Polaris RZR XP 900 manual

Owner's Manual for Maintenance and Saf ety R ANGE R R ZR XP ® 900 R ANGE R R ZR XP ® 4 900[...]

W ARNING Read, understand, and follow all of the in structions and safety precautions in this manual and on all product lab els. Failure to follow the safety precautions could result in serious injury or death . W ARNING The engine exhaust from this p roduct contains chemicals known to the St ate of California to cause cancer , birth defect s or ot[...]

The text is printed on 100% recycled with 40% post-co nsumer waste (PCW).[...]

W ARNING For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924107 Rev 01 Printed in USA Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: AL W A YS: AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR [...]

1 WELCOME Thank you for purch asing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. W e proudly produce an excit- ing line of utility and recreational products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles® • Low Emission V ehicles (LEVs) W e believe POLARIS s[...]

2 POLARIS, RANGER, RANGE R RZR and RANGER RZR XP are regis tered trademarks of POLARIS Industries Inc. Copyright 2012 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 [...]

3 T A BLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 28 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situati[...]

5 INTRODUCTION Failure to heed the warnings and safety precaution s contained in this manual can result in severe injury or death. Y our POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handl es dif ferently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly , even during routine maneuv[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identification numbers an d key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARI S key blank (using your key number) and mating it wi th one of your existing keys. The ignition switch[...]

7 SAFETY Equipment Modifications Y our POLARIS vehicle is designed to pro vide safe operation when used as directed. Modifications to your vehicle may negatively impact vehi- cle stability . Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power . This vehicle may becom[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle. W ear protective clothing for co mfort and to reduce the chance of injury . Helmet W earing a helmet can prevent a severe head injury . Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved he[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a 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 [...]

10 SAFETY Safety W arnings Failure to operate this vehicle properly can result in a collision, loss of contro l, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’s manual. See the OPERA TION section of the owner ’s manual for proper operating procedures. Operatin[...]

11 SAFETY Safety W arnings Failure to Inspect Before Operating Failure to inspect an d verify that the vehicle is in safe operating condition before operating increases the risk of an accide nt. Always inspect the vehicle before each use to make sure it's in sa fe operating condition. Always follow the in spection and maintenance procedures an[...]

12 SAFETY Safety W arnings 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 56-57. A passenger must always be seated in a passenger seat with seat belt secured. Carrying more than one passenger in a 2-sea[...]

13 SAFETY Safety W arnings 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 the passenger seat with seat belt secured. Operating on Pavement Operating this vehicle on pave[...]

14 SAFETY Safety W arnings T urning Improperly T urning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turnin g as described in the owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow spee[...]

15 SAFETY Safety W arnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Use extreme caution when operating on hills. Always foll ow proper procedure s for hill climbing as described in the owner's manual. See page 60. Crossing Hillsides Driving on a sidehill is no t recommended. Impro per procedure cou[...]

16 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlin ed in this manual. See page 64. Before shifting into reverse gear , always check for obstacles or people behind the vehicle. When it's safe to pro[...]

17 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of con trol or overturn. Before operating in a new area, check for obstacles. Never attempt to op erate over large obstacles such as r ocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacl[...]

18 SAFETY Safety W arnings Improper Cargo Loading Overloading the vehicle or carryi ng cargo improperly may cau se changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in the owner's manual for carrying cargo. • Never exceed the stated load capacity for this vehicle. • Carg[...]

19 SAFETY Safety W arnings Handling Gasoline Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whene ver handling gasoline. • Always stop the engine when refueling. • Always refuel outdoors or in a well ventilated area. • Remove flammable material containers from the box before filling. ?[...]

20 SAFETY Safety Labels and Locations W arning 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 dif fer from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle . If an inform[...]

21 SAFETY Safety Labels and Locations Passenger Safety W arning (RZR XP) W ARNING NEVER CARRY A P ASSENGER UNDER AGE 12 NEVER CARR Y MORE THAN ONE P ASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL T o reduce the risk of SEVERE INJURY or DEA TH, NEVER carry a passenger under age 12 or too small to firmly plant feet on the floor and securely grasp h[...]

