow these precautions 1 Avoid excessively steep hills 2 Slow down Never travel down a hill at high speed 3 Always check the terrain carefully before descending a ...

Page 60: ...bility After 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 77 Give special attention to engine oil tr...

Page 61: ...ds 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 all passengers dismount and move away from the vehicle before operating over an obstacle tha...

Page 62: ...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 63: ...ehicle can result in serious injury Avoid parking on 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 Block the rear wheels on the downhill side ...

Page 64: ...n and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS ...

Page 65: ...as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the maximum capacities specified for your vehicle See page 128 Belt Life To extend belt life use low gear when hauling or towi...

Page 66: ...stability The tow loop on the rear of the vehicle is provided for recovery use ONLY Tow a vehicle ONLY of equal or lesser size and weight When towing a disabled RZR vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing WARNING Tow Loop ...

Page 67: ...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 74 7 Always keep the area around the vehicle winch winch cable and ...

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 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 69: ...ter 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 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 will ...

Page 70: ...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 71: ...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 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 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 73: ...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 74: ...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 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 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 76: ...ging 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 pos...

Page 77: ...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 78: ...losed 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 adjustable The e...

Page 79: ...miliar 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 Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Frequent short trip operation in cold weather engin...

Page 80: ...ted service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services ...

Page 81: ... unit if equipped Daily Inspect daily clean often Headlight taillight Daily Check operation Suspension bushings Daily Lubricate daily or after each use in mud or water Spark arrester Daily Clean daily when driving in mud and water replace a cracked or damaged arrester before operating Fuel System 25 H Monthly Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion...

Page 82: ...nt Suspension 50 H 6 M 500 800 Lubricate Ź Rear Suspension 50 H 6 M 500 800 Lubricate Cooling system if applicable 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system yearly Ź Engine oil change 50 H 6 M 1000 1600 Perform a break in oil change at one month Ź Oil filter change 50 H 6 M 1000 1600 Replace with oil change Ź Oil lines fasteners 50 H 6 M 1000 1600 Inspect for leaks ...

Page 83: ...ectors 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 Inspect replace as needed 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 e...

Page 84: ...id DOT 4 Brake Fluid Maintain level between 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 Grease Grease middle and rear fittings Front Control Arm Pivot Bushings All Season Grease or grease conforming to NLGI No 2 Grease 3 fittings on each side of the v...

Page 85: ...83 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings one on each side of vehicle Front Control Arm Pivot Bushings 3 per side Front Suspension ...

Page 86: ... 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 130 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 87: ...ough the right rear wheel well Access the oil fill cap 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 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely Remove the dipstick and check the oil level 5 Remove the oil fill cap to add the recommended oil as needed Maintain th...

Page 88: ...n 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 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...

Page 89: ...kcase drain plug Torque to 12 ft 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 Remove the dipstick Wipe it dry with a clean cloth 11 Reinstall the dipstick completely Remove the dipstick and check the oil level 12 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on t...

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 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 91: ...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 92: ...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 93: ...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 94: ...plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 93 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 Torque Transmission Main Gearcase AGL Gearcase...

Page 95: ...nsulator 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 adjust ments Wet Fouled Plug The wet fouled insulator tip is b...

Page 96: ... the fuse The fuse relay center is located under the driver s seat 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 LIGHTS 10A Fuse Headlights Taillights Dash Lig...

Page 97: ...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 130 for the part numbers of POLARIS products To e...

Page 98: ...e damage Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Always inspect at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure sy...

Page 99: ...or pressure 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 o...

Page 100: ...ottle 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 main tain 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 ...

Page 101: ...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 102: ...fore performing this procedure 2 Remove the engine access panel and thoroughly clean all debris from the aluminum debris basket 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 t...

Page 103: ...wer speeds to extend the life of the PVT components belt 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 thro...

Page 104: ...on page 77 1 Remove the cargo box access panel 2 Clean all dirt and debris from the air box area 3 Unlatch the six 6 air box cover clips and carefully remove the air box cover 4 Inspect the air filter and air box for dirt debris or water 5 To remove the filter slide the filter toward the passenger s side of the vehicle Air Filter Cover Clips ...

Page 105: ...tall 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 approved replacement filter Please see your POLARIS dealer 8 Make sure that there are no gaps between the filter the filter ring and the stop on the intake tube 9 Reinstall the air box cover and ensure...

Page 106: ...een run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never operate without the spark arrester Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time WA...

Page 107: ...ter before operating 1 Remove the arrester retaining bolt and nut 2 Remove the arrester 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 Inspect the screen for wear and damage Replace a worn or damaged screen 5 Reinstall the arrester Torque bolt to 9 ...

Page 108: ...dicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 108 for brake fluid information If you discover any irregularities in brake system operation 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 109: ...or 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 0 030 0 ...

Page 110: ... 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 111: ...te for nearly all riding conditions If desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads Factory Preload Settings RZR XP High Lifter Front 16 438 inches 41 75 cm Rear 22 062 inches 56 cm Front Shock Preload Measurement Rear Shock Preload Measurement ...

