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TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or
tall trailer in high range

Use low range during loading.

Starting out going up a
steep incline

Use low range. See warnings on page 58.

Driving at low RPM or
ground speed (3-7 MPH/
5-11 km/h)

Drive at a higher speed or use low range more frequently.
See page 36.

Insufficient warm-up at
low ambient tempera-
tures

Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.

Slow/easy clutch engage-
ment

Use the throttle quickly and effectively.

Hauling heavy cargo/
pushing at low RPM/low
ground speed

Use low range only.

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.

WARNING!

Excessive throttle may cause loss of control

and vehicle rollover.

Climbing over large
objects from a stopped
position

Shift the transmission to low range and carefully use fast,
brief, aggressive throttle application to engage clutch.

WARNING!

Excessive throttle may cause loss of control

and vehicle rollover.

Belt slippage from water
or snow ingestion into the
PVT system

Dry out the PVT (see page 103). Prevent water from
entering the PVT outlet duct (see page 123). Inspect
clutch seals for damage if repeated leaking occurs.

Clutch malfunction

Your POLARIS dealer can assist.

Poor engine performance

Check for fouled plugs or foreign material in gas tank or
fuel lines. Your POLARIS dealer can assist.

Slippage from failure to
warm up belt

Always warm up the belt by operating below 30 MPH (48
km/h) for one mile (1.5 km) and for 5 miles (8 km) or
more when temperature is below freezing.

Wrong or missing belt

Install the recommended belt.

Improper break-in

Always break in a new belt and/or clutch. See page 48.

Failed belt

Remove the belt and clean away any debris from the
clutch box, clutch duct and engine compartment. Install a
new belt.

WARNING!

Failure to remove ALL debris

when replacing the belt could result in vehicle damage
and severe injury or death. See page 102.

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Содержание 2016 RZR XP Turbo

Страница 1: ...Owner s Manual for Maintenance and Safety RZR XP Turbo...

Страница 2: ...e safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other rep...

Страница 3: ...commendations in this owner s manual Review the safety DVD that came with your vehicle Polaris also recommends that all drivers take the ROHVA safety e course and a ROHVA hands on safety training cour...

Страница 4: ...n 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 depict...

Страница 5: ...ntroduction 4 Safety 7 Features and Controls 25 Operation 48 Winch Guide 67 Emission Control Systems 78 Maintenance 79 Specifications 128 POLARIS Products 130 Troubleshooting 131 Warranty 135 Maintena...

Страница 6: ...tial 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 avo...

Страница 7: ...hold Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a seat belt when riding in this vehicle...

Страница 8: ...number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identific...

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 established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear th...

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: ...lacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Proper Use Warning WARNING Require Proper Use of Your Vehicle Do your part to prevent in...

Страница 13: ...injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason 7179762 Seat Belt Warning WARNING Improper vehicle...

Страница 14: ...go Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly t...

Страница 15: ...owner s manual or see authorized POLARIS dealer 7177469 Air Box Caution CAUTION Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing...

Страница 16: ...4 55 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has compl...

Страница 17: ...vent of an accident Operator and all passengers must always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Seat Belts Riding in this vehicle without wearing...

Страница 18: ...safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and...

Страница 19: ...crease 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 o...

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: ...idding 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 excessi...

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

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

Страница 27: ...25 FEATURES AND CONTROLS Component Locations Cab Door Fuel Tank Cap Cargo Box Passenger Hand Hold ROPS Frame Radiators Gear Selector Throttle Pedal Brake Pedal Cargo Box Tie Down Points 4 corners...

Страница 28: ...passenger seats Ignition Switch The ignition switch is a three position key operated switch Use the ignition switch to start the engine See page 52 for starting procedures The key can be removed from...

Страница 29: ...s two positions All Wheel Drive AWD Two Wheel Drive 2WD Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive See page 38 for AWD op...

Страница 30: ...the screws to 4 ft lbs 5 4 Nm Do not overtighten Seat Removal 1 Pull up on the seat latch lever located under the rear edge of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it fro...

Страница 31: ...the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the post mounting hole adapter bu...

Страница 32: ...essure cap 1 Turn the hood fasteners 1 4 turn 2 Grasp the upper hood edge and pull upward to disengage the fasteners 3 Pivot the hood forward and lift upward to disengage the lower hood hooks 4 Lift t...

Страница 33: ...s soon as possible Do not allow the vehicle to run out of fuel NOTICE Damage to the fuel pump will occur if the vehicle is operated with an empty fuel tank Do not allow the vehicle to run out of fuel...

Страница 34: ...he inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks Pull up...

Страница 35: ...nuing to stretch the seat belt height adjuster slide the adjuster up or down rocking it side to side if necessary until you reach the desired height This may require both hands Do not attempt to adjus...

Страница 36: ...freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly ha...

Страница 37: ...d 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 f...

Страница 38: ...ar H High Gear To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving...

Страница 39: ...Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any...

Страница 40: ...in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled...

