Polaris RZR XP 4 TURBO S VELOCITY 2019 Owner'S Manual For Maintenance And Safety Download Page 201

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ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES

POSSIBLE CAUSE

SOLUTION

Loose, missing or kinked boost
reference lines

Replace boost reference lines

Loose or missing intake system
sensor connections

Inspect connections, tighten or
replace as needed

Fouled or defective spark plugs

Inspect, clean and/or replace spark
plugs

Worn or defective spark plug wires

Your POLARIS dealer can assist.

Incorrect spark plug gap or heat
range

Set gap to specs or 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

Incorrect fuel

Replace with 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 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 can assist.

Low fuel pressure

Your POLARIS dealer can assist.

Loose, missing, torn or kinked boost
reference line from manifold to fuel
pressure regulator or blow-off valve

Replace boost reference line

199

TROUBLESHOOTING

Summary of Contents for RZR XP 4 TURBO S VELOCITY 2019

Page 1: ...Owner s Manual For Maintenance and Safety RZR XP TURBO S RZR XP 4 TURBO S RZR XP TURBO S VELOCITY RZR XP 4 TURBO S VELOCITY ...

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 XP Turbo S XP 4 Turbo S XP Turbo S Velocity XP 4 Turbo S Velocity ...

Page 4: ...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 vehicle...

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: ...us injury or death CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components NOTICE NOTICE provides key information by clarifyi...

Page 7: ...fety 9 Features and Controls 31 Operation 79 Winch Guide 101 Emission Control Systems 111 Maintenance 113 Specifications 189 Polaris Products 193 Troubleshooting 195 Warranty 203 Maintenance Log 213 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: ...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 8 INTRODUCTION ...

Page 11: ...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 spec...

Page 12: ...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 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...

Page 13: ... 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 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 mini...

Page 14: ...roper 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 on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Turbo S Turbo S Velocity Do not exceed sea...

Page 15: ...ther changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding across slopes SEAT BELT 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 flat on the floor and hands on steering wheel or hand holds S...

Page 16: ...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 cargo RZR XP TURBO S RZR XP TURBO S VELOCITY RZR XP 4 TURBO S RZR XP 4 TURBO S VELOCITY MAXIMUM CARGO BOX LOAD 300 lbs 136 kg 300 lbs 136 kg TIRE PRESSURE IN PSI KPa FRONT 16 110 REAR 16 110 ...

Page 17: ...und the clutch and vent system when replacing the belt Read owner s manual or see authorized dealer q Belt Debris Warning 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 i...

Page 18: ...uced prior to January 7th 2019 To identify your vehicle s build date reference the vehicle identification sticker as shown on page 8 or the vehicle purchase documents WARNING DO NOT REMOVE ROOF Roof is part of Roll Over Protective Structure ROPS Roof Warning Decal q 16 SAFETY ...

Page 19: ...er Avoid exhibition driving INTAKE ALERT 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 additional informatio...

Page 20: ...AR MAXIMUM CAPACITY 136 kg Front 110 kPa 1 1 bar Rear 110 kPa 1 1 bar Occupants 2 Occupants Tow Load Weight 336 kg RZR XP 4 Turbo S RZR XP 4 Turbo S Velocity 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 TIRE PRESSURE IN KPA BAR MAXIMUM CAPACITY 136 kg ...

Page 21: ...nd on different types of terrain Take a training course and complete the steps outlined in the New Operator Driving Procedures section 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 steps outlined in the New Operator Driving Procedures section...

Page 22: ...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 described in this owner s manual See the P...

Page 23: ...sed 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 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 f...

Page 24: ...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 25: ...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 26: ... 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 Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual See the Driving ...

Page 27: ...rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions OPERATING IMPROPERLY IN REVERSE Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See the Driving in Reverse section for details Before shifting into reverse gear al...

Page 28: ...use loss of control or rollover Before operating in a new area check for obstacles Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See the Driving Over Obstacles section for details OPERATING THROUGH WATER Operating through deep or fast flowing water can cause loss of tractio...

Page 29: ...h any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water OPERATING A DAMAGED VEHICLE Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect th...

Page 30: ...henever 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 NEVER carry fuel or other flammable liquids on this vehicle Failure to follow this instruction could lead to serious burn injuries or death Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where ...

Page 31: ...fications to your vehicle may negatively impact vehicle stability Failure of critical machine components may result from operation with any modifications especially those that increase speed or power This vehicle may become less stable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Do not install any non POLARIS approved accessory or modify the vehi...

Page 32: ...30 ...

Page 33: ...r r Fuel Tank Cap t Radiators STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference Lift and hold the steering wheel adjustment lever q while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position 31 FEATURES AND CONTROLS ...

Page 34: ... The engine is off Powers the display and terminal block Check engine and power steering warning indicators will appear on the display in this mode but will turn off when the vehicle is started if no issues are present ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when releas...

Page 35: ... AWD switch has two positions All Wheel Drive AWD Two Wheel Drive 2WD 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 the All Wheel Drive AWD System section for AWD operating instructions AUXILIARY OUTLETS The vehicle is equipped with one or more 12 volt accessory outlets One outlet is on the dash a second outlet if equi...

Page 36: ...ion for 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 another qualified person as soon as possible for repair Continued operation ...

Page 37: ...current active vehicle state is present cornering braking accelerating or airborne In Firm Mode the suspension reverts to its most firm compression damping setting This mode is recommended for challenging terrain where large suspension events and complex terrain is encountered In this mode all 4 shocks are at the most firm setting In Sport Mode some level of rider comfort is traded for higher perf...

Page 38: ...en 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 sure the...

Page 39: ...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 37 FEATURES AND CONTROLS ...

Page 40: ... 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 TURBO SYSTEM Do not attempt to perform maintenance or repairs to any component of the turbo system Please see your POLARIS dealer or other qualified service person for this service 38 FEATURES AND CONTROLS ...

Page 41: ...ATIONS Use ONLY 91 octane or higher unleaded fuel minimum pump octane number of 91 R M 2 Do not use any fuel lower than 91 octane Do not use fuel containing more than 10 ethanol including E85 39 FEATURES AND CONTROLS ...

Page 42: ...el as soon as possible Do not allow the vehicle to run out of fuel NOTICE Damage to the fuel pump will occur if the vehicle is operated with an empty fuel tank Do not allow the vehicle to run out of fuel Always refuel when the level is low NOTICE Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended NOTICE Prolonged exposure to petroleum bas...

Page 43: ...elt is securely fastened 3 Position buckle low and centered on pelvis SNUG each side of the lap belt by pulling each adjuster strap 4 Pull torso belts snug 5 Latch chest clip if applicable To release belt Depress button with thumb or finger Tongue will eject from buckle SEAT BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle 1 Pull each seat belt completely ...

Page 44: ...l cap spark plugs and air filter 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 vehicle Always inspect doors and latches for wear and damage before each use of the vehicle Promp...

Page 45: ... the vehicle is moving NOTE Turbo S model shown in image 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 vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at ...

Page 46: ...dal q to slow or stop the vehicle Apply the brakes while starting the engine THROTTLE PEDAL Push the throttle pedal w down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that 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 44 FE...

Page 47: ...n this vehicle is certified in compliance with ROHVA Always have your authorized dealer or qualified person thoroughly inspect the ROPS if it ever becomes damaged in any way q ROPS Label WARNING Never 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...

Page 48: ...hicle is part of the ROPS and should not be removed Always have your authorized dealer or qualified person thoroughly inspect the ROPS if it ever becomes damaged in any way q ROPS Label w Roof Warning Decal 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 f...

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

Page 50: ...s and chemicals will damage the speedometer lens and other plastic 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 q Speedometer w Tachometer e Indicator Lamps r Mode Button t Toggle Buttons y Rider Information Center 48 FEATURES AND CONTROLS ...

Page 51: ... settings menu Press and release the MODE button to cycle through Area 1 modes and to select an item Press and release either toggle button t to cycle through the options menu or Area 2 modes Press and hold either toggle button to reset an item See page 53 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 all...

Page 52: ...esult in permanent damage to the EPS unit and increased steering effort Engine Hot This lamp illuminates to indicate an overheated engine If the indicator flashes a severe overheating condition exists Neutral This lamp when the transmission is in neutral and the ignition key is on the ON position Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The l...

Page 53: ... Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears w AWD Indicator This indicator shows whether 2X4 or AWD is active when the vehicle is in gear e Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached Your POLARIS dealer can provide scheduled maintenance See page 56 for resetting instructions r Fuel Gauge ...

Page 54: ...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 55 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 56 Trip Time Time length of vehicle operation since mode was last reset e Ar...

Page 55: ...sired option 2 Press MODE to select the option 3 Press either toggle button to cycle to the desired setting 4 Press MODE to save and exit to the settings menu 5 Press and hold the MODE button to exit 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...

Page 56: ...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 57: ...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 58: ...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 59: ...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 60: ...c control unit is shorted to a wire at battery voltage DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI Engine Control Module Accelerator Position 2 Data Erratic Intermittent Or Incorrect 29 2 Voltage Above Normal Or Shorted To High Source 29 3 Voltage Below Normal Or Shorted To Low Source 29 4 Throttle Position Sensor 1 Data Valid But Above Normal Operational Range Most Severe Level 51 0 Data Valid B...

Page 61: ...rmal Or Shorted To High Source 84 3 Voltage Below Normal Or Shorted To Low Source 84 4 Abnormal Frequency Or Pulse Width Or Period 84 8 Abnormal Update Rate 84 9 Abnormal Rate Of Change 84 10 Bad Intelligent Device Or Component 84 12 Received Network Data In Error 84 19 Accelerator Position 1 Data Erratic Intermittent Or Incorrect 91 2 Voltage Above Normal Or Shorted To High Source 91 3 Voltage Be...

