Polaris RZR Pro R 2022 Owner'S Manual Download Page 25 | Manualshive

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SAFETY LABELS AND LOCATIONS

OVERVIEW

Warning labels have been placed on the vehicle for your protection. Read and
follow the instructions of the labels on the vehicle carefully. If any of the labels
depicted in this manual differ from the labels on your vehicle, always read and
follow the instructions of the labels on the vehicle

Never remove any labels from your vehicle. If a label becomes illegible or comes
off, contact your POLARIS dealer for a replacement. Replacement safety labels
are provided at no charge.

q

Driver Information Warning

w

Load/Passenger/Tire Pressure Warning

e

Fuel Transport Warning

r

Air Box Caution (On Air Box)

t

Alternator Drive System Warning (On Alternator Cover)

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Summary of Contents for RZR Pro R 2022

Page 1: ...OWNER S MANUAL For Maintenance and Safety 2022 RZR Pro R...

Page 2: ...defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your...

Page 3: ...Owner s Manual RZR Pro R...

Page 4: ...Bluetooth Sig Inc ANSI is a registered trademark of American National Standards Institute WALKER EVANS RACING is a registered trademark of Walker Evans Enterprises Incorporated exFAT is a registered t...

Page 5: ...the engineering design and development of your POLARIS vehicle For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manu...

Page 6: ...on 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 moderate injury NOTICE NOTICE provides key...

Page 7: ...tures and Controls 27 Ride Command Display if equipped 65 Operation 77 Emission Control Systems 81 Maintenance 83 Specifications 149 Polaris Products 151 Troubleshooting 153 Warranty 177 Maintenance L...

Page 8: ...6...

Page 9: ...OHVA Recreational Off Highway Vehicle Association provides both an online safety e course and a hands on safety course To access this training visit www rohva org Other sources of safety information i...

Page 10: ...q and engine serial number w in the spaces provided Remove the spare key and store it in a safe place The ignition switch must be replaced if all keys are lost Vehicle Model Number Vehicle Identifica...

Page 11: ...effect of a modification or accessory on the safe use of your vehicle You are responsible for injuries related to modifications to the vehicle Modifications or accessories may Damage machine componen...

Page 12: ...t flat on the floor and have both hands on the steering wheel or on a passenger hand hold Do not allow children who need child safety seats or booster seats to ride in the vehicle The vehicle is not d...

Page 13: ...operation page 131 Tires Inspect condition and pressure page 25 page 126 Wheels Lug Nuts Inspect ensure fastener tightness page 127 Fuel and oil Ensure proper levels and condition page 92 Coolant Ens...

Page 14: ...other flammable material or debris especially near the exhaust system Passenger Hand Hold Always adjust the hand hold to a comfortable position for your passenger before operating Make sure the clasps...

Page 15: ...s can become higher Make sure tire pressures match the specifications listed in the table below Only use the size and type of tires specified for this vehicle Do not operate your vehicle with worn or...

Page 16: ...terial getting in your eyes and help prevent loss of vision POLARIS recommends wearing approved Personal Protective Equipment PPE that have markings indicating they are designed to standards such as V...

Page 17: ...as gasoline can be extremely flammable To reduce the risk of serious injury or death never carry fuel or other flammable liquids on this vehicle Rollovers crashes rough riding or changes in elevation...

Page 18: ...Always do a low speed reconnaissance run prerun to become aware of anything you may encounter High speed off road operation can lead to loss of control crashes or hard landings that can seriously inju...

Page 19: ...the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path Abrupt application of the accelerator pedal can cause the tires to lose...

Page 20: ...rtopping a hill Slow down when you reach the crest of a hill Never blindly go over the crest of a hill or a drop off at high speed An obstacle a sharp drop or another vehicle or person could be on the...

Page 21: ...ter leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Riding on sand dunes Use extra caution when operating on or near dunes B...

Page 22: ...wly and carefully until you can drive straight downhill Do not continue driving if your vehicle may be damaged or if you were in a crash or rollover Operating the vehicle while damaged or after a cras...

Page 23: ...Materials Engine exhaust and other vehicle components can be very hot during and after use Do not idle or park the vehicle over anything that could contact the exhaust system and catch on fire such as...

