2011 Polaris RZR 4 Owners Manual

2011 Polaris RZR 4 Manual

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2011 Polaris RZR 4 manual content summary:

  • 2011 Polaris RZR 4 | Owners Manual - Page 1
    PMS 419 RANGER RZR RANGER RZR S RANGER RZR 4 Owner's Manual for Maintenance and Safety
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 3
    The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • 2011 Polaris RZR 4 | Owners Manual - Page 4
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 6
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 7
    TABLE OF CONTENTS Introduction...4 Safety ...7 Features and Controls ...28 Operation...50 Emission Control Systems ...68 Maintenance ...69 Specifications...122 POLARIS Products ...126 Troubleshooting ...127 Declaration of Conformity...131 Warranty ...132 Maintenance Log ...139 Index ...142 3
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | 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 56-57
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 11
    SAFETY 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 those that
  • 2011 Polaris RZR 4 | 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. Long Sleeves Eye Protection Long Pants Sturdy Footwear Gloves Helmet Helmet Wearing a helmet can prevent a severe head injury.
  • 2011 Polaris RZR 4 | Owners Manual - Page 13
    SAFETY Safe Riding Gear 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 markings
  • 2011 Polaris RZR 4 | Owners Manual - Page 14
    of terrain. Complete the New Operator Driving Procedures outlined on pages 56-57. 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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    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 16
    SAFETY Safety Warnings Carrying Passengers (RZR 4) 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 56-57. A passenger must always be seated in a passenger seat with seat belt secured. Never
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | 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 61. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn. Maintain a steady speed
  • 2011 Polaris RZR 4 | Owners Manual - Page 20
    or overturn. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating on Slippery Terrain Operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of
  • 2011 Polaris RZR 4 | 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
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    accident. • Always follow the instructions in the owner's manual for carrying cargo or pulling first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you overturn or accident, have a qualified service dealer inspect the entire vehicle for possible
  • 2011 Polaris RZR 4 | Owners Manual - Page 23
    SAFETY Safety Warnings Handling Gasoline 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
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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
  • 2011 Polaris RZR 4 | Owners Manual - Page 25
    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 Tire Pressure/Cargo Overload Warning (RZR 4) WARNING IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of
  • 2011 Polaris RZR 4 | Owners Manual - Page 26
    SAFETY Safety Labels and Locations Age Warning Overturn Warning Discretionary 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 27
    SAFETY Safety Labels and Locations Shift Caution 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 of
  • 2011 Polaris RZR 4 | Owners Manual - Page 28
    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. OR ALCOHOL LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR
  • 2011 Polaris RZR 4 | Owners Manual - Page 29
    INJURY or DEATH NEVER operate: • without first viewing safety video and quick start guide. • with more than three passengers. • on hills steeper than 15 degrees. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR
  • 2011 Polaris RZR 4 | Owners Manual - Page 30
    SAFETY Safety Labels and Locations Passenger Safety Warning Passenger Safety Warning (RZR) 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 under age 12 or
  • 2011 Polaris RZR 4 | Owners Manual - Page 31
    SAFETY Safety Labels and Locations Passenger Safety Warning (RZR 4) WARNING NEVER CARRY PASSENGERS UNDER AGE 12 NEVER CARRY MORE THAN THREE PASSENGERS NEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH, NEVER carry passengers under age 12 or too small to firmly
  • 2011 Polaris RZR 4 | Owners Manual - Page 32
    FEATURES AND CONTROLS Component Locations Rear Passenger Grab Bar Cab Nets Front Passenger Hand Hold Cargo Box Shifter Fuel Tank Cap Hip Bars Tie-Down Points Rack Extenders (RZR/ RZR EPS only) 28
  • 2011 Polaris RZR 4 | Owners Manual - Page 33
    FEATURES AND CONTROLS Component Locations Cab Frame Steering Wheel Storage Compartment (under hood) Headlights Radiator Brush Guard 29
  • 2011 Polaris RZR 4 | Owners Manual - Page 34
    FEATURES AND CONTROLS Component Locations Taillights 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, always heed the warnings
  • 2011 Polaris RZR 4 | Owners Manual - Page 35
    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 all seat backs to ensure the latches are secure. Seat
  • 2011 Polaris RZR 4 | Owners Manual - Page 36
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 37
    FEATURES AND CONTROLS Hood Remove the hood to access the front storage compartment, the radiator cap and the coolant overflow bottle. 1. Turn the hood fasteners Storage Compartment 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the hood from the vehicle. 3. Pivot the hood
  • 2011 Polaris RZR 4 | Owners Manual - Page 38
    FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with ethanol content greater than 10
