Polaris RZR 900 Owner's Manual
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Polaris RZR 900 Owner's Manual

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RZR® 900
RZR® 900 EPS TRAIL
RZR® 900 XC Edition
RZR® S 900
RZR® S 900 EPS
RZR® 4 900 EPS
RZR® S 1000 EPS
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris RZR 900

  • Page 1 RZR® 900 RZR® 900 EPS TRAIL RZR® 900 XC Edition RZR® S 900 RZR® S 900 EPS RZR® 4 900 EPS RZR® S 1000 EPS Owner's Manual for Maintenance and Safety...
  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 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 4 The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2016 RZR 900 / RZR S 900 / RZR 4 900 / RZR S 1000 EPS Owner’s Manual P/N 9926384...

  • Page 5: Table Of Contents

    Specifications ......132 POLARIS Products..... 140 Troubleshooting .

  • Page 6: Introduction

    INTRODUCTION The RZR is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used.
  • Page 7 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 8 Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An 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.

  • Page 9: 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. To access this valuable training, visit www.rohva.org.
  • Page 10 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 11 Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
  • Page 12 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. Seat Belt...
  • Page 13 SAFETY Safety Labels and Locations Drive Responsibly Warning Drive Responsibly Avoid loss of control and rollovers: • Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing, and never do donuts. • Slow down before entering a turn. • Avoid hard acceleration when turning, even from a stop.
  • Page 14 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Never carry passengers in cargo box. Load/Passenger/Tire Pressure • Passengers can be thrown off. This Warning (in cargo box) can cause serious injury or death. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
  • Page 15 POLARIS dealer. 7177469 Air Box Caution CAUTION Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube.
  • Page 16 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 17 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 18 SAFETY Safety Warnings Carrying Multiple Passengers (RZR/RZR S) Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 55-56. A passenger must always be seated in a passenger seat with seat belt secured.
  • Page 19 SAFETY Safety Warnings Passengers in the Cargo Box Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box. A passenger must always be seated in a passenger seat with seat belt secured.
  • Page 20 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.
  • Page 21 SAFETY Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual.
  • Page 22 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 64. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.
  • Page 23 SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle. Always follow proper procedures for operating in water as described in this owner’s manual.
  • Page 24 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See page 66.
  • Page 25 SAFETY Safety Warnings Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle.
  • Page 26 SAFETY Safety Warnings Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.

  • Page 27: Features And Controls

    FEATURES AND CONTROLS Component Locations ROPS Frame RZR 4 Shown Cargo Steering Radiator Wheel Cab Doors Fuel Tank Passenger Hand Hold Brake Cargo Box Tie-Down Gear Selector Pedal Points (4 corners) Throttle Pedal...
  • Page 28 FEATURES AND CONTROLS Switches AWD Switch Instrument Light Switch Cluster 12V Accessory Ignition Switch Outlet Auxiliary Outlets The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a second outlet (if equipped) is in the rear passenger area.
  • Page 29 ON position. The EPS warning indicator will illuminate to indicate the EPS has shut down. If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist.
  • Page 30 FEATURES AND CONTROLS Seats Before operating the vehicle, always push down on all seat backs to ensure the latches are secure. Seat Adjustments Loosen (do not remove) the four screws located on the seat bottom. Slide the seat forward or rearward to the desired position. Tighten the screws to 4 ft.
  • Page 31 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 32 FEATURES AND CONTROLS Hood Remove the hood to access the radiator pressure cap and coolant overflow bottle. 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.
  • Page 33 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane.
  • Page 34 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 passenger before riding. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 35 FEATURES AND CONTROLS Seat Belts Seat Belt Height Adjuster (if equipped) STEP 1 Stretch the seat belt height adjuster toward the front of the vehicle. STEP 1 STEP 2 While continuing to stretch the seat belt height adjuster, slide the adjuster up or down, rocking it side to side if necessary, until you reach the desired height.
  • Page 36 Retractor Latch Housings and/or replaced by an Housing authorized POLARIS dealer. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden...
  • Page 37 Tip: 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 38 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before Throttle Pedal...
  • Page 39 (on ROPS or 1928.53 rollover on passenger performance requirements. hip bar) Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. When...
  • Page 40 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. The switch has two positions, AWD (4x4) and 2WD (2x4). The switch on models equipped with a lockable differential has a third position for unlocking the differential.
  • Page 41 FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction. In some situations, the front gearcase may remain locked after turning the AWD switch off.
  • Page 42 FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.
  • Page 43 EPS Warning This indicator illuminates briefly when the key is turned to the ON position. If the light remains on, the EPS system is inoperative. Your POLARIS dealer can assist. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
  • Page 44 If this occurs, your POLARIS dealer can provide proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 45 5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 45 for resetting instructions. 6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 45 for resetting instructions.
  • Page 46 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) MODE Button The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit the set-up mode, turn the key off.
  • Page 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero.
  • Page 49 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer can provide for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
  • Page 50 3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. Your authorized POLARIS dealer can provide code details and diagnosis.

