Polaris RZR XP 1000 EPS High Lifter Edition Owner'S Manual Download Page 1

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PMS 419

Owner's Manual

for Maintenance and Safety

RZR®

XP 1000 EPS

High Lifter Edition

Summary of Contents for RZR XP 1000 EPS High Lifter Edition

Page 1: ...Owner s Manual for Maintenance and Safety RZR XP 1000 EPS High Lifter Edition ...

Page 2: ...he safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone ...

Page 3: ...ecommendations in this owner s manual Review the safety DVD that came with your vehicle Polaris also recommends that all drivers take the ROHVA safety e course and a ROHVA hands on safety training course www rohva org Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Mast...

Page 4: ...lication 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 vehicle are in English Other languages are provided as translations of the original in...

Page 5: ...Introduction 4 Safety 7 Features and Controls 25 Operation 48 Winch Guide 67 Emission Control Systems 78 Maintenance 79 Specifications 130 POLARIS Products 131 Troubleshooting 132 Warranty 137 Maintenance Log 144 Index 146 ...

Page 6: ...ntial personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that ...

Page 7: ...d hold Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a seat belt when riding in this vehicle Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judg ment and reduce operator ...

Page 8: ... number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number ______________________________________________ Engine Serial Number ___________________________________________________ Key Number _______________________________________________________...

Page 9: ...Your POLARIS 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...

Page 10: ... a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will...

Page 11: ... and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at l...

Page 12: ...placement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label 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 drugs Do not allow operation ...

Page 13: ...ep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason 7179762 Seat Belt Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use cab nets and or doors Each rider must be able to sit with back against seat feet f...

Page 14: ...ING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and ca...

Page 15: ... owner s manual or see authorized POLARIS dealer 7177469 Air Box Caution CAUTION Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing filter ensure there is no dirt or debris in the clean side of the intake tube The air filter must be properly seated before the lid is reinstalled Please reference your owner s manual for additional...

Page 16: ...54 55 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 54 55 Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age ...

Page 17: ...event of an accident Operator and all passengers must always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All rider...

Page 18: ...your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight...

Page 19: ...ncrease the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances 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 di...

Page 20: ...nd Stunts Exhibition driving increases the risk of 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 page 58 Descending H...

Page 21: ...ntain 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 acciden...

Page 22: ...kidding or Sliding Failure to use extra caution 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 regai...

Page 23: ...icle and or the operator 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 y...

Page 24: ...ine is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any source of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to ele...

Page 25: ...t components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system 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 1...

Page 26: ... vehicle for the purpose 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 a...

Page 27: ...EATURES AND CONTROLS Component Locations Cab Doors Fuel Tank Cap Cargo Box Passenger Hand Hold ROPS Frame Gear Selector Throttle Pedal Brake Pedal Cargo Box Tie Down Points 4 corners Winch Tow Loop Snorkels ...

Page 28: ...ed switch Use the ignition switch to start the engine See page 52 for starting procedures The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except accessory 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position...

Page 29: ... Switch Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive See page 38 for AWD operating instructions Winch Switch Press the top of the rocker switch to spool line out from the winch Press the bottom of the rocker switch to spool line in to the winch Move the rocker switch to the center position to stop spooling Remote Winch Sw...

Page 30: ...es loosen 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 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 s...

Page 31: ...e the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole adapter bushing hole both post adjustment holes and lastly through the remaining bushing hole and post mounting hole 5 Reinstall the retainer to the pin Adjustment Position Holes Post Mounting Holes Adjustment...

Page 32: ... coolant overflow bottle 1 Turn the hood fasteners 1 4 turn 2 Grasp the upper hood edge and pull upward to disengage the fasteners 3 Pivot the hood forward and lift upward to disengage the lower hood hooks 4 Lift the hood away from the vehicle Hood Fasteners Pressure Cap Overflow Bottle ...

Page 33: ...use fuel with ethanol content greater than 10 percent such as E 85 fuel Service Access Panels Engine Access Panel The engine access panel is located behind the seats on the 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 ...

Page 34: ...the inner edge of the seat The belt should fit 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 Seat Belt Height Adjuster if equipped A breakthrough in comfort the seat belt height adjuster reduces neck...

Page 35: ...inuing 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 attempt to adjust while vehicle is in motion NOTE Adjustment becomes easier with repeated use CLEANING INSTRUCTIONS The seat belt height adjuster can be cleaned with water STEP 1 STEP 2 ...

Page 36: ...s freely 3 Pull each seat 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 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or house...

Page 37: ...ge gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmission function Your POLARIS dealer can assist in resolving any shifting problems NOTICE Do not attempt to shift the transmission while the vehic...