Page 24: ...or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours...

Page 25: ...our vehicle always read and follow the instructions of the labels on the vehicle Never remove any labels from your vehicle If a label becomes illegible or comes off contact your POLARIS dealer for a r...

Page 26: ...tion when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding across slopes Require Proper Use of Your Ve...

Page 27: ...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 PRO R MAXIMUM CARGO BOX LOAD 300 lbs 136 kg TIRE PR...

Page 28: ...s in the clean side of the intake tube The air filter must be properly seated before the lid is reinstalled Please reference your owner s manual for additional information regarding air filter service...

Page 29: ...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 fo...

Page 30: ...COMPONENT LOCATIONS q Roof w ROPS Frame e Steering Wheel r Front Lights t Radiator y Cargo Box u Tail Lights i Fuel Cap o Cab Door 28 FEATURES AND CONTROLS...

Page 31: ...en the steering wheel is at the desired position TELESCOPE STEERING WHEEL IF EQUIPPED On models equipped with a telescope steering wheel the steering wheel can be adjusted by pressing the release leve...

Page 32: ...nt lights Check engine and power steering warning indicators will appear on the display in this mode but will turn off when the vehicle is started if no issues are present ON Electrical circuits are o...

Page 33: ...hree positions q High Beams w Low Beams e Headlights Off DRIVELINE MODE AWD SWITCH The ignition switch key must be in the ON RUN position to operate the Driveline Mode system The Driveline Mode switch...

Page 34: ...de e Sport Mode MODE DESCRIPTION Race Mode Allows MAX engine feedback when pressing the throttle pedal Rock Mode Allows minimized engine feedback when pressing the throttle pedal Sport Mode Allows sli...

Page 35: ...hicle is equipped with two 12 volt accessory outlets One is in the front portion of the center console in front of the gear selector The other is in the armrest storage bin Use the outlets to power an...

Page 36: ...tion the EPS will shut down after 5 minutes of engine inactivity The EPS warning indicator will illuminate to indicate the EPS has shut down NOTE The EPS shuts down automatically to conserve the batte...

Page 37: ...he momentary MAX FIRM button is on the right When this button is pressed the suspension will immediately switch to maximum compression damping The vehicle will maintain this setting if the button is c...

Page 38: ...mping for frequent cornering events Best feeling of the front wheels for frequent cornering events Comfort Mode Low compression and rebound damping to allow the shock to move and absorb smaller suspen...

Page 39: ...side of the steering wheel Volume can be adjusted by pressing the bottom lower volume or the top higher volume of the button Audio can be paused or resumed by pressing the pause button Refer to the R...

Page 40: ...at Make sure the seat tabs at the front edge of the seat slide onto the seat retainer tubes 5 Press down firmly at the rear of the seat to engage the rear latches SEAT ADJUSTMENTS DRIVER S SEAT ADJUST...

Page 41: ...seat position remove the seat and remove the four bolts e located on the two seat frame members The seat frame members can be moved forward or backward to the desired position The passenger seat can...

Page 42: ...cluding pilot lights from water heaters furnaces or clothes dryers To avoid fires and explosions follow these precautions when refueling Do not smoke Wipe up any spilled fuel WARNING Gasoline is poiso...

Page 43: ...le inside the tank To avoid fires and explosions do not overfill the tank Allow room for gasoline to expand inside the tank by leaving the tank neck empty Use only 91 octane or higher unleaded fuel mi...

Page 44: ...rness with built in interlock The safety harness requires proper adjustment for each rider and will need to be adjusted when riders change seats WARNING Improper use or adjustment of the harness can c...

Page 45: ...wear include the buckle tongue area the shoulder guide area and any place where the belt makes contact with vehicle or seat Corrective Action Replace entire belt system 2 Inspect buckle for proper op...

Page 46: ...retractor operation if equipped When pulled and released slowly seat belt must spool out and retract without locking Corrective Action Replace entire belt system 7 Inspect mounting hardware on all bel...

Page 47: ...uipped on 6 pt harnesses Shoulder belts not adjustable on retractable 6 pt harness How to use the red straps and tilt lock feature to tighten and loosen the belts When the tilt lock is down q the belt...

