Polaris RZR XP 1000, RZR XP 4 1000 Owner's Manual v2 PDF

Pages 188
Year 2021
Language(s)
English en
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1 of 188

Summary of Content for Polaris RZR XP 1000, RZR XP 4 1000 Owner's Manual v2 PDF

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Copyright 2020 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...

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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 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 55 Winch Guide... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 73 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... 85 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 157 Polaris Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 161 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 163 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 169 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 179

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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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We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual... This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals...

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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...

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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

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Keep a firm grip on the steering wheel or hand holds and brace yourself... Do not put any part of your body outside of the vehicle for any reason...

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Use a Polaris approved air filter... The use of a non-Polaris approved air filter may cause engine damage... Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube... The air filter must be properly seated before the lid is reinstalled... Please reference your owners manual for additional information regarding air filter service...

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FUELTRANSPORT WARNING NEVER carry fuel or other flammable liquids on this vehicle... Failure to follow this instruction could lead to serious burn injuries or death...

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Reduce speed and allow greater distance for braking when carrying cargo... Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control... Loads should be centered and carried as low as possible in box...

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OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident... The operator must understand how to operate the vehicle properly in different situations and on different types of terrain... Take a training course and complete the steps outlined in the New Operator Driving Procedures section...

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OPERATOR RESTRICTIONS / AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY... Operation is prohibited for anyone under 16 years of age or anyone without a valid drivers license... All operators and (if applicable) 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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CARRYING MULTIPLE PASSENGERS (RZR 2 SEAT) Never carry a passenger until you have operated this vehicle for at least two hours and have completed the steps in the New Operator Driving Procedures section... A passenger must always be seated in a passenger seat with seat belt secured... 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 ON PAVEMENT This vehicle's tires are designed for off-road use, not for use on pavement... Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover... Avoid operating the vehicle on pavement... If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops...

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OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control... Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and experience and any passengers skills and experience...

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IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover... Use extreme caution when operating on hills... Always follow proper procedures for hill climbing as described in this owner's manual... See the Driving Uphill section for details...

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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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OPERATING OVER OBSTACLES Improperly operating over obstacles could cause loss of control or rollover... Before operating in a new area, check for obstacles... Never attempt to operate over large obstacles such as large rocks or fallen trees... Always follow the proper procedures outlined in this manual when operating over obstacles... See the Driving Over Obstacles 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 any 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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Always exercise extreme caution whenever handling gasoline... Always turn off the engine when refueling... Always refuel outdoors or in a well ventilated area free of any source of flame or sparks...

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The addition of certain accessories, including (but not limited to) overhead audio speakers, may change the forward clearance in the vehicle... Polaris recommends selecting a helmet that is compatible with the equipment on your vehicle and provides the greatest amount of forward clearance... Always wear a helmet that meets or exceeds the specifications in this owners manual... Refer to the Safe Riding Gear section of this owners manual for more information... Use only POLARIS-approved accessories...

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i Tie-Down Points (4 corners) s Gear Selector

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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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Press the top of the rocker switch toward the dash to place the headlights on high beamq... Move the rocker switch to the center position to place the headlights on low beamw... Press the bottom of the rocker switch to turn off the headlights...

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REMOTE WINCH SWITCH Pull the remote winch switch and cable out from the dash storage area... Press and hold the left side of the switch to spool line out from the winch... Press and hold the right side of the switch to spool line in the winch... Release the switch and it returns to the center OFF position to stop spooling...

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SEATADJUSTMENTS On seats equipped with an adjustment lever under the front edge of the seat, pull the lever to the left... Slide the seat forward or rearward to the desired position... Release the lever... The seat will lock into the new position...

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FUEL CAP The fuel tank filler capq is located on the right-hand side of the vehicle near the passenger seat... When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane... Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel...

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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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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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HOOD Remove the hood to access the radiator pressure capq and coolant overflow bottlew...

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SEAT BELTS This POLARIS vehicle is equipped with seat belts for all riders... Always make sure the seat belts are secured for the operator and all passengers before riding... The drivers seat belt is equipped with a seat belt interlock... Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured...

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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 qualified person...

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SEAT BELT HEIGHTADJUSTER (IF EQUIPPED) The seat belt height adjuster reduces neck rub and works as a shock absorber for your shoulder... The height adjuster consists of an adjusterq and a railw... Adjustment becomes easier with repeated use... The seat belt height adjuster can be cleaned with water...

