Polaris RZR Trail S 1000 Premium 2022 Owner'S Manual Download Page 143

Page: 143 / 210

GEARCASE SPECIFICATION CHART

Use of other fluids may result in improper operation of components. See the
Polaris Products section for the part numbers.

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Transmission
(Main Gearcase)

AGL
Gearcase
Lubricant &
Transmis-
sion Fluid

44 fl oz
(1300 mL)

10-14 ft-lbs
(14-19
N·m)

900 SPORT:

Demand Drive Unit
(Front Gearcase)

Demand
Drive Fluid

7.5 fl oz
(222 mL)

8-10 ft-lbs
(11-14 N·m)

1000 PREMIUM /
ULTIMATE

Demand Drive Unit
(Front Gearcase)

Demand
Drive Fluid

9 fl oz
(266 mL)

8-10 ft-lbs
(11-14 N·m)

141

MAINTENANCE

Summary of Contents for RZR Trail S 1000 Premium 2022

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

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: ...2022 Owner s Manual RZR Trail S 900 Sport RZR Trail S 1000 Premium RZR Trail S 1000 Ultimate...

Page 4: ...x Factory Inc Bluetooth is a registered trademark of Bluetooth Sig Inc ANSI is a registered trademark of American National Standards Institute WALKER EVANS RACING is a registered trademark of Walker E...

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: ...d Controls 33 Ride Command Display if equipped 63 Operation 73 Winch Guide 93 Emission Control Systems 103 Maintenance 105 Specifications 177 Polaris Products 181 Troubleshooting 183 Warranty 191 Main...

Page 8: ...6...

Page 9: ...ith the vehicle This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle All riders must be able to sit with backs against the seat b...

Page 10: ...cle 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 service notifications RID...

Page 11: ...NING 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 moderate...

Page 12: ...mperature RADIO COMPLIANCE STATEMENTS NOTE Some vehicle models contain radio equipment as detailed in this section USA RADIO COMPLIANCE This vehicle contains the following radio equipment or component...

Page 13: ...ic Development Canada ISED to operate with Polaris antenna part number 4018713 with gain of 3 dBi Any antenna that has a gain greater than 3 dBi is prohibited for use with this device EUROPEAN UNION E...

Page 14: ...ove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition sw...

Page 15: ...LARIS vehicle is considered an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the r...

Page 16: ...cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain...

Page 17: ...rcle 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 label EYE PROTECTION D...

Page 18: ...Warning e Payload Warning r Riders Warning t Drive Responsibly Warning PROPER USE WARNING WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless...

Page 19: ...et and protective gear ALWAYS use cab nets and or doors Each rider must be able to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside th...

Page 20: ...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 BELT DEBRIS WARNING q Belt Debris Warn...

Page 21: ...n 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 CAUTION Air...

Page 22: ...s low as possible in box For stability on rough or hilly terrain reduce speed and cargo Never carry passengers in cargo box Passengers can be thrown off This can cause serious injury or death RZR 900...

Page 23: ...TRUCTION Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different t...

Page 24: ...icle FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always perform the Pre...

Page 25: ...re closed and latched while riding in this vehicle Cab doors are NOT intended to be used as arm rests Keep hands and feet inside the vehicle at all times CARRYING MULTIPLE PASSENGERS RZR 2 SEAT Never...

Page 26: ...itions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down 2 Verify tire pressure 3 Use extra caution when operating Operating in rough terrain Operating...

Page 27: ...rain the visibility and operating conditions your skills and experience and any passenger s skills and experience TURNING IMPROPERLY Turning improperly could cause loss of traction loss of control acc...

Page 28: ...on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable alway...

Page 29: ...lowly IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control accident or rollover Always use the size and type of tir...

Page 30: ...perating in water as described in this owner s manual See page 84 Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly...

Page 31: ...the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing EXPOSURE TO EXHAUST Engine exhaust fumes are poisonous a...

Page 32: ...move the ignition key when the vehicle is not in use EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed Modifications to your vehicle may negative...