Page 48: ...ten for a click Check fit and make sure buckle is secure 3 Tighten shoulder belts If your harness is equipped with non retracting adjustable shoulder belts tighten the shoulder belts until they are sn...

Page 49: ...in the door or hangs out of the vehicle SUB ZERO SEAT BELT HARNESS CAUTION If the red warning section of the safety label becomes visible at all times this harness must be replaced On models equipped...

Page 50: ...ove the seats then remove the panel to reach serviceable engine components Remove the panel by turning the close off knobs q 1 4 turn CARGO BOX ACCESS The entire cargo box layer can be lifted to acces...

Page 51: ...hifting 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...

Page 52: ...dal w down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine NOTICE When tr...

Page 53: ...nlock When in All Wheel Drive the front drive is engaged with the front differential in the open state The open state allows the front wheels to spin at different speeds for improved turning ability I...

Page 54: ...s containing 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 q Speedometer w Tachomete...

Page 55: ...LE WARNING Do not continue driving if you think or feel the vehicle may be damaged or if you were in a crash or rollover Operating the vehicle while damaged or after a crash or rollover can cause loss...

Page 56: ...ued operation could result in permanent damage to the EPS unit and increased steering effort For more information see the Electronic Power Steering EPS section Engine Hot This lamp illuminates to indi...

Page 57: ...tank is low Neutral The neutral indicator lamp illuminates when the transmission is in neutral and the ignition key is in the ON position Helmet Seat Belt WARNING Seat Belt indicator lamp is a remind...

Page 58: ...CATOR ICON FUNCTION High Beam This lamp illuminates when the headlamp switch is set to high beam Park Brake if equipped Lamp illuminates when the Park Brake is applied if equipped 56 FEATURES AND CONT...

Page 59: ...igh Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears w AWD Indicator This indicator displays the active driveline mode when the vehicle is in gear e Service I...

Page 60: ...distance traveled by the vehicle Trip Meters T1 T2 A trip meter records the distance traveled by the vehicle if reset before each trip To reset see page 61 Engine Hours Total hours of engine operation...

Page 61: ...ired option 2 Press MODE to select the option 3 Press either toggle button to cycle to the desired setting 4 Press MODE to save and exit to the settings menu 5 Press and hold the MODE button to exit t...

Page 62: ...s MODE to select and exit to the settings menu CLOCK The clock must be reset any time the battery has been disconnected or discharged 1 Press and hold the MODE button to enter the settings menu 2 Pres...

Page 63: ...er to track the distance traveled during a specific trip or period of time Reset the meter to zero before traveling 1 Press either toggle button to cycle to the desired trip meter option T1 or T2 2 Pr...

Page 64: ...it or press either toggle button to change the value Press MODE to save and exit to the settings menu PIN ACTIVATED SECURITY SYSTEM P A S S IF EQUIPPED INSTRUMENT CLUSTER For vehicles with the Ride Co...

Page 65: ...nu The vehicle will now require passcode entry before next startup You can exit the OPTIONS menu three different ways Toggle to EXIT and press the MODE button Hold the MODE button for a few seconds Do...

Page 66: ...he EPS lamp illuminates retrieve the active error codes from the display q Failure Mode Indicator FMI w Suspect Parameter Number SPN e Code Count 1 Press and hold the MODE button to enter the settings...

Page 67: ...valid for 90 days after the release date Please keep your trail data up to date Download the latest trails at http ridecommand polaris com NOTICE Using the display for an extended period of time while...

Page 68: ...the following radio equipment or components that contain radio equipment COMPONENT COMPONENT ID MANUFACTURER 9200 Series Display RC 7 Polaris Industries Inc This device contains license exempt transm...

Page 69: ...ting Frequency 2402 2480 MHz Max RF Transmitting PWR 0 2432 W Other transmitting radio frequencies may exist outside of EU markets Hereby Polaris Industries Inc declares that the above radio equipment...

Page 70: ...meter Tachometer i Gear Status RIDE COMMAND BUTTONS BUTTON DESCRIPTION FUNCTION Menu Button Press the Menu button to access the settings To reboot the display press and hold for 5 seconds Gauge Screen...

