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1. Ambient Temperature Range Recommended Oil 35 F to 100 F PS 4 5W 50 4 Cycle Oil 37 C to 38 C O Fto 120 F PS 4 Extreme Duty 18 C to 49 C 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 See page 130 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 84 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 Always use the recommended engine oil Oil Check Always check the oil when the engine is cold If the engine is hot when the oil is checked the level will appear to be overfull Access the oil check dipstick through the right rear wheel well Access the oil fill cap through the service access panel on the floor of the cargo box Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely Remove the dipstick and check the oil level Oil Check 5 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the i minimum
2. Each rider must be able to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING rohva org 7179499 11 SAFETY Safety Labels and Locations Load Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box WARNING 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 Load Passenger Tire Pressure Warning in cargo box Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box RANGER RZR XP 1000 RZR XP 4 1000 MAXIMUM CARGO BOX LOAD 300 Ibs 300 Ibs 136 kg 136 kg TIRE PRESSURE IN PSI KPa FRONT 16 110 FRONT 19 131 REAR 16 110 REAR 21 145 MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR 740 lbs 900 Ibs PASSENGERS CARGO AND ACCESSORIES 336 kg 408 kg Read Operation and Maintenance Manual for more detailed loading i
3. 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 of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product 137 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorizatio
4. RZR XP 1000 A RZR XP 4 1000 Owner s Manual for Maintenance and Safety A 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs e RANGERQ utility vehicles e RZR sport vehicles VICTORY motorcycles e GEMQ electric vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone 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 instructions and recommendations in this owner s manual Review the safety DVD that came
5. 3 Dry the spark plug wells with a clean cloth then remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure 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 procedure on page 101 for drying 117 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 l 2 3 4 118 Position the vehicle on level ground Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay If there is excessive freeplay or strange noises or if the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Your vehicle has an automotive type sealed battery which requires little maintenance Always keep battery terminals and connections free of corrosion If clean
6. Hauling Cargo A WARNING Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Never exceed the stated load capacity for this vehicle REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passengers accessories and loads in the rack or box The combined weight of these items must not exceed the maximum weight capacity Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the 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 OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution V HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operat
7. Stabilizing the Fuel 125 Starting the Engine 50 Steering Wheel Adjustment 28 Steering Wheel Inspection 118 Stopping the Engine 50 Strage l l a eee eee ews 123 127 Storage and Inspection 126 Storage and Lubrication 126 Storage Area 000 126 Storage Battery 120 Storage Covers 0 126 Storage Fluid Levels 125 Storage Oil and Filter 125 Storage Removal 127 Suspension Settings 109 112 Switches AWD Switch 27 36 Igtition 22 AEE ES 26 Mode Button 37 T Tachometer iisdem beds 43 Taillight L4 ois aucwnse nes gta sta 115 Throttle Pedal 23 Tire Tread Depth 113 WAGES teure aari 113 114 Torque Axle Nuts 113 Torque Spark Plug 92 Torque Wheel Nut 113 Towing Loads 64 Trail Etiquette 00 0 51 PRAM REPE 7 Transmission Oil 88 89 Transmission Operation 99 101 Transmission Drying 101 Transporting the Vehicle 127 Tread Depth Tire 113 Tread Lightly 2 8 51 147 INDEX V Vehicle Identification Numbers 6 Vehicle Immersion 117 Vehicle Transport 127 W Warning Symbols 4 Washing the Vehicle 123 124 Water Immersion of Vehicle 1
8. any part needs repair or replacement 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A Akinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been ORIEL TITO ECO SEIS HEISE straightened out is shown at B 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 C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right r Q Promptly discontinue use of a C winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 73 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 by
9. or ice be alert for the possibility of skidding and sliding Follow these precautions when encountering slippery conditions 1 Slow down before entering 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 in the direction of the skid Never apply the brakes during a skid Sideways Turn in skid d direction of C 2e D C 2e D NS 7 Nw DL OT qw te I C C Coeco BS BS CC WV 55 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 2 56 Always check the terrain carefully before ascending a hill Never drive on hills with excessively slippery or loose surfaces Avoid excessively steep hills If ascending a steeper grade is unavoidable engage all wheel drive before ascending Drive straight uphill Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly Avoid unnecessary changes in speed or direction Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill If the vehicle stalls while climbing a hil
10. surfaces gt Cooling Hoses 100 H 12M 1000 1600 Inspect for leaks gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts Drive belt 100 H 12M 1000 1600 Inspect replace as needed gt Shock Seals 100 H Inspect shock seals gt Shocks 12M 1500 2400 See your dealer for oil D change seal inspection D Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings gt Coolant 24M Replace coolant D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 200 H 24M 2000 3200 Clean out Valve lash 200 H 2000 3200 Check adjust as needed gt Spark plugs 500 H 36M 5000 8000 Replace torque to E specification D Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 81 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 or more often under severe use such as wet o
11. the piston rings and ring lands coating the cylinder with a protec tive 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 pages 120 122 for storage and charging procedures Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 126 MAINTENANCE Cleaning and Storage Removal from Storage 1 Charge the battery if necessary 2 Make sure the spark plug is tight 3 Hill the fuel tank with fuel 4 Check all the points listed in the Daily Pre Ride Inspection section on page 48 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning 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 procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Remove the key to prevent loss during transporting 3 Secure the fuel cap and seats Ensure that the seats are at
12. Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Reinstall the crankcase drain plug Torque to 12 ft lbs 16 Nm Remove the oil fill cap and add 2 5 quarts 2 4 1 of recommended oil Reinstall the fill cap Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Remove the dipstick and check the oil level Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on the dipstick Do not overfill Reinstall the fill cap Reinstall the dipstick Dispose of used filter and oil properly 87 MAINTENANCE Transmission Main Gearcase Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 Refer to the Gearcase Specifications Chart on page 92 for 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 ny I plug hole UE E Ni oai p a usi pipere LEURS 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification 88 MAINTENANCE Tra
13. 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 be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed 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 preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by exte
14. Ride Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level 8 Pre Ride 7 E Engine intake pre filter Daily Inspect clean often PVT intake pre filter Daily Inspect clean often Coolant Daily Check coolant level gt Power steering unit if Daily Inspect daily clean often equipped Headlight taillight Daily Check operation gt Engine oil change 25H 1M Perform a break in oil and break in filter change at one month gt Front gearcase 25H 1M Perform a break in oil level demand drive fluid check gt Transmission main 25H 1M E Perform a break in oil level gearcase oil check gt Brake pad wear 10H Monthly 100 160 Inspect periodically D Battery 25H Monthly 250 400 Check terminals clean test gt Engine breather filter 25H Monthly 150 250 Inspect replace if E if equipped necessary gt Air filter 25 H 500 800 Replace filter E gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 79 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt General lubrication 50H 3M 500 800 Lubricate all fittings pivots cables etc D Throttle pedal 50 H 6M
15. Right Rear Wheel in PARK type varies by model 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 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 Valve Stem 3 Attach the wheel nuts and washers and finger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 113 114 MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles Tip If an LED headlamp has moisture or fogging inside disconnect the wiring harness from the headlamp s for a few days to allow the moisture to clear out Taillight Brake Light Replacement The taillight assembly is not serviceable If the taillight or brake light fails to operate properly replace the entire taillight assembly Headlight Replacement If a headlight becomes damaged or inoperable the entire headlight assembly must be replaced Do not operate this vehicle at night or in low light conditions until the headlight is replaced Always make sure lights
