Polaris 2014 RZR 9002014 RZR 4 900 Owner's Manual
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Polaris 2014 RZR 9002014 RZR 4 900 Owner's Manual

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PMS 419
RZR® 900
RZR® 4 900
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 2014 RZR 9002014 RZR 4 900

  • Page 1 PMS 419 RZR® 900 RZR® 4 900 Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 POLARIS® and RZR® are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

  • Page 5: Table Of Contents

    Specifications ......128 POLARIS Products..... 132 Troubleshooting .

  • Page 6: Introduction

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

  • Page 8: Vehicle Identification Numbers

    Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys.

  • Page 9: Safety

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

  • Page 10: Safe Riding Gear

    Helmet Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 11 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 12 If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Proper Use Warning (RZR)
  • Page 13 SAFETY Safety Labels and Locations Seat Belt/Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belts. • Wear an approved helmet and pro- tective gear. • ALWAYS use cab nets and/or doors.
  • Page 14 PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around the clutch and vent system when replacing the belt. Read owner’s manual or see authorized POLARIS dealer. 7177469 Belt Debris Warning...
  • Page 15 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING Load/Passenger/Tire Pressure • Passengers can be thrown off. Warning (in cargo box) This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

  • Page 16: Safety Warnings

    SAFETY Safety Warnings WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.

  • Page 17: Protective Apparel

    SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 18 SAFETY Safety Warnings Carrying Multiple Passengers (RZR 4) Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 52-53. A passenger must always be seated in a passenger seat with seat belt secured.

  • Page 19: Operating On Pavement

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

  • Page 20: Jumps And Stunts

    SAFETY Safety Warnings Jumps and Stunts Exhibition driving increases the risk of an accident or overturn. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover.

  • Page 21: Crossing Hillsides

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

  • Page 22: Skidding Or Sliding

    SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 60. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.

  • Page 23: Operating A Damaged Vehicle

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

  • Page 24: Improper Cargo Loading

    SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See page 62.

  • Page 25: Exposure To Exhaust

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

  • Page 26: Equipment Modifications

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

  • Page 27: Features And Controls

    FEATURES AND CONTROLS Component Locations ROPS Frame Nets Cargo Steering Wheel Radiator Fuel Tank Bars Brake Pedal Front Passenger Hand Hold Throttle Pedal Gear Selector Rear Passenger Hand Hold Cargo Box Tie-Down Points Shifter Fuel Tank Cap...

  • Page 28: Ignition Switch

    FEATURES AND CONTROLS Switches Ignition Instrument Switch Cluster 12V Accessory Light Outlet Switch Switch Auxiliary Outlets The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a second outlet (on RZR 4 models, if equipped) is in the rear passenger area.

  • Page 29: Headlight Switch

    ON position. The EPS warning indicator will illuminate to indicate the EPS has shut down. If the light remains on after starting the engine, the EPS system is inop- erative. See your authorized POLARIS dealer for service.

  • Page 30: Steering Wheel

    FEATURES AND CONTROLS Seats Before operating the vehicle, always push down on all seat backs to ensure the latches are secure. Seat Adjustments Loosen (do not remove) the four screws located on the seat bottom. Slide the seat forward or rearward to the desired position. Tighten the screws to 4 ft.
  • Page 31 FEATURES AND CONTROLS Passenger Hand Hold Always adjust the hand hold to a comfortable position for your front- seat passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments. 1. Remove the retainer from the end of the adjustment pin. 2.
  • Page 32 FEATURES AND CONTROLS Hood Hood Fasteners Remove the hood to access the radiator pressure cap and coolant overflow bottle. 1. Turn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the fasteners. 3. Pivot the hood forward and lift upward to dis- engage the lower hood Overflow...

  • Page 33: Service Access Panels

    FEATURES AND CONTROLS Service Access Panels Engine Access Panel The engine access panel is located behind the seats on the frame of the vehicle. Remove the seats and remove the access panel to reach serviceable engine components. Cargo Box Access Panel The cargo box access panel is located on the floor of the cargo box.

