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WINCH GUIDE

Shock Loading

WARNING!

Your winch cable is very strong but it is NOT designed for dynamic,

or “shock” loading. Shock loading may tension a winch cable beyond its strength
and cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both
wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never

take up slack in the winch cable by moving the winching vehicle in
an attempt to move an object. This is a dangerous practice. It gener-
ates high winch cable loads that may exceed the strength of the
cable. Even a slowly moving vehicle can create large shock loads in
a winch cable.

WARNING!

SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).

This puts extra load on the winch, winch cable, and generates
excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an

object with a winch produces shock loading of the cable even when
towing at slow speeds. Towing from a winch also positions the
towing force high on the vehicle. This can cause instability of the
vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are

designed to stretch and can store energy. This stored energy in the
recovery strap is released if a winch cable fails making the event
even more hazardous. Similarly, never use elastic “bungie” cords
for winching.

5. Never use the winch to tie down a vehicle to a trailer or other

transportation vehicle. This type of use also causes shock loading
that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads
produced by the winch motor when operated from a stationary
vehicle. Always remember that the winch and winch cable are NOT
designed for shock loading.

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Содержание 2014 RZR 800

Страница 1: ...PMS 419 Owner s Manual for Maintenance and Safety RZR 800 RZR S 800 RZR 4 800...

Страница 2: ...ns in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to th...

Страница 3: ...ne into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructi...

Страница 4: ...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...

Страница 5: ...ntroduction 4 Safety 7 Features and Controls 25 Operation 46 Winch Guide 65 Emission Control Systems 76 Maintenance 77 Specifications 132 POLARIS Products 136 Troubleshooting 137 Warranty 141 Maintena...

Страница 6: ...ntial personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not av...

Страница 7: ...ing 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 inside the vehicle at all times Always wear a helmet eye p...

Страница 8: ...keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number _________________________________...

Страница 9: ...our 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...

Страница 10: ...a helmet that meets or exceeds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear t...

Страница 11: ...and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated...

Страница 12: ...IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying ta...

Страница 13: ...nuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sideh...

Страница 14: ...e access collisions with cars and trucks can occur Do not exceed seating capacity 2 occupants 7179978 Proper Use Warning RZR 4 WARNING Require Proper Use of Your Vehicle Do your part to prevent injuri...

Страница 15: ...assenger Hand Hold Warning RZR 4 Always use seat belt helmet and eye protection Always use this passenger hand hold and side nets to keep hands and feet in vehicle at all times 7176701 Shift Caution C...

Страница 16: ...tors must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has completed the New O...

Страница 17: ...njury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Cab Nets R...

Страница 18: ...ur vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle...

Страница 19: ...e the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops Operating on Pub...

Страница 20: ...d Stunts Exhibition driving increases the risk of an accident or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving Improper Hill Climbing Improper hill clim...

Страница 21: ...tain 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 r...

Страница 22: ...s Skidding or Sliding Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on exc...

Страница 23: ...cle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving forc...

Страница 24: ...soline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a we...

Страница 25: ...components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially...

Страница 26: ...ify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bod...

Страница 27: ...25 FEATURES AND CONTROLS Component Locations Hip Bars Fuel Tank Cap Cargo Box Shifter Front Passenger Hand Hold Cab Nets Rear Passenger Hand Hold Rack Extenders RZR RZR EPS only Tie Down Points...

Страница 28: ...ch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 62 64 Hea...

Страница 29: ...on the release lever located under the front edge of the seat Slide the seat forward or rearward to the desired position Release the lever The seat will lock into the new position For other seat styl...

Страница 30: ...t passenger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments 1 Remove the retainer from the end of the adjustment pin 2 Remove the pin from th...

Страница 31: ...the coolant overflow bottle 1 Turn the hood fasteners 1 4 turn 2 Grasp the upper hood edge and pull upward to disengage the hood from the vehicle 3 Pivot the hood forward and lift upward to disen gage...