22 SAFETY Safety Labels and Locations Passenger Safety W arning (RZR XP 4) W ARNING NEVER CARRY P ASSENGERS UNDER AGE 12 NEVER CARR Y MORE THAN THREE P ASSENGERS NEVER RIDE AFTER USING DRUGS OR ALCOHOL T o reduce the risk of SEVERE INJURY or DEA TH, NEVER carry passengers under age 12 or too small to firmly plant feet on the floor and securely gras[...]

23 SAFETY Safety Labels and Locations Rear Passenger Cab Frame W arning (RZR XP 4) W ARNING Do NOT hold onto this bar . Hands and arms could be crushed or seriously injured in event of rollover . AL WA YS kee p hands on passenger grab bar . 7176700 Rear Passenger Grab Bar W arning (RZR XP 4) Always use seat belt, helmet and eye protection. Always u[...]

24 SAFETY Safety Labels and Locations Cab Frame/Seat Belt W arning W ARNING • AL WA YS WEAR YOUR SEA T BEL T and make su re passenger wears seat belt. • AL WA YS SECURE CAB NETS. • VEHICLE OVERTURN could cause severe injury or death. Shif t Caution CAUTION T o avoid transmission damage, shift only when ve hicle is st ationary and at idle. Whe[...]

25 SAFETY Safety Labels and Locations Age W arning W ARNING Operating this vehicle if you are under the age of 16 increases your chance of severe inj ury or death. NEVER operate this vehicle if you are under age 16 or with out a valid driver ’s license. Overturn W arning W ARNING Improper operation can cause this vehicle to overturn and lead to s[...]

26 SAFETY Safety Labels and Locations Discretionary W arning (RZR XP) W ARNING Improper vehicle use can result in SEVERE INJURY or DEA TH NEVER operate: • without first viewing safe ty video and quick start guide. • with more than on e passenger . • on hills steeper than 15 degrees. • on public roads. • on paved surfaces - p avement may s[...]

27 SAFETY Safety Labels and Locations Discretionary W arning (RZR XP 4) W ARNING Improper vehicle use can result in SEVERE INJURY or DEA TH NEVER operate: • without first viewing sa fety video and quick start guide. • with more than three p assengers. • on hills steeper than 15 degrees. • on public roads. • on paved surfaces - p avement m[...]

28 FEA TURES AND CONTROLS Component Locations Hip Bars Fuel T ank Cap Cargo Box Front Passenger Hand Hold Cab Nets ROPS Frame Radiator St e e r i n g Wheel Gear Selector Throttle Pedal Brake Pedal[...]

29 FEA TURES AND CONTROLS Component Locations Fuel T ank Cap Shif ter Rear Passenger Grab Bar Cargo Box T ie-Down Points[...]

30 FEA TURES AND CONTROLS Switches Auxiliary Outlet s 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 passen- ger area. Use the outlets to power an auxili ary light or other optional accessories or lights. For service, the dash outlet connection is under the[...]

31 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the li ghts on and off and to change the lights from high beam to low beam. The ignition switch must be in the ON posi- tion to operate the headlights. Press the top of the rocker switch toward the dash to place the headlights on high beam. Move the rocker switch t[...]

32 FEA TURES AND CONTROLS Seat s Before operating the vehicle, always push down on all seat backs to ensure the latches are secure. Seat Adjustment s 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 Remov[...]

33 FEA TURES AND CONTROLS Passenger Hand Hold Always adjust the hand hold to a comfortable position for your front- seat passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments. 1. Remove the retainer from the end of the adjustment pin. 2. Remove the pin from the post. 3. Slide the post [...]

34 FEA TURES AND CONTROLS Hood Remove the hood to access the radiator pressure cap and coolant overflow bottle. 1. T urn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the fasteners. 3. Pivot the hood forward and lift upward to dis- engage the lower hood hooks. 4. Lift the hood away from the vehicle. Pressure[...]