  • Page 34: Fuel Cap

    Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer. Cab Net Latches...

  • Page 35: Seat Belt Inspection

    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. To wear the seat belt properly, follow this procedure: 1.

  • Page 36: Gear Selector

    FEATURES AND CONTROLS Gear Selector P: Park R: Reverse N: Neutral L: Low Gear H: High Gear To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine Gear Selector speed above idle or while the vehicle is moving.

  • Page 37: Brake Pedal

    The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your autho- rized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover.

  • Page 38: Engaging Awd

    FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the vehi- cle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.

  • Page 39: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.

  • Page 40: Indicator Lamps

    EPS Warning This indicator illuminates briefly when the key is turned to the ON position. If the light remains on, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

  • Page 41: Rider Information Center

    If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
  • Page 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) MODE Button The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit the set-up mode, turn the key off.

  • Page 44: Clock Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or dis- charged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero.
  • Page 46 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).

  • Page 47: Engine Error Codes

    3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See an authorized POLARIS dealer for code details and diagnosis.

  • Page 48: Operation

    Vehicle Break-in Period The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gaso- line. No single action on your part is as important as a proper break-in period.

  • Page 49: Brake System Break-In

    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 32. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 85. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 50 Engine intake pre-filter Inspect, clean PVT intake pre-filter Inspect, clean Headlamp Check operation Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat Latches Push down on both seat backs to ensure the latches are secure Seat Belts...

  • Page 51: Safe Operation Practices

    4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

  • Page 52: Starting The Engine

    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in PARK. 4.

  • Page 53: Parking The Vehicle

    Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by con- tacting your POLARIS dealer, a local riding club, or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
  • Page 54 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course. Hands-on training is also available through ROHVA.
  • Page 55 OPERATION New Operator Driving Procedures 13. Apply the brakes and shift into low gear. 14. Check your surroundings and determine your path of travel. 15. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 16.

  • Page 56: Driving With Passengers

    OPERATION Driving with Passengers 1. Complete the New Operator Driving Procedures outlined on pages 52-53. 2. Perform the pre-ride inspection. See page 48. 3. Do not carry more than one passenger in a 2-seat vehicle. Do not carry more than three passen- gers in a 4-seat vehicle.

  • Page 57: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1. Slow down before entering slippery areas. 2.

  • Page 58: Driving Uphill

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

  • Page 59: Driving Downhill

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

  • Page 60: Driving Through Water

    OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the Floor Level water level is lowest and where both banks have grad-...

  • Page 61: Driving Over Obstacles

    OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.

  • Page 62: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never open the throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 63: Parking On An Incline

    OPERATION Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precau- tions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Turn the engine off. 4.

  • Page 64: Hauling Cargo

    OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 65: Belt Life

    OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry a specific capacity. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo.

  • Page 66: Towing Loads

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

  • Page 67: Winch Guide

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

  • Page 68: Winch Safety Precautions

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

  • Page 70: Winch Operation

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

  • Page 75: Winch Cable Care

    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 76 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 77: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 78: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 79: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 144.

  • Page 80: Periodic Maintenance Chart

    E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) D Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an...
  • Page 81 250 (400) Check terminals; clean; test Engine breather filter 25 H Monthly 150 (250) Inspect; replace if (if equipped) necessary Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 82 Spark plugs 100 H 12 M 1000 (1600) Inspect; replace as needed, torque to specification Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 83 5000 (8000) Replace, torque to specification D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

  • Page 84: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 77, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
  • Page 85 MAINTENANCE Lubrication Recommendations View of Driver’s Side From Bottom of Vehicle Grease Stabilizer Bar Bushings (one on each side of vehicle) Front Control Arm Pivot Bushings (3 per side)

  • Page 86: Engine Oil

    10W-50 4-Cycle Oil (-18 C to +49 Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. Follow the manufacturer's recommen- dations for ambient temperature operation. See page 132 for the part numbers of POLARIS products.