Page 112: ...uspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehi cle stability when operating without a load Always apply the same adjustment setting to all four wheels Do not increase the spring preload by more than one inch 25 4 mm over the factory setting ...

Page 113: ...uspension to fully extend 3 Turn the adjusting ring to the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease preload for a softer ride WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments Front...

Page 114: ...lockwise until it stops the damping is in the fully open position 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping Walker Evans Shocks Setting Compression Damping Softest 16 clicks from closed Factory Front 5 7 clicks from full counter clockwise position Rear 5 7 clicks from full counter clockwise position Firmest 1 c...

Page 115: ...d result 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 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 serv...

Page 116: ... position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS de...

Page 117: ... 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 118: ...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 119: ... dry the air box and replace the filter with a new filter 3 Remove the fuse relay center cover See page 94 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 procedur...

Page 120: ...e Periodic Maintenance Chart beginning on page 77 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or if the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer ...

Page 121: ...ttery 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 See page 28 2 Disconnect the black negative ba...

Page 122: ...ed positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 8 Reinstall the 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 121 or use a POLARIS Battery Tender which can be left connected during the storage period ...

Page 123: ...a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery w...

Page 124: ...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 125: ...emicals 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 water spots Washing T...

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 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 127: ...rbon 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 86 Air Filter Air Box Replace the air filter See page 102 Clean the air box Fluid Levels Inspect ...

Page 128: ... 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 93 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film...

Page 129: ...or death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Remove the key to prevent loss during transporting 3 Secure the fuel cap and seats Ensure that the seats are attached cor rectly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting...

Page 130: ...44 qts 5 1 l Demand Drive Fluid Capacity 8 5 oz 251 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 122 66 74 5 in 310 167 6 189 2 cm Wheelbase 90 in 228 6 cm Ground Clearance 14 25 in 36 2 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 10 5 1 Starting System Electric Fuel System Electr...

Page 131: ...P R N L H Tire Size All 29 5x9 5 14 Tire Pressure All 18 psi 124 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam LED cluster Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V Output Gear Ratios Rear High Gear 12 05 Low Gear 25 59 Reverse 22 92 Front including front drive High Gear 12 82 Low Gear 27 24 Re...

Page 132: ...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 133: ...cle 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 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 101 Prevent water from entering the PVT outlet duct see pag...

Page 134: ... fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your dealer Low battery voltage Recharge the battery to 12 8 VDC Loose ignition connections Check all connections and tighten Mechanical failure See your dealer Possible Cause Solution Out of fuel Refuel Weak spark fro...

Page 135: ...e your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line or filter Inspect and replace Kinked idle air control lines Inspect rotate lines to remove kink Incorrect fuel Replace wi...

Page 136: ...defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and replace Other mechanical failure See your dealer Overheated engine Clean radiator screen ...

Page 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...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 if it is inconsistent with the controlling state law This limited warranty excludes failures not caus...

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

Page 145: ...143 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 146: ...icator 45 Cleaning and Storage 123 127 Cleaning the Air Filter 102 103 Cleaning the Exhaust System 105 Cleaning the Spark Arrestor 105 Clothing 9 Clutching 129 Component Locations 25 Condition Spark Plugs 93 Coolant Level Overflow Bottle 98 Coolant Level Radiator 97 Coolant Adding 95 Coolant Changing 95 97 Coolant Replacing 97 Cooling Fan 96 Cooling System 97 98 Cooling System Operation 95 96 Cove...

Page 147: ...2 Fluid Brake 108 Fogging the Engine 126 Fouled Plugs 93 Freeplay Steering Wheel 118 Fuel Cap 31 Fuel Safety 22 Fuel Stabilizer 125 Fuel Tank Filler Cap 31 Fuse Relay Center 94 G Gap Spark Plug 92 Gasoline Handling 22 Gear Selector 34 Gearcase Capacities 92 Gearcase Oil Demand Drive 90 91 Front 90 91 Main 88 89 Gearcase Specifications 92 Gearcases 88 92 Demand Drive 90 91 Front Gearcase 90 91 Main...

Page 148: ...on Transmission 99 101 Operator Restrictions 14 Outlets Auxiliary 26 Overflow Bottle Coolant Level 98 P Parking on an Incline 61 Parking the Vehicle 51 Passenger Hand Hold Adjustment 29 Periodic Maintenance Chart 77 81 Plug Condition 93 Plug Gap 92 Plug Torque 92 Plugs Fouled 93 Plugs Spark 92 93 Polaris Products 130 Polishing the Vehicle 124 Power Steering 34 Pre Ride Inspection 48 Public Lands 7...

Page 149: ...torage Removal 127 Suspension Settings 109 112 Switches AWD Switch 27 36 Headlight Switch 27 Ignition 26 Mode Button 37 Remote Winch Switch 27 Winch Switch 27 T Tachometer 43 Taillight 115 Throttle Pedal 35 Tire Tread Depth 113 Tires 113 114 Torque Axle Nuts 113 Torque Spark Plug 92 Torque Wheel Nut 113 Towing Loads 64 Trail Etiquette 51 Training 7 Transmission Oil 88 89 Transmission Operation 99 ...

Page 150: ...ury 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 approved accessories they may seriously affect stability For yo...

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