Page 33: ...but not limited to overhead audio speakers may change the forward clearance in the vehicle Polaris recommends selecting a helmet that is compatible with the equipment on your vehicle and provides the...

Page 34: ...32...

Page 35: ...COMPONENT LOCATIONS q Cargo Box w ROPS Frame e Radiator r Cab Door t Fuel Tank Cap y Steering Wheel u Tie Down Points 4 corners i Brake Pedal o Throttle Pedal a Gear Selector s Passenger Hand Hold 33...

Page 36: ...SWITCHES q Instrument Cluster w Ignition Switch e Headlight Switch r All Wheel Drive AWD Switch t 12V Accessory Outlet 34 FEATURES AND CONTROLS...

Page 37: ...present ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released The key...

Page 38: ...ering engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle The EPS warning indicator briefly illuminates when the key is turned to the O...

Page 39: ...ring wheel adjustment lever q while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position SEATS Before operating the vehicle always push dow...

Page 40: ...d or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel To close tighten the fuel cap until it clicks...

Page 41: ...nets or doors the ROPS helps prevent occupants from being ejected from the vehicle Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover...

Page 42: ...Towing section BRAKE AND THROTTLE PEDALS BRAKE PEDAL Depress the brake pedal q to slow or stop the vehicle Apply the brakes while starting the engine THROTTLE PEDAL Push the throttle pedal w down to i...

Page 43: ...ining shift linkage adjustment is important to assure proper transmission function Your POLARIS dealer or qualified person can assist in resolving any shifting problems NOTICE Do not attempt to shift...

Page 44: ...NEL The cargo box access panel is located on the floor of the cargo box Remove the panel to access the engine oil fill cap spark plugs and air filter PASSENGER HAND HOLD Always adjust the hand hold to...

Page 45: ...in through the post mounting hole e adapter bushing hole r both post adjustment holes t and lastly through the remaining bushing hole and post mounting hole 5 Reinstall the retainer to the pin 43 FEAT...

Page 46: ...t is not secured 3 POINT SEAT BELT To wear the 3 point seat belt properly follow this procedure 1 Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the sea...

Page 47: ...elt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system ch...

Page 48: ...er can be cleaned with water To adjust the height of your seat belt for desired comfort and proper fit follow this procedure 1 Stretch the seat belt height adjuster toward the front of the vehicle 2 W...

Page 49: ...length of time the vehicle may remain in AWD ENGAGING AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the...

Page 50: ...remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase...

Page 51: ...prays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster q Speedometer w Tachometer e Indicator Lamps r Mode Button t Toggle Buttons y Rider Information Cen...

Page 52: ...Rider Information Center for 10 seconds to allow viewing of the odometer and the clock SPEEDOMETER The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h TACHO...

Page 53: ...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 57 Engine Hours Total hours of engine operation...

Page 54: ...y is turned to the ON position If the light remains on the EPS system is inoperative See your POLARIS dealer or other qualified person as soon as possible for repair Continued operation could result i...

Page 55: ...n neutral and the ignition key is in the ON position Helmet Seat Belt This lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating The driver s seat...

Page 56: ...igh Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears w AWD Indicator This indicator shows whether 2X4 or AWD is active when the vehicle is in gear e Service I...

Page 57: ...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 58: ...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 59: ...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 60: ...nabled it provides a convenient reminder to perform routine maintenance Refer to the Periodic Maintenance Chart for recommended service intervals Use the following procedure to reset or change the ser...

Page 61: ...utton to enter the OPTIONS menu 2 Use the UP DOWN toggle buttons to cycle through options until REQUIRE PIN TO START appears Press the MODE button to select 3 If required ENTER NEW PIN will appear Use...

Page 62: ...uttons to cycle through options until REQUIRE PIN TO START appears Press the MODE button to select 3 Enter current passcode 4 Use the UP DOWN toggle buttons to change the flashing ON at bottom of scre...

