Polaris RZR S 1000 2020 Owner'S Manual Download

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PMS 419

Owner's Manual

for Maintenance and Safety

2020

RZR S

1000

TRACTOR

Downloaded from

ManualsNet.com

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Summary of Contents for RZR S 1000 2020

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety 2020 RZR S 1000 TRACTOR Downloaded from ManualsNet com search engine ...

Page 2: ... 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 injury or death For vi...

Page 3: ...2020 RZR Tractor Owner s Manual S 1000 Downloaded from ManualsNet com search engine ...

Page 4: ...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 are in English Other l...

Page 5: ...n vehicles Low emission vehicles LEVs RANGER utility vehicles POLARIS PRO XD 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 Your manual contai...

Page 6: ...TION 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 clarifying instructions The Pr...

Page 7: ...ntrols 27 Operation 79 Winch Guide 97 Emission Control Systems 107 Maintenance 109 Specifications 165 Polaris Products 169 Troubleshooting 171 Warranty 177 Maintenance Log 183 5 TABLE OF CONTENTS Downloaded from ManualsNet com search engine ...

Page 8: ...6 Downloaded from ManualsNet com search engine ...

Page 9: ...his 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 all other body parts insi...

Page 10: ...d 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 Downloaded from ManualsNet com search engine ...

Page 11: ...www polaris com Your POLARIS vehicle is considered an on 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 thorough...

Page 12: ...n occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increas...

Page 13: ...lowed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipm...

Page 14: ... depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label 12 SAFETY Downloaded from ManualsNet com search engine ...

Page 15: ...ts This vehicle is approved for on road operation Never allow anyone under 16 years of age to operate this vehicle Avoid operating in a manner that could result in a rollover Jacking positions located beneath vehicle s center points Wear approved helmet goggles and protective clothing Never use alcohol or drugs before or while driving or riding 13 SAFETY Downloaded from ManualsNet com search engin...

Page 16: ...ZR RZR S RZR S4 Maximum Cargo Box Load 136 kg Tire Pressure in kPA Front 69 Rear 83 Front 69 Rear 97 Front 110 Rear 138 Maximum Capacity 336 kg 408 kg CLUTCH COVER ALERT Read your owner s manual Keep body parts away from belt FUEL TRANSPORT WARNING NEVER carry fuel or other flammable liquids on this vehicle Failure to follow this instruction could lead to serious burn injuries or death 14 SAFETY D...

Page 17: ... 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 information regarding air filter service CAUTION Air intake tube w must be fully seated on air box and throttle body Inspect...

Page 18: ...eps 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 in the New Operator Driving Procedures section AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone un...

Page 19: ...llover can result in serious injury or death Avoid operating in a manner that could result in a rollover PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the 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 bo...

Page 20: ...ases 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 OPERATING ON PUBLIC ROADS This vehicle is approved for on road operation JUMPS AND STUNTS Exhibition driving increases the risk of an...

Page 21: ...anual See the Periodic Maintenance section of the Maintenance chapter CARRYING A PASSENGER Never carry a passenger until you have operated this vehicle for at least two hours and have completed the in the New Operator Driving Procedures section A passenger must always be seated in a passenger seat with seat belt secured Carrying more than one passenger in a 2 seat vehicle can affect the operator s...

Page 22: ... be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down 2 Verify tire pressure 3 Use extra caution when operating Operating in rough terrain Operating over ...

Page 23: ... maneuvers Practice turning at slow speeds before attempting to turn at faster speeds OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution when operating on unfamiliar terrain...

Page 24: ...G WHILE CLIMBING A HILL Stalling or rolling backwards while climbing a hill could cause a rollover Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed OPERATING IMPROPERLY I...

Page 25: ... s manual See the Driving on Slippery Surfaces section for details OPERATING OVER OBSTACLES Improperly operating over obstacles could cause 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 D...

Page 26: ... damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling which could caus...

Page 27: ...haust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas HOT EXHAUST SYSTEMS Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep com...

Page 28: ...d warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself ...

Page 29: ...o Box t Cab Door w ROPS Frame y Mirror e Fuel Tank Cap u Steering Wheel r Radiators y Tie Down Points 4 corners u Brake Pedal i Throttle Pedal o Gear Selector a Passenger Hand Hold 27 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 30: ...enger area Use the outlets to power an auxiliary light or other optional accessories For service the dash outlet connection is under the dash The rear outlet connection is under the rear passenger seats HAZARD SWITCH Push the hazard warning switch to cause all turn signal lights to flash simultaneously Use this feature to alert others of an emergency or other situation requiring caution 28 FEATURE...

