Polaris RZR XP TURBO S 2019 Owner's Manual For Maintenance And Safety
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Polaris RZR XP TURBO S 2019 Owner's Manual For Maintenance And Safety

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RZR XP® TURBO S
RZR XP® 4 TURBO S
RZR XP® TURBO S VELOCITY
RZR XP® 4 TURBO S VELOCITY
Owner's Manual
For Maintenance and Safety

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Summary of Contents for Polaris RZR XP TURBO S 2019

  • Page 1 RZR XP® TURBO S RZR XP® 4 TURBO S RZR XP® TURBO S VELOCITY RZR XP® 4 TURBO S VELOCITY Owner's Manual For Maintenance and Safety...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 2019 RZR Owner’s Manual XP Turbo S XP 4 Turbo S XP Turbo S Velocity XP 4 Turbo S Velocity...
  • Page 4 POLARIS® and RZR® are trademarks of POLARIS Industries Inc. Copyright 2018 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Introduction

    WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.

  • Page 6: Safety

    SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 7: Table Of Contents

    Specifications ....189 Polaris Products ....193 Troubleshooting .
  • Page 9 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.

  • Page 10: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 11: Safety Training

    SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course.

  • Page 12: Safe Riding Gear

    Protective gear reduces the chance of injury. HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 13 SAFETY BOOTS Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. CLOTHING Wear long sleeves and long pants to protect arms and legs. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area.
  • Page 14 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. PROPER USE WARNING...
  • Page 15 SAFETY DRIVE RESPONSIBLY WARNING WARNING: Drive Responsibly Rollovers have caused severe injuries and death, even on flat, open areas. Avoid loss of control and rollovers: • Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing, and never do donuts. • Slow down before entering a turn. •...
  • Page 16 SAFETY LOAD / PASSENGER / TIRE PRESSURE WARNING The Load / Passenger / Tire Pressure Warning is located at the rear of the vehicle in the cargo box. • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
  • Page 17 Belt Debris Warning AIR BOX CAUTION CAUTION: Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube.
  • Page 18 SAFETY ROOF WARNING NOTE This page only applies to RZR XP 4 Turbo S vehicles produced prior to January 7th, 2019. To identify your vehicle’s build date, reference the vehicle identification sticker as shown on page 8 or the vehicle purchase documents. WARNING DO NOT REMOVE ROOF Roof is part of Roll Over Protective Structure (ROPS)

  • Page 19: General Alert

    Avoid exhibition driving. INTAKE ALERT Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing fi lter ensure there is no dirt or debris in the clean side of the intake tube.
  • Page 20 SAFETY FUEL / LOAD / PASSENGER / TIRE PRESSURE ALERTS RZR XP Turbo S / RZR XP Turbo S Velocity Never carry passengers in cargo box. Passengers can be thrown off. This can cause serious injury or death. Read owner’s manual. Never carry or transport fuel on this vehicle.

  • Page 21: Safety Warnings

    SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.

  • Page 22: Using Alcohol Or Drugs

    SAFETY USING ALCOHOL OR DRUGS Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating this vehicle. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

  • Page 23: Protective Apparel

    SAFETY PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and all passengers must always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.
  • Page 24 SAFETY CARRYING MULTIPLE PASSENGERS (RZR 4-SEAT) Never carry a passenger until you have operated this vehicle for at least two hours and have completed the steps in the New Operator Driving Procedures section. A passenger must always be seated in a passenger seat with seat belt secured.

  • Page 25: Operating On Pavement

    SAFETY PASSENGERS IN THE CARGO BOX Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box. A passenger must always be seated in a passenger seat with seat belt secured.

  • Page 26: Turning Improperly

    SAFETY TURNING IMPROPERLY Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.

  • Page 27: Stalling While Climbing A Hill

    SAFETY STALLING WHILE CLIMBING A HILL Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped.

  • Page 28: Skidding Or Sliding

    SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.

  • Page 29: Operating A Damaged Vehicle

    SAFETY OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your passengers, and your cargo, together with any other vehicles in your party.

  • Page 30: Improper Cargo Loading

    SAFETY IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See the Hauling Cargo section for details.

  • Page 31: Hot Exhaust Systems

    EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 33: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS NOTE Turbo S feature set shown below. Cargo Box ROPS Frame Cab Door Fuel Tank Cap Radiators STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward.