Page 62: ...Low Source 102 4 Mechanical System Not Responding Or Out Of Adjustment 102 7 Abnormal Rate Of Change 102 10 Intake Air Temperature Sensor Data Erratic Intermittent Or Incorrect 105 2 Voltage Above Normal Or Shorted To High Source 105 3 Voltage Below Normal Or Shorted To Low Source 105 4 Abnormal Rate Of Change 105 10 Data Valid But Above Normal Operating Range Least Severe Level 105 15 60 FEATURES...

Page 63: ...110 2 Voltage Above Normal Or Shorted To High Source 110 3 Voltage Below Normal Or Shorted To Low Source 110 4 Abnormal Rate Of Change 110 10 Data Valid But Above Normal Operating Range Least Severe Level 110 15 Data Valid But Above Normal Operating Range Moderately Severe Level 110 16 Data Valid But Below Normal Operating Range Least Severe Level 110 17 61 FEATURES AND CONTROLS ...

Page 64: ...68 4 Data Valid But Above Normal Operating Range Moderately Severe Level 168 16 Data Valid But Below Normal Operating Range Moderately Severe Level 168 18 Engine Speed Data Valid But Above Normal Operational Range Most Severe Level 190 0 Data Valid But Below Normal Operational Range Most Severe Level 190 1 Data Erratic Intermittent Or Incorrect 190 2 Mechanical System Not Responding Or Out Of Adju...

Page 65: ...Out Of Calibration 630 13 Crankshaft Position Sensor Data Erratic Intermittent Or Incorrect 636 2 Abnormal Frequency Or Pulse Width Or Period 636 8 Injector 1 Front MAG SDI Port Injector Voltage Above Normal Or Shorted To High Source 651 3 Voltage Below Normal Or Shorted To Low Source 651 4 Current Below Normal Or Open Circuit 651 5 Fan Relay Driver Circuit Voltage Above Normal Or Shorted To High ...

Page 66: ...rcuit 1268 5 Fuel Pump Driver Circuit Voltage Above Normal Or Shorted To High Source 1347 3 Voltage Below Normal Or Shorted To Low Source 1347 4 Current Below Normal Or Open Circuit 1347 5 Oxygen Sensor 1 Data Erratic Intermittent Or Incorrect 3056 2 Voltage Above Normal Or Shorted To High Source 3056 3 Voltage Below Normal Or Shorted To Low Source 3056 4 Bad Intelligent Device Or Component 3056 1...

Page 67: ... Valid But Below Normal Operational Range Most Severe Level 3597 1 Voltage Above Normal Or Shorted To High Source 3597 3 Voltage Below Normal Or Shorted To Low Source 3597 4 Data Valid But Above Normal Operating Range Moderately Severe Level 3597 16 Data Valid But Below Normal Operating Range Moderately Severe Level 3597 18 65 FEATURES AND CONTROLS ...

Page 68: ...ge Moderately Severe Level 3598 16 Data Valid But Below Normal Operating Range Moderately Severe Level 3598 18 ECU Output Supply Voltage 3 Data Valid But Above Normal Operational Range Most Severe Level 3599 0 Data Valid But Below Normal Operational Range Most Severe Level 3599 1 Voltage Above Normal Or Shorted To High Source 3599 3 Voltage Below Normal Or Shorted To Low Source 3599 4 Data Valid B...

Page 69: ...20198 2 Voltage Above Normal Or Shorted To High Source 520198 3 Voltage Below Normal Or Shorted To Low Source 520198 4 Abnormal Rate Of Change 520198 10 Out Of Calibration 520198 13 Fuel Correction Front Data Valid But Above Normal Operating Range Least Severe Level 520204 15 Data Valid But Below Normal Operating Range Least Severe Level 520204 17 All Wheel Drive Control Circuit Voltage Above Norm...

Page 70: ...on Sensor 1 or 2 Indeterminable Data Erratic Intermittent Or Incorrect 520276 2 Bad Intelligent Device Or Component 520276 12 Throttle Body Control Power Stage Data Erratic Intermittent Or Incorrect 520277 2 Voltage Above Normal Or Shorted To High Source 520277 3 Voltage Below Normal Or Shorted To Low Source 520277 4 Abnormal Frequency Or Pulse Width Or Period 520277 8 Condition Exists 520277 31 T...

Page 71: ...0283 2 Voltage Above Normal Or Shorted To High Source 520283 3 Voltage Below Normal Or Shorted To Low Source 520283 4 Throttle Body Control Position Deviation Fault Condition Exists 520284 31 ECU Monitoring Error Condition Exists 520286 31 ECU Monitoring Error Level 3 Condition Exists 520287 31 ECU Monitoring of Injection Cut Off Level 1 Condition Exists 520288 31 ECU Monitoring of Injection Cut O...