Page 63: ...re Mode Indicator FMI w Suspect Parameter Number SPN e Code Count 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the DIAGCODE option Press MODE to...

Page 64: ...62...

Page 65: ...o change or update maps trails see page 72 Check https www polaris com en us owners manuals for the latest updates to the owner s manual NOTICE Trails change often and the trail data file is only cons...

Page 66: ...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 67: ...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 68: ...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 see page 5 Tur...

Page 69: ...The vehicle automatically engages 4X4 when operating in reverse if the switch is set to 4X4 position Turf Mode if equipped When operating in TURF mode the inside rear wheel will rotate independently f...

Page 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...e heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use...

Page 76: ...acceleration high speed operation and prolonged operation at a specific RPM during this period SAND DUNE MUD BREAK IN Drive in low gear for the first 5 miles 8 km of operation Avoid prolonged low spee...

Page 77: ...T intake pre filter Inspect clean page 149 Headlights Check operation Brake light taillight Check operation Seat Latches Push down on both seat backs to ensure the latches are secure page 37 Seat Belt...

Page 78: ...irt and gravel roads 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both hands on the stee...

Page 79: ...ge the starter for a maximum of five seconds Release the 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 seco...

Page 80: ...ey to prevent unauthorized use KNOW YOUR RIDING AREA TREAD LIGHTLY Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area Respect the environment in w...

Page 81: ...his vehicle 9 Sit in the driver s seat and fasten the seat belt 10 Place the transmission in PARK 11 Start the engine 12 Apply the brakes and shift into low gear 13 Check your surroundings and determi...

Page 82: ...The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times See the Safe Riding Gear section for details 6 Always...

Page 83: ...straight uphill 4 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 5 Avoid unnecessary changes in speed or direction 6 Never go over the crest of a hill at high...

Page 84: ...er irregular terrain Always move the AWD switch to AWD before ascending or descending a hill 3 Drive slowly and use extreme caution 4 If the vehicle begins to roll over or if it feels as if it may rol...

Page 85: ...before descending a hill Never drive on hills with excessively slippery or loose surfaces 4 Always descend a hill with the transmission in forward gear Never descend a hill with the transmission in ne...

Page 86: ...er test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Avoid applying brake and throttle at the same time NOTICE Major engine damage can resul...

Page 87: ...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 d...

Page 88: ...s 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 lar...

Page 89: ...s 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 stoppin...

Page 90: ...If parking on an incline is unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Slowly release the brake pedal and make sure the transmission...

Page 91: ...GHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passengers accessories and loads in the rack or box The combined weight of thes...

Page 92: ...ility may be adversely affected causing a rollover DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 km h while cornering or while ascending or descending a hill C...

Page 93: ...es specified for your vehicle See the Load Passenger Tire Warning section for details BELT LIFE To extend belt life use low gear in the following conditions when hauling or towing heavy cargo when con...

Page 94: ...eight on the towing bracket 2 When transporting heavy loads and or when towing always operate the vehicle in low gear 3 Do not operate the vehicle faster than 10 mph 16 km h when towing See the Haulin...

Page 95: ...winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 101 7 Always keep the area around t...

Page 96: ...ds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 16 Never touch push pull or straddle the winch cable while winching a lo...

Page 97: ...ing Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 A...

Page 98: ...be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 101 Never hook the winch cable back onto itself This will damage the winch cable a...

Page 99: ...Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are w...

Page 100: ...when winching a vehicle free a Release the winch clutch and spool out the necessary length of winch cable b Align the winch cable as close as possible to the winching vehicle s centerline c Attach the...

Page 101: ...if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task a Release the clutch on the winch b Feed out the winc...

Page 102: ...his cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition A kinked winch cable made of wire rope that has been straightened out is shown a...

Page 103: ...tra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produc...

Page 104: ...your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer or other qualified person 5 Some winch models use...

Page 105: ...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 engi...

Page 106: ...104...

Page 107: ...e service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently SEVERE USE DEFINI...

