Polaris RZR XP 1000 EPS 2019 Owner's Manual
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Polaris RZR XP 1000 EPS 2019 Owner's Manual

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2019
OWNER'S MANUAL
RZR® XP / XP 4 1000 EPS
RZR® XP 1000 EPS
TRAILS AND ROCKS EDITION

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  • Page 1 2019 OWNER’S MANUAL RZR® XP / XP 4 1000 EPS RZR® XP 1000 EPS TRAILS AND ROCKS EDITION...
  • 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 1000 XP / XP 4 EPS 1000 XP Trails and Rocks Edition...
  • 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 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 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 that, if not avoided, will result in death to the operator, bystanders or person(s) inspecting or servicing the vehicle.

  • Page 7: Table Of Contents

    Specifications ....161 Polaris Products ....167 Troubleshooting .

  • Page 9: Introduction

    Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 10 INTRODUCTION EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

  • Page 11: 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 13: Safety

    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 14: Safe Riding Gear

    SAFETY SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over- the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.

  • Page 15: Eye Protection

    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. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
  • Page 16 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. Warning Labels Payload Warning...
  • Page 17 SAFETY PAYLOAD WARNING WARNING If Total Payload Exceeds Never Exceed 68 MPH (109 km/h) 330 lbs. (150 kg) XP 1000 68 MPH (109 km/h) 860 lbs. (390 kg) XP4 1000 SEAT BELT WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. Be Prepared •...
  • Page 18 SAFETY FUEL TRANSPORT WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. DRIVE RESPONSIBLY WARNING WARNING: Drive Responsibly Rollovers have caused severe injuries and death, even on flat, open areas. Avoid loss of control and rollovers: •...
  • Page 19 Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around the clutch and vent system when replacing the belt. Read owner’s manual or see authorized POLARIS dealer or other authorized person. Belt Debris Warning...
  • Page 20 SAFETY LOAD / PASSENGER / TIRE PRESSURE WARNING The Load / Passenger / Tire Pressure Warning is located at the rear of the vehicle in the cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. •...
  • Page 21 Avoid exhibition driving. INTAKE ALERT (7185975) 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 22 SAFETY TIRE PRESSURE / PASSENGER ALERT FOR 2-SEAT VEHICLES (7189871) 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. TIRE PRESSURE MAXIMUM CARGO MAXIMUM CAPACITY (IN KPA/BAR)

  • Page 23: 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 24: Using Alcohol Or Drugs

    SAFETY OPERATOR RESTRICTIONS/ AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.

  • Page 25: 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 26 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 27: 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 28: 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 29: Crossing Hillsides

    SAFETY CROSSING HILLSIDES Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual.

  • Page 30: Improper Tire Maintenance

    SAFETY OPERATING IMPROPERLY IN REVERSE Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See the Driving in Reverse section for details. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.

  • Page 31: Operating A Damaged Vehicle

    SAFETY OPERATING THROUGH WATER Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle. Always follow proper procedures for operating in water as described in this owner’s manual.

  • Page 32: Exposure To Exhaust

    SAFETY REFUELING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always turn off the engine when refueling. • Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

  • Page 33: 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 page 74.

  • Page 34: Equipment Modifications

    SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.

  • Page 35: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS Cargo Box Radiators ROPS Frame Cab Door Fuel Tank Cap Tie-Down Points (4 corners) Gear Selector Brake Pedal Passenger Hand Hold Throttle Pedal...
  • Page 36 FEATURES AND CONTROLS SWITCHES Light Switch Ignition Switch AWD Switch 12V Accessory Outlet Instrument Cluster AUXILIARY OUTLETS The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a second outlet (if equipped) is in the rear passenger area. Use the outlets to power an auxiliary light or other optional accessories.