Page 71: ...Bluetooth connected phone including recent calls contacts dialer and messages Audio Button Press the Audio button to access the Radio Weather USB and connected Bluetooth music interface Volume Decrea...

Page 72: ...eft toolbar 3 Select Engine Start Lockout 4 If this your first time activating P A S S you will be prompted to enter a new passcode Enter and verify new passcode Please record your passcode 5 Turn Eng...

Page 73: ...d All Wheel Drive AWD Unlock When in All Wheel Drive the front drive is engaged with the front differential in the open state The open state allows the front wheels to spin at different speeds for imp...

Page 74: ...your gauge screens press the gear icon located in the lower right corner of the display SETTINGS From the setting menu you can view vehicle information manage Bluetooth devices update display softwar...

Page 75: ...d Digital While in the digital gauge view mode press w to invert the MPH and RPM units DISPLAY MODE From the Control tab e select the display mode from the available options y The display mode can be...

Page 76: ...signal strength e Wireless Internet Signal Strength Displays current wireless internet signal strength r Fuel Level Displays current fuel capacity percentage t Vehicle Direction Displays vehicle dire...

Page 77: ...On the RIDE COMMAND display select the Settings menu on your display by pressing the POLARIS icon at the top of the screen 3 Select General Settings then Update Software 4 Select the file you wish to...

Page 78: ...plete Do not remove the USB flash drive until the display has fully restarted USB HARDWARE SOFTWARE UPDATES For software update POLARIS recommends using a SanDisk or similar USB flash drive with a min...

Page 79: ...ns Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist 6 Carry only light loads 7 During the break in perio...

Page 80: ...eration and prolonged operation at a specific RPM during this period SAND DUNE BREAK IN Drive in low gear for the first 5 miles 8 km of operation Avoid prolonged low speed operation at high throttle A...

Page 81: ...ine 5 Turn the ignition key past the ON RUN position and release immediately to START The engine will turn over for a maximum five seconds until the vehicle has started 6 If the engine does not start...

Page 82: ...vehicle on an incline is unavoidable use extra care Vehicle rollaway can cause serious injury or death This vehicle can roll whenever the gear selector is not in the PARK P position Always shift to PA...

Page 83: ...m Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system EXHAUST EMISSION CONTROL SYSTEM Exhaust emissions are controlled by eng...

Page 84: ...82...

Page 85: ...o reinstall heat shields properly can lead to a fire WARNING Hot parts can cause burns To avoid burns do not touch hot components or attempt maintenance before allowing to cool Surfaces that could be...

Page 86: ...ate long enough to reach full operating temperature IMPORTANT Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or cra...

Page 87: ...f applicable Inspect adjust as needed Battery Check terminals terminals should be tight and free of corrosion Clean test and replace as necessary Engine Oil and Filter Change the engine oil and filter...

Page 88: ...and airbox cover Inspect ducts and screens clean as necessary Battery Check terminals terminals should be tight and free of corrosion Clean test and replace as necessary Brake System Fluid level insp...

Page 89: ...brake pad wear Inspect hoses for damage General Lubrication Locate all applicable fittings and grease Radiator Inspect Clean external surfaces Tires Inspect Adjust pressure level as needed Inspect we...

Page 90: ...s needed Parking Brake if applicable Inspect adjust as needed Fuel System Cycle key to pressurize fuel pump check for leaks at fuel system connections check for leaks at fill cap Intake Ducts Inspect...

Page 91: ...IONAL MAINTENANCE INTERVALS Every 2000 miles 3200KM 24 months 2 years 100 hours Brake Fluid Change fluid Every 2500 miles 4000KM Shock Absorbers Replace or rebuild if applicable Every 5000 miles 8900K...

Page 92: ...e Oil and PS 4 Extreme 0W 50 4 Cycle Oil See page 93 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 120 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Flu...

Page 93: ...be changed more frequently if POLARIS oil is not used Do not use automotive oil Follow the manufacturer s recommendations for ambient temperature operation Part numbers can be found in the POLARIS Pro...

Page 94: ...the engine Allow the engine to idle for two to three 2 3 minutes 4 Stop the engine Wait three 3 minutes before checking the oil level This allows the oil to settle to the bottom of the crankcase Do no...