Page 38: ...ges 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 ON position See page 40 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 ...

Page 39: ...r Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover When used with seat belts and cab nets or doors the ROPS helps prevent occupants from being ejected from the vehicle Always fo...

Page 40: ... in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AW...

Page 41: ...surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 43 Mode Button Use the MODE button to toggle through mode options See page 43 for operation of the mo...

Page 42: ...ht remains on the EPS system is inoperative Your POLARIS dealer can assist Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating The driver...

Page 43: ...d the instrument cluster may have shut off to protect the electronic speedometer If this occurs your POLARIS dealer can provide proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 44 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutra...

Page 44: ...e hour interval 4 Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 5 Clock The clock displays time in a 12 hour or 24 hour format See page 44 fo...

Page 45: ...mode that was displayed prior to setting the units 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining dis...

Page 46: ...lay 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit...

Page 47: ...ets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Engine Temperature Mode This mode displays current temperature of the coolant Battery Voltage Mode This mode displays current system voltage level Tachometer Mode The engine RPM ...

Page 48: ...hen the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Your POLARIS dealer can provide for all major repairs The diagnostic mode is accessible only when the check engine warnin...

Page 49: ...s retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and hold the ...

Page 50: ...carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full 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 Fi...

Page 51: ...rotors PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance If a belt fails always clean any debris from the duct and from the engine compartment Standard Break In Drive at slower speeds for the first 50 miles 80 km of operation Carry only light loads Avoid aggressive acceleration high speed operation and prolonged operation a...

Page 52: ...re free operation 120 Tires Inspect condition and pressure 12 115 Wheels fasteners Inspect ensure fastener tightness 115 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 42 87 Coolant level Ensure proper level 98 99 Coolant hoses Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure proper operation 26 27 Headlights Check operation...

Page 53: ...l 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 steering wheel during operation 8 Never consume alcohol or drugs before or while operating this vehicle 9 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 10 Never ...

Page 54: ... and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmissi...

Page 55: ...icle in your area Respect the environment in which you ride your vehicle Find out where the designated riding areas are by contacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect f...

Page 56: ...o not carry a passenger until you have at least two hours of driving experience with this vehicle 5 Do not carry cargo during this period 6 Select an open area that allows room to familiarize yourself with vehicle operation and handling 7 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 8 Always make s...

Page 57: ...ng maneuvering using the throttle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed 16 Increase speed only after mastering all maneuvers at a slow speed 17 After you become skilled at making turns and begin to operate at faster speeds follow these precautions Avoid sharp turns Never turn while applying heavy throttle Never make ab...

Page 58: ... hand hold 5 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 page 8 6 Always make sure all cab doors are closed and latched when riding in this vehicle 7 Allow a passenger to ride only in a passenger seat 8 Slow down Always travel at a speed appropriate for your skills your passengers skills and o...

Page 59: ...ntain 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 of the s...

Page 60: ...nding 3 Drive 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 speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 7 If the vehicle stalls while climbing a hill apply the brakes Place the transmission i...

Page 61: ... 5 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill Driving Downhill Whenever descending a hill follow these precautions 1 Avoid excessively steep hills 2 Slow down Never travel down a hill at high speed 3 Always check the terrain carefully before descending a ...

Page 62: ...ter leaving water 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 See page 79 Give special attention to engine oil transmissio...

Page 63: ...ds such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as 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 tha...

Page 64: ...ese precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns ...

Page 65: ...n an incline If parking on an incline is unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 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 ...

Page 66: ...n and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS ...

Page 67: ...d cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the maximum capacities specified for your vehicle See page 130 Belt Life To extend belt life use low gear when hauling or towing heavy cargo when hauling or towing heavy cargo when consistently operating at sp...

Page 68: ... 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 recommended Always transport the vehicle on a trailer or flatbed with all four wheels off the ground See page 129 If towing a disabled vehicle is unavoidable place the disabled vehicle s transmission in neutral Tow the shortest dist...

Page 69: ...er 16 years of age to operate the winch 4 Always wear eye protection and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the 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 76 7 Always keep the area around the vehicle winch winch cable and ...

Page 70: ... at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 74 to feed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s...

Page 71: ...er Your dealer can provide service on your winch if this occurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons 25 Never grease or oil the winch cable This wil...

Page 72: ...g 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 73: ...cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load ...

Page 74: ... jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid po...

Page 75: ...slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle I Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the...

Page 76: ...cross 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 the cable in while your assistant moves the end of the winch cable back and fort...

Page 77: ... cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B 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 in...