  • Page 37: Ignition Switch

    FEATURES AND CONTROLS IGNITION SWITCH The ignition switch is a four-position, key-operated switch. Use the ignition switch to start the engine. See page 62 for starting procedures. POSITION FUNCTION The engine is off. Electrical circuits are off, except accessory 12V. The engine is off.
  • Page 38 EPS has shut down. If the light remains on after starting the engine, the EPS system is inoperative. See your POLARIS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

  • Page 39: 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 40: Steering Wheel

    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 41 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 42 FEATURES AND CONTROLS HOOD Remove the hood to access the radiator pressure cap and pressure tank 1. Turn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the fasteners. 3. Pivot the hood forward and lift upward to disengage the lower hood hooks. 4.
  • Page 43 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: Seat Belt Inspection

    If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer or qualified person. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.
  • Page 45 FEATURES AND CONTROLS SEAT BELT HEIGHT ADJUSTER (IF EQUIPPED) The seat belt height adjuster reduces neck rub and works as a shock absorber for your shoulder. The height adjuster consists of an adjuster and a rail Adjustment becomes easier with repeated use. The seat belt height adjuster can be cleaned with water.

  • Page 46: Gear Selector

    Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer or qualified person 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 47 FEATURES AND CONTROLS SERVICE ACCESS PANELS ENGINE ACCESS PANEL The engine access panel is located behind the seats on the frame of the vehicle. Remove the seats and remove the access panel to reach serviceable engine components. CARGO BOX ACCESS PANEL The cargo box access panel is located on the floor of the cargo box.

  • Page 48: Brake Pedal

    FEATURES AND CONTROLS BRAKE AND THROTTLE PEDALS BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. THROTTLE PEDAL Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.
  • Page 49 FEATURES AND CONTROLS ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on ROPS Label this vehicle meets ISO 3471 rollover performance requirements. Always have your authorized dealer or qualified person thoroughly inspect the ROPS if it ever becomes damaged in any way. WARNING Never make modifications to the vehicle’s ROPS structure.

  • Page 50: Engaging Awd

    Always switch to AWD while the rear wheels have traction or are at rest. NOTE For functional descriptions detailing how to operate the DYNAMIX suspension system on certain vehicle models, consult the Polaris RideCommand manual.

  • Page 51: 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 52 FEATURES AND CONTROLS TOGGLE BUTTONS Press and release either toggle button to cycle through the options menu or Area 2 modes. Press and hold either toggle button to reset an item. See page With the ignition key off, pressing the MODE button or either toggle button will power up the Rider Information Center for 10 seconds to allow viewing of the odometer and the clock.

  • Page 53: Indicator Lamps

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

  • Page 54: Rider Information Center

    This indicator shows whether 2X4 or AWD is active. Service A flashing wrench symbol alerts the operator that the preset Indicator service interval has been reached. Your POLARIS dealer, or other qualified person, can provide scheduled maintenance. See page 57 for resetting instructions. Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank.
  • Page 55 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 56 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 page 53. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds.
  • Page 57 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 58 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 59: 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 60 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 61: Operation

    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 62 OPERATION 8. During the break-in period, change both the oil and the filter at 25 hours or one month. 9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter. BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops.

  • Page 63: Safe Operation Practices

    OPERATION ITEM REMARKS Frame nuts, bolts, Inspect, ensure tightness – fasteners Fuel and oil Ensure proper levels page 38 page 118 Coolant level Ensure proper level page 130 Coolant hoses Inspect for leaks – Throttle Ensure proper operation – Indicator lights/ Ensure proper operation page 49 switches...

  • Page 64: Starting The Engine

    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 65: Stopping The Engine

    OPERATION 5. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts. 6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds.

  • Page 66: Trail Etiquette

    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 67: Driving With Passengers

    OPERATION 14. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 15. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

  • Page 68: Driving Uphill

    OPERATION 8. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger. 9. Vehicle handling may change with passengers and/or cargo on board. Allow more time and distance for braking.
  • Page 69 OPERATION 6. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 7. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

  • Page 70: 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 71: 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 or qualified person can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section, and take the vehicle in for service at the first opportunity.

  • Page 72: 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 73: 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 74: 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 75: 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. 3. Stop the engine. 4.

  • Page 76: Hauling Cargo

    OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 77 A passenger must always be seated in a passenger seat with seat belt secured. 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 78: Belt Life

    OPERATION Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle. See the Load / Passenger / Tire Warning section for details. BELT LIFE To extend belt life, use low gear in the following conditions: •...

