Polaris RZR 800 Owner's Manual
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Polaris RZR 800 Owner's Manual

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PMS 419
RZR® 800
RZR® S 800
RZR® 4 800
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris RZR 800

  • Page 1 PMS 419 RZR® 800 RZR® S 800 RZR® 4 800 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 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2014 RZR 800 / RZR S 800 / RZR 4 800 Owner’s Manual P/N 9924707...

  • Page 5: Table Of Contents

    Specifications ......132 POLARIS Products..... 136 Troubleshooting .

  • Page 6: Introduction

    INTRODUCTION The RZR is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used.
  • Page 7 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.

  • Page 8: 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 9: Safety

    SAFETY Safety Training Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. To access this valuable training, visit www.rohva.org.

  • Page 10: 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 11 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 12 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 Warning...
  • Page 13 SAFETY Safety Labels and Locations Seat Belt/Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belts. • Wear an approved helmet and protective gear. • ALWAYS use cab nets and/or doors. Seat Belt/Drive •...
  • Page 14 SAFETY Safety Labels and Locations Proper Use Shift Caution Warning Proper Use Warning (RZR) WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license.
  • Page 15 SAFETY Safety Labels and Locations Rear Passenger Cab Frame Passenger Cab Frame Warning (RZR 4) Warning (both sides) WARNING Do NOT hold onto this bar. Hands and arms could be crushed or seriously injured in event of rollover. ALWAYS keep hands on passenger hand hold.

  • Page 16: 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 17: 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 perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 18 SAFETY Safety Warnings Carrying Multiple Passengers (RZR 4) 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 52-53. A passenger must always be seated in a passenger seat with seat belt secured.

  • Page 19: Operating On Pavement

    SAFETY Safety Warnings Passengers in the Cargo Box Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box. A passenger must always be seated in the passenger seat with seat belt secured.

  • Page 20: Turning Improperly

    SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.

  • Page 21: Crossing Hillsides

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

  • Page 22: Skidding Or Sliding

    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 60. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.

  • Page 23: Operating A Damaged Vehicle

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

  • Page 24: 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 this owner’s manual for carrying cargo. See page 62.

  • Page 25: Exposure To Exhaust

    SAFETY Safety Warnings Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle.

  • Page 26: Equipment Modifications

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

  • Page 27: Features And Controls

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

  • Page 28: Component Locations

    FEATURES AND CONTROLS Component Locations Cab Frame Under Hood Steering Storage Wheel Compartment (LE models) Headlights Radiator Taillights Brush Guard 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 62-64.

  • Page 29: 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 30: 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 31 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 32: Fuel Cap

    Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer.

  • Page 33: 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 34: 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 35: 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 50 for starting procedures. The key can be removed from the switch when it is in the OFF position. The engine is off.

  • Page 36: 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 37: Brake Pedal

    ROPS Label Structure (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 rollover.

  • Page 38: 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 39: 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 40: 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 41: 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 42 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 43 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 44: Clock Mode

    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 45 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 46 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 47: Engine Error Codes

    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 48: 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 49: Brake System Break-In

    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 30. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 85. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 50 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 51: 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 52: 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 53: 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 54 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course. Hands-on training is also available through ROHVA.
  • Page 55 OPERATION New Operator Driving Procedures 13. Apply the brakes and shift into low gear. 14. Check your surroundings and determine your path of travel. 15. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 16.

  • Page 56: Driving With Passengers

    OPERATION Driving with Passengers 1. Complete the New Operator Driving Procedures outlined on pages 52-53. 2. Perform the pre-ride inspection. See page 48. 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 57: 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 58: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending any hill. Never drive on hills with excessively slippery or loose surfaces. 2. Avoid excessively steep hills. If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending.

  • Page 59: Driving Downhill

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

  • Page 60: 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 61: 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 62: 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 63: 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 64: 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 65: 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 66: Towing Loads

    OPERATION Hauling Cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow- ing bracket.

  • Page 67: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

  • Page 68: Winch Safety Precautions

    WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed. 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible.
  • Page 69 WINCH GUIDE Winch Safety Precautions 18. Never release the clutch on the winch when the winch cable is under load. 19. Never use the winch for lifting or transporting people. 20. Never use the winch to hoist or suspend a vertical load. 21.

  • Page 70: Winch Operation

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

  • Page 75: Winch Cable Care

    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 76 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 77: 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.

  • Page 78: 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 79: 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 148.

  • Page 80: 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 81 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 82 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 83 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 84: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 77, 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 85 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 86: 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 oil is not used. Follow the manufacturer's recommendations for ambient tempera- ture operation. See page 136 for the part numbers of POLARIS prod- ucts.

