2010 Polaris RZR EPS Owners Manual
2010 Polaris RZR EPS Manual
2010 Polaris RZR EPS manual content summary:
- 2010 Polaris RZR EPS | Owners Manual - Page 1
Pantone 426C RANGER RZR RANGER RZR EPS TM TM for Maintenance and Safety Owner's Manual - 2010 Polaris RZR EPS | 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 - 2010 Polaris RZR EPS | Owners Manual - Page 3
The text is printed on 100% recycled with 40% post-consumer waste (PCW). - 2010 Polaris RZR EPS | Owners Manual - Page 4
or DEATH NEVER Operate: • without first viewing safety video and quick start guide. • with more than one passenger. • on hills steeper than 15 WITH DRUGS OR ALCOHOL LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A - 2010 Polaris RZR EPS | Owners Manual - Page 5
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. 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 - 2010 Polaris RZR EPS | Owners Manual - Page 6
reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2010 RANGER RZR/RZR EPS Owner's Manual P/N 9922955 2 - 2010 Polaris RZR EPS | Owners Manual - Page 7
TABLE OF CONTENTS Introduction ...4 Safety ...7 Features and Controls ...26 Operation ...48 Emission Control Systems ...66 Maintenance ...67 Specifications ...120 Polaris Products...122 Troubleshooting ...123 Declaration of Conformity ...127 Warranty ...128 Maintenance Log ...135 Index ...138 3 - 2010 Polaris RZR EPS | Owners Manual - Page 8
your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in - 2010 Polaris RZR EPS | Owners Manual - Page 9
on hills or over obstacles, if you fail to take proper precautions. • Read this owner's manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle. • Complete the New Operator Driving Procedures outlined on pages 54-55 - 2010 Polaris RZR EPS | Owners Manual - Page 10
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 - 2010 Polaris RZR EPS | Owners Manual - Page 11
Equipment Modifications SAFETY 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 those that - 2010 Polaris RZR EPS | Owners Manual - Page 12
SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. Wear protective clothing for comfort and to reduce the chance of injury. Eye Protection Long Sleeves Gloves Helmet Sturdy Footwear Long Pants Helmet Wearing a helmet can prevent a severe head injury. Whenever - 2010 Polaris RZR EPS | Owners Manual - Page 13
Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing - 2010 Polaris RZR EPS | Owners Manual - Page 14
of terrain. Complete the New Operator Driving Procedures outlined on pages 54-55. 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 - 2010 Polaris RZR EPS | Owners Manual - Page 15
use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in - 2010 Polaris RZR EPS | Owners Manual - Page 16
SAFETY Safety Warnings Carrying a Passenger Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 54-55. Carrying Multiple Passengers Carrying more than one passenger in this vehicle can affect - 2010 Polaris RZR EPS | Owners Manual - Page 17
could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to - 2010 Polaris RZR EPS | Owners Manual - Page 18
descending a hill could cause loss of control or overturn. Always follow proper procedures for traveling down hills as described in the owner's manual. • Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral. +15° • Always check the - 2010 Polaris RZR EPS | Owners Manual - Page 19
side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 59. SAFETY Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn. Maintain a steady - 2010 Polaris RZR EPS | Owners Manual - Page 20
in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 62. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed - 2010 Polaris RZR EPS | Owners Manual - Page 21
of control or overturn (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in the owner's manual. When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding - 2010 Polaris RZR EPS | Owners Manual - Page 22
cause loss of control or an accident. • Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. • Never exceed injury or death. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not - 2010 Polaris RZR EPS | Owners Manual - Page 23
Safety Warnings Handling Gasoline SAFETY Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. • Always stop the engine when refueling. • Always refuel outdoors or in a well ventilated area. • Remove flammable material - 2010 Polaris RZR EPS | Owners Manual - Page 24
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 - 2010 Polaris RZR EPS | Owners Manual - Page 25
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the box. Read Owner's Manual for more detailed loading information. 7175103 21 - 2010 Polaris RZR EPS | Owners Manual - Page 26
