Manuals / Polaris / Lawn and Garden / Utility Vehicle

Polaris RZR XP 900, RZR XP 4 900 owner manual Maintenance, Brakes, Brake Inspection

Models: RZR XP 900 RZR XP 4 900

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Page 103

Brakes

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. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 100 for brake fluid information.

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

WARNING! Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal.

Brake Inspection

1.Check the brake system for fluid leaks.

2.Check the brake pedal for excessive travel or a spongy feel.

3.Check the friction pads for wear, damage and looseness.

4.Check brake discs for signs of cracks, excessive

	corrosion, warping or other
	corrosion, warping or other	3/64" (1mm)
	damage. Clean any grease	3/64" (1mm)
	using an approved brake
	cleaner or alcohol.

NOTICE: Do not apply WD-40 or any petroleum product to brake discs.

5.Inspect the brake disc spline and pad wear surface for excessive wear. Change pads when worn to 3/64" (1 mm).

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Polaris RZR XP 900, RZR XP 4 900 owner manual Maintenance, Brakes, Brake Inspection

Contents

RANGER RZR XP RANGER RZR XP 4 for Maintenance and SafetyOwners 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 DANGER INTRODUCTIONNOTICE European Vibration and Noise INTRODUCTIONNumber INTRODUCTIONVehicle Identification Numbers Vehicle IdentificationEquipment Modifications SAFETYSafe Riding Gear SAFETYHelmet Gloves SAFETYBoots Eye ProtectionOperating Without Instruction SAFETYAccessories Using Alcohol or DrugsSeat Belts SAFETYFailure to Inspect Before Operating Protective ApparelAlways follow these guidelines SAFETYCarrying Multiple Passengers RZR XP Operating With a Load on the VehicleOperating on Public Roads SAFETYPassengers in the Cargo Box Operating on PavementJumps and Stunts SAFETYTurning Improperly Physical Control of the VehicleStalling While Climbing a Hill SAFETYImproper Hill Climbing Crossing HillsidesOperating on Slippery Terrain SAFETYImproper Tire Maintenance Operating Improperly in ReverseOperating Through Water SAFETYOperating Over Obstacles Skidding or SlidingOperating a Damaged Vehicle SAFETYImproper Cargo Loading Operating on Frozen Bodies of WaterRefueling SAFETYFOR MORE INFORMATION ABOUT SAFETY call POLARIS at Handling GasolineSafety Labels and Locations SAFETYLoad/Passenger/Tire Pressure Warning Passenger Safety Warning RZR XP SAFETYPassenger Safety Passenger Safety Warning RZR XP SAFETYTHE PASSENGERS MUST ALWAYS •wear seat belts Rear Passenger Grab Bar Warning RZR XP SAFETYSafety Labels and Locations Rear Passenger Cab Frame Warning RZR XPAge Overturn Warning Warning SAFETYCab Frame/Seat Belt Warning Shift CautionBelt Debris Warning SAFETYAge Warning Overturn WarningNEVER operate SAFETYDiscretionary Warning RZR XP Discretionary•with more than three passengers SAFETYDiscretionary Warning RZR XP NEVER operateNets FEATURES AND CONTROLSROPS Frame CargoRear Passenger Grab Bar Shifter Fuel Tank Cap FEATURES AND CONTROLSCargo Box Tie-Down Points Auxiliary Outlets FEATURES AND CONTROLSSwitches Ignition SwitchHeadlight Switch FEATURES AND CONTROLSAll Wheel Drive AWD Switch Steering Wheel FEATURES AND CONTROLSSeat Adjustments SeatsPassenger Hand Hold FEATURES AND CONTROLSHood FEATURES AND CONTROLSCargo Box Access Panel FEATURES AND CONTROLSService Access Panels Engine Access PanelFuel Cap FEATURES AND CONTROLSCab Nets Seat Belts FEATURES AND CONTROLSSeat Belt Inspection Using Low Range FEATURES AND CONTROLSGear Selector Rollover Protective Structure ROPS FEATURES AND CONTROLSBrake Pedal Throttle PedalAll Wheel Drive AWD System FEATURES AND CONTROLSEngaging AWD Mode Button FEATURES AND CONTROLSInstrument Cluster SpeedometerIndicates FEATURES AND CONTROLSIndicator Lamps LampRider Information Center FEATURES AND CONTROLS2.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 FEATURES AND CONTROLSRider Information Center Rider Information Center FEATURES AND CONTROLSDisplay Units Standard/Metric Rider Information Center FEATURES AND CONTROLSClock Mode Trip Meter Mode FEATURES AND CONTROLSRider Information Center Odometer ModeRider Information Center FEATURES AND CONTROLSProgrammable Service Interval Diagnostic Display ModeEngine Error Codes FEATURES AND CONTROLSRider Information Center Vehicle Break-inPeriod OPERATIONPVT Break-inClutches/Belt OPERATIONEngine and Drivetrain Break-in Brake System Break-inRemarks OPERATIONPre-RideInspection ItemSafe Operation Practices OPERATIONBraking OPERATIONStarting the Engine Stopping the EngineTrail Etiquette OPERATIONParking the Vehicle