Page 78: ...ging This puts extra 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 pos...

Page 79: ...ctivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 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 ...

Page 80: ...with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System 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 adjustab...

Page 81: ... replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent parts may be used for emissions related service Record maintenance and service in the Maintenance Log beginning on page 144 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 Veh...

Page 82: ...jected to severe use D Have an authorized POLARIS dealer or other qualified person perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer or other qualified person perform these services ...

Page 83: ...ed Daily Inspect daily clean often Headlight taillight Daily Check operation Suspension bushings Daily Lubricate daily or after each use in mud or water Air filter Weekly Inspect replace as needed Fuel System 25 H Monthly Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion Ź Engine oil change break in 25 H 1 M Perform a break in oil and filter change at one mo...

Page 84: ... Ź Front Suspension 50 H 6 M 500 800 Lubricate Ź Rear Suspension 50 H 6 M 500 800 Lubricate Cooling system 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system yearly Ź Engine oil change 50 H 6 M 1000 1600 Perform a break in oil change at one month Ź Oil filter change 50 H 6 M 1000 1600 Replace with oil change Ź Oil lines fasteners 50 H 6 M 1000 1600 Inspect for leaks and loos...

Page 85: ...rive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 H 12 M 1000 1600 Inspect replace as needed Ź Shock Seals 100 H Inspect shock seals Ź D Shocks 12 M 1500 2400 See your dealer for oil change seal inspection D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24 M 2000 3200 Change every two years Ź Spark arrester 200 H 24 M 200...

Page 86: ...id DOT 4 Brake Fluid Maintain level between fill lines See page 110 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 90 Front Gearcase Fluid Demand Drive Demand Drive Fluid See page 92 Prop Shaft U Joint Grease Grease middle and rear fittings Front Control Arm Pivot Bushings All Season Grease or grease conforming to NLGI No 2 Grease 3 fittings on each side of the v...

Page 87: ...85 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings one on each side of vehicle Front Control Arm Pivot Bushings 3 per side Front Suspension ...

Page 88: ... be changed more frequently if POLARIS oil is not used Do not use automotive oil Follow the manufacturer s recommendations for ambient temperature operation See page 132 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Ambient Temperature Range Recommended O...

Page 89: ...ough the right rear wheel well Access the oil fill cap through the service access panel on the floor of the cargo box 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely Remove the dipstick and check the oil level 5 Remove the oil fill cap to add the recommended oil as needed Maintain th...

Page 90: ...n plug is located on the bottom of the crankcase Access the drain plug through the access hole under the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK 2 Clean the area around the crankcase drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 3 Place a drain pan under the engine crankcase and remove the drain plug Allow the oil...

Page 91: ...kcase drain plug Torque to 12 ft lbs 16 Nm 9 Remove the oil fill cap and add 2 5 quarts 2 4 l of recommended oil Reinstall the fill cap 10 Remove the dipstick Wipe it dry with a clean cloth 11 Reinstall the dipstick completely Remove the dipstick and check the oil level 12 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on t...

Page 92: ... recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the rear of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specific...

Page 93: ...2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the 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 Demand Drive Drain Plug Transmission Drain Plug ...

Page 94: ...ded lubricants capacities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug To...

Page 95: ...r 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 Demand Drive Drain Plug Transmission Drain Plug ...

Page 96: ...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 See page 95 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Transmission Main Gearcase AG...

Page 97: ...nsulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Plug The wet fouled insulator tip is b...

Page 98: ...y inspect the fuse box for moisture If moisture is present leave the cover off to allow the moisture to dry Reinstall the cover before operating Label Value Function FAN 20A Circuit Breaker Fan EFI 10A Fuse EFI Relay Injectors Coil ECM Chassis Relay Coil Fan Relay Coil Fuel Pump Relay Coil KEY 10A Fuse Gauge EFI Relay Coil EPS Relay Coil Key Switch TERM 10A Fuse Under Hood Terminal Block Interior ...

Page 99: ...y to use Do not dilute with water See page 132 for the part numbers of POLARIS products 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 See page 98 for changing procedure Any time the cooling system has been drained for maintenance or repair replace the coolant with ...

Page 100: ...ssure cap 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 slightly allowing the air to escape Slowly add additional coolant to the radiator until air no longer escapes and only co...

Page 101: ...w bottle has run dry the level in the radiator should also be inspected 1 Position the vehicle on a level surface 2 Remove the hood See page 30 3 View the coolant level in the overflow bottle 4 Remove the cap and use a funnel to add coolant as needed to main tain 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 the...