35 FEA TURES AND CONTROLS Service Access Panels Engine Access Panel The engine access panel is located behind the seats on the frame of the vehicle. Remove the seats and remove the access panel to reach serviceable engine components. Cargo Box Access Panel The cargo box access panel is located on the floor of the cargo box. Remove the panel to acce[...]

36 FEA TURES 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 gr eater than 10 pe r cent, such as E-85 fuel. Remove flammable[...]

37 FEA TURES AND CONTROLS Seat Belt s This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. T o wear the seat belt properly , follow this procedure: 1. Pull the seat belt latch downward and across your chest toward [...]

38 FEA TURES AND CONTROLS Gear Selector P: Park R: Reverse N: Neutral L: Low Gear H: High Gear T o change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear . Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. Tip : Maintaining shift linkage adjustment is important to assu[...]

39 FEA TURES 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 s peed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. T[...]

40 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The All Wheel Driv e system is controlled by the A WD switch. When the switch is on 2X4, the vehi- cle is in two-wheel drive at all times. When the switch is on A W D, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on. When in A WD, the demand drive u[...]

41 FEA TURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage components. W ash the vehicle by hand or with a garden hose using mil d soap. Certain products, including insect repellents and chemicals, will damage the speedometer len s and other plastic surfaces. Do no t use alcohol to clean the instrument cluster . Do not allo[...]

42 FEA TURES AND CONTROLS Instrument Cluster Indicator Lamp s Lamp Indicates Condition V ehicle S peed When standard mode is selected, speed displays in miles per hour . When metric mode is selected, speed displays in kilometers per hour . Over T emperature This lamp illuminates to indicate an overh eated engine. If the indica tor flashes, the over[...]

43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments 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 electr[...]

44 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last seg me nt clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately . Tip : If the fuel icon fails to display , an open or shor[...]

45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle thr ough the information area options. Display Units (S tandard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip : T o exit the set-up mode, turn the key off. W a it 5 s[...]

46 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip : The clock must be reset any time the battery has been disconnected o r dis- charged. 1. T urn 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.[...]

47 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays th e distance traveled by the vehicle. T r ip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. T o reset, select the trip meter mode. Press and hold the MODE button until the meter re[...]

48 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of en gine 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 maintenanc[...]

49 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK 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 mes- sage is lost, but will reap- pear if the fault reoccurs after resta[...]

50 OPERA TION Failure to operate the vehicle properly can result in a coll ision, loss of control, accident or overturn, which may result in serious injury or dea th. Read and understand all safety warnings outlined in the safety section of this owner ’s manual. V ehicle Break-in Period The break-in period for your new POLARIS vehicle is the firs[...]

51 OPERA TION V ehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 36. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 77. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3. Complete the New Operator Driving Procedu[...]

52 OPERA TION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condi- tion 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 39 99 Brake fluid Ens[...]

53 OPERA TION Safe Operation Practices 1. V isit the Recreational Off-Highway V ehicle Association web site (rohva.org) and take the free on-lin e training course. Complete the New Operator Driving Procedures outlined on pages 56-57. 2. Do not allow anyone under 16 years of age or without a valid driver ’ s license to operate this vehicle. 3. Nev[...]

54 OPERA TION S t arting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in P ARK. 4. Apply the brakes. Do not press the throttle pedal while start ing the engine. 5. T urn the ignition key past th[...]

55 OPERA TION Parking the V ehicle 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 P ARK. 3. T urn the engine off. 4. Remov[...]

56 OPERA TION New Operator Driving Procedures 1. Read and understand the owner' s manual and all warning and instruction labels before operating this vehicle. 2. V isit the Recreational Off-H ighway V ehicle Association web site (rohva.org) and take t he free on-line training course. 3. Perform the pre-ride inspection. See page 52. 4. Do not c[...]

57 OPERA TION New Operator Driving Procedures 12. Apply the brakes and shift into low gear . 13. Check your surroundings and determine your path of travel. 14. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 15. Drive slowly at first. On level surfaces, practice sta[...]

