Polaris RANGER RZR XP 900 Owner's Manual For Maintenance And Safety
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Polaris RANGER RZR XP 900 Owner's Manual For Maintenance And Safety

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Summary of Contents for Polaris RANGER RZR XP 900

  • Page 1 RANGER RZR XP 900 RZR XP 4 900 Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 • Victory Motorcycles ® • Low Emission Vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever pro-...
  • Page 4 The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2012 RANGER RZR XP 900 / RANGER RZR XP 4 900 Owner’s Manual P/N 9923625...

  • Page 5: Table Of Contents

    Specifications ......120 POLARIS Products..... 124 Troubleshooting .

  • Page 6: Introduction

    INTRODUCTION 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 indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
  • Page 7 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.

  • Page 8: 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 of your existing keys.

  • Page 9: Safety

    This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Do not install on a POLARIS vehicle any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 10 Helmet Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 11 Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy footwear. Do not ride a POLARIS vehicle with bare feet. Clothing Wear long sleeves and long pants to protect arms and legs.
  • Page 12 Accessories Non-approved accessories may seriously affect vehicle stability. Using accessories not approved by POLARIS for use on this vehicle could cause loss of control or an accident. Never operate with accessories not approved by POLARIS for use on this vehicle.

  • Page 13: Seat Belts

    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 inspect the vehicle before each use to make sure it's in safe operating condition.
  • Page 14 SAFETY Safety Warnings Carrying Multiple Passengers (RZR XP) 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 56-57. A passenger must always be seated in a passenger seat with seat belt secured.
  • Page 15 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.
  • Page 16 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.
  • Page 17 SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in the owner's manual. See page 60. Crossing Hillsides Driving on a sidehill is not recommended.
  • Page 18 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 64. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.

  • Page 19: Skidding Or Sliding

    SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles. Never attempt to operate over large obstacles such as rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.
  • Page 20 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 the owner's manual for carrying cargo. •...
  • Page 21 Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use. FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764.
  • Page 22 If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Load/Passenger/Tire Pressure Warning...
  • Page 23 SAFETY Safety Labels and Locations Passenger Safety Warning Passenger Safety Warning (RZR XP) WARNING NEVER CARRY A PASSENGER UNDER AGE 12 NEVER CARRY MORE THAN ONE PASSENGER NEVER 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 the floor and securely grasp hand hold.
  • Page 24 SAFETY Safety Labels and Locations Passenger Safety Warning (RZR XP 4) WARNING NEVER CARRY PASSENGERS UNDER AGE 12 NEVER CARRY MORE THAN THREE PASSENGERS PASSENGERS UNDER NEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH, NEVER carry passengers under age 12 or too small to firmly plant feet on the floor and securely grasp hand holds.
  • Page 25 SAFETY Safety Labels and Locations Rear Passenger Cab Frame Passenger Cab Frame Warning (RZR XP 4) Warning (both sides) WARNING Do NOT hold onto this bar. Hands and arms could be crushed or seriously injured in event of rollover. ALWAYS keep hands on passenger grab bar. 7176700 Rear Passenger Grab Bar Warning (RZR XP 4)
  • Page 26 SAFETY Safety Labels and Locations Overturn Warning Warning Cab Frame/Seat Discretionary Shift Belt Warning Warning Caution 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. Shift Caution CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle.
  • Page 27 Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around the clutch and vent system when replacing the belt. Read owner’s manual or see authorized POLARIS dealer. 7177469...
  • Page 28 Discretionary • on paved surfaces - pavement may seriously Warning affect handling and control. • with non-POLARIS approved accessories - they may seriously affect stability. ALWAYS: • keep hands and feet inside vehicle. Use the cab nets. • reduce speed and use extra caution when carrying a passenger.
  • Page 29 • on hills steeper than 15 degrees. • on public roads. • on paved surfaces - pavement may seriously affect handling and control. • with non-POLARIS approved accessories - they may seriously affect stability. ALWAYS: • keep hands and feet inside vehicle.

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Component Locations ROPS Frame Nets Cargo Steering Wheel Radiator Fuel Tank Bars Front Passenger Hand Hold Brake Pedal Throttle Pedal Gear Selector...