Page 108: ...INT L Inspect pad wear Fuel System Turn key on to pressurize fuel pump check lines fittings for leaks and abrasion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hour...

Page 109: ...ngs pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering...

Page 110: ...er first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 111: ...pect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt...

Page 112: ...place worn parts D Front Wheel Bearings Inspect replace as needed Cam Chain Tensioner Inspect clean replace as needed XU Shock Absorbers Inspect for leaks loose joints and wear XU Perform these proced...

Page 113: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 114: ...ings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steerin...

Page 115: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 116: ...nkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Dr...

Page 117: ...every two years DOT 4 Spark Arrestor Clean daily if driven in mud water replace a damaged arrestor before operating Cam Chain Tensioner Inspect clean replace as needed D Valve Clearance Inspect adjus...

Page 118: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 119: ...ittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Stee...

Page 120: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 121: ...nkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Dr...

Page 122: ...ubjected to water mud etc D Front Wheel Bearings Inspect replace as needed Cam Chain Tensioner Inspect clean replace as needed XU Shock Absorbers Inspect for leaks loose joints and wear XU Perform the...

Page 123: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 124: ...ings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steerin...

Page 125: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 126: ...nkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Dr...

Page 127: ...hange every two years DOT 4 Spark Arrestor Clean daily if driven in mud water replace a damaged arrestor before operating Cam Chain Tensioner Inspect clean replace as needed D Valve Clearance Inspect...

Page 128: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 129: ...ings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steerin...

Page 130: ...ter first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Air Filter Inspect replace...

Page 131: ...pect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt...

Page 132: ...Clearance Inspect adjust as needed D Spark Plug Replacement Replace torque to specification XU Coolant Replace coolant D Toe Adjustment Inspect periodically adjust when parts are replaced Cam Chain Te...

Page 133: ...il and PS 4 Extreme Duty 10W 50 4 Cycle Oil See page 135 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 158 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission...

Page 134: ...q Middle Prop Shaft Grease Fitting w Rear Prop Shaft Grease Fitting e Rear Stabilizer Bar Grease Fitting r Front Stabilizer Bar Grease Fitting 132 MAINTENANCE...

Page 135: ...120 F 18 C to 49 C PS 4 Extreme Duty 10W 50 4 Cycle Oil Oil may need to be changed more frequently if POLARIS oil is not used Do not use automotive oil Follow the manufacturer s recommendations for a...

Page 136: ...lace the transmission in PARK NOTE Always check the oil when the engine is cold 3 Remove the seats and remove the engine access panel 4 Remove the dipstick Wipe it dry with a clean cloth 5 Reinstall t...

Page 137: ...n plug Allow the oil to drain completely 4 Remove the seats and remove the engine access panel 5 Using an oil filter wrench turn the filter q counterclockwise to remove it 6 Using a clean dry cloth cl...

Page 138: ...the dipstick and check the oil level 15 Add oil as necessary to bring the level to the upper mark on the dipstick Do not overfill 16 Reinstall the dipstick 17 Reinstall the oil fill cap 18 Dispose of...

Page 139: ...ntain the fluid level so that it is even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level to see if even with botto...

Page 140: ...uid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification listed in the Gearcase Specification Chart of this manual 6 Add the recommended fluid listed in the Ge...

Page 141: ...nd drive unit Maintain the fluid level so that it is even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level to see i...

Page 142: ...ompletely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification listed in the Gearcase Specification Chart of this manual 6 Add the recommended fluid listed in the Gearcase Specifi...

Page 143: ...que Transmission Main Gearcase AGL Gearcase Lubricant Transmis sion Fluid 44 fl oz 1300 mL 10 14 ft lbs 14 19 N m 10 14 ft lbs 14 19 N m 900 SPORT Demand Drive Unit Front Gearcase Demand Drive Fluid 7...

Page 144: ...is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing...

Page 145: ...ICE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments WET FOULED PLUG The wet fouled insulator tip...

