2015 Polaris RZR 900 XC Owners Manual

2015 Polaris RZR 900 XC Manual

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  • 2015 Polaris RZR 900 XC | Owners Manual - Page 1
    RZR® 900 RZR® 900 EPS TRAIL RZR® 900 XC Edition RZR® S 900 RZR® S 900 EPS RZR® 4 900 EPS Owner's Manual for Maintenance and Safety
  • 2015 Polaris RZR 900 XC | Owners Manual - 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
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    -on safety training course (www.rohva.org). Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) Technician. Your POLARIS dealer knows
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    omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 5
    TABLE OF CONTENTS Introduction ...4 Safety ...7 Features and Controls ...25 Operation ...47 Winch Guide ...67 Emission Control Systems ...78 Maintenance ...79 Specifications ...128 POLARIS Products...134 Troubleshooting ...135 Warranty ...139 Maintenance Log ...146 Index ...148 3
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 6
    area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER
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    quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. • Read this owner's manual and review the safety DVD that came with your vehicle. A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer
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    INTRODUCTION 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 9
    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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 10
    SAFETY Safe Riding Gear 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. Protective gear reduces the chance of injury. Long Sleeves Eye Protection Long Pants Over-the-Ankle Boots Gloves Helmet
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    clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. Clothing Wear long sleeves and long pants to protect arms and legs. Rider
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    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. If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer
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    back against seat, feet flat on the floor, and hands on steering wheel or hand holds. Stay completely inside the vehicle. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org). 7179499 11
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 14
    . (336 kg) 740 lbs. (336 kg) 900 lbs. (408 kg) MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information. 7181905 12
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 15
    the intake tube. The air filter must be properly seated before the lid is reinstalled. Please reference your owner's manual for additional information regarding air filter service. 7181111 Intake Duct Caution Air Box Caution Intake Duct Caution CAUTION Air intake tube must be fully seated on air
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    course and complete the New Operator Driving Procedures outlined on pages 53-54. All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. Never allow a guest to operate this vehicle until the guest has completed the New Operator
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    it's in safe operating condition. See page 49. Always follow the inspection and maintenance procedures and schedules described in this owner's manual. See page 79. Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious
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    and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities. The vehicle's maximum weight capacity is listed
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    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 a passenger seat with seat belt secured.
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    control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See page 57. Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 21
    side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See page 58. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed
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    rollover. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in this owner's manual and on safety labels. Skidding or Sliding Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss
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    operating in water as described in this owner's manual. See page 60. Wet brakes may have reduced have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you or other accident, have a qualified service dealer inspect the entire machine for possible
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    carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner's manual for carrying cargo. See page 64. • Never exceed the stated load capacity for this vehicle. See page 12. • Cargo should be
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 25
    SAFETY Safety Warnings Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system
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    SAFETY Safety Warnings Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 27
    FEATURES AND CONTROLS Component Locations ROPS Frame RZR 4 Shown Cargo Box Steering Wheel Radiator Cab Doors Fuel Tank Cap Passenger Hand Hold Cargo Box Tie-Down Points (4 corners) Brake Pedal Gear Selector Throttle Pedal 25
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    , a second outlet (if equipped) is in the rear passenger area. Use the outlets to power an auxiliary light or other optional accessories. For service, the dash outlet connection is under the dash. The rear outlet connection is under the rear passenger seats. Ignition Switch The ignition switch is
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 29
    Turf Mode/ Differential Differential Unlocked (1WD) 2WD Unlock (1WD) See page 36 for AWD operating instructions. Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is system is inoperative. See your authorized POLARIS dealer for service. 27
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    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.
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    FEATURES AND CONTROLS Passenger Hand Hold 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 from the end of the adjustment pin. 2. Remove the pin
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    FEATURES AND CONTROLS Hood 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 disengage the lower hood hooks. 4.