Page 95: ...e a fire hazard CAUTION Engine oil is hot after use and can cause burns to skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Interval Chart 1 Position the veh...

Page 96: ...a film of clean engine oil Check to make sure the o ring is in good condition Tighten to specification TORQUE Oil Filter Turn by hand until filter O ring contacts sealing surface then turn an addition...

Page 97: ...oil as necessary to bring the oil level within the SAFE range between the holes on the dipstick Do NOToverfill IMPORTANT A rising oil level between checks during cold weather operation can indicate co...

Page 98: ...e fill plug using a 8 mm Allen wrench 3 Check the fluid level 4 If necessary add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specifica...

Page 99: ...fer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications FLUID CHECK The fill plug q is located on the bottom right side of the front drive unit Maintai...

Page 100: ...ed in the Gearcase Specification Chart Do not overfill 7 Reinstall the fill plug Torque to specification listed in the Gearcase Specification Chart 8 Check for leaks Discard used fluid properly and cl...

Page 101: ...llen wrench 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the rec...

Page 102: ...ricant Transmission Fluid 29 6 oz 875 ml 10 14 ft lbs 14 19 N m 10 14 ft lbs 14 19 N m Front Gearcase 80W 140 Angle Drive Fluid 12 2 oz 360 ml 10 14 ft lbs 14 19 N m 10 14 ft lbs 14 19 N m Rear Gearca...

Page 103: ...the Specifications section for details Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is drive...

Page 104: ...ug socket with an extension 6 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glas...

Page 105: ...G The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the...

Page 106: ...he blown fuse then replace the fuse There are two fuse relay centers accessible on the vehicle The primary fuse center q is in the driver side rear wheel well Remove the protective shield before acces...

Page 107: ...se Terminal Block Accessory INST ACCY 10A Fuse Diagnostic Accessory Interior LED Light Display Accessory optional PWR PT 1 10A Fuse 12V Socket in front of gear selector INST UNSW 7 5A Fuse Display opt...

Page 108: ...onal Fuses if equipped SCM 10A Fuse Shock Control Module SHOCK 15A Fuse Shock Power PDM FUSE TROUBLESHOOTING IMPORTANT In the event of faults or intermittent power to functions connected to more than...

Page 109: ...the ignition switch to the OFF position 5 Replace the PDM fuse using one of the SPARE fuses IMPORTANT After removing a fuse always check to ensure the two wire terminals that the fuse connects to are...

Page 110: ...the vehicle cools down after operation This is considered normal for the vehicle The pressure tank is designed to contain a volume of air above the coolant level As coolant operating temperature incr...

Page 111: ...icle passenger side 3 Slowly remove the radiator pressure cap e 4 Remove the pressure cap and use a funnel to add coolant as needed Maintain the coolant level at the cold fill mark on the side of the...

Page 112: ...maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix RADIATOR AND COOLING FAN Always check and clean the screens and radiator fins at the intervals outlined in the Periodic Ma...

Page 113: ...nents Always look for and remove debris inside and around the clutch and vent system when replacing the belt Always make sure the PVT housing is securely in place during operation for the safety of ri...

Page 114: ...oosen the clamp q retaining the PVT inlet duct to the outer clutch cover 5 Using a 10 mm wrench remove the five clutch cover bolts securing the upper portion of the clutch cover w 6 Then remove the 5...

Page 115: ...ppear to be damaged your vehicle requires prompt service Your POLARIS dealer can assist 15 Once finished return the clutch spreader tool to the clutch housing and reattach the clutch cover 16 Tighten...

Page 116: ...the transmission in PARK Apply the brakes 3 Start the engine 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for m...

Page 117: ...needed to ensure adequate air flow NOTICE When washing the vehicle always avoid spraying water directly toward the PVT intake If water is sprayed into the PVT intake follow the procedures in the PVT...

Page 118: ...ush it away by hand after removing the filter from the air box 5 To remove the filter slide the filter toward the passenger s side of the vehicle 6 With the filter removed clean the intake tube and ai...

Page 119: ...he edge of the air box IMPORTANT If there is difficulty or resistance when installing the air box cover remove and check alignment and the position of the air filter before continuing 10 Secure the se...

