Polaris RZR S 1000 Owner's Manual PDF

Pages 192
Year 2019
Language(s)
English en
1 of 192
1 of 192

Summary of Content for Polaris RZR S 1000 Owner's Manual PDF

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POLARIS and RZR are trademarks of POLARIS Industries Inc... Copyright 2018 Polaris Industries 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 discrepancies may result between the actual vehicle and the information presented in this publication... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited... The original instructions for this vehicle are in English... Other languages are provided as translations of the original instructions... Printed in Czech Republic 9929241

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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... We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today... Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine weve ever produced...

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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...

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Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81 Winch Guide... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... 109 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 111 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165 Polaris Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 169 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 171 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 177 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 183

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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... A collision or rollover can occur quickly, even during

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VEHICLE IDENTIFICATION NUMBERS Record your vehicles identification numberq, engine serial numberw, and key numbere 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... The ignition switch must be replaced if all keys are lost...

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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... Visit www... rohva... org or call 866- 267-2751...

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RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area... The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time... The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow... Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow...

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EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection... Whenever 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... Make sure protective eye wear is kept clean...

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SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection... Read and follow the instructions of the labels on the vehicle carefully... If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle... If any 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...

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Always read the owners manual... Always use the cab nets or doors... Lubricate as recommended... Avoid exhibition driving... Always wear seat belts... This vehicle is approved for on-road operation...

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LOAD / TIRE PRESSURE / PASSENGER ALERT (7190778) Never carry passengers in cargo box... Passengers can be thrown off... This can cause serious injury or death... Read owners manual... Never carry or transport fuel on this vehicle...

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BELT DEBRIS WARNING Improper service or maintenance of this PVTsystem can result in vehicle damage, SEVERE INJURYor DEATH... Always look for and remove debris inside and around the clutch and vent system when replacing the belt...

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OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident... Take a training course and complete the steps in the New Operator Driving Procedures section... All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle... Never allow a guest to operate this vehicle until the guest has completed the steps in the New Operator Driving Procedures section...

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PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident... Operator and all passengers must always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots...

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CAB DOORS Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover... Always make sure all cab doors are closed and latched while riding in this vehicle... Cab doors are NOT intended to be used as arm rests... Keep hands and feet inside the vehicle at all times...

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A passenger must always be seated in a passenger seat with seat belt secured... Carrying more than one passenger in a 2-seat vehicle can affect the operators ability to steer and operate the controls, which increases the risk of loss of control and accident or rollover... Never carry more than one passenger in a 2- seat vehicle...

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OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and passengers impacts vehicle operation and stability... For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle... Follow the instructions in this manual for loading, tire pressure, gear selection and speed...

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OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover... Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover... Travel slowly and use extra caution when operating on unfamiliar terrain... Always be alert to changing terrain conditions...

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CROSSING HILLSIDES Driving on a sidehill is not recommended... Improper procedure could cause loss of control or rollover... Avoid crossing the side of any hill unless absolutely necessary... If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual... See the Driving on a Sidehill (Sidehilling) section for details...

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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 the Driving in Reverse section for details... Before shifting into reverse gear, always check for obstacles or people behind the vehicle... When it's safe to proceed, back slowly...

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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... Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly)... Always follow proper procedures for operating on slippery surfaces as described in this owner's manual... See the Driving on Slippery Surfaces section for details...

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OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice... Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your passengers, and your cargo, together with any other vehicles in your party... Always check with local authorities and residents to confirm ice conditions and thickness over your entire route... Vehicle operators assume all risk associated with ice conditions on frozen bodies of water...

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HOT EXHAUST SYSTEMS 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... Use caution when traveling through tall grass, especially dry grass, to avoid debris build-up around the exhaust system...

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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... Loss of control may occur at higher speeds... Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power... Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury...

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y Tie-Down Points (4 corners) u Brake Pedal i Throttle Pedal o Gear Selector a Passenger Hand Hold

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AUXILIARY OUTLETS The vehicle is equipped with one or more 12-volt accessory outlets... One outlet is on the dash, a second outlet (if equipped) is in the rear passenger area... Use the outlets to power an auxiliary light or other optional accessories... For service, the dash outlet connection is under the dash... The rear outlet connection is under the rear passenger seats...

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HIGH BEAM SWITCH The headlight high beam is controlled by the turn signal lever... To switch the headlights to high beam, push the lever forward... Pull the lever back to switch to low beam...