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    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. Fuel Cap 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 34
    FEATURES AND CONTROLS Cab Doors 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 35
    FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 36
    Gear Selector Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift
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    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. WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 38
    FEATURES AND CONTROLS All Wheel Drive (AWD) System 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 39
    feet (3 m). 3. Stop completely. 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these instructions, see your dealer for service. Locking/Unlocking the Differential (if equipped) NOTICE: Damage to the differential can occur if it is engaged while the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 40
    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
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    when the key is turned to the ON position. If the light remains on, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral High Beam Helmet/Seat Belt This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position. This
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 42
    FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 43
    - The clock displays time in a 12-hour or 24-hour format. See page 43 for resetting instructions. 6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 44
    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. MODE Button Tip
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display. 2. Press and hold the MODE button until the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 46
    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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 47
    release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval. Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 48
    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays Number (SPN) Number (0-9) only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 49
    , accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 50
    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 7. Carry only light loads. 8. During the break-in period, change both the oil and the filter at 25 hours or one month. 9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 51
    OPERATION Pre-Ride Inspection 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. Item Brake system/pedal travel Brake fluid Front
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    damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage. 11. Never water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your passenger, and
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 53
    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a wellventilated 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 54
    OPERATION Parking the Vehicle 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 55
    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. Hands-
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 56
    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. Drive
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    /or cargo on board. Allow more time and distance for braking. 11. Always follow all operating guidelines as outlined on safety labels and in this manual. 55
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    OPERATION Driving on Slippery Surfaces 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 59
    OPERATION Driving Uphill 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-
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 60
    OPERATION Driving on a Sidehill (Sidehilling) 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.
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 61
    OPERATION Driving 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.
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 62
    at the same time. NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 79. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil, and
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 63
    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 hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 64
    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. Avoid making sharp turns. 62
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 65
    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 precautions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Turn the engine off. 4. Block the rear wheels on the downhill
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    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
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    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 page 128. Belt Life To extend belt life, use low gear in the following
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 68
    OPERATION Towing WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. The tow loop on the rear of the vehicle is provided for recovery use ONLY. Tow a vehicle ONLY of equal or lesser size and weight. When towing a disabled RZR vehicle, place the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 69
    WINCH GUIDE 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. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 70
    WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicle's park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks
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    WINCH GUIDE Winch Safety Precautions 18. Never release the clutch on the winch when a vertical load. 21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23. Never winch the hook
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    GUIDE result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to . 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
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    WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A.
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    WINCH GUIDE Winch Operation 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
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    WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be 's centerline. C. Attach the winch cable hook to the anchor point or the stuck vehicle's frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable
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    WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls
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    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
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    WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or "shock" loading. Shock loading may tension a winch cable
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 79
    WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable.
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 80
    EMISSION CONTROL SYSTEMS Noise Emission Control System 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. Operation on Public Lands in the U.S.A. Your POLARIS vehicle
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    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. Severe Use Definition Frequent immersion in mud, water or sand Racing or race-style high RPM use Prolonged low speed
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    to conduct this maintenance will not void the emissions warranty but may affect emissions.) D Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a "D" could result in component failure and lead to serious injury or death. Have an
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 83
    MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance oil change Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these
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    (1600) Inspect; replace as needed, torque to specification Ź Spark plugs E 100 H 12 M Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these
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    H 200 H 200 H 200 H 500 H - 12 M 12 M 12 M 12 M 24 M 24 M 36 M 60 M - Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 86
    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 79, 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 87
    MAINTENANCE Lubrication Recommendations Front Stabilizer Bar RZR 900 / RZR 900 EPS Trail / RZR 900 EPS XC Rear Stabilizer Bar All Models 85
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    MAINTENANCE Engine Oil Oil Recommendations WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 89
    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 90
    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 79. Always change the oil filter whenever changing oil. Access the oil check dipstick and oil filter through the engine access panel located
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    MAINTENANCE Engine Oil Oil and Filter Change 7. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 8. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 92
    MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Refer to the Gearcase Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications. Fluid Check The fill
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    MAINTENANCE Transmission (Main Gearcase) Fluid Change The drain plug is located on the bottom 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. 3. Remove the drain plug. Allow the fluid to drain
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 94
    MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Refer to the Gearcase Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications. Fluid Check The
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 95
    MAINTENANCE Demand Drive Unit (Front Gearcase) Fluid Change The drain plug is located on the bottom 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. 4. Clean the drain plug. 5. Reinstall the drain plug
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    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 134 for the part numbers of POLARIS products. Gearcase Transmission (Main Gearcase) Lubricant Capacity Fill Plug Torque Drain Plug/ Level Check Plug Torque 10-14 ft.