SAFETY Safety Labels and Locations Age Warning Overturn Warning Cab Frame/Seat Belt Warning Shift Caution Cab Frame/Seat Belt Warning WARNING • ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat belt. • ALWAYS SECURE CAB NETS. • VEHICLE OVERTURN could cause severe injury or death. The - 2010 Polaris RZR EPS | Owners Manual - Page 27
Safety Labels and Locations Shift Caution SAFETY CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place shift in the parked position. APPLY BRAKE TO START 7174843 Age Warning WARNING Operating this vehicle if you are under the age - 2010 Polaris RZR EPS | Owners Manual - Page 28
SAFETY Safety Labels and Locations Discretionary Warning Passenger Safety Warning Passenger Safety Warning WARNING NEVER CARRY A PASSENGER UNDER AGE 12 NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH, NEVER carry a passenger - 2010 Polaris RZR EPS | Owners Manual - Page 29
INJURY or DEATH NEVER operate: • without first viewing safety video and quick start guide. • with more than one passenger. • on hills steeper than 15 degrees ALCOHOL LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A - 2010 Polaris RZR EPS | Owners Manual - Page 30
FEATURES AND CONTROLS Component Locations Your vehicle is equipped with upper and lower cab nets and side guards on both sides of the vehicle. Cab nets and side guards must be used by both operator and passenger at all times. Promptly replace worn or damaged cab nets with new cab nets, available - 2010 Polaris RZR EPS | Owners Manual - Page 31
Component Locations Cab Frame FEATURES AND CONTROLS Storage Compartment (under hood) Steering Wheel Headlights Radiator Brush Guard 27 - 2010 Polaris RZR EPS | Owners Manual - Page 32
FEATURES AND CONTROLS Component Locations Taillights Muffler (Spark Arrestor) Receiver Hitch Trailer Receiver Hitch Bracket 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, - 2010 Polaris RZR EPS | Owners Manual - Page 33
panel is located behind the seats on the frame of the vehicle. Remove the seats to access the service panel. Remove the service panel to access serviceable engine components and clutches. Seats Before operating the vehicle, always push down on both seat backs to ensure the latches are secure - 2010 Polaris RZR EPS | Owners Manual - Page 34
FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. Adjustment Lever - 2010 Polaris RZR EPS | Owners Manual - Page 35
Hood FEATURES AND CONTROLS Remove the hood to access the front storage compartment, the radiator and the coolant overflow bottle. 1. If your model is equipped with removStorage able fasteners at the Compartment upper hood edge, Upper remove the fasteners. Fasteners 2. Grasp the upper hood edge and - 2010 Polaris RZR EPS | Owners Manual - Page 36
FEATURES AND CONTROLS Cab Nets/Side Guards Riding in this vehicle without Latches using the cab nets and side guards increases the risk of serious injury or death in the event of an accident or overturn. Cab nets and side guards must be used by both operator and passenger at all times. Make sure all - 2010 Polaris RZR EPS | Owners Manual - Page 37
Cab Nets/Side Guards FEATURES AND CONTROLS Upper Cab Net Removal (Driver) The upper cab net on the driver's side may be removed only if it interferes with operation of the vehicle. All other cab nets and side guards must remain Step 1 installed. 1. Using a T-25 torx bit and 7/16" open end wrench, - 2010 Polaris RZR EPS | Owners Manual - Page 38
FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding. To wear the seat belt properly, follow this procedure: 1. Pull - 2010 Polaris RZR EPS | Owners Manual - Page 39
Seat Belts FEATURES AND CONTROLS 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 - 2010 Polaris RZR EPS | Owners Manual - Page 40
to the ON position. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized Polaris dealer for service. Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving - 2010 Polaris RZR EPS | Owners Manual - Page 41
rocker switch to engage All Wheel Drive. Press the bottom of the switch to operate in two wheel drive. See page 40 for AWD operating instructions. OFF AWD 2WD 37 - 2010 Polaris RZR EPS | Owners Manual - Page 42
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 - 2010 Polaris RZR EPS | Owners Manual - Page 43
Brake Pedal FEATURES AND CONTROLS Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle - 2010 Polaris RZR EPS | Owners Manual - Page 44
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. 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 AWD indicator light will be on. When in AWD, - 2010 Polaris RZR EPS | Owners Manual - Page 45
Instrument Cluster FEATURES AND CONTROLS Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. In addition to showing vehicle speed, the speedometer - 2010 Polaris RZR EPS | Owners Manual - Page 46
