Polaris RZR XP 1000 EPS 2019 Page 128 Owner'S Manual Download

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SPARK PLUGS

SPARK PLUG GAP / TORQUE

Electrode Gap

Spark Plug Torque

0.7-0.8 mm

7 ft. lbs. (10 Nm)

NOTICE

Using non-recommended spark plugs can result in serious engine damage.

Always use POLARIS-recommended spark plugs or their equivalent. Refer to

the specifications section of this manual.

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 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 a spark plug for inspection.

SPARK PLUG REMOVAL AND REPLACEMENT

1. Remove the cargo box access panel to access the spark plugs

2. Clean the area around the spark plugs before removing the plugs.

126

MAINTENANCE

Summary of Contents for RZR XP 1000 EPS 2019

Page 1: ...2019 OWNER S MANUAL RZR XP XP 4 1000 EPS RZR XP 1000 EPS TRAILS AND ROCKS EDITION ...

Page 2: ...ne expect 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 passenger vehicle WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious ...

Page 3: ...2019 RZR Owner s Manual 1000 XP XP 4 EPS 1000 XP Trails and Rocks Edition ...

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

Page 5: ...biles SPORTSMAN All terrain vehicles Low emission vehicles LEVs RANGER utility vehicles BRUTUS work vehicles SLINGSHOT three wheel motorcycles RZR sport vehicles GEM vehicles INDIAN motorcycles POLARIS POWER generators POLARIS DEFENSE combat vehicles Timbersled Snow Bikes For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual ...

Page 6: ...icates a hazardous situation that if not avoided may result in death to the operator bystanders or person s inspecting or servicing the vehicle CAUTION CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle NOTICE NOTICE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and insp...

Page 7: ...afety 11 Features and Controls 33 Operation 59 Winch Guide 77 Emission Control Systems 87 Maintenance 89 Specifications 161 Polaris Products 167 Troubleshooting 169 Warranty 175 Maintenance Log 185 5 TABLE OF CONTENTS ...

Page 8: ...6 ...

Page 9: ...nual with 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 both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Always use the cab nets or doors while riding in this vehicle Always keep hands feet and al...

Page 10: ...nvironment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such...

Page 11: ...emove 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 switch must be replaced if all keys are lost Vehicle Model Number Vehicle Identification Number Engine Serial Number Key Number 9 INTRODUCTION ...

Page 12: ...10 ...

Page 13: ...OLARIS vehicle is considered an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at speci...

Page 14: ... 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 windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by var...

Page 15: ...nding 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 Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Pers...

Page 16: ...nt Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label q Warning Labels w Payload Warning PROPER USE WARNING WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or d...

Page 17: ...ble to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING rohva org RIDERS WARNING Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk of injury Ke...

Page 18: ...overs have caused severe injuries and death even on flat open areas Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avoid hard acceleration 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 acr...

Page 19: ...lid is reinstalled Please reference your owner s manual for additional information regarding air filter service q Air Box Caution BELT DEBRIS WARNING WARNING Improper service or maintenance of this PVTsystem can result in vehicle damage SEVERE INJURY or DEATH Always look for and remove debris inside and around the clutch and vent system when replacing the belt Read owner s manual or see authorized...

Page 20: ... in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Never carry passengers in cargo box Passengers can be thrown off This can cause serious injury or death RZR XP 1000 RZR XP 4 1000 RZR XP 1000 Trails and Rocks Edition MAXIMUM CARGO BOX LOAD 300 lbs 136 kg 300 lbs 136 kg 300 lbs 136 kg TIRE PRESSURE IN PSI KPa FRONT 18 124 REAR...

Page 21: ... in a rollover Avoid exhibition driving INTAKE ALERT 7185975 Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing fi lter ensure there is no dirt or debris in the clean side of the intake tube The air filter must be properly seated and the hinges fully inserted when the lid is reinstalled Please reference your owner s manual for a...

Page 22: ...ront 124 kPa 1 24 bar Rear 131 kPa 1 31 bar TURBO Front 125 kPa 1 25 bar Rear 130 kPa 1 30 bar TIRE PRESSURE PASSENGER ALERT FOR 4 SEAT VEHICLES 7189872 Never carry passengers in cargo box Passengers can be thrown off This can cause serious injury or death Read owner s manual Never carry or transport fuel on this vehicle MAXIMUM CARGO BOX LOAD MAXIMUM CAPACITY TIRE PRESSURE IN KPA BAR 136 kg Occup...

