Owners Manual
Page 4
... Rev 02 Printed in a 2-seat vehicle. • with non-Polaris approved accessories - ALWAYS: • keep hands and feet inside vehicle. avoid sharp turns or sudden braking. • make sure passengers read and understand all safety labels. • avoid branches or other hazards that could enter vehicle. pavement may seriously affect stability. they may seriously affect handling and control. • with more than...
... Rev 02 Printed in a 2-seat vehicle. • with non-Polaris approved accessories - ALWAYS: • keep hands and feet inside vehicle. avoid sharp turns or sudden braking. • make sure passengers read and understand all safety labels. • avoid branches or other hazards that could enter vehicle. pavement may seriously affect stability. they may seriously affect handling and control. • with more than...
Owners Manual
Page 41
... the dash to operate in the OFF position. The key can be in the ON position to change the lights from the switch when it is in two wheel drive. Use the ignition switch to engage the electric starter. See page 54 for AWD operating instructions. Electrical circuits are on and off and to operate the headlights. FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is off. OFF ON START The engine...
... the dash to operate in the OFF position. The key can be in the ON position to change the lights from the switch when it is in two wheel drive. Use the ignition switch to engage the electric starter. See page 54 for AWD operating instructions. Electrical circuits are on and off and to operate the headlights. FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is off. OFF ON START The engine...
Owners Manual
Page 44
... turned off while the demand drive unit is below 3100. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is no limit to AWD while the rear wheels are at all wheel drive and the 4X4 indicator in AWD. If the switch is in two-wheel drive at rest. 40 If the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may remain in the instrument cluster...
... turned off while the demand drive unit is below 3100. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is no limit to AWD while the rear wheels are at all wheel drive and the 4X4 indicator in AWD. If the switch is in two-wheel drive at rest. 40 If the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may remain in the instrument cluster...
Owners Manual
Page 48
... displays time in the fuel tank. The vehicle should be brought to display, an open or short circuit has occurred in the fuel sensor circuit. Drive at idle and high electrical load (lights, cooling fan, accessories) is operating at an RPM too low to clear the warning. 5. Service Indicator - Fuel Gauge - When the last segment clears, a low fuel warning is on 4X4). 44 Refuel immediately. See page 46 for scheduled maintenance...
... displays time in the fuel tank. The vehicle should be brought to display, an open or short circuit has occurred in the fuel sensor circuit. Drive at idle and high electrical load (lights, cooling fan, accessories) is operating at an RPM too low to clear the warning. 5. Service Indicator - Fuel Gauge - When the last segment clears, a low fuel warning is on 4X4). 44 Refuel immediately. See page 46 for scheduled maintenance...
Owners Manual
Page 55
... the clutch and engine compartments when replacing the belt. 51 Always exercise extreme caution whenever handling gasoline. 2. Perform regular checks on fluid levels, controls and areas outlined on pages 56-57. 4. Pull only light loads. Fill the fuel tank with gasoline. Add the recommended oil as recommended. See page 34. See page 77. Break in the clutches and belt by operating at sustained idle. 6. Aggressive...
... the clutch and engine compartments when replacing the belt. 51 Always exercise extreme caution whenever handling gasoline. 2. Perform regular checks on fluid levels, controls and areas outlined on pages 56-57. 4. Pull only light loads. Fill the fuel tank with gasoline. Add the recommended oil as recommended. See page 34. See page 77. Break in the clutches and belt by operating at sustained idle. 6. Aggressive...
Owners Manual
Page 70
... the hitch point designated for this vehicle. A passenger must not exceed the maximum weight capacity. The combined weight of the vehicle. OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can create unstable operating conditions, which could result in a fall from the vehicle or contact with seat belt secured. 66 When handling off-centered loads that extend over rough or hilly terrain, reduce speed...
... the hitch point designated for this vehicle. A passenger must not exceed the maximum weight capacity. The combined weight of the vehicle. OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can create unstable operating conditions, which could result in a fall from the vehicle or contact with seat belt secured. 66 When handling off-centered loads that extend over rough or hilly terrain, reduce speed...