  • Page 31: Component Locations

    FEATURES AND CONTROLS Component Locations Rear Passenger Grab Bar Shifter Fuel Tank Cargo Box Tie-Down Points...

  • Page 32: Ignition Switch

    FEATURES AND CONTROLS Switches Instrument Ignition Switch Cluster 12V Accessory Light Outlet Switch Switch Auxiliary Outlets The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a second outlet (if equipped) is in the rear passen- ger area.

  • Page 33: Headlight Switch

    FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and HIGH 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 headlights on high beam.

  • Page 34: Steering Wheel

    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.
  • Page 35 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.
  • Page 36 FEATURES AND CONTROLS Hood Hood Fasteners 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 Overflow...
  • Page 37 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 some serviceable engine components. Oil Tank Access Panel The oil tank access panel is located in the forward left corner of the cargo box.

  • Page 38: Fuel Cap

    Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, avail- able from your authorized POLARIS dealer. Cab Net Latches...

  • Page 39: Seat Belt Inspection

    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.

  • Page 40: Gear Selector

    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 Gear Selector speed above idle or while the vehicle is moving.

  • Page 41: Brake Pedal

    The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your autho- rized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover.

  • Page 42: Engaging Awd

    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 will be on.

  • Page 43: Instrument Cluster

    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 to clean the instrument cluster.

  • Page 44: Indicator Lamps

    FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected, speed displays in Vehicle miles per hour. Speed When metric mode is selected, speed displays in kilometers per hour. Over This lamp illuminates to indicate an overheated Temperature engine.
  • Page 45 If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 46 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.
  • Page 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) MODE Button The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit the set-up mode, turn the key off.
  • Page 48 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.
  • Page 49 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. Press and hold the MODE button until the meter resets to zero.
  • Page 50 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
  • Page 51 3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See an authorized POLARIS dealer for code details and diagnosis.

  • Page 52: 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 gaso- line. No single action on your part is as important as a proper break-in period.
  • Page 53 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 36. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 77. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 54 Engine intake pre-filter Inspect, clean PVT intake pre-filter Inspect, clean Headlamp Check operation Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat Latches Push down on both seat backs to ensure the latches are secure Seat Belts...

  • Page 55: Safe Operation Practices

    4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

  • Page 56: Starting The Engine

    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.

  • Page 57: Parking The Vehicle

    Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by con- tacting your POLARIS dealer, a local riding club, or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

  • Page 58: New Operator Driving Procedures

    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. 3. Perform the pre-ride inspection. See page 52. 4.
  • Page 59 OPERATION New Operator Driving Procedures 12. Apply the brakes and shift into low gear. 13. Check your surroundings and determine your path of travel. 14. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 15.
  • Page 60 OPERATION Driving with Passengers 1. Complete the New Operator Driving Procedures outlined on pages 56-57. 2. Perform the pre-ride inspection. See page 52. 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.

  • Page 61: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.

  • Page 62: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. Avoid steep hills (15 maximum). If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending. 3. Drive straight uphill. 4.

  • Page 63: Driving Downhill

    OPERATION Driving on a Sidehill (Sidehilling) 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 hill is unavoidable, follow these precautions: 1.

  • Page 64: Driving Through Water

    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 Floor Level water level is lowest and where both banks have grad-...

  • Page 65: Driving Over Obstacles

    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 haz- ards such as logs, rocks and low hanging branches. 3.

  • Page 66: Driving In Reverse

    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.

  • Page 67: Parking On An Incline

    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.

  • Page 68: Hauling Cargo

    OPERATION Hauling Cargo WARNING 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 DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 69 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 and cargo.

  • Page 70: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 71: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 137.

  • Page 72: Maintenance Chart Key

    E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized...

  • Page 73: Periodic Maintenance Chart

    250 (400) Inspect level; add if needed gearcase) oil Engine breather 25 H Monthly 150 (250) Inspect; replace if neces- filter (if equipped) sary Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services.
  • Page 74 Spark plugs 100 H 12 M 1000 (1600) Inspect; replace as needed, torque to specification Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services.
  • Page 75 5000 (8000) Replace, torque to specification Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services...