Page 120: ...ed carbon A plugged spark arrester will affect engine performance Clean daily when driving in mud and water Replace a cracked or damaged arrester before operating To service spark arrester 1 Turn off...

Page 121: ...system degradation and brake system failure Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and...

Page 122: ...heel well 1 Position the vehicle on a level surface 2 Place transmission in park and turn off engine 3 View the brake fluid level in the reservoir located in the front driver side wheel well The level...

Page 123: ...suspension system may occur if the MAX allowable preload is exceeded RZR PRO R FACTORY DEFAULT PRELOAD SETTINGS GVW SETTING MAX ALLOWABLE PRELOAD Measure ment Fox Walker Evans Fox Walker Evans Front...

Page 124: ...FOX SHOCKS IF EQUIPPED SHOCK LOCATION MEASUREMENT Front Shock Rear Shock 122 MAINTENANCE...

Page 125: ...WALKER EVANS SHOCKS IF EQUIPPED SHOCK LOCATION MEASUREMENT Front Shock Rear Shock 123 MAINTENANCE...

Page 126: ...t The cross over rings need to be locked tight after any adjustment is made To lock the cross over rings take a punch and hammer to hit each side so the rings jam together If the cross over rings are...

Page 127: ...ded tire pressure Check pressure before operating Even if your vehicle has only been driven a short distance the tire pressure readings can be higher Make sure tire pressure is even across all four ti...

Page 128: ...k front and rear sides of both REAR tires If jacking the REAR of the vehicle then chock front and rear sides of both FRONT tires Keep bystanders away and make sure no occupants or cargo are still in t...

Page 129: ...ance service Do not lubricate the stud or the lug nut Lug Nut Aluminum Wheels Front and Rear 148 ft lbs 200 N m Hub Retaining Nut Front and Rear 120 ft lbs 162 7 N m WHEEL REMOVAL 1 Position the vehic...

Page 130: ...al operation Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles TIP LED LAMPS If an LED headlamp appears to have moisture or fogging inside the lens...

Page 131: ...ht beam can be adjusted slightly upward or downward and to the left or right 1 Position the vehicle on a level surface The headlight should be approximately 25 ft 7 6 m q from a wall 2 Measure the dis...

Page 132: ...1 Move the vehicle to dry land 2 Check the air box See the Air Filter section for details If water is present dry the air box and replace the filter with a new filter 3 Remove the fuse relay center c...

Page 133: ...ble first When reinstalling the battery always connect the negative black cable last WARNING Do not jump start using jumper cables that are made to connect one vehicle to another The battery gives off...

Page 134: ...from the battery terminals q 4 Disconnect the red positive battery cable w 5 Remove the two screws e securing the battery hold down strap 6 Remove the battery hold down strap r 7 Lift the battery out...

Page 135: ...GATIVE black battery cable from the battery Secure the cable away from the battery terminals 4 On the left most battery remove the battery terminal post w to disconnect the NEGATIVE black battery cabl...

Page 136: ...most battery remove the battery terminal post e to disconnect the POSITIVE red battery cable 6 On the left most battery remove the battery terminal post r to disconnect the POSITIVE red battery cable...

Page 137: ...7 Remove the four screws t securing the two battery hold down straps 8 Remove the two battery hold down straps y 9 Lift the batteries out of the vehicle 135 MAINTENANCE...

Page 138: ...seat See page 38 3 Place the battery in the battery holder 4 Place the battery hold down strap q across the battery 5 Install the two screws w securing the battery hold down strap Torque fasteners to...

Page 139: ...e driver s seat See page 38 3 Place the both of the batteries in the battery holder 4 Place the battery hold down strap q across the battery 5 Install the four screws w securing the two battery hold d...

Page 140: ...7 On the left most battery connect and tighten the POSITIVE red cable e 8 On the right most battery connect and tighten the POSITIVE red cable r 138 MAINTENANCE...

Page 141: ...e left most battery connect and tighten the NEGATIVE black cable t 10 On the right most battery connect and tighten the NEGATIVE black cable y TORQUE Battery Terminal Fasteners 30 in lbs 7 Nm 139 MAIN...