Page 31: ...adlights are off Position lights are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter See the Starting the Engine section for details HIGH BEAM SWITCH The headlight high beam is controlled by the turn signal lever To switch the headlights to high beam push the lever forward Pull the lever back to switch to low beam HORN SWITCH The horn swi...

Page 32: ...sh The turn signal indicator in the gauge will also flash Move the lever upward w to signal a right turn The right signal lamps and indicator will flash Return the lever to the center position to end the signal ALL WHEEL DRIVE AWD SWITCH The AWD Switch has either two or three positions depending on your model s features q All Wheel Drive AWD w Two Wheel Drive 2WD e Turf Mode Differential Unlocked ...

Page 33: ...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 could result in permanent damage to the EPS unit and increased steering effort STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference Lift and hold the steering wheel adjustment l...

Page 34: ...rward Once released the lever will lock into place Rotate the adjustment knob to move the seat forward and upward or rearward and downward Driver s Seat Up Position Driver s Seat Down Position To adjust the front passenger seat 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 5 4 Nm 4 ft lbs Do not over...

Page 35: ...engage the rear latch q Front Seat Retainer w Seat Latch HOOD Remove the hood to access the radiator pressure cap w and coolant overflow bottle e 1 Turn the hood fasteners q 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 33 FEATURES AND CONTROLS Download...

Page 36: ...etainer 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 34 FEATURES AND CONTROLS Downloaded from ManualsNet c...

Page 37: ...eater than 10 percent such as E 85 fuel E5 or E10 fuels are compatible 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 e...

Page 38: ...rs Always make sure the seat belts are secured for the operator and all passengers before riding The driver s seat belt is equipped with a seat belt interlock Vehicle speed will be limited to 15 MPH 24 km h if the seat belt is not secured 3 POINT SEAT BELT To wear the 3 point seat belt properly follow this procedure 1 Pull the seat belt latch downward and across your chest toward the buckle at the...

Page 39: ...spect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer or other authorized person 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents Rinse the...

Page 40: ...on function Your POLARIS dealer or qualified person can assist in resolving any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle USING LOW RANGE Always shift into low gear for any of the following conditions Operating in rough terrain or over...

Page 41: ...hrottle 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 39 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 42: ...rake pads from excessive wear TIP This feature will not operate properly if the park brake connector or switch under the hood malfunctions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly 1 To set the park brake apply the brakes 2 Pull the park brake lever q upward as far as possible 3 To release the ...

Page 43: ...N Fasteners Metal pin with security cotter pin Weld Length and Positions 4 mm fillet all around Maximum Vertical Load 75 kg applied on coupling point Maximum Towable Mass 830 kg Approval E9 55R 01 6121 REAR HITCH CERTIFICATION LABEL The hitch certification label is located near the hitch on models equipped with a factory installed rear hitch 41 FEATURES AND CONTROLS Downloaded from ManualsNet com ...

Page 44: ... pin Make sure the hitch assembly is secure at that the cotter pin is properly engaged over the hitch pin 7 WAY TRAILER CONNECTOR The 7 way trailer connector q installed on your vehicle meets the requirements of European standard ISO 1724 This connector uses all 7 pins on newer model trailers An older model trailer may not be compatible with this connector Improper electrical wiring changes can re...

Page 45: ...WD SYSTEM The All Wheel Drive system is controlled by the AWD switch The switch has two positions AWD 4x4 and 2WD 2x4 The switch on models equipped with a lockable differential has a third position for unlocking the differential When unlocked only one rear wheel is a drive wheel q All Wheel Drive AWD w Two Wheel Drive 2WD e Turf Mode Differential Unlocked 1WD When the switch is on 2X4 the vehicle ...

Page 46: ... shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest DISENGAGING AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If th...

Page 47: ...he differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to turf driving or whenever aggressive traction is not require...

Page 48: ...t the lens q Speedometer w Indicator Lamps e Rider Information Center r MODE Button MODE BUTTON The MODE button is located on the instrument cluster Use the MODE button to toggle through mode options available in the instrument cluster SPEEDOMETER The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h 46 FEATURES AND CONTROLS Downloaded from ManualsNet com ...

Page 49: ...it and increased steering effort Brake Failure This icon will illuminate if the vehicle sensors detect low pressure in the brake hydraulic system High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating The driver s seat belt is equipped with a seat ...

Page 50: ... gears w Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer e Information Display Area This area displays odometer trip meter ...

Page 51: ...up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display MEASUREMENT STANDARD METRIC Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius Time 12 Hour Clock 24 Hour Clock To change the display units do the following 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to...

Page 52: ...ttings and exit the clock mode 6 Turn the key to the OFF position ODOMETER MODE The odometer records and displays the distance traveled by the vehicle TRIP METER MODE The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter di...