16. air filter 1f 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 8 Make sure that there are no gaps between the filter the filter ring and the stop on the intake tube 9 Reinstall the air box cover and ensure the alignment tabs are properly positioned 10 Secure the four 4 cover clips 11 Reinstall the cargo box access panel 103 MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never operate without the spark arrestor 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 104 MAINTENANCE Spark Arrester Periodically clean the spark arrester to remove accumulated carbon l 2 3 Remove the arrester retaining bolt and nut Remove the arrester from the end of the muffler Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if components
17. and accident or rollover Never carry more than one passenger in a 2 seat vehicle Carrying Multiple Passengers RZR XP 4 Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 52 53 A passenger must always be seated in a passenger seat with seat belt secured Never carry more than three passengers in a 4 seat vehicle Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation and stability For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to 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 1 Slow down maximum weight capacity 2 Verify tire pressure Operating in rough terrain 3 Use extra caution when operating Operating over obstacles P 9 Cl
18. and maximum s marks on the dipstick Do not overfill 6 Reinstall the fill cap 9 jx 9 Reinstall the dipstick S s Cil Fill 85 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 Always change the oil filter whenever changing oil Access the oil check dipstick through the right rear wheel well Access the oil fill cap through the service access panel on the floor of the cargo box The crankcase drain plug is located on the bottom of the crankcase Access the drain plug through the access hole under the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK 2 Clean the area around the crankcase drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 3 Place a drain pan under the engine crankcase and remove the drain plug Allow the oil to drain completely 4 Using an oil filter wrench turn the filter counter clock wise to remove it 5 Using a clean dry cloth clean the filter sealing surface on the crankcase Oil Filter 86 MAINTENANCE Engine Oil Oil and Filter Change 6 7 8 10 11 12 13 14 15 Lubricate the o ring on the new filter with a film of fresh engine oil
19. 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 obstacles Loading the vehicle onto a trailer Towing heavy loads 34 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Brake Always check that the throttle Pedal pedal returns normally before starting the engine Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited Rollover Protective Structure ROPS The Rollover Protective Throttle Pedal Structure ROPS on this z vehicle meets OSHA ROPS Label 1928 53 rollover on ROPS or on performance requirements passenger hip bar Always have your authorized POLARIS dealer thoroughly z lt A inspect the ROPS if it ever becomes damaged in any way E No device can assure occupant protection in the E XQU event of a rollover When P iN used with seat belts and cab nets or doors the ROPS helps prevent oc
20. are adjusted properly for best visibility 115 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward and to the left or right 1 Position the vehicle on a level surface The headlight should be approximately 25 ft 7 6 m from a wall 2 in 5 cm 2 Place the transmission in PARK 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn the headlights to high beam 5 Include the weight of a rider on the seat while performing this step Observe the headlight aim As a starting point the most intense part of the headlight beam should be 2 inches 5 cm below the mark on the wall Adjust to operator preference Adjustment Screws 6 Tighten or loosen the three 3 headlight screws on the rear of the headlight to adjust the beam upward or downward or to the left or right 116 MAINTENANCE Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting 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 See page 103 If water is present dry the air box and replace the filter with a new filter
21. clock must be reset any time the battery has been disconnected or dis charged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 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 display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Engine Temperature Mode This mode displays current temperature of the coolant Battery Voltage Mode This mode displays current system voltage level Tachometer Mode The engine RPM is displayed digitally Tip Small fluctuat
22. esce soam stats 119 COTA LS s cueste etsi ricas 120 Before Riding 48 Belt Burning eem 131 Belt Lifer iraia edens 63 Belt Replacement 100 101 Belt Wear an Sem ees RU eo 131 Belts S at vie ews 32 33 hn pp 9 Brake Fl id 534 25 coo 108 Brake Inspection 107 Brake Light cereri ssi a dione ec ben 115 Brake Pedal si sisciac2 a eaoe sieas 35 Brake System Break in 47 Brakes 4 ce m 106 108 Braking sasear cues pete 50 Break In Period 46 47 Burning Belts oer 131 144 C Cab Doors iii oec Rer peeves 32 Cab Frame ROPS 35 Cap Fuel secsi eere rmm n 31 Care Os eo reu d acsi recede d e 62 63 Cargo Box Access Panel 31 Changing Gears 34 Chart Periodic Maintenance 77 81 Check Engine Indicator 45 Cleaning and Storage 123 127 Cleaning the Air Filter 103 Cleaning the Exhaust System 105 Cleaning the Spark Arrestor 105 Clothe i 2e b EROR ECPROS 9 Clutchimg cae ee beoe trs 129 Component Locations 25 Condition Spark Plugs 93 Coolant Level Overflow Bottle 98 Coolant Level Radiator 97 Coolant Adding 95 Coolant Changing 95 97 Coolant Replacing 97 Cooling Fan sese 96 Cooling System 97 98 Cooling System Operation 95 96 Cover for Storage Ls 126 Crankc
23. for damage if repeated leaking occurs Clutch malfunction See your dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer 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 46 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 100 131 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Mechanical failure See your dealer Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Refuel Clogged fuel filter See your dealer Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with
24. fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase 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 Engine Backfires Possible Cause Out of fuel Solution Refuel Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer 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 132 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel TROUBLESHOOTING Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect
25. 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 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 Always be alert to changing terrain conditions 19 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 60 Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control accident or rollover Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in this owner s manual and on safety labels Skidding or Sliding Failure to use extra caution when operat
26. straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves i Loe WINCH GUIDE Winch Safety Precautions 18 19 20 21 22 23 24 23 Never release the clutch on the winch when the winch cable is under load Never use the winch for lifting or transporting people Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable 67 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Tip Consider practicing the operation and use of your winch before you actually need to use it in the field A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique e e e e Take your time to think through the winching you are about to do Proceed slowly and d
27. the first two tanks full of gasoline 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 components Do not operate at full throttle or high speeds during the first three hours of use Use of any oils other than those recommended by POLARIS may cause serious engine damage We recommend the use of POLARIS PS 4 oils for your 4 cycle engine 46 OPERATION Vehicle Break in Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 31 Always exercise extreme caution whenever handling gasoline 2 Check the oil level See page 85 Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Complete the New Operator Driving Procedures outlined on pages 52 53 4 Avoid aggressive use of the brakes See Brake System Break in on page 47 5 Vary throttle positions Do not operate at sustained idle 6 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 48 Carry only light loads 8 During the break in period change both the oil and the filter at 25 hours or one month 9 Check fluid l
28. the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 65 WINCH GUIDE Winch Safety Precautions 10 11 12 13 14 15 16 17 66 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable 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 operation Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again Never touch push pull or
29. to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 42 2 1 FprlEE3E33E3LETE3E3E duri i2 time Range Pu YERA not Avg Greed L l0kunlih f gelo ven DU DTE AE 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2 Tip 40 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 Information Display Area This area displays odometer trip meter engine hour meter and programmable service hour interval Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Clock The clock displays time in a 12 hour or 24 hour format See page 42 for resetting instructions
30. under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 75 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1C Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system AII exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable Emissions Label The emissions label is located on the frame tube next to the passenger seat Electromagnetic Interfe
