Page 1 2021 For Maintenance and Safety OWNER’S MANUAL RZR Trail 900 RZR Trail S 900...
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 2021 RZR Owner’s Manual Trail 900 Trail S 900...
Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. Sachs® is a registered trademark of ZF Sachs AG Corporation. Recreational Off-Highway Vehicle Association® and ROHVA® are registered trademarks of the Recreational Off-Highway Vehicle Association. Tread Lightly® is a registered trademark of the United States Department of Agriculture.
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 SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
Page 7: Table Of Contents
Specifications ....189 Polaris Products ....195 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: European Vibration And Noise
Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Page 11: Safety
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 12: Safe Riding Gear
SAFETY SAFE RIDING GEAR Always wear a 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 13: 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 14: Safety Labels And Locations
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer or qualified person to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
Page 15: Fuel Transport Warning
SAFETY PAYLOAD WARNING WARNING If Total Payload Exceeds MODEL Never Exceed 43 MPH (69 kph) 430 lbs. (195 kg) 62 MPH (100 kph) 430 lbs. (195 kg) RZR S 55 MPH (88 kph) 430 lbs. (195 kg) RZR XC 68 MPH (110 kph) 860 lbs.
Page 16 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 your POLARIS dealer or authorized equivalent person.
Page 17 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. The air filter must be properly seated before the lid is reinstalled.
Page 18: Maximum Weight Capacity
SAFETY LOAD / PASSENGER / TIRE PRESSURE WARNING Load / Passenger / Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. • Reduce speed and allow greater distance for braking when carrying cargo. •...
Page 19: 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 20: 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 operators and (if applicable) 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 21: 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 22: Operating With A Load On The Vehicle
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 23: Passengers In The Cargo Box
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 24 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 25: Stalling While Climbing A Hill
SAFETY STALLING WHILE CLIMBING A HILL Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped.
Page 26: Skidding Or Sliding
SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
Page 27: Operating On Frozen Bodies Of Water
SAFETY OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and any passengers, and your cargo, together with any other vehicles in your party.
Page 28: Hot Exhaust Systems
SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
Page 29: 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 31: Features And Controls
FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS Cargo Box Cab Door ROPS Frame Fuel Tank Cap Radiators Steering Wheel Tie-Down Points (4 corners) Brake Pedal Throttle Pedal Gear Selector Passenger Hand Hold...
Page 32 FEATURES AND CONTROLS SWITCHES Instrument Cluster All Wheel Drive (AWD) Switch Ignition Switch 12V Accessory Outlet Headlight Switch...
Page 33: 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 84 for starting procedures. POSITION FUNCTION The engine is off. Electrical circuits are off, except accessory 12V. The engine is off.
Page 34: Headlight Switch
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 35: Steering Wheel
FEATURES AND CONTROLS STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.
Page 36 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. HOOD Remove the hood to access the radiator pressure cap...
Page 37: Rollover Protective Structure (Rops)
FEATURES AND CONTROLS ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets ISO 3471 rollover performance requirements. Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. ROPS Label (on ROPS or pass. hip bar) WARNING Never make modifications to the vehicle’s ROPS structure.
Page 38: 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 39: 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 40: Service Access Panels
FEATURES AND CONTROLS • Operating in rough terrain or over obstacles • Loading the vehicle onto a trailer • Towing heavy loads SERVICE ACCESS PANELS ENGINE ACCESS PANEL The engine access panel is located behind the seats on the frame of the vehicle.
Page 41: Passenger Hand Hold
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 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 43: 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 44 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 45: All-Wheel Drive (Awd) System
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. When unlocked, only one rear wheel is a drive wheel.
Page 46 FEATURES AND CONTROLS 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 47: Radio Compliance Statements
• Familiarize yourself with the features and operations of the Display while the vehicle is stationary. • Download the Polaris RIDE COMMAND App from the Apple®/Google Play® store and create your personalized account. • Check your display to ensure you have the appropriate maps and trails visible for your area.
Page 48 COMPONENT ID MANUFACTURER 9200 Series Display Polaris Industries Inc. Hereby, Polaris, Inc. declares that the above radio equipment is in compliance with EU Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address:...