Page 72: ...CO Condition Exists 520309 31 ECU Fault Hardware Disruption Condition Exists 520311 31 Idle Fuel Correction Bank 1 Data Valid But Above Normal Operating Range Least Severe 520342 15 Data Valid But Below Normal Operating Range Least Severe 520342 17 Adaptive Fuel Correction Bank 1 Data Valid But Above Normal Operating Range Least Severe 520344 15 Data Valid But Below Normal Operating Range Least Se...

Page 73: ...Valid But Above Normal Operating Range Severe 16 EPAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520226 2 Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or Component 520228 12 Condition Exists 520228 31 EPAS Software Error Bad Intelligent Device Or Component 520229 12 Condition Exists 520229 31 EPAS Power Save C...

Page 74: ...CAN Communications Receive Error No RX Message for cal parameter seconds 520226 2 Vehicle Speed Vehicle Speed Too High 84 0 Vehicle Speed Implausible 10 Received Vehicle Speed has Errors 19 Engine Speed Engine Speed Too High 190 0 Received Engine Speed has Errors 190 19 Battery Voltage Too High 168 3 Battery Voltage Too Low 168 4 72 FEATURES AND CONTROLS ...

Page 75: ... 12 Boot Count Error 31 ICS Communication Loss of CAN between EPS and Instrument Cluster 520230 31 EPAS Power Save 5 minute time out 520231 31 ECU Memory EEPROM Communication Error 628 12 Application CRC Error 13 VGD Low VGD Low 524086 4 Absolute Position Sensor Absolute Position Sensor Out of Range 1807 31 Absolute Position Sensor Not Calibrated 1807 13 73 FEATURES AND CONTROLS ...

Page 76: ...ource 4 Valve Driver Front Left Turbo S only Voltage Above Normal Or Shorted To High Source 516106 3 Voltage Below Normal Or Shorted To Low Source 4 Valve Driver Front Right Turbo S only Voltage Above Normal Or Shorted To High Source 516107 3 Voltage Below Normal Or Shorted To Low Source 4 Valve Driver Rear Left Turbo S only Voltage Above Normal Or Shorted To High Source 516108 3 Voltage Below Nor...

Page 77: ... Shock Current Error Front Right Turbo S only Root Cause Not Known 516112 11 Absolute Shock Current Error Rear Left Turbo S only Root Cause Not Known 516113 11 Absolute Shock Current Error Rear Right Turbo S only Root Cause Not Known 516114 11 Internal Inertial Measurement Unit Turbo S only Bad Intelligent Device Or Component 516115 12 Data Valid But Above Normal Operating Range Least Severe Level...

Page 78: ...ect 516119 2 CAN Message PGN 65265 Abnormal Update Rate 516120 9 CAN Message PGN 61445 Abnormal Update Rate 516121 9 Steering Angle Adoption Offset Turbo S only Data Valid But Above Normal Operating Range Least Severe Level 516122 15 Vehicle Speed Data Data Erratic Intermittent Or Incorrect 516123 2 Data Drifted High 20 Suspension Control Module Turbo S only Bad Intelligent Device Or Component 516...

Page 79: ...ed To Low Source 4 Data Valid But Above Normal Operating Range Moderately Severe Level 16 Data Valid But Below Normal Operating Range Moderately Severe Level 18 Raw Brake Switch Status Data Erratic Intermittent Or Incorrect 520572 2 Normalized Accelerator Pedal Position Data Erratic Intermittent Or Incorrect 520574 2 Engine Speed Data Data Erratic Intermittent Or Incorrect 524000 2 Steering Angle ...

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Page 81: ...periods vary depending on operating conditions No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engi...

Page 82: ...and all gearcases after the first 25 hours of operation and every 100 hours thereafter BRAKE SYSTEM BREAK IN Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and 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 be...

Page 83: ... 139 Steering Ensure free operation page 178 Tires Inspect condition and pressure page 18 page 173 Wheels fasteners Inspect ensure fastener tightness page 174 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels page 142 Coolant level Ensure proper level page 155 Coolant hoses Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure prope...

Page 84: ...on page 41 Cab Doors Check doors and latches for wear or damage page 21 Exhaust Inspect spark arrester and clean if needed after riding through water and or mud page 164 Grass and leaves Remove grass leaves and other flammable material or debris especially near the exhaust system 82 OPERATION ...

Page 85: ...dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both hands on the 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 pres...

Page 86: ... ignition key past the ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 6 If the engine does not start within five seconds return the ignition switch to the OFF position and wait five seconds Repeat steps 5 and 6 until the engine starts 7 After starting the engine wait 10 seconds before applying throttle STOPPING THE ENGINE 1 Release ...

Page 87: ...s before stopping the engine This will allow the turbo system to cool down 3 Stop the engine 4 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 5 Remove the ignition key to prevent unauthorized use KNOW YOUR RIDING AREA TREAD LIGHTLY Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area Respect th...