Page 53: ... 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 or qualified person can provide for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the ...

Page 54: ...eter SPN e Failure Mode Indicator FMI 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 MODE b...

Page 55: ...als will damage the instrument cluster lens 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 PREMIUM GAUGE 1 Gear Display This area displays gear shifter positions H High Gear L Low Gear N Neutral R Reverse P Park Gear Signal Error or shifter between gears 2 Display Area 2 Th...

Page 56: ...e in a 12 hour or 24 hour format 7 AWD Indicator Segments of the indicator illuminate based on drive mode engaged INDICATOR LAMPS LAMP INDICATES CONDITION 1 Check Engine This indicator appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result Your authorized POLARIS dealer can assist 2 EPS Warning if equipped This indicator illumin...

Page 57: ... ignition key is on the ON position 5 Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to wear helmet and seat belt before operating 6 High Beam This lamp illuminates when the headlamp switch is set to high beam 7 Chassis Fault Not applicable 8 Performance Limited Not applicable 55 FEATURES AND CONTROLS Downloaded from ManualsN...

Page 58: ...ssing the MODE button will change the information displayed in Area 1 Display Area 1 options Speed RPM Engine Temperature Ambient Temperature optional 56 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 59: ...imer Engine Tempurature Ambiant Temperature optional RPM Engine Hours Service Hours Speed OPTIONS MENU Press and hold the MODE button to enter the Options Menu OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Units Distance Select MPH or KPH 57 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 60: ...2HR vs 24HR for example Once the desired digit or setting is found press the MODE button to set 5 Continue the process outlined in Step 4 until the options have cycled back to the CLOCK menu Use the UP or DOWN arrows to choose other Options Menu items or press MODE to cycle through clock settings again 6 To exit the OPTIONS Menu hold the MODE button momentarily or press no buttons for 10 seconds O...

Page 61: ...aler can provide for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as...

Page 62: ...istoric fault codes 3 Your authorized POLARIS dealer can provide code details and diagnosis NOTE Stored fault codes are cleared from the gauge during a power cycle Fault codes must be retrieved from the gauge before turning key to the OFF position The codes will be cleared from memory if this happens 60 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 63: ...uge and select BT PAIR The Bluetooth icon q will begin to blink 3 Find and select Polaris Gauge on your phone s Bluetooth menu or prompt Pairing should occur momentarily Pairing mode will continue for up to 90 seconds or if you exit the BT PAIR menu After successfully pairing the phone the vehicle s digital gauge will automatically reconnect with the phone each time it is powered on and within ran...

Page 64: ...tooth menus and the vehicle starts to move faster than 2 KPH the menu will automatically display VEHICLE MOVING If you attempt to access Bluetooth menus while the vehicle is moving faster than 2 KPH the screen will display VEHICLE MOVING momentarily and then it will redirect to the options menu 62 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 65: ...ted 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 But Below Normal Operat...

Page 66: ... 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 Below Normal Or Shorted To Low Source 91 4 Manifold Absolute Pressure Sensor Data Erratic Intermittent Or Incorrect ...

Page 67: ...ge Least Severe Level 105 15 Engine Temperature Sensor Data Valid But Above Normal Operational Range Most Severe Level 110 0 Data Erratic Intermittent Or Incorrect 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 Nor...

Page 68: ...ata 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 Adjustment 190 7 Received Network Data In Error 190 19 Condition Exists 190 31 Gear S...

Page 69: ...d 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 Source 1071 3 Voltage Below Normal Or Shorted To Low Source 1071 4 Current Below Normal Or Open Circuit 1071 5 Ignition Coil Primary Driver 1 Front MAG Voltage Above Normal Or Shorted To High Source 1268 3 Voltage Bel...

Page 70: ...Operational Range Most Severe Level 3597 0 Data 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 ECU Output Supply Voltage 2...

Page 71: ... 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 But Above Normal Operating Range Moderately Severe Level 3599 16 Data Valid But Below Normal Operating Range Moderately Severe Level 3599 18 ETC Accelerator Position Sensor Outputs 1 2 Correlation Data Erratic ...

Page 72: ...ing 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 Normal Or Shorted To High Source 520207 3 Voltage Below Normal Or Shorted To Low Source 520207 4 Current Below Normal Or Open Circuit 520207 5 Oxygen Sensor Heater 1 Data Erratic Intermittent Or Incorrect 520209 2 Voltage Above Normal Or Shor...

Page 73: ...0277 3 Voltage Below Normal Or Shorted To Low Source 520277 4 Abnormal Frequency Or Pulse Width Or Period 520277 8 Condition Exists 520277 31 Throttle Body Control Return Spring Check Failed Condition Exists 520278 31 Throttle Body Control Adaption Aborted Condition Exists 520279 31 Throttle Body Control Limp Home Position Check Failed Condition Exists 520280 31 Throttle Body Control Mechanical St...