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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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GEAR SELECTOR 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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ALLWHEEL DRIVE (AWD) SYSTEM The All Wheel Drive system is controlled by the AWD switch... When the switch is on 2X4w, the vehicle is in two-wheel drive at all times... When the switch is on AWDq, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on... When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction... When the rear wheels regain traction, the demand drive unit will automatically disengage... There is no limit to the length of time the vehicle may remain in AWD...

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repellents and chemicals, will damage the speedometer lens and other plastic surfaces... Do not use alcohol to clean the instrument cluster... Do not allow insect sprays to contact the lens... Immediately clean off any gasoline that

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TOGGLE BUTTONS Press and release either toggle buttont to cycle through the options menu or Area 2 modes... Press and hold either toggle button to reset an item... See page 50...

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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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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 POLARIS dealer, or other qualified person, can provide proper diagnosis... The information center is set to display standard units of measurement and a 12-hour clock at the factory... To change to metric and/or a 24-hour clock hold the mode button and cycle to the clock menu... Use the directional arrows to change the clock settings...

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Trip Meters (T1/T2) A trip meter records the distance traveled by the vehicle if reset before each trip... To reset, see page 52...

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ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays... See the Mode Information Displays section for details...

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4... Press either toggle button to change each segment of the clock... Press MODE to accept a change and advance to the next segment...

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TRIP METER Use a trip meter to track the distance traveled during a specific trip or period of time... Reset the meter to zero before traveling...

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PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory... As hours of engine operation increase, the counter decreases... The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset...

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ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator 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...

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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...

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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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Grass and Leaves Remove grass, leaves, foreign matter, and other flammable material or debris, especially near the exhaust system

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11... 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 any passengers, and your cargo, together with any other vehicles in your party...

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6... If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds... Repeat steps 5 and 6 until the engine starts...

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TRAIL ETIQUETTE Always practice good etiquette when riding... Allow a safe distance between your vehicle and other vehicles operating in the same area... Communicate to oncoming operators by signaling the number of vehicles in your group... When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely...

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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... DO NOT do power slides, donuts, jumps or other driving stunts...

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8... Slow down... Always travel at a speed appropriate for your skills, your passengers skills and operating conditions... Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger...

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7... If the vehicle stalls while climbing a hill, apply the brakes... Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed...

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3... Always check the terrain carefully before descending a hill... Never drive on hills with excessively slippery or loose surfaces...

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or qualified person can provide this service... If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section, and take the vehicle in for service at the first opportunity...

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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...

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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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A rolling vehicle can result in serious injury... Avoid parking on an incline... If parking on an incline is unavoidable, follow these precautions:

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NEVER EXCEED THE MAXIMUMWEIGHT CAPACITYof the vehicle... When determining the weight you are adding to the vehicle, include the weight of the operator, passengers, accessories and loads in the rack or box... The combined

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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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Always read and understand the load distribution warnings listed on warning labels and in this manual... Never exceed the maximum capacities specified for your vehicle... See the Load / Passenger / Tire Warning section for details...

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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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23... Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons...

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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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Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable...

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7... Pulling out as much cable as possible maximizes the winchs pulling capacity... 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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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 82... For your safety, always follow these guidelines when winching a vehicle free:

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12... Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack... Vehicle damage may result... Instead, attach the winch to a strong portion of the vehicle frame or hitch...

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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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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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MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle... An authorized POLARIS dealer can perform any service that may be necessary for your vehicle... POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used...

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MAINTENANCE CHART TABLES The maintenance interval charts outline required maintenance and inspection based on vehicle hours / miles... Each table states the number of hours / miles that service is required on the vehicle... Some items or components may need to be serviced more often due to severe use, such as operation in water or under severe loads... When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over...

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Shift Cable / Linkage Inspect; adjust as needed D Steering Lubricate (if applicable) XU Front / Rear Suspension Lubricate (if applicable)

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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XU Radiator Inspect; clean external surfaces XU Cooling Hoses Inspect for leaks; pressure test system XU Engine Mounts Inspect, torque to specification

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D Front Wheel Bearings Inspect; replace as needed Cam Chain Tensioner Inspect/clean; replace as needed

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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Shift Cable / Linkage Inspect; adjust as needed D Steering Lubricate (if applicable) XU Front / Rear Suspension Lubricate (if applicable)

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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XU Radiator Inspect; clean external surfaces XU Cooling Hoses Inspect for leaks; pressure test system XU Engine Mounts Inspect, torque to specification

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Cam Chain Tensioner Inspect/clean; replace as needed D Valve Clearance Inspect; adjust as needed XU Shock Absorbers Inspect for leaks, loose joints, and wear