Page 88: ...this vehicle 9 Sit in the driver s seat and fasten the seat belt 10 Place the transmission in PARK 11 Start the engine 12 Apply the brakes and shift into low gear 13 Check your surroundings and determine your path of travel 14 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 15 Drive slowly at first On level surfaces ...

Page 89: ...tance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehicles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 87 OPERATION ...

Page 90: ...ssengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times See the Safe Riding Gear section for details 6 Always 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 91: ...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 92: ... 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 in reverse and...

Page 93: ...her irregular terrain Always move the AWD switch to AWD before ascending or descending a hill 3 Drive slowly and use extreme caution 4 If the vehicle begins to roll over or if it feels as if it may roll over immediately turn downhill 5 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 6 If the vehicle begins to slide downhill immed...

Page 94: ... 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 92 OPERATION ...

Page 95: ...ealer can provide this service If it s impossible to bring the vehicle in before starting the engine perform the service outlined on page 178 and take the vehicle in for service at the first opportunity Your vehicle can operate through water with a maximum recommended depth equal to floor level Follow these precautions when operating through water 1 Determine the water depth and current before ent...

Page 96: ...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 97: ...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 95 OPERATION ...

Page 98: ...s 1 Apply the brakes 2 Place the transmission in PARK NOTE After a ride allow the engine to idle for 30 seconds before stopping the engine This will allow the turbo system to cool down 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 96 OPERATION ...

Page 99: ...ght 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 maintain stable driving conditions Always operate the...

Page 100: ...RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while cornering or while ascending or descending a hill Your POLARIS vehicle has been designed to carry a specific capacity Reduce speed and allow a greater distance for braking when carrying cargo Loads should be centered and carried as low as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exerc...

Page 101: ...se ONLY Tow a vehicle ONLY of equal or lesser size and weight If preferred the tow loop w on the front of the vehicle is provided for recovery use ONLY as well 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 99 OPERATION ...

Page 102: ...ler or flatbed with all four wheels off the ground See the Transporting the Vehicle section for details If towing a disabled vehicle is unavoidable place the disabled vehicle s transmission in neutral Tow the shortest distance possible Do not operate faster than 16 km h 10 MPH 100 OPERATION ...

Page 103: ...Loading section on page 109 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 104: ...ching 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 105: ...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 t...

Page 106: ...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 109 Never hook the winch cable back onto itself This will damage the winch cable and may result in winch ca...

Page 107: ...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 108: ... 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 109: ... 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 110: ...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 111: ...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 112: ... 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 pu...

Page 113: ... 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...

Page 114: ...112 ...

Page 115: ... 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 116: ...eck 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 months thereafter XU Front Gearcase Lubricant Initial fluid level inspect...

Page 117: ...l 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 Inspect replace as needed...

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

Page 119: ...ded 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 Change lubricant XU Tr...

Page 120: ...en Inspect clean replace worn parts D 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 other qualified person perform these services 118 MAINTENANCE ...

Page 121: ...fter 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 authorized Polaris d...

Page 122: ...ll 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 Inspect replace as neede...

Page 123: ...fter 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 authorized Polaris d...

Page 124: ...bricate 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 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 tension as needed XU ...

Page 125: ...ock 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 other qualified person perf...

Page 126: ...fter 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 authorized Polaris d...

Page 127: ...ll 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 Inspect replace as neede...

Page 128: ...fter 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 authorized Polaris d...

Page 129: ...bricate 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 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 tension as needed XU ...

Page 130: ...d to water mud etc D 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 other qualified person perform these services 128 MAINTENANCE ...

Page 131: ...fter 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 authorized Polaris d...

Page 132: ...ll 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 Inspect replace as neede...

Page 133: ...fter 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 authorized Polaris d...

Page 134: ...bricate 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 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 tension as needed XU ...

Page 135: ...e 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 E 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 other qualified perso...

Page 136: ...fter 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 authorized Polaris d...

Page 137: ...ll 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 Inspect replace as neede...

Page 138: ...fter 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 authorized Polaris d...

Page 139: ...ded 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 Change lubricant XU Tr...

Page 140: ...estor before operating Cam Chain Tensioner Inspect replace as needed 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 141: ...PS 4 5W 50 4 Cycle Oil and PS 4 Extreme Duty 10W 50 4 Cycle Oil See page 143 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 168 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 146 Front Gearcase Fluid Demand Drive Demand Drive Fluid See page 149 Prop Shaft U Joint Grease Grease the fitting Rear Stabilizer Bar Bushings All Season Grease or...

Page 142: ...q Middle Prop Shaft Grease Fitting w Rear Stabilizer Bar Bushings one on each side of vehicle 140 MAINTENANCE ...

Page 143: ...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 144: ...surface 2 Place the transmission in PARK 3 Start the engine Allow the engine to idle for 30 seconds 4 Stop the engine Wait two 2 minutes to allow oil to drain back to the sump 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely Remove the dipstick and check the oil level 7 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level betwe...