Страница 41: ...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 42: ...t remains on the EPS system is inoperative Your POLARIS dealer can assist Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This la...

Страница 43: ...the instrument cluster may have shut off to protect the electronic speedometer If this occurs your POLARIS dealer can provide proper diagnosis The information center is set to display standard units...

Страница 44: ...hour interval 4 Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high ele...

Страница 45: ...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 46: ...ay 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button...

Страница 47: ...ts to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine h...

Страница 48: ...en 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 Di...

Страница 49: ...retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button t...

Страница 50: ...ly NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first t...

Страница 51: ...rotors PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance If a belt fails always clean any debris from the duct and from the...

Страница 52: ...pect condition and pressure 12 114 Wheels fasteners Inspect ensure fastener tightness 114 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 42 87 Coolant level Ensu...

Страница 53: ...way including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both ha...

Страница 54: ...e 5 Turn the ignition key past the ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 6 If the engine does not start within five seconds r...

Страница 55: ...is in PARK before exiting the vehicle 5 Remove the ignition key to prevent unauthorized use Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the operat...

Страница 56: ...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...

Страница 57: ...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 16 Increase speed only after mastering all maneuv...

Страница 58: ...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 times See page 8 6...

Страница 59: ...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 60: ...ding 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 61: ...5 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill Driving Do...

Страница 62: ...er leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads Avoid applying brake and throttle at the same time NOTICE Major engine da...

Страница 63: ...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 64: ...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 65: ...e precautions 1 Apply the brakes 2 Place the transmission in PARK NOTE After a ride allow the engine to idle for 30 seconds before stopping the engine This will allow the turbo system to cool down 3 S...

Страница 66: ...and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WIT...

Страница 67: ...and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the ma...

Страница 68: ...vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing Towing a RZR Towing this vehicle is not recommended Always transport the...

Страница 69: ...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 70: ...at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 74 to feed and rewind the cable evenly before continuing the winch opera...

Страница 71: ...r Your dealer can provide service on your winch if this occurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch...

Страница 72: ...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 73: ...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 74: ...jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to yo...

Страница 75: ...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 76: ...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 77: ...cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at...

Страница 78: ...ng 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...

Страница 79: ...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 80: ...d with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust...

Страница 81: ...n lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent parts may be used for e...

Страница 82: ...aintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 50 Front suspension Pre Ride Rear suspension Pre...

Страница 83: ...130 Nm Battery 25 H Monthly 250 400 Check terminals clean test Engine breather filter if equipped 25 H Monthly 150 250 Inspect replace if necessary Air filter 25 H 500 800 Inspect replace if soiled Ge...

Страница 84: ...il and fuel pump replace lines every two years Spark plugs 100 H 12 M 1000 1600 Inspect replace as needed torque to specification Radiators 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling...

Страница 85: ...ars Spark arrester 24 M 2000 3200 Clean daily when driving in mud and water replace a cracked or damaged arrester before operating see pages 106 107 Ratcheting cam chain tensioner 200 H 2000 3200 Chec...

Страница 86: ...See page 86 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 109 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 90 Front Gearcase Fluid Deman...

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

Страница 88: ...be changed more frequently if POLARIS oil is not used Do not use automotive oil Follow the manufacturer s recommendations for ambient temperature operation See page 130 for the part numbers of POLARIS...

Страница 89: ...ervice access panel on the floor of the cargo box 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow the engine to idle for 30 seconds 4 Stop the engin...

Страница 90: ...plug is located on the bottom of the crankcase Access the drain plug through the access hole under the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK 2 Clean the a...

Страница 91: ...add the recommended oil See page 128 for capacity Reinstall the fill cap 10 Start the engine Allow the engine to idle for 30 seconds 11 Stop the engine Wait two 2 minutes to allow oil to drain back to...

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

Страница 93: ...Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the recommended flui...

Страница 94: ...ed lubricants capacities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fi...

Страница 95: ...the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug Torque to specification 6 Add the recommended fluid to the bottom thread o...

Страница 96: ...he spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 95 CAUTION A hot...

Страница 97: ...nsulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service Tip T...

Страница 98: ...enter is located under the driver s seat Label Value Function FAN 30A Circuit Breaker Fan EFI 10A Fuse EFI Relay Injectors Coil ECM Chassis Relay Coil Fan Relay Coil Fuel Pump Relay Coil KEY 10A Fuse...

Страница 99: ...l drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain cold coolant level as recommended by adding coolant to the pressure tank CAUTION Esc...

Страница 100: ...obstruct or deflect air flow through the radiators by installing unauthorized accessories in front of the radiators or behind the cooling fan Interference with radiator air flow can lead to overheatin...

Страница 101: ...ide of the pressure tank 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...

Страница 102: ...he side of the pressure tank CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 4 Rem...

Страница 103: ...he PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follo...