  • Page 79: Winch Guide

    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 80 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 81: 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 82 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 83 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 84 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 85 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 86: 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 87 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 88: 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 89: 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 91: 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 92 Initial fluid level inspection; add lubricant if Lubricant needed Transmission Lubricant Initial fluid level inspection; add lubricant if (AGL) needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or equivalent person perform these services.
  • Page 93 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 equivalent person perform these services.
  • Page 94 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 equivalent person perform these services.
  • Page 95 MAINTENANCE 100 HOUR / 1000 MILE (1600 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear; replace if worn beyond Brake Pads (INT’L) service limit Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 96 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 equivalent person perform these services.
  • Page 97 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 equivalent person perform these services.
  • Page 98 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 equivalent person perform these services.
  • Page 99 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 equivalent person perform these services.
  • Page 100 MAINTENANCE 200 HOUR / 2000 MILE (3200 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear; replace if worn beyond XU / Brake Pads (INT’L) service limit Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable XU / Inspect;...
  • Page 101 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 equivalent person perform these services.
  • Page 102 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 equivalent person perform these services.
  • Page 103 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 equivalent person perform these services.
  • Page 104 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 equivalent person perform these services.
  • Page 105 MAINTENANCE 300 HOUR / 3000 MILE (4800 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear; replace if worn beyond Brake Pads (INT’L) service limit Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 106 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 equivalent person perform these services.
  • Page 107 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 equivalent person perform these services.
  • Page 108 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 equivalent person perform these services.
  • Page 109 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 equivalent person perform these services.
  • Page 110 MAINTENANCE 400 HOUR / 4000 MILE (6400 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear; replace if worn beyond Brake Pads (INT’L) service limit Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 111 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 equivalent person perform these services.
  • Page 112 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 equivalent person perform these services.
  • Page 113 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 equivalent person perform these services.
  • Page 114 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 equivalent person perform these services.
  • Page 115 MAINTENANCE 500 HOUR / 5000 MILE (8000 KM) SERVICE ITEM REMARKS Brake Pads / Parking Inspect pad wear; replace if worn beyond Brake Pads (INT’L) service limit Turn key on to pressurize fuel pump; check Fuel System lines / fittings for leaks and abrasion Parking Brake Cable Inspect;...
  • Page 116 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or equivalent person perform these services. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours /...

  • Page 117: Lubrication Recommendations

    MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 90, 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 118 MAINTENANCE Middle Prop Shaft Grease Fitting Stabilizer Bar Bushings (one on each side of vehicle) Rear Prop Shaft Grease Fitting...

  • Page 119: Engine Oil

    (-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 120: 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 121 MAINTENANCE 1. Position the vehicle on a level surface. Place the transmission in PARK. 2. Clean the area around the crankcase drain plug. CAUTION Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 3. Place a drain pan under the engine crankcase and remove the drain plug. Allow the oil to drain completely.
  • Page 122 MAINTENANCE 14. Remove the oil fill cap to add the recommended oil as needed. Maintain the oil level between the minimum and maximum marks on the dipstick. Do not overfill. 15. Reinstall the fill cap. 16. Reinstall the dipstick. 17. Dispose of used filter and oil properly.
  • Page 123 MAINTENANCE TRANSMISSION (MAIN GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 90. Refer to the Gearcase Specifications Chart on page 125 for recommended lubricants, capacities and torque specifications. FLUID CHECK The fill plug is located on the rear of the gearcase.

  • Page 124: 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 125 MAINTENANCE DEMAND DRIVE UNIT (FRONT GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 90. Refer to the Gearcase Specifications Chart on page 125 for recommended lubricants, capacities and torque specifications.
  • Page 126 MAINTENANCE DEMAND DRIVE FLUID CHANGE The demand drive drain plug is located on the bottom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4.

  • Page 127: Gearcase Specification Chart

    MAINTENANCE GEARCASE SPECIFICATION CHART Use of other fluids may result in improper operation of components. See the Polaris Products section for the part numbers. Fill Plug Drain Plug Capacity Gearcase Lubricant Torque Torque Transmission 44 oz. 10-14 ft. lbs. 10-14 ft. lbs.