Gear 2 H = High Gear 2. AWD Indicator - This indicator illuminates 1 when the AWD switch is in the AWD position. 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too - 2010 Polaris RZR EPS | Owners Manual - Page 47
Instrument Cluster FEATURES AND CONTROLS Rider Information Center Standard Modes Use the yellow mode switch located near the instrument gauge to toggle through the mode options. See page 36. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter - 2010 Polaris RZR EPS | Owners Manual - Page 48
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To - 2010 Polaris RZR EPS | Owners Manual - Page 49
, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. Toggle to the service interval screen. 2. Press and hold the mode switch for 2-3 seconds, until the wrench icon flashes. Release the switch - 2010 Polaris RZR EPS | Owners Manual - Page 50
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers Toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either - 2010 Polaris RZR EPS | Owners Manual - Page 51
Instrument Cluster Downloading Codes Blink Code -21 45 46 22 22 23 42 42 51 51 51 52 52 52 54 54 54 55 55 55 56 56 56 58 58 58 41 41 61 FEATURES AND CONTROLS Rider Information Center Failure Description No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric - 2010 Polaris RZR EPS | Owners Manual - Page 52
, accident or overturn, 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 - 2010 Polaris RZR EPS | Owners Manual - Page 53
Vehicle Break-in Period OPERATION Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 75. Add the recommended oil as needed to maintain the oil level in the safe operating - 2010 Polaris RZR EPS | Owners Manual - Page 54
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 - 2010 Polaris RZR EPS | Owners Manual - Page 55
tires specified for your vehicle. Always maintain proper tire pressure. 10. Never operate a damaged vehicle. After any overturn 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. 12. Do not touch hot - 2010 Polaris RZR EPS | Owners Manual - Page 56
OPERATION Starting the Engine 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. Secure the cab nets. 3. Place the transmission in PARK. 4. Apply the brakes. Do not press the throttle pedal while starting the - 2010 Polaris RZR EPS | Owners Manual - Page 57
Parking the Vehicle OPERATION 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 - 2010 Polaris RZR EPS | Owners Manual - Page 58
OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Perform the pre-ride inspection. See page 50. 3. Wear an approved helmet that fits properly and eye protection (goggles or - 2010 Polaris RZR EPS | Owners Manual - Page 59
New Operator Driving Procedures OPERATION 11. Apply the brakes and shift into low gear. 12. Check your surroundings and determine your path of travel. 13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 14. Drive - 2010 Polaris RZR EPS | Owners Manual - Page 60
/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. 56 - 2010 Polaris RZR EPS | Owners Manual - Page 61
Driving on Slippery Surfaces WARNING OPERATION Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of - 2010 Polaris RZR EPS | Owners Manual - Page 62
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. Avoid steep hills (15° maximum). If ascending a steeper grade is unavoid15° maximum able, engage allwheel drive before ascending. 3. Drive straight uphill. - 2010 Polaris RZR EPS | Owners Manual - Page 63
Driving on a Sidehill (Sidehilling) OPERATION Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1. Engage all-wheel - 2010 Polaris RZR EPS | Owners Manual - Page 64
help dry out the pads. 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 67. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil, and - 2010 Polaris RZR EPS | Owners Manual - Page 65
Driving Over Obstacles OPERATION 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 - 2010 Polaris RZR EPS | Owners Manual - Page 66
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 - 2010 Polaris RZR EPS | Owners Manual - Page 67
Parking on an Incline OPERATION A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Place the transmission in PARK. 2. Turn the engine off. 3. Block the rear wheels on the downhill side, or park the - 2010 Polaris RZR EPS | Owners Manual - Page 68
with extra caution. Always attach the tow load to the hitch point designated for your vehicle. 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 - 2010 Polaris RZR EPS | Owners Manual - Page 69
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 120. Belt Life To extend belt life, use low gear when hauling or towing - 2010 Polaris RZR EPS | Owners Manual - Page 70
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 - 2010 Polaris RZR EPS | Owners Manual - Page 71