Page 145: ...the Periodic Maintenance Chart beginning on page 114 1 Position the vehicle on a level surface Place the transmission in PARK 2 Allow engine to cool down before draining oil 3 Place a drain pan under the engine crankcase and remove the drain plug q 4 Access the oil filter through the driver s side rear wheel well NOTE The engine should be off for at least 2 minutes prior to removing the oil filter...

Page 146: ...o specification Turn by hand until filter O ring contacts sealing surface then turn an additional 3 4 turn 8 Inspect the sealing washer on the drain plug for burrs or nicks Replace the washer if it is damaged 9 Reinstall the engine crankcase drain plug Torque drain plug to specification 12 ft lbs 16 Nm 10 Remove the cargo box access panel Add engine oil through the oil fill cap w located on top of...

Page 147: ...oil as necessary to bring the oil level within the SAFE range between the holes on the dipstick Do NOToverfill NOTE A rising oil level between checks during cold weather operation can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the upper mark change the oil immediately 18 When finished reinstall dipstick and lock the lever 19 Reinstall the car...

Page 148: ...ants 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 146 MAINTEN...

Page 149: ...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 147 MAINTENANCE ...

Page 150: ...hange the fluid at the intervals outlined in the Periodic Maintenance Chart section Refer to the Gearcase Specifications Chart section for recommended lubricants capacities and torque specifications Fill Plug Location Drain Plug Location 148 MAINTENANCE ...

Page 151: ...einstall the fill plug Torque to specification DEMAND DRIVE FLUID CHANGE The demand drive drain plug is located on the bottom of the gearcase 1 Remove the fill plug 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 250 ml Do not overfill 7 Reinsta...

Page 152: ...s Products section Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Transmission Main Gearcase AGL Gearcase Lubricant Transmission Fluid 61 oz 1800 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 150 MAINTENANCE ...

Page 153: ...ndicative 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 ...

Page 154: ...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 155: ...below and to the left of the steering wheel The fuse for the engine cooling fan is an external fuse in a holder on top of the fuse box LABEL VALUE FUNCTION FAN 50A Fuse separate fuse holder on top of fuse box Engine Cooling Fan WATER 7 5A Fuse Water Pump FUEL 7 5A Fuse Fuel Pump FUEL EVAP ONLY 10A Fuse Fuel Pump TERM ACCY 10A Fuse Terminal Block Accessory INST ACCY 7 5A Fuse Diagnostic Accessory I...

Page 156: ...hts optional Brake Lights CHASSIS 7 5A Fuse AWD Switch Light Oxygen Sensor Heater EPS Wake Up Vehicle Speed Sensor Seat Belt Switch SCM Wake Up optional SCM Mode Switch optional AWD Coil Gauge Waste Gate EFI 10A Fuse Accessory Relay Coil ECM Wake Up Pump Relay Coil Chassis Relay Coil Start Relay Coil EFI Relay Coil Injectors SCM Relay Coil optional Lights Relay Coil Ignition Coil Starter Solenoid ...

Page 157: ...fore removing the pressure cap ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50 50 Premix This antifreeze 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 fre...

Page 158: ... Use a funnel and slowly add coolant as needed 5 Before reinstalling the pressure cap bleed the system of trapped air Locate the coolant bleed screw on the engine above the exhaust head pipe on the power take off side Use a socket wrench to turn the bleed screw slightly allowing the air to escape Slowly add additional coolant to the pressure tank until air no longer escapes and only coolant flows ...

Page 159: ...f the pressure tank CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 4 Remove the pressure cap and use a funnel to add coolant as needed Maintain the coolant level within one inch 2 5 cm of the cold full mark on the side of the pressure tank when the fluid is cool 5 Reinstall the pr...

Page 160: ...onsibilities 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 in the owner s manual and on safety labels This PVTsystem is intended for use on POLARIS products only Do not install it ...

Page 161: ...ents to cool before performing this procedure 2 Remove the engine access panel and thoroughly clean ALL debris from the engine compartment NOTE Removal of the left rear wheel or shock is not necessary for belt replacement 3 Loosen the clamp q retaining the PVT inlet duct to the outer clutch cover 4 Remove the nine 9 clutch cover screws w 5 Maneuver the outer clutch cover outward to access the driv...

Page 162: ...Remove ALL debris from the entire clutch air duct passage 12 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 opera...

Page 163: ... 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 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 slippag...

Page 164: ...fore each use of the vehicle to ensure adequate air flow If necessary remove the pre filter and clean with soapy 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 recom...

Page 165: ...ean 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 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 ma...

Page 166: ... death in a very short time Do NOT perform service on the spark arrester while the system is HOT Exhaust system temperatures can reach extreme temperatures Allow components to cool sufficiently before proceeding Do not stand behind 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 ...

Page 167: ... 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 7 9 ft lbs 9 12 Nm 165 MAINTENANCE ...

Page 168: ...y the brake pedal Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied the brake pedal should feel firm Any sponginess would indicate a possible fluid leak or low brake fluid level which must be corrected before riding See the Brake Fluid section for further details If you discover any irregularities in brake system operation including exc...