  • Page 34: Ignition Switch

    FEATURES AND CONTROLS SWITCHES IGNITION SWITCH NOTE Turbo S feature set shown. The ignition switch is a four-position, key-operated switch. Use the ignition switch to start the engine. See page 84 for starting procedures. POSITION FUNCTION The engine is off. Electrical circuits are off, except accessory 12V.

  • Page 35: Headlight Switch

    FEATURES AND CONTROLS HEADLIGHT SWITCH The ignition switch key must be in the ON/RUN position to operate the headlights. Press the top of the switch to place the headlights on high beam. Move the switch to the center position to place the headlights on low beam.

  • Page 36: Operation

    EPS has shut down. If the light remains on after starting the engine, the EPS system is inoperative. See your POLARIS dealer, or another qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit...
  • Page 37 FEATURES AND CONTROLS SUSPENSION MODE SWITCH (IF EQUIPPED) The RZR XP Turbo S and RZR XP 4 Turbo S are equipped with a suspension control mode switch that allows you to change the suspension control mode of your DYNAMIX™ Active Suspension system on-the-fly.

  • Page 38: Seat Removal

    FEATURES AND CONTROLS SEATS Before operating the vehicle, always push down on all seat backs to ensure the latches are secure. SEAT ADJUSTMENTS On seats equipped with an adjustment lever under the front edge of the seat, pull the lever to the left. Slide the seat forward or rearward to the desired position.
  • Page 39 FEATURES AND CONTROLS PASSENGER HAND HOLD Always adjust the hand hold to a comfortable position for your passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments. 1. Remove the retainer from the end of the adjustment pin 2.
  • Page 40 3. Pivot the hood forward and lift upward to disengage the lower hood hooks. 4. Lift the hood away from the vehicle. TURBO SYSTEM Do not attempt to perform maintenance or repairs to any component of the turbo system. Please see your POLARIS dealer or other qualified service person for this service.

  • Page 41: Fuel Recommendations

    FEATURES AND CONTROLS FUEL RECOMMENDATIONS • Use ONLY 91 octane (or higher) unleaded fuel (minimum pump octane number of 91 R+M/2) • Do not use any fuel lower than 91 octane • Do not use fuel containing more than 10% ethanol (including E85)

  • Page 42: Fuel Level

    FEATURES AND CONTROLS FUEL LEVEL The fuel tank filler cap is located on the right side of the vehicle near the passenger seat. NOTE Turbo S feature set shown. The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1/8th tank.

  • Page 43: Seat Belt Inspection

    FEATURES AND CONTROLS SEAT BELTS This POLARIS vehicle is equipped with seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured.
  • Page 44 Always make sure all cab doors are closed and latched when riding in this vehicle. Always inspect doors and latches for wear and damage before each use of the vehicle. Promptly replace any worn or damaged parts with new parts available from your authorized POLARIS dealer or qualified person.

  • Page 45: Gear Selector

    Turbo S model shown in image. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.

  • Page 46: Brake Pedal

    FEATURES AND CONTROLS USING LOW RANGE Always shift into low gear for any of the following conditions: • Operating in rough terrain or over obstacles • Loading the vehicle onto a trailer BRAKE AND THROTTLE PEDALS BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle.
  • Page 47 FEATURES AND CONTROLS ROLLOVER PROTECTIVE STRUCTURE (ROPS) NOTE This page applies to all 2019 RZR XP Turbo S, RZR XP Turbo S Velocity, and RZR XP 4 Turbo S Velocity vehicles, and RZR XP 4 Turbo S vehicles if those vehicles were produced after January 7th, 2019.
  • Page 48 FEATURES AND CONTROLS ROLLOVER PROTECTIVE STRUCTURE (ROPS) NOTE This page only applies to RZR XP 4 Turbo S vehicles produced prior to January 7th, 2019. To identify your vehicle’s build date, reference the vehicle identification sticker as shown on page 8 or the vehicle purchase documents. WARNING Never make modifications to the vehicle’s ROPS structure.

  • Page 49: Engaging Awd

    FEATURES AND CONTROLS ALL WHEEL DRIVE (AWD) SYSTEM The All Wheel Drive system is controlled by the AWD switch. Once the vehicle is in gear, the switch is set to one of two modes. When the switch is on 2X4 , the vehicle is in two-wheel drive at all times.

