Polaris PMS 419 manual

PMS 419 Owner's Manual for Maintenance and Saf ety R ANGE R RZ R R ANGE R R ZR S R ANGE R R ZR 4[...]

W ARNING Read, understand, and follow all of the in structions and safety precautions in this manual and on all product labels. 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 S tate of California to cause cancer , birth defects or othe[...]

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

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1 WELCOME Thank you for pu rchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owne rs. W e proudly prod uce an excit- ing line of utility and recreational product s. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® • Low Emission V ehicles (LEVs) W e believe POLAR[...]

2 POLARIS, THE W A Y OUT , RANGER and RANGER RZR are registered tradem arks of POLARIS Industries Inc. Copyright 2010 POLARIS Sales Inc. All information contained with in this publication is based on the latest product information at the time of publicati on. Due to constant improvements in the design and quality of production components, some mino[...]

3 T ABLE OF CONTENTS Intr oduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Featur es and Controls . . . . . . . . . . . . . . . . . . . . . . . 28 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Emission C[...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y ou r 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 haza rd. W ARNING A W ARNING indicates a hazardous[...]

5 INTRODUCTION Failure to heed the warnings and safety prec autions 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 handles differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly , even during routine maneuver[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er 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 k ey number) and mating it with o ne of your existing keys. The ignition swit[...]

7 SAFETY Equipment Modifications Y our POLARIS vehicle is designed to provide 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, esp ecially those that increase speed or power . This vehicle ma y beco[...]

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

9 SAFETY Safe Riding Gear Eye Pr otection 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 sh ield. POLARIS recommends wearing approved Personal Protective Equipm ent (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su[...]

10 SAFETY Safety W arnings Failure to operate this vehicle properly can result in a collision, loss of control, 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. Operating[...]

11 SAFETY Safety W arnings Failure to Inspect Befor e Op erating Failure to inspect and verify that th e vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehi cle before ea ch use to make sure it' s in safe operating condition. Always follow the in spection and maintenance procedures[...]

12 SAFETY Safety W arnings Carrying Passengers (RZR 4) Never carry a passenger until you have operated this vehicle for at l east two hours and have completed the New Operator Driving Procedu res outlined on pages 56-57. A passenger must always be seated in a passenger seat with seat belt secured. Never carry more than three passengers in a 4-seat [...]

13 SAFETY Safety W arnings 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. In many areas it's illegal to operate vehicles of this type on public streets, roa[...]

14 SAFETY Safety W arnings Physical Control of the V ehicle Removing hands from the steering wheel or hand hold s or removin g feet from the floor while riding increases the ri sk of loss of control and accident or overturn. The operator should always keep both hands on th e steering wheel during operation. Passengers sho uld al ways be seated in a[...]

15 SAFETY Safety W arnings Crossing Hills ides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary . If crossing a hillside is unavoidabl e, always follow proper procedures as described in the owner's manual. See page 61 . S tallin[...]

16 SAFETY Safety W arnings Operating Improperly in Rev erse 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 pr[...]

17 SAFETY Safety W arnings Operating Over Obstacles 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 obstacle[...]

18 SAFETY Safety W arnings Improper Cargo Loading Overloading the vehicle or carryi ng/towing cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Alw ays follow th e instructions in the owner's manual for carrying cargo or pull- ing a trailer . • Ne ver exceed the stated load ca[...]

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. • Alw ays stop the engine when refueling. • Alw ays refuel outdoors or in a well ventilated area. • Re mo v e flammable material containers from the box befo re filli[...]

20 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your p r otec tion. Read and follow the instructions of the labe ls on the vehicle carefully . If any of the labels depicted in this ma nual dif fer from the labels on your vehicle, always read and fo llow the instructions of the labels on the vehicle . If an [...]

21 SAFETY Safety Labels and Locations Tir e Pressur e/Cargo Overload W arning (RZR) W ARNING IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING ca n cause loss of control resulting in SEVERE INJURY OR DEA TH. TIRE PRESSURE IN PSI (KPa): 4X4 - FRONT 8 (55.2) REAR 8 (55.2) MAXIMUM WEIGHT CAP ACITY INCLUD ING DRIVER, P ASSENGER, CARGO AND ACCESSORIES: 4X4 i[...]