Page 169: ...tem for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness 4 Check brake discs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 0 030 0 762 mm q 167 ...

Page 170: ...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 171: ...ndicate factory settings Driver only 0 Remove 0 2 inch 5 mm preload front and rear Driver 1 0 Factory default preload Driver 1 100 lbs 45 kg Add 0 2 inch 5 mm preload front and rear Driver 1 200 lbs 91 kg Add 0 4 inch 10 mm preload front and rear Driver 1 300 lbs 136 kg Add 0 6 inch 15 mm preload front and rear SHOCK ADJUSTMENTS RZR XP 4 Turbo S and 4 Turbo S Velocity Weight Condition assuming eac...

Page 172: ...n the adjusting ring to the left to add preload Turn the adjusting ring to the right to remove preload 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 or qualified person perform the adjustments DYNAMIX SHOCKS q Front Shock Preload Measurement w Rear Shock Pr...

Page 173: ...inches 7 32 cm Rear 6 38 inches 16 21 cm RZR 4 Turbo S DYNAMIX Front 2 5 inches 6 35 cm Rear 6 5 inches 16 51 cm RZR Turbo S Velocity NON DYNAMIX Front 0 84 inches 2 13 cm Rear 0 96 inches 2 44 cm RZR 4 Turbo S Velocity NON DYNAMIX Front 0 72 inches 1 83 cm Rear 0 77 inches 1 96 cm 171 MAINTENANCE ...

Page 174: ...eservoir 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping Front Rear SHOCK COMPRESSION SETTINGS Setting Compression Damping WALKER Softest Full counter clockwise position 16 clicks Factory Center position 8 clicks Firmest Full clockwise position 0 clicks 172 MAINTENANCE ...

Page 175: ...easures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always 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 le...

Page 176: ...ve been loosened for maintenance service Do not lubricate the stud or the lug nut Lug Nut Aluminum Wheels Front and Rear 120 ft lbs 162 7 Nm Hub Retaining Nut Front and Rear 180 ft lbs 244 Nm WHEEL REMOVAL 1 Position the vehicle on a level surface 2 Place the transmission in PARK NOTE After a ride allow the engine to idle for 30 seconds before stopping the engine This will allow the turbo system t...

Page 177: ...ot service axle nuts that have a cotter pin installed Your POLARIS dealer 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 Attach the wheel nuts and finger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to ...

Page 178: ... t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp TAILLIGHT BRAKE LIGHT 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 m...

Page 179: ...ht 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 headlig...

Page 180: ...rn 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 procedure 8 Take the vehicle in for service as soon as possible whether you succeed in starting it or not Your POLARIS dealer can provide the required service 9 If water has been ingested into the PVT follow the procedure on page 161 for drying...

Page 181: ...ore removing the battery 2 Remove the driver s seat XP or the left rear passenger seat XP 4 See the Seats section for details 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable last 5 Remove the battery hold down strap 6 Lift the battery out of the vehicle BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery an...

Page 182: ...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 183: ...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 181 MAINTENANCE ...

Page 184: ...radiator fins and impair a radiator s effectiveness High pressure may also damage other vehicle components Certain products including insect repellents and chemicals 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 c...

Page 185: ... entered the engine or exhaust 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 POLISHING THE VEHICLE POLARIS recommend...

Page 186: ...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 143 AIR FILTER AIR BOX Replace the air filter See page 163 Clean the air box FLUID LEVELS Inspect the fluid levels Add or change fluids as recommended in the Pe...

Page 187: ...you miss the 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 151 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...

Page 188: ...on sectionb 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 114 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area TRANSPORTING THE ...

Page 189: ...um compression damping setting prior to securing the vehicle can potentially lead to a reduction of intended strap tension while trailering 5 After the vehicle has been secured verify the gauge indicates PARK and turn the vehicle power off Verify also that the suspension compression damping values are still soft after securing the vehicle If after securing the suspension demo mode has timed out or...

Page 190: ...q Rear Tie Down w Front Tow Loop Tie Down 188 MAINTENANCE ...

Page 191: ...ar Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload S and S Velocity 740 lbs 336 kg 4 S and 4 S Velocity 900 lbs 408 kg including riders cargo and accessories Fuel Capacity 9 5 gal 36 L Engine Oil Capacity 2 75 qts 2 6 L Coolant Capacity 10 8 qts 10 22 L Demand Drive Fluid Capacity 8 5 oz 250 ml Transmission Oil Capacity 61 oz 1800 ml Overall Length Width Height S and S Velocity 1...

Page 192: ... a arm with 19 in 48 3 cm travel Rear Suspension Independent trailing arms with 21 in 53 3 cm travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Tire Size Front 32x10xR15 Tire Size Rear 32x10xR15 Tire Pressure Front 16 psi 110 kPa Rear 16 psi 110 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual...

