Manuals / Polaris / Lawn and Garden / Utility Vehicle

Polaris RZR XP 900, RZR XP 4 900 Maintenance, Belt Replacement/Debris Removal, PVT Drying

Models: RZR XP 900 RZR XP 4 900

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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.

Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch

components and causes outerClutch Air Duct clutch covers to fail. Switch to low

range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

PVT Drying

There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing.

1.Remove the clutch cover drain plug.

2.Allow the water to drain. Reinstall the drain plug.

3.Place the transmission in PARK. Apply the brakes.

4.Start the engine.

5.Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

6.Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range.

7.Test for belt slippage. If the belt slips, repeat the process.

8.Take the vehicle to your dealer for service as soon as possible.

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Polaris RZR XP 900, RZR XP 4 900 owner manual Maintenance, Belt Replacement/Debris Removal, PVT Drying

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 INTRODUCTIONVehicle Identification Numbers INTRODUCTIONVehicle Identification NumberEquipment Modifications SAFETYSafe Riding Gear SAFETYHelmet Boots SAFETYEye Protection GlovesAccessories SAFETYUsing Alcohol or Drugs Operating Without InstructionFailure to Inspect Before Operating SAFETYProtective Apparel Seat BeltsCarrying Multiple Passengers RZR XP SAFETYOperating With a Load on the Vehicle Always follow these guidelinesPassengers in the Cargo Box SAFETYOperating on Pavement Operating on Public RoadsTurning Improperly SAFETYPhysical Control of the Vehicle Jumps and StuntsImproper Hill Climbing SAFETYCrossing Hillsides Stalling While Climbing a HillImproper Tire Maintenance SAFETYOperating Improperly in Reverse Operating on Slippery TerrainOperating Over Obstacles SAFETYSkidding or Sliding Operating Through WaterImproper Cargo Loading SAFETYOperating on Frozen Bodies of Water Operating a Damaged VehicleFOR MORE INFORMATION ABOUT SAFETY call POLARIS at SAFETYHandling Gasoline RefuelingSafety 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 Safety Labels and Locations SAFETYRear Passenger Cab Frame Warning RZR XP Rear Passenger Grab Bar Warning RZR XPCab Frame/Seat Belt Warning SAFETYShift Caution Age Overturn Warning WarningAge Warning SAFETYOverturn Warning Belt Debris WarningDiscretionary Warning RZR XP SAFETYDiscretionary NEVER operateDiscretionary Warning RZR XP SAFETYNEVER operate •with more than three passengersROPS Frame FEATURES AND CONTROLSCargo NetsRear Passenger Grab Bar Shifter Fuel Tank Cap FEATURES AND CONTROLSCargo Box Tie-Down Points Switches FEATURES AND CONTROLSIgnition Switch Auxiliary OutletsHeadlight Switch FEATURES AND CONTROLSAll Wheel Drive AWD Switch Seat Adjustments FEATURES AND CONTROLSSeats Steering WheelPassenger Hand Hold FEATURES AND CONTROLSHood FEATURES AND CONTROLSService Access Panels FEATURES AND CONTROLSEngine Access Panel Cargo Box Access PanelFuel Cap FEATURES AND CONTROLSCab Nets Seat Belts FEATURES AND CONTROLSSeat Belt Inspection Using Low Range FEATURES AND CONTROLSGear Selector Brake Pedal FEATURES AND CONTROLSThrottle Pedal Rollover Protective Structure ROPSAll Wheel Drive AWD System FEATURES AND CONTROLSEngaging AWD Mode Button FEATURES AND CONTROLSInstrument Cluster SpeedometerIndicator Lamps FEATURES AND CONTROLSLamp IndicatesRider 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 Clock Mode FEATURES AND CONTROLSRider Information Center Odometer Mode FEATURES AND CONTROLSTrip Meter Mode Hour Meter ModeProgrammable Service Interval FEATURES AND CONTROLSDiagnostic Display Mode Rider Information CenterEngine Error Codes FEATURES AND CONTROLSRider Information Center Vehicle Break-inPeriod OPERATIONEngine and Drivetrain Break-in OPERATIONBrake System