Страница 32: ...shown Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Cab nets or doors must be used by bo...

Страница 33: ...on Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicat...

Страница 34: ...quipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle The EPS warning indicator briefly illuminates when the key is turned to the...

Страница 35: ...dash to place the headlights on high beam Move the rocker switch to the center position to place the headlights on low beam Press the bottom of the rocker switch to turn off the headlights All Wheel D...

Страница 36: ...e adjustment is important to assure proper transmis sion function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or...

Страница 37: ...sition when the operator releases the throttle pedal engine speed will be limited and power to the rear wheels will be reduced Rollover Protective Structure ROPS The Rollover Protective Structure ROPS...

Страница 38: ...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 enable...

Страница 39: ...urfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Speedometer The spe...

Страница 40: ...to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignit...

Страница 41: ...ter may have shut off to protect the electronic speedome ter If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set to display standard units of meas...

Страница 42: ...Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lig...

Страница 43: ...ode that was displayed prior to setting the units 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance s...

Страница 44: ...lay 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE butto...

Страница 45: ...he MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mod...

Страница 46: ...hen the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic D...

Страница 47: ...ates retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE butt...

Страница 48: ...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 com...

Страница 49: ...8 During the break in period change both the oil and the filter at 25 hours or one month 9 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hour...

Страница 50: ...ls fasteners Inspect ensure fastener tightness 115 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 40 85 Coolant level Ensure proper level 100 99 Coolant hoses In...

Страница 51: ...this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating...

Страница 52: ...seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after...

Страница 53: ...u ride your vehicle Find out where the designated riding areas are by con tacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As a...

Страница 54: ...a passenger until you have at least two hours of driving experience with this vehicle 5 Do not tow or carry cargo during this period 6 Select an open area that allows room to familiarize yourself with...

Страница 55: ...g maneuvering using the throttle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed 17 Increase speed only after mastering all maneuv...

Страница 56: ...the steering wheel if driving or on a passenger hand hold 5 The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all...

Страница 57: ...tain 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 tr...

Страница 58: ...nding 3 Drive straight uphill 4 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 5 Avoid unnecessary changes in speed or direction 6 Never go over the crest of a...

Страница 59: ...If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and care fully until the vehicle can be driven straight downhill Driving Dow...

Страница 60: ...y have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads NOTICE Major engine damage can result...

Страница 61: ...s such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacle...

Страница 62: ...se precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightl...

Страница 63: ...in serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precau tions 1 Place the transmission in PARK 2 Turn the engine off 3 Block the rear wheels on the d...

Страница 64: ...cured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that canno...

Страница 65: ...w as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load dis...

Страница 66: ...increases braking distance Do not operate the vehi cle faster than 10 MPH 16 km h when towing 4 Do not tow more than the recommended weight for the vehicle 5 Attach a trailer to the trailer hitch brac...

Страница 67: ...r 16 years of age to operate the winch 4 Always wear eye protection and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook wh...

Страница 68: ...at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 72 to feed and rewind the cable evenly before continuing the winch opera...

Страница 69: ...er Take your winch to your dealer for service if this occurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch co...

Страница 70: ...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...

Страница 71: ...able at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts...

Страница 72: ...jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to yo...

Страница 73: ...lack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply...

Страница 74: ...ross 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...

Страница 75: ...cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at...

Страница 76: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object wit...

Страница 77: ...tivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models us...

Страница 78: ...ow 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...

Страница 79: ...for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns mus...

Страница 80: ...ead to serious injury or death Have an authorized POLARIS dealer perform these services Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related s...

Страница 81: ...ter Daily Inspect clean often replace as needed Coolant if applicable Daily Check level daily change coolant every 2 years Power steering unit if equipped Daily Inspect daily clean often Headlamp tail...

Страница 82: ...nes fasteners 50 H 6 M 1000 1600 Inspect for leaks and loose fittings Shift Linkage 50 H 6 M 500 800 Inspect lubricate adjust D Steering 50 H 6 M 500 800 Lubricate Front Suspension 50 H 6 M 500 800 Lu...

