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Polaris RANGER RZR Owner's Manual

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RANGER RZR
RANGER RZR S
RANGER RZR 4
Owner's Manual
for Maintenance and Safety

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Table of Contents
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  Summary of Contents for Polaris RANGER RZR

  • Page 1 RANGER RZR RANGER RZR S RANGER RZR 4 Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 • On public roads. • 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.
  • 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.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2013 RANGER RZR / RANGER RZR S / RANGER RZR 4 Owner’s Manual P/N 9924099...
  • Page 7: Table Of Contents

    Specifications ......122 POLARIS Products..... 126 Troubleshooting .
  • Page 8: Introduction

    INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 9 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 10: Vehicle Identification Numbers

    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 11: Safety

    This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Do not install on a POLARIS vehicle any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 12: Safe Riding Gear

    Helmet Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 13 Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots. Do not ride a POLARIS vehicle with bare feet. Clothing Wear long sleeves and long pants to protect arms and legs.
  • Page 14: Safety Warnings

    Accessories Non-approved accessories may seriously affect vehicle stability. Using accessories not approved by POLARIS for use on this vehicle could cause loss of control or an accident. Never operate with accessories not approved by POLARIS for use on this vehicle.
  • Page 15: Protective Apparel

    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 inspect the vehicle before each use to make sure it's in safe operating condition.
  • Page 16 SAFETY Safety Warnings Carrying Multiple Passengers (RZR) 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 56-57. A passenger must always be seated in a passenger seat with seat belt secured.
  • Page 17: Operating On Pavement

    SAFETY Safety Warnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots, and driveways) may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. This vehicle's tires are designed for off-road use only, not for use on pavement.
  • Page 18: Turning Improperly

    SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.
  • Page 19: Descending Hills Improperly

    SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. Always follow proper procedures for traveling down hills as described in the owner's manual. • Always descend a hill with the transmission in forward gear.
  • Page 20: Improper Tire Maintenance

    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 21: Skidding Or Sliding

    SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles. Never attempt to operate over large obstacles such as rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.
  • Page 22: Improper Cargo Loading

    SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying/towing cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in the owner's manual for carrying cargo or pull- ing a trailer.
  • Page 23: Handling Gasoline

    Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use. FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764.
  • Page 24 If an informational or graphic label becomes illegible or comes off, con- tact 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. Load/Passenger/Tire Pressure...
  • Page 25 Loads should be centered and carried as low as possible in box. • For stability on rough or hilly terrain, reduce speed and cargo. • Be careful if load extends over the side of the box. RANGER RZR RZR 570 RZR 4 RZR XP MAXIMUM CARGO BOX LOAD 300 lbs.
  • Page 26 SAFETY Safety Labels and Locations Overturn Warning Warning Cab Frame/Seat Discretionary Shift Belt Warning Warning Caution Cab Frame/Seat Belt Warning WARNING • ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat belt. • ALWAYS SECURE CAB NETS. • VEHICLE OVERTURN could cause severe injury or death.
  • Page 27: Age Warning

    SAFETY Safety Labels and Locations Shift Caution CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place shift in the parked position. APPLY BRAKE TO START 7174843 Age Warning WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.
  • Page 28 Discretionary • on paved surfaces - pavement may seriously Warning affect handling and control. • with non-POLARIS approved accessories - they may seriously affect stability. ALWAYS: • keep hands and feet inside vehicle. • reduce speed and use extra caution when carrying a passenger.
  • Page 29 • on hills steeper than 15 degrees. • on public roads. • on paved surfaces - pavement may seriously affect handling and control. • with non-POLARIS approved accessories - they may seriously affect stability. ALWAYS: • keep hands and feet inside vehicle.
  • Page 30 SAFETY Safety Labels and Locations Passenger Safety Warning Passenger Safety Warning (RZR) WARNING NEVER CARRY A PASSENGER UNDER AGE 12 NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH, NEVER carry a passenger under age 12 or too small to firmly plant feet on the floor and securely grasp hand holds.
  • Page 31 SAFETY Safety Labels and Locations Passenger Safety Warning (RZR 4) WARNING NEVER CARRY PASSENGERS UNDER AGE 12 NEVER CARRY MORE THAN THREE PASSENGERS PASSENGERS UNDER NEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH, NEVER carry passengers under age 12 or too small to firmly plant feet on the floor and securely grasp hand holds.
  • Page 32: Features And Controls

