Polaris 2008 Ranger RZR- Manuals

5 SAFETY Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual,...

6 SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructio...

7 SAFETY Safety Decals and Locations Cab Frame/Seat Belt Warning WARNING• ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat belt. • ALWAYS SECURE CAB NETS.• VEHICLE OVERTURN could cause severe injury or death. The cab frame is not designed or intended to provide rollover protection. Shif...

8 SAFETY Safety Decals and Locations Passenger Safety Warning WARNINGNEVER CARRY A PASSENGER UNDER AGE 12NEVER CARRY MORE THAN ONE PASSENGERNEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH, NEVER carry a passenger under age 12 or too small to firmly plant feet on ...

9 SAFETY Safety Decals and Locations Discretionary Warning WARNINGALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGERNEVER USE ON PUBLIC ROADSNEVER USE WITH DRUGS OR ALCOHOLImproper vehicle use can result in SEVERE INJURY or DEATHNEVER operate:• without first viewing safety ...

11 SAFETY Rider Safety • This vehicle handles differently than cars, trucks or other off-road vehicles. Turning improperly can result in an overturn. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Operate at speeds appropriate for your skills, the ...

13 SAFETY Rider Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we design accessories for your vehicle that take into consideration safe vehicle handling and stability. Never operate with accessories not approved by Polaris for u...

14 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Eye Protection Gloves Sturdy Footwear Long Pants Long Sleeves

15 SAFETY Safe Riding Gear Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.Approved helm...

16 SAFETY Rider Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license. Never operate with a passenger under the age of 12. Make sure any passenger is tall enough to comfortably and safely rea...

17 SAFETY Rider Safety Know Your Riding Area/Tread Lightly Your Polaris vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated ridi...

31 SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.Always stop the engine when refueling.Always refuel outdoors or in a well ventilated area.Remove flammable material containers from the box...

32 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with upper and lower cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger at all times. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized Polaris dea...

34 FEATURES AND CONTROLS Component Locations Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.To avoid injury and property damage, always heed the warnings and towing capacities outli...

35 FEATURES AND CONTROLS Rear Service Panel The rear service panel is located behind the seats on the frame of the vehicle. Remove the seats to access the service panel. Remove the ser- vice panel to access serviceable engine components and clutches. Seats Before operating the vehicle, always push d...

36 FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider pref- erence.Lift and hold the steering wheel adjustment lever while moving the steer- ing wheel upward or downward. Release the lever when the steering wheel is at the desired position. Passenger H...

37 FEATURES AND CONTROLS Storage Compartment Remove the hood to access the front storage compartment. Refer to the specifications section beginning on page 126 for storage compartment capacity. Hood Remove the hood to access the front storage compartment, the radiator and the coolant overflow bottle...

38 FEATURES AND CONTROLS Cab Nets Your vehicle is equipped with upper and lower cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger at all times. Make sure all latches are secure before operating the vehicle.Always inspect cab nets for tightness, wear and dama...

39 FEATURES AND CONTROLS Cab Nets Upper Cab Net Removal (Driver) The upper cab net on the driver’s side may be removed only if it inter- feres with operation of the vehicle . All other cab nets must remain installed.1. Using a T-25 torx bit and 7/16" open end wrench, remove the mounting screw an...

40 FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. To wear the seat belt properly, follow this procedure:1. Pull the seat belt latch down- ward and across your chest toward the buckle at the inner edge of ...

41 FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle.1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the ...

42 FEATURES AND CONTROLS Switches Mode Switch The yellow switch located near the instrument gauge is used to toggle through mode options available such as odometer, trip meter, hour meter, tachometer and clock. See page 49 for operation of the modes. Work Light Switch Use the work light switch to tu...

43 FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. Use the ignition switch to start the engine. See page 57 for starting procedures.The key can be removed from the switch when it is in the OFF position. Light Switch Use the headlight switc...

44 FEATURES AND CONTROLS Gear Selector P: ParkR: ReverseN: NeutralL: Low GearH: High GearTo change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. NOTE: Maintaining shi...

45 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while start- ing the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pe...

46 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is con- trolled by the AWD switch. When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the AWD indicator light will be on.When in A...

47 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. NOTE: In addition to showing vehicle speed, the speed...

48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the inst...

49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode switch located near the instrument gauge to toggle through the mode options. See page 42. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter recor...

50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode.T...

52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers Toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.1. Enter the diagnostic mode.2. Toggle to the screen that displays either ki...

53 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code Failure Description -- No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to Ground...

54 OPERATION Vehicle Break-In Period The break-in period for your new Polaris vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and...

55 OPERATION Vehicle Break-In Period The break-in period for your vehicle is defined on the previous page. Please read the information carefully. Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 37.2. Check the oil level. See page 83. Add the recommended oil as needed to ...

56 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation 45 105 Brake ...

57 OPERATION Starting the Engine 1. Sit in the driver's seat and fasten the seat belt.2. Place the transmission in PARK.3. Apply the brakes. NOTE: Do not press the throttle pedal while starting the engine. 4. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum o...

58 OPERATION Braking 1. Release the throttle pedal completely.2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls. NOTE: When the throttle pedal is released completely and engine speed slows to near idle, the vehicl...

59 OPERATION Parking the Vehicle 1. Stop the vehicle on a level surface. Place the transmission in PARK.2. Turn the engine off.3. Remove the ignition switch key to prevent unauthorized use. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. When parking inside a g...

60 OPERATION New Operator Driving Procedures 1. Do not carry a passenger until you have at least two hours of driving experience with this vehicle. 2. Do not tow or carry cargo during this period.3. Select an open area that allows room to familiarize yourself with vehicle operation and handling. Che...

61 OPERATION New Operator Driving Procedures 5. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed. 6. Check for upper c...

62 OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on pages 60-61. 2. Perform the pre-ride inspection. See page 56.3. Make sure the passenger is at least 12 years of age and is tall enough to comfortably and safely sit in the passenger seat with the seat b...

63 OPERATION Driving with a Passenger 7. Allow a passenger to ride only in the passenger seat.8. Do not carry more than one passenger. Additional passengers can affect the operator’s ability to steer and operate the controls. 9. Slow down. Always travel at a speed appropriate for your skills, your p...

64 OPERATION Driving on Slippery Surfaces When driving on slip- pery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, fol-low these precautions:1. Slow down when entering slippery areas. 2. Maintain a high level of alert...

65 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions:1. Drive straight uphill. 2. Proceed at a steady rate of speed and throttle opening. Avoid unnecessary changes in speed or direction. 3. Avoid steep hills (15 ° maximum). NOTE: If ascending a steeper grade is unavoidable...

66 OPERATION Driving on a Sidehill (Sidehilling) Avoid driving across the side of a hill. Control becomes difficult and there is an increased chance of vehicle overturn when driving on a hill- side.If crossing a hill is unavoidable, follow these precautions:1. Engage all-wheel drive.2. Drive slowly ...

67 OPERATION Driving Downhill Whenever descending a hill, follow these precautions:1. Slow down. 2. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral . 3. Travel straight downhill.4. Apply the brakes lightly to aid in slowing. WARNING ...

68 OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Never operate in water that exceeds the maximum recommended ...

69 OPERATION Driving Over Obstacles 1. Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches. 2. Before operating in a new area, check for obstacles.3. Avoid operating over large obstacles such as rocks and fallen trees...

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

71 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Place the transmission in PARK.2. Turn the engine off.3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury. Al...

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

73 OPERATION Hauling Cargo Your Polaris vehicle has been designed to carry or tow specific capaci- ties. Reduce speed and allow a greater distance for braking when carry- ing cargo.Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce bot...

74 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...

75 MAINTENANCE 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 part...

76 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dea...

80 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrica...

81 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Control Arm Pivot Bushings

82 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulat...

83 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine, behind the passenger seat.1. Position the vehicle on a...

84 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always change the oil filter whenever changing oil.The engine drain plug is located on the bottom of the crankcase.1. Position the vehicl...

85 MAINTENANCE Engine Oil Oil and Filter Change 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crank- case. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check t...

86 MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill pl...

87 MAINTENANCE Gearcases Transfer Case Fluid Change The drain plug is located on the bottom of the transfer case. Access the drain plug through the drain hole in the skid plate.1. Remove the fill plug.2. Place a drain pan under the drain plug.3. Remove the drain plug. Allow the fluid to drain comple...

88 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Ch...

89 MAINTENANCE Gearcases Transmission (Main Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. Access the drain plug through the drain hole in the skid plate.1. Remove the fill plug.2. Place a drain pan under the drain plug.3. Remove the drain plug. Allow the fluid to dr...

91 MAINTENANCE Gearcases Rear Gearcase Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 75. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill pl...

92 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 128 for the part numbers of Polaris products. Gearcase Lubricant Capacity Fill Plug Torque Drain Plug/ Level Check Plug Torque Transmission (Main Gearcase) Premium AGL S...

93 MAINTENANCE Spark Plugs Spark Plug Gap/Torque 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. See page 94. CAUTI...

94 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not b...

95 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radia- tor filler neck, radiator pressure cap and connecting hose.As coolant operating temperature increases, the expanding (he...

96 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 75. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of...

97 MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart begin- ning on page 75. Maintain the coolant level between the minimum and maxi- mum marks on the bottle (when the fluid is cool).1. Position the vehicle on a l...

98 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 75. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of t...

99 MAINTENANCE Polaris Variable Transmission (PVT) System 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 PVT components (belt, cov...

100 MAINTENANCE Polaris Variable Transmission (PVT) System PVT Drying Before washing the vehicle, locate the PVT outlet duct under the right rear wheel well. Avoid spraying water directly toward the duct when washing the vehicle from the rear. See page 120. There may be some instances when water is ...

101 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75.1. Access the air box from behind the left rear wheel. 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover aro...

102 MAINTENANCE Spark Arrestor Periodically clean the spark arrestor to remove accumulated carbon.1. Remove the retaining screw and remove the arrestor from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen. A syn- thetic brush may melt if components are warm. NOTE: I...

103 MAINTENANCE Throttle System Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis- adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle ma...

104 MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove both seats. Remove the rear service panel. See page 35. 2. Locate the thr...

105 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 45. 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...

106 MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 128 for the part num- bers of Polaris products.Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid l...

107 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake pad wear surface for excessive wear. 5. Change pads when worn to 3/64"...

108 MAINTENANCE Suspension Adjustment The front and rear suspensions are preload adjustable, with five settings on each axle. The suspensions are set on the lowest (softest) setting at the factory. This setting is appropriate for nearly all riding conditions. Since the vehicle is equipped with full ...

109 MAINTENANCE Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. NOTE: Do not lubricate the stud or t...

110 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface.2. Place the transmission in PARK. Stop the engine.3. Loosen the wheel nuts slightly.4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. ...

111 MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, n...

112 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height...

113 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.1. Turn the ignition switch to the ON position.2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel. If the light doesn't...

114 MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.Always keep bat...

115 MAINTENANCE Battery Battery Removal 1. Remove the driver’s seat. See page 35. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be carefu...

116 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 118 before installing the battery.1. Ensure that the batter...

117 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...

118 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 115. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

119 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

120 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components.Before washing the vehicle, locate the PVT outlet duct under the right rear wheel well. Avoid spraying water directly...

121 MAINTENANCE Cleaning and Storage Washing the Vehicle 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 decals. Avoid directing the water stream at the follow- ing items: • Wheel bearings• R...

122 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscepti...

123 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 120. Stabilize the Fuel 1. Fill the fuel tank.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container...

124 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 75. Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc- tions on the...

125 MAINTENANCE Cleaning and Storage Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces- sary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tig...

126 SPECIFICATIONS RANGER RZR Gross Vehicle Weight 1727 lbs. (783 kg) Dry Weight 945 lbs. (429 kg) Fuel Capacity 7 gal. (26.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 4.8 qts. (4.5 l) Rear Gearcase Oil Capacity 18 oz. (532 ml) Demand Drive Fluid Capacity 6.75 oz. (200 ml) Transmission ...

128 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubr...

129 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 65. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...

130 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose ...

131 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...

132 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires S...

133 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of your Polaris vehicle against defects in mate- rial or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective pa...

134 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES ...

135 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION.This policy does not apply to vehicles that have received authorization for ex...

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

140 INDEX A Accessory Outlet . . . . . . . . . . . . . . . 43 Adding Coolant . . . . . . . . . . . . . . . . 95 Adjustment Headlight Beam . . . . . . . . . . . 112 Seat . . . . . . . . . . . . . . . . . . . . . 35 Steering Wheel. . . . . . . . . . . . . 36 Suspension . . . . . . . . . . . . . . . 10...

141 INDEX E EFI Blink Codes . . . . . . . . . . . . . 52-53 Electromagnetic Interference . . . . . . 74 Emission Control, Crankcase . . . . . . 74 Emission Control, Exhaust . . . . . . . . 74 Emission Control, Noise . . . . . . . . . . 74 Emissions Limited Warranty . . . . . 136 Engaging AWD. . . . ...

142 INDEX I Idle Speed . . . . . . . . . . . . . . . . . . . 104 Ignition Switch. . . . . . . . . . . . . . . . . 43 Indicator, Service Interval . . . . . . . . 51 Inspection Axle Nuts . . . . . . . . . . . . . . . . 109 Brakes . . . . . . . . . . . . . . . . . . 107 Pre-Ride . . . . . . . . . . . ....