Page 49 For applications that use vehicle-to-vehicle (V2V) communication, radio transmitter IC: 5966A-P001 has been approved by Innovation, Science and Economic Development Canada (ISED) to operate with the Polaris antenna (part number 4018713) with gain of 3 dBi. Any antenna that has a gain greater than 3 dBi is prohibited for use with this device.
Page 50 FEATURES AND CONTROLS RIDE COMMAND BUTTONS BUTTON DESCRIPTION FUNCTION Menu/Power Press the Menu/Power button to access Button the settings. To reboot the display, press and hold for 5 seconds. Gauge Screen Press the Gauge Screen button to select Button from available screens. Map Button Press the Map button to access the map, manage your rides and waypoints,...
Page 51 FEATURES AND CONTROLS BUTTON DESCRIPTION FUNCTION Volume Decrease Press the Volume Decrease button to Button decrease the volume. Press and hold to mute volume. Volume Increase Press the Volume Increase button to Button increase the volume.
Page 52: Indicator Description
FEATURES AND CONTROLS DRIVELINE MODE INDICATOR DESCRIPTION FUNCTION When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When in All-Wheel Drive, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.
Page 53: Gauge Screens
To access the Setting menu, press the Menu/ Power button You can also navigate to the settings menu by pressing the POLARIS logo at the top of the display screen . This will open the Control Panel. From the Control Panel,...
Page 54 FEATURES AND CONTROLS GAUGE VIEW MODE Press to toggle between the two available gauge view modes, Analog and Digital. While in the digital gauge view mode, press invert the MPH and RPM units. ICON BAR ICON DESCRIPTION FUNCTION Headset Displays icon if headset is connected Signal Strength Displays current cell signal strength Fuel Level...
Page 55: Update Software
1. Go to ridecommand.polaris.com/update. 2. Log into your account, or create a new account. 3. Using the Vehicle Identification Number (VIN), add your new Polaris vehicle to your Garage. 4. Locate and download the latest software to a USB flash drive (8+ GB).
Page 56: Update Maps
FEATURES AND CONTROLS UPDATE MAPS To update the maps on your display, do the following: 1. Go to ridecommand.polaris.com/update and download the map update to a USB flash drive. 2. Insert USB flash drive into the USB port on your vehicle.
Page 57: 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 58 FEATURES AND CONTROLS SPEEDOMETER The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). TACHOMETER The tachometer displays engine speed in revolutions per minute (RPM). MODE AND TOGGLE BUTTONS Press and hold the MODE button to enter or exit the settings menu.
Page 59: Indicator Lamps
ON position. If the light remains on, the EPS system is inoperative. See your EPS Warning POLARIS dealer, or another qualified person, (if equipped) as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
Page 60: Rider Information Center
Service A flashing wrench symbol alerts the operator that the preset Indicator service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 63 for resetting instructions. Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank.
Page 61 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 62: Backlight Color
FEATURES AND CONTROLS ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays. See the Mode Information Displays section for details. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds.
Page 63: Backlight Brightness
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 64: Trip Meter
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 65: 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 66: Engine Error Codes
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 67: Diagnostic Codes
FEATURES AND CONTROLS DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
Page 68 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Data Valid But Above Normal Vehicle Speed Sensor Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source...
Page 69 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Manifold Absolute Data Erratic, Intermittent Or Pressure Sensor Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Mechanical System Not Responding Or Out Of Adjustment Abnormal Rate Of Change Intake Air Data Erratic, Intermittent Or...
Page 70 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Engine Temperature Data Valid But Above Normal Sensor Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Data Valid But Above Normal Operating Range - Least Severe...
Page 71 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION System Power Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operating Range - Moderately...
Page 72 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Gear Sensor Signal Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Update Rate ECU Memory Bad Intelligent Device Or Component Out Of Calibration Calibration...
Page 73 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 1268 Ignition Coil Primary Voltage Above Normal, Or Driver 1 (Front) Shorted To High Source (MAG) Voltage Below Normal, Or 1268 Shorted To Low Source Current Below Normal Or Open 1268 Circuit Fuel Pump Driver Voltage Above Normal, Or 1347 Circuit...
Page 74 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Data Valid But Above Normal 3597 ECU Output Supply Voltage 1 Operational Range - Most Severe Level Data Valid But Below Normal 3597 Operational Range - Most Severe Level 3597 Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or 3597...