riding conditions and an average vehicle speed of approximately ten (10) miles per hour. Vehicles subjected to severe use 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, heavy - 2010 Polaris RZR EPS | Owners Manual - Page 72
Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services. WARNING! Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an - 2010 Polaris RZR EPS | Owners Manual - Page 73
Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Q Steering MAINTENANCE Perform all services at whichever maintenance interval is reached first. Remarks Miles (Km) 100 (160) 250 (400) 250 (400) 250 (400) 250 (400) 250 (400) Inspect; clean often; - 2010 Polaris RZR EPS | Owners Manual - Page 74
E X Engine oil change X Oil filter change 100 H 100 H 100 H 12M 6M 6M X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these - 2010 Polaris RZR EPS | Owners Manual - Page 75
wheel bearings Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these - 2010 Polaris RZR EPS | Owners Manual - Page 76
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 67, 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 - 2010 Polaris RZR EPS | Owners Manual - Page 77
Lubrication Recommendations MAINTENANCE Stabilizer Bar Bushings Control Arm Pivot Bushings 73 - 2010 Polaris RZR EPS | Owners Manual - Page 78
MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Always change the oil filter whenever changing oil. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause - 2010 Polaris RZR EPS | Owners Manual - Page 79
engine, behind the passenger seat. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove both seats. Remove the rear service panel. See page 29. 4. Lift the lever lock to remove the dipstick. Wipe it dry with a clean cloth. 5. Reinstall the dipstick completely, but - 2010 Polaris RZR EPS | Owners Manual - Page 80
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 67. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle - 2010 Polaris RZR EPS | Owners Manual - Page 81
Engine Oil MAINTENANCE Oil and Filter Change 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to - 2010 Polaris RZR EPS | Owners Manual - Page 82
MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fill Plug Level Check Plug - 2010 Polaris RZR EPS | Owners Manual - Page 83
Gearcases MAINTENANCE Transfer Case Fluid Change The drain plug is located on the bottom of the transfer case. 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 - 2010 Polaris RZR EPS | Owners Manual - Page 84
MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check - 2010 Polaris RZR EPS | Owners Manual - Page 85
Gearcases 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 - 2010 Polaris RZR EPS | Owners Manual - Page 86
MAINTENANCE Gearcases Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid - 2010 Polaris RZR EPS | Owners Manual - Page 87
Gearcases MAINTENANCE Rear Gearcase Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug - 2010 Polaris RZR EPS | Owners Manual - Page 88
MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 122 for the part numbers of Polaris products. Gearcase Transmission (Main Gearcase) Transmission (Transfer Case) Lubricant Premium AGL Synthetic Gearcase Fluid Premium AGL - 2010 Polaris RZR EPS | Owners Manual - Page 89
resistor (if equipped) is used by your Polaris dealer for power steering diagnostics. Fuse 15A 15A 15A 15A 20A 30A Feature Supported Accessories, 12V Power Receptacle Electronic Fuel Injection Engine Control Module Lights Main Fuse - Ignition, Instrument Cluster Power Steering (if equipped) Spark - 2010 Polaris RZR EPS | Owners Manual - Page 90
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 - 2010 Polaris RZR EPS | Owners Manual - Page 91
Cooling System Operation MAINTENANCE The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding ( - 2010 Polaris RZR EPS | Owners Manual - Page 92
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 67. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the - 2010 Polaris RZR EPS | Owners Manual - Page 93
Cooling System Coolant Level MAINTENANCE Always check and change the coolant at the intervals Coolant outlined in the Periodic Overflow Radiator Maintenance Chart beginBottle Cap ning on page 67. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool - 2010 Polaris RZR EPS | Owners Manual - Page 94
MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the - 2010 Polaris RZR EPS | Owners Manual - Page 95
) System WARNING MAINTENANCE Failure to comply with the instructions in this warning can result in severe injury or Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not - 2010 Polaris RZR EPS | Owners Manual - Page 96
114. There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Remove the seats. See page 29. 2. Loosen the lower screws the process. 10. Take the vehicle to your dealer for service as soon as possible. 92 - 2010 Polaris RZR EPS | Owners Manual - Page 97