  • Page 50: Instrument Cluster

    FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.
  • Page 51 FEATURES AND CONTROLS SPEEDOMETER The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). TACHOMETER The tachometer displays engine speed in revolutions per minute (RPM). MODE AND TOGGLE BUTTONS Press and hold the MODE button to enter or exit the settings menu.

  • Page 52: Indicator Lamps

    ON position. If the light remains on, the EPS system is inoperative. See your EPS Warning POLARIS dealer, or another qualified person, (if equipped) as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

  • Page 53: Rider Information Center

    Service A flashing wrench symbol alerts the operator that the preset Indicator service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 56 for resetting instructions. Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank.
  • Page 54 FEATURES AND CONTROLS MODE INFORMATION DISPLAYS The rider information center contains three areas that display mode information. Description Area 1 Modes Engine Temperature Temperature of engine coolant Vehicle Speed Speed of vehicle Tachometer Engine speed (RPM) Description Area 2 Modes Odometer The odometer records and displays the distance traveled by the vehicle.
  • Page 55 FEATURES AND CONTROLS ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays. See the Mode Information Displays section for details. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds.
  • Page 56 FEATURES AND CONTROLS BACKLIGHT BRIGHTNESS The information center backlight can be set to either blue or red. 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the “BL LEVEL” option. Press MODE to select.
  • Page 57 FEATURES AND CONTROLS DISPLAY UNITS (STANDARD/METRIC) 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the desired “UNITS” option (distance, temperature or volume). Press MODE to select. 3. Press either toggle button to cycle to the desired setting. 4.