31. 1 10 54 Complete the New re Operator Driving Procedures outlined on pages 52 53 Perform the pre ride inspection See page 48 Do not carry more than one passenger in a 2 seat vehicle Do not carry more than three passen X A N gers in a 4 seat vehicle A Additional passengers can affect the operator s ability to steer and oper US ate the controls NH iam Make sure all passengers QA are at least 12 years of age 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 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 Always make sure all cab doors are closed and latched when riding in this vehicle Allow a passenger to ride only in a passenger seat Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger Vehicle handling may change with passengers and or cargo on board Allow more time and distance for braking Always follow all operating guidelines as outlined on safety labels and in this manual OPERATION Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails loose gravel
32. 17 Wear Drive Belt 131 Wheel Installation 114 Wheel Nut Torque 113 Wheel Removal 114 Winch Cable Care 73 Winch Maintenance Service Safety 75 Winch Operation 68 72 Winch Safety Precautions 65 67 Winch Shock Loading 74 148 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license Without first viewing safety video and taking a ROHVA training course at www rohva org On excessively steep hills On public roads unless designated for off road use With a passenger who is not seated in a passenger seat or with passengers under age 12 or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover can cause severe injury or death Secure cab nets or doors and keep hands and feet inside vehicle at all times Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all
33. 500 800 Inspect for free movement E replace pedal as needed E Throttle body air 50 H 6M 300 500 Inspect duct for proper intake ducts flange sealing air leaks Shift Linkage 50 H 6M 500 800 Inspect adjust gt Front Suspension 50 H 6M 500 800 Lubricate gt Rear Suspension 50 H 6M 500 800 Lubricate Cooling system 50 H 6M 500 800 Inspect coolant strength if applicable seasonally pressure test System yearly gt Engine oil change 50H 6M 1000 1600 Perform a break in oil change at one month gt Oil filter change 50 H 6M 1000 1600 Replace with oil change gt Cil lines fasteners 50H 6M 1000 1600 Inspect for leaks and loose fittings gt Front gearcase 100 H 12M 1000 1600 Change fluid demand drive fluid gt Transmission 100 H 12M 1000 1600 Change fluid main gearcase oil D Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap E lines filter pump throttle body gt Spark plugs 100 H 12M 1000 1600 Inspect replace as needed E torque to specification gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 80 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Radiator 100 H 12M 1000 1600 Inspect clean external
34. ART Engage the starter for a maximum of five seconds Release the key when the engine starts 6 Ifthe engine does not start within five seconds return the ignition switch to the OFF position and wait five seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmission in PARK 3 Turn the engine off Braking 1 Release the throttle pedal completely Tip When the throttle pedal is released completely and engine speed slows to near idle the vehicle has no engine braking 2 Presson the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re famil iar with the controls 50 OPERATION Parking the Vehicle 1 Stop the vehicle on a level surface 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 2 Place the transmission in PARK 3 Turn the engine off 4 Remove the ignition key to prevent unauthorized use Know Your Riding Area Tread Lightly Familiarize y
35. CONTROLS Component Locations ROPS Frame RZR XP 4 Shown Cargo Steering Box Wheel AC Radiator z c s Fuel Tank een Cap Passenger Hand Hold Brake Pedal Gear Selector Cargo Box Tie Down Points 4 corners Throttle Pedal 25 FEATURES AND CONTROLS Switches Light AWD Instrument Switch Switch Cluster laniti 12V Accessory Swich Outlet Auxiliary Outlets The vehicle is equipped with one or more 12 volt accessory outlets One outlet is on the dash a second outlet if equipped is in the rear passenger 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 Ignition Switch The ignition switch is a three position key operated switch Use the ignition switch to start the engine See page 50 for starting procedures The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except accessory 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released 26 FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low HI
36. D while the rear wheels are spinning or slipping may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 36 FEATURES AND CONTROLS Instrument Cluster NOTICE High water pressure may damage components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster PELARIS N so a Se Gl we A WoW amp fN a SN J por BPEGGOGGOGOOGEGF Trip 12 ime Mange RPW zh 4 A J USA LAURI edendi DUAE me V eS E zm Rider Information Center Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 41 Mode Button Use the MODE button to toggle through mode options See page 41 for operation of the modes 37 FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected speed displays in Vehicle miles per hour Speed i When metric mode is selected speed displays in kilometers per hour E Over This lam
37. GH beam The ignition switch must be in the ON position to operate the headlights LOW Press the top of the rocker switch toward the 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 If the headlight switch is ON when the ignition switch is turned off the lights will remain on for AWD approximately 30 seconds All Wheel Drive AWD Switch The AWD Switch has two positions o All Wheel Drive AWD 2WD Ha Two Wheel Drive 2WD Press the top of the rocker switch to engage AII Wheel Drive Press the bottom of the switch to operate in two wheel drive See page 36 for AWD operating instructions Electronic Power Steering EPS Electronic power steering if equipped 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 ON position See page 38 To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down If the light remains on after starting the engine the EPS system is inoperative See your authorized POLARIS dealer for service 27 FEATURES AND CONTROLS Seats Before operating t
38. PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 136 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair
39. S 96 Radiator Coolant Level 97 Refueling Safety 22 Removal Battery 119 Removal Seat 28 Removal Wheels 114 Removing Vehicle from Storage 127 Restrictions Age 14 Reverse uu 2 eae ae parte wae 60 Rider Information Center 39 45 Riding Area oer em en ol Riding Gear 8 9 Rollover Protective Structure 35 ROPS Cab Frame 35 S Safe Operation Practices 49 Safety Labels 10 13 Safety Symbols 4 Safety Training 7 Safety Training ROHVA 49 52 Safety Warnings 14 24 Safety Winch Maintenance 75 Seat Adjustment 0 28 Seat Belts m cans cove e 32 33 Seat Removal 28 Selector Gedi i ss e rs 34 Service Access Panels 31 Severe Use Definition TI Shifting Gears s cese dre e 34 Shock Compression 112 Shock Loading the Winch 74 Signal Words 04 4 Spark Arrester Warning 104 105 Spark Arrestor Cleaning 105 Spark Plug Condition 93 Spark Plug Gap 92 Spark Plug Removal 93 Spark Plug Torque 92 Spark Plugs eren 92 93 Spark Plugs Fouled 93 Specifications Gearcase 92 S Speedometer ccc eese rn 37 Spring Preload 109 111
40. Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 42 for resetting instructions 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on 4X4 FEATURES AND CONTROLS Instrument Cluster Rider Information Center tty Use the MODE button to toggle through the information area options Display Units Standard Metric The display can be changed to show either standard or metric units of measurement for each of the following settings Tip To exit the set up mode turn the key off Wait 5 seconds then turn the key on The gauge display the mode that was displayed prior to setting the units Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip The
41. ads unless designated for off highway vehicle access collisions with cars and trucks can occur RZR XP Do not exceed seating capacity 2 occupants RZR XP 4 Do not exceed seating capacity 4 occupants 10 SAFETY Safety Labels and Locations Drive Responsibly Warning Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts 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 sidehilling riding across slopes Rollovers have caused severe injuries and death even on flat open areas 7179761 Payload Warning WARNING RZR Never Exceed If Total Payload Exceeds XP 1000 68 MPH 109 km h 430 Ibs 195 kg XP4 1000 68 MPH 109 km h 860 Ibs 390 kg Riders Warning Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk of 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 use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use cab nets and or doors
42. air the radiator s effectiveness Using a high pressure system is not recommended 96 Cooling System Radiator Coolant Level Changing Coolant This procedure is required only if the cooling system has been drained for maintenance and or repair If the overflow bottle has run dry the level in the radiator should also be inspected MAINTENANCE 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 1 2 Tip Remove the hood See page 30 Slowly remove the radiator pressure cap View the coolant level through the opening Use a funnel and slowly add coolant as needed Before reinstalling the pres sure cap bleed the system of trapped air Remove the engine access panel behind the seats and use a flat blade screwdriver to turn the bleed screw slightly allowing the air to escape Slowly add additional coolant to the radiator until air no longer escapes and only coolant flows from the bleed hole then tighten the bleed screw Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part Pressure Overflow Cap Bottle MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beg
43. and experience 17 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in this owner s manual Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Exhibition driving increases the risk of an accident or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or rollover Use extreme caution when operating on hills Always follow proper procedures for hill climbing as ee in this owner s manual See page Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual See page 57 18 SAFETY Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in this owner s manual See page 57 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a