Page 193: ... 11 58 1 Low Gear 20 25 1 Reverse 23 36 1 Front including front drive High Gear 12 19 1 Low Gear 21 31 1 Reverse 24 57 1 Drive Ratio Front 3 17 1 CLUTCHING Please see your POLARIS dealer for clutching specifications 191 SPECIFICATIONS ...

Page 194: ...192 ...

Page 195: ...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 196: ...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 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 194 POLARIS PRODUCTS ...

Page 197: ...n short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Hauling heavy cargo pushing at low RPM low 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 198: ...from failure to warm up belt Always warm up the belt by operating below 30 MPH 48 km h for one mile 1 5 km and for 5 miles 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 79 Failed belt Remove the belt and clean away any debris from the clutch box clutch duct and engine compartmen...

Page 199: ...AUSE SOLUTION Out of fuel Refuel Clogged fuel filter Your POLARIS dealer or other qualified person can assist Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace 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 POL...

Page 200: ...n timing Your POLARIS dealer or other qualified person can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Exhaust leak Check all connections Mechanical failure Your POLARIS dealer or other qualified person can assist ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended ...

Page 201: ...with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line or filter Inspect and replace Incorrect fuel Replace with 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 can assist Possible Lean Fuel Cause Solution Low or contaminated fue...

Page 202: ... 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 can assist Overheated engine Clean radiator screen and core clean engine exterior check coolant level Your POLARIS dealer can assist Loose missing torn or kinked boost reference line from ...

Page 203: ...E SOLUTION Worn or defective wastegate actuation system Your POLARIS dealer can assist Overheated intake air system Inspect intercooler water lines for leaks or kinks repair or replace as needed 201 TROUBLESHOOTING ...

Page 204: ...202 ...

Page 205: ... 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 206: ...her foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments 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 materials or workman...

Page 207: ...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 CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE...

Page 208: ...ealer 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 country to country You may be required to ...

Page 209: ...ontinue 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 because of feder...

Page 210: ... 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 covered subject to the terms of any such paid ...

Page 211: ... 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 FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL E...

Page 212: ...ems on your vehicle An authorized POLARIS dealer can perform any service that may be necessary for your vehicle POLARIS also recommends POLARIS parts however equivalent parts may be used for such service It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission contro...

Page 213: ...The California Air Resources Board and Polaris Industries Inc is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle In California new off highway recreational vehicles must be designed built and equipped to meet the State s stringent anti smog standards Polaris must warrant the emission control system on your OHRV EVAP for the...

Page 214: ...nt 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 maintenance or unapproved modifications ADD ON OR MODIFIED PARTS An add on or modified part must be compliant with applicable CARB emission control standards A violation of this requirement is punishable by ...

Page 215: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 213 MAINTENANCE LOG ...

Page 216: ...214 ...

Page 217: ...ng Hillsides 24 D Demand Drive Fluid Change 149 Fluid Check 149 Demand Drive Unit Front Gearcase 148 Descending Hills Improperly 24 Diagnostic Display Code Definitions 58 Display Units Standard Metric 55 Drive Belt Wear Burn 195 Drive Responsibly Warning 13 Driving Downhill 92 Driving in Reverse 95 Driving on a Sidehill Sidehilling 91 Driving on Slippery Surfaces 89 Driving Over Obstacles 94 Drivi...

Page 218: ... Instrument Cluster 48 Intake Alert 7185975 17 Intake Pre Filters 162 J Jumps and Stunts 24 K Know Your Riding Area Tread Lightly 85 L Lights 176 Limited Warranty 203 Load Passenger Tire Pressure Warning 14 Lubrication Recommendations 139 M Maintenance Charts 114 Maintenance Log 213 Metric Display 55 Mode Button 49 N New Operator Driving Procedures 86 Noise Emission Control System 111 Notice 207 O...

Page 219: ...afety Labels and Locations 12 Safety Symbols 4 Safety Training 9 Safety Warnings 19 Safety Winch Maintenance 110 Seat Belt 41 Seat Belt Inspection 41 Seat Belt Warning 13 Seat Belts 21 Seats 36 Service Access Panels 42 Shock Adjustment Recommendations 169 Shock Loading the Winch 109 Signal Words 4 Skidding or Sliding 26 Spark Arrester 164 Spark Plug Condition 152 Spark Plug Gap Torque 151 Spark Pl...

Page 220: ...Period 79 Vehicle Identification Numbers 8 Vehicle Immersion 178 W Warning Symbols 4 Warranty Coverage and Exclusions 204 Washing the Vehicle 182 Wheel Installation 175 Wheel Removal 174 Winch Cable Care 108 Winch Maintenance and Service Safety 110 Winch Operation 103 Winch Safety Precautions 101 Winch Shock Loading 109 218 ...

Page 221: ......

Page 222: ...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 9929465 Rev 02 Printed in USA ...

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Polaris RZR XP 4 TURBO S VELOCITY 2019, Owner'S Manual For Maintenance And Safety

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