Страница 104: ...all debris from the engine compartment NOTE Removal of the left rear wheel or shock is not necessary for belt replacement 3 Loosen the clamp retaining the PVT inlet duct to the outer clutch cover 4 R...

Страница 105: ...of the PVT components belt cover etc PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remov...

Страница 106: ...f the vehicle to ensure adequate air flow If necessary remove the pre filter and clean with soapy water Dry with low pressure compressed air Periodically inspect the clutch PVT air intake for debris a...

Страница 107: ...clean dry cloth NOTICE Dirt or debris in the intake tube could result in severe engine damage Always clean all dirt and debris from the intake tube before installing the filter 7 Reinstall the air fi...

Страница 108: ...en run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves...

Страница 109: ...operating 1 Remove the arrester retaining bolt and nut 2 Remove the arrester from the end of the muffler 3 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if componen...

Страница 110: ...ith a spongy brake pedal can result in loss of braking which could cause an accident resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal Brake Inspection 1...

Страница 111: ...fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand o...

Страница 112: ...the vehicle NOTE These settings are only guidelines The spring preload and shock clickers can be adjusted further to match your personal riding style and location of weight on the vehicle FOX Interna...

Страница 113: ...o this suspension Always return the suspension to factory settings after the load is removed from the vehicle The increased suspension height will negatively impact vehicle performance when operating...

Страница 114: ...2 to remove preload 4 Lock the adjustment rings by rotating the top ring clockwise until tight WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always...

Страница 115: ...1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping Shock Compression Settings Setting Compression Damping Softest Full c...

Страница 116: ...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 repla...

Страница 117: ...smission in PARK 2 Place the wheel in the 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 Improperl...

Страница 118: ...for a few days to allow the moisture to clear out Taillight Brake Light Replacement The taillight assembly is not serviceable If the taillight or brake light fails to operate properly replace the enti...

Страница 119: ...and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn the headlights to high beam 5 Include the weight of a rider on the seat while performing this step Observe the...

Страница 120: ...Turn the engine over several times 6 Dry the spark plugs and reinstall them or install new plugs 7 Attempt to start the engine If necessary repeat the drying procedure 8 Take the vehicle in for servic...

Страница 121: ...tery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well w...

Страница 122: ...d positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 8 Reinstall the seat Battery Storage Whenever the vehicle is not used for a period o...

Страница 123: ...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...

Страница 124: ...ps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hou...

Страница 125: ...emicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and...

Страница 126: ...afety labels are damaged contact your POLARIS dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have en...

Страница 127: ...recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to...

Страница 128: ...e at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 95 4 Apply dielectric grease to the inside of each spark plug cap Do not r...

Страница 129: ...hicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK NOTE After a ride allow the engine to idle for 30 seconds before stopping the engine This will allow the tu...

Страница 130: ...and Drive Fluid Capacity 8 5 oz 251 ml Transmission Oil Capacity 64 oz 1900 ml Overall Length Width Height 119 64 73 75 in 302 3 162 5 187 3 cm Wheelbase 90 in 228 6 cm Ground Clearance 13 5 in 34 3 c...

Страница 131: ...ar 29x11 14 Tire Pressure Front 18 psi 125 kPa Rear 19 psi 130 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam LED cluster Taillights 2 LED cluster Brake Lights 2 LE...

Страница 132: ...uid 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...

Страница 133: ...mbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause...

Страница 134: ...replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Your POLARIS dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Loose...

Страница 135: ...or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VD...

Страница 136: ...r Inspect and replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Your POLARIS dealer can assist Overheated engine Clean radiator screen and core c...

Страница 137: ...inal registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation a...

Страница 138: ...S AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR...

Страница 139: ...s vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain document...

Страница 140: ...hased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropr...

Страница 141: ...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 142: ...TS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD D...

Страница 143: ...aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS Off Road...

Страница 144: ...142 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 145: ...143 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 146: ...Storage 123 127 Cleaning the Air Filter 105 Cleaning the Exhaust System 107 Cleaning the Spark Arrestor 107 Clothing 9 Clutching 129 Component Locations 25 Condition Spark Plugs 95 Coolant Level Pres...

Страница 147: ...95 FOX Internal Bypass Shocks 110 111 Freeplay Steering Wheel 118 Fuel Level 31 Fuel Recommendations 31 Fuel Safety 22 Fuel Stabilizer 125 Fuse Relay Center 96 G Gap Spark Plug 94 Gasoline Handling 2...

Страница 148: ...Recommendations 86 Operation on Public Lands 78 Operation Cooling System 97 98 Operation Transmission 101 103 Operator Restrictions 14 Outlets Auxiliary 26 P Parking on an Incline 63 Parking the Vehic...

Страница 149: ...nd Inspection 126 Storage and Lubrication 126 Storage Area 126 Storage Battery 120 Storage Covers 126 Storage Fluid Levels 125 Storage Oil and Filter 125 Storage Removal 127 Suspension Settings 110 11...

Страница 150: ...ry or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passengers read and understand all safety labels Operate slow...

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