Страница 83: ...muffler pipe 100 H 12 M 1000 1600 Inspect D Ignition timing 100 H 12 M 1000 1600 Inspect Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected...

Страница 84: ...id Maintain level between fill lines See page 108 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 90 Transmission Oil Transfer Case AGL Gearcase Lubricant Transmissio...

Страница 85: ...INTENANCE Lubrication Recommendations RZR S RZR 4 Control Arm Pivot Bushings RZR S RZR 4 Control Arm Pivot Bushings RZR 4 Stabilizer Bar Bushings RZR Stabilizer Bar Bushings RZR Control Arm Pivot Bush...

Страница 86: ...l will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil may need to be changed mo...

Страница 87: ...r service panel See page 27 4 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick completely but do not lock it The dipstick must be inserted completely...

Страница 88: ...n PARK Apply the brakes 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil...

Страница 89: ...ition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Remove the dipstick and fill the sump with two quarts 1 9 l o...

Страница 90: ...g and level check plug are located on the left side of the transfer case The fluid level is sufficient when fluid flows out of the check plug hole at step 4 1 Position the vehicle on a level surface 2...

Страница 91: ...g 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Remove the level check plug 7 Add the recomm...

Страница 92: ...or recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the left side of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Posi...

Страница 93: ...n under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Add the recommended flu...

Страница 94: ...urface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug...

Страница 95: ...urface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug...

Страница 96: ...speeds Immediately check the spark plug for correct color See page 95 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Gearcase...

Страница 97: ...own There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service Tip The tip should not be white A white...

Страница 98: ...ent Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Fuse Feature Supported 20A Lights Headlights Taillights 10A Drive AWD 20A Accessory Winch Switch 12V...

Страница 99: ...htly toward the right side of the vehicle to disengage it from the mount 3 Remove the fuse box cover 4 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same...

Страница 100: ...intain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be complet...

Страница 101: ...effectiveness Using a high pressure system is not recommended Radiator Coolant Level This procedure is required only if the cooling system has been drained for maintenance and or repair But if the ove...

Страница 102: ...tion the vehicle on a level surface 2 Remove the hood See page 29 3 View the coolant level in the overflow bottle 4 If the coolant level is below the safe operating range remove the cap and use a funn...

Страница 103: ...u have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch a...

Страница 104: ...covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc PVT Drying Before washing the vehicle locate the PVT outlet duct under the...

Страница 105: ...ver and inspect the gasket It should adhere tightly to the cover around the entire edge 3 Remove the air filter 4 Install a new filter if needed Do not attempt to clean the air filter Apply a small am...

Страница 106: ...Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Periodically clean the spark arrester to remo...

Страница 107: ...e pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal h...

Страница 108: ...ter at the throttle body 3 Slide the cable adjuster boot off the cable adjuster 4 Using a 10 mm open end wrench loosen the adjustment jam nut 5 Using an 8 mm open end wrench move the cable adjuster un...

Страница 109: ...icate a possible fluid leak or low brake fluid level which must be corrected before riding See page 108 for brake fluid information If you discover any irregularities in brake system operation includi...

Страница 110: ...e possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid...

Страница 111: ...scs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These...

Страница 112: ...e Periodic Maintenance Chart beginning on page 77 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is e...

Страница 113: ...vate the vehicle slightly for easier adjustment Always heed the following rules if you make adjustments to this suspen sion Always return the suspension to the lowest softest setting after the load is...

Страница 114: ...tment 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...

Страница 115: ...djusting ring to the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease preload for a softer ride WARNING Uneven adjustment may cause poor handling of the...

Страница 116: ...k reservoir When the knob is turned clockwise until it stops the damping is in the fully closed position 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwi...

Страница 117: ...l 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...

Страница 118: ...e correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect...