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Move the turn signal lever downwardq to signal a left turn... The left turn signal lamps in the taillight and below the front headlight will flash... The turn signal indicator in the gauge will also flash... Move the lever upwardw to signal a right turn... The right signal lamps and indicator will flash... Return the lever to the center position to end the signal...

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ELECTRONIC POWER STEERING (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position... EPS remains engaged whether the vehicle is moving or idle... The EPS warning indicator briefly illuminates when the key is turned to the ON position... See the Indicator Lamps section for details...

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SEAT ADJUSTMENTS The drivers seat is equipped with an adjustment lever and adjustment knob for optimal spacing... Pull the adjustment lever to the left to move the seat forward or rearward... Once released, the lever will lock into place...

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4... Reverse this procedure to reinstall the seat... Make sure the seat tabs at the front edge of the seat slide under the seat retainer bar...

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PASSENGER HAND HOLD Always adjust the hand hold to a comfortable position for your passenger before operating... Make sure the adjustment pin and retainer are securely installed after making adjustments...

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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...

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CAB DOORS This vehicle is equipped with cab doors... Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover... Always make sure all cab doors are closed and latched when riding in this vehicle... Always inspect doors and latches for wear and damage before each use of the vehicle...

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3... Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness... If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer or other authorized person...

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To change gears, stop the vehicle, and with the engine idling, move the leverq to the desired gear... Do not attempt to shift gears with engine speed above idle or while the vehicle is moving...

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THROTTLE PEDAL Push the throttle pedalw 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...

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PARK BRAKE LEVER (IF EQUIPPED) Always apply the service brakes before engaging or releasing the park brake... To help prevent the vehicle from rolling, set the park brake when parking the vehicle... When the park brake is set and the park brake indicator is illuminated, engine speed is limited... If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear...

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REAR HITCH CERTIFICATION LABEL The hitch certification label is located near the hitch on models equipped with a factory-installed rear hitch...

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Improper electrical wiring changes can result in damage to both vehicle and trailer components... When in doubt about your trailer connection, please contact a qualified towbar specialist for assistance...

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ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OECD Code 4 rollover performance requirements... Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way... No device can assure occupant protection in the event of a rollover... When used with seat belts and cab nets or doors, the ROPS helps prevent occupants from being ejected from the vehicle... Always follow all safe operating practices outlined in this manual to avoid vehicle rollover...

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ENGAGING AWD The AWD switch may be turned on or off while the vehicle is moving... Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100... Once enabled, the AWD remains enabled until the AWD switch is turned off... If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction... Engage the AWD switch before getting into conditions where front wheel drive may be needed... If the rear wheels are spinning, release the throttle before switching to AWD...

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Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently... This mode of operation is well suited to turf driving or whenever aggressive traction is not required...

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INSTRUMENT CLUSTER High water pressure may damage components... Wash the vehicle by hand or with a garden hose using mild soap... Do not use alcohol to clean the instrument cluster... Do not allow insect sprays to contact the lens...

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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 POLARIS dealer, or other qualified person, as soon as possible for repair... Continued operation could result in permanent damage to the EPS unit and increased steering effort...

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RIDER INFORMATION CENTER The rider information center is located in the instrument cluster... All segments will light up for one second at start-up... If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer... If this occurs, your dealer can provide proper diagnosis...

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A flashing wrench symbol alerts the operator that the preset service interval has been reached... Your dealer can provide scheduled maintenance...

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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... In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point...

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PROGRAMMABLE SERVICE INTERVAL When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started... When this feature is enabled, it provides a convenient reminder to perform routine maintenance... The service interval is programmed at 50 hours at the factory... To change the service interval, do the following:

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ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle... Error codes are not stored... When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine... If the CHECK ENGINE light illuminates, retrieve the error codes from the display...

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washer may damage the instrument cluster... Wash the vehicle by hand or with a garden hose using mild soap... Certain products, including insect repellents and chemicals, will damage the instrument cluster lens... Do not use alcohol to clean the instrument cluster... Do not allow insect sprays to contact the lens... Immediately clean off any gasoline that splashes on the instrument cluster...

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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 POLARIS dealer, or other qualified person, as soon as possible for repair... Continued operation could result in permanent damage to the EPS unit and increased steering effort...

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This lamp flashes for several seconds when the key is turned to the ON position... The lamp is a reminder to wear helmet and seat belt before operating...