  • Page 128: Spark Plugs

    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 of this manual. 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 129: 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 130 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 131 MAINTENANCE LABEL VALUE FUNCTION AWD Switch, Oxygen Sensor Heater, EPS Wake-Up, VSS, Seat Belt, AWD Coil, Gauge, Winch CHASSIS 10A Fuse DYNAMIX vehicles: SCM Wake-Up, SCM Mode Switch EVAP vehicles: Waste Gate Accessory Relay Coil, ECM Wake-Up, Pump Relay Coil, Chassis Relay Coil, Start Relay Coil, EFI Relay Coil, Mag/PTO Inject, Lights Relay Coil, Fan Relay Coil, 10A Fuse...

  • Page 132: Cooling System

    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 133 MAINTENANCE RADIATOR COOLANT LEVEL / CHANGING COOLANT This procedure is required only if the cooling system has been drained for maintenance and/or repair. If the overflow bottle has run dry, the level in the radiator should also be inspected. CAUTION Escaping steam can cause burns.
  • Page 134 5. Reinstall the cap. If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer or authorized person.
  • Page 135 • 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 136 MAINTENANCE BELT REPLACEMENT / DEBRIS REMOVAL If a belt fails, always clean any debris from the PVT ducting 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 137 MAINTENANCE 3. Remove the clutch cover screws and open the clutch cover. (It does not have to be removed from the vehicle.) Remove all debris wrapped in and around the PVT system. Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation.

  • Page 138: 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 139: Filter Systems

    MAINTENANCE FILTER SYSTEMS INTAKE PRE-FILTERS The engine intake pre-filter is located on the right side of the vehicle. The clutch air intake is located on the left side of the vehicle. Inspect the engine pre-filter before each use of the vehicle to ensure adequate air flow.
  • Page 140 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 141: Spark Arrester

    MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrestor. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.

  • Page 142: Brake Inspection

    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 143: 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 144: Suspension Settings

    WARNING Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer or qualified person perform the adjustments.
  • Page 145 MAINTENANCE WALKER EVANS SHOCKS Front Shock Preload Measurement Rear Shock Preload Measurement DYNAMIX SHOCKS Front Shock Preload Measurement Rear Shock Preload Measurement...
  • Page 146 MAINTENANCE FACTORY DEFAULT PRELOAD SETTINGS FACTORY DEFAULT PRELOAD SETTINGS WALKER 1.49 inches (38 mm) Front 8.21 inches (209 mm) Rear RZR XP EPS DYNAMIX 2.74 inches (6.96 cm) Front 9.47 inches (24.05 cm) Rear WALKER 2.04 inches (51 mm) Front 5.13 inches (130 mm) Rear RZR XP 4 EPS...

  • Page 147: 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 148: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer or other qualified person can assist. Right Rear Wheel 1.

  • Page 149: Headlight Beam Adjustment

    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. 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 150: Vehicle Immersion

    If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer or other qualified person can provide this service. If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

  • Page 151: Steering Wheel Inspection

    MAINTENANCE 8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer or other qualified person can provide the required service. 9. If water has been ingested into the PVT follow the procedure on page 136 for drying.

  • Page 152: 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 153: 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 154 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 155: 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 156 MAINTENANCE 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. WASHING TIPS • Avoid the use of harsh cleaners, which can scratch the finish. •...

  • Page 157: Polishing The Vehicle

    MAINTENANCE POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

  • Page 158: Battery Maintenance

    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 159: Removal From Storage

    4. Check all the points listed in the Daily Pre-Ride Inspection section. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer or other qualified service facility. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 90.

  • Page 160: Transporting The Vehicle

    MAINTENANCE TRANSPORTING THE VEHICLE NOTE For functional descriptions detailing how to operate the DYNAMIX suspension system, consult the DYNAMIX Active Suspension chapter in this manual. Follow these procedures when transporting the vehicle. NOTICE 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 161 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 162 MAINTENANCE Rear Tie-Down Front Tow Loop Tie-Down...