  • Page 76: Lubrication Recommendations

    Gearcase Lube Front Gearcase Fluid Demand Drive Plus Fluid See page 82. (Demand Drive) Prop Shaft POLARIS Premium U-Joint Grease middle and rear fittings. Lube Front Control Arm Pivot POLARIS Premium all Grease 3 fittings on each side of Bushings Season Grease or grease the vehicle.
  • Page 77 MAINTENANCE Lubrication Recommendations View of Driver’s Side From Bottom of Vehicle Grease Stabilizer Bar Bushings (one on each side of vehicle) Front Control Arm Pivot Bushings (3 per side)

  • Page 78: Engine Oil

    Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart. Oil may need to be changed more frequently if POLARIS PS-4 PLUS Synthetic engine oil is not used. Follow the manufacturer's recommen- dations for ambient temperature operation. See page 124 for the part numbers of POLARIS products.

  • Page 79: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Always use the recommended engine oil. Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull.
  • Page 80 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 69. Always change the oil filter whenever changing oil. The oil tank drain plug is on the bot- Oil Tank Drain Plug tom of the oil tank.
  • Page 81 MAINTENANCE Engine Oil Oil and Filter Change 5. Locate the oil catch tool in the tool kit. Position the oil catch tool below the oil filter to catch spills when the filter is removed. 6. Using an oil filter wrench, turn the filter counter-clock- wise to remove it.
  • Page 82 MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase.
  • Page 83 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.
  • Page 84 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 69. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the demand...
  • Page 85 MAINTENANCE Demand Drive Unit (Front Gearcase) Fluid Change The drain plug is located on the bot- tom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely.

  • Page 86: Spark Plugs

    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 124 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL 44 oz.
  • Page 87 MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove the cargo box Spark Plugs 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-...
  • Page 88 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short cir- cuits that may have caused the blown fuse, then replace the fuse. Main Fuse Feature Supported Lights: Headlights, Taillights...
  • Page 89 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 Step 1 - Lift tabs panel.

  • Page 90: Cooling System

    See page 89 for changing procedure. POLARIS recommends the use of POLARIS Premium 60/40 anti- freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is already premixed and ready to use.
  • Page 91 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. Never remove the pressure cap while the engine is warm or hot.

  • Page 92: Overflow Bottle Coolant Level

    5. Reinstall the cap. Tip: If coolant must be added often, or if the overflow bot- tle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer.
  • Page 93 • See your dealer as recommended in the owner’s manual and on safety labels. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 94 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 damage and severe injury or death.

  • Page 95: Pvt Drying

    MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 3. Remove all debris from the entire clutch air duct passage. 4. Check for signs of damage to seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged.
  • Page 96 MAINTENANCE Filter Systems Fuel Tank Vent Filter 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.

  • Page 97: Air Filter

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. 1. Remove the cargo box Wing Nuts/Bolts access panel. 2. Loosen the air box cover wing nuts and rotate the bolts away from the cover.

  • Page 98: Spark Arrester

    MAINTENANCE Spark Arrester WARNING 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 with the exhaust components.
  • Page 99 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 warm.

  • Page 100: Throttle System

    If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic. If engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment. Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If...

  • Page 101: Brake Inspection

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 39. 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.

  • Page 102: 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 124 for the part num- bers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.
  • Page 103 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. Fox Shock Preload Walker Evans Front Walker Evans Rear Measurement Shock Preload Shock Preload...
  • Page 104 WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. 5. Tighten the jam nut firmly against the adjuster ring.
  • Page 105 Ring WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments.
  • Page 106 MAINTENANCE Suspension Settings Front/Rear Shock Compression Decrease 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. Increase 1. Turn the clicker clockwise to increase compression damping.

  • Page 107: Tire Tread Depth

    MAINTENANCE Tires WARNING 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-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.

  • Page 108: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS Forward Valve Stem dealer. Rotation 3. Attach the wheel nuts and washers and finger tighten.

  • Page 109: Brake Lights

    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(s) for a few days to allow the moisture to clear out.

  • Page 110: Headlight Beam Adjustment

    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. 25 ft.

  • Page 111: Vehicle Immersion

    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 outlined below.

