2020 RZR 900 / S 900 Owner’s Manual

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

Record your vehicle’s identification number 1, engine serial number 2, and key number 3 in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

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 course. To access this valuable training, visit www.rohva.org.

Your POLARIS vehicle is considered an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

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

For more information about recreational off-road vehicle safety in the United States, visit www.rohva.org or call POLARIS at 1-800-342-3764.

Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury.

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle

• 1 Proper Use Warning

• 2 Seat Belt Warning

• 3 Payload Warning

• 4 Riders Warning

• 5 Drive Responsibly Warning

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer or qualified person to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever 1 while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

Before operating the vehicle, always push down on all seat backs to ensure the latches are secure.

The fuel tank filler cap 1 is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel. To close, tighten the fuel cap until it clicks twice.

This vehicle is equipped with cab doors. Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched when riding in this vehicle.

Always inspect doors and latches for wear and damage before each use of the vehicle.

Promptly replace any worn or damaged parts with new parts available from your authorized POLARIS dealer or qualified person.

• The Rollover Protective Structure (ROPS) on this vehicle meets ISO 3471 rollover performance requirements. Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

• 1 ROPS Label (on ROPS or pass. hip bar)

No device can assure occupant protection in the event of a rollover. When used with seat belts and cab nets or doors, the ROPS helps prevent occupants from being ejected from the vehicle. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

Remove the hood to access the radiator pressure cap 2 and coolant overflow bottle 3.

1. Turn the hood fasteners 1 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 disengage the lower hood hooks.

4. Lift the hood away from the vehicle.

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and towing capacities outlined in the Hauling Cargo section or the Towing section.

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 1 to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

Always adjust the hand hold to a comfortable position for your passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments.

1. Remove the retainer 1 from the end of the adjustment pin 2.

2. Remove the pin from the post.

3. Slide the post inward or outward to the desired position.

4. Reinstall the pin through the post mounting hole 3, adapter bushing hole 4, both post adjustment holes 5, and lastly through the remaining bushing hole and post mounting hole.

   

5. Reinstall the retainer to the pin.

This POLARIS vehicle is equipped with seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 mph (24 kph) if the seat belt is not secured.

The All Wheel Drive system is controlled by the AWD switch. The switch has two positions, AWD (4x4) and 2WD (2x4). The switch on models equipped with a lockable differential has a third position for unlocking the differential. When unlocked, only one rear wheel is a drive wheel.

1 All Wheel Drive (AWD) 2 Two Wheel Drive (2WD) 3 Turf Mode / Differential Unlocked (1WD)

When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.

When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

There is no limit to the length of time the vehicle may remain in AWD.

High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens.

The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. Clutch and drive belt break-in periods vary depending on operating conditions.

No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.

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.

1. Visit the Recreational Off-Highway Vehicle Association® web site (rohva.org) and take the free on-line training course. Complete the steps in the New Operator Driving Procedures section.

2. Do not allow anyone under 16 years of age or without a valid driver’s license to operate this vehicle.

3. Never carry a passenger on a 1-seat vehicle. Never carry more than one passenger in a 2-seat vehicle. Never carry more than three passengers in a 4-seat vehicle. Never allow a passenger to ride in the cargo box.

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.

7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep both hands on the steering wheel during operation.

8. Never consume alcohol or drugs before or while operating this vehicle.

9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

10. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

11. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and any passengers, and your cargo, together with any other vehicles in your party.

12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

1. Position the vehicle on a level surface outdoors or in a well-ventilated area.

2. Sit in the driver's seat and fasten the seat belt. Always make sure all cab doors are closed and latched when riding in this vehicle.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the engine.

5. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

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

7. After starting the engine, wait 10 seconds before applying throttle.

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

5. Engage the park brake (if equipped).

1. Release the throttle pedal completely.

   TIP

   When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.

2. Press on the brake pedal evenly and firmly.

3. Practice starting and stopping (using the brakes) until you're familiar with the controls.

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 transmission in PARK.

3. Stop the engine.

4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

5. Engage the park brake (if equipped).

6. Remove the ignition key to prevent unauthorized use.

Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting 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. Tread lightly®. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

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

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 also available through ROHVA®.

3. Perform the pre-ride inspection.

4. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

5. Do not carry cargo during this period.

6. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

7. 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.

8. Always make sure all cab doors are closed and latched when riding in this vehicle.

9. Sit in the driver's seat and fasten the seat belt.

10. Place the transmission in PARK.

11. Start the engine.

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. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

16. Increase speed only after mastering all maneuvers at a slow speed.

17. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:
    

    • Avoid sharp turns.

    • Never turn while applying heavy throttle.

    • Never make abrupt steering maneuvers.

    • Operate at speeds appropriate for your skills, the conditions and the terrain.

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

1. Complete the New Operator Driving Procedures outlined on New Operator Driving Procedures.

2. Perform the pre-ride inspection. See the Pre-Ride Inspection section for details.

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 passengers can affect the operator’s ability to steer and operate the controls.

4. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.

5. 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. See the Safe Riding Gear section for details.

6. Always make sure all cab doors are closed and latched when riding in this vehicle.

7. Allow a passenger to ride only in a passenger seat.

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

9. Vehicle handling may change with passengers and/or cargo on board. Allow more time and distance for braking.

10. Always follow all operating guidelines as outlined on safety labels and in this manual.

Whenever traveling uphill, follow these precautions:

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

2. Avoid excessively steep hills. If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending.

3. Drive straight uphill.

4. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

5. Avoid unnecessary changes in speed or direction.

6. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

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

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 drive.

