Polaris Ranger RZR Owner's Manual For Maintenance And Safety
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Polaris Ranger RZR Owner's Manual For Maintenance And Safety

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  • Page 3 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 4 • 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 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 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 6: Table Of Contents

    Specifications ......126 Polaris Products..... . . 128 Troubleshooting .

  • Page 7: 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 8: Rider Safety

    SAFETY Rider Safety 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, on your vehicle or in this manual, alerts you to the potential for injury.

  • Page 9: Safety

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
  • Page 10 SAFETY Safety Decals and Locations Cab Frame/Seat Belt Warning WARNING Overturn 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 11 SAFETY Safety Decals 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 12 • make sure passenger reads and understands all safety labels. • watch for branches or other hazards that could enter vehicle. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.
  • Page 13 Failure to follow the warnings 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. A...
  • Page 14 Practice turning at slow speeds before attempting to turn at faster speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities.
  • Page 15 • Remove flammable material containers from the box before filling. • Always remove the ignition key when the vehicle is not in use to pre- vent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800- 342-3764.
  • Page 16 Your Polaris vehicle is designed to provide safe operation when used as directed. • Do not make any modifications to this Polaris vehicle. • Never operate with accessories not approved by Polaris for use on this vehicle. • The operator must check all safety components before each ride.
  • Page 17 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. Wear protective clothing for comfort and to reduce the chance of injury. Protection Long Helmet Sleeves Gloves Long Sturdy Pants Footwear...
  • Page 18 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 19: Age Restrictions

    SAFETY Rider Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license. Never operate with a passenger under the age of 12. Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor.

  • Page 20: Trail Etiquette

    Rider Safety Know Your Riding Area/Tread Lightly Your Polaris vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding club, or local officials.
  • Page 21 SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.
  • Page 22 SAFETY Rider Safety WARNING POTENTIAL HAZARD Riding in this vehicle without using the cab nets WHAT CAN HAPPEN Serious injury or death in the event of an accident or overturn HOW TO AVOID THE HAZARD Always use the cab nets while operating the vehicle. WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle...
  • Page 23 SAFETY Rider Safety WARNING POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Accident resulting in serious injury or death due to affected judgment, balance and perception and slower reaction time HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while riding this vehicle.
  • Page 24 WHAT CAN HAPPEN Loss of control, accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Never operate with accessories not approved by Polaris for use on this vehicle. Non-approved accessories may seriously affect vehicle stability. WARNING...
  • Page 25 SAFETY Rider Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 26 SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating through deep or fast-flowing water WHAT CAN HAPPEN Loss of traction, loss of control, overturn or accident resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for operating in water as described in the owner's manual.
  • Page 27 SAFETY Rider Safety WARNING POTENTIAL HAZARD Overloading the vehicle or carrying/towing cargo improperly WHAT CAN HAPPEN Loss of control, accident due to instability and changes in vehicle handling HOW TO AVOID THE HAZARD Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer.
  • Page 28 SAFETY Rider Safety WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for +15° climbing hills as described in the owner's manual.
  • Page 29 SAFETY Rider Safety WARNING POTENTIAL HAZARD Crossing hills and turning on hills WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Avoid operating on steep hills (15° maximum). Avoid crossing the side of a hill. WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing...
  • Page 30 SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating on excessively rough, slippery or loose terrain WHAT CAN HAPPEN Loss of traction, loss of control, accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain.
  • Page 31 SAFETY Rider Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Operating on frozen bodies of water...
  • Page 32 SAFETY Rider Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 33 SAFETY Rider Safety WARNING Operating a damaged vehicle can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
  • Page 34 SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Remove flammable material containers from the box before filling. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.

  • Page 35: Features And Controls

    Cab nets must be used by both operator and passenger at all times. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized Polaris dealer. NOTE: The vehicle illustrated below is shown without cab nets only to allow component identification.

  • Page 36: Component Locations

    FEATURES AND CONTROLS Component Locations Storage Compartment (under hood) Steering Wheel Headlights Radiator Brush Guard...
  • Page 37 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 72-73.

  • Page 38: Seat Adjustments

    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 39: Steering Wheel

    FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or Adjustment Lever downward for rider pref- erence. 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 40: Storage Compartment

    FEATURES AND CONTROLS Storage Compartment Remove the hood to access the front storage compartment. Refer to the specifications section beginning on page 126 for storage compartment capacity. Hood Remove the hood to access the front storage compartment, the radiator and the coolant overflow bottle. 1.

