Manuals / Polaris / Lawn and Garden / Utility Vehicle

Polaris RZR XP 4 900 Maintenance, Throttle System, Throttle Freeplay, Throttle Body/Idle RPM

Models: RZR XP 900 RZR XP 4 900

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Throttle System

MAINTENANCE

Throttle System

WARNING

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 pedal.

Immediately contact your dealer for service if throttle problems arise.

Always check the pedal for free movement and return before starting the engine and occasionally during operation.

Throttle Freeplay

If the throttle pedal has excessive play due to cable stretch or misad- justment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully.

If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic. If engine idle speed is not satisfactory,

please see your POLARIS dealer forThrottle Pedal adjustment.

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.

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Polaris RZR XP 4 900, RZR XP 900 owner manual Maintenance, Throttle System, Throttle Freeplay, Throttle Body/Idle RPM

Contents

for Maintenance and Safety RANGER RZR XP RANGER RZR XP 4Owners Manual Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels Page NEVER Operate WELCOME Printed in U.S.A TABLE OF CONTENTS INTRODUCTION DANGERNOTICE INTRODUCTION European Vibration and NoiseVehicle Identification INTRODUCTIONVehicle Identification Numbers NumberSAFETY Equipment ModificationsSAFETY Safe Riding GearHelmet Eye Protection SAFETYBoots GlovesUsing Alcohol or Drugs SAFETYAccessories Operating Without InstructionProtective Apparel SAFETYFailure to Inspect Before Operating Seat BeltsOperating With a Load on the Vehicle SAFETYCarrying Multiple Passengers RZR XP Always follow these guidelinesOperating on Pavement SAFETYPassengers in the Cargo Box Operating on Public RoadsPhysical Control of the Vehicle SAFETYTurning Improperly Jumps and StuntsCrossing Hillsides SAFETYImproper Hill Climbing Stalling While Climbing a HillOperating Improperly in Reverse SAFETYImproper Tire Maintenance Operating on Slippery TerrainSkidding or Sliding SAFETYOperating Over Obstacles Operating Through WaterOperating on Frozen Bodies of Water SAFETYImproper Cargo Loading Operating a Damaged VehicleHandling Gasoline SAFETYFOR MORE INFORMATION ABOUT SAFETY call POLARIS at RefuelingSAFETY Safety Labels and LocationsLoad/Passenger/Tire Pressure Warning SAFETY Passenger Safety Warning RZR XPPassenger Safety SAFETY Passenger Safety Warning RZR XPTHE PASSENGERS MUST ALWAYS •wear seat belts Rear Passenger Cab Frame Warning RZR XP SAFETYSafety Labels and Locations Rear Passenger Grab Bar Warning RZR XPShift Caution SAFETYCab Frame/Seat Belt Warning Age Overturn Warning WarningOverturn Warning SAFETYAge Warning Belt Debris WarningDiscretionary SAFETYDiscretionary Warning RZR XP NEVER operateNEVER operate SAFETYDiscretionary Warning RZR XP •with more than three passengersCargo FEATURES AND CONTROLSROPS Frame NetsFEATURES AND CONTROLS Rear Passenger Grab Bar Shifter Fuel Tank CapCargo Box Tie-Down Points Ignition Switch FEATURES AND CONTROLSSwitches Auxiliary OutletsFEATURES AND CONTROLS Headlight SwitchAll Wheel Drive AWD Switch Seats FEATURES AND CONTROLSSeat Adjustments Steering WheelFEATURES AND CONTROLS Passenger Hand HoldFEATURES AND CONTROLS HoodEngine Access Panel FEATURES AND CONTROLSService Access Panels Cargo Box Access PanelFEATURES AND CONTROLS Fuel CapCab Nets FEATURES AND CONTROLS Seat BeltsSeat Belt Inspection FEATURES AND CONTROLS Using Low RangeGear Selector Throttle Pedal FEATURES AND CONTROLSBrake Pedal Rollover Protective Structure ROPSFEATURES AND CONTROLS All Wheel Drive AWD SystemEngaging AWD Instrument Cluster FEATURES AND CONTROLSMode Button SpeedometerLamp FEATURES AND CONTROLSIndicator Lamps IndicatesFEATURES AND CONTROLS Rider Information CenterFEATURES AND CONTROLS 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 immediatelyRider Information Center FEATURES AND CONTROLS Rider Information CenterDisplay Units Standard/Metric FEATURES AND CONTROLS Clock ModeRider Information Center Trip Meter Mode FEATURES AND CONTROLSOdometer Mode Hour Meter ModeDiagnostic Display Mode FEATURES AND CONTROLSProgrammable Service Interval Rider Information CenterFEATURES AND CONTROLS Engine Error CodesRider Information Center OPERATION Vehicle Break-inPeriodBrake System Break-in OPERATIONEngine and Drivetrain Break-in PVT Break-inClutches/BeltItem OPERATIONPre-RideInspection RemarksOPERATION Safe Operation PracticesStopping the Engine OPERATIONStarting the Engine BrakingKnow Your Riding Area/Tread Lightly OPERATIONParking the Vehicle Trail EtiquetteNew Operator Driving Procedures OPERATIONOPERATION 