44. and check for fluid leakage around the fittings 108 Suspension Settings Front Rear Spring Preload The factory setting is appropriate for nearly all riding conditions If MAINTENANCE desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads Front Shock Preload Measurement Rear Shock Preload Measurement Factory Preload Settings RZR XP Front 17 11 inches 43 5 cm Rear 22 825 inches 58 cm RZRXP4 Front 17 59 inches 44 67 cm Rear 23 22 inches 58 98 cm 109 MAINTENANCE Suspension Settings Front Rear Spring Preload Walker Evans Shock Preload Adjustment 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 vehi cle stability when operating without a load Always apply the same adjustment setting to all four wheels Do not increase the spring preload by more than one inch 25 4 mm over the factory setting 110 MAINTENANCE Suspension Settings Front Rear Spring Preload Walker Evans Shock Preload Adjustment 1 Use the shock clutch tool from the tool kit to aid in making suspen sion adjustments 2 Elevate the vehicle
45. are warm If necessary blow debris from the screen with compressed air Inspect the screen for wear and damage Replace a worn or damaged screen Reinstall the arrester Torque bolt to 9 11 ft Ibs 12 15 Nm b Bolt Arrester Screen b d Nut 105 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal See page 35 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 page 108 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs WARNING Operating the vehicle with a spongy brake pedal can result in loss of braking which could cause an accident resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal 106 MAINTENANCE Brakes Brake Inspection 1 2 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not app
46. arge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 121 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 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 122 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE Water in the PVT system could cause the drive belt to become wet and slip in the clutches Always avoid spraying water directly toward any intake pre filters High water pressure may damage the radiator fins and impair the radiator s effectiveness High pressure may also damage
47. ase Emission Control System 76 D Demand Drive Fluid 90 91 Display Units Standard Metric 41 DDO OES sch CE oae Dos mere 32 Drive Belt Wear eese 131 Drivetrain Break In 47 Driving Downhill 57 Driving in Reverse 60 Driving on a Sidehill 57 Driving on Slippery Surfaces 55 Driving Over Obstacles 59 Driving Procedures 52 53 Driving Through Water 58 Driving Uphill suus 56 Driving with Passengers 54 Driving After Driving in Water 101 Drying the Transmission 101 E Electromagnetic Interference 76 Electronic Power Steering 27 Emission Control Crankcase 76 Emission Control Exhaust 76 Emission Control Noise 76 Emissions Limited Warranty 139 141 Engaging AWD 36 Engine Access Panel 31 Engine Break In 47 Engine Fogging 126 Engine Intake Pre Filter 102 Engine Oil suse 84 87 Engine Starting 50 Engine Stopping 50 EPS Logis e D RP PRESA sens 27 Equipment Modifications 24 Error Codes Engine 45 Etiquette Trail Riding 51 Exhaust Cleaning 105 Exhaust Emission Control System 76 Exhaust System Warning 104 105 Eye Protection 0 0 c see ees 9 F Fan Cooling 0
48. ated on the right side of the vehicle The clutch air intake is located on the left side of the vehicle Inspect the engine pre filter before each use of the vehicle to ensure adequate air flow If necessary remove the pre filter and clean with soapy water Dry with low pressure compressed air Periodically inspect the clutch PVT air intake for debris and clean as needed to ensure adequate air flow Tip When washing the vehicle always avoid spraying water directly toward the PVT intake duct See page 123 for recommended washing procedures PVT Intake Engine Intake Pre Filter Pre Filter 102 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 1 Remove the cargo box access panel 2 Clean all dirt and debris from the air box area 3 Unlatch the four 4 air box cover clips and carefully remove the air box cover 4 Inspect the air filter and air box for dirt debris or water 5 Toremove the filter slide the filter toward the passenger s side of the vehicle 6 With the filter removed clean the intake tube and air box thoroughly Wipe well with a clean dry cloth NOTICE Dirt or debris in the intake tube could result in severe engine damage Always clean all dirt and debris from the intake tube before installing the filter 7 Reinstall the air filter 1f clean or install a new
49. behind the seats on the frame of the vehicle Remove the seats and remove the access panel to reach serviceable engine components Fuel Cap Cargo Box Access Panel The cargo box access panel is located on the floor of the cargo box Remove the panel to access the engine oil fill cap spark plugs and air filter 31 FEATURES AND CONTROLS Cab Doors This vehicle is equipped with cab doors Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover Always make sure all cab doors are closed and latched when riding in this vehicle Always inspect doors and latches for wear and damage before each use of the vehicle Promptly replace any worn or damaged parts with new parts available from your authorized POLARIS dealer Seat Belts This POLARIS vehicle is equipped with seat belts for all riders Always make sure the seat belts are secured for the operator and all passengers before riding 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 inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks Pull up on the strap to tighten 3 Press the red release latch on the buckle to re
50. ble 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 56 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 34 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 101 Prevent water from entering the PVT outlet duct see page 123 Inspect clutch seals
51. cee cee eee 96 Filter Air iius dene teehee ie saos 103 Filter Care During Storage 125 Filter Cleaning Air 103 Filter Systems 102 103 Fluid Demand Drive 90 91 Front Gearcase 90 91 Main Gearcase 88 89 Transmission 88 89 Fluid Change Demand Drive 91 Front Gearcase 91 Main Gearcase 89 Transmission 89 Fluid Check Demand Drive 90 Front Gearcase 0 90 Main Gearcase 4 88 Transmission 88 INDEX F Fluid Levels During Storage 125 Fluid Recommendations Gearcase 92 Fluid Brake 108 Fogging the Engine 126 Fouled Plugs 2er mien 93 Freeplay Steering Wheel 118 Fuel Cap serre es Saree RES 31 Fuel Safety 5 2 ies 22 Fuel Stabilizer 125 Fuel Tank Filler Cap 31 Fuse Relay Center 94 G Gap Spark Plug 92 Gasoline Handling 22 Gear Selector i isses 34 Gearcase Capacities 92 Gearcase Oil Demand Drive 90 91 Fronta ea etbcee pp red 90 91 Min iu ses tok sree uS Eee 88 89 Gearcase Specifications 92 Gearcases eee 88 89 92 Demand Drive 90 91 Front Gearcase 90 91 Main Gearcase 88 89 Specification Chart 92 Transmiss
52. clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line or filter Inspect and replace Kinked idle air control lines Inspect rotate lines to remove kink Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter See your dealer Low fuel pressure See your dealer 133 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel tank vent line or filter Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug 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
53. conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any source of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing 22 SAFETY Safety Warnings Exposure to Exhaust Engine exhaust 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 combustible materials away from the exhaust System Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age o
54. 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 core clean engine exterior check coolant level see your dealer if condition persists 134 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty
55. ctive gear reduces the chance of injury Over the Ankle Boots Gloves Helmet Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots for support and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can eleva
56. cupants from being ejected from the vehicle Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover 35 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the 5 vehicle is in two wheel drive at all times When AWD M the switch is on AWD the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on When in AWD the demand drive unit will F automatically engage any time the rear wheels lose 2WD gts traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AW
57. d warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS 140 WARRANTY U S A EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to th
58. damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT
59. e contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system lgnition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units 139 WARRANTY U S A EPA Emissions Limited Warranty The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector e o o o o o o e o o o o As related to the evaporative emission control system The exclusive remedy f
60. eliberately Never hurry or rush during winching Always pay attention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lift ing an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or service 3 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel Hook Strap a P d chocks if needed fF 68 Ca WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY NO YES A Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the wi
61. er clockwise position Firmest 1 click from closed 112 MAINTENANCE Tires A WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure Always use POLARIS approved size and type of tires for this vehicle when replacing tires Tire Tread Depth 4 Always replace tires 1 8 3 mm Z when tread depth is worn to 1 8 3 mm or less CP AS Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut dies Lug Nut b Front and Rear 108 ft Ibs Aluminum Me C 146 4 Nm Wheels MEA LU Hub Retaining Nut Front and Rear 110 ft Ibs 149 Nm 113 MAINTENANCE Tires Wheel Removal Position the vehicle on a level surface Place the transmission in PARK Stop the engine Loosen the wheel nuts slightly APEROS Elevate the side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel lug nuts Remove the wheel Wheel Installation 1 Place the transmission