Page 74: ...sts 520287 31 ECU Monitoring of Injection Cut Off Level 1 Condition Exists 520288 31 ECU Monitoring of Injection Cut Off Level 2 Condition Exists 520289 31 Throttle Body Control Requested Throttle Angle Not Plausible Condition Exists 520305 31 ECU ADC Fault No Load Condition Exists 520306 31 ECU ADC Fault Voltage Condition Exists 520307 31 Accelerator Sensor Sync Fault Sensor Diff Exceeds Limit Co...

Page 75: ... Error Current Above Normal Or Grounded Circuit 520222 6 Steering Torque Partial Failure Condition Exists 520223 31 Steering Torque Full Failure Condition Exists 520224 31 EPAS Inverter Temperature Data Valid But Above Normal Operational Range Most Severe 520225 0 Data Valid But Above Normal Operating Range Severe 16 EPAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520...

Page 76: ...Communications Receive Error No RX Message for 2 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 Position Encoder Error Loss of SPI Communication 520228 12 Encoder Variance Error 31...

Page 77: ...ta Data Erratic Intermittent Or Incorrect 162 2 Suspension Mode Switch Input Data Erratic Intermittent Or Incorrect 516098 2 Voltage Above Normal Or Shorted To High Source 3 Voltage Below Normal Or Shorted To Low Source 4 Valve Driver Front Left Voltage Above Normal Or Shorted To High Source 516106 3 Voltage Below Normal Or Shorted To Low Source 4 Valve Driver Front Right Voltage Above Normal Or S...

Page 78: ...t Known 516111 11 Absolute Shock Current Error Front Right Root Cause Not Known 516112 11 Absolute Shock Current Error Rear Left Root Cause Not Known 516113 11 Absolute Shock Current Error Rear Right Root Cause Not Known 516114 11 Internal Inertial Measurement Unit Bad Intelligent Device Or Component 516115 12 Data Valid But Above Normal Operating Range Least Severe Level 15 Data Valid But Below N...

Page 79: ...mittent Or Incorrect 516123 2 Data Drifted High 20 Suspension Control Module Bad Intelligent Device Or Component 516124 12 CAN 1 Root Cause Not Known 516125 11 System Voltage Data Valid But Above Normal Operational Range Most Severe Level 516126 0 Data Valid But Below Normal Operational Range Most Severe Level 1 Voltage Above Normal Or Shorted To High Source 3 Voltage Below Normal Or Shorted To Lo...

Page 80: ...rect 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 Input Data Erratic Intermittent Or Incorrect 524114 2 78 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 81: ...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 engine parts and drive comp...

Page 82: ...r 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 belt fails always clean ...

Page 83: ...ee operation page 154 Tires Inspect condition and pressure page 149 Wheels fasteners Inspect ensure fastener tightness page 150 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels page 47 page 120 Coolant level Ensure proper level page 131 Coolant hoses Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure proper operation page 47 Eng...

Page 84: ...proper operation page 37 Cab Doors Check doors and latches for wear or damage page 36 Mirrors Adjust for best side rear vision page 31 Horn Ensure operation page 29 Turn Signal Ensure operation of all signal lamps page 30 82 OPERATION Downloaded from ManualsNet com search engine ...

Page 85: ...he 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 operate a damaged vehicle After any rollover or accident have a qualified service dealer inspect the entire machine for possible damage 11 Never operate the vehicle on a frozen bod...

Page 86: ...N e POSITION LIGHTS ON r START 7 If the engine does not start within five seconds return the ignition switch to the OFF position and wait five seconds Repeat steps 6 and 7 until the engine starts 8 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 war...

Page 87: ... familiar with the controls PARKING THE VEHICLE To park the vehicle do the following 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Engage the park brak...

Page 88: ...arning and instruction labels before operating this vehicle 2 Take a training course 3 Perform the pre ride inspection See the Pre Ride Inspection section for details 4 Do 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 ha...

Page 89: ...tering all maneuvers at a slow speed 18 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 abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts DRIVING WITH PASSENGERS...

Page 90: ...d unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 10 Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 11 Always follow all operating guidelines as outlined on safety labels and in this manual DRIVING UPHILL Whenever traveling uphill follow these precautions 1 Always check the terrain carefully before...

Page 91: ...rossing a hill is unavoidable follow these precautions 1 Engage all wheel drive 2 Never operate in TURF mode if equipped while operating on a hill or other 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 obstac...

Page 92: ...ill 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 90 OPERATION Downloaded from ManualsNet com s...

