Polaris RANGER XP 900 Owner'S Manual For Maintenance And Safety Download | Manualshive

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PMS 419

WARNING

For your nearest Polaris dealer,

call 1-800-POLARIS

or visit www.polarisindustries.com
Polaris Sales Inc.,

2100 Hwy. 55

Medina, MN 55340

Phone 1-888-704-5290
Part No. 9923625 Rev 01

Printed in USA

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:
• without first viewing safety video and quick start guide.
• with more than one passenger in a 2-seat vehicle.
• with more than three passengers in a 4-seat vehicle.
• on hills steeper than 15 degrees.
• on public roads.
• on paved surfaces - pavement may seriously affect handling and control.

ALWAYS:
• keep hands and feet inside vehicle. Use the cab nets.
• reduce speed and use extra caution when carrying passengers.
• operate slowly in reverse - avoid sharp turns or sudden braking.

• avoid branches or other hazards that could enter vehicle.

• make sure passengers read and understand all safety labels.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR

OPERATOR AND PASSENGERS. NEVER USE ON PUBLIC ROADS.

NEVER USE WITH DRUGS OR ALCOHOL.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

• with non-Polaris approved accessories - they may seriously affect stability.

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Summary of Contents for RANGER XP 900

Page 1: ...Owner s Manual for Maintenance and Safety RANGER RZR XP 900 RZR XP 4 900 TM TM ...

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

Page 3: ... sure to follow the instructions and recommendations in this owner s manual Visit the Recreational Off Highway Vehicle Association web site rohva org and take the free on line training course Your owner s manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Ser vic...

Page 4: ...r discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instruction...

Page 5: ...NTENTS Introduction 4 Safety 7 Features and Controls 28 Operation 50 Emission Control Systems 68 Maintenance 69 Specifications 120 POLARIS Products 124 Troubleshooting 125 Warranty 129 Maintenance Log 137 Index 140 ...

Page 6: ...al injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The ...

Page 7: ...ned on pages 56 57 Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured p...

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: ... may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equip ment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS vehicle is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle ...

Page 10: ...ceeds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the...

Page 11: ...ace shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy footwear Do not ride a POLARIS vehicle with bare feet Clothing Wear long sleeves and long pants to protect arms and le...

Page 12: ...r allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 56 57 Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license Never operate with a passenger under the age of 12 Make sure all passengers are tall enough t...

Page 13: ...hout wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Seat belts reduce the severity of injury in the event of a sudden stop or accident Always make sure the seat belts are secured for both the operator and all passengers before riding Cab Nets Riding in this vehicle without using the cab nets increases t...

Page 14: ...fety 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 is add...

Page 15: ...road use only not for use on pavement Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make 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 I...

Page 16: ...passenger seat with seat belt secured with both feet on the floor and with both hands securely grasping the passenger hand hold or grab bar Always keep hands and feet inside the vehicle at all times Jumps and Stunts Exhibition driving increases the risk of an accident or overturn DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving Descending Hills Improperly Improp...

Page 17: ...1 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Maintain 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...

Page 18: ...tenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control accident or overturn Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Slippery Terrain Operating on excessively rough slippery or loose terrain could cause lo...

Page 19: ...rfaces as described in the owner s manual When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Water Operating through deep or fast flowing water can cause loss of traction loss of control overturn or accident Never operate in fast flowing wate...

Page 20: ...hrough 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 your entire route Vehicle operat...

Page 21: ...any source of flame or sparks Gasoline is extremely flammable Remove flammable material containers from the box before filling Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas Hot Exhaust Systems Exhaust system co...

Page 22: ... PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying 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...

Page 23: ... age 12 or too small to firmly plant feet on the floor and securely grasp hand hold THE PASSENGER MUST ALWAYS wear seat belt use an approved helmet and protective gear securely grasp hand hold and plant feet firmly on the floor tell operator to slow down or stop if uncomfortable get off and walk if conditions require keep hands and feet inside vehicle at all times watch for branches brush and othe...

Page 24: ...under age 12 or too small to firmly plant feet on the floor and securely grasp hand holds THE PASSENGERS MUST ALWAYS wear seat belts use approved helmets and protective gear securely grasp hand holds and plant feet firmly on the floor tell operator to slow down or stop if uncomfortable get off and walk if conditions require keep hands and feet inside vehicle at all times avoid branches brush and o...

Page 25: ...ed or seriously injured in event of rollover ALWAYS keep hands on passenger grab bar 7176700 Rear Passenger Grab Bar Warning RZR XP 4 Always use seat belt helmet and eye protection Always use passenger grab bar and side nets to keep hands and feet in vehicle at all times 7176701 Passenger Grab Bar Warning Passenger Cab Frame Warning both sides ...

Page 26: ...SECURE CAB NETS VEHICLE OVERTURN could cause severe injury or death Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle When vehicle is stopped place shift in the parked position APPLY BRAKE TO START 7174843 Shift Caution Cab Frame Seat Belt Warning Age Warning Overturn Warning Discretionary Warning ...

Page 27: ...cars trucks or other off road vehicles In order to avoid overturns avoid sharp turns never turn while applying heavy throttle never make abrupt steering maneuvers operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts 7175105 Belt Debris Warning WARNING Improper service or maintenance of this PVT system can result in...

Page 28: ...tability ALWAYS keep hands and feet inside vehicle Use the cab nets reduce speed and use extra caution when carrying a passenger operate slowly in reverse avoid sharp turns or sud den braking make sure passenger reads and understands all safety labels watch for branches or other hazards that could enter vehicle ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE ...

Page 29: ...ey may seriously affect stability ALWAYS keep hands and feet inside vehicle reduce speed and use extra caution when carrying passengers operate slowly in reverse avoid sharp turns or sud den braking make sure passengers read and understand all safety labels avoid branches or other hazards that could enter vehicle ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGERS NEVER U...

Page 30: ...28 FEATURES AND CONTROLS Component Locations Hip Bars Fuel Tank Cap Cargo Box Front Passenger Hand Hold Cab Nets ROPS Frame Radiator Steering Wheel Gear Selector Throttle Pedal Brake Pedal ...

Page 31: ...29 FEATURES AND CONTROLS Component Locations Fuel Tank Cap Shifter Rear Passenger Grab Bar Cargo Box Tie Down Points ...

Page 32: ...he rear passenger seats Ignition Switch The ignition switch is a three position key operated switch Use the ignition switch to start the engine See page 54 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 k...

Page 33: ... the dash to place the headlights on high beam Move the rocker switch to the center position to place the headlights on low beam Press the bottom of the rocker switch to turn off the headlights All Wheel Drive AWD Switch The AWD Switch has two positions All Wheel Drive AWD Two Wheel Drive 2WD Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in ...

Page 34: ... 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 35: ... Remove the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole 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 Adju...

Page 36: ...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 dis engage the lower hood hooks 4 Lift the hood away from the vehicle Pressure Cap Overflow Bottle Hood Fasteners ...

Page 37: ...s panel to reach some serviceable engine components Oil Tank Access Panel The oil tank access panel is located in the forward left corner of the cargo box Remove the panel to check and add oil Cargo Box Access Panel The cargo box access panel is located on the floor of the cargo box Remove the panel to access the spark plugs and air filter Oil Tank Access Panel Cargo Box Access Panel ...

Page 38: ...s are equipped with cab nets which may differ slightly in appearance from those shown Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn Cab nets must be used by operator and passengers at all times Make sure all latches are secure before operating the vehicle Always inspect cab nets for tightness wear and damage ...

Page 39: ...eat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length...

Page 40: ...ge adjustment is important to assure proper transmis sion function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Using Low Range Always shift into low gear for any of the following conditions Operating...

Page 41: ...Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your autho rized 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 Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNIN...

Page 42: ...n 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 A...

Page 43: ...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 45 Mode Button Use the MODE button to toggle through mode options See page 45 for operation of the mo...

Page 44: ...ically reduce engine power 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 This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat b...

Page 45: ...ster may have shut off to protect the electronic speedome ter If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 46 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Rev...

Page 46: ...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 46 for resetting inst...

Page 47: ...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 48: ...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 49: ...the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Engine Temperature Mode This mode displays current temperature of the coolant Tachometer Mode The engine RPM is displayed digitally Tip Small f...

Page 50: ...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 51: ...nates 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 ...

Page 52: ...gle action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these compo nents Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full...

Page 53: ... on the daily pre ride inspection checklist See page 52 7 Carry only light loads 8 During the break in period change both the oil and the filter at 25 hours or one month Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors PVT Break in Clutches Belt A proper break in of t...

Page 54: ...105 Wheels fasteners Inspect ensure fastener tightness 105 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 44 77 Coolant level Ensure proper level 89 90 Coolant hoses Inspect for leaks Throttle Ensure proper operation 98 Indicator lights switches Ensure proper operation 30 31 Engine intake pre filter Inspect clean 94 PVT intake pre filter Inspect clean 94 Head...

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

Page 56: ...e seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete sto...

Page 57: ...ou ride your vehicle Find out where the designated riding areas are by con tacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on t...

Page 58: ...ion See page 52 4 Wear an approved helmet that fits properly and eye protection gog gles or face shield 5 Do not carry a passenger until you have at least two hours of driving experience with this vehicle 6 Do not carry cargo during this period 7 Select an open area that allows room to familiarize yourself with vehicle operation and handling 8 Sit in the driver s seat and fasten the seat belt 9 Al...

Page 59: ...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 60: ...d grasp the passenger hand hold or grab bar 5 Make sure all passengers are wearing appropriate riding gear including an approved helmet and eye protection See page 8 6 Make sure all passengers secure their seat belts 7 Make sure all cab nets are properly secured 8 Allow a passenger to ride only in a passenger seat 9 Slow down Always travel at a speed appropriate for your skills your passengers ski...

Page 61: ...possibility of skidding and sliding Follow these precautions when encountering slippery conditions 1 Slow down before entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels...

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

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

Page 64: ...ay have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 69 Give special attention to engine oil transmission oil demand dri...

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 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 that c...

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

Page 67: ...t in serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precau tions 1 Place the transmission in PARK 2 Turn the engine off 3 Block the rear wheels on the downhill side or park the vehicle in a sidehill position instead ...

Page 68: ...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 Use ex...

Page 69: ...ough 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 capaci ties specified for your vehicle See page 120 Belt Life To extend belt life use low gear when hauling a heavy load at less than 7 MPH 11 km h for ext...

Page 70: ...y 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 injec tion EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is located on...

Page 71: ...d dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 MPH 16 km h Vehicles subjected to severe use must be inspected and ser viced 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 ...

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

Page 73: ...e Frame fasteners Pre Ride Engine oil level Pre Ride E Engine intake pre filter Daily Inspect clean often PVT intake pre filter Daily Inspect clean often Coolant Daily Check coolant level Headlight taillight Daily Check operation apply dielectric grease if replac ing X Q Brake pad wear 10 H Monthly 100 160 Inspect periodically X Engine oil change break in 25 H 1 M Perform a break in oil and filter...

Page 74: ...l ing air leaks X Engine oil change 50 H 6 M 1000 1600 Perform a break in oil change at one month X Oil filter change 50 H 6 M 1000 1600 Replace with oil change Shift Linkage 50 H 6 M 500 800 Inspect adjust X Front Suspension 50 H 6 M 500 800 Lubricate X Rear Suspension 50 H 6 M 500 800 Lubricate Cooling system if applicable 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system...

Page 75: ...ing 100 H 12 M 1000 1600 Inspect X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 H 12 M 1000 1600 Inspect replace as needed Q Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed X Coolant 24 M Replace coola...

Page 76: ...ransmission Oil Main Gearcase Premium AGL Synthetic Gearcase Lube See page 80 Front Gearcase Fluid Demand Drive Demand Drive Plus Fluid See page 82 Prop Shaft POLARIS Premium U Joint Lube Grease middle and rear fittings Front Control Arm Pivot Bushings POLARIS Premium all Season Grease or grease conforming to NLGI No 2 Grease 3 fittings on each side of the vehicle Stabilizer Bar Bushings POLARIS P...

Page 77: ...75 MAINTENANCE Lubrication Recommendations Grease Stabilizer Bar Bushings one on each side of vehicle Front Control Arm Pivot Bushings 3 per side View of Driver s Side From Bottom of Vehicle ...

Page 78: ... injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil may need to be changed more frequently if POLARIS PS 4 PLUS Synthetic engine oil is not used Follow the manufacturer s recommen dations for ambient temperature operation See page 124 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine...

Page 79: ... left forward corner of the cargo box 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine and allow it to idle for 30 seconds 4 Stop the engine and wait 15 seconds before removing the dipstick 5 Open the oil tank access panel Remove the dipstick from the oil tank Wipe it dry with a clean cloth 6 Reinstall the dipstick completely Remove the dipstick and che...

Page 80: ...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 areas around the oil tank and crankcase drain plugs CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 3 Place a drain pan under the oil tank and remove the drain plug Allow the oil to drain com ...

Page 81: ...e filter gasket contacts the sealing surface then turn and additional 1 2 turn 10 Reinstall the oil tank and crankcase drain plugs Torque both drain plugs to 12 ft lbs 16 Nm 11 Remove the dipstick and fill the oil tank with 3 5 quarts 3 3 l of recommended oil 12 Start the engine and allow it to idle for 30 seconds 13 Stop the engine and wait 15 seconds before removing the dipstick 14 Remove the di...

Page 82: ...r 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 specifi...

Page 83: ...lug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specifica tion 6 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 Drain Plug bottom view ...

Page 84: ...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 85: ...n plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug If the o ring is damaged install a new o ring 5 Reinstall the drain plug Torque to specification 6 Add the 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 Drain Plug bottom view ...

Page 86: ...g 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 85 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 Premium AGL Syn...

Page 87: ...nsulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service Tip 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 ...

Page 88: ...dash above the brake and throt tle pedals Spare fuses are provided in the fuse box The power fuse box is located under the driver s seat Remove the engine access panel to access the fuse box Main Fuse Feature Supported 20A Lights Headlights Taillights 10A Drive AWD 20A Accessory Winch Switch 12V Power Receptacle 10A Fuel Pump 20A Electronic Engine Control Starting Power Fuse Feature Supported 30A ...

Page 89: ...from the mount 3 Remove the fuse box cover 4 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rat ing 5 Reinstall the fuse box cover Reinstall the fuse box over the mount and slide it toward the left to engage the tabs Be sure the fuse box is securely mounted Step 3 Cover removed Step 1 Lift tabs ...

Page 90: ...r added See page 89 for changing procedure POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water See page 124 for the part numbers of POLARIS products Tip Always follow the manufacturer s mixing recommen...

Page 91: ...r pressure cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed 5 Before reinstalling the pres sure cap bleed the system of trapped air Remove the engine 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 cool ant to the radiator until air no longer escapes and ...

Page 92: ...s run dry the level in the radi ator should also be inspected 1 Position the vehicle on a level surface 2 Remove the hood See page 34 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 bot tle runs completely dry there may be ...

Page 93: ...h speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing th...

Page 94: ...the engine access cover and thoroughly clean all debris from the aluminum debris basket and from the engine compartment 2 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 install...

Page 95: ...c PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Remove the clutch cover drain plug 2 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 the bel...

Page 96: ...ove the filter and install the new filter Make sure the direction of the arrow is the same as noted before fil ter removal 3 Reinstall the access panel and seats Intake Pre Filters The engine intake pre filter is located on the left side of the cargo box The PVT intake pre filter is located on the right side of the cargo box Inspect the pre filters before each use of the vehicle Remove the pre fil...

Page 97: ...cover wing nuts and rotate the bolts away from the cover 3 Release the cover latches 4 Pull the cover rearward far enough to remove the air filter 5 Inspect the air box for oil or water deposits Wipe away any deposits with a clean cloth 6 Install a new filter if needed Do not attempt to clean the air filter 7 Close the air box cover and tighten the wing nuts securely Wing Nuts Bolts Air Filter Cov...

Page 98: ...ter the engine has been 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 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 WARNING ...

Page 99: ... 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 dam aged screen 5 Reinstall the arrester Torque bolt to 9 11 ft lbs 12 15 Nm Arrester Screen Bolt Muffler Nut ...

Page 100: ... starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or misadjustment it will cause a delay in throttle response espe cially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic If engine idle speed is not ...

Page 101: ...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 resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal Brake Inspection 1 Check the brake system for fl...

Page 102: ... fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes con taminated the fluid level is below the minimum or if the type and brand 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 brak...

Page 103: ...ension may be adjusted to maintain vehicle clearance height when carrying loads Factory Preload Settings RZR XP Premium Front 7 625 193 7 mm RZR XP Premium Rear 3 625 92 1 mm RZR XP 4 Front 6 560 166 6 mm RZR XP 4 Rear 0 940 23 9 mm Fox Shock Preload Measurement Walker Evans Rear Shock Preload Measurement Walker Evans Front Shock Preload Measurement ...

Page 104: ...mm over the factory setting 1 Use the shock clutch tool from the tool kit to aid in making suspension adjustments 2 Elevate the vehicle to allow the suspension to fully extend 3 Loosen the jam nut and back it away from the adjusting ring 4 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 WARNIN...

Page 105: ... Do not increase the spring preload by more than one inch 25 4 mm over the factory setting 1 Use the shock clutch tool from the tool kit to aid in making suspension adjustments 2 Elevate the vehicle to allow the sus pension 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 WARN...

Page 106: ...rn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping FOX Shocks Setting Compression Damping Softest 20 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed Walker Evans Shocks Setting Compression Damping Softest 16 clicks from closed Factory 7 clicks from closed Firmest 1 click from closed Decrease In...

Page 107: ...ich could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubri...

Page 108: ...ub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 3 Attach the wheel...

Page 109: ... headlamp s for a few days to allow the moisture to clear out Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Apply the brakes The brake light should come on after about 10 mm 0 4 in of pedal travel If the light doesn t come on check the bulb Headlight Replacement If a headlight becomes d...

Page 110: ... the headlight and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn the headlights to high beam 5 Include the weight of a rider on the seat while performing this step Observe the headlight aim As a starting point the most intense part of the head light beam should be 2 inches 5 cm below the mark on the wall Adjust to operator prefer ence 6 Tighten or loosen the t...

Page 111: ...land 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Dry the spark plug wells with a clean cloth then remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure 7 Take the vehicle to your dealer for service as soon...

Page 112: ...e Periodic Maintenance Chart beginning on page 69 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 113: ...ways keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water 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 32 2 Disconnect the black...

Page 114: ...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 dis charge see page 113 or use a POLARIS Battery Tender which can be left connected during the storage pe...

Page 115: ...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 116: ...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 117: ...als 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 gar den 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 Tips...

Page 118: ...damaged 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 containe...

Page 119: ...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 78 Air Filter Air Box Replace the air filter See page 95 Clean the air box Drain the sediment tube Fluid Lev...

Page 120: ...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 85 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 121: ...t beginning on page 69 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Remove the key to prevent loss during transporting 3 Secure the fuel cap and seats 4 Always tie the fram...

Page 122: ...200 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 108 4 64 73 in 275 162 5 185 4 cm Wheelbase 81 4 in 206 8 cm Ground Clearance 13 in 33 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93mm x 64 4mm Alternator Output 720 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark Plug ...

Page 123: ... 45 1 Gear Reduction Reverse 5 776 1 Gear Reduction High 3 037 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 53 1 Tire Size Front 27x9 12 Tire Size Rear 27x11 12 Tire Pressure Front 12 psi 82 7 KPa Tire Pressure Rear 14 psi 96 5 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 6 LED cluster 40w High 27w Low Taillights 2 single beam 5w Brake Lights 2 single beam 5...

Page 124: ...0 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 134 4 64 77 in 341 4 162 5 195 6 cm Wheelbase 107 4 in 272 8 cm Ground Clearance 12 5 in 31 7 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93mm x 64 4mm Alternator Output 720 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark ...

Page 125: ...6 45 1 Gear Reduction Reverse 5 776 1 Gear Reduction High 3 037 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 53 1 Tire Size Front 27x9 12 Tire Size Rear 27x11 12 Tire Pressure Front 14 psi 96 5 KPa Tire Pressure Rear 16 psi 110 3 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 6 LED cluster 40w High 27w Low Taillights 2 single beam 5w Brake Lights 2 single beam...

Page 126: ...mand Drive Plus Fluid qt 95 l 2877923 Demand Drive Plus Fluid gal 3 8 l Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartr...

Page 127: ...icle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT see page 93 Prevent water from enter ing the PVT outlet duct see pa...

Page 128: ...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 from spark plug Inspect clean and or repl...

Page 129: ...e 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 with recommended fuel Clogged air filter Inspect and ...

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

Page 131: ...gistration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy plea...

Page 132: ...y to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effe...

Page 133: ... repair or replacement of any defective materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TO...

Page 134: ... will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engine oi...

Page 135: ...m any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence...

Page 136: ...e safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assignment out...

Page 137: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followi...

Page 138: ...d by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or...

Page 139: ...137 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 140: ...138 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 141: ...139 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 142: ...p Fuel 36 Cargo 66 67 Cargo Box Access Panel 35 Changing Gears 38 Chart Periodic Maintenance 69 73 Check Engine Indicator 49 Cleaning and Storage 115 119 Cleaning the Air Filter 95 Cleaning the Exhaust System 97 Cleaning the Spark Arrestor 97 Clothing 9 Clutching 121 123 Component Locations 28 29 Condition Spark Plugs 85 Coolant Level Overflow Bottle 90 Level Radiator 89 Adding 88 Changing 88 89 R...

Page 143: ... Transmission 80 81 Fluid Change Demand Drive 83 Front Gearcase 83 Main Gearcase 81 Transmission 81 Fluid Check Demand Drive 82 Front Gearcase 82 Main Gearcase 80 Transmission 80 F Fluid Levels During Storage 117 Fluid Recommendations Gearcase 84 Fluid Brake 100 Fogging the Engine 118 Fouled Plugs 85 Freeplay Steering Wheel 110 Freeplay Throttle 98 Fuel Cap 36 Fuel Safety 19 Fuel Stabilizer 117 Fu...

Page 144: ...ine 76 79 Front Gearcase 82 83 Main Gearcase 80 81 Transmission 80 81 O Oil and Filter Care During Storage 117 Oil Change Demand Drive 83 Engine 79 Engine Oil 78 Front Gearcase 83 Main Gearcase 81 Transmission 81 Oil Check Demand Drive 82 Engine Oil 77 Front Gearcase 82 Main Gearcase 80 Transmission 80 Oil Recommendations 76 Oil Tank Access Panel 35 Operation on Public Lands 68 Operation Cooling S...

Page 145: ...Gearcase 84 Speed Idle 98 Speedometer 41 Spring Preload 101 103 Stabilizing the Fuel 117 Starting the Engine 54 Steering Wheel Adjustment 32 Steering Wheel Inspection 110 S Stopping the Engine 54 Storage 115 119 Inspection 118 Lubrication 118 Area 118 Battery 112 Covers 118 Fluid Levels 117 Oil and Filter 117 Removal 119 Suspension Settings 101 104 Switches AWD Switch 31 40 Ignition Switch 30 Mode...

Page 146: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 147: ...degrees on public roads on paved surfaces pavement may seriously affect handling and control ALWAYS keep hands and feet inside vehicle Use the cab nets reduce speed and use extra caution when carrying passengers operate slowly in reverse avoid sharp turns or sudden braking avoid branches or other hazards that could enter vehicle make sure passengers read and understand all safety labels ALWAYS USE...

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