22 SAFETY Safety Labels and Locations Cab Frame/Seat Belt W arning W ARNING • AL WA YS WEAR YOUR SEA T BEL T and make sure passenger wears seat belt. • AL WA YS SECURE CAB NETS. • VEHICLE OVERTURN could cause severe inju ry or dea th. Shift Caution Cab Frame/Seat Belt Wa r n i n g Age Wa r n i n g Overturn Wa r n i n g Discretionary Wa r n i [...]

23 SAFETY Safety Labels and Locations Shift Caution CAUTION T o avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place shift in the parked position. APPL Y BRAKE T O ST ART 7174843 Age W arning W ARNING Operating this vehicle if you are under the age of 16 increases your chance of severe inj ury[...]

24 SAFETY Safety Labels and Locations Discretionary W arning (RZR) W ARNING Improper vehicle use can result in SEVERE INJURY or DEA TH NEVER operate: • with out first viewing safety video a nd quick start guide. • wi th more than one passenger . • on h ills steeper than 15 degrees. • on p ublic roads. • on paved surfac es - pa vement may [...]

25 SAFETY Safety Labels and Locations Discretionary W arning (RZR 4) W ARNING Improper vehicle use can resu lt in SEVERE INJURY or DEA TH NEVER operate: • wi thout first viewing safety video a nd quick start guide. • with more than three passengers. • on h ills steeper than 15 degrees. • on p ublic roads. • on paved surfaces - pavement ma[...]

26 SAFETY Safety Labels and Locations Passenger Safety W arning (RZR) 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 an d securely grasp han[...]

27 SAFETY Safety Labels and Locations Passenger Safety W arning (RZR 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 an d securely grasp [...]

28 FEA TURES AND CONTROLS Component Locations Hip Bars Fuel T ank Cap Cargo Box Shifter Front Passenger Hand Hold Cab Nets Rear Passenger Grab Bar Rack Extenders (RZR/ RZR EPS only) Ti e - D o w n Points[...]

29 FEA TURES AND CONTROLS Component Locations Headlights Brush Guard Radiator Steering Wheel Storage Compartment (under hood) Cab Frame[...]

30 FEA TURES AND CONTROLS Component Locations T railer Receiver Hitch Bracket This vehicle is equipped with a recei ver hitch bracket for a trailer hitch. T railer towing equipment is no t supplied with this vehicle. T o avoid in jury and property damage, always heed the warnings and towing capacities outlin ed on pages 66-67. T aillights Receiver [...]

31 FEA TURES AND CONTROLS Rear Service Panel The rear service panel is located behind the seats on the frame of the vehicle. Remove the seats to access the service panel. Remove the ser- vice panel to access serviceable engine components and clutches. Seats Before operating the vehicle, always push down on all seat backs to ensure the latches are s[...]

32 FEA TURES AND CONTROLS S teering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hol d the steering wheel adjustment lever while movin g the st eering wheel upward or down- ward. Release the lever when the steering wheel is at the desired position. Passenger Hand Hold Always adjust the hand hold to a comf[...]

33 FEA TURES AND CONTROLS Hood Remove the hood to access the front storage compartment, the radiator cap and the coolant overflow bottle. 1. T u rn the hood fasteners 1/4 turn. 2. Grasp the up per hood edge and pull upward to disengage the hood from the vehicle. 3. Pivot the hood forward and lift upward to disen- gage the lower hood hooks. 4. Lift [...]

34 FEA TURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right-hand side of the vehicle near the pa ssenger seat. When refueling, always use either leaded or unleaded gaso- line with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with eth- anol content gr eater than 10 per cent, such as E-85 fue l. Remove flam[...]

35 FEA TURES AND CONTROLS Seat Belts 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 t[...]

36 FEA TURES AND CONTROLS Switches Auxiliary Outlet The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a s econd 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 [...]