Page 75 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Data Valid But Above Normal 3598 ECU Output Supply Voltage 2 Operational Range - Most Severe Level Data Valid But Below Normal 3598 Operational Range - Most Severe Level 3598 Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or 3598...
Page 76 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 65613 ETC Accelerator Data Erratic, Intermittent Or Position Sensor Incorrect Outputs 1 & 2 Correlation Throttle Position Data Valid But Above Normal 520198 Sensor 2 Operational Range - Most Severe Level Data Valid But Below Normal 520198 Operational Range - Most Severe Level...
Page 77 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION 520209 Oxygen Sensor Data Erratic, Intermittent Or Heater 1 Incorrect Voltage Above Normal, Or 520209 Shorted To High Source Voltage Below Normal, Or 520209 Shorted To Low Source Current Below Normal Or Open 520209 Circuit Accelerator...
Page 78 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Throttle Body Condition Exists 520280 Control - Limp Home Position Check Failed Throttle Body Condition Exists 520281 Control - Mechanical Stop Adaptation Failure Throttle Body Condition Exists 520282 Control - Repeated Adaptation Failed Throttle Body Data Erratic, Intermittent Or 520283...
Page 79 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION ECU ADC Fault - No Condition Exists 520306 Load ECU ADC Fault - Condition Exists 520307 Voltage Accelerator Sensor Condition Exists 520308 Sync Fault - Sensor Diff Exceeds Limit ECU Fault - ICO Condition Exists 520309 ECU Fault -...
Page 80 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPAS Module Steering Over Current Above Normal Or 520221 Current Shut Down Grounded Circuit 520222 Steering Excessive Current Above Normal Or Current Error Grounded Circuit Steering Torque Condition Exists 520223 Partial Failure Steering Torque Full Condition Exists 520224 Failure...
Page 81 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Steering Torque Full Torque Sensor Out of Range 520223 Failure Torque Sensor Linearity Error 520224 EPS CAN No RX Message for {{cal 520226 Communications parameter}} seconds Receive Error Vehicle Speed Vehicle Speed Too High Vehicle Speed Implausible Received Vehicle Speed has Errors...
Page 82 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Position Encoder Loss of SPI Communication 520228 Error Encoder Variance Error EPS Software Error Manufacturing CRC Error 520229 Boot Count Error ICS Communication Loss of CAN between EPS and 520230 Instrument Cluster EPAS Power Save 5 minute time out 520231 ECU Memory...
Page 83: 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 84: Brake System Break-In
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 85: Safe Operation Practices
OPERATION ITEM REMARKS Wheels/fasteners Inspect, ensure fastener tightness page 174 Frame nuts, bolts, Inspect, ensure tightness – fasteners Fuel and oil Ensure proper levels page 34 page 142 Coolant level Ensure proper level page 154 Coolant hoses Inspect for leaks –...
Page 86: 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 87: 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 88: Know Your Riding Area / Tread Lightly
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 89 OPERATION 10. Place the transmission in PARK. 11. Start the engine. 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.
Page 90: Driving Uphill
OPERATION 5. The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. See the Safe Riding Gear section for details. 6. Always make sure all cab doors are closed and latched when riding in this vehicle.
Page 91: Driving On A Sidehill (Sidehilling)
OPERATION 4. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 5. Avoid unnecessary changes in speed or direction. 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.
Page 92: 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 93: 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 94: 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 95: 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 96: 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 97: 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 98: 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 99 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 100 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 101: Towing A Rzr
OPERATION TOWING A RZR Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See the Transporting the Vehicle section for details. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral.
Page 103: Winch Guide
WINCH GUIDE WINCH GUIDE WINCH SAFETY These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Page 104 WINCH GUIDE 12. If winching at an angle is unavoidable, follow these precautions: a. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
Page 105: Winch Operation
WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Page 106 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, or other qualified dealer.
Page 107 WINCH GUIDE • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead. • If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation.
Page 108 WINCH GUIDE 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. d.
Page 109 WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
Page 110: Winch Cable Care
Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
Page 111: Shock Loading
WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Page 112: Winch Maintenance And Service Safety
3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
Page 113: Emission Control Systems
OPERATION ON PUBLIC LANDS IN THE U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.