Page 23: ...WITHOUT INSTRUCTION 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 types of terrain Take a training course and complete the New Operator Driving Procedures outlined on page 64 All operators must read and understand the owner s manual and all warning and ins...

Page 24: ...ILURE 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 Ride Inspection outlined in the Operation chapter before each use of your vehicle to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules describe...

Page 25: ...are 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 carry a passenger until you have operated this vehicle for at least two hours and have completed the steps in the New Operator Driving Procedures section A passenger must always be seated in a passen...

Page 26: ...e vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the spec...

Page 27: ...oss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops OPERATING ON PUBLIC ROADS Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads u...

Page 28: ... an accident or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover Use extreme caution when operating on hills Always follow proper procedures for hill climbing as described in this owner s manual See the Driving Uphill section for details DESCENDING HILLS IMPROPERLY Imp...

Page 29: ...ver Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an ...

Page 30: ...ution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow prop...

Page 31: ...erator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route V...

Page 32: ...iately wash it off with soap and water and change clothing EXPOSURE TO EXHAUST Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle Ho...

Page 33: ...e the Load Passenger Tire Pressure Warning section for details Cargo should be properly distributed and securely attached See page 74 Reduce speed when carrying cargo Allow a greater distance for braking UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training Thi...

Page 34: ...urpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bodily injury The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain...

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

Page 36: ...with one or more 12 volt accessory outlets One outlet is on the dash a second outlet if equipped is in the rear passenger area Use the outlets to power an auxiliary light or other optional accessories For service the dash outlet connection is under the dash The rear outlet connection is under the rear passenger seats 34 FEATURES AND CONTROLS ...

Page 37: ... the START position to engage the electric starter The key returns to the ON position when released The key can be removed from the switch when it is in the OFF position HEADLIGHT SWITCH Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The ignition switch must be in the ON position to operate the headlights Press the top of the rocker switc...

Page 38: ...or details To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down If the light remains on after starting the engine the EPS system is inoperative See your POLARIS dealer or other qualified person as soon as possible for repair Continued operation could r...

Page 39: ...n do not remove the four screws located on the seat bottom Slide the seat forward or rearward to the desired position Tighten the screws to 4 ft lbs 5 4 Nm Do not overtighten SEAT REMOVAL 1 Pull up on the seat latch q lever located under the rear edge of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure th...

Page 40: ...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 CAB DOORS This vehicle is equipped with cab doors Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover Always make sure all cab doors are closed and latched when riding in this veh...

Page 41: ...stments 1 Remove the retainer q from the end of the adjustment pin w 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole 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 39 FEATURES AND CONTROLS ...

Page 42: ...d pressure tank w 1 Turn the hood fasteners e 1 4 turn 2 Grasp the upper hood edge and pull upward to disengage the fasteners 3 Pivot the hood forward and lift upward to disengage the lower hood hooks 4 Lift the hood away from the vehicle 40 FEATURES AND CONTROLS ...

Page 43: ...snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks Pull up on the strap to tighten 3 Press the red release latch on the buckle to release the seat belt 6 POINT SEAT BELT TRAILS AND ROCKS EDITION This vehicle is equipped with a Click 6 safety harness with built in interlock To wear the 6 point seat belt p...

Page 44: ...belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer or qualified person 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household d...

Page 45: ...ter 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 While continuing to stretch the seat belt height adjuster slide the adjuster up or down rocking it side to side if necessary until you reach the desired height This may require both hands Do not attem...

Page 46: ...sure proper transmission function Your POLARIS dealer or qualified person can assist in resolving any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle USING LOW RANGE Always shift into low gear for any of the following conditions Operating in...

Page 47: ...e frame of the vehicle Remove the seats and remove the access panel to reach serviceable engine components CARGO BOX ACCESS PANEL The cargo box access panel is located on the floor of the cargo box Remove the panel to access the engine oil fill cap spark plugs and air filter 45 FEATURES AND CONTROLS ...

Page 48: ...OTTLE 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 the throttle pedal returns normally before starting the engine TIP If the throttle pedal and brake pedal are applied simultaneously engine power may be limited 46 FEATURES AND CONTROLS ...