Page 142: ...t immediately or the battery runs the risk of sulfation and reduced battery life This vehicle is equipped with a vehicle battery charge port located on the dash This allows the operator to charge the...

Page 143: ...st 13 hours 0 25 12 0 volts or less Needs charge At least 20 hours Using AGM specific charger at standard amps specified on top of battery CLEANING AND STORAGE WASHING THE VEHICLE WARNING Clean seat b...

Page 144: ...types of products to contact the vehicle The best way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper b...

Page 145: ...THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container POLISHING TIPS Avoid the u...

Page 146: ...case fluid if equipped Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill INSPECT AND LUBRICATE Inspect all cables and l...

Page 147: ...ck all the points listed in the Daily Pre Ride Inspection section Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer or other qualified service facility...

Page 148: ...t they cannot contact any part of the vehicle and become worn or loose during transport Do not use winch to secure vehicle to trailer Towing this vehicle is not recommended Transport this vehicle on a...

Page 149: ...doors if equipped 8 Using suitable straps secure the vehicle to the trailer at the designated tie down points front and rear The straps must be secured in a manner that provides support in all direct...

Page 150: ...TIE DOWN LOCATIONS q Front tie down point w Rear tie down points 148 MAINTENANCE...

Page 151: ...sential to the vehicle s basic operation as outlined in the ANSI ROHVA 1 2016 standard Rear Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 kg including riders cargo and...

Page 152: ...h 24 4 in 62 cm travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Tire Size Front 32x10 R15 Tire Size Rear 32x10 R15 Tire P...

Page 153: ...Fluid 95 l 2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid 3 8 l 2876160 80W 140 Angle Drive Fluid 95 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2880514 Antifreeze 50 50 Premix 95 l...

Page 154: ...MBER DESCRIPTION Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 152 POLARIS PR...

Page 155: ...short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Hauling heavy cargo pushing at low RPM low g...

Page 156: ...st Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH 48 km h for one mile 1 5 km and for 5 miles 8 km or more when temperature is below freezing Wrong or missing...

Page 157: ...ody air inlet opening in an attempt to start the vehicle This could result in a flash fire causing serious injury or death POSSIBLE CAUSE SOLUTION Out of fuel Refuel Clogged fuel filter Your POLARIS d...

Page 158: ...ange Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires Your POLARIS dealer or other qualified person can assist I...

Page 159: ...ed or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replac...

Page 160: ...OSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel tank vent line or filter Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect cle...

Page 161: ...uel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed...

Page 162: ...Voltage High 168 3 Intake Air Temperature Sensor 1 Circuit Intermittent Bank 1 105 10 Fuel Level Sensor A Circuit Low 96 4 Throttle Pedal Position Sensor Switch A Circuit High 51 3 Throttle Pedal Pos...

Page 163: ...tion Sensor A Circuit Range Performance 731 2 Starter Relay A Circuit Low 677 4 Ignition Coil B Primary Control Circuit High 1269 3 Cylinder 2 Injector A Circuit High 652 3 ECU Output Supply Voltage 2...

Page 164: ...Fueling Disabled 65590 31 ECU Output Supply Voltage 2 Voltage Below Warning Level 3598 18 EVAP System Purge Control Valve A Circuit Open 520202 5 Cylinder 1 Misfire Detected 65591 7 Cylinder 3 Misfir...

Page 165: ...sor Passed Test 520276 12 Function Monitoring MoFTrq Comparison Error 520385 31 Throttle Body Control Mechanical Stop Adptation Failure Condition Exists 520281 31 RBA Monitoring Error Memory Read Writ...

Page 166: ...nsor Positive Line Voltage Too Low 520331 4 Brake Switch 1 or 2 Indeterminable Brake Switch Correlation Fault 520285 2 Intake Air System Leak Bank 1 520338 31 Drive Mode Select Switch Signal Fault 524...

Page 167: ...nitoring Error ECU Ignition Check 520388 31 Throttle Body Control Return Spring Check Failed Condition Exists 520278 31 Function Monitoring MoFAir Group 520249 31 RBA Monitoring Error Keep Alive 52038...