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    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. Tip: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 98
    MAINTENANCE Fuse/Relay Center 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 99
    MAINTENANCE Cooling System 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 100
    MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 101
    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.
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 102
    MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). If the overflow
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 103
    (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or clutch and vent system when replacing the belt. • 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 104
    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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 105
    to seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged. Tip: Belt slip is instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Remove the clutch cover drain plug.
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 106
    MAINTENANCE Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. 1. Remove the cargo box access panel. 2. Clean all dirt and debris from the air box area. 3. Unlatch the two (2) air box cover straps and carefully remove the air box
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 107
    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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 108
    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 35. 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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 109
    MAINTENANCE Brakes 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 damage. Clean any
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 110
    MAINTENANCE Brakes 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 134 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 111
    MAINTENANCE Suspension Settings (RZR) The front and rear suspensions are preload adjustable, with five settings on each axle. The suspensions are set on the lowest (softest) setting at the factory. This setting is appropriate for nearly all riding conditions. If desired, the suspension may be
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 112
    MAINTENANCE Suspension Settings (RZR S/RZR XC/RZR 4) Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. Since the vehicle is equipped with full skid plates, adjustment is not necessary. If desired, the suspension may be adjusted to maintain vehicle
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 113
    MAINTENANCE Suspension Settings (RZR S/RZR XC/RZR 4) Front/Rear Spring Preload 1. Elevate the vehicle to allow the suspension to fully extend. 2. Loosen the jam nut and back it away from the adjusting ring. 3. Turn the adjusting ring to the left (1) to increase preload for a stiffer ride. Turn the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 114
    MAINTENANCE Suspension Settings (RZR S/RZR XC/RZR 4) Front/Rear Shock Compression 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. 1. Turn the clicker clockwise to increase
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 115
    or less. 1/8" (3 mm) Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Lug Nut (Aluminum Wheels) Lug Nut (Steel Wheels) Hub Retaining Nut Front and Rear 108
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 116
    tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. Right Rear Wheel (type varies by model) Valve Stem 3. Attach the wheel nuts
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 117
    the headlamp(s) for a few days to allow the moisture to clear out. Taillight/Brake Light Replacement The taillight assembly is not serviceable. If the taillight or brake light fails to operate properly, replace the entire taillight assembly. Headlight Replacement If a headlight becomes damaged
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 118
    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. (7.6 m) X X 2 in. (5 cm) 2. Place the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 119
    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 procedure on page
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 120
    MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 121
    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
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 122
    not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 121 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Coat the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 123
    . Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 124
    MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% Charge Time Voltage 12.8-13.0 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge given, check in 3 months Needs
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 125
    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: Water in the PVT system could cause the drive belt to become wet and slip in the clutches. When washing the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 126
    the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 127
    . See page 123. 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 recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 128
    as recommended in the Periodic Maintenance Chart beginning on page 79. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 129