Page 93: ... 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 a passenger dismount and move away from the vehicle before operating over an obstacle that could cause a rollover DRIVING IN REVERSE Follow these precautions when operating in reverse 1 Always check for obstacles or peopl...

Page 94: ...ring slippery areas 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 ...

Page 95: ...s 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 Periodic Maintenance Chart section Give special attention to engine oil transmission oil demand drive fluid re...

Page 96: ...e speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling cargo Slow down 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 Your POLARIS vehicle has been designed to carry a specific capacity Reduce speed and al...

Page 97: ...a rollover DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 16 km h 10 MPH while cornering or while ascending or descending a hill Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components Never allow a passenger to ride in the cargo box A passenger must always be seated in a passenger seat with seat belt secured BEL...

Page 98: ...he vehicle faster than 16 km h 10 MPH 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 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 th...

Page 99: ...e 105 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 this wrapped cable allow...

Page 100: ...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 Always inspect your wi...

Page 101: ...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 the first 3 feet 1 mete...

Page 102: ...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 105 Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure 100 WINCH ...

Page 103: ... 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 around the winch drum a...

Page 104: ...low 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 in the slack in the win...

Page 105: ...e 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 the cable in while your ...

Page 106: ... 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 in this condition A wi...

Page 107: ...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 accident 4 Never use r...

Page 108: ...place 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 purchased in a hardware ...

Page 109: ...e 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 ELECTROMAGNETIC INTERFERENCE This vehicle complies with the EMC requirements of Regulation EU No 2015 208 Annex XV Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantabl...

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Page 111: ...n elevated on a floor jack for an extended period of time PLACING ONTO JACK STANDS 1 Place the floor jack directly beneath the center of the vehicle either front or rear 2 This vehicle is not equipped with dedicated jacking points Make sure that the floor jack only makes contact with the vehicle frame only while lifting 3 After vehicle is elevated to desired height place jack stands under the vehi...

Page 112: ...ocedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently SEVERE USE DEFINITION Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Frequent short trip operation in cold weather engine frequently does not operate long enough ...

Page 113: ...services Perform all services at whichever maintenance interval is reached first Record maintenance and service in the Maintenance Log at the end of the manual ITEM MAINTENANCE INTERVAL WHICHEVER COMES FIRST REMARKS HOURS CLNDR KM MILES Steering Pre Ride Make adjustments as needed See Pre Ride Checklist section for details Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake flu...

Page 114: ...n often Headlight taillight Daily Check operation Air Filter Weekly Inspect replace as needed D Brake pad wear 10 H Monthly 160 100 Inspect periodically XU Front gearcase demand drive fluid 25 H 1 M Perform a break in oil level check XU Transmission main gearcase oil 25 H 1 M 400 250 Perform a break in oil level check XU Engine oil change break in 25 H 1 M Perform a break in oil change XU Engine b...

Page 115: ...Throttle pedal 50 H 6 M 800 500 Inspect for free movement replace pedal as needed Throttle body air intake ducts flange 50 H 6 M 800 500 Inspect duct for proper sealing air leaks Shift Linkage 50 H 6 M 800 500 Inspect adjust XU Front Suspension 50 H 6 M 800 500 Lubricate and inspect bushings XU Rear Suspension 50 H 6 M 800 500 Lubricate and inspect bushings Cooling system if applicable 50 H 6 M 16...

Page 116: ...ed bolt and all pivot pins XU Engine oil change 100 H 6 M 1600 1000 Change the oil and filter XU Front gearcase demand drive fluid 100 H 12 M 1600 1000 Change fluid XU Transmission main gearcase oil 100 H 12 M 1600 1000 Change fluid D Fuel system filter 100 H 12 M 1600 1000 Cycle key to pressurize fuel pump check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years XU ...

Page 117: ...ar routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive and driven 100 H 12 M 1600 1000 Inspect clean replace worn parts XU Shock Seals 100 H Inspect shock seals XU D Shocks 12 M 2400 1500 See your dealer for oil change seal inspection D Front wheel bearings 100 H 12 M 1600 1000 Inspect replace as needed D Brake fluid 200 H 24 M 3200 2000 Change every ...

Page 118: ... section in this chapter Valve clearance 500 H 8000 5000 Check adjust as needed XU Coolant 60 M Replace coolant D Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim 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 perform these services 116 MAINTENANCE Downloaded ...

Page 119: ...uty 10W 50 4 Cycle Oil See page 121 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 143 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 123 Front Gearcase Fluid Demand Drive Demand Drive Fluid See page 125 Prop Shaft U Joint Grease Grease the middle and rear fittings Stabilizer Bar Bushings All Season Grease or grease conforming to NLGI No...