Page 49: ... make modifications to the vehicle s ROPS structure No device can assure occupant protection in the event of a rollover When used with seat belts and cab nets or doors the ROPS helps prevent occupants from being ejected from the vehicle Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avo...

Page 50: ...y the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels...

Page 51: ...ely 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 Center SPEEDOMETER The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 56 TACHOMETER The tachometer displays engine speed in revolutions per minute RPM MODE BUTTON Press and hold the M...

Page 52: ... or Area 2 modes Press and hold either toggle button to reset an item See page 54 TIP With the ignition key off pressing the MODE button or either toggle button will power up the Rider Information Center for 10 seconds to allow viewing of the odometer and the clock 50 FEATURES AND CONTROLS ...

Page 53: ...lamp illuminates when the headlamp switch is set to high beam 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 belt is equipped with a seat belt interlock Vehicle speed will be limited to 15 MPH 24 km h if the seat belt is not secured Check Engine This indicator appears if an Electronic Fuel Injectio...

Page 54: ...g is activated The outline of the fuel display will flash Refuel immediately t Speed Limitation if equipped This vehicle may be equipped with a maximum speed limitation function This would be displayed on the screen as LIM followed by the speed LIM 30 for example The rider information center is located in the instrument cluster All segments will light up for one second at start up If the instrumen...

Page 55: ...veled 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 56 Engine Hours Total hours of engine operation since manufacture Service Hours A flashing wrench symbol indicates that the preset service interval has been reached To reset see page 57 Trip Time Time length of vehicle operation since mode was last reset e Ar...

Page 56: ...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 the settings menu BACKLIGHT COLOR The information center backlight can be set to either blue or red 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the BL COLOR option ...

Page 57: ...ss 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 Press either toggle button to cycle to the CLOCK option Press MODE to select 3 Press either toggle button to cycle to the desired setting 12H or 24H Press MODE to select 4 Press either toggle button to c...

Page 58: ...ter 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 Press and hold either toggle button until the meter resets to zero TRIP TIME Use a trip time meter to track the travel time during a specific trip Reset the meter to zero before traveling 1 Press eithe...

Page 59: ...enabled 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 service interval 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the Service Hours option Press MODE to select 3 Press MODE to reset the existing val...

Page 60: ...lure 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 select 3 More than one diagnostic code may be present Press the toggle UP button to see if more codes are present Press MODE to select a code NOTE If the displayed code is an engine fault code the ...

Page 61: ...ld up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any improper oils may cause serious engine damage POLARIS Premium 4 Synthetic Oil is specifically formulated for your 4 cycle engine ENGINE AND DRIVETRAIN BREAK IN 1 Fill the fuel tank with the recommend...

Page 62: ...ration 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 speed operation at high throttle Avoid aggressive acceleration high speed operation and prolonged operation at a specific RPM during this period PRE RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operatin...

Page 63: ... Push down on both seat backs to ensure the latches are secure page 37 Seat Belts Check length of belt for damage check latches for proper operation page 42 Cab Doors Check doors and latches for wear or damage page 23 Grass and Leaves Remove grass leaves and other flammable material or debris especially near the HOTexhaust system SAFE OPERATION PRACTICES 1 Visit the Recreational Off Highway Vehicl...

Page 64: ...d vehicle After any rollover or accident have a qualified service dealer inspect the entire machine for possible damage 11 Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party 12 Do not touch hot...

Page 65: ...e exiting the vehicle BRAKING 1 Release the throttle pedal completely TIP When the throttle pedal is released completely and engine speed slows to near idle the vehicle has no engine braking 2 Press on the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re familiar with the controls PARKING THE VEHICLE 1 Stop the vehicle on a level surface When parking ins...

Page 66: ... far as possible to allow others to pass safely NEW OPERATOR DRIVING PROCEDURES 1 Read and understand the owner s manual and all warning and instruction labels before operating this vehicle 2 Visit the Recreational Off Highway Vehicle Association web site rohva org and take the free on line training course Hands on training is also available through ROHVA 3 Perform the pre ride inspection 4 Do not...