Page 146: ...then replace the fuse The fuse relay center q is located near the driver s left knee LABEL VALUE FUNCTION FAN 20A Circuit Breaker Fan EFI 10A Fuse EFI Relay Injectors Coil ECM Chassis Relay Coil Fan...

Page 147: ...rt Accent Lights FUEL 7 5A Fuse Fuel pump CHASSIS 10A Fuse AWD Relay Coil AWD Switch Electronic Power Steering EPS Instrument Cluster Activation Seatbelt Switch Vehicle Speed Sensor Purge Valve SOCKET...

Page 148: ...eeze is already premixed and ready to use Do not dilute with water See the Polaris Products section for the part numbers To ensure that the coolant maintains its ability to protect the engine we recom...

Page 149: ...radiator pressure cap w 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed 5 Before reinstalling the pressure cap bleed the system of trapped air Remove the e...

Page 150: ...ould also be inspected 1 Position the vehicle on a level surface 2 Remove the hood See the Hood section for details 3 View the coolant level in the overflow bottle q 4 Remove the cap w and use a funne...

Page 151: ...nsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replac...

Page 152: ...injury or death If a belt fails always clean any debris from the duct and from the clutch and engine compartments when replacing the belt 1 Allow hot components to cool before performing this procedu...

Page 153: ...y force to opposite end of tool to spread sheaves 4 Remove ALL DEBRIS from the entire clutch air duct passage w 5 Check for signs of damage to seals on the transmission and engine See your dealer prom...

Page 154: ...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 belt and clutches D...

Page 155: ...efully remove the air box cover 4 Inspect the air filter w and air box for dirt debris or water 5 To remove the filter slide the filter toward the passenger s side of the vehicle 6 With the filter rem...

Page 156: ...could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exha...

Page 157: ...synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 4 Inspect the screen for wear and damage Replace a worn or damaged screen 5 Reinstall the a...

Page 158: ...eration Allow the discs to cool before performing maintenance to prevent risk of burns Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied t...

Page 159: ...em for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness 4 Check brake discs for signs of cracks excessive corrosion war...

Page 160: ...is Products section for the part numbers Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid i...

Page 161: ...a higher ride height Turn the adjusting ring to the right to decrease preload for a lower ride height LOCATION MEASUREMENT Front 6 10 in 155 mm Rear 3 31 in 84 mm Follow these guidelines if you make a...

Page 162: ...reservoir 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping FACTORY PRELOAD SETTINGS Setting Compression Damping Softest...

Page 163: ...eload Turn the adjusting ring to the right to remove preload 4 Tighten the jam nut firmly against ring LOCATION FACTORY PRELOAD MEASUREMENT Front 7 94 202 mm Rear 3 31 84 mm Follow these guidelines if...

Page 164: ...res 1 8 in 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always ma...

Page 165: ...tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Lug Nut Aluminum Wheels Front and Rear 120 ft lbs 162 7 N m Lug Nut Steel Wheels Front and Rear...

Page 166: ...us injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed Your POLARIS dealer can assist 1 Place the transmission in PARK 2...

Page 167: ...n t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp TAILLIGHT BRAKE LIGHT TURN SIGNAL LAMP REPLACEMENT The taillight asse...

Page 168: ...he vehicle on a level surface The headlight should be approximately 25 ft 7 6 m from a wall 2 Place the transmission in PARK 3 Measure the distance from the floor to the center of the headlight and ma...

Page 169: ...e 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 th...

Page 170: ...removing the battery 2 Remove the driver s seat See the Seats section for details 3 Disconnect the black negative battery cable first and secure away from the battery terminals 4 Disconnect the red p...

Page 171: ...immediately or the battery runs the risk of sulfation and reduced battery life If you do not drive the vehicle for more than TWO WEEKS Polaris recommends using a BatteryMINDer 2012 AGM 2 AMP charger P...

Page 172: ...e DC Action Charge Time 100 12 8 13 0 volts None check monthly None required 75 100 12 6 12 8 volts May need slight charge if no charge given check in 2 weeks 3 6 hours 50 75 12 3 12 6 volts Needs cha...