  • Page 58: Programmable Service Interval

    FEATURES AND CONTROLS PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory. As hours of engine operation increase, the counter decreases. The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset.
  • Page 59 FEATURES AND CONTROLS ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.
  • Page 60 FEATURES AND CONTROLS DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • Page 61 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Data Valid But Above Normal Vehicle Speed Sensor Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source...
  • Page 62 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Manifold Absolute Data Erratic, Intermittent Or Pressure Sensor Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Mechanical System Not Responding Or Out Of Adjustment Abnormal Rate Of Change Intake Air Data Erratic, Intermittent Or...
  • Page 63 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Engine Temperature Data Valid But Above Normal Sensor Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Data Valid But Above Normal Operating Range - Least Severe...
  • Page 64 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION System Power Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operating Range - Moderately...
  • Page 65 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Gear Sensor Signal Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Update Rate ECU Memory Bad Intelligent Device Or Component Out Of Calibration Calibration...
  • Page 66 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 1268 Ignition Coil Primary Voltage Above Normal, Or Driver 1 (Front) Shorted To High Source (MAG) Voltage Below Normal, Or 1268 Shorted To Low Source Current Below Normal Or Open 1268 Circuit Fuel Pump Driver Voltage Above Normal, Or 1347 Circuit...
  • Page 67 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Data Valid But Above Normal 3597 ECU Output Supply Voltage 1 Operational Range - Most Severe Level Data Valid But Below Normal 3597 Operational Range - Most Severe Level 3597 Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or 3597...
  • Page 68 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Data Valid But Above Normal 3598 ECU Output Supply Voltage 2 Operational Range - Most Severe Level Data Valid But Below Normal 3598 Operational Range - Most Severe Level 3598 Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or 3598...
  • Page 69 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 65613 ETC Accelerator Data Erratic, Intermittent Or Position Sensor Incorrect Outputs 1 & 2 Correlation Throttle Position Data Valid But Above Normal 520198 Sensor 2 Operational Range - Most Severe Level Data Valid But Below Normal 520198 Operational Range - Most Severe Level...
  • Page 70 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 520209 Oxygen Sensor Data Erratic, Intermittent Or Heater 1 Incorrect Voltage Above Normal, Or 520209 Shorted To High Source Voltage Below Normal, Or 520209 Shorted To Low Source Current Below Normal Or Open 520209 Circuit Accelerator...
  • Page 71 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Throttle Body Condition Exists 520280 Control - Limp Home Position Check Failed Throttle Body Condition Exists 520281 Control - Mechanical Stop Adaptation Failure Throttle Body Condition Exists 520282 Control - Repeated Adaptation Failed Throttle Body Data Erratic, Intermittent Or 520283...
  • Page 72 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION ECU ADC Fault - No Condition Exists 520306 Load ECU ADC Fault - Condition Exists 520307 Voltage Accelerator Sensor Condition Exists 520308 Sync Fault - Sensor Diff Exceeds Limit ECU Fault - ICO Condition Exists 520309 ECU Fault -...
  • Page 73 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPAS Module Steering Over Current Above Normal Or 520221 Current Shut Down Grounded Circuit 520222 Steering Excessive Current Above Normal Or Current Error Grounded Circuit Steering Torque Condition Exists 520223 Partial Failure Steering Torque Full Condition Exists 520224 Failure...
  • Page 74 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Steering Torque Full Torque Sensor Out of Range 520223 Failure Torque Sensor Linearity Error 520224 EPS CAN No RX Message for {{cal 520226 Communications parameter}} seconds Receive Error Vehicle Speed Vehicle Speed Too High Vehicle Speed Implausible Received Vehicle Speed has Errors...
  • Page 75 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Position Encoder Loss of SPI Communication 520228 Error Encoder Variance Error EPS Software Error Manufacturing CRC Error 520229 Boot Count Error ICS Communication Loss of CAN between EPS and 520230 Instrument Cluster EPAS Power Save 5 minute time out 520231 ECU Memory...
  • Page 76 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Suspension Control Module Vehicle Speed Data Drifted High Sensor Data Drifted Low Transmission Data Erratic, Intermittent Or Requested Range Incorrect Data 516098 Suspension Mode Data Erratic, Intermittent Or Switch Input (Turbo Incorrect S only) Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or...
  • Page 77 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 516110 Shock Valve Power Voltage Above Normal, Or Supply Relay Driver Shorted To High Source (Turbo S only) Voltage Below Normal, Or Shorted To Low Source Absolute Shock Root Cause Not Known 516111 Current Error - Front Left (Turbo S only) Absolute Shock...
  • Page 78 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Abnormal Update Rate 516116 CAN Message PGN 65382 CAN Message PGN Abnormal Update Rate 516117 65396 CAN Message PGN Abnormal Update Rate 516118 65314 SW Version & HW Data Erratic, Intermittent Or 516119 Version Mismatch Incorrect CAN Message PGN...
  • Page 79 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 516126 System Voltage Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal...
  • Page 81 VEHICLE BREAK-IN PERIOD The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. Clutch and drive belt break-in periods vary depending on operating conditions.
  • Page 82 OPERATION ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with the recommended fuel. See the Refueling section for details. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See the Oil Check section for details. Add the recommended oil as needed to maintain the oil level in the safe operating range.
  • Page 83 OPERATION PRE-RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. ITEM REMARKS Brake system/pedal Ensure proper operation...
  • Page 84 OPERATION ITEM REMARKS Seat Belts Check length of belt for damage, page 41 check latches for proper operation Cab Doors Check doors and latches for wear page 21 or damage. Exhaust Inspect spark arrester and clean if page 164 needed after riding through water and/or mud.

  • Page 85: Safe Operation Practices

    4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

  • Page 86: Starting The Engine

    OPERATION STARTING THE ENGINE NOTICE Do not apply throttle during or immediately after starting a turbo model. After starting the engine, wait 10 seconds to allow engine oil to circulate and lubricate the engine and turbo system. 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2.

  • Page 87: Parking The Vehicle

    Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
  • Page 88 OPERATION NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course. Hands-on training is also available through ROHVA.

  • Page 89: Trail Etiquette

    OPERATION TRAIL ETIQUETTE Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

  • Page 90: Driving With Passengers

    OPERATION DRIVING WITH PASSENGERS 1. Complete the steps in the New Operator Driving Procedures section. 2. Perform the pre-ride inspection. 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 affect the operator’s ability to steer and operate the controls.

  • Page 91: Driving On Slippery Surfaces

    OPERATION DRIVING ON SLIPPERY SURFACES When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1. Slow down before entering slippery areas. 2.

  • Page 92: Driving Uphill

    OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. Never drive on hills with excessively slippery or loose surfaces. 2. Avoid excessively steep hills. If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending.
  • Page 93 OPERATION DRIVING ON A SIDEHILL (SIDEHILLING) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1.

  • Page 94: Driving Downhill

    OPERATION DRIVING DOWNHILL Whenever descending a hill, follow these precautions: 1. Avoid excessively steep hills. 2. Slow down. Never travel down a hill at high speed. 3. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces. 4.