Page 168: ...ial Output Driver Circuit Grounded 746 4 Knock Combustion Vibration Sensor A Circuit Range Performance 731 2 Rear Differential Output Driver Circuit Short to B 746 3 System Power Voltage Below Critica...

Page 169: ...or Signal Biased Stuck Lean Bank 1 Sensor 1 3056 17 O2 Sensor Heater Circuit Bank 1 Sensor 1 520209 2 Ambient Air Temperature Sensor Circuit A Range Performance 171 2 Crankshaft Position Sensor A Circ...

Page 170: ...ircuit Low 1268 4 O2 Sensor Heater Circuit Bank 2 Sensor 1 520210 2 Charge Air Cooler Cooling Fan 2 Control Circuit Open 524281 5 Ignition Coil B Primary Control Circuit Low 1269 4 O2 Sensor Circuit B...

Page 171: ...iled Condition Exists 520278 31 System Too Lean at Idle Bank 2 520343 17 Transmission Mode Switch B Circuit 520468 31 ECU Output Supply Voltage 1 Voltage Too Low 3597 4 System Too Rich at Idle Bank 2...

Page 172: ...tage Too High 168 3 Steering angle sensor out of range 1807 31 EPS internal temperature warning 520225 16 External fault engine speed reception 524000 19 Steering angle sensor not calibrated 1807 13 S...

Page 173: ...Module Acceleration Sensor Measurement Out of Range 516115 12 Engine Speed Data Invalid 524000 2 Absolute Shock Current Error Rebound Rear Right 516314 11 Steering Angle and Velocity Signal Not Recei...

Page 174: ...d Low or Open Circuit Compression Front Right 516107 4 Valve Driver Shorted Low or Open Circuit Rebound Front Right 523991 4 Absolute Shock Current Error Compression Rear Left 516113 11 Suspension Con...

Page 175: ...r Incorrect 523962 2 Valve Driver Shorted Low or Open Circuit Rebound Rear Right 523993 4 System Voltage below minimum moderately severe level 516126 18 Valve Driver Shorted High Rebound Front Right 5...

Page 176: ...ty Data Inconsistent 516119 2 Suspension Mode Switch Input Voltage Above Maximum Threshold 516098 3 Absolute Shock Current Error Compression Front Left 516111 11 Accelerator Pedal Position Data Invali...

Page 177: ...DIAGNOSTIC CODES CONDITION SPN FMI Lost Communication With Power Steering Control Module A 520230 31 Ride Command Display Battery Potential Power Input 1 168 1 175 TROUBLESHOOTING...

Page 178: ...176...

Page 179: ...ARIS dealer but any such 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...

Page 180: ...er foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after...

Page 181: ...Y POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE O...

Page 182: ...aler s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure t...

Page 183: ...equire any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or...

Page 184: ...emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend i...

Page 185: ...PRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING T...

Page 186: ...r person may maintain replace or repair the emission control devices or systems on your vehicle An authorized POLARIS dealer can perform any service that may be necessary for your vehicle POLARIS also...

Page 187: ...evaporative emission control system and is labeled with a Vehicle Evaporative Emissions Control Information label indicating that the vehicle conforms to California evaporative emissions regulations a...

Page 188: ...s an owner you are responsible for presenting your OHRV EVAP to a Polaris dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 da...

Page 189: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 187 MAINTENANCE LOG...

Page 190: ...188...

Page 191: ...em 81 D Device Compliance Statements 66 Diagnostic Display Code Definitions 159 Display Mode 73 Display Units Standard Metric 61 Drive Belt Wear Burn 153 E Electromagnetic Interference 81 Electronic P...

Page 192: ...ttings 121 Programmable Service Interval 62 PVT Drying 114 R Radiator 110 Radiator Coolant Level Changing Coolant 109 Registration 177 Ride Command Before You Ride 65 Buttons 68 Driveline Mode 71 Gaug...

Page 193: ...8 Tires 125 Tire Rotation 127 Tire Tread Depth 126 Tools for Safe Riding 7 Trademarks 2 Trailering Safety 145 Transmission Front Gearcase 97 Main Gearcase 96 Rear Gearcase 98 Transporting the Vehicle...

Page 194: ......

Page 195: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9931527 Rev 01 Printed in USA...

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