Page 173: ...damage the radiator fins and impair the radiator s effectiveness High pressure may also damage other vehicle components Certain products including insect repellents and chemicals will damage plastic s...

Page 174: ...s and decals Electrical components and wiring Air intake components If warning and safety labels are damaged contact your POLARIS dealer for free replacement Grease all zerk fittings immediately after...

Page 175: ...bon 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...

Page 176: ...he 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 protective film of fresh oil 6 If POLARIS fuel s...

Page 177: ...cap and seats Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and ins...

Page 178: ...176...

Page 179: ...mum Weight Capacity Payload 740 lb 336 4 kg including riders cargo accessories tongue weight Towing Capacity 1500 lb 682 kg Hitch Tongue Capacity 150 lb 68 kg Fuel Capacity 9 5 gal 36 L Engine Oil Cap...

Page 180: ...le a arm with 13 2 in 33 5 cm of travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission EPS Lockable Differential Shift Type Dual Range P R N L H Tires Tire Pre...

Page 181: ...OUTPUT GEAR RATIOS Rear High Gear 10 73 Low Gear 18 77 Reverse 20 41 Front including front drive Non EPS EPS High Gear 13 71 11 88 Low Gear 23 94 20 74 Reverse 26 07 22 59 Drive Ratio Front 3 82 3 31...

Page 182: ...180...

Page 183: ...ricants 2878068 AGL Full Synthetic Gearcase Lubricant Transmission Fluid 1 qt 0 95 L 2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid 1 gal 3 8 L 2877922 Demand Drive Fluid 1 qt 0 95 L...

Page 184: ...Joint Grease 3 fl oz 89 mL Cartridge 2871551 U Joint Grease 14 fl oz 414 mL Cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT...

Page 185: ...tle quickly and effectively Hauling heavy cargo pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range a...

Page 186: ...lean away any debris from the clutch box clutch duct and engine compartment Install a new belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe in...

Page 187: ...se Your POLARIS dealer or other qualified person can assist Low battery voltage Recharge the battery to 12 8 VDC Loose ignition connections Check all connections and tighten Mechanical failure Your PO...

Page 188: ...qualified person can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Exhaust leak Check all connections Mechanical failur...

Page 189: ...TION Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your POLARIS dealer or other qualified person can assist Incorrect spark plug gap or heat range Set gap to...

Page 190: ...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 191: ...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...

Page 192: ...190...

Page 193: ...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 Warranty Reg...

Page 194: ...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 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ...rnia Air Resources Board and Polaris Industries Inc are pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle In California new off...

Page 202: ...t of time not to 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 maintena...

Page 203: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 201 MAINTENANCE LOG...

Page 204: ...202...

Page 205: ...Emission Control System 103 Crossing Hillsides 26 D Demand Drive Fluid Check 139 Demand Drive Unit Front Gearcase 139 Descending Hills Improperly 26 Disengaging AWD 48 Display Mode 69 Display Units S...

Page 206: ...Cluster 49 J Jumps and Stunts 25 K Know Your Riding Area Tread Lightly 78 L Lights 165 Limited Warranty 191 Load Passenger Tire Pressure Warning 20 Lubrication Recommendations 131 M Maintenance Inter...

Page 207: ...Driveline Mode 67 Gauge Screens 68 Gauge View Mode 69 Icon Bar 70 Overview 64 Settings 68 Rider Information Center 54 Riders Warning 16 Rollover Protective Structure ROPS 39 RZR Trail S Specification...

Page 208: ...are 71 Using Alcohol or Drugs 22 V Vehicle Break in Period 73 Vehicle Identification Numbers 12 Vehicle Immersion 167 W Walker Evans Racing Shock Compression Adjustment 160 Walker Evans Racing Shocks...

Page 209: ......

Page 210: ...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 9940359 Rev 01 Printed in USA...

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Polaris RZR Trail S 1000 Premium 2022, Owner'S Manual

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