  • Page 95: Driving Through Water

    If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 178, and take the vehicle in for service at the first opportunity.

  • Page 96: Driving Over Obstacles

    OPERATION DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.

  • Page 97: Driving In Reverse

    OPERATION 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.

  • Page 98: Parking On An Incline

    OPERATION PARKING ON AN INCLINE A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in PARK. NOTE After a ride, allow the engine to idle for 30 seconds before stopping the engine. This will allow the turbo system to cool down.

  • Page 99: Hauling Cargo

    OPERATION HAULING CARGO WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle.

  • Page 100: Belt Life

    10 MPH (16 km/h) while cornering or while ascending or descending a hill. Your POLARIS vehicle has been designed to carry a specific capacity. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo.
  • Page 101 OPERATION TOWING WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. The tow loop on the rear of the vehicle is provided for recovery use ONLY. Tow a vehicle ONLY of equal or lesser size and weight. If preferred, the tow loop on the front of the vehicle is provided for recovery use ONLY as well.
  • Page 102 OPERATION TOWING A RZR Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See the Transporting the Vehicle section for details. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral.
  • Page 103 WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 104 WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

  • Page 105: Winch Operation

    WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 106 WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
  • Page 107 INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle.
  • Page 108 WINCH GUIDE b. Lay the damper on top of the mid-point of the winch cable length that is spooled out. c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
  • Page 109 WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 110: Winch Cable Care

    Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
  • Page 111 WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 112: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

  • Page 113: Emission Control Systems

    OPERATION ON PUBLIC LANDS IN THE U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 115: Maintenance

    Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your POLARIS dealer or other authorized person can assist.
  • Page 116 Spark Arrestor Otherwise, clean at 2000 mile (3200 km) mark. XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 117 Inspect; clean; replace worn parts Driven) Engine Oil Lines/ Inspect for leaks and loose fittings Fasteners XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 118 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.

  • Page 119: Specifications

    MAINTENANCE 100 HOUR / 1000 MILE (1600 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear Brake Pads (INT’L) Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 120 Visually inspect shock seals; change oil and XU Shocks seals if leaking Inspect/clean; replace as needed Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 121 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 122 Inspect; clean; replace worn parts Driven) Engine Oil Lines/ Inspect for leaks and loose fittings Fasteners XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 123 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 124 MAINTENANCE 200 HOUR / 2000 MILE (3200 KM) SERVICE ITEM REMARKS Brake Pads / Parking XU / Inspect pad wear Brake Pads (INT’L) Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable XU / Inspect;...
  • Page 125 Inspect/clean; replace as needed Cam Chain Tensioner Inspect; adjust as needed Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 126 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 127 Inspect; clean; replace worn parts Driven) Engine Oil Lines/ Inspect for leaks and loose fittings Fasteners XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 128 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 129 MAINTENANCE 300 HOUR / 3000 MILE (4800 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear Brake Pads (INT’L) Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 130 Visually inspect shock seals; change oil and XU Shocks seals if leaking Inspect/clean; replace as needed Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 131 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 132 Inspect; clean; replace worn parts Driven) Engine Oil Lines/ Inspect for leaks and loose fittings Fasteners XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 133 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 134 MAINTENANCE 400 HOUR / 4000 MILE (6400 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear Brake Pads (INT’L) Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 135 Inspect/clean; replace as needed Cam Chain Tensioner Inspect; adjust as needed Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 136 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 137 Inspect; clean; replace worn parts Driven) Engine Oil Lines/ Inspect for leaks and loose fittings Fasteners XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 138 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 139 MAINTENANCE 500 HOUR / 5000 MILE (8000 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear Brake Pads (INT’L) Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 140 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours /...

  • Page 141: Lubrication Recommendations

    MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 114, 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.
  • Page 142 MAINTENANCE Middle Prop Shaft Grease Fitting Rear Stabilizer Bar Bushings (one on each side of vehicle)

  • Page 143: Polaris Products

    (-18° C to +49° C) 10W-50 4-Cycle Oil Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. Follow the manufacturer's recommendations for ambient temperature operation. Part numbers can be found in the POLARIS Products chapter.

  • Page 144: Oil Check

    MAINTENANCE OIL CHECK Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. Access the oil check dipstick through the right rear wheel well. Access the oil fill cap through the service access panel on the floor of the cargo box.