Page 67: ...des donuts jumps or other driving stunts DRIVING WITH PASSENGERS 1 Complete the New Operator Driving Procedures outlined on page 64 2 Perform the pre ride inspection See the Pre Ride Inspection section for details 3 Do not carry more than one passenger in a 2 seat vehicle Do not carry more than three passengers in a 4 seat vehicle Additional passengers can affect the operator s ability to steer an...

Page 68: ...ng guidelines as outlined on safety labels and in this manual DRIVING UPHILL Whenever traveling uphill follow these precautions 1 Always check the terrain carefully before ascending a hill Never drive on hills with excessively slippery or loose surfaces 2 Avoid excessively steep hills If ascending a steeper grade is unavoidable engage all wheel drive before ascending 3 Drive straight uphill 4 Proc...

Page 69: ...ld cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a hill is unavoidable follow these precautions 1 Engage all wheel drive 2 Drive slowly and use extreme caution 3 If the vehicle begins to roll over or if it feels as if it may roll over immediately turn downhill 4 Avoid obstacles and changes in terrain that may lower or raise one side o...

Page 70: ... 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 neutral 5 Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill 6 Apply the brakes lightly to aid in slowing 68 OPERATION ...

Page 71: ...ter test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Avoid applying brake and throttle at the same time NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart section Give special attention to engine oil transmission oil demand drive...

Page 72: ...s 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 4 Correct a skid by turning the steering wheel in the direction o...

Page 73: ...gs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly 5 Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause...

Page 74: ...ns when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns 72 OPERATION ...

Page 75: ...e 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 is in PARK before exiting the vehicle 5 Block the rear wheels on the downhill side 73 OPERATION ...

Page 76: ...IGHT 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 these items must not exceed the maximum weight capacity Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to ...

Page 77: ...bility 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 Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components Never allow a passenger to ride in the cargo box A passenger must always be seated in a ...

Page 78: ...lter vehicle handling and may cause loss of control or brake instability The tow loop q on the rear of the vehicle is provided for recovery use ONLY Tow a vehicle ONLY of equal or lesser size and weight When towing a disabled RZR vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing TOWING A RZR Towing this vehicle is not rec...

Page 79: ... Loading section on page 85 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by th...

Page 80: ...nching a load 17 Never let the winch cable run through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Your dealer can provide service on your winch if this occurs 22...

Page 81: ... strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to ...

Page 82: ... cable TIP A tow strap is NOT intended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 85 Never hook the winch cable back onto itself This will damage the winch cable and may result in winch ca...

Page 83: ...s fully seated when the load is attached Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch 5 Never remove the hook strap from the hook 6 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 wrapped ...

Page 84: ... your safety always follow these guidelines 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 winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual d Re engage the clutch on the winch e Slowly winch ...

Page 85: ... 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 winch cable that is unevenly bunched up in one area c Re engage the winch clutch d Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook strap e Slowly winch t...

Page 86: ... this 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 at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable...

Page 87: ...xtra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an...

Page 88: ...r 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 wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be p...

Page 89: ... crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system EXHAUST EMISSION CONTROL SYSTEM Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissi...

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Page 91: ... replace parts as necessary When inspection reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent parts may be used for emissions related service Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can perform these operations Vehicles subjec...

Page 92: ...T 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 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Break In Perform a break in oil and filter change at 25 hours or one month perform every 50 hours or 6 mo...

Page 93: ...ubrication Lubricate all fittings 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 Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt In...

Page 94: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 95: ...spect 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 Inspect replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Cha...

Page 96: ...es Drive and Driven Inspect clean replace worn parts D Front Wheel Bearings Inspect replace as needed XU Shocks Visually inspect shock seals change oil and seals if leaking Cam Chain Tensioner Inspect clean replace as needed XU Perform these procedures more often for vehicles subjected to severe use D Have an authorized Polaris dealer or equivalent person perform these services 94 MAINTENANCE ...

Page 97: ...spect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have a...

Page 98: ...Lubrication Lubricate all fittings 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 Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt I...

Page 99: ...spect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have a...

Page 100: ... 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 Inspect replace as needed D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust ten...

Page 101: ...ded XU D Shocks Change shock oil and inspect seals D Brake Fluid Change 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 adjust as needed XU Perform these procedures more often for vehicles subjected to severe use D Have an authorized Polaris dealer or eq...