58 OPERA TION Driving with Passengers 1. Complete the New Operator Driving Procedures outlined on pages 56-57. 2. Perform the pre-ride inspection. See page 52. 3. Do not carry more than one passenger in a 2-seat vehicle. Do not carry more than three passen- gers in a 4-seat vehicle. Additional passengers can af fect the operator ’ s ability to st[...]

59 OPERA TION Driving on Slippery Surfaces Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operati ng on slippery surfaces such as ice or loose gra vel, reduce speed and use extra cauti on to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfac[...]

60 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. A void steep hills (15° maximum). If ascending a steeper grade is unavoidable, engage all-w heel drive before ascending. 3. Drive straight uphill. 4. Never climb hills with excessively slippery or loos[...]

61 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommend ed. Improper procedure could cause loss of control or overturn. A void 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. [...]

62 OPERA TION Driving Through W a ter Y our vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when op erating 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. N[...]

63 OPERA TION Driving Over Obst acles 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. T ravel slowly and use extra caution when operating on unfamiliar [...]

64 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly . Never open the throttle suddenly . 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void making sharp turns.[...]

65 OPERA TION Parking on an Incline A rolling vehicle can result in serious injury . A void parking on an incline. If parking on an incline is unavoidable , follow these precau- tions: 1. Place the transmission in P ARK. 2. T urn the engine off. 3. Block the rear wheels on the downhill side, or park the vehicle in a sidehill position instead.[...]

66 OPERA TION Hauling Cargo Overloading the vehicle or carryi ng cargo improperly can alter vehicle handling and may cause loss of control or brake instability . Always follow th ese precautions when hauling cargo : Never exceed the stated load cap acity for this vehicle. REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. NE[...]

67 OPERA TION Hauling Cargo Y our 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 car go. Exercise caution if the cargo load ex[...]

68 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. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our POLARIS vehicle has a spark arrester that was tested and qualif[...]

69 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 period ic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the nee[...]

70 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key  Perform these operations more often for ve hicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may af fect emissions.) D Have an authorized POLARIS dealer perform these services. W ARNING! Improper[...]

71 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calend[...]

72 MAINTENANCE Periodic Maintenance Chart  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  General lubrication 50 H 3 M 500 (800) Lubricate all fi[...]

73 MAINTENANCE Periodic Maintenance Chart  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km)  Radiator (if equipped) 100 H 12 M 1000 (1 600) Inspect;[...]

74 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil PS-4 PL[...]

75 MAINTENANCE Lubrication Recommendations Grease S t abilizer Bar Bushings (one on each side of vehicle) Front Control Arm Pivot Bushings (3 per side) View of Driver’s Side From Bottom of V e hicle[...]

76 MAINTENANCE Engine Oil Oil Recommendations W ARNING! V ehicle operatio n with insuf ficient, deteriorated, or cont aminated engine oil will cause acce lerated wear and may result in engine seizure, accident, and injury . Always pe rform the maintenance procedures as outlined in the Periodic Maintenance Chart. Oil may need to be changed more freq[...]

77 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. 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 t o be overfull. Access the oil check dipstick [...]

78 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 69. Always change the oil filter whenever changing oil. Access the oil check dipstick through the service access panel behind the seats. Access the oil fill cap through the service access pan[...]

79 MAINTENANCE Engine Oil Oil and Filter Change 6. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 7. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 8. Reinstall the crankcase drain plug. T o [...]

80 MAINTENANCE T ransmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase. M[...]

81 MAINTENANCE T ransmission (Main Gearcase) Fluid Change The drain plug is located on the bot- tom of the gearcase . Access the drain plug throug h 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. Reinsta[...]

82 MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side [...]

83 MAINTENANCE Demand Drive Unit (Front Gearcase) Fluid Change The drain plug is located on the bot- tom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely . 4. Clean the drain plug. If the o- ring is damaged, install a new o- ring. 5. Reinstall the drai[...]