62. ese features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 141 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 142 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 143 INDEX A Access Panel Cargo BOX seek 31 Erngines id ete eee eee 3l Access Panels for Service 31 Accessory Outlets suu 26 Adjustment Hand Hold 29 CAL Praca ns esed etse tent SIER 28 Steering Wheel 28 Age Restrictions 14 AirFilter 2e el 103 Air Filter Cleaning 103 All Wheel Drive Switch 27 All Wheel Drive System 36 Arrester Spark Warning 104 105 Auxiliary Outlets 26 AWD Switch 27 36 AWD System esee ys 36 Axle Nut Torque 113 B Battery eeeeee 119 122 Charging iius 121 122 Installation suus 120 REMOVAL 4
63. evels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Carry only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean any debris from the duct and from the engine compartment 47 OPERATION Pre Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Item Remarks Page Brake system pedal travel Ensure proper operation s Brake fluid Ensure proper level 108 Front suspension Inspect lubricate if necessary 82 Rear suspension Inspect lubricate if necessary 82 Steering Ensure free operation 118 Tires Inspect condition and pressure 15 Wheels fasteners Inspect ensure fastener tightness 113 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil En
64. f 16 without a drivers license or without proper training This could result in an accident or rollover Always remove the ignition key when the vehicle is not in use 23 SAFETY Safety Warnings Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed Modifications to your vehicle may negatively impact vehicle stability Failure of critical machine components may result from operation with any modifications especially those that increase speed or power This vehicle may become less stable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Do not install any non POLARIS approved accessory or modify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bodily injury The 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 with their function and effect on the vehicle FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 24 FEATURES AND
65. g 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 74 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware 2 Permit your winch motor to cool down prior to servicing your winch 3 Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope
66. g the storage period Battery Tender will automatically charge the battery if voltage drops below a pre determined point See page 130 for the part numbers of POLARIS products During the storage period park the vehicle out of the sun in a cool dry place or remove the battery and store it in a cool dry place 120 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this 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 resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts rech
67. he winch to prevent the battery from running low if winching for long periods 71 WINCH GUIDE Winch Operation 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum F Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m PODS 72 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if
68. he vehicle always push down on all seat backs to ensure the latches are secure Seat Adjustments On seats equipped with an adjustment lever under the front edge of the seat pull the lever to the left Slide the seat forward or rearward to the desired position Release the lever The seat will lock into the new position For other seat styles loosen do not remove the four screws located on the seat bottom Slide the seat forward or rearward to the desired position Tighten the screws to 4 ft lbs 5 4 Nm Do not overtighten Seat Removal 1 Pull up on the seat latch lever located under the rear edge of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle 4 Reverse this procedure to reinstall the seat Make sure the seat tabs at the front edge of the seat slide under the seat retainer bar 5 Press down firmly at the Front Seat pu rear of the seat to engage Retainer aic the rear latch Steering Wheel The steering wheel can be tilted upward or downward for rider preference Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Adjustment Lever 28 FEATURES AND CONTROLS Passenger Hand Hold Always adjust the hand hold to a comfortable position for your passenger before operating Make sure the adjustment pin and retainer are securely
69. ide Travel straight downhill 6 Apply the brakes lightly to aid in slowing 57 OPERATION Driving Through Water Your vehicle can operate through Sk P water with a maximum tags recommended depth equal to floor level Follow these precautions when operating through water 1 Determine water depth and current before entering water 2 Choose a crossing where the water level is lowest and where both banks have grad ual inclines Never operate in water that exceeds the maximum recommended depth WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast flowing water which could result in loss of traction loss of control rollover or accident 3 Wet brakes may 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 Avoid applying brake and throttle at the same time NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 77 Give special attention to engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings If your vehicle becomes immersed or is operated in water that exceeds the floor level take it to your dealer for service before starting the engine If it s impossible to bring the vehicle to your dealer before starting the engi
70. imbing an incline Towing 16 SAFETY Safety Warnings Passengers in the Cargo Box 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 Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use In some areas it s unlawful to operate this vehicle on public streets roads and highways Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and experience and your passengers skills
71. ing is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Battery Removal Remove the driver s seat XP or the left rear passenger seat XP 4 See page 28 Disconnect the black negative battery cable first Disconnect the red positive battery cable last Remove the battery hold down strap Lift the battery out of the vehicle ph decur p 119 MAINTENANCE Battery 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 battery charging instructions on page 121 before installing the battery 1 Ensure that the battery is fully charged Place the battery in the battery holder Coat the terminals with dielectric grease or petroleum jelly Secure the battery hold down strap Connect and tighten the red positive cable first Connect and tighten the black negative cable last Verify that cables are properly routed 90 2X Qv tn de Uy e Reinstall the seat Battery Storage Whenever the vehicle is not used for a period of three months or more recharge the battery about once a month to make up for normal self discharge see page 121 or use a POLARIS Battery Tender which can be left connected durin
72. ing on SS excessively rough slippery or loose terrain ae could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow proper procedures for operating on slippery surfaces as described in this owner s manual See page 55 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 page 59 20 SAFETY Safety Warnings Operating Through Water Operating through deep or fast flowing water can cause loss of traction loss of control rollover or accident Never operate in fast flowing water or in water that exceeds the floor level of the vehicle Always follow proper procedures for operating in water as described in this owner s manual See page 58 Wet brakes may 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 Operating on Frozen Bodies of Water Severe injur
73. ing with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing a rollover DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h 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 62 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry a specific capacity Reduce speed and allow a greater distance for braking when carrying cargo Loads should be centered and carried as low as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the maximum capacities specified for your vehicle See page 128 Belt Life To extend belt life use low gear when hauling or towing heavy cargo 63 OPERATION Towing A WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability The tow loop on the rear of the vehicle is provided for recovery use ONLY Tow a vehicle ONLY of equal or lesser size and weight When towing a disab
74. inning on page 77 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool If the overflow bottle has run dry the level in the radiator should also be inspected 1 Position the vehicle on a Pressure level surface Overflow 2 Remove the hood See page 30 3 View the coolant level in the overflow bottle 4 Remove the cap and use a funnel to add coolant as needed to 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 system inspected by your POLARIS dealer 98 MAINTENANCE POLARIS Variable Transmission PVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the f
75. installed after making adjustments 1 2 3 4 Remove the retainer from the end of the adjustment pin Remove the pin from the post Slide the post inward or outward to the desired position Reinstall the pin through the post mounting hole adapter bushing hole both post adjustment holes and lastly through the remaining bushing hole and post mounting hole Reinstall the retainer to the pin Adapter Bushing Pin Retainer Z Adjustment Fost Mounting Pin oles 29 FEATURES AND CONTROLS Hood Remove the hood to access the radiator pressure cap and coolant overflow bottle 1 2 3 30 Turn the hood fasteners 1 4 turn Grasp the upper hood edge and pull upward to disengage the fasteners Pivot the hood forward and lift upward to disengage the lower hood hooks Lift the hood away from the vehicle Hood Fasteners FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Service Access Panels Engine Access Panel The engine access panel is located