Page 115: Maintenance
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log at the end of the manual.
Page 116: Maintenance Intervals
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 qualified person perform these services.
Page 117 Inspect for leaks and loose fittings Fasteners Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 118 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 119 MAINTENANCE 100 HOUR / 1000 MILES (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 120 Inspect/clean; replace as needed Cam Chain Tensioner Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 121 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 122 Inspect for leaks and loose fittings Fasteners Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 123 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 124 MAINTENANCE 200 HOUR / 2000 MILES (3200 KM) SERVICE ITEM REMARKS Brake Pads / Parking XU / 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 XU / Inspect;...
Page 125 Inspect; adjust as needed Valve Clearance Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 126 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 127 Inspect for leaks and loose fittings Fasteners Replace or rebuild (if applicable) Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 128 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 129 MAINTENANCE 300 HOUR / 3000 MILES (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 130 Inspect/clean; replace as needed Cam Chain Tensioner Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 131 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 132 Inspect for leaks and loose fittings Fasteners Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 133 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 134 MAINTENANCE 400 HOUR / 4000 MILES (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 135 Inspect; adjust as needed Valve Clearance Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 136 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 137 Inspect for leaks and loose fittings Fasteners Inspect for leaks, loose joints, and wear XU Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 138 Inspect / add lubricant if needed Lubricant Transmission Lubricant Inspect / add lubricant if needed (AGL) XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services.
Page 139 MAINTENANCE 500 HOUR / 5000 MILES (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 140 Shock Absorbers XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. When the vehicle goes beyond 500 hours / 5000 miles (8000 km), return to the...
Page 141: Lubrication Recommendations
MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart section, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
Page 142 MAINTENANCE Middle Prop Shaft Grease Fitting Rear Prop Shaft Grease Fitting Rear Stabilizer Bar Grease Fitting Front Stabilizer Bar Grease Fitting...
Page 143: 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 144: Oil Check
MAINTENANCE OIL CHECK Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. Access the oil filter and oil check dipstick through the engine access panel located behind the seats.
Page 145: Oil And Filter Change
MAINTENANCE OIL AND FILTER CHANGE Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart section. 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 146 MAINTENANCE 14. Remove the dipstick. Wipe it dry with a clean cloth. 15. Reinstall the dipstick completely. Remove the dipstick and check the oil level. 16. Add oil as necessary to bring the level to the upper mark on the dipstick. Do not overfill.
Page 147: Transmission (Main Gearcase)
MAINTENANCE TRANSMISSION (MAIN GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications. FLUID CHECK The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.
Page 148: 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 149 MAINTENANCE DEMAND DRIVE UNIT (FRONT GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications. DEMAND DRIVE FLUID CHECK The fill plug is located on the bottom right side of the demand drive unit.
Page 150 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 151: 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 fl oz 10-14 ft-lbs 10-14 ft-lbs...
Page 152: Spark Plug Gap / Torque
7 ft-lbs (10 N·m) NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. Refer to the Specifications section for details. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
Page 153: Spark Plug Condition
MAINTENANCE SPARK PLUG CONDITION NORMAL PLUG The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTICE The tip should not be white.
Page 154 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 155 MAINTENANCE LABEL VALUE FUNCTION DRIVE 10A Fuse All-Wheel Drive, TURF (optional) ACCESSORY 10A Fuse (RZR) 12V Receptacle 15A Fuses (2) (RZR S4)
Page 156: 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 157 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 158: Overflow Bottle Coolant Level
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 159 • 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 160 MAINTENANCE BELT REPLACEMENT / DEBRIS REMOVAL WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death. If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt.
Page 161 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 162: 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 163: Filter Systems
MAINTENANCE FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart section. 1. Remove the cargo box access panel. 2. Clean all dirt and debris from the air box area. 3. Unlatch the two (2) air box cover straps and carefully remove the air box cover.
Page 164: Spark Arrester
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. Please see your POLARIS dealer or authorized person.
Page 165 MAINTENANCE 3. Use a non-synthetic brush to clean the arrester screen . A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 4. Inspect the screen for wear and damage. Replace a worn or damaged screen.
Page 166 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 167: Brake Inspection
MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40® or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks. 2.