  • Page 112: Steering Wheel Inspection

    2. Lightly turn the steering wheel left and right. 3. There should be 0.8-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or if the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer.

  • Page 113: Battery Removal

    MAINTENANCE Battery WARNING 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. Your vehicle has a sealed battery, which requires little maintenance.

  • Page 114: Battery Installation

    Whenever the vehicle is not used for a period of three months or more, recharge the battery about once a month to make up for normal self-dis- charge (see page 113), or use a POLARIS Battery Tender, which can be left connected during the storage period. Battery Tender will automati- cally charge the battery if voltage drops below a pre-determined point.

  • Page 115: Battery Charging

    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 charged at the factory.
  • Page 116 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.

  • Page 117: Cleaning And Storage

    Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

  • Page 118: Polishing The Vehicle

    • Labels and decals • Electrical components and wiring • Air intake components If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

  • Page 119: Oil And Filter

    115. 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 for the recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 120 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug caps to the spark plugs.

  • Page 121: Transporting The Vehicle

    2. Remove the key to prevent loss during transporting. 3. Secure the fuel cap and seats. 4. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.

  • Page 122: Specifications

    SPECIFICATIONS RANGER RZR XP 900 Gross Vehicle Weight 1930 lbs. (875 kg) Dry Weight 1190 lbs. (540 kg) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 740 lbs. (336.4 kg) (including riders, cargo and (Payload) accessories) Fuel Capacity 7.75 gal.
  • Page 123 Foot Activated, 4-wheel hydraulic disc Headlights 2 dual beam, 6-LED cluster, 40w High / 27w Low Taillights 2 single beam, 5w Brake Lights 2 single beam, 5w Instrument Cluster Auxiliary DC Outlet Clutching Please see your POLARIS dealer for clutching specifications.
  • Page 124 SPECIFICATIONS RANGER RZR XP 4 900 Gross Vehicle Weight 2375 lbs. (1077 kg) Dry Weight 1390 lbs. (630.5 kg) Rear Cargo Box Capacity 300 lbs. (136 kg) Maximum Weight Capacity 900 lbs. (408 kg) (including riders, cargo and (Payload) accessories) Fuel Capacity 7.75 gal.
  • Page 125 Foot Activated, 4-wheel hydraulic disc Headlights 2 dual beam, 6-LED cluster, 40w High / 27w Low Taillights 2 single beam, 5w Brake Lights 2 single beam, 5w Instrument Cluster Auxiliary DC Outlet Clutching Please see your POLARIS dealer for clutching specifications.

  • Page 126: Polaris Products

    Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger...

  • Page 127: Troubleshooting

    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See warnings on page 60. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently.
  • Page 128 TROUBLESHOOTING Engine Doesn't Turn Over 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 electronic control box connections Inspect, clean, reinstall connectors Mechanical failure See your dealer Engine Turns Over, Fails to Start...
  • Page 129 TROUBLESHOOTING Engine Pings or Knocks 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 Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
  • Page 130 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel tank vent line or Inspect and replace filter 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 See your dealer Incorrect spark plug gap or heat range...

  • Page 131: Warranty

    WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 132 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 133 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materi- als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 134 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 form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 135 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and...
  • Page 136 How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 137 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 138 POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 139: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 140 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 141 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 142: Index

    INDEX Access Panel Cab Frame, ROPS ....39 Cargo Box ....35 Cab Nets .
  • Page 143 INDEX Electromagnetic Interference ..68 Fluid Levels During Storage..117 Emission Control, Crankcase ..68 Fluid Recommendations, Gearcase . 84 Emission Control, Exhaust ..68 Fluid, Brake .

  • Page 144: Oil Change

    Plugs, Spark ....84-85 Polaris Products ....124 Nets, Cab ..... 36 Polishing the Vehicle.
  • Page 145 INDEX Radiator..... . . 88 Stopping the Engine ... . . 54 Radiator Coolant Level .
  • Page 146 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 147 • on hills steeper than 15 degrees. • on public roads. • on paved surfaces - pavement may seriously affect handling and control. • with non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • keep hands and feet inside vehicle. Use the cab nets.

This manual is also suitable for:

Ranger rzr xp 4 900

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