  • Page 87: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. 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 88: 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 77. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase.
  • Page 89 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 90 MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 77. Refer to the Gearcase Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications. Fill Plug Level Check...
  • Page 91 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 92 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 77. Refer to the Gearcase Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the left side of the gearcase.
  • Page 93 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 94 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 77. Refer to the Gearcase Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications.

  • Page 95: 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 77. Refer to the Gearcase Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the right side of the rear gearcase.

  • Page 96: Gearcase Specification Chart

    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 136 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Drain Plug/ Torque Level Check Plug Torque Transmission AGL Gearcase 24 oz.

  • Page 97: 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 27. 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 98 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 99: Fuses

    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 100: Cooling System

    POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. POLARIS Antifreeze is already premixed and ready to use.

  • Page 101: 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 77. 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 102: 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 103 • See your dealer as recommended in the owner’s manual and on safety labels. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 104: 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, loss of control and severe injury or death.

  • Page 105: Air Filter

    MAINTENANCE Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. 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 106: 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 107: 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 108: 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 27.
  • Page 109 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 35. 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 110: 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 136 for the part num- bers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 111: Brake Inspection

    MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other 3/64"...

  • Page 112: Steering Wheel 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 113: 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 114 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 Preload Setting vehicle slightly for easier Measurement adjustment.
  • Page 115 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 116 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 117: 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 118: 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 119 MAINTENANCE Lights Do not operate the vehicle at night or in low light conditions without properly working headlights. Always make sure lights are adjusted properly for best visibility. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out.
  • Page 120 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 121: 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 122 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 123: 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 124: 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 124 before installing the battery.

  • Page 125: Battery Storage

    See page 124. 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 126 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 121. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 127 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 128: 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 129: 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 130 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 131: Storage Tips

    126. 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 132 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug caps to the spark plugs.

  • Page 133: Removal From Storage

    Secure or remove all cargo, and inspect the unit for loose parts prior to transport. 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 134: Specifications

    SPECIFICATIONS RZR / RZR S Gross Vehicle Weight Rating RZR: 1727 lbs. (783 kg) RZR S: 1782 lbs. (808 kg) Dry Weight RZR: 993 lbs. (450 kg) RZR EPS: 1041 lbs. (472 kg) RZR S: 1029 lbs. (467 kg) RZR S EPS: 1055 lbs. (479 kg) Test GVW - Rollover Protection RZR: 1745 lbs.
  • Page 135 SPECIFICATIONS RZR / RZR S Lubrication System Wet Sump 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 136 SPECIFICATIONS RZR 4 Gross Vehicle Weight Rating 2206 lbs. (1000 kg) Dry Weight 1255 lbs. (569 kg) (RZR 4) 1271 lbs. (576.5 kg) (RZR 4 EPS) Test GVW - Rollover Protection 2250 lbs. (1021 kg) per OSHA 29 CFR 1928.53 System (ROPS) Rear Cargo Box Capacity 300 lbs.
  • Page 137 SPECIFICATIONS RZR 4 Lubrication System Wet Sump 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 Drive Ratio - Final 3.70:1...

  • Page 138: Polaris Products

    2877923 Demand Drive Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug Coolant 2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l) 2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l) Grease / Specialized Lubricants 2871312 Grease Gun Kit, All Season Grease 2871322 All Season Grease (3 oz./89 ml cartridge)

  • Page 139: Troubleshooting

    PVT outlet duct (see page 126). Inspect PVT system clutch 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 140 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 141 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 142 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 143: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 144 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 145 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied.
  • Page 146 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 147 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase...
  • Page 148 *As related to the evaporative emission control system. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 149 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 150: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 151 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 152: Index

    INDEX Accessory Outlet ....32 Cab Frame, ROPS ....35 Adding Coolant ....98 Cab Nets .

  • Page 153: Gearcase Oil

    INDEX Electromagnetic Interference ..76 Fluid Check Electronic Power Steering ..32 Demand Drive ....92 Front Gearcase .
  • Page 154 INDEX Hand Hold, Passenger ... 28 Maintenance Log ... 148-149 Hauling a Load ....62-64 Maintenance, Periodic .
  • Page 155 Seat Removal ....27 Polaris Products ....136 Selector, Gear ....34 Polishing the Vehicle .
  • Page 156 INDEX Storage Area ....130 Vehicle Identification Numbers..6 Storage, Battery ....123 Vehicle Immersion .
  • Page 157 12 or who cannot comfortably reach the floor and hand holds. • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death.

This manual is also suitable for:

Rzr s 8002014 rzr 4 8002014 rzr 8002014 rzr s 800

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