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DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1...

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3... Press the UP or DOWN arrows to toggle to the CLOCK menu option, then press MODE...

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PROGRAMMABLE SERVICE INTERVAL When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started... When this feature is enabled, it provides a convenient reminder to perform routine maintenance... The service interval is programmed at 25 hours at the factory... Use the following procedure to change the service interval...

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ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle... Error codes are not stored in the gauge when the key is turned off... The code and message is lost, but will reappear if the fault reoccurs after restarting the engine...

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NOTE Once the digital gauge is powered off, Bluetooth connectivity will cease... Also, when a new phone is paired with the digital gauge, all missed call and text information from the previous phone will be erased... Up to 16 different phone pairings can be saved to the digital gauge... The digital gauge does not support

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If you attempt to access Bluetooth menus while the vehicle is moving faster than 2 KPH, the screen will display VEHICLE MOVINGmomentarily, and then it will redirect to the options menu...

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DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc... ), or the item has failed... Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart...

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Data Valid But Below Normal Operational Range - Most Severe Level

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System Power Data Valid But Above Normal Operational Range - Most Severe Level

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Engine Speed Data Valid But Above Normal Operational Range - Most Severe Level

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Voltage Above Normal, Or Shorted To High Source

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Data Valid But Above Normal Operating Range - Moderately Severe Level

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Data Valid But Above Normal Operating Range - Moderately Severe Level

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Data Valid But Above Normal Operating Range - Least Severe Level

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Throttle Body Control - Mechanical Stop Adaptation Failure

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Throttle Body Control - Requested Throttle Angle Not Plausible

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Data Valid But Above Normal Operational Range - Most Severe 520225

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ICS Communication Loss of CAN between EPS and Instrument Cluster

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Voltage Above Normal, Or Shorted To High Source

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Data Valid But Above Normal Operating Range - Least Severe Level

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System Voltage Data Valid But Above Normal Operational Range - Most Severe Level

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Steering Angle Input Data Erratic, Intermittent Or Incorrect

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VEHICLE BREAK-IN PERIOD The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline... Clutch and drive belt break-in periods vary depending on operating conditions... No single action on your part is as important as a proper break-in period... Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components... Perform the following procedures carefully...

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SAND / DUNE BREAK-IN Drive in low gear for the first 5 miles (8 km) of operation... Avoid prolonged low speed operation at high throttle... Avoid aggressive acceleration, high-speed operation and prolonged operation at a specific RPM during this period...

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PRE-RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident... Always inspect the vehicle before each use to make sure it's in safe operating condition...

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Seat Belts Check length of belt for damage, check latches for proper operation page 39

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BOARDING AND EXITING THE VEHICLE Never try to climb onto or exit the vehicle while it is moving... Do not exit the vehicle by jumping off... Always face the vehicle when boarding or exiting... Do not grab controls as hand supports... This may cause inadvertent machine movements...

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6... Turn the ignition key to the START position... Engage the starter for a maximum of five seconds... Release the key when the engine starts... Turn the key to either LIGHTS ON or POSITION LIGHTS ON...

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2... When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights...

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7... The driver and passenger must wear helmet, eye protection, gloves, long- sleeve shirt, long pants, over-the-ankle boots and seat belt at all times...

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18... After you become skilled at making turns and begin to operate at faster speeds, follow these precautions: Avoid sharp turns... Never turn while applying heavy throttle... Never make abrupt steering maneuvers... Operate at speeds appropriate for your skills, the conditions and the terrain...

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5... Make sure the passenger is at least 12 years of age... All 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 hold...

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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:

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4... Avoid operating over large obstacles such as large rocks and fallen trees... If unavoidable, use extreme caution and operate slowly...

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2... Apply the throttle lightly... Never open the throttle suddenly...

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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:

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drive fluid, rear gearcase oil, and all grease fittings... If your vehicle becomes immersed or is operated in water that exceeds the floor level, take it to your dealer for service before starting the engine... If it's impossible to bring the vehicle to your dealer before starting the engine,

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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... Exercise caution if the cargo load extends over the side of the box...

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descending a hill... 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

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TOWING A RZR Towing this vehicle is not recommended... Always transport the vehicle on a trailer or flatbed with all four wheels off the ground... See the Transporting the Vehicle section for details... If towing a disabled vehicle is unavoidable, place the disabled vehicles transmission in neutral... Tow the shortest distance possible... Do not operate faster than 16km/h (10MPH)...