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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Shift Cable / Linkage Inspect; adjust as needed D Steering Lubricate (if applicable) XU Front / Rear Suspension Lubricate (if applicable)

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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XU Radiator Inspect; clean external surfaces XU Cooling Hoses Inspect for leaks; pressure test system XU Engine Mounts Inspect, torque to specification

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D Front Wheel Bearings Inspect; replace as needed Cam Chain Tensioner Inspect/clean; replace as needed

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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Shift Cable / Linkage Inspect; adjust as needed D Steering Lubricate (if applicable) XU Front / Rear Suspension Lubricate (if applicable)

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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XU Radiator Inspect; clean external surfaces XU Cooling Hoses Inspect for leaks; pressure test system XU Engine Mounts Inspect, torque to specification

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Cam Chain Tensioner Inspect/clean; replace as needed D Valve Clearance Inspect; adjust as needed XU Shock Absorbers Inspect for leaks, loose joints, and wear

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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Shift Cable / Linkage Inspect; adjust as needed D Steering Lubricate (if applicable) XU Front / Rear Suspension Lubricate (if applicable)

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Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

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XU Radiator Inspect; clean external surfaces XU Cooling Hoses Inspect for leaks; pressure test system XU Engine Mounts Inspect, torque to specification

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When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over...

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LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 88, 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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q Middle Prop Shaft Grease Fitting w Stabilizer Bar Bushings (one on each side of vehicle) e Rear Prop Shaft 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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5... Remove the oil fill cap to add the recommended oil as needed... Maintain the oil level between the minimum and maximum marks on the dipstick... Do not overfill...

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OIL AND FILTER CHANGE Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 88... Always change the oil filter whenever changing oil...

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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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4... Add the recommended fluid (listed in the Gearcase Specifications Chart section of this manual) to the bottom of the fill plug hole... Do not overfill...

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DEMAND DRIVE UNIT (FRONT GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 88... Refer to the Gearcase Specifications Chart on page 122 for recommended lubricants, capacities and torque specifications...

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6... Add the recommended fluid (listed in the Gearcase Specification Chart) to the bottom thread of the fill plug hole...

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

Page 125

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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4... Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counterclockwise...

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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 (XP) or under the left rear passenger seat (XP 4)...

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RADIATORS AND COOLING FAN Always check and clean the screens and radiator fins at the intervals outlined in the Periodic Maintenance Chart section... Do not obstruct or deflect air flow through the radiators by installing unauthorized accessories in front of the radiators or behind the cooling fan... Interference with radiator air flow can lead to overheating and consequent engine damage...

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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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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 (belt, cover, etc... )...

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2... Remove the clutch cover screwsq and open the clutch cover... (It does not have to be removed from the vehicle... ) Remove all debris wrapped in and around the PVTsystem...

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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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6... Allow the engine RPM to settle to idle speed... Apply the brakes... Shift the transmission to the lowest available range...

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NOTICE Use of a non-POLARIS-approved air filter may cause engine damage... Always use a POLARIS-approved replacement filter... Replacement filters are available

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8... Make sure that there are no gaps between the filter, the filter ring and the stop on the intake tube...

Page 138

Periodically clean the spark arrester to remove accumulated carbon... A plugged spark arrester will affect engine performance... Clean daily when driving in mud and water... Replace a cracked or damaged arrester before operating...

Page 139

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 140

Do not apply WD-40 or any petroleum product to brake discs... These types of products are flammable and may also reduce the friction between the brake

Page 141

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...

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SUSPENSION SETTINGS FRONT / REAR SPRING PRELOAD ADJUSTMENT 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...

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1... Turn the clicker clockwise to increase compression damping... 2... Turn the clicker counter-clockwise to decrease compression damping...

Page 144

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 3 mm (1/8) or less...

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2... 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...

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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...

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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...

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If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected... Take the vehicle in for service before starting the engine... Your POLARIS dealer or other qualified person can

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Your vehicle has a low-maintenance 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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The single most important thing about maintaining a sealed battery is to keep it fully charged... Check the battery voltage with a voltmeter or multimeter... A fully charged battery will register 12... 8 V or higher... If the voltage falls below 12... 5V, charge it immediately, or the battery runs the risk of sulfation and reduced battery life...

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If using a constant current charger (instead of BatteryMINDer 2012 AGM - 2 AMP charger), use the guidelines below... Always verify battery condition before and 1-2 hours after the end of charging...

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If a high pressure water system is used for cleaning (not recommended), exercise extreme caution... The water may damage components and could remove paint and labels... Avoid directing the water stream at the following items:

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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...