Filter Systems Air Filter MAINTENANCE Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. 1. Access the air box from Air Box Cover behind the left rear wheel. 2. Remove the air box cover Gasket and inspect the gasket. It should adhere - 2010 Polaris RZR EPS | Owners Manual - Page 98
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform clean-out immediately after the engine has been run, as the exhaust - 2010 Polaris RZR EPS | Owners Manual - Page 99
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 - 2010 Polaris RZR EPS | Owners Manual - Page 100
engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove both seats. Remove the rear service panel. See page 29. 2. Locate the throttle cable adjuster at the throttle body. 3. Slide the cable adjuster boot off the cable adjuster - 2010 Polaris RZR EPS | Owners Manual - Page 101
Brakes MAINTENANCE 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 - 2010 Polaris RZR EPS | Owners Manual - Page 102
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 122 for the part numbers of Polaris products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or - 2010 Polaris RZR EPS | Owners Manual - Page 103
Brakes MAINTENANCE 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. Inspect the brake pad wear surface for excessive wear. 5. Change pads when worn to 3/64" (1 - 2010 Polaris RZR EPS | Owners Manual - Page 104
MAINTENANCE Suspension Settings (RZR only) The front and rear suspensions are preload adjustable, with five settings on each axle. Adjustment Cam Highest (Stiffest) Setting Lowest (Softest) Setting The suspensions are set on the lowest (softest) setting at the factory. This setting is - 2010 Polaris RZR EPS | Owners Manual - Page 105
Suspension Settings (RZR S) Front/Rear Shock Compression MAINTENANCE Clicker 2 1 Use a flat-blade screwdriver to make damping adjustments. The compression damping clicker is located on top of the shock reservoir, under the rear fender. When the adjuster screw is turned clockwise until it stops, - 2010 Polaris RZR EPS | Owners Manual - Page 106
MAINTENANCE Suspension Settings (RZR S) Front/Rear Spring Preload 1. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension that will be adjusted to fully extend. 2. Loosen the jam nut - 2010 Polaris RZR EPS | Owners Manual - Page 107
) 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. 90 ft. lbs. (122 Nm) Cast Aluminum Wheel Type Cast Aluminum Steel Any 27 ft. lbs - 2010 Polaris RZR EPS | Owners Manual - Page 108
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. 3. Attach the wheel nuts and washers and finger tighten. 4. Carefully lower the - 2010 Polaris RZR EPS | Owners Manual - Page 109
with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement Do not service the headlamps until they've cooled sufficiently. 1. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the - 2010 Polaris RZR EPS | Owners Manual - Page 110
MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on - 2010 Polaris RZR EPS | Owners Manual - Page 111
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 - 2010 Polaris RZR EPS | Owners Manual - Page 112
MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable - 2010 Polaris RZR EPS | Owners Manual - Page 113
Battery WARNING MAINTENANCE 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 - 2010 Polaris RZR EPS | Owners Manual - Page 114
has 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 112 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. On - 2010 Polaris RZR EPS | Owners Manual - Page 115
Battery MAINTENANCE Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed - 2010 Polaris RZR EPS | Owners Manual - Page 116
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. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less - 2010 Polaris RZR EPS | Owners Manual - Page 117
Battery MAINTENANCE Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge - 2010 Polaris RZR EPS | Owners Manual - Page 118
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. Before washing the vehicle, locate the PVT outlet duct under the right rear wheel well. Avoid spraying water directly - 2010 Polaris RZR EPS | Owners Manual - Page 119
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 - 2010 Polaris RZR EPS | Owners Manual - Page 120
and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the - 2010 Polaris RZR EPS | Owners Manual - Page 121
. See page 114. 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 - 2010 Polaris RZR EPS | Owners Manual - Page 122
as recommended in the Periodic Maintenance Chart beginning on page 67. 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 - 2010 Polaris RZR EPS | Owners Manual - Page 123