  • Page 163: Specifications

    SPECIFICATIONS SPECIFICATIONS RZR XP 1000 / EPS / TRAILS AND ROCKS EDITION Gross Vehicle Weight RZR XP EPS: 2270 lbs (1031 kg) RZR XP (Dynamix): 2280 lbs. (1036 kg) RZR Trails and Rocks Edition: 2395 lbs. (1088 kg) Dry Weight RZR XP EPS: 1448 lbs.
  • Page 164 Rear Suspension Independent trailing arms with 18 in. (45.7 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 29x9-14 RZR Trails and Rocks Edition: 30x10-14 Tire Size - Rear...
  • Page 165 SPECIFICATIONS RZR XP 4 1000 EPS Gross Vehicle Weight RZR XP4 EPS: 2640 lbs. (1200 kg) RZR XP4 Dynamix: 2651 lbs. (1205 kg) Dry Weight RZR XP4 EPS: 1659 (754 kg) RZR XP4 Dynamix: 1670 lbs. (759 kg) Test GVW - Rollover 2750 lbs.
  • Page 166 Rear Suspension Independent trailing arms with 18 in. (45.7 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 29x9-14 Tire Size - Rear 29x11-14 Tire Pressure...
  • Page 167 SPECIFICATIONS OUTPUT GEAR RATIOS OUTPUT GEAR RATIOS Trails and RZR XP RZR XP 4 Rocks Edition Rear High Gear 10.73 12.05 11.79 Low Gear 18.77 18.79 29.02 Reverse 20.41 22.92 25.99 Front (including front drive) High Gear 11.42 12.82 11.87 Low Gear 19.98 19.98...

  • Page 169: Polaris Products

    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 170 POLARIS PRODUCTS PART NUMBER DESCRIPTION 2871460 Premium Starter Grease 2871515 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...

  • Page 171: Troubleshooting

    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 66. Driving at low RPM or ground speed Drive at a higher speed or use low (3-7 MPH/ 5-11 km/h)
  • Page 172 (see page 133). Inspect clutch seals for damage if repeated leaking occurs. Clutch malfunction Your POLARIS dealer or other qualified person can assist. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. Your POLARIS dealer or other qualified person can assist.
  • Page 173 SOLUTION 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 174 POSSIBLE CAUSE SOLUTION 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 175 Inspect and replace Clogged intake pre-filter Inspect and clean (with soapy water) or replace Other mechanical failure Your POLARIS dealer or other qualified person can assist. Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel...
  • Page 176 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Worn or defective spark plug wires Your POLARIS dealer or other qualified person can assist. Incorrect spark plug gap or heat Set gap to specs or replace plug range Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC...

  • Page 177: 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 178 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 179 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 180 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 181 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
  • Page 182 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 183 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 184 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
  • Page 185 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 187: 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 189 3-Point Seat Belt ....... 41 Adding or Changing ....130 6-Point Seat Belt (Trails and Cooling System....... 130 Rocks Edition) ......41 Crankcase Emission Control System ........87 Crossing Hillsides ...... 27 Adding or Changing Coolant ..130 Air Box Caution ......17 Air Filter.........
  • Page 190 Factory Default Preload Jumps and Stunts ...... 26 Settings ....... 144 Failure to Inspect Before Operating ....... 22 Fluid Change ....122, 124 Know Your Riding Area / Tread Fluid Check ......121 Front / Rear Shock Lightly ........64 Compression Adjustment..
  • Page 191 Payload Warning ....... 15 Spark Plug Gap / Torque ... 126 Periodic Maintenance Chart ..89 Spark Plug Removal and Polaris Products ...... 167 Replacement ......126 POLARIS Variable Stalling While Climbing a Hill ..27 Transmission (PVT) System ..133 Starting the Engine ....
  • Page 192 Unauthorized Use of the Vehicle ... 31 Using Alcohol or Drugs ....22 Vehicle Break-in Period....59 Vehicle Identification Numbers ..9 Vehicle Immersion ....148 Washing the Vehicle....153 Wheel Installation ....146 Wheel Removal....... 146 Winch Cable Care ..... 84 Winch Maintenance and Service Safety ......
  • Page 194 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. 9929134 Rev 01 Printed in USA...

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