Page 168: 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 169: Suspension Settings
• Never operate the vehicle on the highest or second highest preload settings without a total combined payload in the vehicle of 450 lb (204 kg) or more. Payload includes the driver, passenger, POLARIS-approved accessories and cargo. Never exceed the stated load capacity for the vehicle.
Page 170 MAINTENANCE FOX® SHOCKS (IF EQUIPPED) Spring Preload Adjustment The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain ground clearance when carrying additional weight. To adjust the preload, do the following: 1.
Page 171 Full clockwise position (0 clicks) 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/authorized person perform the adjustments.
Page 172 MAINTENANCE WALKER EVANS SHOCKS (IF EQUIPPED) The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. To adjust the preload, do the following: 1. Elevate the vehicle to allow the suspension to fully extend. 2.
Page 173 MAINTENANCE WALKER EVANS SHOCK COMPRESSION ADJUSTMENT (IF EQUIPPED) The compression damping clicker knob is located at the top of the shock reservoir. 1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression damping. FACTORY PRELOAD SETTINGS Setting Compression Damping...
Page 174: 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 175: Axle And Wheel Nut Torque Specifications
MAINTENANCE AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Front and Rear 120 ft-lbs Lug Nut (Aluminum Wheels) (162.7 N·m) Lug Nut (Steel Wheels) Front and Rear...
Page 176: 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 can assist. 1. Place the transmission in PARK.
Page 177: Headlight Replacement
MAINTENANCE LIGHTS Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. LED LAMPS If an LED headlamp appears to have moisture or fogging inside the lens, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out.
Page 178: Headlight Beam Adjustment
MAINTENANCE HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted slightly upward or downward and to the left or right. 1. Position the vehicle on a level surface. The headlight should be approximately 25 ft (7.6 m) from a wall. 2.
Page 179: Vehicle Immersion
MAINTENANCE 5. Include the weight of a rider on the seat while performing this step. Observe the headlight aim. As a starting point, the most intense part of the headlight beam should be 2 in (5 cm) below the mark on the wall. Adjust to operator preference.
Page 180: Steering Wheel Inspection
3. There should be 0.8-1.0 in (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 or other qualified personnel.
Page 181: Battery Removal
MAINTENANCE BATTERY WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Your vehicle has a low-maintenance battery.
Page 182: Battery Maintenance And Charging
If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer.
Page 183 MAINTENANCE When using an automatic charger other than a BatteryMINDer® 2012-AGM - 2 AMP charger, refer to the charger manufacturer's instructions for recharging. If using a constant current charger (instead of BatteryMINDer® 2012 AGM - 2 AMP charger), use the guidelines below. Always verify battery condition before and 1-2 hours after the end of charging.
Page 184: Cleaning And Storage
Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.
Page 185: Washing Tips
• Labels and decals • Electrical components and wiring • Air intake components If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
Page 186: Clean The Exterior
STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
Page 187: Fog The Engine
6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug caps to the spark plugs.
Page 188 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 section.
Page 189: Transporting The Vehicle
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 191: Specifications
SPECIFICATIONS SPECIFICATIONS TRAIL 900 SPECIFICATIONS TRAIL 900 Gross Vehicle Weight SPORT: 2062 lb (935 kg) PREMIUM: 2080 lb (943 kg) ULTIMATE: 2117 lb (960 kg) Dry Weight SPORT: 1238 lb (562 kg) Dry weight can also be found PREMIUM: 1260 lb (572 kg) on the manufacture’s ULTIMATE: 1297 lb (588 kg) statement of origin (MSO).
Page 192 Independent double a-arm with 10 in (25.4 cm) of travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission EPS: Lockable Differential Shift Type Dual Range P/R/N/L/H Tires / Tire Pressure - Front 26x8-12 / 10 psi (69 kPa)
Page 193 SPECIFICATIONS OUTPUT GEAR RATIOS OUTPUT GEAR RATIOS 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 authorized dealer for clutching specifications...
Page 194 SPECIFICATIONS TRAIL S 900 SPECIFICATIONS TRAIL S 900 Gross Vehicle Weight 2103 lb (954 kg) Dry Weight 1283 lb (582 kg) Dry weight can also be found on the manufacture’s statement of origin (MSO). Test GVW - Rollover 2300 lb (1043 kg) per OSHA® 29 CFR Protection System (ROPS) 1928.53 Rear Cargo Box Capacity...