    FEATURES AND CONTROLS Component Locations Rear Passenger Grab Bar Cab Nets Front Passenger Cargo Hand Hold Shifter Fuel Tank Hip Bars Tie-Down Points Rack Extenders (RZR/RZR EPS only)
  • Page 33: Component Locations

    FEATURES AND CONTROLS Component Locations Frame Under Hood Storage Compartment Steering (LE models) Wheel Headlights Radiator Brush Guard...
  • Page 34 FEATURES AND CONTROLS Component Locations Taillights Receiver Hitch Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 66-67.
  • Page 35: Seat Removal

    FEATURES AND CONTROLS Rear Service Panel The rear service panel is located behind the seats on the frame of the vehicle. Remove the seats to access the service panel. Remove the ser- vice panel to access serviceable engine components and clutches. Radiator Access/Grill Removal The front grill can be removed to clean debris from the radiator.
  • Page 36: 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 down- ward. Release the lever when the steering wheel is Adjustment Lever at the desired position.
  • Page 37 FEATURES AND CONTROLS Hood Remove the hood to access the front storage compartment (if equipped), the radiator cap and the coolant overflow bottle. 1. Turn the hood fasteners Storage Compartment 1/4 turn. (LE models) 2. Grasp the upper hood edge and pull upward to disengage the hood from the vehicle.
  • Page 38: Fuel Cap

    Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, avail- able from your authorized POLARIS dealer.
  • Page 39: Seat Belts

    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. To wear the seat belt properly, follow this procedure: 1.
  • Page 40: Auxiliary Outlet

    (under cover) in the 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. See your authorized POLARIS dealer for service.
  • Page 41: Ignition Switch

    FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. Use the ignition switch to start the engine. See page 54 for starting procedures. The key can be removed from the switch when it is in the OFF position. The engine is off.
  • Page 42: Gear Selector

    FEATURES AND CONTROLS Gear Selector P: Park R: Reverse N: Neutral L: Low Gear H: High Gear To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle Gear Selector is moving.
  • Page 43: Brake Pedal

    (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. 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 roll- over.
  • Page 44: Engaging Awd

    FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the vehi- cle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.
  • Page 45: 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. Do not use alcohol to clean the instrument cluster.
  • Page 46: Indicator Lamps

    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. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
  • Page 47: Rider Information Center

    If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
  • Page 49 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 50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or dis- charged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 51 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 52 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer 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 53 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. See an authorized POLARIS dealer for code details and diagnosis.
  • Page 54: 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 gaso- line. No single action on your part is as important as a proper break-in period.
  • Page 55: Brake System Break-In

    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 77. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 56 Throttle Ensure proper operation Indicator lights/switches Ensure proper operation Air filter, pre-filter Inspect, clean Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat Latches...
  • Page 57: Safe Operation Practices

    4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.
  • Page 58: Starting The Engine

    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in PARK. 4.
  • Page 59: Parking The Vehicle

    Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by con- tacting 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 60 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Perform the pre-ride inspection. See page 52. 3. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
  • Page 61 OPERATION New Operator Driving Procedures 10. Apply the brakes and shift into low gear. 11. Check your surroundings and determine your path of travel. 12. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 13.
  • Page 62: Driving With Passengers

    OPERATION Driving with Passengers 1. Complete the New Operator Driving Procedures outlined on pages 56-57. 2. Perform the pre-ride inspection. See page 52. 3. Do not carry more than one passenger in a 2-seat vehicle. Do not carry more than three passengers in a 4-seat vehicle.
  • Page 63: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 64: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. Avoid steep hills (15° maximum). If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending. 3. Drive straight uphill. 4.
  • Page 65: Driving Downhill

    OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1.
  • Page 66: Driving Through Water

    OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the Floor Level water level is lowest and where both banks have grad-...
  • Page 67: 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 haz- ards such as logs, rocks and low hanging branches. 3.
  • Page 68: 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 69: 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 precau- tions: 1. Place the transmission in PARK. 2. Turn the engine off. 3.
  • Page 70: Hauling Cargo

    OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing 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 71: Belt Life

    OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities. 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 72: 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 accor- dance 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 73: 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 beginning on page 138.
  • Page 74: Periodic Maintenance Chart

    Emission-related service (failure to conduct this maintenance will not void the emissions warranty but may affect emissions) Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an...
  • Page 75 Main gearcase oil 25 H Break-in oil level check Transfer case oil 25 H Break-in oil level check Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 76 Spark plug 100 H 600 (1000) Inspect; replace as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 77 Adjust as needed 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. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 78: Lubrication Recommendations

    See page 84. (Front Gearcase) Rear Gearcase Oil Premium ATV Angle Drive See page 85. Fluid Prop Shaft POLARIS Premium U-Joint Locate fittings and grease. Lube Control Arm Pivot POLARIS Premium all Locate fittings and grease. Bushings, Front/Rear Season Grease or grease conforming to NLGI No.
  • Page 79 MAINTENANCE Lubrication Recommendations RZR S/RZR 4 Control Arm Stabilizer Bar Pivot Bushings Bushings RZR 4 Stabilizer Bar Bushings Control Arm Pivot Bushings RZR S/RZR 4 Control Arm Pivot Bushings...
  • Page 80: Engine Oil

    Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart. Oil may need to be changed more frequently if POLARIS PS-4 PLUS Synthetic engine oil is not used. Follow the manufacturer's recommen- dations for ambient temperature operation. See page 126 for the part numbers of POLARIS products.
  • Page 81: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine, behind the passenger seat (behind the right rear passenger seat on RZR 4 models).
  • Page 82: Oil And Filter Change

    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 69. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase.
  • Page 83 MAINTENANCE Engine Oil Oil and Filter Change 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crank- case. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.
  • Page 84 MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fill Plug Level Check...
  • Page 85 MAINTENANCE Gearcases Transfer Case Fluid Change The drain plug is located on the bottom of the transfer case. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3.
  • Page 86 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the left side of the gearcase.
  • Page 87 MAINTENANCE Gearcases 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 88 MAINTENANCE Gearcases Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications.
  • Page 89: Rear Gearcase

    MAINTENANCE Gearcases Rear Gearcase Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the right side of the rear gearcase.
  • Page 90: Spark Plugs

    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 126 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Drain Plug/ Torque Level Check Plug Torque Transmission Premium AGL 24 oz.
  • Page 91: Spark Plug Condition

    MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove both seats. 2. Remove the rear service Spark Plugs panel. See page 31. 3. Remove the spark plug cap. 4. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise.
  • Page 92 MAINTENANCE Fuses 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. Fuse Feature Supported Lights: Headlights, Taillights...
  • Page 93 MAINTENANCE Fuses The fuse box is located above the power Fuse Label steering unit. Spare fuses are provided in the fuse box. 1. From the left side of the vehicle, reach in and lift up on the two fuse box tabs. 2.
  • Page 94: Cooling System

    POLARIS Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 126 for the part numbers of POLARIS products.
  • Page 95: Radiator And Cooling Fan

    MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 69. Do not obstruct or deflect air flow through the radiator by installing unauthor- ized accessories in front of the radiator or behind the cooling fan.
  • Page 96: Coolant Level

    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. Have the cooling system inspected by your POLARIS dealer.
  • Page 97 • See your dealer as outlined in the owner's manual. • 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 98: Pvt Drying

    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 and severe injury or death.
  • Page 99: Air Filter

    MAINTENANCE Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. 1. Access the air box from Air Box Cover behind the left rear wheel. 2. Remove the air box cover Gasket and inspect the gasket.
  • Page 100: Spark Arrester

    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 101: Throttle System

    MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.
  • Page 102: Throttle Freeplay Adjustment

    Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment. Throttle Freeplay Adjustment 1. Remove both seats. Remove the rear service panel. See page 31.
  • Page 103 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 39. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm.
  • Page 104: 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 page 126 for the part num- bers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.
  • Page 105: Brake Inspection

    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 the steering feels rough or “catchy,” have the steering system inspected by an autho- rized POLARIS dealer.
  • Page 106: Suspension Settings

    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 slightly for easier adjustment.
  • Page 107 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 slightly for easier adjustment.
  • Page 108 MAINTENANCE Suspension Settings (RZR S Premium and RZR 4 Premium Models) 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 109: Tire Tread Depth

    MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.
  • Page 110: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 3. Attach the wheel nuts and washers and finger tighten.
  • Page 111: Headlight Lamp Replacement

    MAINTENANCE Lights Poor lighting while driving can result in severe injury or death. Head- light and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
  • Page 112: Headlight High Beam Adjustment

    MAINTENANCE Lights Headlight High Beam Adjustment 25 ft. (7.6 m) 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 113: Vehicle Immersion

    MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.
  • Page 114 MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 115: 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. Battery Removal 1.
  • Page 116: Battery Installation

    MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 114 before installing the battery.
  • Page 117: Battery Storage

    See page 114. Tip: Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-dis- charge.
  • Page 118 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 111. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 119 MAINTENANCE Battery Battery Charging (Sealed Battery) 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 120: Cleaning And Storage

    Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den 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 121: Washing The Vehicle

    • Cab and body panels • Labels and decals • Electrical components and wiring 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 122 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
  • Page 123: Storage Tips

    116. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 124 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 125: Removal From Storage

    2. Remove the key to prevent loss during transporting. 3. Secure the fuel cap and seats. 4. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to...
  • Page 126: Specifications

    SPECIFICATIONS RANGER RZR / RZR S Gross Vehicle Weight 1727 lbs. (783 kg) (RZR) 1782 lbs. (808 kg) (RZR S) Dry Weight 978 lbs. (444 kg) (RZR) 994 lbs. (451 kg) (RZR EPS) 1022 lbs. (464 kg) (RZR S) Rear Cargo Box Capacity 300 lbs.
  • Page 127 SPECIFICATIONS RANGER RZR / RZR S Lubrication System Wet Sump Engine Oil 2W-50 Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High 3.14:1 Drive Ratio - Front 3.82:1...
  • Page 128 SPECIFICATIONS RANGER RZR 4 Gross Vehicle Weight 2206 lbs. (1000 kg) Dry Weight 1255 lbs. (569 kg) (RZR 4) 1271 lbs. (576.5 kg) (RZR 4 EPS) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 900 lbs. (408.2 kg) (riders/cargo/accessories/...
  • Page 129 SPECIFICATIONS RANGER RZR 4 Lubrication System Wet Sump Engine Oil 2W-50 Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High 3.14:1 Drive Ratio - Front 3.82:1...
  • Page 130: Polaris Products

    Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...
  • Page 131: Troubleshooting

    PVT outlet duct (see page 116). Inspect clutch PVT system seals for damage if repeated leaking occurs. Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.
  • Page 132 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
  • Page 133 Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter See your POLARIS dealer Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel...
  • Page 134 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace 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 Incorrect spark plug gap or heat range...
  • Page 135: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 136 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materi- als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 137 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 138 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and...
  • Page 139 How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 140 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 141 POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. 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 142: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 143 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 144: Index

    INDEX Accessory Outlet ....36 Cab Frame, ROPS ....39 Adding Coolant ....90 Cab Nets .
  • Page 145 INDEX Electromagnetic Interference ..68 Fluid Check Electronic Power Steering ..36 Demand Drive....84 Emission Control, Crankcase .
  • Page 146 INDEX Hand Hold, Passenger ... 32 Maintenance Log ... 138-139 Hauling a Load ....66-67 Maintenance, Periodic .
  • Page 147 Severe Use Definition... . 69 Polaris Products ....126 Shifting Gears ....38 Polishing the Vehicle .
  • Page 148 INDEX Storage, Covers ....120 Vehicle Identification Numbers..6 Storage, Fluid Levels ... 119 Vehicle Immersion .