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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...

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2... Remove the spark plugs and add 2-3 tablespoons of engine oil... To access the plug holes, use a section of clear 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...

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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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2... Stop the engine... Turn the key back on to the accessory or ON position without starting the engine... Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle, verifying that the PARK position is shown on the display...

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*Dry weight is also listed on the Certificate of Origin for your vehicle in the Shipping Weight field... The dry weight is estimated based on the manufactured weight of the vehicle minus any serviceable fluids and may also exclude the weight of factory installed accessories not essential to the vehicles basic operation as outlined in the ANSI/ROHVA 1-2016 standard...

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Front Suspension Independent double a-arm with 16 in... (40... 6 cm) travel

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CLUTCHING Please see your POLARIS dealer for clutching specifications

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

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

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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...

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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...

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Water or fuel in crankcase Your POLARIS dealer or other qualified person can assist...

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Incorrectly installed spark plug wires Your POLARIS dealer or other qualified person can assist...

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

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Overheated engine Clean radiator screen and core, clean engine exterior, check coolant level... Your POLARIS dealer or other qualified person can assist...

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REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase... Upon receipt of this registration, POLARIS will record the registration for warranty... No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage... If you have not signed the original registration and received the customer copy, please contact your dealer immediately... NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS... Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation... Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage...

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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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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...

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NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins... Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty...

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The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first... The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first... 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 additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension...

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Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance... 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 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 CONSEQUENTIAL, 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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Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle... An authorized POLARIS dealer can perform any service that may be necessary for your vehicle... POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service... 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... Tampering with emission controls is prohibited by federal law...

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CALIFORNIA RESIDENTS Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions... Only the 50-state models are certified for sale in California... The 50- state models available for sale in California are identified by the letter B in the ninth position of the model number (e... g... , R16RTE87B)... The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity... Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer...

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OWNER'S WARRANTY RESPONSIBILITIES: As the OHRV-EVAP owner, you are responsible for the performance of the required maintenance listed in your owner's manual... Polaris recommends that you retain all receipts covering maintenance on your OHRV-EVAP, but Polaris cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of a scheduled maintenance... As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists... The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days... As an OHRV-EVAP owner, you should also be aware that Polaris may deny you warranty coverage if your OHRV-EVAP or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications...

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

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E Electromagnetic Interference ... 85 Electronic Power Steering (EPS)... 32 Engine and Drivetrain Break-in ... 55 Engine Backfires ... 165 Engine Doesnt Turn Over ... 164 Engine Pings or Knocks ... 166 Engine Runs Irregularly, Stalls or Misfires ... 166 Engine Stops or Loses Power ... 168 Engine Turns Over, Fails to Start ... 165 Equipment Modifications ... 27 Error Codes, Engine... 54 Exhaust Emission Control System ... 85 Exposure to Exhaust ... 24 Eye Protection ... 11

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Operating a Damaged Vehicle ... 24 Operating at Excessive Speeds ... 21 Operating Improperly in Reverse... 23 Operating in Unfamiliar Terrain ... 23 Operating on Frozen Bodies of Water ... 25 Operating on Public Roads ... 21 Operating Over Obstacles ... 24 Operation on Public Lands in the U... S... A... 85

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Safety, Winch Maintenance... 83 Seat Belt Height Adjuster ... 40 Seat Belt Inspection ... 39 Seat Belt Warning... 14 Seat Belts ... 18, 38 Seats ... 33 Service Access Panels ... 41 Shock Loading the Winch ... 82 Skidding or Sliding ... 23 Spark Arrester ... 136 Spark Plug Condition... 125 Spark Plug Gap / Torque ... 123 Spark Plug Removal and Replacement ... 124 Stalling While Climbing a Hill ... 22 Starting the Engine ... 58 Steering Wheel ... 34 Steering Wheel Inspection... 146 Stopping the Engine... 59 Storage Tips... 152 Switches... 30 Mode Button... 46

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Welcome Page ... 3 Wheel Installation ... 143 Wheel Removal... 143 Winch Cable Care ... 81 Winch Maintenance and Service Safety ... 83 Winch Operation ... 76 Winch Safety Precautions ... 73 Winch Shock Loading... 82

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For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www... polaris... com

Manualsnet FAQs

If you want to find out how the RZR XP 1000 Polaris works, you can view and download the Polaris RZR XP 1000, RZR XP 4 1000 Owner's Manual v2 on the Manualsnet website.

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The Owner's Manual should include all the details that are needed to use a Polaris RZR XP 1000. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

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