76. ion 88 89 Gears shifting 34 GIOVE ies ete eret redeo i r 9 H Hand Hold Passenger 29 Hauling a Load 62 63 Hauling Cargo 62 63 Headlight Replacement 115 Headlight Switch 27 Helmet s sep gesedeer aus 8 Hood Removal 0 30 145 INDEX l Ignition Switch 26 Indicator Lamps 38 Inspection Axle Nuts 113 Inspection Brakes 107 Inspection Pre Ride 48 Inspection Steering Wheel 118 Inspection Wheel Nuts 113 Installation Battery 120 Installation Wheels 114 Instrument Cluster 37 45 Interference Electromagnetic 76 K Key Periodic Maintenance Chart 78 L Lights Headlight Beam Adjustment 116 Headlight Replacement 115 Headlight Switch 27 Taillight Brake Light 115 Loads Towing 64 Low Beam Adjustment 116 Lubricant Part Numbers 130 Lubrication for Storage 126 Lubrication Recommendations 82 83 M Maintenance Periodic 77 81 Metric Display 41 Mode Button 37 N New Operator Procedures 52 53 Noise Emission Control System 76 0 Obstacles saune sieys iia 59 Oil Demand Drive 90 91 EDEME iui rhe S 84 87 Front Gearcase 90 91 Main Gearca
77. ions in the RPM from day to day may be normal because of changes in humidity temperature and elevation 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer 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 intermittent faults Inactive codes are stored in the history
78. ish Other languages are provided as translations of the original instructions Printed in U S A 2014 RZR XP 1000 RZR XP 4 1000 Owner s Manual P N 9924687 2 TABLE OF CONTENTS IntrodUcllOn sscunse e REREERRRERERRRER EE 4 Safety v T 7 Features and Controls 25 Operation cuo xat ER ERE ETC TREE ES 46 Winch Guide scis kk eT IREFESRUSERRSAE ES 65 Emission Control Systems 76 Maintenance LL 77 Specifications eec RR RR ERERR ET ERES 128 POLARIS Products 130 Troubleshooting Lese 131 Warranty oc caceccceedceceeteeiedeccees 135 Maintenance Log 142 NAEK MMC anwa 144 INTRODUCTION The RZR is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if no
79. l apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a hill is unavoidable follow these precautions 1 Engage all wheel drive 2 Drive slowly and use extreme caution 3 Ifthe vehicle begins to roll over or if it feels as if it may roll over immediately turn downhill 4 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 5 Ifthe vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill Driving Downhill Whenever descending a hill follow these precautions 1 Avoid excessively steep hills 2 Slow down Never travel down a hill at high speed 3 Always check the terrain carefully before descending a hill Never drive on hills with excessively slippery or loose surfaces 4 Always descend a hill with the transmission in forward gear Never descend a hill with the transmission in neutral 5 Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one s
80. lease the seat belt 32 FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle jn Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched Push the red release latch in the middle of the buckle to make sure it releases freely Pull each seat belt com pletely out and inspect the full length for any damage including cuts wear fray ing or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or Retractor replaced by an authorized Latch Housings Housing POLARIS dealer To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household deter gents Rinse the entire length of the belt webbing Use a garden hose to flush out the retractor and latch housings regularly 33 FEATURES AND CONTROLS Gear Selector P Park 4 R Reverse N Neutral Gear Selector L Low Gear 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 O speed above idle or while R the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience
81. led RZR vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing Tow Loop 64 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions T5099 toe Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 74 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five 5 full turns of winch cable are wrapped around
82. ly WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper 3 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm 107 MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation If the fluid level is low add DOT 4 brake fluid only See page 130 for the part numbers of POLARIS products WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown Access the brake fluid reservoir through the left front wheel well Maximum Minimum 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 View the brake fluid level in the reservoir The level should be between the maximum and minimum level lines 4 If the fluid level is lower than the lower level line add brake fluid to the upper line 5 Apply the brake forcefully for a few seconds
83. n 297 2 cm Ground Clearance 13 5 in 34 3 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 999 cc Bore x Stroke 93mm x 73 5mm Alternator Output 560 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark Plug Gap XG4YCX 0 7 0 8 mm Front Suspension Independent double a arm with 16 in 40 6 cm travel Rear Suspension Independent trailing arms with 18 in 45 7 cm travel 128 SPECIFICATIONS RZR XP 1000 RZR XP 4 1000 Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P R N L H Tire Size Front 29x9 14 Tire Size Rear 29x11 14 Tire Pressure RZR XP Front 16 psi 110 kPa RZR XP Rear 16 psi 110 kPa RZR XP 4 Front 19 psi 131 kPa RZR XP 4 Rear 21 psi 145 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 dual beam LED cluster Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V Output Gear Ratios Rear High Gear 10 73 Low Gear 22 79 Reverse 20 41 Front including front drive High Gear 11 42 Low Gear 24 25 Reverse 21 73 Drive Ratio Front 3 182 1 Clutching Please see your POLARIS dealer for clutching s
84. n for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins NOTICE If your 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 covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 138 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in additi
85. nch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 74 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a d hook or latch Always replace damaged parts before using the winch YES NO 69 WINCH GUIDE Winch Operation 5 6 7 10 70 Never remove the hook strap from the hook Release the winch clutch and pull out the winch cable Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of
86. nd of tool to spread sheaves 100 MAINTENANCE POLARIS Variable Transmission PVT System Belt Replacement Debris Removal 4 Tip Remove all debris from the entire clutch air duct passage 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 Belt slip is responsible for creating excessive heat that destroys belts bp clutch components and causes outer i clutch covers to fail Switch to low Clutch Air Duct range while operating at slower speeds to extend the life 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 Remove the clutch cover drain plug 2 Allow the water to drain Reinstall the drain plug 3 Place the transmission in PARK Apply the brakes 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 101 MAINTENANCE Filter Systems Intake Pre Filters The engine intake pre filter is loc
87. ne perform the service outlined on page 117 and take the vehicle to your dealer at the first opportunity Floor Level gt 58 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly 5 Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover 59 OPERATION Driving in Reverse Follow these precautions when operating in reverse l Un e 9 qo 60 Always check for obstacles or people behind the vehicle Apply the throttle ightly Never open the throttle suddenly Back slowly Apply the brakes lightly for stopping Avoid making sharp turns OPERATION Parking on an Incline A rolling vehicle can result in serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 4 Block the rear wheels on the downhill side 61 OPERATION
88. nformation 12 SAFETY Safety Labels and Locations Belt Debris Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage SEVERE INJURY or DEATH Always look for and remove debris inside and around the clutch and vent System when replacing the belt Read owner s manual or see authorized POLARIS dealer 7177469 Air Box Caution CAUTION Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing filter ensure there is no dirt or peu the o side of the intake OMY BIHB 7 EB tube The air filter must be properly P r seated before the lid is reinstalled i z Please reference your owner s manual for additional information regarding air puni filter service Air Box Caution SSE 13 SAFETY Safety Warnings A WARNING Failure to operate this vehicle properly can result in a collision loss of control accident or rollover which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual and in the safety DVD provided with your vehicle See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different
89. nition 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 Identification Number Engine Serial Number Vehicle Model Number Vehicle Identification Number Engine Serial Number Key Number SAFETY Safety Training Safety training is a top priority for POLARIS POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course ROHVA Recreational Off Highway Vehicle Association provides both an online safety e course and a hands on safety course To access this valuable training visit www rohva org Your POLARIS vehicle is considered an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals For more information about recreational off road vehicle safety in Ep pr States visit www rohva org or call POLARIS at 1 800 SAFETY Safe Riding Gear 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 Prote
90. nsmission Main Gearcase Fluid Change The drain plug is located on the bottom of the gearcase Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly Demand Drive Transmission Drain Plug Drain Plug Mo ay 77 TAX s 1 i p Ec 7 e mman a C Li ANE E 89 MAINTENANCE Demand Drive Unit Front Gearcase Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand drive unit Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole Fill Plug 4 Reinstall the fill plug Torque to specification 90 MAINTENANCE Demand Drive Unit Fro