  • Page 41: Cab Nets

    Lower Cab Net Upper Cab Net 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 42 FEATURES AND CONTROLS Cab Nets Upper Cab Net Removal (Driver) The upper cab net on the driver’s side may be removed only if it inter- feres with operation of the vehicle. All other cab nets must remain installed. 1. Using a T-25 torx bit and 7/16" open end wrench, remove the mounting screw and washers secur- ing the upper and lower cab nets to...

  • Page 43: 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. WARNING Riding in this vehicle without wearing the seat belt can result in serious injury or death in the event of an accident or sudden stop. Always make sure the seat belts are secured for both the operator and passenger before riding.

  • Page 44: Seat Belt Inspection

    3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying, dirt, debris or stiffness. If any damage is found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

  • Page 45: Mode Switch

    FEATURES AND CONTROLS Switches Instrument Ignition Cluster Switch Mode Switch Work Light Switch Light 12V Accessory Switch Outlet Switch Mode Switch The yellow switch located near the instrument gauge is used to toggle through mode options available such as odometer, trip meter, hour meter, tachometer and clock.

  • Page 46: Ignition Switch

    FEATURES AND CONTROLS Switches Ignition Switch WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. The ignition switch is a three-position, key-operated switch. Use the ignition switch to start the engine.
  • Page 47 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 48: 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 49 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 50: 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. Speedometer Speedometer Needle Rider Information Center...
  • Page 51 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 electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear shifter position.
  • Page 52 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 42. 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 53 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 54 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 55 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 53 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
  • Page 56 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 57: Operation

    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 58: Brake System Break-In

    OPERATION Vehicle Break-In Period The break-in period for your vehicle is defined on the previous page. Please read the information carefully. Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 37. 2. Check the oil level. See page 83. Add the recommended oil as needed to maintain the oil level in the safe operating range.
  • Page 59 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 60: Starting The Engine

    OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Sit in the driver's seat and fasten the seat belt. 2.
  • Page 61 OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls. NOTE: When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.

  • Page 62: Parking The Vehicle

    OPERATION Parking the Vehicle WARNING Gasoline is extremely flammable and can be explosive under certain conditions. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
  • Page 63 OPERATION New Operator Driving Procedures WARNING Operating improperly can cause an accident or overturn which could result in severe injury or death. This vehicle handles differently than cars, trucks or other off-road vehicles. Operators of this vehicle must become familiar with vehicle handling at slow speeds before operating at faster speeds.
  • Page 64 OPERATION New Operator Driving Procedures 5. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed. 6.
  • Page 65 OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on pages 60-61. 2. Perform the pre-ride inspection. See page 56. 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 66 OPERATION Driving with a Passenger 7. Allow a passenger to ride only in the passenger seat. 8. Do not carry more than one passenger. Additional passengers can affect the operator’s ability to steer and operate the controls. 9. Slow down. Always travel at a speed appropriate for your skills, your passenger's skills, and operating conditions.

  • Page 67: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces When driving on slip- pery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, fol- low these precautions: 1. Slow down when entering slippery areas.

  • Page 68: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Proceed at a steady rate of speed and throttle opening. Avoid unnecessary changes in speed or direction. 15° maximum 3. Avoid steep hills (15° maximum). NOTE: If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending.
  • Page 69 OPERATION Driving on a Sidehill (Sidehilling) Avoid driving across the side of a hill. Control becomes difficult and there is an increased chance of vehicle overturn when driving on a hill- side. If crossing a hill is unavoidable, follow these precautions: 1.

  • Page 70: Driving Downhill

    OPERATION Driving Downhill Whenever descending a hill, follow these precautions: 1. Slow down. 2. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral. 3. Travel straight downhill. 4. Apply the brakes lightly to aid in slowing. WARNING Traveling downhill improperly could cause loss of control or vehicle overturn.

  • Page 71: Driving Through Water

    OPERATION Driving Through Water WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast- flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your vehicle. Your vehicle can operate through water with a maximum recommended...

  • Page 72: Driving Over Obstacles

    OPERATION Driving Over Obstacles 1. Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches. 2. Before operating in a new area, check for obstacles. 3. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

  • Page 73: Driving In Reverse

    OPERATION Driving in Reverse Follow these guidelines 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 74 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Place the transmission in PARK. 2. Turn the engine off. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury. Always place the transmission in PARK when stopping the engine.
  • Page 75 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 76: 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 77: 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 USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 78: 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 137.

  • Page 79: Maintenance Chart Key

    Perform these operations more often for vehicles subjected to severe use. 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.

  • Page 80: 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 81 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 82 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 83: 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 83. Brake Fluid DOT 4 Maintain level between fill lines.
  • Page 84 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Control Arm Pivot Bushings...

  • Page 85: 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 86 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine, behind the passenger seat.
  • Page 87 MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75.
  • Page 88 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 89: Transfer Case

    MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fill Plug Level Check...
  • Page 90 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 91 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the left side of the gearcase.
  • Page 92 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 93 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 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications.
  • Page 94 MAINTENANCE Gearcases Rear Gearcase Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the right side of the rear gearcase.
  • Page 95 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 128 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 96: Spark Plugs

    MAINTENANCE Spark Plugs CAUTION 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 126. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER .035"...
  • Page 97 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. NOTE: The tip should not be white.

  • Page 98: Cooling System

    Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 128 for the part numbers of Polaris prod- ucts. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.
  • Page 99 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 75. 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 100: Coolant Level

    Reinstall the cap. NOTE: 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 101 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 75. 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 102 • 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 103 MAINTENANCE Polaris Variable Transmission (PVT) System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Remove the seats. See page 35.

  • Page 104: Air Filter

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. 1. Access the air box Air Box Cover from behind the left rear wheel. Gasket 2. Remove the air box cover and inspect the gasket.

  • Page 105: 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 106: 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 107: Throttle Freeplay Adjustment

    MAINTENANCE 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 35.
  • Page 108 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 45. 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 109: 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 128 for the part num- bers of Polaris products. Change the brake fluid every two Brake Fluid...

  • Page 110: 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 111: Suspension Adjustment

    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 112: 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 113: 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. Wheel Removal 1. Position the vehicle on a level surface.
  • Page 114 MAINTENANCE Lights 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
  • Page 115 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 116: Brake Lights

    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 117 MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion.
  • Page 118 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 119: 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 118 before installing the battery.

  • Page 120: Battery Storage

    See page 118. NOTE: 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- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 121 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 115. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 122 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: 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...

  • Page 123: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.
  • Page 124 • Labels and decals • Electrical components and wiring NOTE: 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 125 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. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 126: Oil And Filter

    Make any necessary repairs and clean the vehicle as recommended. See page 120. 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. NOTE:...

  • Page 127: 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 128: Transporting The Vehicle

    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 129: Specifications

    SPECIFICATIONS RANGER RZR Gross Vehicle Weight 1727 lbs. (783 kg) Dry Weight 945 lbs. (429 kg) Fuel Capacity 7 gal. (26.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 4.8 qts. (4.5 l) Rear Gearcase Oil Capacity 18 oz. (532 ml) Demand Drive Fluid Capacity 6.75 oz.
  • Page 130 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 NOTE: See your Polaris dealer for clutching specifications.

  • Page 131: 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 132: Troubleshooting

    PVT system 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. Slippage from failure to...
  • Page 133 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 134 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 135 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 136: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 137 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.
  • Page 138 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 139 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 140: Maintenance Log

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

  • Page 143: Index

    INDEX Accessory Outlet ....43 Cab Net Interference (Driver) ..38 Adding Coolant ....95 Cab Net Removal (Driver) .
  • Page 144 INDEX EFI Blink Codes ... . . 52-53 Fluid Levels During Storage..123 Electromagnetic Interference ..74 Fluid Recommendations, Gearcase . 92 Emission Control, Crankcase .
  • Page 145 Maintenance, Periodic ..75-79 Polaris Products ....128 Miles to Kilometers Toggle ..52 Polishing the Vehicle.

  • Page 146: Index

    INDEX Removing the Vehicle from Storage 125 Suspension Adjustment ..108 Replacement, Headlight Lamp ..111 Switches ....42-43 Reverse .

This manual is also suitable for:

2008 ranger rzr

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