Page 102: ...ds on components The PVT system 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 as recommended in the ...

Page 103: ...ore performing this procedure 2 Remove the engine access panel and thoroughly clean all debris from the aluminum debris bracket and from the engine compartment 3 Remove the clutch cover screws and open the clutch cover It does not have to be removed from the vehicle Remove all debris wrapped in and around the PVT system Tip Use the shock clutch tool from the tool kit to slightly open the sheaves t...

Page 104: ...Replace damaged seals 6 Check for signs of damage to seals on the transmission and engine If any seals appear to be damaged your vehicle requires prompt service Your POLARIS dealer can assist Tip Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the l...

Page 105: ...n 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 throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 7 Test for belt slippage If the belt slips repea...

Page 106: ...ps and carefully remove the air box cover 4 Inspect the air filter and air box for dirt debris or water 5 To remove the filter slide the filter toward the pas senger s side of the vehi cle 6 With the filter removed clean the intake tube and air box thoroughly Wipe well with a clean dry cloth NOTICE Dirt or debris in the intake tube could result in severe engine damage Always clean all dirt and deb...

Page 107: ...S approved air filter may cause engine damage Always use a POLARIS approved replacement filter Please see your POLARIS dealer 8 Make sure that there are no gaps between the filter the filter ring and the stop on the intake tube 9 Reinstall the air box cover and ensure the alignment tabs are properly positioned 10 Secure the six 6 cover clips 11 Reinstall the cargo box access panel ...

Page 108: ...een run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never operate without the spark arrester Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time WA...

Page 109: ...ter before operating 1 Remove the arrester retaining bolt and nut 2 Remove the arrester from the end of the muffler 3 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 4 Inspect the screen for wear and damage Replace a worn or damaged screen 5 Reinstall the arrester Torque bolt to 9 ...

Page 110: ...dicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 110 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs WARNING Operating the vehicle with a spongy brake pedal can result in loss of braking which could cause an accident resu...

Page 111: ...or signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol 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 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 0 030 0 ...

Page 112: ... fade and the possibility of accident or severe injury 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...

Page 113: ...te for nearly all riding conditions If desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads Factory Preload Settings RZR XP High Lifter Front 16 438 inches 41 75 cm Rear 22 062 inches 56 cm Front Shock Preload Measurement Rear Shock Preload Measurement ...

Page 114: ...uspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehi cle stability when operating without a load Always apply the same adjustment setting to all four wheels Do not increase the spring preload by more than one inch 25 4 mm over the factory setting ...

Page 115: ...uspension to fully extend 3 Turn the adjusting ring to the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease preload for a softer ride WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments Front...

Page 116: ...lockwise until it stops the damping is in the fully open position 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping Walker Evans Shocks Setting Compression Damping Softest 16 clicks from closed Factory Front 5 7 clicks from full counter clockwise position Rear 5 7 clicks from full counter clockwise position Firmest 1 c...

Page 117: ...d result 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 or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance serv...

Page 118: ...sition on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed Your POLARIS dealer ca...

Page 119: ... for a few days to allow the moisture to clear out Taillight Brake Light Replacement The taillight assembly is not serviceable If the taillight or brake light fails to operate properly replace the entire taillight assembly Headlight Replacement 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...

Page 120: ...t and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn the headlights to high beam 5 Include the weight of a rider on the seat while performing this step Observe the headlight aim As a starting point the most intense part of the headlight beam should be 2 inches 5 cm below the mark on the wall Adjust to operator preference 6 Tighten or loosen the three 3 headligh...

Page 121: ...t dry the air box and replace the filter with a new filter 3 Remove the fuse relay center cover See page 96 Allow any moisture to dry then reinstall the cover 4 Dry the spark plug wells with a clean cloth then remove the spark plugs 5 Turn the engine over several times 6 Dry the spark plugs and reinstall them or install new plugs 7 Attempt to start the engine If necessary repeat the drying procedu...

Page 122: ...e Periodic Maintenance Chart beginning on page 79 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or if the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer ...

Page 123: ...ttery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Battery Removal 1 Remove the driver s seat See page 28 2 Disconnect the black negative ba...

Page 124: ...ed positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 8 Reinstall the seat Battery Storage Whenever the vehicle is not used for a period of three months or more recharge the battery about once a month to make up for normal self discharge see page 123 or use a POLARIS Battery Tender which can be left connected during the storage period ...

Page 125: ...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 charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery w...

Page 126: ...mps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 ...

Page 127: ...emicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a 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 Washing T...

Page 128: ...amaged contact your POLARIS dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container...

