Polaris RZR 200 EFI 2021 Owner's Manual
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Polaris RZR 200 EFI 2021 Owner's Manual

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2021-2022
For Maintenance and Safety
OWNER'S
MANUAL
RZR 200 EFI

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Summary of Contents for Polaris RZR 200 EFI 2021

  • Page 1 2021-2022 For Maintenance and Safety OWNER’S MANUAL RZR 200 EFI...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR Code® with your smartphone.
  • Page 3 This safety video can also be found at http://www.polaris.com/en-us/rider-support/safety. If you are on the homepage of the Polaris website, click on the Rider Community heading and select “Product Safety and Training Information” from the dropdown menu to access this page.
  • Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. Tread Lightly® is a registered trademark of the United States Department of Agriculture. Recreational Off-Highway Vehicle Association® and ROHVA® are registered trademarks of Recreational Off-Highway Vehicle Association. BatteryMINDer® is a registered trademark of VDC Electronics Inc. Loctite® is a registered trademark of Henkel Corporation.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.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 6 WELCOME...

  • Page 7: Table Of Contents

    Specifications ....129 Polaris Products ....133 Troubleshooting .

  • Page 9: Messages

    Polaris vehicle. Prior to driving or riding in the vehicle, please read and make sure they read this owner’s manual. Watch the instructional video with them.
  • Page 10 You must learn how to keep yourself and those around you safe while you're riding. Your parent or supervising adult and POLARIS want you to be safe while you enjoy riding your new vehicle, and that's why it’s very important that you read this owner’s manual and watch the instructional video.

  • Page 11: Introduction

    INTRODUCTION INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
  • Page 12 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. The ignition switch must be replaced if all keys are lost.
  • Page 13 (IF EQUIPPED) Some Polaris vehicles come equipped with a near-field communication (NFC) chip. The NFC chip is embedded in the Polaris emblem located at the front of the vehicle and seamlessly connects you to a digital platform of vehicle information and tools. See your dealer for more information.
  • Page 14 INTRODUCTION DEVICE COMPLIANCE STATEMENTS NOTICE Some vehicle models contain radio equipment as follows: USA RADIO COMPLIANCE This vehicle contains the following radio equipment or components that contain radio equipment: COMPONENT COMPONENT ID MANUFACTURER B1 Gauge Bluetooth® CYBLE-222014–01 Cypress Semiconductor Helmet Aware Beacon Minew Technologies This device complies with part 15 of the FCC Rules.
  • Page 15 MAX RF 0.00078 W 0.00116 W TRANSMITTING PWR Hereby, Polaris Industries Inc. declares that the above radio equipment is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address:...
  • Page 16 INTRODUCTION DECLARATION OF CONFORMITY This document is setting out the contents of the EC Declaration of Conformity. The particulars of machinery may differ for specific model.