91. nt Gearcase Fluid Change The drain plug is located on the bottom of the gearcase Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug If the o ring is damaged install a new o ring 5 Reinstall the drain plug Torque to specification 6 ns the recommended fluid to the bottom thread of the fill plug ole 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly Demand Drive Transmission Drain Plug Drain Plug LL Fia e s L6 gc erer ot j PGE ee Jo W pns 2 91 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components See page 130 for the part numbers of POLARIS products Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission AGL Gearcase 44 Oz 10 14 ft lbs 10 14 ft Ibs Main Gearcase Lubricant amp 1300 ml 14 19 Nm 14 19 Nm Transmission Fluid Demand Drive Demand Drive 8 5 oz 8 10 ft Ibs 8 10 ft Ibs Unit Front Fluid 250 ml 11 14 Nm 11 14 Nm Gearcase Spark Plugs Spark Plug Gap Torque Spark Plug Torque 7 ft Ibs 10 Nm Electrode Gap 0 7 0 8 mm NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark pl
92. nt short trip operation in cold weather engine frequently does not operate long enough to reach full operating temperature Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 77 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 78 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Pre Ride bias acjystments as need gt ed See Pre Ride Checklist Front suspension Pre Ride Gne qo 45 Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre
93. of the unit 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter The error screen displays Error Code N PN only when the CHECK Number 0 9 Hine COPI ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine Failure Mode Indicator FMI If the CHECK ENGINE light illuminates retrieve the error codes from the display 1 Ifthe 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 button to exit the diagnostics code menu 6 Seean authorized POLARIS dealer for code details and diagnosis 45 OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or rollover which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Vehicle Break in Period The break in period for your new POLARIS vehicle is the first 25 hours of operation or the time it takes to use
94. ollowing responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as recommended in the owner s manual and on safety labels This PVT system is intended for use on POLARIS products only Do not install itin any other product Always make sure the PVT housing is securely in place during operation 99 MAINTENANCE POLARIS Variable Transmission PVT System Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compartments when replacing the belt WARNING Failure to 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 panel and thoroughly clean all debris from the aluminum debris basket and from the engine compartment 3 Remove the clutch cover screws and open the clutch cover It does not have to be removed from the vehicle Remove all debris wrapped in and around the PVT system Remove ALL Debris Tip Use the shock clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation Continued on next page Insert hooked end of tool Apply force to opposite e
95. on to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid servic
96. op on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain 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 completely drained every two years and a fresh mixture of antifreeze and water added See page 97 for changing procedure POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 130 for the part numbers of POLARIS products Tip Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant 95 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and imp
97. or breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limite
98. other vehicle components Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water PVT Intake Pre Filter 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 123 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system 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 Hlectrical components and wiring Airintake components If warning and safety labels are damaged contact your POLARIS dealer for free replacement Grease all zerk fittings immediately af
99. ourself with all laws and regulations concerning the operation of this vehicle in your area Respect the environment in which you ride your vehicle Find out where the designated riding areas are by contacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehicles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 51 OPERATION New Operator Driving Procedures 9 Read and understand the owner s manual and all warning and instruction labels before operating this vehicle Visit the Recreational Off Highway Vehicle Association web site rohva org and take the free on line training course Hands on training is also available through ROHVA Perform the pre ride inspection See page 48 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Do not carry cargo during this period Select an open area that allo
100. p illuminates to indicate an overheated eU Temperature engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power aM EPS Warning This indicator illuminates briefly when the key is turned 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 ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating Check Engine This indicator appears if an EFl related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one second at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set
101. pecifications 129 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 1 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 I 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 I 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 I Gearcase Transmission Lubricants 2878068 RE Synthetic Gearcase Lubricant amp Transmission Fluid qt 2878069 cies diea Gearcase Lubricant amp Transmission Fluid 2877922 Demand Drive Fluid qt 95 1 2877923 Demand Drive Fluid gal 3 8 1 2870465 Pump for Gallon 3 8 I Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 I 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 1 Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 130 TROUBLESHOOTING Drive Belt Wear Burn Possi
102. r dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Demand Drive Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil and See page 84 PS 4 Extreme Duty 10W 50 4 Cycle Oil Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 108 Transmission Oil AGL Gearcase Lubricant amp See page 88 Main Gearcase Transmission Fluid Front Gearcase Fluid Demand Drive Fluid See page 90 Prop Shaft U Joint Grease Grease middle and rear fittings Front Control Arm Pivot Bushings All Season Grease or grease conforming to NLGI No 2 Grease 3 fittings on each side of the vehicle Stabilizer Bar Bushings All Season Grease or grease conforming to NLGI No 2 Remove engine access panel and grease 2 fittings one on each side of vehicle Middle Prop Shaft Grease Fitting 82 Rear Prop Shaft Grease Fitting MAINTENANCE Lubrication Recommendations Front Suspension viewed from rear Front Control Arm Pivot Bushings 8 per side Stabilizer Bar Bushings one on each side of vehicle 83 MAINTENANCE Engine Oil Oil Recommendations WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil 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
103. rence This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 76 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 142 Service and adjustments are important 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 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 Freque
104. riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a seat belt when riding in this vehicle Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judg ment and reduce operator reaction time Complete the New Operator Driving Procedures outlined on pages 52 53 Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ig
105. rnal stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 135 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES 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 coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components e o o o o oo o e o o o o o o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine
106. s are not worn Fouling may be caused by excessive oil or by frequent short trips especially in cold weather 93 MAINTENANCE Fuse Relay Center If the engine stops or will not start if the power steering stops working if equipped or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse The fuse relay center is located under the driver s seat XP or under the left rear passenger seat XP 4 Label Value Function FAN 20A Circuit Breaker Fan EFI 20A Fuse Gauge Injectors Coil ECM FUEL PUMP 10A Fuse Fuel Pump BRAKE LT 5A Fuse Brake Light EPS 20A Fuse Power Steering LIGHTS 10A Fuse Headlights Taillights Dash Lights DRIVE 10A Fuse All Wheel Drive ACCESSORY 20A Fuse 12V Receptacle Under Hood Terminal Block 94 MAINTENANCE Cooling System The engine coolant level is maintained by the recovery system The recovery system components are the overflow bottle radiator vent fitting radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Tip Some coolant level dr
107. s manual See page 77 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 FLA shirt long pants and over the ankle boots Vy Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Cab Doors Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover Always make sure all cab doors are closed and latched while riding in this vehicle Cab doors are NOT intended to be used as arm rests Always keep hands and feet inside the vehicle at all times 15 Safety Warnings Carrying Multiple Passengers RZR XP Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 52 53 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 ability to steer and operate the controls which increases the risk of loss of control
108. safety labels ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR ALL RIDERS MUST WEAR SEAT BELTS NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS m POLARIS For your nearest Polaris dealer 1 call 1 800 POLARIS l or visit www polaris com m m Polaris Sales Inc 2100 Hwy 55 For a closer look at your RZR s features rr Penner and recommended maintenance Part No 9924687 Rev 03 scan this QR code with your smartphone Printed in USA