  • Page 145: Oil And Filter Change

    MAINTENANCE OIL AND FILTER CHANGE WARNING Spilled oil left on engine components or in the engine area may pose a fire hazard. Use shop rags to clean any spilled oil. If needed, use a non- flammable solvent on the rag to aid the cleaning process. Do not use any device such as pressurized water or air as this may disperse the oil onto engine components and could pose a fire hazard.
  • Page 146 MAINTENANCE 6. Clean the filter sealing surface on the engine crankcase with a clean rag and ensure the original oil filter o-ring is not stuck to the crankcase. WARNING Do not use a hose/pressure washer to clean up spilled oil on a vehicle. This may spread oil into surfaces that may get hot which may lead to a fire.
  • Page 147 MAINTENANCE 14. Unlock the dipstick lever . Remove the dipstick and wipe it dry with a clean rag. 15. Reinstall the dipstick to fully seat it. Do not lock the dipstick. NOTE Make certain the dipstick is inserted all the way down to ensure an accurate reading.
  • Page 148 MAINTENANCE TRANSMISSION (MAIN GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications. FLUID CHECK The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.

  • Page 149: Fluid Change

    MAINTENANCE 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.
  • Page 150 MAINTENANCE DEMAND DRIVE UNIT (FRONT GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications. Fill Plug Location Drain Plug Location...
  • Page 151 MAINTENANCE DEMAND DRIVE FLUID CHECK The fill plug is located on the bottom right side of the demand drive unit. Maintain recommended fluid volume (250 ml). Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3.

  • Page 152: Gearcase Specification Chart

    MAINTENANCE GEARCASE SPECIFICATION CHART Use of other fluids may result in improper operation of components. See the part numbers in the Polaris Products section. Fill Plug Drain Plug Capacity Gearcase Lubricant Torque Torque Transmission 61 oz. 10-14 ft. lbs. 10-14 ft. lbs.

  • Page 153: Spark Plugs

    0.7-0.8 mm NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. Refer to the Specifications section for details. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.

  • Page 154: Spark Plug Condition

    MAINTENANCE 3. Remove the spark plug caps. 4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counterclockwise. 5. Reverse the procedure for spark plug installation. Torque to specification. SPARK PLUG CONDITION NORMAL PLUG The normal insulator tip is gray, tan or light brown.
  • Page 155 MAINTENANCE FUSE / RELAY CENTER If the engine stops or will not start, if the power steering stops working (if equipped), or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.
  • Page 156 MAINTENANCE LABEL VALUE FUNCTION SCM (Turbo S only) 7.5A Fuse Suspension Control Module (SCM), Shocks Relay Coil SHOCKS (Turbo S 7.5A Fuse Shocks only) INST UNSW 7.5A Fuse Display (optional), Gauge, Diagnostic LIGHTS 7.5A Fuse Headlights, Taillights, Accent Lights (optional), Brake Lights CHASSIS 7.5A Fuse AWD Switch Light, Oxygen...

  • Page 157: Cooling System

    Always allow the engine to cool before removing the pressure cap. ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See the Polaris Products section for the part numbers.
  • Page 158 6. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
  • Page 159 (when the fluid is cool). 5. Reinstall the pressure cap. If coolant must be added often, or if the pressure tank runs completely dry, there may be a leak in the system. Your POLARIS dealer can inspect the cooling system.
  • Page 160 • See your dealer or other qualified service person as recommended in the owner’s manual and on safety labels. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 161 MAINTENANCE BELT REPLACEMENT / DEBRIS REMOVAL If a belt fails, always clean any debris from the outlet duct and from the clutch and engine compartments when replacing the belt. WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
  • Page 162 12. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer can assist. Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.

  • Page 163: Pvt Drying

    6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your POLARIS dealer or authorized person can assist.

  • Page 164: Filter Systems

    MAINTENANCE FILTER SYSTEMS INTAKE PRE-FILTERS The clutch air intake is located on the left side of the vehicle. The engine intake pre-filter is located on the right side of the vehicle. NOTE Turbo S feature set shown. Inspect the engine pre-filter before each use of the vehicle to ensure adequate air flow.

