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Polaris RANGER RZR Owner's Manual

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RANGER RZR
RANGER RZR EPS
Owner's Manual
for Maintenance and Safety
Pantone 426C
TM
TM

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Table of Contents
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  Summary of Contents for Polaris RANGER RZR

  • Page 1 Pantone 426C RANGER RZR RANGER RZR EPS 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 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 5 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 6 POLARIS, POLARIS THE WAY OUT, RANGER and RANGER RZR are registered trademarks of Polaris Industries Inc. Copyright 2010 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...
  • Page 7: Table Of Contents

    Specifications ......120 Polaris Products..... . . 122 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. WARNING A WARNING indicates a hazardous situation which, if not avoided, may 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: Safety

    Footwear Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 13: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • 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: Carrying A Passenger

    SAFETY Safety Warnings Carrying a Passenger 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 54-55. Carrying Multiple Passengers Carrying more than one passenger in this vehicle can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and...
  • Page 17: Turning Improperly

    SAFETY Safety Warnings Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and your passenger’s skills. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn.
  • Page 18: 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 transmis- sion in forward gear. Never descend a hill with the transmission in neutral.
  • Page 19: Crossing Hillsides

    SAFETY Safety Warnings Crossing Hillsides 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 hillside is unavoidable, always follow proper procedures as described in the owner's manual.
  • Page 20: Improper Tire Maintenance

    SAFETY Safety Warnings Operating on Slippery Terrain Operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain. Always use extra caution on rough, slippery or loose terrain. Operating Improperly in Reverse Improperly operating in reverse could...
  • 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 pulling 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. Cargo Box Warning...
  • Page 25 SAFETY Safety Labels and Locations Cargo Box Warning WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. • Maximum 4X4 Box Load is 300 lbs. (136.4 kg) Tire Pressure/Cargo Overload Warning WARNING IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
  • Page 26 SAFETY Safety Labels and Locations Overturn Warning Warning Cab Frame/Seat Shift Belt 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. The cab frame is not designed or intended to provide rollover protection.
  • 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: Passenger Safety Warning

    SAFETY Safety Labels and Locations Discretionary Passenger Safety Warning Warning Passenger Safety Warning 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 29: Discretionary Warning

    • 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: Features And Controls

    Cab nets and side guards must be used by both operator and passenger at all times. Promptly replace worn or dam- aged cab nets with new cab nets, available from your authorized Polaris dealer. The vehicle illustrated below is shown without cab nets only to allow component identification.
  • Page 31 FEATURES AND CONTROLS Component Locations Storage Compartment (under hood) Frame Steering Wheel Headlights Radiator Brush Guard...
  • Page 32 FEATURES AND CONTROLS Component Locations Taillights Receiver Muffler Hitch (Spark Arrestor) 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 64-65.
  • Page 33: 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. Seats Before operating the vehicle, always push down on both seat backs to ensure the latches are secure.
  • Page 34: Steering Wheel

    FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider pref- Adjustment erence. Lever Lift and hold the steering wheel adjustment lever while moving the steer- ing wheel upward or downward. Release the lever when the steering wheel is at the desired position.
  • Page 35: Storage Compartments

    FEATURES AND CONTROLS Hood Remove the hood to access the front storage compartment, the radiator and the coolant overflow bottle. 1. If your model is equipped with remov- Storage able fasteners at the Compartment upper hood edge, Upper remove the fasteners. Fasteners 2.
  • Page 36 Promptly replace worn or damaged cab nets with new cab nets, available from your authorized Polaris dealer. Upper Cab Net Interference (Driver) The upper cab net on the driver’s side may interfere with vehicle opera- tion for some operators due to operator body type, driving style or riding apparel.
  • Page 37 FEATURES AND CONTROLS Cab Nets/Side Guards Upper Cab Net Removal (Driver) The upper cab net on the driver’s side may be removed only if it interferes with operation of the vehicle. All other cab nets and side guards must remain Step 1 installed.
  • Page 38: Seat Belts

    FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding. To wear the seat belt properly, follow this procedure: 1.
  • Page 39: 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. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.
  • Page 40: Auxiliary Outlet

    The EPS warning indicator briefly illuminates when the key is turned to the ON position. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized Polaris dealer for service. Electronic power steering (if equipped) engages when the ignition key is turned to the ON position.
  • 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 52 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 Gear Selector 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 is moving.
  • Page 43: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while start- ing the engine. Throttle Pedal Push the pedal down to Brake increase engine speed. Pedal Spring pressure returns the pedal to the rest position when released.
  • Page 44: Engaging Awd

    FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is con- trolled by the AWD switch. When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the AWD indicator light will be on.
  • Page 45: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. In addition to showing vehicle speed, the speedometer needle flashes when the fuel level is low.
  • Page 46: Rider Information Center

    Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the elec- tronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis.
  • Page 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode switch located near the instrument gauge to toggle through the mode options. See page 36. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 49: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informa- tional purposes only. Please see your dealer for all major repairs. Gear Circuit Diagnostic Screen This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge.
  • Page 50 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 47 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
  • Page 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground Engine Temp Sensor Circuit: Open or Short to Battery...
  • Page 52: 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. No single action on your part is as important as a proper break-in period.
  • Page 53: Brake System Break-In

    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 75. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 54 Ensure proper operation Indicator lights/switches Ensure proper operation Air filter, pre-filter Inspect, clean Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced Brake light/tail lamp Check operation, apply Polaris dielec- tric grease when lamp is replaced Seat Latches...
  • Page 55: 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 56: 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 57: 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 58 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 50. 3. Wear an approved helmet that fits properly and eye protection (gog- gles or face shield).
  • Page 59 OPERATION New Operator Driving Procedures 11. Apply the brakes and shift into low gear. 12. Check your surroundings and determine your path of travel. 13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 14.
  • Page 60: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on pages 54-55. 2. Perform the pre-ride inspection. See page 3. Make sure the passenger is at least 12 years of age and is tall enough to comfortably and safely sit in the passenger seat with the seat belt secured, put both feet on the floor and grasp the hand holds.
  • Page 61: 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 62: 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 unavoid- 15° maximum able, engage all- wheel drive before ascending.
  • Page 63: 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 64: 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 65: 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 66: 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 67: 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 68: 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 69: Belt Life

    OPERATION Hauling Cargo Your Polaris vehicle has been designed to carry or tow specific capaci- ties. Reduce speed and allow a greater distance for braking when carry- ing cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo.
  • Page 70: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
  • Page 71: 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 135.
  • Page 72 E 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 could result in component failure and lead to serious injury or death. Have an authorized...
  • Page 73: Periodic Maintenance Chart

    250 (400) Inspect level; change yearly Transfer case oil 25 H Monthly 250 (400) Inspect level; change yearly Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services.
  • Page 74 1000 (1600) Perform a break-in oil change at one month Oil filter change 100 H 1000 (1600) Replace with oil change Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services.
  • Page 75 Idle speed Adjust as needed 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 Have an authorized Polaris dealer perform these services...
  • Page 76: Lubrication Recommendations

    Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil Polaris Premium 4 Synthetic Add to proper level on dipstick. 0W40 See page 75. Brake Fluid DOT 4 Maintain level between fill lines.
  • Page 77 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Control Arm Pivot Bushings...
  • Page 78: Engine Oil

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W- 40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient tem- perature operation.
  • Page 79: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine, behind the passenger seat.
  • Page 80: 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 67. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase.
  • Page 81 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 82 MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fill Plug Level Check...
  • Page 83 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 84 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the left side of the gearcase.
  • Page 85 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 86 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 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications.
  • Page 87: 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 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the right side of the rear gearcase.
  • Page 88: Gearcase Specification Chart

    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 122 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 89: Spark Plugs

    (24 Nm) (24 Nm) NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 120. 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 90: Spark Plug Condition