37 FEA TURES AND CONTROLS Switches Ignition Swi tch The ignition switch is a three-positio n, key-operated switch. Use the ignition switch to start the engine. See page 54 for starting procedures. The key can be re moved from the switch when it is in the OF F position. Headlight Switch Use the headlight switch to turn the lights on and off and to c[...]

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 start- ing the engine. Thr ottle 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 start- ing the engi[...]

40 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The All Whee l Drive system is controlled by the A WD switch. When the switc h is on 2X4, the veh i- cle is in two-wheel drive at all times. When the switch is on A WD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on. When in A W D, the dema nd driv[...]

41 FEA TURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage components. W ash the vehicle b y 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 not use alcohol to clean the instrument cluster . Do not allo[...]

42 FEA TURES AND CONTROLS Instrument Cluster Indicator Lamps 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 illumin ates to indicate an overheated engine. If the indicator flashes, the overhe[...]

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 ma y have shut of f to protect the ele[...]

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 ment clears, a low fuel warning is activated. All segments including th e 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 of f. W ait 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 fl ashes. 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 rip Meter Mode The trip meter records the distance traveled by the vehicle if res et 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 engine operation equal the prog rammed service interval setting, the wr ench icon will flash for 5 seconds each time the engine is started. When this featur e is enabled, it provides a convenient reminder to perform routine maintena[...]

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 collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual. V ehicle Break-in Period The break-in pe riod for your new POLARIS ve hicle is the fir[...]

51 OPERA TION V ehicle Break-in Period Engine and Drivetrain Br eak-in 1. Fill the fuel tank with gasoline. See page 34. 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 Driv ing Proce[...]

52 OPERA TION Pre-Ride Inspection Failure to inspect and verify that th e 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 En sure proper operation 39 99 Brake fluid E[...]

53 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before operatin g this vehicle. 2. Do not allow anyone under 16 years of age or without a valid driver ’ s license to operate this vehicle. 3. Never operate with a passenger under the age of 12. Never carry more one passenger in a 2-sea t vehicle. Never carry more[...]

54 OPERA TION S tarting the Engine 1. Position the vehicle on a level su rface 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 th e throttle pedal while start ing the engine. 5. T u rn the ignition key past [...]

55 OPERA TION Parking the V ehicle 1. Stop the vehicle on a level surface. When parkin g inside a garage or other structure, be sure that the st ructure is well ventilat ed and that the vehicle is not close to any sour ce of flame or sparks, including any appliance with pilot lights. 2. Place the transmission in P ARK. 3. T u rn the engine off. 4. [...]

56 OPERA TION New Operator Driv ing Pr ocedures 1. Read and understand the ow ner' s manual and all warning and instruction labels before operating this vehicle. 2. Perform the pre-ride inspection. See page 52. 3. W ea r an approved helmet that fits properly and eye protection (gog- gles or face shield). 4. Do not carry a passenger until you h[...]

57 OPERA TION New Operator Driv ing Pr ocedures 1 1. Apply the brakes and shift into low gear . 12. Check your surroun dings and de termine your path of travel. 13. Keeping both han ds on the steer ing wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 14. Drive slowly at first. On leve l surfaces, prac[...]

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 passengers in a 4-seat vehicle. Additional passengers can a f fect the operator ’ s ability to ste[...]

59 OPERA TION Driving on Slippery Surfaces Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When opera ting on slippery surfaces such as ice or loose gravel, reduce speed and use extra cauti on to re duce 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 care fully before ascending a hill. 2. A voi d steep hills (15 ° maximum). If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending. 3. Drive straight uphill. 4. Never climb hills with excessive ly slippery or l[...]

61 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a hill is unavoidable , follow these precautions: 1. Engage all-wheel drive. 2. Drive slowly and use extre me cautio[...]

62 OPERA TION Driving Thr ough W ater Y our vehicle can operate through water with a maximum recommended de pth 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 bank s ha ve grad- ual inclines.[...]