109. se 88 89 Transmission 88 89 Oil and Filter Care During Storage 125 146 0 Oil Change Demand Drive 91 Engine Oil 86 87 Front Gearcase 91 Main Gearcase 89 Transmission 00 89 Oil Check Demand Drive 90 Engine Oll scri 85 Front Gearcase 90 Main Gearcase sss 88 Transmission 00 88 Oil Recommendations 84 Operation on Public Lands 76 Operation Cooling System 95 96 Operation Transmission 99 101 Operator Restrictions 14 Outlets Auxiliary 26 Overflow Bottle Coolant Level 98 P Parking on an Incline 61 Parking the Vehicle 51 Passenger Hand Hold Adjustment 29 Periodic Maintenance Chart 77 81 Plug Condition 93 Plug Gap 5 etr act oe en 92 Plug Torque sere Rr 92 Plugs Fouled e eere erm 93 Plugs Spark i sees 92 93 Polaris Products 130 Polishing the Vehicle 124 Power Steering 00 27 Pre Filters Intake 102 Pre Ride Inspection 48 Public Lands 00 76 PVT Break In 47 PVT DOr yA 8 sucio tont rte tes 101 PVT Intake Pre Filter 102 PVT System Operation 99 101 PVT Cleaning Debris 100 101 R Radiator oeil RET Y
110. standers 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 loadin
111. sure proper levels En Coolant level Ensure proper level 97 98 Coolant hoses Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure proper operation 26 27 Engine intake pre filter Inspect clean 102 PVT intake pre filter Inspect clean 102 Headlights Check operation Brake light taillight Check operation Seat Latches Push down on both seat backs to 28 ensure the latches are secure Seat Belts Check length of belt for damage 32 check latches for proper operation Cab Doors Check doors and latches for wear or 32 damage 48 OPERATION Safe Operation Practices 1 10 11 12 13 Visit the Recreational Off Highway Vehicle Association web site rohva org and take the free on line training course Complete the New Operator Driving Procedures outlined on pages 52 53 Do not allow anyone under 16 years of age or without a valid driver s license to operate this vehicle Never operate with a passenger under the age of 12 Never carry more one passenger in a 2 seat vehicle Nver carry more than three passengers in a 4 seat vehicle Never allow a passenger to ride in the cargo box Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Never operate with accessories not approved by POLARIS for use on this vehicle Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway incl
112. t avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death Your POLARIS vehicle is not a toy and can be hazardous to operate This vehicle handles differently than cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual and review the safety DVD that came with your vehicle A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All rid ers 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
113. tached cor rectly 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 4 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 bolt pockets 2 Rear Tie Down Points or Tow Loop 2 Front Tie Down Points 127 SPECIFICATIONS RZR XP 1000 RZR XP 4 1000 Gross Vehicle Weight RZR XP 2200 Ibs 998 kg RZR XP 4 2560 Ibs 1161 kg Dry Weight RZR XP 1379 lbs 625 5 kg RZR XP 4 1596 Ibs 724 kg Test GVW Rollover Protection System ROPS RZR XP 2200 Ibs 998 kg per OSHA 29 CFR 1928 53 RZR XP 4 2760 Ibs 1252 kg per OSHA 29 CFR 1928 53 Rear Cargo Box Capacity 300 Ibs 136 kg Maximum Weight Capacity Payload RZR XP 740 lbs 336 kg RZR XP 4 900 Ibs 408 kg including riders cargo and accessories Fuel Capacity 9 5 gal 36 1 Engine Oil Capacity 2 5 qts 2 4 1 Coolant Capacity RZR XP 5 44 qts 5 1 1 RZR XP 4 6 08 qts 5 75 1 Demand Drive Fluid Capacity 8 5 oz 251 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height RZR XP 119 64 73 75 in 302 3 162 5 187 3 cm RZR XP 4 146 64 73 75 in 370 8 162 5 187 3 cm Wheelbase RZR XP 90 in 228 6 cm RZR XP 4 117 i
114. te temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the abels on the vehicle If an informational or graphic 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 Proper Use Drive Responsibly Payload Riders Warning Warning Warning Warning Seat Belt Warning Proper Use Warning WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public ro
115. ter See page 103 Clean the air box Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 77 Demand drive fluid front gearcase Rear gearcase fluid if equipped Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill 125 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 77 Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 93 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 5 Turn the engine over several times Oil will be forced in and around
116. ter washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 124 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 123 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 86 Air Filter Air Box Replace the air fil
117. to allow the suspension to fully extend 3 Turn the adjusting ring to the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease preload for a softer ride WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments Adjusting Ring Adjusting S ds Ring SG IL 111 MAINTENANCE Suspension Settings Front Rear Shock Compression The compression damping clicker knob is located at the top of the shock reservoir When the knob is turned clockwise until it stops the damping is in the fully closed position When turned counter clockwise until it stops the damping is in the fully open position 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping Increase Decrease Des Decrease Increase Front Walker Evans Shocks Setting Compression Damping Softest 16 clicks from closed Factory Front 5 7 clicks from full counter clockwise position Rear 5 7 clicks from full count
118. types of terrain Take a training course and complete the New Operator Driving Procedures outlined on pages 52 53 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 52 53 Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license Never operate with a passenger under the age of 12 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 Using Alcohol or Drugs Riding in this vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating or riding in this vehicle 14 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always perform the pre ride inspection before each use of your vehicle to make sure it s in safe operating condition See page 48 Always follow the inspection and maintenance procedures and schedules described in this owner
119. uding dirt and gravel roads Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both hands on the steering wheel during operation Never consume alcohol or drugs before or while operating this vehicle Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged vehicle After any rollover or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 49 OPERATION Starting the Engine 1 Position the vehicle on a level surface outdoors or in a well venti lated area 2 Sitin the driver s seat and fasten the seat belt Always make sure all cab doors are closed and latched when riding in this vehicle 3 Place the transmission in PARK 4 Apply the brakes Do not press the throttle pedal while starting the engine 5 Turn the ignition key past the ON RUN position to ST
120. ugs Refer to the specifications section beginning on page 128 Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 93 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 92 MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1 Remove the cargo box access panel 2 Clean the area around the spark plugs before removing the plugs 3 Remove the spark plug caps 4 Using the spark plug wrench provided in the tool kit remove the plugs by rotating them counter clockwise 5 Reverse the procedure for spark plug installation Torque to specification See page 92 Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrode
121. vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 74 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the winch cable as close as possible to the winching vehicle s centerline C Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle l Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating t
122. winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you Lay the damper on top of the mid point of the winch cable length that is spooled out On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn WINCH GUIDE Winch Operation 11 12 13 The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped
123. with your vehicle Polaris also recommends that all drivers take the ROHVA safety e course and a ROHVA hands on safety training course www rohva org Your manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD Technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS i u 2 u For a closer look at your RZR s features and recommended maintenance scan this QR code with your smartphone POLARIS and RZRQ are registered trademarks of POLARIS Industries Inc Copyright 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in Engl
124. ws room to familiarize yourself with vehicle operation and handling 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 Always make sure all cab doors are closed and latched when riding in this vehicle Sit in the driver s seat and fasten the seat belt 10 Place the transmission in PARK 11 52 Start the engine OPERATION New Operator Driving Procedures 12 13 14 15 16 17 Apply the brakes and shift into low gear Check your surroundings and determine your path of travel Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving Drive slowly at first On level surfaces practice starting stopping turning 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 Increase speed only after mastering all maneuvers at a slow speed 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 53 OPERATION Driving with Passengers
125. y or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems 21 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling which could cause loss of control or an accident Always follow the instructions in this owner s manual for carrying cargo See page 62 Never exceed the stated load capacity for this vehicle See page 12 Cargo should be properly distributed and securely attached See page 62 Reduce speed when carrying cargo Allow a greater distance for braking Refueling Gasoline is highly flammable and explosive under certain

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