Page 102: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 103: ...Lubrication Lubricate all fittings 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 Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt I...

Page 104: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 105: ...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 Inspect replace as needed D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tens...

Page 106: ...onnectors subjected to water mud etc D Front Wheel Bearings Inspect replace as needed XU Shocks Visually inspect shock seals change oil and seals if leaking Cam Chain Tensioner Inspect clean replace as needed XU Perform these procedures more often for vehicles subjected to severe use D Have an authorized Polaris dealer or equivalent person perform these services 104 MAINTENANCE ...

Page 107: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 108: ...Lubrication Lubricate all fittings 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 Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt I...

Page 109: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 110: ...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 Inspect replace as needed D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tens...

Page 111: ... needed XU D Shocks Change shock oil and inspect seals D Brake Fluid Change 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 adjust as needed XU Perform these procedures more often for vehicles subjected to severe use D Have an authorized Polaris dealer o...

Page 112: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 113: ...Lubrication Lubricate all fittings 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 Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt I...

Page 114: ...pect adjust tension after 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 Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles subjected to severe use D Have an...

Page 115: ...spect 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 Inspect replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Cha...

Page 116: ...y if driven in mud water replace a damaged arrestor before operating D Valve 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 Tensioner Inspect clean replace as needed XU Perform these procedures more often for vehicles subjected to severe use D Have ...

Page 117: ...W 50 4 Cycle Oil and PS 4 Extreme Duty 10W 50 4 Cycle Oil See page 118 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 141 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 121 Front Gearcase Fluid Demand Drive Demand Drive Fluid See page 123 Prop Shaft U Joint Grease Grease the middle and rear fitting Stabilizer Bar Bushings All Season Grea...

Page 118: ...q Middle Prop Shaft Grease Fitting w Stabilizer Bar Bushings one on each side of vehicle e Rear Prop Shaft Grease Fitting 116 MAINTENANCE ...

Page 119: ...o 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 ambient temperature operation Part numbers can be found in the POLARIS Products chapter NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended o...

Page 120: ...level 5 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on the dipstick Do not overfill 6 Reinstall the fill cap Reinstall the dipstick OIL AND FILTER CHANGE Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 90 Always change the oil filter whenever changing oil Acc...

Page 121: ...il Check to make sure the o ring is in good condition 7 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn an additional 3 4 turn 8 Reinstall the crankcase drain plug with a new sealing washer Torque to 12 ft lbs 16 Nm NOTE The sealing surface on the drain plug should be clean and free of burns nicks or scratches 9 Remove the oil fill cap and add...

Page 122: ... the recommended oil as needed Maintain the oil level between the minimum and maximum marks on the dipstick Do not overfill 15 Reinstall the fill cap 16 Reinstall the dipstick 17 Dispose of used filter and oil properly 120 MAINTENANCE ...

Page 123: ...d lubricants capacities and torque specifications FLUID CHECK The fill plug q is located on the rear of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification 121...

Page 124: ...ace a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly 122 MAINTENANCE ...

Page 125: ...acities and torque specifications DEMAND DRIVE FLUID CHECK The fill plug q is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug Torqu...

Page 126: ...n under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the recommended fluid to the bottom thread of the fill plug hole 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly 124 MAINTENANCE ...

Page 127: ...r the part numbers Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Transmission Main Gearcase AGL Gearcase Lubricant Transmission Fluid 44 oz 1300 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm Demand Drive Unit Front Gearcase Demand Drive Fluid 8 5 oz 250 ml 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 125 MAINTENANCE ...

Page 128: ... indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection SPARK PLUG REMOVAL AND REPLACEMENT 1 Remove the cargo box access panel t...

Page 129: ...es are not burned or eroded This indicates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments WET FOULED PLUG The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose...

Page 130: ...LABEL VALUE FUNCTION FAN 20A Circuit Breaker Engine Coolant Fan FUEL 7 5A Fuse Fuel Pump TERM 10A Fuse Under Hood Terminal Block RZR XP 4 vehicles Rear 12V Receptacle INSTR 7 5A Fuse Interior LED Diagnostic Port DYNAMIX RideCommand vehicles Gauge Display SOCKET 10A Fuse Dash 12V Receptacle EPS 30A Fuse Power Steering SCM 7 5A Fuse DYNAMIX vehicles Suspension Control Module SHOCK 7 5A Fuse DYNAMIX ...