Page 120: ... Middle Prop Shaft Grease Fitting w Rear Prop Shaft Grease Fitting e Rear Stabilizer Bar Grease Fitting r Front Stabilizer Bar Grease Fitting 118 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 121: ... 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 oil Never substitute or ...

Page 122: ...gage the park brake NOTE Always check the oil when the engine is cold 4 Remove the seats and remove the engine access panel 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 e to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on the dipstick D...

Page 123: ...engine crankcase and remove the drain plug Allow the oil to drain completely 5 Remove the seats and remove the engine access panel 6 Using an oil filter wrench turn the filter q counter clock wise to remove it 7 Using a clean dry cloth clean the filter sealing surface on the crankcase 8 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good ...

Page 124: ...move the dipstick and check the oil level 16 Add oil as necessary to bring the level to the upper mark on the dipstick Do not overfill 17 Reinstall the dipstick 18 Reinstall the oil fill cap 19 Dispose of used filter and oil properly 122 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 125: ...ed 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 listed in the Gearcase Specifications Chart section of this manual to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification listed in the Gearcase...

Page 126: ...ly 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification listed in the Gearcase Specification Chart of this manual 6 Add the recommended fluid listed in the Gearcase Specification Chart to the bottom of the fill plug hole Do not overfill 7 Reinstall the fill plug Torque to specification listed in the Gearcase Specification Chart 8 Check for leaks Discard used fluid properly 124...

Page 127: ... 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 listed in the Gearcase Specification Chart of this manual to the bottom thread of the fill plug hole 4 Reinstall the fill plug Torque to specification listed i...

Page 128: ... drain plug 5 Reinstall the drain plug Torque to specification listed in the Gearcase Specification Chart of this manual 6 Add the recommended fluid listed in the Gearcase Specification Chart to the bottom thread of the fill plug hole 7 Reinstall the fill plug Torque to specification listed in the Gearcase Specification Chart 8 Check for leaks Discard used fluid properly 126 MAINTENANCE Downloaded...

Page 129: ...SE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG TORQUE Transmission Main Gearcase AGL Gearcase Lubricant Transmission Fluid 1200 ml 40 5 oz 14 19 Nm 10 14 ft lbs 14 19 Nm 10 14 ft lbs Demand Drive Unit Front Gearcase Demand Drive Fluid 222 ml 7 5 oz 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 127 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 130: ...s driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection SPARK PLUG REMOVAL AND REPLACEMENT 1 Remove the cargo box access panel to access the spark plugs q 2 Clean the area around the spark plugs before removing the plugs 3 Remove the spark plug caps 4 Using ...

Page 131: ...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 Generally the electrodes are not worn Fouling may be caused by excessive oil or by frequent short trips especially in cold weat...

Page 132: ...driver s seat 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 LED EPS 20A Fuse Power Steering optional LIGHTS 15A Fuse Headlights Taillights Dash Lights DRIVE 10A Fuse All Wheel Drive TURF opti...

Page 133: ...xed and ready to use Do not dilute with water See the Polaris Products section for the part numbers To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every five 5 years and fresh Antifreeze 50 50 Premix added Any time the cooling system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 ...

Page 134: ... w 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed 5 Before reinstalling the pressure cap bleed the system of trapped air Remove the engine access panel behind the seats and use a flat blade screwdriver to turn the bleed screw q slightly allowing the air to escape Slowly add additional coolant to the radiator until air no longer escapes and only coolant...

Page 135: ... 1 Position the vehicle on a level surface 2 Remove the hood See the Hood section for details 3 View the coolant level in the overflow bottle q 4 Remove the cap w and use a funnel to add coolant as needed to maintain the level between the two marks 5 Reinstall the cap TIP If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling...

Page 136: ...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 in any other product A...

Page 137: ...o remove ALL debris when replacing the belt could result in vehicle damage loss of control and severe injury or death 1 Allow hot components to cool before performing this procedure 2 Remove the engine access cover and thoroughly clean all debris from the aluminum debris basket q and from the engine compartment 135 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 138: ...nd of tool to spread sheaves 4 Remove ALL DEBRIS from the entire clutch air duct passage w 5 Check for signs of damage to seals on the transmission and engine See your dealer promptly for service if any seals appear to be damaged 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 oper...

Page 139: ...ain 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 rep...

Page 140: ...hing the vehicle always avoid spraying water directly toward the PVT intake duct See the Cleaning and Storage section for recommended washing procedures AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart section 1 Remove the cargo box access panel 2 Clean all dirt and debris from the air box area 3 Unlatch the two 2 air box cover straps q and carefu...