2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill.

3. Drive slowly and use extreme caution.

4. If the vehicle begins to roll over, or if it feels as if it may roll over, immediately turn downhill.

5. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.

6. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.

Whenever descending a hill, follow these precautions:

1. Avoid excessively steep hills.

2. Slow down. Never travel down a hill at high speed.

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

4. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral.

5. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill.

6. Apply the brakes lightly to aid in slowing.

Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water:

1. Determine the water depth and current before entering the water.

2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. Never operate in water that exceeds the maximum recommended depth (floor level) 1.

   WARNING

   The large tires on your vehicle may cause the vehicle to float in deep or fast-flowing water, which could result in loss of traction, loss of control, rollover or accident.

3. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads. Avoid applying brake and throttle at the same time.

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 level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

3. Engage all-wheel drive before wheels begin to lose traction.

   NOTICE

   Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

4. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

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 use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

4. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

5. Always have any passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover.

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.

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

1. Apply the brakes.

2. Place the transmission in PARK.

3. Stop the engine.

4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

5. Block the rear wheels on the downhill side.

WARNING

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing a rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while cornering or while ascending or descending a hill.

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.

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. Exercise caution if the cargo load extends over the side of the box.

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

Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See the Transporting the Vehicle section for details.

If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral. Tow the shortest distance possible. Do not operate faster than 10 mph (16 kph).

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.

Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise.

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on Shock Loading.

7. Always keep the area around the vehicle, winch, winch cable, and load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.

12. If winching at an angle is unavoidable, follow these precautions:

    1. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

    2. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s rated capacity.

15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the winch cable while winching a load.

17. Never let the winch cable run through your hands, even if wearing heavy gloves.

    

18. Never release the clutch on the winch when the winch cable is under load.

19. Never use the winch for lifting or transporting people.

20. Never use the winch to hoist or suspend a vertical load.

21. Always inspect your winch and winch cable before each use.

22. Never winch the hook fully into the winch. This can cause damage to winch components.

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

24. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.

Read the Winch Safety Precautions in the preceding pages before using your winch.

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first 3 ft (1 m) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicle’s park brake and/ or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

4. Always use the hook strap when handling the hook.

   
   WARNING

   Never put your fingers into the hook. This could lead to SEVERE INJURY.

   • 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 intended to stretch. A “recovery strap” is designed to stretch.

   WARNING

   Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on Shock Loading.

   • Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

   WARNING

   Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer.

   • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.

   • If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to Tread Lightly® (treadlightly.org).

   • Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached.

   • Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.

   

   

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 the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

8. Read and adhere to the following information for winch damping to ensure safe winch use.

   1. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.

   2. Lay the damper on top of the mid-point of the winch cable length that is spooled out.

   3. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.

   4. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or worn.

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on Shock Loading. For your safety, always follow these guidelines when winching a vehicle free:

    1. Release the winch clutch and spool out the necessary length of winch cable.

    2. Align the winch cable as close as possible to the winching vehicle’s centerline.

    3. Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following instructions in this manual.

    4. Re-engage the clutch on the winch.

    5. Slowly winch in the slack in the winch cable.

    6. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching.

    7. Shift to the lowest gear available on the stuck vehicle.

    8. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.

    9. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch.

    10. Detach the winch cable hook.

    11. Rewind the winch cable evenly back onto the winch drum following the instructions in this manual.

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

13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods.

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 winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task.

    1. Release the clutch on the winch.

    2. Feed out the winch cable that is unevenly bunched up in one area.

    3. Re-engage the winch clutch.

    4. Have an assistant pull the winch cable tightly with about 100 lb (45 kg) of tension using the hook strap.

    5. Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum.

    6. Doing this reduces the chances of the winch cable “wedging” itself between lower layers of winch cable.

For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable.

   A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

   

   A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.

   
   

   A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown below). Promptly discontinue use of a winch cable in this condition. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

   
   

Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.

   WARNING

   SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.

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.

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.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.ecfr.gov..

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

The emissions label is located on the left front frame of the vehicle.

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

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 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 at the end of the manual.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart section, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Lubricate as recommended.

1 Middle Prop Shaft Grease Fitting 2 Rear Prop Shaft Grease Fitting

3 Rear Stabilizer Bar Grease Fitting 4 Front Stabilizer Bar Grease Fitting

Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications.

Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications.

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

If the engine stops or will not start, if the power steering stops working (if equipped), or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The fuse/relay center 1 is located under the driver’s seat.

The engine coolant level is maintained by the recovery system. The recovery system components are the overflow bottle, radiator vent fitting, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator.

Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal.

Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See the Brake Fluid section for further details.

If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs.

Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles.

If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land.

2. Check the air box. See the Air Filter section for details. If water is present, dry the air box and replace the filter with a new filter.

3. Dry the spark plug wells with a clean cloth, then remove the spark plugs.

4. Turn the engine over several times.

5. Dry the spark plugs and reinstall them, or install new plugs.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

8. If water has been ingested into the PVT follow the procedures in the PVT Drying section.

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8-1.0 in (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 or other qualified personnel.

Your vehicle has a low-maintenance battery. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

Please see your authorized dealer for clutching specifications

Please see your authorized dealer for clutching specifications