Page 131: ...ehicles SCM Wake Up SCM Mode Switch EVAP vehicles Waste Gate EFI 10A Fuse Accessory Relay Coil ECM Wake Up Pump Relay Coil Chassis Relay Coil Start Relay Coil EFI Relay Coil Mag PTO Inject Lights Relay Coil Fan Relay Coil Ignition Relay Coil Starter Solenoid Coil Brake Relay Coil DYNAMIX vehicles SCM Relay Coil 129 MAINTENANCE ...

Page 132: ...reeze 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 recommend that the system be completely drained every five 5 years and fresh Antifreeze 50 50 Premix added Any time the cooling system has been drained for maintenance or repair replace the coolant with f...

Page 133: ... 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 engine access panel behind the seats and use a flat blade screwdriver to turn the bleed screw q slightly allowing the air to escape Slowly add additional coolant to the radiator until air no longer es...

Page 134: ...hould 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 funnel to add coolant as needed to maintain the level between the two marks 5 Reinstall the cap TIP If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the ...

Page 135: ...ystem rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer or other qualified service person as recommended...

Page 136: ...he belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of control and severe injury or death 1 Allow hot components to cool before performing this procedure 2 Remove the engine access panel and thoroughly clean all debris from the aluminum debris bracket q and from the engine compartment 134 MAINTENANCE ...

Page 137: ... from the vehicle Remove all debris wrapped in and around the PVTsystem TIP Use the shock clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation Insert hooked end of tool Apply force to opposite end of tool to spread sheaves 135 MAINTENANCE ...

Page 138: ...stances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remove the clutch cover drain plug 2 Allow the water to drain Reinstall the drain plug 3 Place the transmission in PARK Apply the brakes 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the thr...

Page 139: ...apy water Dry with low pressure compressed air Periodically inspect the clutch PVT air intake for debris and clean as needed to ensure adequate air flow TIP When washing the vehicle always avoid spraying water directly toward the PVT intake duct See the Washing the Vehicle section for recommended washing procedures AIR FILTER Always change the air filter at the intervals outlined in the Periodic M...

Page 140: ...irt and debris from the intake tube before installing the filter 7 Reinstall the air filter if clean or install a new air filter if soiled Do not attempt to clean the air filter NOTICE Use of a non POLARIS approved air filter may cause engine damage Always use a POLARIS approved replacement filter Replacement filters are available at your POLARIS dealer 8 Make sure that there are no gaps between t...

Page 141: ... or in front of the vehicle while purging the exhaust system Never go under the vehicle while it is inclined Wear eye protection and gloves while servicing Periodically clean the spark arrester to remove accumulated 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 1 Remove the arrester re...

Page 142: ...on for further details If you discover any irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs BRAKE INSPECTION WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper 1 Check the brake system for fluid leaks ...

Page 143: ...ris 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 in the reservoir are unknown Access the brake fluid reservoir through the left front wheel well 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 View the brake fluid level ...

Page 144: ...USTMENT The factory setting is appropriate for nearly all riding conditions If desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads To adjust the preload do the following 1 Elevate the vehicle to allow the suspension to fully extend 2 Turn the adjusting ring to the left to add preload Turn the adjusting ring to the right to remove preload WARNING Uneven a...

Page 145: ...WALKER EVANS SHOCKS q Front Shock Preload Measurement w Rear Shock Preload Measurement DYNAMIX SHOCKS q Front Shock Preload Measurement w Rear Shock Preload Measurement 143 MAINTENANCE ...

Page 146: ... cm RZR XP Trails and Rocks Edition Front 1 30 inches 3 3 cm Rear 8 17 inches 20 75 cm Follow these guidelines if you make adjustments to this suspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting to all ...

Page 147: ...sult in vehicle damage or personal injury Always maintain proper tire pressure Always use POLARIS approved size and type of tires for this vehicle when replacing tires TIRE TREAD DEPTH Always replace tires when tread depth is worn to 1 8 3 mm q or less AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness and if they ve been loosened for maintenance servic...

Page 148: ...serious 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 or other qualified person can assist 1 Place the transmission in PARK 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem q is toward the outside and rotation arrows on the tire point toward forward rotation 3 A...