Page 141: ...er if clean or install a new air filter if soiled Do not attempt to clean the air filter NOTICE Use of a non POLARIS approved air filter may cause engine damage Always use a POLARIS approved replacement filter Please see your POLARIS dealer or authorized person 8 Make sure that there are no gaps between the filter and the driver s side of the air box 9 Reinstall the air box cover Make sure the tab...

Page 142: ...se loss of consciousness or death in a very short time Periodically clean the spark arrester to remove accumulated carbon A plugged spark arrester will affect engine performance Clean daily when driving in mud and water Replace a cracked or damaged arrester before operating 1 Remove the arrester retaining bolt q and nut w 2 Remove the arrester from the end of the muffler e 3 Use a non synthetic br...

Page 143: ...cs to cool before performing maintenance to prevent risk of burns Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied 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 irregu...

Page 144: ...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 0 762 mm 0 030 q 142 MAINTENANCE Downloaded...

Page 145: ...r 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 in the reservoir The le...

Page 146: ...n the adjusting ring to the right to decrease preload for a lower ride height LOCATION MEASUREMENT Front 155 mm 6 10 Rear 84 mm 3 31 Follow these guidelines if you make adjustments to this suspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Al...

Page 147: ...ker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping FACTORY PRELOAD SETTINGS Setting Compression Damping Softest Full counter clockwise position 16 clicks Factory Center position 8 Clicks Firmest Full clockwise position 0 clicks 145 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 148: ...ion to the lowest setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting to all four wheels Never operate the vehicle on the highest or second highest preload settings without a total combined payload in the vehicle of 204 kg 450 lbs or more Payload includes t...

Page 149: ...e adjusting ring to the right to remove preload 4 Tighten the jam nut firmly against ring LOCATION RZR S RZR S 4 Front 202 mm 7 94 154 mm 6 08 Rear 84 mm 3 31 29 mm 1 15 Follow these guidelines if you make adjustments to this suspension Always return the suspension to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stabi...

Page 150: ...RY PRELOAD SETTINGS Setting Compression Damping Softest Full counter clockwise position 24 clicks Factory Center position 12 Clicks Firmest Full clockwise position 0 clicks 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 authorized person perform the adjustme...

Page 151: ...ss 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 3 mm 1 8 or less 149 MAINTENANCE Downl...

Page 152: ...Lug Nut Steel Wheels Front and Rear 81 3 Nm 60 ft lbs Hub Retaining Nut Front and Rear 149 Nm 110 ft lbs WHEEL REMOVAL 1 Position the vehicle on a level surface 2 Place the transmission in PARK Stop the engine 3 Engage the park brake 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the frame 6 Remove the wheel lug nuts Remove the wheel 150 MAINTE...

Page 153: ...icle to the ground 6 Torque the wheel nuts to specification See the Axle and Wheel Nut Torque Specifications section for details 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 See your POLARIS dealer ...

Page 154: ...life of the lamp TAILLIGHT BRAKE LIGHT TURN SIGNAL LAMP 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 until the headli...

Page 155: ...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 headlight screws q on the rea...

Page 156: ...all new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedures in the PVT Drying section STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outli...

Page 157: ... s seat See the Seat Removal section for details 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the ...

Page 158: ...is battery A sealed battery must always be maintained with a full charge Since the battery is sealed and the sealing strip 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 charging if the battery becomes very warm to the touch Allow it to cool before res...

Page 159: ...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 157 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 160: ... the PVTsystem could cause the drive belt to become wet and slip in the clutches When washing the vehicle always avoid spraying water directly toward the PVT intake duct q High water pressure may damage the radiator fins and impair the radiator s effectiveness High pressure may also damage other vehicle components Certain products including insect repellents and chemicals will damage plastic surfa...

Page 161: ... is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring Air intake components If warning and safety labels are damaged contact your POLARIS dealer for...

Page 162: ...tons 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 the Oil and Filter Change section for details AIR FILTER AIR BOX Replace the air filter See the Air Filter section for details Clean the air box FLUID LEVELS Inspect the fluid levels Add or change ...

Page 163: ... Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline 7 Reinstall the spark plug caps to the spark plugs BATTERY MAINTENANCE See the Battery section for storage and charging ...

Page 164: ...ightness 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 section 162 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 165: ...ats Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport 6 Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front control arm bol...

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Page 167: ...acity 250 kg Maximum Weight Capacity Payload 336 4 kg riders cargo accessories tongue weight Fuel Capacity 36 l Engine Oil Capacity 2 4 l Coolant Capacity 4 7 l Demand Drive Fluid Capacity 222 ml Transmission Oil Capacity 1200 ml Overall Length Width Height 274 3 152 4 182 9 cm Wheelbase 200 cm Ground Clearance 31 75 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 999 cc Bore x Stroke 93mm x 73...