    MAINTENANCE Cleaning and Storage Removal from Storage 1. 2. 3. 4. Charge the battery if necessary. Make sure the spark plug is tight. Fill the fuel tank with fuel. Check all the points listed in the Daily Pre-Ride Inspection section on page 49. Tightness of the bolts, nuts and other fasteners should
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 130
    SPECIFICATIONS RZR 900 / RZR 900 EPS Gross Vehicle Weight Dry Weight Test GVW - Rollover Protection System (ROPS) Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/Width/
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 131
    SPECIFICATIONS RZR 900 / RZR 900 EPS Lubrication System Driving System Type Shift Type Tires / Tire Pressure - Front Tires / Tire Pressure - Rear Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump Automatic POLARIS Variable Transmission, EPS:
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 132
    SPECIFICATIONS RZR S 900 / RZR S 900 EPS Gross Vehicle Weight Dry Weight Test GVW - Rollover Protection System (ROPS) Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 133
    SPECIFICATIONS RZR S 900 / RZR S 900 EPS Lubrication System Driving System Type Shift Type Tires / Tire Pressure - Front Tires / Tire Pressure - Rear Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump Automatic POLARIS Variable Transmission EPS:
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 134
    SPECIFICATIONS RZR 4 900 EPS Gross Vehicle Weight Dry Weight Test GVW - Rollover Protection System (ROPS) Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/Width/Height
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 135
    SPECIFICATIONS RZR 4 900 EPS Lubrication System Driving System Type Shift Type Tires / Tire Pressure - Front Tires / Tire Pressure - Rear Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump Automatic POLARIS Variable Transmission EPS: Lockable
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 136
    POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878920 2878919 2878068 2878069 2877922 2877923 2870465 2880514 2880513 2871312 2871322 2871423 2876160 2872276 2871460 2871515 2871551 2871329 2871326 2870652 2872189 Description Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 Full
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 137
    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 138
    TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Mechanical failure Solution Recharge the
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 139
    TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 140
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel tank vent line or filter Water is present in fuel Fouled
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 141
    BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. Warranty Coverage And Exclusions
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 142
    WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 143
    must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the Country where your product
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 144
    where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 145
    extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension. This emissions limited warranty covers
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 146
    WARRANTY U.S.A. EPA Emissions Limited Warranty The following parts are considered emission-related components for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 147
    for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been . POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 148
    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 146
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 149
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 147
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 150
    INDEX A Access Panel Cargo Box ...31 Engine ...31 Access Panels for Service ...31 Accessory Outlets ...26 Adjustment Hand Hold...29 Seat ...28 Steering Wheel ...28 Age Restrictions...14 Air Filter ...104 Air Filter Cleaning...104 All Wheel
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 151
    INDEX E Electromagnetic Interference ...78 Electronic Power Steering ...27 Emission Control, Crankcase ...78 Emission Control, Exhaust ...78 Emission Control, Noise ...78 Emissions Limited Warranty . 143-145 Engaging AWD...36 Engine Access Panel ...31 Engine Break-In ...47-48 Engine Fogging...126
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 152
    INDEX K Key, Periodic Maintenance Chart . . 80 O Oil Recommendations ...86 Operation on Public Lands ...78 Operation, Cooling System ...97-98 Operation, Transmission ...101-103 Operator Restrictions...14 Outlets, Auxiliary ...26 Overflow Bottle Coolant Level ...100 L Lights ...115-116 Headlight
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 153
    50, 53 Safety Warnings ...14-24 Safety, Winch Maintenance ...77 Seat Adjustment ...28 Seat Belts ...32-33 Seat Removal ...28 Selector, Gear ...34 Service Access Panels...31 Severe Use Definition ...79 Shifting Gears ...34 Shock Compression (RZR S/XC/4) 112 Shock Loading the Winch...76 Signal Words
  • 2015 Polaris RZR 900 XC | Owners Manual - Page 154
    AND PROTECTIVE GEAR. ALL RIDERS MUST WEAR SEAT BELTS. NEVER USE ON PUBLIC ROADS. NEVER USE WITH DRUGS OR ALCOHOL. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc., 2100 Hwy
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Owner's Manual
for Maintenance and Safety
RZR
®
900
RZR
®
900 EPS TRAIL
RZR
®
900 XC Edition
RZR
®
S 900
RZR
®
S 900 EPS
RZR
®
4 900 EPS