63 OPERA TION Driving Over Obstacles Follow these precautions whe n 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 an d use extra cau tion when operating on unfamilia[...]

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

65 OPERA TION Parking on an Incline A rolling vehicle can result in seri ous 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 u rn the engine off. 3. Block the rear wheels on the downh ill side, or park the vehicle in a sidehill position instead.[...]

66 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo improperly ca n alter vehicle handling and may cause loss of control or brake instability . Always follow the s e 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 HAUL[...]

67 OPERA TION Hauling Cargo Y our POLARIS vehicle has been d esigned to carry or tow specific capacities. Reduce speed and allow a greater distance fo r braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrai n, reduce both speed and car go. Exercise caution if the carg[...]

68 EMISSION CONTROL SYSTEMS Noise Emission Contr ol 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 arrestor that was tested and quali[...]

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 periodic main ten a nc e ch art. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the[...]

70 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may af fect emissions.) n Have an authorized POLARIS dealer perform these services. W ARNING! Improperl[...]

71 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedu res more often fo r vehicles subjected to severe use. E Emission-Related Service n Have an authorized POLARIS d ealer perform these se rvices. Item Main tenance Interval (whichever comes first) Remarks Hours Ca[...]

72 MAINTENANCE Periodic Maintenance Chart X Perform these procedu res more often fo r vehicles subjected to severe use. E Emission-Related Service n Have an authorized POLARIS d e aler perform these ser vices. Item Main tenance Interval (whichever comes first) Remarks Hours Cal endar Miles (Km) X E Engine breather filter (if equi pped) 25 H Monthly[...]

73 MAINTENANCE Periodic Maintenance Chart X Perform these procedu res more often fo r vehicles subjected to severe use. E Emission-Related Service n Have an authorized POLARIS dealer perform these services Item Main tenance Interval (whichever comes first) Remarks Hours Cal endar Miles (Km) X Radiator (if equipped ) 100 H 12 M 1000 (1600) Inspect; [...]

74 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 6 9, or more often under severe use, such as wet or dusty cond itions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil PS-4[...]

75 MAINTENANCE Lubrication Recommendations RZR S/RZR 4 Control Arm Pivo t Bushings RZR S/RZR 4 Control Arm Pivot Bushings RZR 4 Stabilizer Bar Bushings RZR Stabilizer Bar Bushings RZR Control Arm Pivot Bushings[...]

76 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 PLUS Synthetic engine oil. W ARNING! V ehicle operation with insufficient , deteriorate d, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury . Always perform the maintenance p rocedures as outlined in [...]

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 The oil dipstick and fill tube is located on the engine, be hind the passenger seat (behind the right rear passenger seat on RZR 4 models). 1. Position the vehi[...]

78 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 69. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Place the transmission in[...]

79 MAINTENANCE Engine Oil Oil and Filter Change 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crank- case. 10. Lubricate the o-ring on the new filte r with a film of fresh engine oil. Check to make sure the o- ring is in good condition. 1 1[...]

80 MAINTENANCE Gearcases T ransfer Case Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 fo r recommended lubricants, capacities and torque specifications. Fluid Check The fill plug and level check plug ar e located on the lef[...]

81 MAINTENANCE Gearcases T ransfer Case Fluid Change The drain plug is located on the bottom of the transfer case. 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 t[...]

82 MAINTENANCE Gearcases T ransmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 fo r recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the left side o[...]

83 MAINTENANCE Gearcases T ransmission (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. [...]

84 MAINTENANCE Gearcases Demand Drive Unit (Front Gear case) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 fo r recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the botto[...]

85 MAINTENANCE Gearcases Rear Gearcase Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 fo r recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the right side of the rear gear[...]

86 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operatio n of components. See page 126 for the p art numbers of POLARIS products. Spark Plugs Spark Plug Gap/T orque NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Refer to the [...]

87 MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove both seats. 2. Remove the rear service panel. See page 31. 3. Remove the spark plug cap. 4. Using the spark plu g wrench provided in the tool kit, remove the plug by rot ating it counter- clockwise. 5. Reverse the procedure for spark plug installation. T orque to specification.[...]