Page 168: ...ckable Differential Shift Type Dual Range P R N L H Tires Tire Pressure Front Dirt Commander 27x9 12 69 kPa Tires Tire Pressure Rear Dirt Commander 27x11 12 97 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 Dual Beam Halogen or LED Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V Noise at Operator s Ear 78 6 dB ...

Page 169: ...NG Please see your authorized dealer for clutching specifications CARBON DIOXIDE EMISSIONS CO2 Emissions 678 4 g kWh This CO2 measurement results from testing over a fixed test cycle under laboratory conditions a n parent engine representative of the engine type engine family and shall not imply or express any guarantee of the performance of a particular engine 167 SPECIFICATIONS Downloaded from M...

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Page 171: ...nt 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 2871322 All Season Grease 3 ...

Page 172: ...1 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 170 POLARIS PRODUCTS Downloaded from ManualsNet com search engine ...

Page 173: ...ively 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 WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to...

Page 174: ...ove the belt and clean away any debris from the clutch box clutch duct and engine compartment Install a new belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death See the Belt Replacement Debris Removal section for details ENGINE DOESN T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12 8 VDC Loose ...

Page 175: ...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 Immediately see your dealer Low battery voltage Recharge the battery to 12 8 VDC Loose ignition connections Check all connections and tighten Mechanical failure See your dealer 173 TROUBLESHOOTING Downloaded from ManualsNet...

Page 176: ... Incorrect ignition timing See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Exhaust leak Check all connections Mechanical failure See your dealer ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark p...

Page 177: ...e 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 recommended fuel Clogged air filter Inspect and replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure See your dealer POSSIBLE LEAN FUEL CAUSE SOLUTION Low or contam...

Page 178: ...ge 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 Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure See your dealer Overheated engine Clean radiator screen and cor...

Page 179: ...iginal 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 verification of registration will ...

Page 180: ...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 workmanship and provides no c...

Page 181: ...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 IMPLIED WARRANTY OF F...

Page 182: ...tion 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 present documentation o...

Page 183: ... product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be cove...

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Page 185: ...ENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 183 MAINTENANCE LOG Downloaded from ManualsNet com search engine ...

Page 186: ...184 Downloaded from ManualsNet com search engine ...

Page 187: ...onent Locations 27 Coolant Adding or Changing 131 Cooling System 131 Crossing Hillsides 22 D Demand Drive Fluid Check 125 Demand Drive Unit Front Gearcase 125 Descending Hills Improperly 22 Diagnostic Display Code Definitions 63 Diagnostic Display Mode 51 Digital Gauge 53 Disengaging AWD 44 Display Area 1 56 Display Area 2 57 Display Units 49 Drive Belt Wear Burn 171 Driving Downhill 90 Driving in...

Page 188: ...am Switch 29 Hitch Removal Installation 42 Hitches 41 Hood 33 Horn Switch 29 Hot Exhaust Systems 25 Hour Meter Mode 50 How to Obtain Warranty Service 180 I Ignition Switch Light Switch 29 Improper Cargo Loading 24 Improper Hill Climbing 21 Improper Tire Maintenance 23 Indicator Lamps 47 54 Instrument Cluster 46 Intake Pre Filters if equipped 138 J Jumps and Stunts 18 L Lightning and Powerlines 26 ...

Page 189: ...uge 53 Programmable Service Interval 51 Protective Apparel 17 PVT Drying 137 R Radiator Coolant Level Changing Coolant 132 Radiators and Cooling Fan 131 Rear Hitch 41 Rear Hitch Certification Label 41 Refueling 25 Registration 177 Rider Information Center 48 58 Rollover Protective Structure ROPS 43 RZR S 1000 Tractor 165 S Sachs Shocks if equipped 146 Safe Operation Practices 83 Safe Riding Gear 1...

Page 190: ... Use of the Vehicle 25 V Vehicle Break in Period 79 Vehicle Identification Numbers 8 Vehicle Immersion 154 W Walker Evans Shock Compression Adjustment 145 Walker Evans Shocks 144 Warning Symbols 4 Washing the Vehicle 158 Washing Tips 159 Wheel Installation 151 Wheel Removal 150 Winch Cable Care 104 Winch Maintenance and Service Safety 106 Winch Operation 99 Winch Safety Precautions 97 Winch Shock ...

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Page 192: ...For your nearest Polaris dealer visit www polaris com Polaris Sales Europe Sarl Place de l Industrie 2 1180 Rolle Switzerland Part No 9930862 Rev 01 PMS 419 Downloaded from ManualsNet com search engine ...

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Polaris RZR S 1000 2020, Owner'S Manual

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