  • 2011 Polaris RZR 4 | Owners Manual - Page 39
    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. To wear the seat belt properly, follow this procedure: 1. Pull the seat belt
  • 2011 Polaris RZR 4 | Owners Manual - Page 40
    (if equipped) is in the rear passenger area. Use the outlets to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash. The rear outlet connection is under the rear passenger seats. Electronic Power Steering (EPS) Electronic
  • 2011 Polaris RZR 4 | 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. AWD 2WD 37
  • 2011 Polaris RZR 4 | 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 43
    FEATURES AND CONTROLS Brake Pedal 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 pedal
  • 2011 Polaris RZR 4 | 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 4X4 indicator in the instrument cluster will
  • 2011 Polaris RZR 4 | Owners Manual - Page 45
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 46
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 47
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 48
    - The clock displays time in a 12-hour or 24-hour format. See page 46 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 49
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 50
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 51
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 52
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 53
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 54
    , 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 55
    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 77. Add the recommended oil as needed to maintain the oil level in the safe operating range.
  • 2011 Polaris RZR 4 | Owners Manual - Page 56
    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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    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 58
    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 engine
  • 2011 Polaris RZR 4 | Owners Manual - Page 59
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 60
    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 52. 3. Wear an approved helmet that fits properly and eye protection (goggles or
  • 2011 Polaris RZR 4 | Owners Manual - Page 61
    OPERATION New Operator Driving Procedures 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 62
    /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. 58
  • 2011 Polaris RZR 4 | Owners Manual - Page 63
    OPERATION Driving on Slippery Surfaces WARNING 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 64
    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 unavoidable, engage all-wheel drive before ascending. 3. Drive straight uphill. 4. Never
  • 2011 Polaris RZR 4 | Owners Manual - Page 65
    OPERATION Driving on a Sidehill (Sidehilling) 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 drive.
  • 2011 Polaris RZR 4 | Owners Manual - Page 66
    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 69. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil, and
  • 2011 Polaris RZR 4 | Owners Manual - Page 67
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 68
    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. 64
  • 2011 Polaris RZR 4 | Owners Manual - Page 69
    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. Place the transmission in PARK. 2. Turn the engine off. 3. Block the rear wheels on the downhill side, or park the
  • 2011 Polaris RZR 4 | Owners Manual - Page 70
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 71
    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 122. Belt Life To extend belt life, use low gear when hauling or towing
  • 2011 Polaris RZR 4 | Owners Manual - Page 72
    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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    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 74
    Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) n Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a n could result in component failure and lead to serious injury or death. Have an
  • 2011 Polaris RZR 4 | Owners Manual - Page 75
    MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval ( oil X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service n Have an authorized POLARIS dealer perform these
  • 2011 Polaris RZR 4 | Owners Manual - Page 76
    -in oil change at one month 1000 (1600) Replace with oil change X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service n Have an authorized POLARIS dealer perform these
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    wheel bearings n Brake fluid Spark arrestor Idle speed n Toe adjustment Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service n Have an authorized POLARIS dealer perform these
  • 2011 Polaris RZR 4 | Owners Manual - Page 78
    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 69, 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 79
    MAINTENANCE Lubrication Recommendations RZR Stabilizer Bar Bushings RZR S/RZR 4 Control Arm Pivot Bushings RZR 4 Stabilizer Bar Bushings RZR Control Arm Pivot Bushings RZR S/RZR 4 Control Arm Pivot Bushings 75
  • 2011 Polaris RZR 4 | Owners Manual - Page 80
    MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 PLUS Synthetic engine oil. 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 81
    passenger seat on RZR 4 models). 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 31. 4. Lift the lever lock to remove the dipstick. Wipe it dry with a clean cloth. 5. Reinstall the dipstick completely, but
  • 2011 Polaris RZR 4 | Owners Manual - Page 82
    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 69. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle
  • 2011 Polaris RZR 4 | Owners Manual - Page 83
    MAINTENANCE Engine Oil 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 84
    MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fill Plug Level Check Plug
  • 2011 Polaris RZR 4 | Owners Manual - Page 85
    MAINTENANCE Gearcases 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 86
    MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fluid Check
  • 2011 Polaris RZR 4 | Owners Manual - Page 87
    MAINTENANCE Gearcases 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 88
    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 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fluid
  • 2011 Polaris RZR 4 | Owners Manual - Page 89
    MAINTENANCE Gearcases Rear Gearcase Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Refer to the Gearcase Specifications Chart on page 86 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is
  • 2011 Polaris RZR 4 | Owners Manual - Page 90
    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 126 for the part numbers of POLARIS products. Gearcase Transmission (Main Gearcase) Transmission (Transfer Case) Demand Drive Unit (Front Gearcase) Rear Gearcase Lubricant
  • 2011 Polaris RZR 4 | Owners Manual - Page 91
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 92
    Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Fuse 20A 10A 20A 10A 20A Feature Supported Lights: Headlights, Taillights Drive: AWD Accessory: Winch Switch, 12V Power Receptacle Fuel Pump Electronic Engine Control, Starting Power Fuse 20A 30A 30A
  • 2011 Polaris RZR 4 | Owners Manual - Page 93
    MAINTENANCE Fuses The fuse box is located above the power steering unit. Spare fuses are provided in the fuse box. 1. From the left side of the vehicle, reach in and lift up on the two fuse box tabs. 2. Slide the fuse box slightly toward the right side of the vehicle to disengage it from the mount.
  • 2011 Polaris RZR 4 | Owners Manual - Page 94
    MAINTENANCE Cooling System Operation 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 (heated
  • 2011 Polaris RZR 4 | Owners Manual - Page 95
    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 69. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the
  • 2011 Polaris RZR 4 | Owners Manual - Page 96
    MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level
  • 2011 Polaris RZR 4 | Owners Manual - Page 97
    (PVT) System WARNING 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 install
  • 2011 Polaris RZR 4 | Owners Manual - Page 98
    page 116. 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 both seats. Remove the rear service panel. See page 31. 2. Loosen the lower screws that secure the clutch cover. 3. Allow the water to
  • 2011 Polaris RZR 4 | Owners Manual - Page 99
    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 100
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 101
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 102
    the 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 31. Jam Nut Adjuster 2. Locate the throttle cable adjuster at the throttle body. 3. Slide the cable adjuster boot off
  • 2011 Polaris RZR 4 | Owners Manual - Page 103
    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 39. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a
  • 2011 Polaris RZR 4 | Owners Manual - Page 104
    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 126 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or
  • 2011 Polaris RZR 4 | Owners Manual - Page 105
    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. Inspect the brake pad wear surface for excessive wear. 5. Change pads when worn to 3/64" (1 mm
  • 2011 Polaris RZR 4 | Owners Manual - Page 106
    MAINTENANCE Suspension Settings (RZR and RZR S Base Models) 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. Since the vehicle
  • 2011 Polaris RZR 4 | Owners Manual - Page 107
    MAINTENANCE Suspension Settings (RZR S Premium Models and 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 108
    MAINTENANCE Suspension Settings (RZR S Premium Models and RZR 4) Front/Rear Shock Compression 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 109
    ) 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) Front and Rear 30 ft. lbs. (41 Nm) PLUS 1/4 TURN 2-Piece
  • 2011 Polaris RZR 4 | Owners Manual - Page 110
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 111
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 112
    MAINTENANCE Lights Headlight High 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 113
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 114
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 115
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 116
    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 114 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. On
  • 2011 Polaris RZR 4 | Owners Manual - Page 117
    MAINTENANCE Battery 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 to
  • 2011 Polaris RZR 4 | Owners Manual - Page 118
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 119
    MAINTENANCE Battery Battery Charging (Sealed Battery) 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 120
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 121
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 122
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 123
    . See page 116. 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 124
    as recommended in the Periodic Maintenance Chart beginning on page 69. 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 125
    MAINTENANCE Cleaning and Storage Removal from Storage 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. 3.