84 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in imp roper operation of components. See page 124 for the pa rt numbers of POLARIS products. Spar k Pl u g s Sp ark Plug Gap/T orque NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Refer to[...]

85 MAINTENANCE Spar k Pl u g s Sp ark Plug Removal and Replacement 1. Remove the cargo box access panel. 2. Clean the area around the spark plugs before remov- ing 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 spar[...]

86 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short cir - cuits that may have caused the blown fuse, then replace the fuse. The main fuse box is located under the dash, above the brake and throt- tle pedals. Spare fuses are provided in [...]

87 MAINTENANCE Fuses Main Fuse Box 1. Lift up on the two fuse box tabs. 2. Slide the fuse box slightly toward the right side of the vehicle to disengage it from the mount. 3. Remove the fuse box cover . 4. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rat- ing. 5. Reinstall the fuse box[...]

88 MAINTENANCE Cooling System The engine coolant level is maintained by the recovery system. The recovery system components are the overflow bottle, radiator vent fit- ting, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the ra diator , past the pressure [...]

89 MAINTENANCE 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. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine [...]

90 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 69 . Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). If the overfl ow bottle has run dry , the level in the radi- ator [...]

91 MAINTENANCE POLARIS V ariable T ransmission (PVT) System Failure to comply with the instructions in this warning can resul t 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 oc cur at a high speed. The PVT system has been precision balanced. Any modification will cau[...]

92 MAINTENANCE POLARIS V ariable T ransmission (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. W ARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death. 1. Remove th[...]

93 MAINTENANCE POLARIS V ariable T ransmission (PVT) System Belt Replacement/Debris Removal 3. Remove all debris from the entire clutch air duct passage. 4. Check for signs of damage to seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged. Tip : Belt slip is responsible for creating excessive [...]

94 MAINTENANCE Filter Systems Fuel T ank V ent Filter If the engine sputters, the inline fuel tank vent filter may be clogged. Do not attempt to clean the filter . Replace the filter with a new filter . 1. Remove the seats and remove the engine access panel. Tip : Note the direction of the arrow on the filter before removing it. 2. Remove the filte[...]

95 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined i n the Periodic Maintenance Chart beginn ing on page 69. 1. Remove the cargo box access panel. 2. Loosen the air box cover wing nuts and rotate the bolts away from the cover . 3. Release the cover latches. 4. Pull the cover rearward far enough to remove[...]

96 MAINTENANCE S p ark Arrester Failure to heed the following warni ngs 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 [...]

97 MAINTENANCE S p ark Arrester Periodically clean the spark arrester to remove accumulated carbon. 1. Remove the arrester retaining bolt and nut. 2. Remove the arrester from the end of the muf fler . 3. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm. If necessary , blow debris from the scr[...]

98 MAINTENANCE Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal s ticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal . Immediately contact your dealer for servic[...]

99 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 39. 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, wh[...]

100 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 124 for the part num- bers of POLARIS products. W ARNING! Af ter opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygros[...]

101 MAINTENANCE Suspension Settings Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjuste d to maintain vehicle clearance height when carrying loads. Factory Preload Settings RZR XP Premium Front 7.625” (193.7 mm) RZR XP Premium Rear 3.625” (92.1 mm) RZR XP 4 Fro[...]

102 MAINTENANCE Suspension Settings Front/Rear Spring Preload Fox 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 w[...]

103 MAINTENANCE Suspension Settings Front/Rear Spring Preload W alker 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 o[...]

104 MAINTENANCE Suspension Settings Front/Rear Shock Compression The compression damping cli cker knob is located on top of the shock reservoir . When the knob is turned clockwise until it stops, the damping is in the fully closed position. 1. T urn the clicker clockwise to increase compression damping. 2. T urn the clicker counter-clockwise to dec[...]

105 MAINTENANCE Ti re s Operating your vehicle with worn tires will increase the po ssibility of skidding, loss of control and an accident, which could result in serious in jury 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 adversel[...]

106 MAINTENANCE Ti re s Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. Stop the engine. 3. Loosen the wheel nuts slightly . 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. Wheel Inst allation 1. Place the transmissi[...]