  • Page 165: Air Filter

    7. Reinstall the air filter (if clean) or install a new air filter (if soiled). Do not attempt to clean the air filter. NOTICE Use of a non-POLARIS-approved air filter may cause engine damage. Always use a POLARIS-approved replacement filter. Replacement filters are available at your POLARIS dealer.

  • Page 166: Spark Arrester

    MAINTENANCE 9. Reinstall the air box cover and ensure the alignment tabs are properly positioned. 10. Secure the four (4) cover clips. 11. Reinstall the cargo box access panel. SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrester. •...
  • Page 167 MAINTENANCE 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 screen with compressed air. 4. Inspect the screen for wear and damage. Replace a worn or damaged screen.
  • Page 168 MAINTENANCE BRAKES WARNING Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal. The front and rear brakes are hydraulic disc type brakes activated by the brake pedal.

  • Page 169: Brake Inspection

    MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.

  • Page 170: 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 the Polaris Products section for the part numbers. Change the brake fluid every two years and any time the fluid becomes...

  • Page 171: Suspension System

    MAINTENANCE SUSPENSION SYSTEM SHOCK ADJUSTMENT RECOMMENDATIONS WARNING Be advised that the shocks contain nitrogen at high pressure. Damaged shocks could cause injury if not replaced or addressed promptly by qualified personnel. SHOCK ADJUSTMENTS RZR XP Turbo S and Turbo S Velocity Weight Condition Spring Preload assuming each rider, wearing gear, is 215 lbs.
  • Page 172 Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer or qualified person perform the adjustments. DYNAMIX SHOCKS Front Shock Preload Measurement...
  • Page 173 MAINTENANCE FACTORY DEFAULT PRELOAD SETTINGS FACTORY DEFAULT PRELOAD SETTINGS DYNAMIX Front 2.88 inches (7.32 cm) RZR Turbo S Rear 6.38 inches (16.21 cm) DYNAMIX Front 2.5 inches (6.35 cm) RZR 4 Turbo S Rear 6.5 inches (16.51 cm) NON-DYNAMIX Front 0.84 inches (2.13 cm) RZR Turbo S Velocity Rear...
  • Page 174 MAINTENANCE FRONT / REAR SHOCK COMPRESSION ADJUSTMENT NOTE Applies to Velocity models only. The compression damping clicker knob is located at the top of the shock reservoir. 1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression damping. Front Rear SHOCK COMPRESSION SETTINGS...

  • Page 175: Tire Tread Depth

    Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS- approved size and type of tires for this vehicle when replacing tires.

  • Page 176: Tire Rotation

    MAINTENANCE TIRE ROTATION Tire rotation is recommended for every 500-mile (805-km) interval. Perform tire rotation on the vehicle by following the rearward cross strategy shown below. AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service.

  • Page 177: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist. 1. Place the transmission in PARK.
  • Page 178 MAINTENANCE LIGHTS Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. LED LAMPS If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out.

  • Page 179: Headlight Beam Adjustment

    MAINTENANCE 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.

  • Page 180: Vehicle Immersion

    8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 9. If water has been ingested into the PVT follow the procedure on page 161 for drying.

  • Page 181: Battery Removal

    MAINTENANCE BATTERY WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Your vehicle has a maintenance-free battery.

  • Page 182: Battery Storage

    Whenever the vehicle is not used for a period of three months or more, recharge the battery about once a month to make up for normal self-discharge (see the Battery Charging section for details), or use a POLARIS Battery Tender, which can be left connected during the storage period. Battery Tender will automatically charge the battery if voltage drops below a pre-determined point.
  • Page 183 MAINTENANCE STATE OF VOLTAGE ACTION CHARGE TIME* CHARGE 100% 12.8-13.0 volts None, check at 3 None required mos. from date of manufacture 75%-100% 12.5-12.8 volts May need slight 3-6 hours charge, if no charge given, check in 3 months 50%-75% 12.0-12.5 volts Needs charge 5-11 hours...

  • Page 184: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 185: Polishing The Vehicle

    • Labels and decals • Electrical components and wiring • Air intake components If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

  • Page 186: Storage Tips

    STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 187 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug caps to the spark plugs.