    MAINTENANCE Spark Plugs 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 indi- cates the proper type and heat range for the engine and the service. Tip: The tip should not be white.
  • Page 91: Cooling System

    Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 122 for the part numbers of Polaris prod- ucts. Tip: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.
  • Page 92: 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 67. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.
  • Page 93: 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 94: Radiator Coolant Level

    MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 67. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.
  • Page 95 • Always follow all recommended maintenance procedures. 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 96: Pvt Drying

    MAINTENANCE Polaris Variable Transmission (PVT) System PVT Drying Before washing the vehicle, locate the PVT outlet duct under the right rear wheel well. Avoid spraying water directly toward the duct when washing the vehicle from the rear. See page 114.
  • Page 97: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. 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 98: Spark Arrestor

    MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor 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 99: 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 100: 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 29.
  • Page 101 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 102: 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 122 for the part num- bers of Polaris products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.
  • Page 103: 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 104 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 105: Suspension Settings (Rzr S)

    MAINTENANCE Suspension Settings (RZR S) Front/Rear Shock Compression Use a flat-blade screwdriver to make damping Clicker adjustments. The compression damping clicker is located on top of the shock reservoir, under the rear fender. When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position.
  • Page 106 WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments. 4. Tighten the jam nut firmly against the adjuster ring.
  • Page 107: 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 108: Wheel Removal

    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. 4. Carefully lower the vehicle to the ground.
  • Page 109: 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 110: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight 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 111: 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 112 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 113: 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 114: 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 112 before installing the battery.
  • Page 115: Battery Storage

    See page 112. 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 116 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 109. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 117 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 118: 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 garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
  • Page 119: 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 120 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 121: Oil And Filter

    114. 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 recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 122: Battery Maintenance

    6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug caps to the spark plugs.
  • Page 123: 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 the...
  • Page 124: Specifications

    SPECIFICATIONS RANGER RZR / RZR S Gross Vehicle Weight 1727 lbs. (783 kg) (RZR) 1782 lbs. (808 kg) (RZR S) Dry Weight 945 lbs. (429 kg) (RZR) 961 lbs. (436 kg) (RZR EPS) 1000 lbs. (454 kg) (RZR S) Rear Cargo Box Capacity 300 lbs.
  • Page 125: Specifications

    8 psi (55 KPa) Brakes, Front/Rear Foot Activated, 4-wheel hydraulic disc Headlights 2 single beam, 55W, quartz/halogen Taillights 2 single beam, 5W Brake Lights 2 single beam, 5W Instrument Cluster Auxiliary DC Outlet Clutching See your Polaris dealer for clutching specifications.
  • Page 126: Polaris Products

    Premium U-Joint Lube (3 oz.) 2871551 Premium U-Joint Lube (14 oz.) 2871329 Dielectric Grease (Nyogel Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger...
  • Page 127: Troubleshooting

    PVT outlet duct (see page 114). 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 128 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 129 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 130 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 131: Declaration Of Conformity

    Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS...
  • Page 132: Warranty

    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of your Polaris vehicle against defects in mate- rial or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 133 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 134 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 materials, 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 135 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 Registra- tion form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 136 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 137 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 applica- ble U.S.
  • Page 138 Polaris dealer to perform any service that may be necessary for your vehicle. 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 139: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 140 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 141 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 142: Index

    INDEX Accessory Outlet ....36 Cab Nets ....32-33 Adding Coolant .
  • Page 143: Index

    INDEX EFI Blink Codes ... . . 46-47 Fluid Levels During Storage..117 Electromagnetic Interference ..66 Fluid Recommendations, Gearcase . 84 Electronic Power Steering .
  • Page 144: Oil Change

    Noise Emission Control System . . . 66 Polaris Products ....122 Polishing the Vehicle... . 115 Power Steering.
  • Page 145 INDEX Radiator..... . . 88 Safety Warnings ... . 10-19 Radiator Coolant Level .
  • Page 146 INDEX Storage ....114-119 Towing Loads ....65 Covers .