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9... Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times... The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load...

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15... 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...

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Take your time to think through the winching you are about to do... Proceed slowly and deliberately... Never hurry or rush during winching... Always pay attention to your surroundings... You may need to change your winching strategy if it is not working... Always remember that your winch is very powerful... There are simply some situations that you and your winch will not be able to deal with... Do not be afraid to ask others to help when this happens...

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WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks... This can result in SEVERE INJURY

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a... In order to absorb energy that could be released by a winch cable failure, always place a damper on the winch cable... A damper can be heavy jacket, tarp, or other soft, dense object... A damper can absorb much of the energy released if a winch cable breaks when winching... Even a tree limb can help as a damper if no other items are available to you...

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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 107... For your safety, always follow these guidelines when winching a vehicle free:

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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...

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A winch cable made of synthetic rope should be inspected for signs of fraying... Replace the cable if fraying is observed (shown below)... Promptly discontinue use of a winch cable in this condition... Also replace the winch cable if there are fused or melted fibers... Such an area of the synthetic rope will be stiff and appear smooth or glazed... Promptly discontinue use of a winch cable in this condition...

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1... Never attempt to jerk a load with the winch... For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object... This is a dangerous practice... It generates high winch cable loads that may exceed the strength of the cable... Even a slowly moving vehicle can create large shock loads in a winch cable...

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6... Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store... Although they may look similar, they are NOTalike... A polymer rope not designed for winch use will stretch and store excessive energy when winching...

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ELECTROMAGNETIC INTERFERENCE This vehicle complies with the EMC requirements of Regulation (EU) No... 2015/ 208 Annex XV... Non-ionizing Radiation: This vehicle emits some electromagnetic energy... People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle...

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PERIODIC MAINTENANCE CHART Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition... Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart... 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...

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Pay special attention to the oil level... A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase... Change oil immediately if the oil level begins to rise... Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your authorized dealer...

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WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death... Have an authorized

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Air Filter - Weekly - Inspect; replace as needed

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Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

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Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail

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Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc...

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Clean daily when driving in mud and water; replace a cracked or damaged arrester before operating (see the Spark Arrester section in this chapter)

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LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart section, 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...

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e Rear Stabilizer Bar Grease Fitting r Front Stabilizer Bar Grease Fitting

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Oil may need to be changed more frequently if POLARIS oil is not used... Do not use automotive oil... Follow the manufacturer's recommendations for ambient temperature operation... Part numbers can be found in the POLARIS Products chapter...

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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... Access the oil filterq and oil check dipstickw through the engine access panel located behind the seats...

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OIL AND FILTER CHANGE Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart section... Always change the oil filter whenever changing oil... Access the oil check dipstick and oil filter through the engine access panel located behind the seats...

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16... Add oil as necessary to bring the level to the upper mark on the dipstick... Do not overfill...

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TRANSMISSION (MAIN GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart section... Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications...

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FLUID CHANGE The drain plugq is located on the bottom of the gearcase... Access the drain plug through the drain hole in the skid plate...

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DEMAND DRIVE UNIT (FRONT GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart... Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications...

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DEMAND DRIVE FLUID CHANGE The demand drive drain plugq is located on the bottom of the gearcase...

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GEARCASE SPECIFICATION CHART Use of other fluids may result in improper operation of components... See the POLARIS Products section for part numbers...

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Spark plug condition is indicative of engine operation... The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds... Immediately check the spark plug for correct color...

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WET FOULED PLUG The wet fouled insulator tip is black... A damp oil film covers the firing end... There may be a carbon layer over the entire nose... Generally, the electrodes are not worn... Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather...

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FUSE / RELAY CENTER 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... The fuse/relay centerq is located under the drivers seat...

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COOLING SYSTEM The engine coolant level is maintained by the recovery system... The recovery system components are the overflow bottle, radiator vent fitting, radiator pressure cap and connecting hose... As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle... As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator...

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5... Before reinstalling the pressure cap, bleed the system of trapped air... Remove the engine access panel behind the seats and use a flat-blade screwdriver to turn the bleed screwq slightly, allowing the air to escape... Slowly add additional coolant to the radiator until air no longer escapes and only coolant flows from the bleed hole, then tighten the bleed screw...

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OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart section... Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool)... If the overflow bottle has run dry, the level in the radiator should also be inspected...