88 MAINTENANCE Fuses If the engine stops or will not start, if the power steering stops working (if equipped), or i f you experience other electrical failures, a fuse may need replacement. Locate and correct any short c ircuits that may have caused the blown fuse, then replace the fuse. Fuse Feature Supported 20A Lights: Headlights, T aillights 10A[...]

89 MAINTENANCE Fuses The fuse box is located above the power steering unit. Spare fuses are provided in the fuse box. 1. From the left side of the vehic le, reach in and 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 bo x cover . 4. Remove the [...]

90 MAINTENANCE Cooling System Operation The engine coolant level is controlled or mainta ined by the recovery system. The recovery system componen ts are the ove rflow bottle, radia- tor filler neck, radiator pr essure cap and connecting hose. As coolant operating temperature increases, the expa nding (hea ted) excess coolant is forced out of the r[...]

91 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 69. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiat or or behind the cooling fan. Inter- [...]

92 MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart begin- ning on page 69. Maintain the coolant level between the minimum an d ma xi- mum marks on the bottle (when the fluid is co ol). 1. Position the vehicle on a level surface. 2. Remove the hood. See page 33.[...]

93 MAINTENANCE POLARIS V ariable T ran smission (PVT) System 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 hig h speed. The PVT system has been precision balanced. Any modification will cau[...]

94 MAINTENANCE POLARIS V ariable T ran smission (PVT) System PVT Drying Before washing the vehicle, locate the PVT outlet duct un der the right rear wheel well. A void spraying wate r directly toward the duct when washing the vehicle from the rear . See page 1 16. There may be some instances when wate r is accidently ingested into the PVT system. U[...]

95 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginn ing on page 69. 1. Access the air box from behind the left rear wheel. 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover around the entire edge. 3. Remove the air filter . 4[...]

96 MAINTENANCE Spark Arrestor Failure to heed the following warnings whil e servicing the spark arrestor 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 su[...]

97 MAINTENANCE Thr ottle System Failure to check or maintain proper opera tion of the throttle system can result i n an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for servi[...]

98 MAINTENANCE Thr ottle System Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your POLARIS dealer for adjustment. Throttle Fr eeplay Adjustment 1. Remove both seats. Remove the rear service panel. See page 31. 2. Locate the throttle cable adjuster at the throttle body . 3.[...]

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. W hen applied, the brake pedal should feel firm. Any sponginess would indi cate a possible fluid leak or low brake fluid level,[...]

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 on ly . See page 12 6 for the part num- bers of POLARIS products. W ARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygro[...]

101 MAINTENANCE Brakes Brake Inspection 1. Check the br ak e sy s t em for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear , damage and looseness. 4. Inspect the brake pad wear surface for excessive wear . 5. Change pads wh en worn to 3/64" (1 mm). S teering Wheel Inspection Chec[...]

102 MAINTENANCE Suspension Settings (RZR and RZR S Base Models) The front and rear suspensions are preload adju stable, with five settings on each axle. The suspensions are set on the lowest (softest) setting at the factory . This setting is appropriate for near ly all riding conditions. Since the vehicle is equipped with full skid pl ates, suspens[...]

103 MAINTENANCE Suspension Settings (RZR S Pr emium Models and RZR 4) Front/Rear Spring Pr eload The factory setting is appropriate for nearly all riding conditions. Since th e vehicle is equipped with full skid plates, ad justment is not necessary . If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads[...]

104 MAINTENANCE Suspension Settings (RZR S Pr emium Models and RZR 4) Front/Rear Shock Compr ession Use a flat -blade screwdriver to make damping adjustments. The compress ion damping clicker is located on top of the sho ck reservoir , under the rear fender . When the ad juster screw is turned clockwise until it stops, the damping is in the fully c[...]

105 MAINTENANCE Ti res 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 adversely[...]

106 MAINTENANCE Ti res 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 Installation 1. Place the transmission[...]

107 MAINTENANCE Lights Poor lighting while driving can result in severe injury or death. Head- light and taill ight lenses become dirty duri ng normal operation. W ash the headlights frequently to maintain lighting quality . When servicing a halog en lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a h[...]