Page 149: ...EPLACEMENT If a headlight becomes damaged or inoperable the entire headlight assembly must be replaced Do not operate this vehicle at night or in low light conditions until the headlight is replaced Always make sure lights are adjusted properly for best visibility HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted slightly upward or downward and to the left or right 1 Position the vehicl...

Page 150: ...cted Take the vehicle in for service before starting the engine Your POLARIS dealer or other qualified person can provide this service If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the fuse relay center cov...

Page 151: ...INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or if the steering feels rough or catchy have the steering system inspecte...

Page 152: ...driver s seat RZR or the left rear passenger seat RZR 4 See the Seats section for details 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can al...

Page 153: ...lectrolyte and has been fully charged at the factory Never pry the battery caps off or add any other fluid to this battery Always keep a maintenance free battery fully charged Since the battery caps cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop chargi...

Page 154: ...d slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours Using constant current charger standard amps specified on top of battery 152 MAINTENANCE ...

Page 155: ...vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots If a high pressure water system is used for cleaning not recommended exercise extreme caution The ...

Page 156: ...aust system WASHING TIPS Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 154 MAINTENANCE ...

Page 157: ...y necessary repairs and clean the vehicle as recommended See the Washing the Vehicle section for details STABILIZE THE FUEL 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes ...

Page 158: ...e plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 126 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 5 Turn the engine over several times Oil will be forced in and around the piston rin...

Page 159: ...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 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 90 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed a...

Page 160: ...ion without starting the engine Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle verifying that the PARK position is shown on the display 3 Prior to securing the vehicle adjust the vehicle s compression damping settings to their lowest softest setting by turning the clickers all the way out On vehicles equipped with DYNAMIX active suspension the k...

Page 161: ...ompression damping values are still soft after securing the vehicle If after securing the suspension demo mode has timed out or the suspension has moved to a FIRM setting as indicated on the Suspension control screen cycle the key switch place the mode switch in COMFORT mode and re tighten the straps per step number 3 6 Remove the key to prevent loss during transporting Secure the fuel cap and sea...

Page 162: ...q Rear Tie Down w Front Tow Loop Tie Down 160 MAINTENANCE ...

Page 163: ...s 136 kg Maximum Weight Capacity Payload 740 lbs 336 kg including riders cargo and accessories Fuel Capacity 9 5 gal 36 l Engine Oil Capacity 2 5 qts 2 4 l Coolant Capacity 5 44 qts 5 1 l Demand Drive Fluid Capacity 8 5 oz 251 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height RZR XP 119 64 73 75 in 302 3 162 5 187 3 cm RZR Trails and Rocks Edition 120 64 74 25 in 304 8 162 6 1...

Page 164: ...ion System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Tire Size Front 29x9 14 RZR Trails and Rocks Edition 30x10 14 Tire Size Rear 29x11 14 RZR Trails and Rocks Edition 30X10 14 Tire Pressure RZR XP Front 18 psi 124 kPa Rear 19 psi 131 kPa RZR Trails and Rocks Edition Front 12 psi 83 kPa Rear 16 psi 110 kPa Brakes Front Rear Foot Activated ...

Page 165: ...ories Fuel Capacity 9 5 gal 36 l Engine Oil Capacity 2 5 qts 2 4 l Coolant Capacity 6 08 qts 5 75 l Demand Drive Fluid Capacity 8 5 oz 251 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 146 64 73 75 in 370 8 162 5 187 3 cm Wheelbase 117 in 297 2 cm Ground Clearance 13 5 in 34 3 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 999 cc Bore x Stroke 93mm x 73 5mm Alternator ...

Page 166: ...p Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Tire Size Front 29x9 14 Tire Size Rear 29x11 14 Tire Pressure Front 22 psi 152 kPa Rear 22 psi 152 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam LED cluster Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V 16...

Page 167: ... 05 11 79 Low Gear 18 77 18 79 29 02 Reverse 20 41 22 92 25 99 Front including front drive High Gear 11 42 12 82 11 87 Low Gear 19 98 19 98 29 22 Reverse 21 73 24 41 26 17 Drive Ratio Front 3 182 1 3 182 1 3 83 1 CLUTCHING Please see your authorized dealer for clutching specifications 165 SPECIFICATIONS ...