Cleaning and Storage Removal from Storage MAINTENANCE 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. - 2010 Polaris RZR EPS | Owners Manual - Page 124
SPECIFICATIONS RANGER RZR / RZR S Gross Vehicle Weight Dry Weight 1727 lbs. (783 kg) (RZR) 1782 lbs. (808 kg) (RZR S) 945 lbs. (429 kg) (RZR) 961 lbs. (436 kg) (RZR EPS) 1000 lbs. (454 kg) (RZR S) 300 lbs. (136 kg) 740 lbs. (336.4 kg) (riders/cargo/accessories/ trailer tongue weight) 150 lbs. (68 kg - 2010 Polaris RZR EPS | Owners Manual - Page 125
SPECIFICATIONS RANGER RZR / RZR S Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear - 2010 Polaris RZR EPS | Owners Manual - Page 126
POLARIS PRODUCTS Part Number 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2876251 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 - 2010 Polaris RZR EPS | Owners Manual - Page 127
in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range during loading. Use low range. See warnings on page 58. Drive at a higher speed or use low range more frequently - 2010 Polaris RZR EPS | Owners Manual - Page 128
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution Recharge the battery to - 2010 Polaris RZR EPS | Owners Manual - Page 129
Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range TROUBLESHOOTING Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause - 2010 Polaris RZR EPS | Owners Manual - Page 130
TROUBLESHOOTING Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plugs Worn or defective spark - 2010 Polaris RZR EPS | Owners Manual - Page 131
DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN - 2010 Polaris RZR EPS | Owners Manual - Page 132
COVERAGE WILL 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. 128 - 2010 Polaris RZR EPS | Owners Manual - Page 133
for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing - 2010 Polaris RZR EPS | Owners Manual - Page 134
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, - 2010 Polaris RZR EPS | Owners Manual - Page 135
THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will - 2010 Polaris RZR EPS | Owners Manual - Page 136
must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle - 2010 Polaris RZR EPS | Owners Manual - Page 137
U.S.A. EPA Emissions Limited Warranty WARRANTY This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it - 2010 Polaris RZR EPS | Owners Manual - Page 138
responsible for performing the scheduled maintenance identified in the owner's manual. Polaris may deny warranty claims for failures that have been recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that - 2010 Polaris RZR EPS | Owners Manual - Page 139
MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 135 - 2010 Polaris RZR EPS | Owners Manual - Page 140
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 136 - 2010 Polaris RZR EPS | Owners Manual - Page 141
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 137 - 2010 Polaris RZR EPS | Owners Manual - Page 142
INDEX A Accessory Outlet ...36 Adding Coolant ...87 Adjustments Headlight Beam ...106 Passenger Hand Hold...30 Seat ...29 Steering Wheel...30 Throttle Freeplay ...96 Air Filter ...93 Air Filter Cleaning...93 All Wheel Drive Switch...37 All Wheel Drive System ...40 Arrestor, Spark, Warning...94 - 2010 Polaris RZR EPS | Owners Manual - Page 143
INDEX E EFI Blink Codes ...46-47 Electromagnetic Interference ...66 Electronic Power Steering ...36 Emission Control, Crankcase ...66 Emission Control, Exhaust ...66 Emission Control, Noise ...66 Emissions Limited Warranty ...133 Engaging AWD...40 Engine Break-In ...49 Engine Fogging...118 Engine - 2010 Polaris RZR EPS | Owners Manual - Page 144
36 Plugs, Fouled ...86 Plugs, Spark ...85-86 Polaris Products ...122 Polishing the Vehicle...115 Power Steering...36 Pre-Ride Inspection ...50 Programmable Service Interval ...45 Public Lands ...66 PVT Break-In ...49 PVT Drying ...92 PVT System Operation ...91-92 N Nets, Cab ...32-33 New Operator - 2010 Polaris RZR EPS | Owners Manual - Page 145
Belts ...34-35 Seat Removal ...29 Selector, Gear ...38 Service Interval Indicator ...45 Service Panel, Rear ...29 Severe Use Definition...67 Shifting Gears ...18 Improper Hill Climbing ...14 Improper Tire Maintenance ...16 Instruction ...10 Jumps and Stunts ...13 Multiple Passengers ...12 Obstacles - 2010 Polaris RZR EPS | Owners Manual - Page 146
INDEX S Storage ...114-119 Covers ...118 Fluid Levels ...117 Inspection...118 Lubrication...118 Oil and Filter ...117 Removal From ...119 Storage Area ...118 Storage Compartments...31 Storage, Battery ...111 Suspension Settings (RZR S). . 101-102 Suspension Settings (RZR) ...100 Switches AWD Switch
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Pantone 426C
Owner's Manual
for Maintenance and Safety
RANGER RZR
RANGER RZR
EPS
TM
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