Polaris RZR S 800 - 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 protective gear. • ALWAYS use cab nets and/or doors. • Each rider must be able to sit with back a...

13 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 the passenger seat with seat belt secured. A p...

18 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual.Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering...

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

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 Shifter Front Passenger Hand Hold Cab Nets Rear Passenger Hand Hold Rack Extenders (RZR/RZR EPS only) Tie-Down Points

27 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. Radiator Access/Grill Removal The front grill can ...

28 FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or down-ward. Release the lever when the steering wheel is at the desired position. Passenger Han...

29 FEATURES AND CONTROLS Hood Remove the hood to access the front storage compartment (if equipped), the radiator cap and the coolant overflow bottle. 1. Turn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the hood from the vehicle. 3. Pivot the hood forward a...

30 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 gaso-line with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with eth- anol content greater tha...

31 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...

32 FEATURES AND CONTROLS Switches Auxiliary Outlet 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 passen-ger area. Use the outlets to power an auxiliary light or other optional accessories or lights. For ser...

33 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 50 for starting procedures. The key can be removed from the switch when it is in the OFF position. Headlight Switch Use the headlight ...

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 starting 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 peda...

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 30. 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 recommended safety training before operating this vehicle. 2. Do not allow anyone under 16 years of age or without a valid driv...

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 passengers in a 4-seat vehicle. Additional passenge...

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. Place the transmission in PARK. 2. Turn the engine off. 3. Block the rear wheels on the downhill side, or park the ...

62 OPERATION Hauling Cargo 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 ALLOW GR...

63 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities. 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 s...

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 compli-ance 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 vehicl...

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 WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services. Symbol Description Ź Perform these operatio...

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 RZR S/RZR 4 Control Arm Pivot Bushings RZR S/RZR 4 Control Arm Pivot Bushings RZR 4 Stabilizer Bar Bushings RZR Stabilizer Bar Bushings RZR Control Arm Pivot Bushings

84 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W-50 oil. WARNING! Vehicle operation with insufficient, deter...

85 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine, behind the passenger seat (behind the right rear passe...

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. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehi...

87 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...

88 MAINTENANCE Gearcases Transfer Case 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 94 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plu...

89 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 com...

93 MAINTENANCE Gearcases Rear 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 94 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plu...

94 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 136 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...

95 MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove both seats. 2. Remove the rear service panel. See page 27. 3. Remove the spark plug cap. 4. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise. 5. Reverse the procedure for spa...

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

97 MAINTENANCE Fuses The fuse box is located above the power steering unit. Spare fuses are provided in the fuse box. 1. From the left side of the vehicle, reach in and 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 moun...

98 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...

99 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 77. Do not obstruct or deflect air flow through the radiator by installing unauthor-ized accessories in front of t...

100 MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart begin-ning on page 77. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a le...

101 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...

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

103 MAINTENANCE Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. 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 around the entire...

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 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...

106 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 27. 2. Locate the thr...

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...

109 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. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean ...

110 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...

111 MAINTENANCE Suspension Settings(RZR and RZR S Base Models) 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 vehic...

112 MAINTENANCE Suspension Settings(RZR S Premium Models and RZR 4) Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. Since the vehicle is equipped with full skid plates, adjustment is not necessary. If desired, the suspension may be adjusted to maintain ...

113 MAINTENANCE Suspension Settings(RZR S Premium Models and RZR 4) Front/Rear Spring Preload 1. Elevate the vehicle to allow the sus- pension to fully extend. 2. Loosen the jam nut and back it away from the adjusting ring. 3. Turn the adjusting ring to the left (1) to increase preload for a stiffer...

114 MAINTENANCE Suspension Settings(RZR S Premium and RZR 4 Premium Models) 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 cl...

115 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 non...

116 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...

117 MAINTENANCE Lights Do not operate the vehicle at night or in low light conditions without properly working headlights. Always make sure lights are adjusted properly for best visibility. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for...

118 MAINTENANCE Lights Headlight High 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 h...

119 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...

120 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.Antidote: External : Flush with water. Internal : Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil...

121 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. Ba...

122 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 124 before installing the battery. 1. Ensure that the batter...

123 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...

124 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 121. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

125 MAINTENANCE Battery Battery Charging (Sealed Battery) 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....

126 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 directl...

127 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...

128 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. Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptibl...

129 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...

130 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...

131 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...

132 SPECIFICATIONS RZR / RZR S Gross Vehicle Weight Rating RZR: 1727 lbs. (783 kg)RZR S: 1782 lbs. (808 kg) Dry Weight RZR: 993 lbs. (450 kg)RZR EPS: 1041 lbs. (472 kg)RZR S: 1029 lbs. (467 kg)RZR S EPS: 1055 lbs. (479 kg) Test GVW - Rollover ProtectionSystem (ROPS) RZR: 1745 lbs. (791.5 kg) per OSH...

135 SPECIFICATIONS Clutching RZR 4 Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High 3.14:1 Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Ti...

136 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...

137 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) Drive at a higher speed or use...

138 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 ...

139 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...

140 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...

141 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...

142 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 ...

143 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...

144 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...

147 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...

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

150 INDEX A Accessory Outlet . . . . . . . . . . . . . . . 32Adding Coolant . . . . . . . . . . . . . . . . 98 Adjustment Hand Hold . . . . . . . . . . . . . . . . . . 28Seat . . . . . . . . . . . . . . . . . . . . . . . 27Steering Wheel . . . . . . . . . . . . . . 28 Adjustment, Headlight Beam. . ....