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Always follow all recommended maintenance procedures... Always look for and remove debris inside and around the clutch and vent system when replacing the belt...

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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...

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TIP Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail... Switch to low range while operating at slower speeds to extend the life of the PVTcomponents

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5... Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches... Do not hold the throttle wide open for more than 10 seconds...

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FILTER SYSTEMS INTAKE PRE-FILTERS (IF EQUIPPED) Inspect the engine pre-filter before each use of the vehicle to ensure adequate air flow... If necessary, remove the pre-filter and clean with soapy water... Dry with low pressure compressed air... Periodically inspect the clutch (PVT) air intake for debris and clean as needed to ensure adequate air flow...

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NOTICE Use of a non-POLARIS-approved air filter may cause engine damage... Always use a POLARIS-approved replacement filter... Please see your POLARIS dealer

Page 144

Wear eye protection and gloves... Never operate without the spark arrester... Never run the engine in an enclosed area... Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time...

Page 145

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... See the Brake Fluid section for further details...

Page 146

Inspect the level of the brake fluid before each operation... If the fluid level is low add DOT 4 brake fluid only... See the Polaris Products section for the part numbers... Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown... Access the brake fluid reservoir through the left front wheel well...

Page 147

SUSPENSION SETTINGS WALKER EVANS SHOCKS (IF EQUIPPED) 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... To adjust the preload, do the following:

Page 148

WALKER EVANS SHOCK COMPRESSION ADJUSTMENT (IF EQUIPPED) The compression damping clicker knob is located at the top of the shock reservoir...

Page 149

Always apply the same adjustment setting to all four wheels... Never operate the vehicle on the highest or second highest preload settings without a total combined payload in the vehicle of 204 kg (450 lbs... ) or more... Payload includes the driver, passenger, POLARIS-approved accessories and cargo... Never exceed the stated load capacity for the vehicle...

Page 150

FOX SHOCKS (IF EQUIPPED) Spring Preload Adjustment The factory setting is appropriate for nearly all riding conditions... If desired, the suspension may be adjusted to maintain ground clearance when carrying additional weight...

Page 151

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

Page 152

Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death... Always replace tires when the tread depth measures 1/8 (3 mm) or less...

Page 153

AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service... Do not lubricate the stud or the lug nut...

Page 154

3... Place the wheel in the correct position on the wheel hub... Be sure the valve stemq is toward the outside and rotation arrows on the tire point toward forward rotation...

Page 155

HEADLIGHT REPLACEMENT If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced... Do not operate this vehicle at night or in low light conditions until the headlight is replaced... Always make sure lights are adjusted properly for best visibility...

Page 156

5... Include the weight of a rider on the seat while performing this step... Observe the headlight aim... As a starting point, the most intense part of the headlight beam should be 2 inches (5 cm) below the mark on the wall... Adjust to operator preference...

Page 157

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 158

Your vehicle has a maintenance-free battery... Always keep battery terminals and connections free of corrosion... If cleaning is necessary, remove the corrosion with a stiff wire brush... Wash with a solution of one tablespoon baking soda and one cup water... Rinse well with tap water and dry off with clean shop towels... Coat the terminals with dielectric grease or petroleum jelly...

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BATTERY STORAGE 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-discharge (see the Battery Charging section for details), or use a POLARIS Battery Tender, which can be left connected during the storage period... Battery Tender will automatically charge the battery if voltage drops below a pre-determined point... See the POLARIS products section for the part numbers... During the storage period, park the vehicle out of the sun in a cool, dry place or remove the battery and store it in a cool, dry place...

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75%-100% 12... 5-12... 8 volts May need slight charge, if no charge given, check in 3 months

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toward the PVT intake ductq... High water pressure may damage the radiator fins and impair the radiators effectiveness... High pressure may also damage other vehicle components... Certain products, including insect repellents and chemicals, will damage

Page 162

WASHING TIPS Avoid the use of harsh cleaners, which can scratch the finish... Do not use a power washer to clean the vehicle... Do not use medium to heavy duty compounds on the finish... 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...

Page 163

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 164

2... Remove the spark plugs and add 2-3 tablespoons of engine oil... To access the plug holes, use a section of clear 6... 35mm (1/4) hose and a small plastic squeeze bottle filled with the pre-measured amount of oil... Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak...

Page 165

4... Check all the points listed in the Daily Pre-Ride Inspection section... Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer or other qualified service facility...