Страница 119: ...lighting quality Headlight Replacement LED If an LED headlight becomes damaged or inoperable the entire head light assembly must be replaced Tip This type of headlight may have a short jumper cable b...

Страница 120: ...the wall at the same height 3 Apply the brakes Start the engine Turn the headlights to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below t...

Страница 121: ...tarting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the...

Страница 122: ...when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied...

Страница 123: ...ttery Removal 1 Remove the driver s seat See page 27 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery...

Страница 124: ...ave a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could ac...

Страница 125: ...ery Tender charger or by charging about once a month to make up for normal self dis charge Battery Tender can be left connected during the storage period and will automatically charge the battery if t...

Страница 126: ...e sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing st...

Страница 127: ...ndard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months...

Страница 128: ...ther vehicle components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do...

Страница 129: ...act your POLARIS dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust s...

Страница 130: ...t Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodic...

Страница 131: ...from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the...

Страница 132: ...he hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 95 4 Apply dielectric grease to the inside of each spark plug cap Do...

Страница 133: ...ginning on page 77 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 Vehicle Follow these...

Страница 134: ...ant Capacity 4 8 qts 4 5 l Rear Gearcase Oil Capacity 26 oz 769 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Overall Len...

Страница 135: ...69 KPa Rear 12 psi 83 KPa RZR S Front 10 psi 69 KPa Rear 10 psi 69 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 60W 55W halogen Taillights 2 single beam 5W Brake...

Страница 136: ...ty 5 5 qts 5 2 l Rear Gearcase Oil Capacity 26 oz 769 ml Demand Drive Fluid Capacity 6 75 oz 200 ml Transmission Oil Capacity 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Overall Length Width...

Страница 137: ...ize Rear 27x12 12 Tire Pressure Front 12 psi 83 KPa Tire Pressure Rear 14 psi 97 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam 60W 55W halogen Taillights 2 single...

Страница 138: ...5 l 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Grease Specialized...

Страница 139: ...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 trans...

Страница 140: ...d 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 POLARIS deal...

Страница 141: ...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 Kinke...

Страница 142: ...Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery volt...

Страница 143: ...the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer prepa...

Страница 144: ...NY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANT...

Страница 145: ...he selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another coun...

Страница 146: ...tside 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 s...

Страница 147: ...ar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a...

Страница 148: ...ERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do...

Страница 149: ...upplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POL...

Страница 150: ...148 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 151: ...149 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 152: ...Frame ROPS 35 Cab Nets 30 Cap Fuel 30 Cargo 62 64 Changing Coolant 98 Changing Gears 34 Chart Periodic Maintenance 77 81 Check Engine Indicator 45 Chrome Wheel Care 128 Cleaning and Storage 126 131 C...

Страница 153: ...Case 88 89 Transmission 90 91 Fluid Change Demand Drive 92 Front Gearcase 92 Main Gearcase 91 Rear Gearcase 93 Transfer Case 89 Transmission 91 F Fluid Check Demand Drive 92 Front Gearcase 92 Main Gea...

Страница 154: ...Replacement LED 117 Headlight Switch 33 High Beam Adjustment 118 Loads Towing 64 Lubricant Part Numbers 136 Lubrication for Storage 130 Lubrication Recommendations 82 83 M Maintenance Log 148 149 Main...

Страница 155: ...lover Protective Structure 35 ROPS Cab Frame 35 RPM Idle Throttle Body 106 S Safe Operation Practices 49 Safety Labels 10 13 Safety Symbols 4 Safety Training 7 Safety Training ROHVA 49 52 Safety Warni...

Страница 156: ...heel Nut 115 Towing Loads 64 Towing Speed 64 Trail Etiquette 51 Trailer Hitch 26 Training 7 Transfer Case Oil 88 89 Transmission Oil 90 91 Transmission Operation 101 102 Transmission Drying 102 Transp...

Страница 157: ...ar your seat belt Vehicle rollover can cause severe injury or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passe...

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