108 MAINTENANCE Lights Headlight High Beam Adjustment 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in P ARK. 2. Measure the distance from the floo r to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the engine. T[...]

109 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each rid e. 1. T urn the ignition switch to the ON position. 2. Apply the brakes. The brake light should co me on after about 10 mm (0.4 in.) of pedal travel. If th e light doesn't come on, check the bulb. V ehicle Imme[...]

110 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burn s can result from contact with skin, eyes or clothing. Antidote: External : Flush with water . Internal : Drink large qua ntities of wate r or milk. Follow with milk of magnesia, beaten egg, or ve getable oil. Call physician immediately . Eyes : Flush [...]

111 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosion and cause serious injury or death. When removing the battery , alw ays disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery Removal 1. Remove the driver ’ s seat.[...]

112 MAINTENANCE Battery Battery Installation 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 charging instructio ns on page 1 14 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in [...]

113 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to maintain a full char ge. See page 1 [...]

114 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electrolyt e du ring charging. See page 1 1 1. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.[...]

115 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. St ate of Charge V olt age Action Charge Time (Using constant current charger @ standa rd amps specifie d on to p o f ba t t er y) 100% 12.8-13.0 volts None, che ck at 3 mos. from date of manufacture None requir[...]

116 MAINTENANCE Cleaning and S torage W ashing the V ehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. Before washing the vehicle, locate the PVT outlet duct under the right rear wheel well. A void spraying water directly toward the duct when washing the vehicle fro[...]

117 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and labels. A void direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator • T ra nsmission seals •B[...]

118 MAINTENANCE Cleaning and S torage Chrome Wheel Car e (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “lik e new” appearance for many years. Tip : Chrome wh ee l s ex posed to road salt (or sa l t in th e a i r in coa st al areas) are more susceptible to corrosion if not properly[...]

119 MAINTENANCE Cleaning and S torage S torage Tips NOTICE: S tarting the engin e during the storage period will di sturb 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 16. S tabilize the[...]

120 MAINTENANCE Cleaning and S torage S torage Tips Inspect and Lubricate Inspect all cables and lubrica te all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 69. Fog the En gine 1. T re at the fuel system with PO LARIS Carbon Cl ean. Follow the instructions on the container . Star t the engine. Allow it to [...]

121 MAINTENANCE Cleaning and S torage Removal from S torage 1. Check the battery electrolyte leve l and char ge the battery if neces- sary . Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way . 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4.[...]

122 SPECIFICA TIONS RANGER RZR / RZR S Gross V ehicle W eight 1727 lbs. (783 kg) (RZR) 1782 lbs. (808 kg) (RZR S) Dry W eight 945 lbs. (429 kg) (RZR) 961 lbs. (436 kg) (RZR EPS) 1000 lbs. (454 kg) (RZR S) Rear Cargo Box Capacity 3 00 lbs. (136 kg) Maximum W eight Capacity (Payload) 740 lbs. (336.4 kg) (riders/cargo/accessor ies/ trailer tongue weig[...]

123 SPECIFICA TIONS Clutching RANGER RZR / RZR S Lubrication System W et Sump Engine Oil 2W - 50 Driving System T y pe Automati c POLARIS V ariable T ransmission Shift T ype Dual Range P/R/N/L/H Gear Reduction - Low 8 .71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High 3.14:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 T ire Size [...]

124 SPECIFICA TIONS RANGER RZR 4 Gross V ehicle W eight 2206 lbs. (1000 kg) Dry W eight 1255 lbs. (569 kg) (RZR 4) 1271 lbs. (576.5 kg) (RZR 4 EPS) Rear Cargo Box Capacity 3 00 lbs. (136 kg) Maximum W eight Capacity (Payload) 900 lbs. (408.2 kg) (riders/cargo/accessor ies/ trailer tongue weight) Receiver Hitch T ongue Capacity 150 lbs. (68 kg) Rece[...]