  • Page 17: Safety

    SAFETY SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. WARNING Modifying this vehicle in any way can change the top speed, stability and handling performance of this vehicle. Modifications that increase speed,...
  • Page 18 SAFETY HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Always buckle and pull straps tight to ensure the helmet is secured. Parents and supervising adults should verify that the provided helmets fit properly.
  • Page 19 MUST be avoided at all times. See the OPERATION section of this owner’s manual for proper operating procedures. FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1–800–342– 3764. OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident.
  • Page 20 SAFETY OPERATOR RESTRICTIONS / AGE RESTRICTIONS This vehicle is for recreational use by young operators under adult supervision ONLY. Operation is prohibited for anyone under 10 years of age. Never operate with a passenger under age 10. All operators and riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand...
  • Page 21 Ride Inspection outlined in the Operation chapter before each use of your vehicle to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this owner’s manual. See the Polaris Maintenance Schedule section of the Maintenance chapter. PROTECTIVE APPAREL...
  • Page 22 SAFETY CARRYING MULTIPLE PASSENGERS (RZR 2-SEAT) Never carry a passenger until you have operated this vehicle for at least four hours and have completed the steps in the New Operator Driving Procedures section. A passenger must always be seated in a passenger seat with seat belt secured.
  • Page 23 SAFETY 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 a passenger seat with seat belt secured.
  • Page 24 SAFETY OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and experience and any passenger’s skills and experience. PHYSICAL CONTROL OF THE VEHICLE Removing hands from the steering wheel or hand holds or removing feet from the floor while riding increases the risk of loss of control and accident or rollover.
  • Page 25 SAFETY IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See the Driving Uphill section for details. DESCENDING HILLS IMPROPERLY Improperly descending a hill could cause loss of control or rollover.
  • Page 26 SAFETY STALLING WHILE CLIMBING A HILL Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped.
  • Page 27 SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
  • Page 28 SAFETY OPERATING IN COLD WEATHER WARNING Always be adequately prepared when operating in cold weather, especially below-freezing temperatures. Cold weather can affect the engine’s ability to start, which can be dangerous when operating in unfamiliar or remote areas. OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice.
  • Page 29 SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
  • Page 30 SAFETY 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 31 If an informational or graphic label becomes illegible or comes off, contact 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. TIRE PRESSURE AND LOAD WARNING...
  • Page 32 • on hills steeper than 15˚. • on paved surfaces - pavement may seriously affect handling and control. • with non-Polaris approved accessories - they may seriously affect stability. • at speeds that are too fast for the operators skills, the conditions and/or the...
  • Page 33 NEVER permit children under age 10 to operate this vehicle. NEVER permit a passenger whose feet cannot touch the floor. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. Part Number: 7300583...
  • Page 34 If an informational or graphic label becomes illegible or comes off, contact 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. TIRE PRESSURE AND LOAD WARNING...
  • Page 35 SAFETY GENERAL USE WARNING WARNING The general use warning is located on the inside of the driver’s door panel. • Read the owner’s manual. • Always wear the seat belts. • Use and secure cab nets and door close-offs. • Use an approved helmet and protective gear for all occupants.
  • Page 36 SAFETY HOT SURFACES ALERT WARNING The hot surfaces alert is located on the body above the muffler. Hot component. Hot components can cause burns and fire. Do not touch hot component. Part Number: 7185151...

  • Page 37: Features And Controls

    Your vehicle is equipped with cab nets and door close-offs on both sides of the vehicle. Cab nets and door close-offs must be used by both operator and passenger at all times. Promptly replace worn or damaged parts with new, available from your authorized POLARIS dealer. Daytime Running Lights...
  • Page 38 FEATURES AND CONTROLS SEATS DRIVER’S SEAT ADJUSTMENT 1. Lift the seat latch lever located under the right front edge of the driver’s seat. 2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever.
  • Page 39 3. Tighten the knob. SEAT BELTS This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 40 Always inspect doors and cab nets for tightness, wear, and damage before each use of the vehicle. Promptly replace worn or damaged doors, cab nets, or latches with new components. Your Polaris dealer can assist. FUEL CAP WARNING Never allow a child to refuel or handle gasoline.
  • Page 41 FEATURES AND CONTROLS IGNITION SWITCH The ignition switch is a three- position, key-operated switch. Use the ignition switch to start the engine. See page 77 for starting procedures. The key can be removed from the switch when it is in the OFF position. The engine is off.
  • Page 42 • N: Neutral • R: Reverse Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving. This could damage the transmission.
  • Page 43 FEATURES AND CONTROLS PARKING BRAKE WARNING Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the vehicle.
  • Page 44 FEATURES AND CONTROLS BRAKE/THROTTLE PEDAL BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. THROTTLE PEDAL Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.
  • Page 45 The helmet aware beacon and mounting adhesive comes shipped with the owner’s manual. This allows parents to mount to the Polaris supplied helmet or helmet of their choice. The helmet aware beacon should be mounted on a flat surface on the helmet.

  • Page 47: Instrument Cluster

    The clock displays time in a 12-hour or 24-hour format. Clock See page 69 for more information. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your Polaris Service dealer can provide scheduled maintenance. See page 73 Indicator...
  • Page 48 Do not operate the vehicle if this Check warning appears. Serious engine damage could Engine result. Your authorized Polaris dealer can assist. This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a...
  • Page 49 INSTRUMENT CLUSTER DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1...
  • Page 50 INSTRUMENT CLUSTER Speed Engine Temperature...
  • Page 51 INSTRUMENT CLUSTER DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 Odometer Service Hours...
  • Page 52 INSTRUMENT CLUSTER Trip 1 Trip 2 Trip Timer...
  • Page 53 INSTRUMENT CLUSTER Engine Temperature Voltage Geofence Status...
  • Page 54 INSTRUMENT CLUSTER Engine Hours...
  • Page 55 INSTRUMENT CLUSTER Speed Helmet Aware Status...
  • Page 56 INSTRUMENT CLUSTER OPTIONS MENU Press and hold the MODE button to enter the Options Menu. OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Youth Menu Set passcode, maximum speed, GeoFence, and helmet aware settings. Units - Distance Select MPH or KPH Units - Temp...
  • Page 57 INSTRUMENT CLUSTER DIAGNOSTIC CODE NOTICE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
  • Page 58 INSTRUMENT CLUSTER YOUTH MENU The Youth Menu contains features that a parent can utilize to help limit the performance of the vehicle for new and inexperienced operators. 1. Press and hold the MODE button to enter the Options Menu. NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item.
  • Page 59 ENTER PIN NOTICE If personal identification number (PIN) is lost or displaced please contact your Polaris dealer for assistance. 1. Press and hold the MODE button to enter the Options Menu. NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item.
  • Page 60 INSTRUMENT CLUSTER 3. Enter PIN. 4. To exit the Youth Menu the user can select Exit Menu function from Youth Menu, can hold MODE button and exit out of Youth Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. CHANGE PIN 1.
  • Page 61 The unrestricted top speed for this model is 29 mph (46 km/h). Maximum speed can be set using the process below or by using the Polaris Ride Command app.
  • Page 62 NOTICE To use the geofence features, first download the Polaris Ride Command™ app and sign up. Turning the geofence on and off and changing the speeds can be done through the vehicle display once a geofence boundary has been created through the Ride Command app.
  • Page 63 INSTRUMENT CLUSTER Press the MODE button. Toggle the Up/Down buttons to cycle through options (On/Off). With the desired option displayed, press the MODE button which will set function and return to the Youth Menu. 5. To exit the Youth Menu the user can select Exit Menu function from Youth Menu, can hold Mode Button and exit out of Youth Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
  • Page 64 INSTRUMENT CLUSTER OUTSIDE GEOFENCE SPEED 1. Press and hold the MODE button to enter the Options Menu. NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item. 2. Select YOUTH MENU by pressing the MODE button. 3.
  • Page 65 INSTRUMENT CLUSTER REQUIRE PIN TO START 1. Press and hold the MODE button to enter the Options Menu. NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item. 2. Select YOUTH MENU by pressing the MODE button. 3.
  • Page 66 INSTRUMENT CLUSTER PIN DELAY 1. Press and hold the MODE button to enter the Options Menu. NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item. 2. Select YOUTH MENU by pressing the MODE button. 3.
  • Page 67 NOTICE To use all of the helmet aware features first download the Polaris Ride Command app and sign up. Turning the helmet aware feature on and off can be done through the vehicle display but the helmet not detected behavior must be selected through the Ride Command app.
  • Page 68 INSTRUMENT CLUSTER CHANGE PIN 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” by pressing the MODE button. 3.
  • Page 69 INSTRUMENT CLUSTER UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units-Distance” from the Options Menu by pressing the MODE button.
  • Page 70 INSTRUMENT CLUSTER UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 71 INSTRUMENT CLUSTER CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
  • Page 72 INSTRUMENT CLUSTER 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button. Toggle the Up/Down Buttons to change the units (12H or 24H) With the correct unit displayed, Press the mode button which will set the unit.
  • Page 73 INSTRUMENT CLUSTER BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Color” from the Options Menu by pressing the MODE button.
  • Page 74 INSTRUMENT CLUSTER BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Level” from the Options Menu by pressing the MODE button.
  • Page 75 INSTRUMENT CLUSTER SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.

  • Page 77: Operation

    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 78 OPERATION 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. Tread lightly® Operate with respect for the terrain, avoid littering, and always stay on the designated trails.
  • Page 79 OPERATION ITEM REMARKS PAGE Helmet Aware System Check the condition of the battery in the helmet page 43 beacon. Grass and Leaves Remove grass, leaves, foreign matter, and other flammable material or debris, especially near the exhaust system STARTING THE ENGINE 1.
  • Page 80 OPERATION DAYTIME RUNNING LAMPS Your vehicle is equipped with daytime running lamps. The lamps illuminate for extra visibility, but are not designed for night driving. Do not allow operation of the machine in the dark. COLD WEATHER OPERATION If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase.
  • Page 81 OPERATION 4. Slowly release the brake pedal. 5. Block the rear wheels on the downhill side. 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: •...
  • Page 82 OPERATION DRIVING PROCEDURES 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 and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA®.
  • Page 83 OPERATION DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection. 2. Make sure all passengers are at least 10 years of age and 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 hold. 3.
  • Page 84 OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 85 OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1. Avoid excessively steep hills. 2. Always travel straight uphill. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 5.
  • Page 86 Give special attention to engine oil, transmission oil, and all grease fittings. If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your Polaris dealer can provide this service. If it’s impossible to bring the vehicle in before starting the engine, perform the services outlined on page 113, and take the vehicle in for service at the first opportunity.

  • Page 87: Emission Control Systems

    EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1a.
  • Page 88 EMISSION CONTROL SYSTEMS POLLUTANT EMISSIONS Engine exempt from non-road mobile machinery (NRMM) pollutant emissions Regulation (EU) 2016/1628. Engine used in reduced-scale vehicle model for recreational purposes, net power < 19 kW.

  • Page 89: Maintenance

    OVERVIEW Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized Polaris dealer can perform any service that may be necessary for your vehicle. Polaris also recommends Polaris parts for emissions-related service, however equivalent parts can be used.
  • Page 90 The items outlined in this service interval only need to be performed at the first 12 hours of operation. They do not need to be performed every 12 hours. * Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 91 Throttle Body Intake Ducts Inspect for proper sealing and air leaks. / Flanges Wheels / Tires / Lug Nuts Inspect; replace as needed. Inspect; adjust as needed. Valve Lash* * Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 92 MAINTENANCE Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation. EVERY 100 HOURS / 1000 MILES (1600 KM) OR YEARLY Replace air filter.
  • Page 93 Inspect; replace as needed. Wiring Inspect for wear, routing, and retention. * Have an authorized Polaris dealer or other qualified person perform these services. Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.
  • Page 94 Maintenance Schedule beginning on page 87. Polaris recommends the use of Polaris PS-4 5W-50 4-Cycle Oil for this vehicle. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 133 for the part numbers of Polaris products.
  • Page 95 MAINTENANCE OIL CHECK Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick . Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4.
  • Page 96 MAINTENANCE OIL CHANGE 1. Position the vehicle on a level surface. Set the parking brake. 2. Clean the area around the drain plug 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. WARNING Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 5.
  • Page 97 MAINTENANCE TORQUE Drain Plug: 10 ft-lbs (14 N·m) 10. Remove the dipstick. Add 35.5 fl oz (1050 mL) of the recommended oil. Do not overfill. See the specifications section for capacities. 11. Reinstall the dipstick. 12. Start the engine. Allow it to idle for 30 seconds. 13.
  • Page 98 Follow Fluid Change Procedure to verify transmission is filled with fluid. Always change the fluid at the intervals outlined in the Maintenance Schedule, see page 87. Polaris recommends the use of AGL Gearcase Lubricant and Transmission Fluid for this vehicle.
  • Page 99 MAINTENANCE The fill plug can be accessed on the right side of the transmission gearcase. The drain plug is located on the bottom of the transmission gearcase. Access the drain plug from the bottom of the vehicle. To change the transmission fluid, do the following: 1.
  • Page 100 DRIVE CHAIN LUBRICATION AND ADJUSTMENT Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Maintenance Schedule, see page 87. Lubricate more often under severe use, such as in dirty or wet conditions.
  • Page 101 MAINTENANCE 4. Repeat these steps until chain is adjusted to desired deflection. MEASUREMENT Chain Deflection: Using 22 lbs (100N) of force New Chain: 3/16 - 13/32” (5 - 10 mm) Broken In Chain: 13/32 - 19/32” (10 - 15 mm) NOTICE A new chain will stretch after the vehicle is used for a period of time.
  • Page 102 MAINTENANCE PARKING BRAKE ADJUSTMENT 1. Inspect and perform any needed service on the brake pads before adjusting the parking brake. 2. Position the vehicle on a level surface. Place the transmission in neutral. 3. Carefully elevate the rear of the vehicle slightly.
  • Page 103 MAINTENANCE SPARK PLUG SPARK PLUG REMOVAL AND REPLACEMENT WARNING A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. 1. Remove the spark plug cap 2. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise.
  • Page 104 POLARIS dealer, or other qualified person, for service and repair assistance. • This CVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the CVT housing is securely in place during operation.
  • Page 105 MAINTENANCE 1. Shift the transmission to neutral. Set the parking brake. 2. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. NOTICE Do not hold the throttle pedal wide open for more than 5 seconds. 3.
  • Page 106 MAINTENANCE AIR FILTER Inspect the air filter at the intervals outlined in the Maintenance Schedule, see page 87. In extremely dusty conditions, air filter replacement will be required more often. Access the air box near the right rear wheel. 1. Disengage the two cover latches 2.
  • Page 107 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 service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. •...
  • Page 108 MAINTENANCE FUSE REPLACEMENT 1. Remove fuse box cover 2. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage. 3. Secure the fuse box cover.
  • Page 109 MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. 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. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding.
  • Page 110 Tighten any loose fittings and replace any worn or damaged parts. 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 133 for the part numbers of POLARIS products. WARNING After opening a bottle of brake fluid, always discard any unused portion.
  • Page 111 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 authorized Polaris dealer or other qualified service facility before operating the vehicle.
  • Page 112 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. The front and rear shock absorber springs are adjustable to increase or decrease spring tension.
  • Page 113 MAINTENANCE 1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position. NOTICE It is important the height of both marks be equally positioned to get an accurate measurement.
  • Page 114 MAINTENANCE WHEEL TOE ALIGNMENT 1. Hold tie rod end to keep it from rotating. 2. Loosen jam nuts at both end of the tie rod. 3. Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in above.
  • Page 115 8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 9. If water has been ingested into the transmission follow the procedure in the...
  • Page 116 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 117 MAINTENANCE WHEEL INSTALLATION WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.
  • Page 118 MAINTENANCE 6. If hub nut was removed, install a new cotter pin after the hub nut has been tightened. If the holes do not line up, turn the hub nut until the cotter pin can be installed. 7. Install the hub cap LIGHTS DAYTIME RUNNING LIGHT REPLACEMENT To remove the headlight, do the following:...
  • Page 119 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 120 MAINTENANCE BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the steps in the Battery Charging section before installing the battery. 1.
  • Page 121 * Using AGM specific charger at standard amps specified on top of battery CLEANING AND STORAGE WASHING THE VEHICLE Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE High water pressure may damage components.
  • Page 122 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 123 MAINTENANCE POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish. CHROME WHEEL CARE (IF EQUIPPED) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new”...
  • Page 124 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 125 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. STORAGE AREA / COVERS Be sure the storage area is well ventilated.
  • Page 126 MAINTENANCE REMOVAL FROM STORAGE WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area. 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle.
  • Page 127 MAINTENANCE TRAILERING THE VEHICLE LOADING AND UNLOADING The weight distribution of the cargo loaded onto the trailer is important and will have an impact on how the vehicle handles on the road. Ensure the weight of the cargo is distributed properly and the trailer is not rear, front, or side heavy. Always use a spotter if you are uncomfortable loading the vehicle on your own.
  • Page 128 MAINTENANCE 1. Properly load the vehicle onto the trailer or towing vehicle. WARNING If transporting the vehicle in a non-enclosed trailer, the vehicle must FACE FORWARD, or the roof, if equipped, must be removed. Failure to comply may allow airflow, vibration, or other factors to separate the roof from the vehicle and cause an accident, resulting in serious personal injury or death.
  • Page 129 MAINTENANCE 9. Using suitable straps, secure the vehicle to the trailer at the designated tie- down points (front and rear). The straps must be secured in a manner that provides support in all directions. Ensure that the straps are not making contact with any other part of the trailer or cargo, and that they are set with enough tension as to compress the suspension and prevent vehicle movement during transport.
  • Page 130 MAINTENANCE TIE-DOWN LOCATIONS Front tie-down point (only one side shown, use same spot on other side). Rear tie-down points...

  • Page 131: Specifications

    SPECIFICATIONS SPECIFICATIONS RZR 200 EFI VEHICLE DIMENSIONS Length 85 in (215.9 cm) 48 in (121.9 cm) Width Height 58 in (147.3 cm) 65 in (165 cm) Wheel Base 9 in (22.9 cm) Ground Clearance Minimum Turning Radius 110 in (279.4 cm) Gross Vehicle Weight 1060 lb (481 kg) Dry Weight...
  • Page 132 SPECIFICATIONS ENGINE Engine Oil Requirement / 35.5 oz (1050 mL) Capacity Exhaust System Single Headpipe / Single Silencer FUEL SYSTEM Throttle Body / Size Bosch® / 32 mm Fuel Delivery Electronic Fuel Pump (in tank) 4 bar / 58 psi (400 kPa) Fuel Pressure Fuel Capacity 2.5 gal (9.5 L)
  • Page 133 Rating/Speed Rating 5 psi (34,5 kPa) Front Tire Air Pressure 5 psi (34,5 kPa) Rear Front Wheel Hydraulic Disc Brakes Rear Axle Hydraulic Disc Brake Fluid Polaris DOT 4 Brake Fluid CLUTCH SETTINGS SHIFT DRIVE DRIVEN ALTITUDE WEIGHT SPRING SPRING 0-3000 Meters No changes for high altitude.

  • Page 135: Polaris Products

    POLARIS PRODUCTS POLARIS PRODUCTS ENGINE LUBRICANT PART NUMBER DESCRIPTION 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 Synthetic 5W-50 4-Cycle Oil (qt./.95 2876245 PS-4 Synthetic 5W-50 4-Cycle Oil (gal./ 3.8 l) GEARCASE / TRANSMISSION LUBRICANTS PART NUMBER DESCRIPTION 2878068 AGL Full Synthetic Gearcase Lubricant &...
  • Page 136 POLARIS PRODUCTS PART NUMBER DESCRIPTION 2871956 Loctite® 565 Thread Sealant 2859044 POLARIS Battery Charger...

  • Page 137: Troubleshooting

    See page 102. Inspect clutch seals for damage if system repeated leaking occurs. Clutch malfunction Your Polaris dealer can assist. Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines. Your Polaris dealer can assist.
  • Page 138 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Water or fuel in crankcase Your POLARIS dealer can assist. Clogged Fuel Filter Your POLARIS dealer can assist. Low battery voltage Recharge the battery to 12.8 VDC. Mechanical failure Your POLARIS dealer can assist. ENGINE BACKFIRES...
  • Page 139 Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter Your POLARIS dealer can assist malfunction Electronic throttle control Your POLARIS dealer can assist malfunction Other mechanical failure Your POLARIS dealer can assist...
  • Page 140 Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plugs Worn or defective spark plug Your POLARIS dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plug heat range...
  • Page 141 TROUBLESHOOTING DIAGNOSTIC TROUBLE CODES COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P1228 Voltage Above Normal, Or Shorted To High Source Accelerator Position 2 P1227 Voltage Below Normal, Or Shorted To Low Source P0123 Voltage Above Normal, Or Shorted To High Source Throttle Position Sensor...
  • Page 142 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P0112 Voltage Below Normal, Or Shorted To Low Source P2229 Voltage Above Normal, Or Shorted To High Source Barometric Pressure Sensor P2228 Voltage Below Normal, Or Shorted To Low Source P1217 Data Valid But Above Normal...
  • Page 143 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P0914 Data Erratic, Intermittent Or Incorrect Gear Sensor P0916 Voltage Below Normal, Or Shorted Signal To Low Source P1914 Abnormal Update Rate P153D Condition Exists Cruise Control Panel Switches P0335 Data Erratic, Intermittent Or Incorrect...
  • Page 144 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P1691 Current Below Normal Or Open Circuit P0647 Voltage Above Normal, Or Shorted To High Source AC Compressor P0646 Voltage Below Normal, Or Shorted Clutch Relay To Low Source P0645 Current Below Normal Or Open...
  • Page 145 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 1347 P0232 Voltage Above Normal, Or Shorted To High Source 1347 Fuel Pump P0231 Voltage Below Normal, Or Shorted Driver Circuit To Low Source 1347 P0230 Current Below Normal Or Open Circuit 1557...
  • Page 146 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 3597 P16A1 Voltage Below Normal, Or Shorted To Low Source 3598 P16A9 Voltage Above Normal, Or Shorted To High Source ECU Output Supply Voltage 3598 P16A8 Voltage Below Normal, Or Shorted To Low Source 3599...
  • Page 147 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520200 P1502 Voltage Below Normal, Or Shorted To Low Source 520200 P1504 Special Instructions 520202 Voltage Above Normal, Or Shorted To High Source Canister Purge 520202 P0445 Voltage Below Normal, Or Shorted Valve...
  • Page 148 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520207 P1834 Voltage Below Normal, Or Shorted To Low Source 520207 P1836 Current Below Normal Or Open Circuit 520208 P1614 Voltage Above Normal, Or Shorted To High Source 520208 P1613 Voltage Below Normal, Or Shorted...
  • Page 149 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520268 P1515 Current Below Normal Or Open Circuit 520269 P1529 Voltage Above Normal, Or Shorted To High Source Idle Air Control 520269 P1528 Voltage Below Normal, Or Shorted M17 Stepper To Low Source Pin 4...
  • Page 150 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520279 P151D Condition Exists Throttle Body Control - Adaption Aborted 520280 P151E Condition Exists Throttle Body Control - Limp Home Position Check Failed 520281 P152A Condition Exists Throttle Body Control - Mechanical...
  • Page 151 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520305 P1530 Condition Exists Throttle Body Control - Requested Throttle Angle Not Plausible 520306 P1531 Condition Exists ECU ADC Fault - No Load 520307 P1532 Condition Exists ECU ADC Fault - Voltage 520308...
  • Page 152 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520333 P1139 Bad Intelligent Device Or Component 520336 P1545 Condition Exists ECU Monitoring (Pedal Map Mismatch) 520338 P2279 Condition Exists Gross Air Leak 520341 P0243 Voltage Above Normal, Or Shorted To High Source Wastegate 520341...
  • Page 153 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520467 P071A Condition Exists Momentary Driveline Left Press 520468 P071D Condition Exists Momentary Driveline Right Press 520496 P107D Voltage Above Normal, Or Shorted To High Source Intercooler 520496 P107C...
  • Page 154 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 524080 U1405 Condition Exists Cruise Control Input Message Counter 524081 U1407 Condition Exists Foot On Cruise Control Input Message Counter 524082 U1406 Condition Exists Foot On Cruise Control Input Checksum 524145...

  • Page 155: Warranty

    This warranty is transferable to another owner during the warranty period through a Polaris dealer, or other qualified person, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 156 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 157 TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW. HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer;...
  • Page 158 IS 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 159 U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 160 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...
  • Page 161 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
  • Page 162 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Polaris Industries inc. is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle. In California, new off-highway recreational vehicles must be designed, built and equipped to meet the State's stringent anti-smog standards.
  • Page 163 The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As an OHRV-EVAP owner, you should also be aware that Polaris may deny you warranty coverage if your OHRV-EVAP or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 165: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 167 Device Compliance Statements ..12 Diagnostic Trouble Codes ..139 Air Filter....... . . 104 Doors and Cab Nets.
  • Page 168 Fuse Replacement....106 Know Your Riding Area/Tread Lightly® ....... . . 75 Gear Selector .
  • Page 169 Physical Control of the Vehicle ..22 Operating Through Water ..25 Polaris Products Operator Restrictions/ Age Additives ......133 Restrictions .
  • Page 170 Vehicle Identification Numbers ..10 Vehicle Immersion ....113 Vehicle Tie-Down Loading and unloading ..125 Minimum Working Load Limit (WLL) .
  • Page 172 15 . • on paved surfaces - pavement may seriously affect handling and control. • with non-Polaris approved accessories - they may seriously affect stability. • at speeds that are too fast for the operator’ s skills, the conditions and/or the terrain.

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