  • Page 87: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. Always use the recommended engine oil. Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull.

  • Page 88: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. Always change the oil filter whenever changing oil. Access the oil check dipstick through the service access panel behind the seats.
  • Page 89 MAINTENANCE Engine Oil Oil and Filter Change 6. 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. 7. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.
  • Page 90 MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 77. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase.
  • Page 91 MAINTENANCE Transmission (Main Gearcase) Fluid Change The drain plug is located on the bot- tom 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.
  • Page 92 MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 77. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the demand...
  • Page 93 MAINTENANCE Demand Drive Unit (Front Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely.

  • Page 94: Spark Plugs

    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 132 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission AGL Gearcase 44 oz.

  • Page 95: Spark Plug Condition

    MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove the cargo box Spark Plugs access panel. 2. Clean the area around the spark plugs before remov- ing the plugs. 3. Remove the spark plug caps. 4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counter-...
  • Page 96 MAINTENANCE Fuses If the engine stops or will not start, if the power steering stops working (if equipped), or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Main Fuse Feature Supported Lights: Headlights, Taillights...
  • Page 97 MAINTENANCE Fuses Main Fuse Box 1. Lift up on the two fuse box tabs. 2. Slide the fuse box slightly toward the right side of the vehicle to disengage it from the mount. 3. Remove the fuse box cover. 4. Remove the suspect fuse from the fuse Step 1 - Lift tabs panel.

  • Page 98: Cooling System

    See page 97 for changing procedure. POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. POLARIS Antifreeze is already premixed and ready to use.
  • Page 99 MAINTENANCE Cooling System Radiator Coolant Level/Changing Coolant This procedure is required only if the cooling system has been drained for maintenance and/or repair. If the overflow bottle has run dry, the level in the radiator should also be inspected. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot.
  • Page 100 5. Reinstall the cap. Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer.
  • Page 101 • See your dealer as recommended in the owner’s manual and on safety labels. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 102 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.

  • Page 103: Pvt Drying

    MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 4. Remove all debris from the entire clutch air duct passage. 5. Check for signs of damage to seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged.

  • Page 104: Filter Systems

    MAINTENANCE Filter Systems Fuel Tank Vent Filter If the engine sputters, the inline fuel tank vent filter may be clogged. Do not attempt to clean the filter. Replace the filter with a new filter. 1. Remove the seats and remove the engine access panel.

  • Page 105: Air Filter

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. 1. Remove the cargo box Wing Nuts/Bolts access panel. 2. Loosen the air box cover wing nuts and rotate the bolts away from the cover.

  • Page 106: Spark Arrester

    MAINTENANCE Spark Arrester WARNING • Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components.
  • Page 107 MAINTENANCE Spark Arrester Periodically clean the spark arrester to remove accumulated carbon. 1. Remove the arrester retaining bolt and nut. 2. Remove the arrester from the end of the muffler. 3. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm.

  • Page 108: Throttle System

    POLARIS dealer for Throttle Pedal adjustment. 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.

  • Page 109: Brake Inspection

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 35. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm.

  • Page 110: Brake Fluid

    Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 132 for the part num- bers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 111: Suspension Settings

    MAINTENANCE Suspension Settings Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. Fox Shock Preload Walker Evans Front Walker Evans Rear Measurement Shock Preload Shock Preload...
  • Page 112 WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. 5. Tighten the jam nut firmly against the adjuster ring.
  • Page 113 WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. Front Rear...
  • Page 114 MAINTENANCE Suspension Settings Front/Rear Shock Compression The compression damping clicker knob is located on top of the shock reservoir. When the knob is turned clockwise until it stops, the damping is in the fully closed position. 1. Turn the clicker clockwise to increase compression damping. 2.