107 MAINTENANCE Light s Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as vis- ibility to other vehicles. Tip : If an LED headlamp h as moisture or fogging in side, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to cl[...]

108 MAINTENANCE Light s 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. Place the transmission in P ARK. 3. Measure the distance from the floor to the center of the headl[...]

109 MAINTENANCE V ehicle Immersion NOTICE: If your vehicle becomes immersed, major engine dama ge can result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below . 1. Move the vehicle to [...]

110 MAINTENANCE S teering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8-1.0" (20-25 mm) of freeplay . 4. If [...]

111 MAINTENANCE Battery 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) ca ble first. When reinstalling the battery , always connect the negative (black) cable last. Y our vehicle has a sealed battery , which requir[...]

112 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 1 13 before installing the battery . 1. Ensure that the battery is fully charged. 2. Place the battery in [...]

113 MAINTENANCE Battery Battery Charging The following battery char ging instructions apply only to the installa- tion 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 char ged at the factory . Never pry the seali[...]

114 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. St ate of Charge V oltage Action Charge Time (Using constant current charger @ standa rd amps specifie d on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100% 12.5-12 .8 vol[...]

115 MAINTENANCE Cleaning and St orage W ashing the V ehicle Keeping your POLARIS vehicle clean will not only improve its appear - ance but it can also extend the life of various components. NOTICE: W ater 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- [...]

116 MAINTENANCE Cleaning and St orage W ashing the V ehicle 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. A void directing the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission seals •B r a [...]

117 MAINTENANCE Cleaning and St orage Sto ra ge Tips NOTICE: S tarting 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 peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 1 15. St abilize the [...]

118 MAINTENANCE Cleaning and St orage Sto ra ge Tips Inspect and Lubricate Inspect all cables and lubricat e all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 69. Fog the Engine 1. T reat the fuel system with POLARIS Carbon Clean. Follow the instructions on the container . Start the engine. Allow it to idle[...]

119 MAINTENANCE Cleaning and St orage Removal from Storage 1. Charge the battery if necessary . 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 52. T ightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer[...]

120 SPECIFICA TIONS RANGER RZR XP 900 Gross V ehicle W eight 1930 lbs. (875 kg) Dry W eight 1 190 lbs. (540 kg) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum W eight Capacity (Payload) 740 lbs. (336.4 kg) (including riders, cargo and accessories) Fuel Capacity 7.25 gal. (27.4 l) Engine Oil Capacity 2.5 qts. (2.4 l) Coolant Capacity 4.9 qts. (4.[...]

121 SPECIFICA TIONS Clutching Please see your POLARIS dealer for clutching specifications. RANGER RZR XP 900 Lubrication System W et Sump Driving System T ype Automatic POLAR IS V ariable Transmission Shift T ype Dual Range P/R/N/L/H Gear Reduction - Low 6.45:1 Gear Reduction - Reverse 5.776:1 Gear Reduction - High 3.037:1 Drive Ratio - Front 3.82:[...]

122 SPECIFICA TIONS RANGER RZR XP 4 900 Gross V ehicle W eight 2375 lbs. (1077 kg) Dry W eight 1390 lbs. (630.5 kg) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum W eight Capacity (Payload) 900 lbs. (408 kg) (includin g riders, cargo and accessories) Fuel Capacity 7.25 gal. (27.4 l) Engine Oil Capacity 2.5 qts. (2.4 l) Coolant Capacity 9.7 qts. [...]

123 SPECIFICA TIONS Clutching Please see your POLARIS dealer for clutching specifications. RANGER RZR XP 4 900 Lubrication System W et Sump Driving System T ype Automatic POLAR IS V ariable Transmission Shift T ype Dual Range P/R/N/L/H Gear Reduction - Low 6.45:1 Gear Reduction - Reverse 5.776:1 Gear Reduction - High 3.037:1 Drive Ratio - Front 3.8[...]