Break-in PVT Break-inClutches/BeltPre-RideInspection OPERATIONItem RemarksSafe Operation Practices OPERATIONStarting the Engine OPERATIONStopping the Engine BrakingParking the Vehicle OPERATIONKnow Your Riding Area/Tread Lightly Trail EtiquetteOPERATION 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 OPERATIONDriving in Reverse OPERATION3.Back slowly 4.Apply the brakes lightly for stoppingParking on an Incline OPERATION1.Place the transmission in PARK 2.Turn the engine offHauling Cargo OPERATIONBelt Life OPERATIONNoise Emission Control System EMISSION CONTROL SYSTEMSOperation on Public Lands in the U.S.A Crankcase Emission Control SystemPeriodic Maintenance Chart MAINTENANCESevere Use Definition Maintenance Chart Key MAINTENANCEMaintenance Interval MAINTENANCEItem RemarksMaintenance Interval MAINTENANCEItem RemarksMaintenance Interval MAINTENANCEItem RemarksFitting Access as viewed from top with MAINTENANCEMiddle Prop Shaft Grease Fitting center floor panel removedView 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 Gearcase Specification Chart MAINTENANCEGearcases Spark PlugsSpark Plug Removal and Replacement MAINTENANCESpark Plug Condition Normal PlugFeature Supported MAINTENANCEFeature Supported FusesMain Fuse Box MAINTENANCECooling System MAINTENANCEAdding or Changing Coolant Radiator and Cooling FanRadiator 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 Filter Systems MAINTENANCEFuel Tank Vent Filter Intake Pre-FiltersAir Filter MAINTENANCESpark Arrester MAINTENANCE1.Remove the arrester retaining bolt and nut MAINTENANCEThrottle System MAINTENANCEThrottle Freeplay Throttle Body/Idle RPMBrakes MAINTENANCEBrake Inspection Brake Fluid MAINTENANCEFactory Preload Settings MAINTENANCEFront/Rear Spring Preload Fox Shock PreloadFox Shock Preload Adjustment MAINTENANCEAdjusting Ring Front/Rear Spring PreloadWalker Evans Shock Preload Adjustment MAINTENANCEAdjusting Ring 1 Front/Rear Spring PreloadFront/Rear Shock Compression MAINTENANCERear FrontAxle and Wheel Nut Torque Specifications MAINTENANCETires Tire Tread DepthWheel Installation MAINTENANCEWheel Removal 1. Place the transmissionHeadlight Replacement MAINTENANCELights Brake LightsHeadlight Beam Adjustment MAINTENANCEVehicle Immersion MAINTENANCESteering Wheel Inspection MAINTENANCEBattery MAINTENANCEBattery Removal Battery Installation MAINTENANCEBattery Storage Battery Charging MAINTENANCEBattery Charging MAINTENANCEState of VoltageCleaning and Storage MAINTENANCEWashing the Vehicle Washing TipsWashing the Vehicle MAINTENANCEPolishing the Vehicle Polishing TipsClean the Exterior MAINTENANCEStorage Tips Stabilize the FuelBattery Maintenance MAINTENANCEStorage Tips Inspect and LubricateCleaning and Storage MAINTENANCETransporting the Vehicle Removal from StorageRANGER RZR XP SPECIFICATIONSRANGER RZR XP SPECIFICATIONSClutching RANGER RZR XP 4 SPECIFICATIONSRANGER RZR XP 4 SPECIFICATIONSClutching Lubrication SystemPart Number POLARIS PRODUCTSDescription Engine LubricantSolution TROUBLESHOOTINGDrive Belt Wear/Burn Possible CauseSolution TROUBLESHOOTINGSolution SolutionSolution TROUBLESHOOTINGSolution SolutionEngine Stops or Loses Power TROUBLESHOOTINGSolution Possible CauseLIMITED WARRANTY WARRANTYREGISTRATION Wheels and tires WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIES WARRANTYHOW TO OBTAIN WARRANTY SERVICE WARRANTYSPARK ARRESTER LubricantsHow to Get Service WARRANTYIn the Country where your vehicle was purchased Exported VehiclesHow to Get Service WARRANTYNotice If Purchased From A Private PartyU.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 SERVICE PERFORMED / COMMENTS MAINTENANCE LOGDATE MILES KMSERVICE PERFORMED / COMMENTS MAINTENANCE LOGDATE MILES KMSERVICE PERFORMED / COMMENTS MAINTENANCE LOGDATE MILES KMAdjustments INDEXBattery CoolantFilter INDEXFluid Fluid ChangeLights INDEXOil Change Oil CheckINDEX SwitchesSpark Plugs . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . .