Polaris RZR 200 EFI 2021 Owner'S Manual Download Page 138

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POSSIBLE CAUSE

SOLUTION

Water or fuel in crankcase

Your POLARIS dealer can assist.

Clogged Fuel Filter

Your POLARIS dealer can assist.

Low battery voltage

Recharge the battery to 12.8 VDC.

Mechanical failure

Your POLARIS dealer can assist.

ENGINE BACKFIRES

POSSIBLE CAUSE

SOLUTION

Weak spark from spark plug

Inspect, clean and/or replace spark plug.

Incorrect spark plug gap or
heat range

Set gap to specs or replace plug.

Old or non-recommended fuel

Replace with fresh recommended fuel.

Incorrectly installed spark plug
wires

Your POLARIS dealer can assist.

Mechanical failure

Your POLARIS dealer can assist.

Loose ignition connections

Check all connections and tighten.

Water present in fuel

Replace with fresh recommended fuel.

Exhaust system leak

Your POLARIS dealer can assist.

ENGINE PINGS OR KNOCKS

POSSIBLE CAUSE

SOLUTION

Poor quality or low octane fuel

Replace with recommended fuel.

Incorrect ignition timing

Your authorized dealer can assist.

Incorrect spark plug gap or
heat range

Set gap to specs or replace plugs.

ENGINE RUNS IRREGULARLY, STALLS OR
MISFIRES

POSSIBLE CAUSE

SOLUTION

Fouled or defective spark plug
(s)

Inspect, clean and/or replace spark plugs

Worn or defective spark plug
wires

Your POLARIS dealer can assist

136

TROUBLESHOOTING

Summary of Contents for RZR 200 EFI 2021

Page 1: ...OWNER S MANUAL For Maintenance and Safety RZR 200 EFI 2021 2022...

Page 2: ...e except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passeng...

Page 3: ...ortant Safety Video regarding your Polaris vehicle This safety video can also be found at http www polaris com en us rider support safety If you are on the homepage of the Polaris website click on the...

Page 4: ...Bluetooth Sig Inc Apple App Store is a registered trademark of Apple Inc Google Play is a registered trademark of Google LLC Copyright 2021 Polaris Industries Inc All information contained within this...

Page 5: ...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...

Page 6: ...4 WELCOME...

Page 7: ...uction 9 Safety 15 Features and Controls 35 Instrument Cluster 45 Operation 75 Emission Control Systems 85 Maintenance 87 Specifications 129 Polaris Products 133 Troubleshooting 135 Warranty 153 Maint...

Page 8: ...6...

Page 9: ...anual Never allow a child under age 10 to operate or ride as a passenger in this vehicle Young operators differ in skills physical abilities and judgement Please supervise the use of the vehicle at al...

Page 10: ...ngs in this owner s manual and video Ask a parent or supervising adult to explain anything you don t understand Your safety and the safety of others is the most important thing to think about at all t...

Page 11: ...NG WARNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided COULD result in minor to mo...

Page 12: ...IS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost The VIN can be found stamped on a plate q riveted to the right...

Page 13: ...do the following View vehicle specific information Access your Polaris Garage Download and view the owner s manual View accessory instructions Watch how to videos Access warranty information Check for...

Page 14: ...accept any interference received including interference that may cause undesired operation CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void th...

Page 15: ...B1 Gauge Bluetooth LE Helmet Aware Beacon COMPONENT ID CYBLE 222014 01 E8 MANUFACTURER Cypress Semiconductor Minew Technologies TRANSMITTING FREQUENCY 2402 2480 MHz 2402 2480 MHz MAX RF TRANSMITTING...

Page 16: ...DECLARATION OF CONFORMITY This document is setting out the contents of the EC Declaration of Conformity The particulars of machinery may differ for specific model 14 INTRODUCTION...

Page 17: ...could result in loss of control and serious injury or death Use only POLARIS approved accessories to modify this vehicle Review all vehicle changes with your child prior to operating The POLARIS limi...

Page 18: ...terproof goggles or use a shatterproof helmet face 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...

Page 19: ...mes See the OPERATION section of this owner s manual for proper operating procedures FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 OPERATING WITHOUT INSTRUCTION Operating this vehic...

Page 20: ...and both hands on the steering wheel if driving or on a passenger hand hold RIDER HEIGHT Some riders may be too tall to ride safely in this vehicle Do not operate or ride in this vehicle if the cleara...

Page 21: ...eyewear increases the risk of a serious injuries in the event of an accident Operator and all passengers must always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankl...

Page 22: ...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...

Page 23: ...ct the handling of the vehicle and may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances an...

Page 24: ...ccident or rollover The operator should always keep both hands on the steering wheel during operation A passenger should always be seated in the passenger seat with both feet on the floor and with bot...

Page 25: ...loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual See the Driving Downhill section for details CROSSING HILLSIDES Driving on a s...

Page 26: ...ollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions OPERATING IMPROPERLY IN REVERSE Improperly operating in reverse could re...

Page 27: ...ch as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See the Driving Over Obstacles section for details OPERATING THROUGH WATER O...

Page 28: ...G A DAMAGED VEHICLE Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including...

Page 29: ...r 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 flam...

Page 30: ...e terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mow...

Page 31: ...WARNING WARNING The tire pressure and load warning q is located on the front of the cargo compartment WARNING Never carry passengers in cargo box Passengers can be thrown off This can cause serious i...

Page 32: ...s located on the inside of the driver s door panel WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be Operated without all occupants first viewing and understa...

Page 33: ...njury or death Adult supervision required for children under age 16 NEVER permit children under age 10 to operate this vehicle NEVER permit a passenger whose feet cannot touch the floor LOCATE AND REA...

Page 34: ...to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label TIRE PRESSURE AND LOAD WARNING WARNING The tire pressure and load warni...

Page 35: ...ed for off highway vehicle access Exhibition driving increases the risk of accident or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving Do not operate vehi...

Page 36: ...OT SURFACES ALERT WARNING The hot surfaces alert is located on the body above the muffler Hot component Hot components can cause burns and fire Do not touch hot component Part Number 7185151 34 SAFETY...

Page 37: ...e offs must be used by both operator and passenger at all times Promptly replace worn or damaged parts with new available from your authorized POLARIS dealer q Daytime Running Lights w Console e Door...

Page 38: ...seat forward and rearward to ensure the latch is engaged Before operating the vehicle always make sure both seats are securely installed SEAT REMOVAL 1 Slide the seat completely forward to access the...

Page 39: ...not secured To wear the seat belt properly do the following 1 Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across...

Page 40: ...detergents DOORS AND CAB NETS Riding in this vehicle without using the cab nets or doors increases the risk of serious injury or death in the event of an accident or rollover Cab nets must be used by...

Page 41: ...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 Lights ON Electrical circuits are on Electrical equipment can be use...

Page 42: ...hile the vehicle is moving F Forward N Neutral R Reverse TIP Maintaining shift linkage adjustment is important to assure proper transmission function Your POLARIS dealer can assist in resolving any sh...

Page 43: ...ngage the parking brake before operating the vehicle 1 Apply the brakes 2 When the vehicle is fully stopped pull the parking brake lever q rearward as far as possible to set the parking brake 3 Stop t...

Page 44: ...pply the brakes while starting the engine THROTTLE PEDAL Push the throttle pedal w down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that...

Page 45: ...hould be mounted on a flat surface on the helmet The display will issue a low battery message if the beacon is below 10 battery level Parents can replace the battery beacon with a CR2032 To replace th...

Page 46: ...44...

Page 47: ...ware Signal Strength This indicates the signal strength of the helmet beacon This symbol will flash if the helmet aware system is activated and the helmet beacon is not in range The symbol will remain...

Page 48: ...indicator appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result Your authorized Polaris dealer can assist e Helmet Seat Belt This...

Page 49: ...DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 q 47 INSTRUMENT CLUSTER...

Page 50: ...Speed Engine Temperature RPM 48 INSTRUMENT CLUSTER...

Page 51: ...DISPLAY AREA 2 Toggle the Up Down buttons to change the information displayed in Area 2 w Odometer Service Hours 49 INSTRUMENT CLUSTER...

Page 52: ...Trip 1 Trip 2 Trip Timer 50 INSTRUMENT CLUSTER...

Page 53: ...Engine Temperature Voltage Geofence Status 51 INSTRUMENT CLUSTER...

Page 54: ...RPM Engine Hours 52 INSTRUMENT CLUSTER...

Page 55: ...Speed Helmet Aware Status 53 INSTRUMENT CLUSTER...

Page 56: ...red Youth Menu Set passcode maximum speed GeoFence and helmet aware settings Units Distance Select MPH or KPH Units Temp Select between F and C Clock Select between 12H or 24H and set time Backlight C...

Page 57: ...through Code s NOTICE This option will only be available if a fault code was set or is active during the current ignition key on cycle Turning off the ignition will clear any save fault codes from the...

Page 58: ...ng first menu item 2 Select YOUTH MENU from the Options Menu by pressing the MODE button YOUTH MENU NOTES Maximum Speed Set maximum Speed Geofence Enable Disable Geofence Inside Geofence Speed Set ins...

Page 59: ...out a PIN for a specified period of time after engine stall or shutdown Change PIN Change PIN Exit Youth Menu Exit PERSONAL IDENTIFICATION NUMBER PIN ENTER PIN NOTICE If personal identification number...

Page 60: ...the UP DOWN buttons to increase decrease the first digit of the new PIN e With the desired first digit of the new PIN displayed Press the MODE button which will set the digit and move to the 2nd digit...

Page 61: ...lay on the screen for 3 seconds before showing first menu item 2 Select YOUTH MENU by pressing the MODE Button 3 Enter PIN 4 Select MAX SPEED from the Youth Menu by pressing the MODE button Reference...

Page 62: ...ofence features first download the Polaris Ride Command app and sign up Turning the geofence on and off and changing the speeds can be done through the vehicle display once a geofence boundary has bee...

Page 63: ...TIONS will display on the screen for 3 seconds before showing first menu item 2 Select YOUTH MENU by pressing the MODE button 3 Enter PIN 4 Select INSIDE from the Youth Menu by pressing the MODE butto...

Page 64: ...Reference the image shown above q Press the MODE button w Toggle the UP DOWN buttons to increase decrease OUTSIDE Geofence maximum speed e With the desired speed displayed press the MODE button which...

Page 65: ...e MODE button Reference the image shown above q Press the MODE button w Toggle the UP DOWN buttons to enable disable requiring PIN to start vehicle e With the desired option displayed press the MODE b...

Page 66: ...ODE button Reference the image shown above q Press the MODE button w Toggle the UP DOWN buttons to enable disable the pin delay e With the desired option displayed press the MODE button which will set...

Page 67: ...er the Options Menu NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item 2 Select YOUTH MENU by pressing the MODE button 3 Enter PIN 4 Select HELMET A from the Youth...

Page 68: ...new PIN displayed Press the MODE button which will set the digit and move to the 2nd digit r Toggle the Up Down Buttons to increase decrease the 2nd digit of the new PIN Press MODE button to set 2nd d...

Page 69: ...the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units MPH or KPH e With the correct unit displayed Press the mode button which will set the unit and return to...

Page 70: ...ce the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units F or C e With the correct unit displayed Press the mode button which will set the unit and return to t...

Page 71: ...CLOCK 1 Press and hold the MODE button to enter the Options Menu NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item 69 INSTRUMENT CLUSTER...

Page 72: ...will set the unit y Toggle the Up Down Buttons to change the units Cycles 10s of Minutes u With the correct unit displayed Press the mode button which will set the unit i Toggle the Up Down Buttons to...

Page 73: ...e image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Blue or Red e With the correct unit displayed Press the mode button which will set the unit and return to t...

Page 74: ...shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Increase or De crease Level e With the correct unit displayed Press the mode button which will set the unit and ret...

Page 75: ...to change the units 0 5 10 95 100 e With the correct unit displayed press the MODE button which will set the unit and return you to the Options Menu NOTICE To reset service hours after they have coun...

Page 76: ...74...

Page 77: ...high speeds during the first 3 hours of use 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 dam...

Page 78: ...uspension Inspect lubricate if necessary page 92 Rear suspension Inspect lubricate if necessary page 92 Steering Ensure free operation Tires Inspect condition and pressure page 114 Wheels fasteners In...

Page 79: ...he key when the engine starts 6 If the engine does not start within five seconds return the ignition switch to the OFF position and wait five seconds Repeat steps 5 and 6 until the engine starts 7 Var...

Page 80: ...ly and engine speed slows to near idle the vehicle has no engine braking 2 Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the con...

Page 81: ...ng over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling loads SECURE ALL LOADS BEFORE OPERATING Unsecured...

Page 82: ...n riding in this vehicle 9 Place the transmission in NEUTRAL 10 Start the engine and disengage the parking brake 11 Apply the brakes and shift into gear 12 Check your surroundings and determine your p...

Page 83: ...r seat belt 5 Make sure all cab nets are properly secured 6 Do not carry more than the recommended number of passengers for your vehicle 7 Allow a passenger to ride only in a passenger seat 8 Slow dow...

Page 84: ...ss reading the trail and avoiding quick sharp turns which can cause skids 4 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid DRIVING OVER...

Page 85: ...hill follow these precautions 1 Avoid excessively steep hills 2 Always descend a hill with the direction selector switch on forward Never descend a hill with the switch on neutral 3 Drive straight dow...

Page 86: ...e special attention to engine oil transmission oil and all grease fittings If your vehicle becomes immersed or is operated in water that exceeds the floor level service is required before starting the...

Page 87: ...uipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system EXHAUST EMISSION CONTROL SYSTEM Exh...

Page 88: ...SSIONS Engine exempt from non road mobile machinery NRMM pollutant emissions Regulation EU 2016 1628 Engine used in reduced scale vehicle model for recreational purposes net power 19 kW 86 EMISSION CO...

Page 89: ...he safest most reliable condition Inspection adjustment and lubrication of important components are explained in the Polaris maintenance chart Inspect clean lubricate adjust and replace parts as neces...

Page 90: ...ive Chain Adjust and lubricate Engine Oil and Filter Change the engine oil and filter Valve Lash Adjust The break in period consists of the first 12 hours of operation Careful treatment of a new engin...

Page 91: ...ilter Front Rear Suspension Lubricate Fuel System Filter Inspect cycle key to pressurize fuel pump check for leaks at fuel system connections check for leaks at fill cap General Lubrication Locate all...

Page 92: ...replace as needed Brake System Inspect for fluid leaks add recommended brake fluid from a sealed container if needed Clutches Drive and Driven Inspect clean replace as needed Drive Belt Inspect repla...

Page 93: ...Lug Nuts Inspect replace as needed Wiring Inspect for wear routing and retention Have an authorized Polaris dealer or other qualified person perform these services Vehicles subjected to severe use mus...

Page 94: ...n Grease or grease conforming to NLGI No 2 Grease at general lubrication interval also after washing vehicle or driving in water XU Steering Arm Pivots XU Perform these procedures more often for vehic...

Page 95: ...einstall the dipstick completely 4 Remove the dipstick and check if oil level is within safe range w TIP A rising oil level between checks in cool weather driving can indicate contaminants such as gas...

Page 96: ...he external oil filter and oil cooler e are mounted to the chassis under the engine The oil filter is accessible on the right side of the vehicle The spin on oil filter should be replaced when oil is...

Page 97: ...section for capacities 11 Reinstall the dipstick 12 Start the engine Allow it to idle for 30 seconds 13 Stop the engine and inspect for leaks 14 Wait at least 15 seconds before removing the oil dipsti...

Page 98: ...arcase Lubricant and Transmission Fluid for this vehicle The fill plug q and sealing washer w can be accessed on the right side of the transmission gearcase TRANSMISSION OIL CHANGE NOTICE Maximum tran...

Page 99: ...and sealing washer r from the bottom of the gearcase and allow lubricant to drain completely 4 Clean the drain plug magnetic surface 5 Reinstall the drain plug and sealing washer Torque to specificat...

Page 100: ...ean the drive chain Operating the vehicle with improper rear drive chain deflection can result in severe damage to the transmission and drive components Always make sure the chain adjusted within the...

Page 101: ...nspect and perform any needed service on the brake pads before adjusting parking brake cable freeplay 2 Make sure the parking brake is NOTset the lever should be in the DOWN position 3 Pull the brake...

Page 102: ...urn the adjustment nut w counterclockwise until significant brake drag is detected Then turn the adjustment nut in 1 4 turn 6 Hold the parking brake cable sleeve and adjustment nut in place and tighte...

Page 103: ...otating it counter clockwise 3 Reverse the procedure for spark plug installation Torque to specification SPARK PLUG GAP TORQUE Electrode Gap New Plug Torque Used Plug Torque 0 6 0 7 mm 11 ft lbs 15 N...

Page 104: ...TANT VARIABLE TRANSMISSION CVT SYSTEM WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the CVTsystem Doing so may red...

Page 105: ...e than 5 seconds 3 Allow the engine RPM to return to idle then shift the transmission into gear 4 Test the CVTsystem for belt slippage If the belt slips repeat the process or remove the outer clutch c...

Page 106: ...the filter w 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean shop towel NOTICE If the filter has been soaked with fuel or oil it must be replaced 5 Inspect the air...

Page 107: ...on monoxide gas To remove accumulated carbon clean the spark arrestor at the intervals recommended in the Maintenance Schedule beginning on page 87 1 Remove the 3 fasteners q and remove the arrestor w...

Page 108: ...FUSE REPLACEMENT 1 Remove fuse box cover q 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the fuse box cover 106 MAINTENANCE...

Page 109: ...es 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...

Page 110: ...OLARIS products WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from...

Page 111: ...l for specified freeplay and smooth operation at the intervals outlined in the Maintenance Schedule see page 87 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right...

Page 112: ...right spring preloads equally or have your POLARIS dealer perform the adjustments The front and rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster q...

Page 113: ...rement 3 Subtract measurement 3 from measurement 2 The difference between measurements 2 and 3 is the vehicle toe alignment The recommended vehicle toe tolerance is 0 to 1 8 0 to 3 2 mm toe out This m...

Page 114: ...ired to achieve the proper toe setting as specified in above IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage m...

Page 115: ...filter Thoroughly dry the air pre filter 3 Remove the air box drain plug to drain any water Reinstall the drain plug securely 4 Remove the spark plug 5 Turn the engine over several times using the el...

Page 116: ...al 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 t...

Page 117: ...the parking brake is still applied 2 Place the wheel in the correct position on the wheel hub q Be sure the valve stem w is toward the outside and rotation arrows on the tire point toward forward rot...

Page 118: ...nut until the cotter pin can be installed 7 Install the hub cap y LIGHTS DAYTIME RUNNING LIGHT REPLACEMENT To remove the headlight do the following 1 Disconnect the headlight to harness connection q...

Page 119: ...battery Always 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...

Page 120: ...h charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Sealed batteries are already filled with electrolyte and have been seal...

Page 121: ...nt current charger instead of BatteryMINDer 1510 1 5 AMP charger use the guidelines below Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage DC Acti...

Page 122: ...ase 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 If a high pressure water system is used fo...

Page 123: ...re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap deterge...

Page 124: ...lizes 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 sy...

Page 125: ...head and appear to be an oil leak 3 Reinstall the spark plug Torque to specification 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the cap onto the plug at this step...

Page 126: ...vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 2 Make sure spark plugs are tight 3 Fill the fuel tank with fuel 4 Check all the points li...

Page 127: ...cargo properly Improperly securing a load can result in severe injury or death Securing devices such as tie down straps are manufactured to support a load that can be applied during normal service Th...

Page 128: ...y or death 2 Apply the brakes 3 Place the transmission in NEUTRAL Stop the engine 4 Set the parking brake 5 Slowly release the brake pedal and make sure the vehicle doesn t move before exiting the veh...

Page 129: ...could lead to premature component failure and or excess wear on the tie down straps WARNING Always secure the vehicle with at least four straps when trailering Use two straps in the front and two in...

Page 130: ...TIE DOWN LOCATIONS q Front tie down point only one side shown use same spot on other side w Rear tie down points 128 MAINTENANCE...

Page 131: ...acity 25 lb 11 kg Maximum Rider Weight 162 lb 73 5 kg each rider Maximum Weight Capacity 350 lb 158 kg Driver Cargo ENGINE Platform Single Cylinder Air Oil Cooled 4 Stroke Engine Displacement cc 180 c...

Page 132: ...minimum ELECTRICAL Alternator Output 11 5 AMP 4000 RPM Voltage Regulator 3 Phase 35 AMP Daytime Running Lights 2 Single Beam Daytime Running Lamps DRL Tail Brake Lights Single Tail Light Ignition Timi...

Page 133: ...Cam Adjustable Factory Setting Softest WHEELS BRAKES Front Wheel Size 12 x 6 Stamped Steel Front Tire Brand Size Load Rating Speed Rating CST 24 x 8 12 38B Rear Wheel Size 12 x 8 Stamped Steel Rear Ti...

Page 134: ...132...

Page 135: ...Transmission Fluid qt 95 l 2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid gal 3 8 l 2872348 Chain Lube Aerosol GREASE SPECIALIZED LUBRICANTS PART NUMBER DESCRIPTION 2871312 Grease G...

Page 136: ...PART NUMBER DESCRIPTION 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Charger 134 POLARIS PRODUCTS...

Page 137: ...alfunction Your Polaris dealer can assist Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines Your Polaris dealer can assist Wrong or missing belt Install the r...

Page 138: ...Your POLARIS dealer can assist Mechanical failure Your POLARIS dealer can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel...

Page 139: ...ectronic throttle control malfunction Your POLARIS dealer can assist Other mechanical failure Your POLARIS dealer can assist POSSIBLE LEAN FUEL CAUSE SOLUTION Low or contaminated fuel Add or change fu...

Page 140: ...plugs Worn or defective spark plug wires Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and ti...

Page 141: ...ed To High Source 91 4 P0227 Voltage Below Normal Or Shorted To Low Source 96 2 Fuel Level Signal P0461 Data Erratic Intermittent Or Incorrect 96 3 P0463 Voltage Above Normal Or Shorted To High Source...

Page 142: ...ce 110 4 P0117 Voltage Below Normal Or Shorted To Low Source 110 10 P0119 Abnormal Rate Of Change 110 15 P1116 Data Valid But Above Normal Operating Range Least Severe Level 110 16 P0217 Data Valid Bu...

Page 143: ...High Source 651 4 P1262 Voltage Below Normal Or Shorted To Low Source 651 5 P0261 Current Below Normal Or Open Circuit 652 3 Injector 2 Rear PTO SDI Port Injector P0265 Voltage Above Normal Or Shorte...

Page 144: ...Or Open Circuit 1127 0 Boost Pressure Sensor P0234 Data Valid But Above Normal Operational Range Most Severe Level 1127 2 P0236 Data Erratic Intermittent Or Incorrect 1127 3 P0238 Voltage Above Norma...

Page 145: ...Or Shorted To High Source 1856 4 B1250 Voltage Below Normal Or Shorted To Low Source 1856 5 B1350 Current Below Normal Or Open Circuit 1856 31 Condition Exists 2629 3 Engine Turbocharger 1 Compressor...

Page 146: ...Responding Or Out Of Adjustment 65592 7 Cylinder 2 Misfire P0302 Mechanical System Not Responding Or Out Of Adjustment 65613 2 ETC Accelerator Position Sensor Outputs 1 2 Correlation P1135 Data Errati...

Page 147: ...20203 5 P1685 Current Below Normal Or Open Circuit 520204 15 Fuel Correction Front P0172 Data Valid But Above Normal Operating Range Least Severe Level 520204 17 P0171 Data Valid But Below Normal Oper...

Page 148: ...Source 520209 4 P0031 Voltage Below Normal Or Shorted To Low Source 520209 5 Current Below Normal Or Open Circuit 520210 2 Oxygen Sensor Heater 2 P0141 Data Erratic Intermittent Or Incorrect 520210 3...

Page 149: ...low Normal Or Open Circuit 520271 3 Idle Air Control M17 Stepper Pin 1 P1509 Voltage Above Normal Or Shorted To High Source 520271 4 P1508 Voltage Below Normal Or Shorted To Low Source 520271 5 P1505...

Page 150: ...52B Condition Exists 520283 3 Throttle Body Control P152C Voltage Above Normal Or Shorted To High Source 520283 4 P152D Voltage Below Normal Or Shorted To Low Source 520284 31 Throttle Body Control Po...

Page 151: ...uption P1537 Condition Exists 520329 9 Operator Switch Status pOSS1 P1063 Abnormal Update Rate 520331 3 Knock Sensor Positive Line P1327 Voltage Above Normal Or Shorted To High Source 520331 4 P1328 V...

Page 152: ...ing Range Least Severe Level 520342 17 P116D Data Valid But Below Normal Operating Range Least Severe Level 520343 15 Idle Fuel Correction Bank 2 P116E Data Valid But Above Normal Operating Range Leas...

Page 153: ...Normal Or Shorted To High Source 520624 4 P15F4 Voltage Below Normal Or Shorted To Low Source 520624 5 P15F3 Current Below Normal Or Open Circuit 520625 3 Alternator Charge Disable Relay P1D45 Voltag...

Page 154: ...SOFTWARE 524080 31 Cruise Control Input Message Counter U1405 Condition Exists 524081 31 Foot On Cruise Control Input Message Counter U1407 Condition Exists 524082 31 Foot On Cruise Control Input Che...

Page 155: ...uch transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the...

Page 156: ...ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs o...

Page 157: ...ERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY O...

Page 158: ...istered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dea...

Page 159: ...m 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 EP...

Page 160: ...OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE...

Page 161: ...maintain replace or repair the emission control devices or systems on your vehicle An authorized POLARIS dealer or other qualified person can perform any service that may be necessary for your vehicle...

Page 162: ...Resources Board and Polaris Industries inc is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle In California new off highway...

Page 163: ...exceed 30 days As an OHRV EVAP owner you should also be aware that Polaris may deny you warranty coverage if your OHRV EVAP or a part has failed due to abuse neglect improper maintenance or unapproved...

Page 164: ...162...

Page 165: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 163 MAINTENANCE LOG...

Page 166: ...164...

Page 167: ...rly 23 Device Compliance Statements 12 Diagnostic Trouble Codes 139 Doors and Cab Nets 38 Drive Belt Wear Burn 135 Drive Chain Adjustment 98 Lubrication 98 Driver s Seat Adjustment 36 Driving Downhill...

Page 168: ...ervice Hours 73 Unit Selection Distance 67 Unit Selection Temperature 68 K Know Your Riding Area Tread Lightly 75 L Limited Warranty 153 M Maintenance Log 163 Maintenance Overview 87 N Near field Comm...

Page 169: ...ols 9 Safety Warnings 17 Carrying Multiple Passengers 2 Seat 20 Improper Cargo Loading 26 Jumps and Stunts 21 Operating at Excessive Speeds 22 Operating Improperly in Reverse 24 Operating Over Obstacl...

Page 170: ...s 128 W Warning Symbols 9 Washing the Vehicle 119 Welcome Page 3 Wheel Installation 115 Wheel Removal 114 Wheel Toe Adjustment 110 with a Load on the Vehicle 20 Y Youth Menu 56 Change PIN 66 Helmet Aw...

Page 171: ......

Page 172: ...video and warning labels with more than one passenger on hills steeper than 15 degrees 15 on paved surfaces pavement may seriously affect handling and control with non Polaris approved accessories the...

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Polaris RZR 200 EFI 2021, Owner'S Manual

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Summary of Contents for RZR 200 EFI 2021

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