  • Page 115: Tire Tread Depth

    Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS- approved size and type of tires for this vehicle when replacing tires.

  • Page 116: 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 Forward Valve Stem dealer. Rotation 3. Attach the wheel nuts and washers and finger tighten.

  • Page 117: Brake Lights

    MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as vis- ibility to other vehicles. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out.

  • Page 118: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward and to the left or right. 1. Position the vehicle on a level surface. The headlight should be approximately 25 ft. (7.6 m) from a wall. 25 ft.

  • Page 119: Vehicle Immersion

    MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below.

  • Page 120: Steering Wheel Inspection

    2. Lightly turn the steering wheel left and right. 3. There should be 0.8-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or if the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer.

  • Page 121: Battery Removal

    MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Your vehicle has a sealed battery, which requires little maintenance.

  • Page 122: Battery Installation

    Whenever the vehicle is not used for a period of three months or more, recharge the battery about once a month to make up for normal self-dis- charge (see page 121), or use a POLARIS Battery Tender, which can be left connected during the storage period. Battery Tender will automati- cally charge the battery if voltage drops below a pre-determined point.

  • Page 123: Battery Charging

    MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installa- tion of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 124 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.

  • Page 125: Cleaning And Storage

    Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

  • Page 126: Washing The Vehicle

    • Labels and decals • Electrical components and wiring • Air intake components 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 127: Storage Tips

    123. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 128 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 129: Removal From Storage

    Secure or remove all cargo, and inspect the unit for loose parts prior to transport. 4. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.

  • Page 130: Specifications

    SPECIFICATIONS RZR 900 Gross Vehicle Weight Rating 1930 lbs. (875 kg) Dry Weight 1190 lbs. (540 kg) Test GVW - Rollover Protection 1975 lbs. (896 kg) per OSHA 29 CFR 1928.53 System (ROPS) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 740 lbs.
  • Page 131 SPECIFICATIONS RZR 900 Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Gear Reduction - Low 6.45:1 Gear Reduction - Reverse 5.776:1 Gear Reduction - High 3.037:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1...
  • Page 132 SPECIFICATIONS RZR 4 900 Gross Vehicle Weight Rating 2375 lbs. (1077 kg) Dry Weight 1390 lbs. (630.5 kg) Test GVW - Rollover Protection 2375 lbs. (1077 kg) per OSHA 29 CFR 1928.53 System (ROPS) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 900 lbs.
  • Page 133 SPECIFICATIONS RZR 4 900 Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Gear Reduction - Low 6.45:1 Gear Reduction - Reverse 5.776:1 Gear Reduction - High 3.037:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1...

  • Page 134: Polaris Products

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

  • Page 135: Troubleshooting

    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See warnings on page 56. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently.
  • Page 136 TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect, clean, reinstall connectors Mechanical failure See your dealer Engine Turns Over, Fails to Start...
  • Page 137 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
  • Page 138 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel tank vent line or Inspect and replace filter 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 139: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 140 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 141 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied.
  • Page 142 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 143 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase...
  • Page 144 *As related to the evaporative emission control system. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 145 POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 146: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 147 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 148: Index

    INDEX Access Panel Cab Frame, ROPS ....35 Cargo Box ....31 Cab Nets .
  • Page 149 INDEX Electromagnetic Interference ..76 Fluid Check Electronic Power Steering ..27 Demand Drive....90 Emission Control, Crankcase .
  • Page 150 INDEX Hand Hold, Passenger ... 29 Maintenance, Periodic ..77-81 Hauling a Load ....62-64 Metric Display .
  • Page 151 Seat Belts ..... 33 Polaris Products ....132 Seat Removal .
  • Page 152 INDEX Suspension Settings ..109-112 Vehicle Identification Numbers..6 Switches Vehicle Immersion ... . . 117 AWD Switch ... 27, 36 Vehicle Transport .
  • Page 153 12 or who cannot comfortably reach the floor and hand holds. • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death.

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