Owners Manual
Page 71
... this manual. The total load (operator, passengers, accessories, cargo and weight on rough or hilly terrain, reduce both speed and cargo. Never exceed the maximum capacities specified for braking when carrying cargo. See page 122. Exercise caution if the cargo load extends over the side of control or brake instability. OPERATION Hauling Cargo Your POLARIS vehicle has been designed to the trailer hitch bracket...
... this manual. The total load (operator, passengers, accessories, cargo and weight on rough or hilly terrain, reduce both speed and cargo. Never exceed the maximum capacities specified for braking when carrying cargo. See page 122. Exercise caution if the cargo load extends over the side of control or brake instability. OPERATION Hauling Cargo Your POLARIS vehicle has been designed to the trailer hitch bracket...
Owners Manual
Page 92
MAINTENANCE Fuses If the engine stops or will not start, if the power steering stops working (if equipped), or if you experience other electrical failures, a fuse may have caused the blown fuse, then replace the fuse. Fuse 20A 10A 20A 10A 20A Feature Supported Lights: Headlights, Taillights Drive: AWD Accessory: Winch Switch, 12V Power Receptacle Fuel Pump Electronic Engine Control, Starting Power Fuse 20A 30A 30A Feature Supported Engine Control Lights, Drive, Accessories Power Steering (if equipped) 88 Locate and correct any short circuits that may need replacement.
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 have caused the blown fuse, then replace the fuse. Fuse 20A 10A 20A 10A 20A Feature Supported Lights: Headlights, Taillights Drive: AWD Accessory: Winch Switch, 12V Power Receptacle Fuel Pump Electronic Engine Control, Starting Power Fuse 20A 30A 30A Feature Supported Engine Control Lights, Drive, Accessories Power Steering (if equipped) 88 Locate and correct any short circuits that may need replacement.
Owners Manual
Page 110
Do not service axle nuts that all nuts are torqued to specification. Carefully lower the vehicle to specification. Stop the engine. Loosen the wheel nuts slightly. Place the wheel in serious injury or death. Wheel Installation 1. Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in the correct position on the wheel hub. Attach the wheel nuts and washers and finger tighten...
Do not service axle nuts that all nuts are torqued to specification. Carefully lower the vehicle to specification. Stop the engine. Loosen the wheel nuts slightly. Place the wheel in serious injury or death. Wheel Installation 1. Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in the correct position on the wheel hub. Attach the wheel nuts and washers and finger tighten...
Owners Manual
Page 111
Oil from the wiring harness. Headlight Lamp Replacement LED Headlamps (if equipped) If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. Halogen Headlamps Do not service the headlamps until they've cooled sufficiently. 1. Make sure the tab on the wiring. 2. Reinstall the harness assembly into the headlight assembly. Turn the lamp counterclockwise to maintain lighting quality. Install the new lamp. MAINTENANCE Lights Poor lighting while driving can result in...
Oil from the wiring harness. Headlight Lamp Replacement LED Headlamps (if equipped) If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. Halogen Headlamps Do not service the headlamps until they've cooled sufficiently. 1. Make sure the tab on the wiring. 2. Reinstall the harness assembly into the headlight assembly. Turn the lamp counterclockwise to maintain lighting quality. Install the new lamp. MAINTENANCE Lights Poor lighting while driving can result in...
Owners Manual
Page 112
... ft. (7.6 m) from the floor to the center of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall at the same height. 3. Place the vehicle on the seat while performing this step. 5. Start the engine. Turn the headlights to adjust the beam. 6. If adjustment is properly adjusted. 108 Apply the brakes. Observe the headlight aim. Repeat steps...
... ft. (7.6 m) from the floor to the center of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall at the same height. 3. Place the vehicle on the seat while performing this step. 5. Start the engine. Turn the headlights to adjust the beam. 6. If adjustment is properly adjusted. 108 Apply the brakes. Observe the headlight aim. Repeat steps...
Owners Manual
Page 113
... engine over several times. 5. Turn the ignition switch to dry land. 2. The brake light should come on after about 10 mm (0.4 in starting the engine. If water is not thoroughly inspected. Attempt to take your dealer before each ride. 1. If water has been ingested into the PVT follow the steps outlined below. 1. Apply the brakes. If the light doesn't come on , check the bulb. Vehicle...
... engine over several times. 5. Turn the ignition switch to dry land. 2. The brake light should come on after about 10 mm (0.4 in starting the engine. If water is not thoroughly inspected. Attempt to take your dealer before each ride. 1. If water has been ingested into the PVT follow the steps outlined below. 1. Apply the brakes. If the light doesn't come on , check the bulb. Vehicle...
Owners Manual
Page 123
... pistons, rings, valves and exhaust systems. 3. Clean the Exterior Make any time the fluid looks dark or contaminated) • Coolant (test strength/fill) 119 Drain the sediment tube. Fill the fuel tank. 2. Follow the instructions on page 69. • Demand drive fluid (front gearcase) • Rear gearcase fluid • Transmission fluid • Brake fluid (change every two years and any necessary repairs and clean the vehicle as recommended in...
... pistons, rings, valves and exhaust systems. 3. Clean the Exterior Make any time the fluid looks dark or contaminated) • Coolant (test strength/fill) 119 Drain the sediment tube. Fill the fuel tank. 2. Follow the instructions on page 69. • Demand drive fluid (front gearcase) • Rear gearcase fluid • Transmission fluid • Brake fluid (change every two years and any necessary repairs and clean the vehicle as recommended in...
Owners Manual
Page 126
SPECIFICATIONS RANGER RZR / RZR S Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Transfer Case Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 1727 lbs. (783 kg) (RZR) 1782 lbs. (...
SPECIFICATIONS RANGER RZR / RZR S Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Transfer Case Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 1727 lbs. (783 kg) (RZR) 1782 lbs. (...
Owners Manual
Page 128
SPECIFICATIONS RANGER RZR 4 Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Transfer Case Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 2206 lbs. (1000 kg) 1255 lbs. (569 kg) (...
SPECIFICATIONS RANGER RZR 4 Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Transfer Case Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 2206 lbs. (1000 kg) 1255 lbs. (569 kg) (...
Owners Manual
Page 140
... the date of the vehicle owner. For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following...
... the date of the vehicle owner. For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following...
Owners Manual
Page 144
... Cab Nets ...34 Cap, Fuel ...34 Cargo ...66-67 Changing Coolant ...90 Changing Gears ...38 Chart, Periodic Maintenance ...69-73 Check Engine Indicator ...49 Chrome Wheel Care ...118 Cleaning and Storage...116-121 Cleaning the Air Filter...95 Cleaning the Exhaust System ...96 Cleaning the Spark Arrestor ...96 Clothing ...9 Clutching ...123, 125 Component Locations ...28-30 Condition, Spark Plugs ...87 Coolant Level ...92 Coolant Level, Radiator...91 Coolant, Adding or Changing ...90 Cooling Fan ...91 Cooling System...
... Cab Nets ...34 Cap, Fuel ...34 Cargo ...66-67 Changing Coolant ...90 Changing Gears ...38 Chart, Periodic Maintenance ...69-73 Check Engine Indicator ...49 Chrome Wheel Care ...118 Cleaning and Storage...116-121 Cleaning the Air Filter...95 Cleaning the Exhaust System ...96 Cleaning the Spark Arrestor ...96 Clothing ...9 Clutching ...123, 125 Component Locations ...28-30 Condition, Spark Plugs ...87 Coolant Level ...92 Coolant Level, Radiator...91 Coolant, Adding or Changing ...90 Cooling Fan ...91 Cooling System...
Owners Manual
Page 145
... Transfer Case ...80 Transmission...82 Fluid Levels During Storage...119 Fluid Recommendations, Gearcase . 86 Fluid, Battery ...113 Fluid, Brake ...100 Fogging the Engine...120 Fouled Plugs ...87 Freeplay Adjustment, Throttle ...98 Freeplay, Steering Wheel ...101 Fuel Cap ...34 Fuel Safety ...19 Fuel Stabilizer ...119 Fuel Tank Filler Cap ...34 Fuses ...88-89 G Gap, Spark Plug ...86 Gasoline Handling ...19 Gear Selector ...38 Gearcase Capacities ...86 Gearcase Oil Demand Drive...84 Front ...84 Main ...82-83 Rear...85 Transfer Case ...80...
... Transfer Case ...80 Transmission...82 Fluid Levels During Storage...119 Fluid Recommendations, Gearcase . 86 Fluid, Battery ...113 Fluid, Brake ...100 Fogging the Engine...120 Fouled Plugs ...87 Freeplay Adjustment, Throttle ...98 Freeplay, Steering Wheel ...101 Fuel Cap ...34 Fuel Safety ...19 Fuel Stabilizer ...119 Fuel Tank Filler Cap ...34 Fuses ...88-89 G Gap, Spark Plug ...86 Gasoline Handling ...19 Gear Selector ...38 Gearcase Capacities ...86 Gearcase Oil Demand Drive...84 Front ...84 Main ...82-83 Rear...85 Transfer Case ...80...
Owners Manual
Page 146
... Headlight Lamp Replacement ...107 Headlight Switch ...37 Helmet ...8 Hitch ...30 Hitch Weight ...67 Hood Removal ...33 M Maintenance Log ...138-139 Maintenance, Periodic ...69-73 Metric Display ...45 Mode Button ...41 N Nets, Cab ...34 New Operator Procedures ...56-57 Noise Emission Control System ...68 I Idle Speed ...98 Ignition Switch...37 Indicator Lamps ...42 Inspection, Axle Nuts ...105 Inspection, Brakes ...101 Inspection, Pre-Ride ...52 Inspection, Steering Wheel ...101 Inspection, Throttle Freeplay...97 Inspection, Wheel...
... Headlight Lamp Replacement ...107 Headlight Switch ...37 Helmet ...8 Hitch ...30 Hitch Weight ...67 Hood Removal ...33 M Maintenance Log ...138-139 Maintenance, Periodic ...69-73 Metric Display ...45 Mode Button ...41 N Nets, Cab ...34 New Operator Procedures ...56-57 Noise Emission Control System ...68 I Idle Speed ...98 Ignition Switch...37 Indicator Lamps ...42 Inspection, Axle Nuts ...105 Inspection, Brakes ...101 Inspection, Pre-Ride ...52 Inspection, Steering Wheel ...101 Inspection, Throttle Freeplay...97 Inspection, Wheel...
Owners Manual
Page 147
..., Gear ...38 Service Panel, Rear ...31 Severe Use Definition...69 Shifting Gears ...38 Shock Compression ...104 Signal Words ...4 Spark Arrester Warning ...96 Spark Arrestor Cleaning ...96 Spark Plug Condition ...87 Spark Plug Gap ...86 Spark Plug Removal ...87 Spark Plug Torque ...86 Spark Plugs ...86-87 Spark Plugs, Fouled ...87 Specifications ...122-125 Specifications, Gearcase ...86 Speed, Idle ...98 Speed, Towing ...67 Speedometer ...41 Spring Preload ...103 Spring Preload (RZR) ...102 Stabilizing the Fuel ...119 Starting the Engine ...54 Steering Wheel Adjustment ...32 Steering Wheel...
..., Gear ...38 Service Panel, Rear ...31 Severe Use Definition...69 Shifting Gears ...38 Shock Compression ...104 Signal Words ...4 Spark Arrester Warning ...96 Spark Arrestor Cleaning ...96 Spark Plug Condition ...87 Spark Plug Gap ...86 Spark Plug Removal ...87 Spark Plug Torque ...86 Spark Plugs ...86-87 Spark Plugs, Fouled ...87 Specifications ...122-125 Specifications, Gearcase ...86 Speed, Idle ...98 Speed, Towing ...67 Speedometer ...41 Spring Preload ...103 Spring Preload (RZR) ...102 Stabilizing the Fuel ...119 Starting the Engine ...54 Steering Wheel Adjustment ...32 Steering Wheel...