Page 195 Independent double a-arm with 13.2 in (33.5 cm) of travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission EPS: Lockable Differential Shift Type Dual Range P/R/N/L/H Tires / Tire Pressure - Front 27x9-12 / 10 psi (69 kPa)
Page 196 SPECIFICATIONS OUTPUT GEAR RATIOS OUTPUT GEAR RATIOS 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 authorized dealer for clutching specifications...
Page 197: Polaris Products
POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PART NUMBER DESCRIPTION Engine Lubricant 2870791 Fogging Oil — 12 fl oz (355 mL) Aerosol 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil — 1 qt (0.95 L) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil — 1 gal (3.8 L) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil —...
Page 198: Part Number Description
U-Joint Grease — 3 fl oz (89 mL) Cartridge 2871551 U-Joint Grease — 14 fl oz (414 mL) Cartridge 2871329 Dielectric Grease (Nyogel®) Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite® 565 Thread Sealant 2859044 POLARIS Battery Tender Charger...
Page 199: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR / BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See the Low Range section for steep incline details.
Page 200: Possible Cause
Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors; connections blow on EFI fuse to remove impurities Mechanical failure Your POLARIS dealer or other qualified person can assist.
Page 201: Engine Turns Over, Fails To Start
ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel Refuel Clogged fuel filter Your POLARIS dealer or other qualified person can assist. Water is present in fuel Drain the fuel system and refuel Old or non-recommended fuel Replace with fresh recommended...
Page 202 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Incorrect ignition timing Your POLARIS dealer or other qualified person can assist. Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Exhaust leak Check all connections Mechanical failure Your POLARIS dealer or other qualified person can assist.
Page 203: Engine Pings Or Knocks
ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your POLARIS dealer or other qualified person can assist. Incorrect spark plug gap or heat Set gap to specs or replace plugs range...
Page 204: Engine Runs Irregularly, Stalls, Or Misfires
SOLUTION Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer or qualified person can assist Incorrect spark plug gap or heat Set gap to specs or replace plugs range...
Page 205: Engine Stops Or Loses Power
TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel tank vent line Inspect and replace or filter Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your dealer...
Page 207: Limited 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 208: Warranty Coverage And Exclusions
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 209: Lubricants And Fluids
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 210: How To Obtain Warranty Service
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 211: Exported Products
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 212: U.s.a. Epa Emissions Limited Warranty
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 213 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 214 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 215: California Residents
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Polaris Inc. are pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle. In California, new off-highway recreational vehicles must be designed, built and equipped to meet the State's stringent anti- smog standards.
Page 216 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 217: 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 219 3-Point Seat Belt ....... 40 Cooling System....... 154 Crankcase Emission Control System ......... 111 Crossing Hillsides ...... 22 Adding or Changing Coolant ..154 Air Box and Intake Duct Cautions ........ 15 Air Filter......... 161 Demand Drive Fluid Check ..147 All Wheel Drive (AWD) Switch ..
Page 220 Failure to Inspect Before Know Your Riding Area / Tread Operating ....... 18 Lightly® ......... 86 Fluid Change ....146, 148 Fluid Check ......145 FOX® Shock Compression Adjustment ......169 FOX® Shocks......168 Lights........175 Fuel Cap........34 Limited Warranty ..... 205 Fuel Transport Warning....
Page 221 Service Access Panels ....38 Payload Warning ....... 13 Service Intervals Periodic Maintenance Chart ..113 Maintenance ......114 Polaris Products ...... 195 Severe Use Definition ....113 POLARIS Variable Shock Loading the Winch ..109 Transmission (PVT) System ..157 Signal Words ......4 Polishing the Vehicle ....
Page 222 Trailer Receiver Hitch Bracket ..36 Transmission (Main Gearcase) ... 145 Transporting the Vehicle.... 187 Turning Improperly..... 22 U.S.A. EPA Emissions Limited Warranty ......210 Unauthorized Use of the Vehicle ... 26 Update Maps ......54 Update Software ....... 53 Using Alcohol or Drugs ....
Page 224 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Part No. 9931539 Rev 01 Medina, MN 55340 Printed in USA...

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Polaris RZR Trail 900 2021 Owner's Manual

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