Polaris RZR 4 900 - Manuals

5 INTRODUCTION 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 ...

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

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

8 SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding th...

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When-ever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing mar...

10 SAFETY 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 instructi...

11 SAFETY Safety Labels and Locations Seat Belt/Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belts. • Wear an approved helmet and pro- tective gear. • ALWAYS use cab nets and/or doors. • Each rider must be able to sit with back...

12 SAFETY Safety Labels and Locations Rear Passenger Cab Frame Warning (RZR 4) WARNINGDo NOT hold onto this bar. Hands and arms could be crushed or seriously injured in event of rollover.ALWAYS keep hands on passenger hand hold. 7176700 Rear Passenger Hand Hold Warning (RZR 4) Always use seat belt, ...

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

15 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating co...

16 SAFETY Safety Warnings Carrying Multiple Passengers (RZR 4) Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 52-53.A passenger must always be seated in a passenger seat with seat belt secur...

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

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

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

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

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

22 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See page 62. • Never exceed...

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

24 SAFETY Safety Warnings Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especial...

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

26 FEATURES AND CONTROLS Switches Auxiliary Outlets The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a second outlet (on RZR 4 models, if equipped) is in the rear passenger area. Use the outlets to power an auxiliary light or other optional accessories o...

27 FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The ignition switch must be in the ON posi-tion to operate the headlights. Press the top of the rocker switch toward the dash to place the he...

28 FEATURES AND CONTROLS Seats Before operating the vehicle, always push down on all seat backs to ensure the latches are secure. Seat Adjustments Loosen (do not remove) the four screws located on the seat bottom. Slide the seat forward or rearward to the desired position. Tighten the screws to 4 ft...

29 FEATURES AND CONTROLS Passenger Hand Hold Always adjust the hand hold to a comfortable position for your front-seat passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments. 1. Remove the retainer from the end of the adjustment pin. 2. ...

30 FEATURES AND CONTROLS Hood Remove the hood to access the radiator pressure cap and coolant overflow bottle. 1. Turn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the fasteners. 3. Pivot the hood forward and lift upward to dis-engage the lower hood hooks. 4...

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

32 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap 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 1...

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

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

35 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 ped...

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

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

38 FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition VehicleSpeed When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. Over Temperature This lamp illuminates to indicate an overheated en...

39 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 one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument c...

40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately. Tip: If the...

41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit ...

42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or dis-charged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display. 2. Press and hold the MODE button until t...

43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Pres...

44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a c...

45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and mes-sage is lost, but wi...

46 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in peri...

47 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 32. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 85. Add the recommended oil as needed to maintain the oil level in the safe operating ran...

48 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condi-tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel En...

49 OPERATION Safe Operation Practices 1. Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course. Complete the New Operator Driving Procedures outlined on pages 52-53. 2. Do not allow anyone under 16 years of age or without a valid driver...

50 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in PARK. 4. Apply the brakes. Do not press the throttle pedal while starting the e...

51 OPERATION Parking the Vehicle 1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 2. Place the transmis...

52 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site (rohva.org) and take the free on-line training course. Hands-on training is ...

53 OPERATION New Operator Driving Procedures 13. Apply the brakes and shift into low gear. 14. Check your surroundings and determine your path of travel. 15. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 16. Drive ...

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

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

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

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

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

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

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

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

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

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

64 OPERATION Hauling Cargo Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow- ing bracket. 2. When towing a disabled RZR vehicl...

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

68 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all wi...

69 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip: A “tow strap” is NOT in...

70 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around t...

71 WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch-equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loadi...

72 WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15. After winching is complete, especially if winc...

73 WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your w...

74 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or D...

75 WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable....

76 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...

77 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 par...

78 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Ź 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.) D Have an authorized POLARIS dea...

82 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 77, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubricat...

83 MAINTENANCE Lubrication Recommendations Grease Stabilizer Bar Bushings (one on each side of vehicle) Front Control Arm Pivot Bushings (3 per side) View of Driver’s Side From Bottom of Vehicle

84 MAINTENANCE Engine Oil Oil Recommendations WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance C...

86 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. Always change the oil filter whenever changing oil. Access the oil check dipstick through the service access panel behind the seats. Acce...

87 MAINTENANCE Engine Oil Oil and Filter Change 6. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 7. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2...

88 MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 77. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fil...

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

90 MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 77. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check T...

92 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 132 for the part numbers of POLARIS products. Spark Plugs Spark Plug Gap/Torque NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use...