12.Apply the brakes and shift into low gearOPERATION Driving with PassengersOPERATION Driving on Slippery SurfacesOPERATION Driving UphillOPERATION Driving on a Sidehill SidehillingDriving Downhill OPERATION Driving Through WaterOPERATION Driving Over Obstacles3.Back slowly OPERATIONDriving in Reverse 4.Apply the brakes lightly for stopping1.Place the transmission in PARK OPERATIONParking on an Incline 2.Turn the engine offOPERATION Hauling CargoOPERATION Belt LifeOperation on Public Lands in the U.S.A EMISSION CONTROL SYSTEMSNoise Emission Control System Crankcase Emission Control SystemMAINTENANCE Periodic Maintenance ChartSevere Use Definition MAINTENANCE Maintenance Chart KeyItem MAINTENANCEMaintenance Interval RemarksItem MAINTENANCEMaintenance Interval RemarksItem MAINTENANCEMaintenance Interval RemarksMiddle Prop Shaft Grease Fitting MAINTENANCEFitting Access as viewed from top with center floor panel removedMAINTENANCE View of Driver’s Side From Bottom of VehicleFront Control Arm Pivot Bushings 3 per side Engine Oil MAINTENANCEAmbient Temperature Range Oil RecommendationsMAINTENANCE Oil CheckMAINTENANCE Oil and Filter ChangeMAINTENANCE 15.Reinstall the dipstickOil and Filter Change MAINTENANCE Transmission Main GearcaseFluid Check MAINTENANCE Fluid ChangeMAINTENANCE Demand Drive Unit Front GearcaseFluid Check MAINTENANCE Fluid Change1.Remove the fill plug Gearcases MAINTENANCEGearcase Specification Chart Spark PlugsSpark Plug Condition MAINTENANCESpark Plug Removal and Replacement Normal PlugFeature Supported MAINTENANCEFeature Supported FusesMAINTENANCE Main Fuse BoxAdding or Changing Coolant MAINTENANCECooling System Radiator and Cooling FanMAINTENANCE Radiator Coolant Level/Changing CoolantMAINTENANCE Overflow Bottle Coolant LevelMAINTENANCE POLARIS Variable Transmission PVT SystemMAINTENANCE Belt Replacement/Debris RemovalContinued on next page MAINTENANCE Belt Replacement/Debris RemovalPVT Drying Fuel Tank Vent Filter MAINTENANCEFilter Systems Intake Pre-FiltersMAINTENANCE Air FilterMAINTENANCE Spark ArresterMAINTENANCE 1.Remove the arrester retaining bolt and nutThrottle Freeplay MAINTENANCEThrottle System Throttle Body/Idle RPMMAINTENANCE BrakesBrake Inspection MAINTENANCE Brake FluidFront/Rear Spring Preload MAINTENANCEFactory Preload Settings Fox Shock PreloadAdjusting Ring MAINTENANCEFox Shock Preload Adjustment Front/Rear Spring PreloadAdjusting Ring 1 MAINTENANCEWalker Evans Shock Preload Adjustment Front/Rear Spring PreloadRear MAINTENANCEFront/Rear Shock Compression FrontTires MAINTENANCEAxle and Wheel Nut Torque Specifications Tire Tread DepthWheel Removal MAINTENANCEWheel Installation 1. Place the transmissionLights MAINTENANCEHeadlight Replacement Brake LightsMAINTENANCE Headlight Beam AdjustmentMAINTENANCE Vehicle ImmersionMAINTENANCE Steering Wheel InspectionMAINTENANCE BatteryBattery Removal MAINTENANCE Battery InstallationBattery Storage MAINTENANCE Battery ChargingState of MAINTENANCEBattery Charging VoltageWashing the Vehicle MAINTENANCECleaning and Storage Washing TipsPolishing the Vehicle MAINTENANCEWashing the Vehicle Polishing TipsStorage Tips MAINTENANCEClean the Exterior Stabilize the FuelStorage Tips MAINTENANCEBattery Maintenance Inspect and LubricateTransporting the Vehicle MAINTENANCECleaning and Storage Removal from StorageSPECIFICATIONS RANGER RZR XPSPECIFICATIONS RANGER RZR XPClutching SPECIFICATIONS RANGER RZR XP 4Clutching SPECIFICATIONSRANGER RZR XP 4 Lubrication SystemDescription POLARIS PRODUCTSPart Number Engine LubricantDrive Belt Wear/Burn TROUBLESHOOTINGSolution Possible CauseSolution TROUBLESHOOTINGSolution SolutionSolution TROUBLESHOOTINGSolution SolutionSolution TROUBLESHOOTINGEngine Stops or Loses Power Possible CauseWARRANTY LIMITED WARRANTYREGISTRATION WARRANTY Wheels and tiresWARRANTY LIMITATIONS OF WARRANTIES AND REMEDIESSPARK ARRESTER WARRANTYHOW TO OBTAIN WARRANTY SERVICE LubricantsIn the Country where your vehicle was purchased WARRANTYHow to Get Service Exported VehiclesNotice WARRANTYHow to Get Service If Purchased From A Private PartyWARRANTY U.S.A. EPA Emissions Limited WarrantyWARRANTY U.S.A. EPA Emissions Limited WarrantyThe exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI- DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR- RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR- POSE DATE MAINTENANCE LOGSERVICE PERFORMED / COMMENTS MILES KMDATE MAINTENANCE LOGSERVICE PERFORMED / COMMENTS MILES KMDATE MAINTENANCE LOGSERVICE PERFORMED / COMMENTS MILES KMBattery INDEXAdjustments CoolantFluid INDEXFilter Fluid ChangeOil Change INDEXLights Oil CheckSpark Plugs . . . . . . . . . . . . . . . . SwitchesINDEX Storage . . . . . . . . . . . . . . . . . .