Page 129: ... recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 88 Air Filter Air Box Replace the air filter See page 104 Clean the air box...

Page 130: ...lug 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 95 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a...

Page 131: ...n enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 3 Remove the key to prevent loss during transporting 4 Secure the fuel cap and seats Ensure that the seats are attached cor rectly and are not loose WARNI...

Page 132: ...4 qts 5 1 l Demand Drive Fluid Capacity 8 5 oz 251 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 122 66 74 5 in 310 167 6 189 2 cm Wheelbase 90 in 228 6 cm Ground Clearance 14 25 in 36 2 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 999 cc Bore x Stroke 93mm x 73 5mm Alternator Output 560 W 3000 RPM Compression Ratio 11 0 1 Starting System Electric Fuel System Electro...

Page 133: ...P R N L H Tire Size All 29 5x9 5 14 Tire Pressure All 18 psi 124 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 Output Gear Ratios Rear High Gear 12 05 Low Gear 25 59 Reverse 22 92 Front including front drive High Gear 12 82 Low Gear 27 24 Re...

Page 134: ...luid 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 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle Driv...

Page 135: ...imbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Belt slippage from water or snow ingestion into the PVT system Dry out the PVT see page 103 Prevent water from entering the PVT outlet duct see page 125 Inspect c...

Page 136: ...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 can assist Low battery voltage Recharge the battery to 12 8 VDC Loose ignition connections Check all connections and tighten Mechanical failure Your POLARIS dealer can assist Possible Cause Solution Out of fuel Refuel Weak spark f...

Page 137: ...ssist Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line or filter Inspect and replace Kinked idle air control lines Inspect rotate lines to remove kink Incorrect fuel Replace with recom...

Page 138: ...ark plug wires Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and replace Other mechanical failure Your POLARIS dealer can assist Overheated engine Clea...

Page 139: ...ginal registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage And...

Page 140: ...ES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE ...

Page 141: ...es vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue...

Page 142: ...chased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void bec...

Page 143: ...dar months from 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 p...

Page 144: ...ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply i...

Page 145: ...n aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS Off Road Vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the lett...

Page 146: ...144 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 147: ...145 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 148: ...el 31 Cargo 64 65 Cargo Box Access Panel 31 Changing Gears 35 Chart Periodic Maintenance 79 83 Check Engine Indicator 47 Cleaning and Storage 125 129 Cleaning the Air Filter 104 105 Cleaning the Exhaust System 107 Cleaning the Spark Arrestor 107 Clothing 9 Clutching 131 Component Locations 25 Condition Spark Plugs 95 Coolant Level Overflow Bottle 99 Coolant Level Radiator 98 Coolant Adding 97 Cool...

Page 149: ...d Drive 92 Front Gearcase 92 Main Gearcase 90 Transmission 90 Fluid Levels During Storage 127 Fluid Recommendations Gearcase 94 Fluid Brake 110 Fogging the Engine 128 F Fouled Plugs 95 Freeplay Steering Wheel 120 Fuel Cap 31 Fuel Safety 22 Fuel Stabilizer 127 Fuel Tank Filler Cap 31 Fuse Relay Center 96 G Gap Spark Plug 94 Gasoline Handling 22 Gear Selector 35 Gearcase Capacities 94 Gearcase Oil D...

Page 150: ... 92 Engine Oil 87 Front Gearcase 92 Main Gearcase 90 Transmission 90 O Oil Recommendations 86 Operation on Public Lands 78 Operator Restrictions 14 Outlets Auxiliary 26 Overflow Bottle Coolant Level 99 P Parking on an Incline 63 Parking the Vehicle 53 Passenger Hand Hold Adjustment 29 Periodic Maintenance Chart 79 83 Plug Condition 95 Plug Gap 94 Plug Torque 94 Plugs Fouled 95 Plugs Spark 94 95 Po...

Page 151: ...rage Area 128 Storage Battery 122 Storage Covers 128 Storage Fluid Levels 127 Storage Oil and Filter 127 Storage Removal 129 Suspension Settings 111 114 Switches AWD Switch 27 38 Headlight Switch 27 Ignition 26 Mode Button 39 Remote Winch Switch 27 Winch Switch 27 T Tachometer 45 Taillight 117 Throttle Pedal 37 Tire Tread Depth 115 Tires 115 116 Torque Axle Nuts 115 Torque Spark Plug 94 Torque Whe...

Page 152: ...ury or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passengers read and understand all safety labels Operate slowly in reverse avoid sharp turns or sudden braking On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability For yo...

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Polaris RZR XP 1000 EPS High Lifter Edition, Owner'S Manual

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