Page 168: ...166 ...

Page 169: ...hetic Gearcase Lubricant Transmission Fluid qt 95 l 2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid gal 3 8 l 2877922 Demand Drive Fluid qt 95 l 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 287132...

Page 170: ...r Grease 2871515 U Joint Grease 3 oz 89 ml cartridge 2871551 U Joint Grease 14 oz 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 168 POLARIS PRODUCTS ...

Page 171: ...n short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engage ment Use the throttle 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 and carefully use fast aggressive throttle application to engage clutch...

Page 172: ...ing 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 belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 59 Failed belt Remove the belt and clean away any debris from the clutch box clutch duct and engine compartment Install a new belt WARNING Failure to remove ALL debris when...

Page 173: ...ace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase 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 POLARIS deale...

Page 174: ...ist ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION 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 specs or replace plugs ENGINE RUNS IRREGULARLY STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Loose missing or kinked boost reference lines Replace boost refe...

Page 175: ...r replace Other mechanical failure Your POLARIS dealer or other qualified person can assist Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Your POLARIS dealer or other qualified person can assist Low fuel pressure Your POLARIS dealer or other qualified person can assist ENGINE STO...

Page 176: ...tery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Your POLARIS dealer or other qualified person can assist Overheated engine Clean radiator screen and core clean engine exterior check coolant level Your POLARIS dealer...

Page 177: ... 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 Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verificatio...

Page 178: ... ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in...

Page 179: ...TY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE TH...

Page 180: ...ation from the country of the selling dealer 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 to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from cou...

Page 181: ... country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered 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 wo...

Page 182: ...om the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be c...

Page 183: ... 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 INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND ...

Page 184: ...d by the manufacturer The California evaporative emissions control system limited warranty statement below applies to your Off Highway Recreational Vehicle in California if the vehicle is equipped with an evaporative emission control system and is labeled with a Vehicle Evaporative Emissions Control Information label indicating that the vehicle conforms to California evaporative emissions regulati...

Page 185: ...ance of a scheduled maintenance As 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 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 main...

Page 186: ...184 ...

Page 187: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 185 MAINTENANCE LOG ...

Page 188: ...186 ...

Page 189: ...Adding or Changing 130 Cooling System 130 Crankcase Emission Control System 87 Crossing Hillsides 27 D Demand Drive Fluid Check 123 Demand Drive Unit Front Gearcase 123 Descending Hills Improperly 26 Display Units Standard Metric 56 Drive Belt Wear Burn 169 Drive Responsibly Warning 16 Driving Downhill 68 Driving in Reverse 72 Driving on a Sidehill Sidehilling 67 Driving on Slippery Surfaces 70 Dr...

Page 190: ...Loading 31 Improper Hill Climbing 26 Improper Tire Maintenance 28 Indicator Lamps 51 Instrument Cluster 49 Intake Alert 7185975 19 Intake Pre Filters 137 J Jumps and Stunts 26 K Know Your Riding Area Tread Lightly 64 L Lights 147 Limited Warranty 175 Load Passenger Tire Pressure Warning 18 Lubrication Recommendations 115 M Maintenance Charts 90 Maintenance Log 185 Metric Display 56 Mode Button 49 ...

Page 191: ...ve Structure ROPS 47 RZR XP 1000 4 Specifications 163 RZR XP 1000 Specifications 161 S Safe Operation Practices 61 Safe Riding Gear 12 Safety Labels and Locations 14 Safety Training 11 Safety Warnings 21 Safety Winch Maintenance 86 Seat Belt Height Adjuster 43 Seat Belt Inspection 42 Seat Belt Warning 15 Seat Belts 22 41 Seats 37 Service Access Panels 45 Shock Loading the Winch 85 Skidding or Slid...

Page 192: ...Break in Period 59 Vehicle Identification Numbers 9 Vehicle Immersion 148 W Washing the Vehicle 153 Wheel Installation 146 Wheel Removal 146 Winch Cable Care 84 Winch Maintenance and Service Safety 86 Winch Operation 79 Winch Safety Precautions 77 Winch Shock Loading 85 190 ...

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Page 194: ...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 9929134 Rev 01 Printed in USA ...

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Polaris RZR XP 1000 EPS 2019, Owner'S Manual

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