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6... 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 167

336... 4 kg (riders, cargo, accessories, tongue weight)

Page 168

Driving System Type Automatic POLARIS Variable Transmission EPS: Lockable Differential

Page 169

CLUTCHING Please see your authorized dealer for clutching specifications

Page 171

2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal... /3... 8 l)

Page 172

2871551 U-Joint Grease (14 oz... /414 ml cartridge)

Page 173

Stuck in mud or snow Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch... WARNING! Excessive throttle may cause loss of control and vehicle rollover...

Page 174

Failed belt Remove the belt and clean away any debris from the clutch box, clutch duct and engine compartment... Install a new belt... WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death... See the Belt Replacement / Debris Removal section for details...

Page 175

Fouled or defective spark plugs Inspect plugs and replace if necessary

Page 176

Weak spark from spark plug Inspect, clean and/or replace spark plugs

Page 177

Worn or defective spark plug wires Your POLARIS dealer or qualified person can assist

Page 178

Overheated engine Clean radiator screen and core, clean engine exterior, check coolant level, see your dealer if condition persists

Page 179

WARRANTY LIMITED WARRANTY POLARIS Industries Inc... , 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a TWO YEAR LIMITED WARRANTYon all components of your POLARIS vehicle against defects in material or workmanship... POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations... This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser... This warranty is transferable to another owner during the warranty period through a POLARIS dealer, 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 180

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... This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed... This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center...

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This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time... THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OFANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS... THE REMEDIES SET FORTH IN THIS WARRANTYARE 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 OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move... Product importation rules vary considerably from country to country... You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage... You may also be required to obtain documentation from POLARIS in order to register your product in your new country... You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle...

Page 183

EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT 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... This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location... This policy does not apply to Safety Bulletins...

Page 185

MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance...

Page 187

D Demand Drive Fluid Check ... 127 Demand Drive Unit (Front Gearcase) ... 127 Descending Hills Improperly ... 22 Diagnostic Display Code Definitions ... 64 Diagnostic Display Mode... 53 Digital Gauge... 55 Disengaging AWD ... 46 Display Area 1 ... 58 Display Area 2 ... 58 Display Units ... 51 Drive Belt Wear / Burn ... 171 Driving Downhill ... 91 Driving in Reverse ... 93 Driving on a Sidehill (Sidehilling) ... 91 Driving on Slippery Surfaces ... 94 Driving Over Obstacles ... 92 Driving Through Water... 95 Driving Uphill ... 90 Driving With Passengers ... 89

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H Hauling Cargo... 96 Hazard Switch ... 30 Headlight Beam Adjustment... 154 Headlight Replacement... 153 Helmet ... 10 High Beam Switch ... 31 Hitch Removal / Installation... 44 Hitches... 43 Hood ... 35 Horn Switch... 31 Hot Exhaust Systems ... 26 Hour Meter Mode ... 52 How to Obtain Warranty Service ... 180

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S Sachs Shocks (if equipped) ... 147 Safe Operation Practices ... 85 Safe Riding Gear... 10 Safeguards ... 63 Safety Labels and Locations ... 12 Safety Symbols ... 4 Safety Training... 9 Safety Warnings... 16 Safety, Winch Maintenance... 108 Seat Adjustments ... 34 Seat Belt Inspection ... 39 Seat Belts ... 18, 38 Seat Removal ... 34 Seats ... 34 Severe Use Definition... 112 Shock Loading the Winch ... 107 Signal Words ... 4 Skidding or Sliding ... 24 Spark Arrester ... 109, 142 Spark Plug Condition... 131 Spark Plug Gap / Torque ... 130 Spark Plug Removal and Replacement ... 130 Speedometer... 48 Stalling While Climbing a Hill ... 23 Starting the Engine ... 86 Steering Wheel ... 33 Steering Wheel Inspection... 155 Stopping the Engine... 86 Storage Tips... 161 Switches... 30

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W Walker Evans Shock Compression Adjustment... 146 Walker Evans Shocks... 145 Warning Symbols ... 4 Washing the Vehicle... 159 Washing Tips... 160 Wheel Installation ... 152 Wheel Removal... 151 Winch Cable Care ... 106 Winch Maintenance and Service Safety ... 108 Winch Operation ... 101 Winch Safety Precautions ... 99 Winch Shock Loading... 107

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Polaris Sales Europe Sarl Place de lIndustrie 2 1180 Rolle, Switzerland

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