124 POLARIS PRODUCTS Part Number Description Engine Lub ricant 2870791 Fogging Oil (12 oz./355 ml Aeroso l) 2876244 PS-4 PLUS Synthetic 4-Cycl e Engine Oil (qt./.95 l) 2876245 PS-4 PLUS Synthetic 4-Cy cle Engine Oil (gal./3.8 l) 2878920 PS-4 Extreme Duty Synthetic 4-Cycle Oil (qt./.95 l) 2878922 PS-4 Extreme Duty Synthetic 4-Cycle Oil (2 qt./1.9 l)[...]

125 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range. See warnings on page 60. Driving at low RPM or ground speed (3-7 MPH/ 5-1 1 km/h) Drive at a higher speed or use low range more frequently . See page[...]

126 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to S t art Engine Backfires Possible Cause Solution Low battery voltage 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 Inspe[...]

127 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly , St alls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs Insp[...]

128 TROUBLESHOOTING Engine Stop s or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel tank vent line or filter Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug W orn or defective spark plug wires See your dealer Incorrect spark p[...]

129 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor char ges for repair or replacement of defective parts which are covered by this warranty . This warr[...]

130 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures th at are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any vehicle th[...]

131 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfe ctions caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; f[...]

132 W ARRANTY HOW TO OBT AIN W ARRANTY 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 W arranty Registration form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that[...]

133 W ARRANTY Exported V ehicles EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Dealer[...]

134 W ARRANTY How to Get Service If Pur chased Fr om A Private Party: If you purchase a POLARIS product fr om a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Y ou must nonetheless warranty register your vehicle under your name and address with a local[...]

135 W ARRANTY U.S.A. EP A Emissions Limited Warranty This emissions limi ted warranty is in add ition to the POLARIS standard limited war - ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-c ertified vehicle is designed, built and equipped so it conforms with applicable U.S. Environme[...]

136 W ARRANTY U.S.A. EP A Emissions Limited Warranty The exclusive remedy for breach of this limi ted warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRAN TY ARE THE ONL Y REMED IES A V AILABLE TO ANY PERSON FOR BREACH OF THIS[...]

137 MAINTENANCE LOG Use the following chart to record periodic maintenance. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

138 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

139 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

140 INDEX A Access Panel Cargo Box . . . . . . . . . . . . . . . . 35 Engine . . . . . . . . . . . . . . . . . . . 35 Oil Tank . . . . . . . . . . . . . . . . . . 35 Accessory Outlets . . . . . . . . . . . . . . 30 Adjustments Hand Hold . . . . . . . . . . . . . . . . 33 Seat . . . . . . . . . . . . . . . . . . . . . 32 Steering Wheel. . . . . . . [...]

141 INDEX E Electromagnet ic Interference . . . . . . 68 Emission Control, Crankcase . . . . . . 68 Emission Control, Exhaust . . . . . . . . 68 Emission Control, Noise . . . . . . . . . . 68 Emissions Limited Warranty . 135-136 Engaging AWD. . . . . . . . . . . . . . . . . 40 Engine Access Pane l . . . . . . . . . . . . . 35 Engine Break-In . . . [...]

142 INDEX I Idle Speed . . . . . . . . . . . . . . . . . . . . 98 Ignition Switch. . . . . . . . . . . . . . . . . 30 Indicator Lamps . . . . . . . . . . . . . . . . 42 Inspection, Axle Nuts . . . . . . . . . . 105 Inspection, Brakes . . . . . . . . . . . . . . 99 Inspection, Pre-Ride . . . . . . . . . . . . 52 Inspection, Steering Wheel . . . . . [...]

143 INDEX R Radiator . . . . . . . . . . . . . . . . . . . . . . . 88 Radiator Coolant Level . . . . . . . . . . . 89 Removing Vehicle from Storage . . 119 Restrictions, Age . . . . . . . . . . . . . . . . 10 Reverse . . . . . . . . . . . . . . . . . . . . . . . 64 Rider Information Center . . . . . . 43-49 Riding Area . . . . . . . . . . . . . . .[...]