  • Page 51: 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 52 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 7. Carry only light loads. 8. During the break-in period, change both the oil and the filter at 25 hours or one month. 9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.
  • Page 53 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel...
  • Page 54 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 55 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Always make sure all cab doors are closed and latched when riding in this vehicle. 3.
  • Page 56 Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
  • Page 57 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 58 OPERATION New Operator Driving Procedures 12. Apply the brakes and shift into low gear. 13. Check your surroundings and determine your path of travel. 14. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 15.
  • Page 59 OPERATION Driving with Passengers 1. Complete the New Operator Driving Procedures outlined on pages 55-56. 2. Perform the pre-ride inspection. See page 51. 3. Do not carry a passenger until you have at least two hours of driving experience with this vehicle. 4.
  • Page 60 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 61 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, shift to low gear and engage all-wheel drive before ascending.
  • Page 62 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 63 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.
  • Page 64 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 121, and take the vehicle in for service at the first opportunity.
  • Page 65 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 66 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 67 OPERATION Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Turn the engine off. 4.
  • Page 68 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 69 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow a specific capacity. Reduce speed and allow a greater distance for braking when towing or 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 70 OPERATION Towing Loads WARNING! Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1.

  • Page 71: 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 72 WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed. 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible.
  • Page 73 WINCH GUIDE Winch Safety Precautions 18. Never release the clutch on the winch when the winch cable is under load. 19. Never use the winch for lifting or transporting people. 20. Never use the winch to hoist or suspend a vertical load. 21.
  • Page 74 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 75 WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 76 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
  • Page 77 WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 78.
  • Page 78 WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 79 WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 80 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 81 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.

  • Page 82: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 83: Maintenance

    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. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
  • Page 84 POLARIS dealer or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log beginning on page 152. RZR 900 / RZR S 900 / RZR 4 900 Item Maintenance Interval Remarks...
  • Page 85 Spark plugs 100 H 12 M 1000 (1600) Inspect; replace as needed, torque to specification 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 86 Replace coolant D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed 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 87 D Drive clutch bolt 25 H See your dealer to have re-torque bolt re-torqued to 96 ft-lbs (130 Nm) 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 88 1000 (1600) Change fluid (demand drive) fluid Transmission 100 H 12 M 1000 (1600) Change fluid (main gearcase) oil 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 89 Replace coolant D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed 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 90 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method...
  • Page 91 MAINTENANCE Lubrication Recommendations Front Stabilizer Bar RZR 900 / RZR 900 EPS Trail / RZR 900 EPS XC Rear Stabilizer Bar All Models...
  • Page 92 10W-50 4-Cycle Oil (-18 C to +49 Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 140 for the part numbers of POLARIS products.
  • Page 93 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull.
  • Page 94 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. Access the oil check dipstick and oil filter through the engine access panel located behind the seats.
  • Page 95 MAINTENANCE Engine Oil Oil and Filter Change 7. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 8. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 1/2 turn.
  • Page 96 MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 98 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase.
  • Page 97 MAINTENANCE Transmission (Main Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3.
  • Page 98 MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 98 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the demand...
  • Page 99 MAINTENANCE Demand Drive Unit (Front Gearcase) Fluid Change The 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 100 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 140 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Drain Plug/ Torque Level Check Plug Torque Transmission AGL Gearcase 44 oz.
  • Page 101 MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove the cargo box access panel. 2. Clean the area around the spark plugs before removing the plugs. 3. Remove the spark plug caps. 4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counter-clockwise.
  • Page 102 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 103 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 page 140 for the part numbers of POLARIS products. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
  • Page 104 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan.
  • Page 105 6. Reinstall the pressure cap. Tip: 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. Bleed Screw...
  • Page 106 5. Reinstall the cap. Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Your POLARIS dealer can inspect the cooling system.
  • Page 107 • See your dealer as recommended in the owner’s manual and on safety labels. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 108 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
  • Page 109 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 can assist.
  • Page 110 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.
  • Page 111 MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components.
  • Page 112 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm.
  • Page 113 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage.
  • Page 114 Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 140 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.
  • Page 115 If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. Your POLARIS dealer can provide the tool required to make suspension adjustments. Elevate the vehicle slightly for easier adjustment.
  • Page 116 If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. Please see your POLARIS dealer for the tool required to make suspension adjustments. Elevate the vehicle Preload Setting slightly for easier adjustment.
  • Page 117 WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. 4. Tighten the jam nut firmly against the adjuster ring.
  • Page 118 MAINTENANCE Suspension Settings (RZR S/RZR XC/RZR 4) Front/Rear Shock Compression Increase Decrease The compression damping clicker knob is located on top of the shock reservoir. When the knob is turned clockwise until it stops, the damping is in the fully closed position. 1.
  • Page 119 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 120 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. Valve Stem 3. Attach the wheel nuts and washers and finger tighten.
  • Page 121 MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out.
  • Page 122 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward and to the left or right. 1. Position the vehicle on a level surface. The headlight should be approximately 25 ft. (7.6 m) from a wall. 25 ft.
  • Page 123 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 124 2. Lightly turn the steering wheel left and right. 3. There should be 0.8-1.0” (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or if the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer.
  • Page 125 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 an automotive-type sealed battery, which requires little maintenance.
  • Page 126 Whenever the vehicle is not used for a period of three months or more, recharge the battery about once a month to make up for normal self- discharge (see page 125), 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 127 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 128 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
  • Page 129 The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
  • Page 130 • 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 131 127. 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 132 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 133 Secure or remove all cargo, and inspect the unit for loose parts prior to transport. 5. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.