93 MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove the cargo box access panel. 2. Clean the area around the spark plugs before remov-ing the plugs. 3. Remove the spark plug caps. 4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counter-c...

94 MAINTENANCE Fuses If the engine stops or will not start, if the power steering stops working (if equipped), or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The main fuse ...

95 MAINTENANCE Fuses Main Fuse Box 1. Lift up on the two fuse box tabs.2. Slide the fuse box slightly toward the right side of the vehicle to disengage it from the mount. 3. Remove the fuse box cover.4. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the sa...

96 MAINTENANCE Cooling System The engine coolant level is maintained by the recovery system. The recovery system components are the overflow bottle, radiator vent fit-ting, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is...

97 MAINTENANCE Cooling System Radiator Coolant Level/Changing Coolant This procedure is required only if the cooling system has been drained for maintenance and/or repair. If the overflow bottle has run dry, the level in the radiator should also be inspected. CAUTION! Escaping steam can cause burns....

98 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). If the overflow b...

99 MAINTENANCE POLARIS Variable Transmission (PVT) System Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been ...

100 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle...

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

104 MAINTENANCE Spark Arrester • Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact wi...

105 MAINTENANCE Spark Arrester Periodically clean the spark arrester to remove accumulated carbon.1. Remove the arrester retaining bolt and nut.2. Remove the arrester from the end of the muffler. 3. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are ...

106 MAINTENANCE Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.Never start or operate this vehicle if it has a sticking or improperly operating throttle p...

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

108 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 132 for the part num-bers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store ...

109 MAINTENANCE Suspension Settings Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. Factory Preload Settings RZR 900 Premium Front 7.625” (193.7 mm) RZR...

110 MAINTENANCE Suspension Settings Front/Rear Spring Preload Fox Shock Preload Adjustment Follow these guidelines if you make adjustments to this suspension. • Always return the suspension to the factory setting after the load is removed from the vehicle. The increased suspension height will negati...

111 MAINTENANCE Suspension Settings Front/Rear Spring Preload Walker Evans Shock Preload Adjustment Follow these guidelines if you make adjustments to this suspension. • Always return the suspension to the factory setting after the load is removed from the vehicle. The increased suspension height wi...

112 MAINTENANCE Suspension Settings Front/Rear Shock Compression The compression damping clicker knob is located on top of the shock reservoir. When the knob is turned clockwise until it stops, the damping is in the fully closed position.1. Turn the clicker clockwise to increase compression damping....

113 MAINTENANCE Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of no...

114 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 whee...

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

116 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward and to the left or right. 1. Position the vehicle on a level surface. The headlight should be approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in PARK. 3. Measure the di...

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

118 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should...

119 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Yo...

120 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 121 before installing the battery. 1. Ensure that the batter...

121 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installa-tion of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully...

122 MAINTENANCE Battery Battery Charging 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 3 mos. from date of man...

123 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear-ance but it can also extend the life of various components. NOTICE: Water in the PVT system could cause the drive belt to become wet and slip in the clutches. Always avoid spr...

124 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 labels. Avoid directing the water stream at the follow-ing items: • Wheel bearings• Ra...

125 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as...

126 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 77. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the c...

127 MAINTENANCE Cleaning and Storage Removal from Storage 1. Charge the battery if necessary. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 48. Tightness of the bolts, nuts and other fasteners sh...

128 SPECIFICATIONS RZR 900 Gross Vehicle Weight Rating 1930 lbs. (875 kg) Dry Weight 1190 lbs. (540 kg) Test GVW - Rollover Protection System (ROPS) 1975 lbs. (896 kg) per OSHA 29 CFR 1928.53 Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity (Payload) 740 lbs. (336.4 kg) (including r...

129 SPECIFICATIONS Clutching RZR 900 Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Gear Reduction - Low 6.45:1 Gear Reduction - Reverse 5.776:1 Gear Reduction - High 3.037:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:...

132 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS...

133 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 56. Driving at low RPM or ground speed (3-7 MPH/5-11 km/h) Drive at a higher sp...

134 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 ...

135 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...

136 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel tank vent line or filter 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 spa...

137 WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the effici...

138 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction ...

139 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YO...

140 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for expor...

143 WARRANTY U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance or use, by accidents for which PO...

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

146 INDEX A Access Panel Cargo Box . . . . . . . . . . . . . . . . 31Engine . . . . . . . . . . . . . . . . . . . 31 Access Panels for Service . . . . . . . . 31Accessory Outlets . . . . . . . . . . . . . . 26 Adjustment Hand Hold . . . . . . . . . . . . . . . . 29Seat . . . . . . . . . . . . . . . ...