  • Page 188: Battery Maintenance

    STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
  • Page 189 Secure or remove all cargo, and inspect the unit for loose parts prior to transport. 7. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm...
  • Page 190 MAINTENANCE Rear Tie-Down Front Tow Loop Tie-Down...
  • Page 191 SPECIFICATIONS SPECIFICATIONS RZR XP TURBO S / RZR XP 4 TURBO S RZR XP TURBO S VELOCITY / RZR XP 4 TURBO S VELOCITY Gross Vehicle Weight S: 2575 lbs. (1168 kg) 4 S: 2985 lbs. (1354 kg) S Velocity: 2561 lbs. (1162 kg) 4 S Velocity: 2939 lbs.
  • Page 192 Rear Suspension Independent trailing arms with 21 in. (53.3 cm) travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Tire Size - Front 32x10xR15 Tire Size - Rear 32x10xR15 Tire Pressure...
  • Page 193 SPECIFICATIONS OUTPUT GEAR RATIOS Rear High Gear 11.58:1 Low Gear 20.25:1 Reverse 23.36:1 Front (including front drive) High Gear 12.19:1 Low Gear 21.31:1 Reverse 24.57:1 Drive Ratio - Front 3.17:1 CLUTCHING Please see your POLARIS dealer for clutching specifications...
  • Page 195 POLARIS PRODUCTS POLARIS PRODUCTS PART NUMBER DESCRIPTION Engine Lubricant 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./ .95 l)
  • Page 196 U-Joint Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...
  • Page 197 TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR / BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall trailer in Use low range during loading. high range Starting out going up a steep incline Use low range. See warnings on page 90. Driving at low RPM or ground speed Drive at a higher speed or use low (3-7 MPH/ 5-11 km/h)
  • Page 198 (see page 158). Inspect clutch seals for damage if repeated leaking occurs. Clutch malfunction Your POLARIS dealer can assist. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. Your POLARIS dealer can assist.
  • Page 199 Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors; connections blow on EFI fuse to remove impurities Mechanical failure Your POLARIS dealer or other qualified person can assist. ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel...
  • Page 200 Set gap to specs or replace plugs range Old or non-recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires Your POLARIS dealer or other qualified person can assist. Incorrect ignition timing Your POLARIS dealer or other qualified person can assist. Loose ignition connections...
  • Page 201 Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer can assist. Incorrect spark plug gap or heat Set gap to specs or replace plugs range Loose ignition connections...
  • Page 202 Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your POLARIS dealer can assist. Incorrect spark plug gap or heat Set gap to specs or replace plug range Loose ignition connections...
  • Page 203 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Worn or defective wastegate Your POLARIS dealer can assist. actuation system Overheated intake air system Inspect intercooler water lines for leaks or kinks, repair or replace as needed...

  • Page 205: Warranty

    This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 206 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 207 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 208 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 209 If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect. For questions call POLARIS Customer Assistance: United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334...
  • Page 210 U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 211 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...
  • Page 212 WARRANTY been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle.
  • Page 213 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Polaris Industries Inc. is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle. In California, new off-highway recreational vehicles must be designed, built and equipped to meet the State's stringent anti-smog standards.
  • Page 214 As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

  • Page 215: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 217 Adding or Changing Coolant ..155 Demand Drive Air Box Caution ......15 Fluid Change ....... 149 Air Filter......... 163 Fluid Check ......149 All Wheel Drive (AWD) Switch ..33 Demand Drive Unit (Front All Wheel Drive (AWD) System ..47 Gearcase) ......
  • Page 218 Failure to Inspect Before Operating ....... 20 Know Your Riding Area / Tread Fluid Change ......147 Lightly ........85 Foot Pedals......44 Front / Rear Shock Compression Adjustment..172 Front / Rear Spring Preload Adjustment (FOX) ....170 Lights........176 Fuel Level ........
  • Page 219 Passengers in the Cargo Box ..23 Spark Arrester ......164 Periodic Maintenance Chart ..113 Spark Plug Condition....152 Polaris Products ...... 193 Spark Plug Gap / Torque ... 151 POLARIS Variable Spark Plug Removal and Transmission (PVT) System ..158 Replacement ......
  • Page 220 U.S.A. EPA Emissions Limited Warranty ......208 Unauthorized Use of the Vehicle ... 29 Using Alcohol or Drugs ....20 Vehicle Break-in Period....79 Vehicle Identification Numbers ..8 Vehicle Immersion ....178 Warning Symbols ......4 Warranty Coverage and Exclusions ......
  • Page 222 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9929465 Rev 02 Printed in USA...

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