  • Page 134: Specifications

    SPECIFICATIONS RZR 900 / RZR 900 EPS Gross Vehicle Weight RZR 900/EPS Trail: 1971 lbs. (894 kg) XC: 2070 lbs. (939 kg) Dry Weight RZR 900/EPS Trail: 1150 lbs. (521.6 kg) XC: 1249 lbs. (566.5 kg) Test GVW - Rollover 2300 lbs.
  • Page 135 Shift Type Dual Range P/R/N/L/H Tires / Tire Pressure - Front RZR 900/EPS TRAIL: PXT 26x8-12 / 10 psi (69 kPa) EPS XC: Dirt Commander 27x9-14 / 10 psi (69 kPa) Tires / Tire Pressure - Rear RZR 900/EPS TRAIL: PXT 26x9-12 / 12 psi (83 kPa)
  • Page 136 SPECIFICATIONS RZR S 900 / RZR S 900 EPS Gross Vehicle Weight 2025 lbs. (918 kg) Dry Weight 1204 lbs. (546 kg) Test GVW - Rollover 2300 lbs. (1043 kg) per OSHA 29 CFR 1928.53 Protection System (ROPS) Rear Cargo Box Capacity 300 lbs.
  • Page 137 Rear High Gear 10.73 Low Gear 18.77 Reverse 20.41 Front (including front drive) Non-EPS High Gear 13.71 11.88 Low Gear 23.94 20.74 Reverse 26.07 22.59 Drive Ratio - Front 3.82 3.31 Clutching Please see your POLARIS dealer for clutching specifications.
  • Page 138 SPECIFICATIONS RZR 4 900 EPS Gross Vehicle Weight 2442 lbs. (1107.7 kg) Dry Weight 1476 lbs. (669.5 kg) Test GVW - Rollover 2700 lbs. (1225 kg) per OSHA 29 CFR 1928.53 Protection System (ROPS) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 900 lbs.
  • Page 139 2 12V Output Gear Ratios Rear High Gear 12.05 Low Gear 18.79 Reverse 22.92 Front (including front drive) High Gear 12.82 Low Gear 19.98 Reverse 24.41 Drive Ratio - Front 3.18 Clutching Please see your POLARIS dealer for clutching specifications.
  • Page 140 SPECIFICATIONS RZR S 1000 EPS Gross Vehicle Weight 2056 lbs. (933 kg) Dry Weight 1235 lbs. (560 kg) Test GVW - Rollover 2300 lbs. (1043 kg) per OSHA 29 CFR 1928.53 Protection System (ROPS) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 740 lbs.
  • Page 141 Rear High Gear 10.73 Low Gear 18.77 Reverse 20.41 Front (including front drive) Non-EPS High Gear 13.71 11.88 Low Gear 23.94 20.74 Reverse 26.07 22.59 Drive Ratio - Front 3.82 3.31 Clutching Please see your POLARIS dealer for clutching specifications.

  • Page 142: Polaris Products

    POLARIS PRODUCTS Part Description Number 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) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)

  • Page 143: Troubleshooting

    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. Slippage from failure to Always warm up the belt by operating below 30 MPH (48 warm up belt km/h) for one mile (1.5 km) and for 5 miles (8 km) or...
  • Page 144 Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect, clean, reinstall connectors Mechanical failure Your POLARIS dealer can assist Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Refuel...
  • Page 145 Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause...
  • Page 146 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 range Set gap to specs or replace plug Loose ignition connections...

  • Page 147: Warranty

    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 148 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 149 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.
  • Page 150 Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries.
  • Page 151 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase...
  • Page 152 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 REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 153 POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 154: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 155 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 156: Index

    INDEX Access Panel Cab Doors ..... 35 Cargo Box ....31 Cab Frame, ROPS .
  • Page 157 INDEX Electromagnetic Interference ..80 Fuel Cap ..... . 31 Electronic Power Steering ..27 Fuel Safety .
  • Page 158 Maintenance, Periodic ..81-87 Polaris Products ....140 Metric Display ....44 Polishing the Vehicle.
  • Page 159 Vehicle Immersion ... . . 121 Spring Preload (RZR 900) ..113 Vehicle Transport ....131 Spring Preload (S/XC/4) .
  • Page 160 12 or who cannot comfortably reach the floor and hand holds. • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death.

This manual is also suitable for:

Rzr 900 eps trailRzr s 900Rzr s 900 epsRzr 4 900 epsRzr s 1000 eps2015 rzr 900 xc edition

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