125 SPECIFICA TIONS Clutching RANGER RZR 4 Lubrication System W et Sump Engine Oil 2W - 50 Driving System T y pe Automati c POLARIS V ariable T ransmission Shift T ype Dual Range P/R/N/L/H Gear Reduction - Low 8 .71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High 3.14:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 T ire Size - Fron[...]

126 POLARIS PRODUCTS Part Number Description Engine Lubr icant 2870791 Fogging Oil (12 oz./35 5 ml Aerosol) 2876244 PS-4 PLUS Synthetic Engine Oil (qt./.95 l) 2876245 PS-4 PLUS Syntheti c Engine Oil (gal./3.8 l) Gearcase / T ransmission Lubricants 2878068 AGL PLUS T ransmissi on Fl uid (qt./.95 l) 2878069 AGL PLUS T ransmi ssi on Fl uid (gal./3.8 l[...]

127 TROUBLESHOOTING Drive Belt W ear/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 wa rnings on page 60. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher sp eed or us e low range more frequently . See page 38. Ins[...]

128 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to S tart Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Loose electronic control box connections Insp[...]

129 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irre gularly , S talls or Misfires Possible Cause Solution Poor quality or low octane fu el 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 In[...]

130 TROUBLESHOOTING Engine S tops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Insp ect, clean and/or replace spark plug W orn or defective spark plug wires See your dealer Incorrect spark plug gap or hea[...]

131 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 April 22, 2010 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirem ents applicable to off-ro ad all-terrai n vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN [...]

132 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 workmans hip. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty . This war[...]

133 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REME DIES W arranty applies to the product only and does not allow for cov erage of personal loss. Some items are c onsidered “consumable,” m e aning they are considered part of normal maintenance or part of completing an effec tive repair . The following items are excluded from warranty coverage i[...]

134 W ARRANTY HOW T O OBT AIN W ARRANTY SER VICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warra nty service you must present your copy of the W arranty Registration form to the dealer . (THE COST OF TRA NSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY) . POLARIS suggests[...]

135 W ARRANTY Exported V ehicles EXCEP T 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. Deale[...]

136 W ARRANTY How to Get Service If Pur chased Fr om A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was origin ally purchased, all wa rranty cover age will be denied. Y ou must nonetheless warranty re gister your vehicle under your name and address with a lo[...]

137 W ARRANTY U.S.A. EP A Emissions Limited W arranty This emissions li mited warranty is in addition to the POLARIS sta ndard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this e missions-certified vehicl e is designed, built and equi pped so it conforms with applicable U.S. Environ[...]

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

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

140 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / COMMENTS[...]

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

142 INDEX A Accessory Outlet . . . . . . . . . . . . . . . . . . . 36 Adjustment Hand Hold . . . . . . . . . . . . . . . . . . . . 32 Seat . . . . . . . . . . . . . . . . . . . . . . . . . 31 Steering Wheel . . . . . . . . . . . . . . . . 32 Adjustment, Headligh t Beam . . . . . . . . . 108 Adjustment, Thrott le Freeplay . . . . . . . . . 98 Air Fi[...]

143 INDEX F Fluid Demand Drive . . . . . . . . . . . . . . . . . 8 4 Front Gearcase . . . . . . . . . . . . . . . . . 8 4 Main Gearcase . . . . . . . . . . . . . . 8 2-83 Rear Gearcase . . . . . . . . . . . . . . . . . 85 Transfer Case . . . . . . . . . . . . . . . 80-8 1 Transmission . . . . . . . . . . . . . . . 82 -83 Fluid Levels During Storage[...]

144 INDEX P Parking on an I ncline . . . . . . . . . . . . . . . . 65 Parking the Veh icle . . . . . . . . . . . . . . . . . 55 Passenger Hand Hold Adjustm ent . . . . . . 32 Periodic Maintena nce Chart . . . . . . . . . 69-73 Plug Condition . . . . . . . . . . . . . . . . . . . . . 87 Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . 86[...]