  • 2011 Polaris RZR 4 | Owners Manual - Page 126
    SPECIFICATIONS RANGER RZR / RZR S Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity
  • 2011 Polaris RZR 4 | Owners Manual - Page 127
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 128
    SPECIFICATIONS RANGER RZR 4 Gross Vehicle Weight Dry Weight Rear Cargo Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission
  • 2011 Polaris RZR 4 | Owners Manual - Page 129
    SPECIFICATIONS RANGER RZR 4 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 130
    POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878068 2878069 2871653 2872276 2870465 2877922 2877923 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 PLUS
  • 2011 Polaris RZR 4 | Owners Manual - Page 131
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 132
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 133
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 134
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark
  • 2011 Polaris RZR 4 | Owners Manual - Page 135
    DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010 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.
  • 2011 Polaris RZR 4 | Owners Manual - Page 136
    and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 137
    WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are
  • 2011 Polaris RZR 4 | Owners Manual - Page 138
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 139
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 140
    it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment outside of the country
  • 2011 Polaris RZR 4 | Owners Manual - Page 141
    WARRANTY U.S.A. EPA Emissions Limited 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
  • 2011 Polaris RZR 4 | Owners Manual - Page 142
    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
  • 2011 Polaris RZR 4 | Owners Manual - Page 143
    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 139
  • 2011 Polaris RZR 4 | Owners Manual - Page 144
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 140
  • 2011 Polaris RZR 4 | Owners Manual - Page 145
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 141
  • 2011 Polaris RZR 4 | Owners Manual - Page 146
    INDEX A Accessory Outlet ...36 Adjustment Hand Hold ...32 Seat ...31 Steering Wheel ...32 Adjustment, Headlight Beam ...108 Adjustment, Throttle Freeplay ...98 Air Filter ...95 All Wheel Drive Switch ...37 All Wheel Drive System ...40 Auxiliary Outlet ...36 Axle Nut Torque...105 C Coolant Level ...
  • 2011 Polaris RZR 4 | Owners Manual - Page 147
    INDEX F Fluid Demand Drive ...84 Front Gearcase ...84 Main Gearcase ...82-83 Rear Gearcase ...85 Transfer Case ...80-81 Transmission ...82-83 Fluid Levels During Storage...119 Fluid Recommendations, Gearcase...86 Fluid, Battery ...113 Fluid, Brake ...100 Fogging the Engine ...120 Fouled Plugs ...87
  • 2011 Polaris RZR 4 | Owners Manual - Page 148
    ...53 Safety Labels ...20-27 Safety Symbols...4 Safety Warnings ...10-19 Seat Adjustment ...31 Seat Belts ...35 Seat Removal ...31 Service Panel, Rear ...31 Severe Use Definition ...69 Shifting Gears...38 Shock Compression ...104 Signal Words ...4 Spark Arrestor Cleaning...96 Spark Arrestor
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PMS 419
Owner's Manual
for Maintenance and Safety
RANGER
RZR
RANGER
RZR
S
RANGER
RZR
4