Know Your Riding Area/Tread LightlyOPERATION New Operator Driving Procedures12.Apply the brakes and shift into low gear OPERATIONDriving with Passengers OPERATIONDriving on Slippery Surfaces OPERATIONDriving Uphill OPERATIONDriving on a Sidehill Sidehilling OPERATIONDriving Downhill Driving Through Water OPERATIONDriving Over Obstacles OPERATION4.Apply the brakes lightly for stopping OPERATIONDriving in Reverse 3.Back slowly2.Turn the engine off OPERATIONParking on an Incline 1.Place the transmission in PARKHauling Cargo OPERATIONBelt Life OPERATIONCrankcase Emission Control System EMISSION CONTROL SYSTEMSNoise Emission Control System Operation on Public Lands in the U.S.APeriodic Maintenance Chart MAINTENANCESevere Use Definition Maintenance Chart Key MAINTENANCERemarks MAINTENANCEMaintenance Interval ItemRemarks MAINTENANCEMaintenance Interval ItemRemarks MAINTENANCEMaintenance Interval Itemcenter floor panel removed MAINTENANCEFitting Access as viewed from top with Middle Prop Shaft Grease FittingView of Driver’s Side From Bottom of Vehicle MAINTENANCEFront Control Arm Pivot Bushings 3 per side Ambient Temperature Range MAINTENANCEEngine Oil Oil RecommendationsOil Check MAINTENANCEOil and Filter Change MAINTENANCE15.Reinstall the dipstick MAINTENANCEOil and Filter Change Transmission Main Gearcase MAINTENANCEFluid Check Fluid Change MAINTENANCEDemand Drive Unit Front Gearcase MAINTENANCEFluid Check Fluid Change MAINTENANCE1.Remove the fill plug Spark Plugs MAINTENANCEGearcase Specification Chart GearcasesNormal Plug MAINTENANCESpark Plug Removal and Replacement Spark Plug ConditionFuses MAINTENANCEFeature Supported Feature SupportedMain Fuse Box MAINTENANCERadiator and Cooling Fan MAINTENANCECooling System Adding or Changing CoolantRadiator Coolant Level/Changing Coolant MAINTENANCEOverflow Bottle Coolant Level MAINTENANCEPOLARIS Variable Transmission PVT System MAINTENANCEBelt Replacement/Debris Removal MAINTENANCEContinued on next page Belt Replacement/Debris Removal MAINTENANCEPVT Drying Intake Pre-Filters MAINTENANCEFilter Systems Fuel Tank Vent FilterAir Filter MAINTENANCESpark Arrester MAINTENANCE1.Remove the arrester retaining bolt and nut MAINTENANCEThrottle Body/Idle RPM MAINTENANCEThrottle System Throttle FreeplayBrakes MAINTENANCEBrake Inspection Brake Fluid MAINTENANCEFox Shock Preload MAINTENANCEFactory Preload Settings Front/Rear Spring PreloadFront/Rear Spring Preload MAINTENANCEFox Shock Preload Adjustment Adjusting RingFront/Rear Spring Preload MAINTENANCEWalker Evans Shock Preload Adjustment Adjusting Ring 1Front MAINTENANCEFront/Rear Shock Compression RearTire Tread Depth MAINTENANCEAxle and Wheel Nut Torque Specifications Tires1. Place the transmission MAINTENANCEWheel Installation Wheel RemovalBrake Lights MAINTENANCEHeadlight Replacement LightsHeadlight Beam Adjustment MAINTENANCEVehicle Immersion MAINTENANCESteering Wheel Inspection MAINTENANCEBattery MAINTENANCEBattery Removal Battery Installation MAINTENANCEBattery Storage Battery Charging MAINTENANCEVoltage MAINTENANCEBattery Charging State ofWashing Tips MAINTENANCECleaning and Storage Washing the VehiclePolishing Tips MAINTENANCEWashing the Vehicle Polishing the VehicleStabilize the Fuel MAINTENANCEClean the Exterior Storage TipsInspect and Lubricate MAINTENANCEBattery Maintenance Storage TipsRemoval from Storage MAINTENANCECleaning and Storage Transporting the VehicleRANGER RZR XP SPECIFICATIONSRANGER RZR XP SPECIFICATIONSClutching RANGER RZR XP 4 SPECIFICATIONSLubrication System SPECIFICATIONSRANGER RZR XP 4 ClutchingEngine Lubricant POLARIS PRODUCTSPart Number DescriptionPossible Cause TROUBLESHOOTINGSolution Drive Belt Wear/BurnSolution TROUBLESHOOTINGSolution SolutionSolution TROUBLESHOOTINGSolution SolutionPossible Cause TROUBLESHOOTINGEngine Stops or Loses Power SolutionLIMITED WARRANTY WARRANTYREGISTRATION Wheels and tires WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIES WARRANTYLubricants WARRANTYHOW TO OBTAIN WARRANTY SERVICE SPARK ARRESTERExported Vehicles WARRANTYHow to Get Service In the Country where your vehicle was purchasedIf Purchased From A Private Party WARRANTYHow to Get Service NoticeU.S.A. EPA Emissions Limited Warranty WARRANTYU.S.A. EPA Emissions Limited Warranty 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 MILES KM MAINTENANCE LOGSERVICE PERFORMED / COMMENTS DATEMILES KM MAINTENANCE LOGSERVICE PERFORMED / COMMENTS DATEMILES KM MAINTENANCE LOGSERVICE PERFORMED / COMMENTS DATECoolant INDEXAdjustments BatteryFluid Change INDEXFilter FluidOil Check INDEXLights Oil ChangeStorage . . . . . . . . . . . . . . . . . . SwitchesINDEX Spark Plugs . . . . . . . . . . . . . . . .