POLARIS RANGER RZR XP 900 2012 (01) PDF Document

Always wear appropriate protective clothing for comfort and to reduce the chance of injury when riding a POLARIS RANGER RZR XP 900 2012. Recommended gear includes:

Helmet: Wearing a helmet can prevent a severe head injury. Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.

Eye Protection: Do not depend on eyeglasses or sunglasses for eye protection. Always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Ensure protective eyewear is kept clean.

Gloves: Wear gloves for comfort and for protection from sun, cold weather and other elements.

Boots: Wear sturdy footwear. Do not ride a POLARIS vehicle with bare feet.

Clothing: Wear long sleeves and long pants to protect arms and legs.

The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate it. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the specifications section and on a label on the vehicle. When more passenger weight is added, cargo weight may need to be reduced accordingly.

• The recommended tire pressures are listed in the specifications section and on a label on the vehicle.

Always follow these guidelines:

Improper tire pressure or overloading can cause loss of control resulting in serious injury or death. Always adhere to the following specifications for your POLARIS RANGER RZR XP 900 2012.

Read the Operation and Maintenance Manual for more detailed loading information.

The ignition switch on your POLARIS RANGER RZR XP 900 2012 is a three-position, key-operated switch used to start the engine. The key can be removed from the switch when it is in the OFF position. The functions are as follows:

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The ignition switch must be in the ON position to operate the headlights.

• Press the top of the rocker switch toward the dash to place the headlights on high beam.

• Move the rocker switch to the center position to place the headlights on low beam.

• Press the bottom of the rocker switch to turn off the headlights.

All Wheel Drive (AWD) Switch

The AWD Switch has two positions: All Wheel Drive (AWD) and Two Wheel Drive (2WD).

• Press the top of the rocker switch to engage All Wheel Drive.

• Press the bottom of the switch to operate in two wheel drive.

Seat Adjustments

1. Loosen (do not remove) the four screws located on the seat bottom.

2. Slide the seat forward or rearward to the desired position.

3. Tighten the screws to 4 ft. lbs. (5.4 Nm). Do not overtighten.

Seat Removal

1. Pull up on the seat latch lever located under the rear edge of the seat.

2. Tilt the seat forward.

3. Lift the seat upward to remove it from the vehicle.

4. To reinstall, reverse this procedure. Ensure the seat tabs at the front edge slide under the seat retainer bar.

5. Press down firmly at the rear of the seat to engage the rear latch.

Steering Wheel Adjustment

The steering wheel can be tilted upward or downward for rider preference.

1. Lift and hold the steering wheel adjustment lever.

2. Move the steering wheel upward or downward to the desired position.

3. Release the lever to lock the steering wheel in place.

Always adjust the hand hold to a comfortable position for your passenger before operating. Ensure the adjustment pin and retainer are securely installed after making adjustments.

1. Remove the retainer from the end of the adjustment pin.

2. Remove the pin from the post.

3. Slide the post inward or outward to the desired position.

4. Reinstall the pin through the post mounting hole, adapter bushing hole, both post adjustment holes and lastly through the remaining bushing hole and post mounting hole.

5. Reinstall the retainer to the pin.

Remove the hood to access the radiator pressure cap and coolant overflow bottle.

1. Turn the hood fasteners 1/4 turn.

2. Grasp the upper hood edge and pull upward to disengage the fasteners.

3. Pivot the hood forward and lift upward to disengage the lower hood hooks.

4. Lift the hood away from the vehicle.

Wearing the Seat Belt Properly

1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap; it will self-tighten.

4. To release, press the red release latch on the buckle.

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. A click indicates that it’s securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden hose to flush out the retractor and latch housings regularly.

Changing Gears

The gear selector positions are P (Park), R (Reverse), N (Neutral), L (Low Gear), and H (High Gear).

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

Using Low Range

Always shift into low gear for any of the following conditions:

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the vehicle is in two-wheel drive. When the switch is on AWD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.

The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

The Rider Information Center displays various vehicle information:

1. Gear Indicator: This indicator displays gear shifter position. H = High Gear, L = Low Gear, N = Neutral, R = Reverse Gear, P = Park, — = Gear Signal Error (or shifter between gears).

2. Fuel Gauge: The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

3. Information Display Area: This area displays odometer, trip meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage: This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.

5. Clock: The clock displays time in a 12-hour or 24-hour format.

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.

7. 4X4 Indicator: This indicator illuminates when the 4X4 system is engaged (switch is on 4X4).

The display can be changed to show either standard or metric units of measurement for each of the following settings. To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key on. The gauge will display the mode that was displayed prior to setting the units.

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to the ON position.

3. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button to save the setting and advance to the next display option.

5. Repeat the procedure to change remaining display settings.

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 hour segment flashes. Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. The service interval is programmed at 50 hours at the factory. Use the following procedure to change it:

1. Press the MODE button until the remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and 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.

The EFI diagnostic display mode is for informational purposes only. The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. If the CHECK ENGINE light illuminates, retrieve the error codes from the display.

1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See an authorized POLARIS dealer for code details and diagnosis.

The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. Careful treatment of a new engine and drive components will result in more efficient performance and longer life.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline.

2. Check the oil level. Add the recommended oil as needed.

3. Complete the New Operator Driving Procedures.

4. Avoid aggressive use of the brakes.

5. Vary throttle positions. Do not operate at sustained idle.

6. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.

7. Carry only light loads.

8. During the break-in period, change both the oil and the filter at 25 hours or one month.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Carry only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

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.

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.

5. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 5 and 6 until the engine starts.

7. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

Braking

1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you’re familiar with the controls.

1. Read and understand the owner’s manual and all warning and instruction labels before operating this vehicle.

2. Perform the pre-ride inspection.

3. Wear an approved helmet that fits properly and eye protection (goggles or face shield).

4. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

5. Do not carry cargo during this period.

6. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

7. Sit in the driver’s seat and fasten the seat belt.

8. Always use the cab nets while riding in this vehicle.

9. Place the transmission in PARK.

10. Start the engine.

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 slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

15. Increase speed only after mastering all maneuvers at a slow speed.

16. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

• Operate at speeds appropriate for your skills, the conditions and the terrain.

• DO NOT do power slides, “donuts”, jumps or other driving stunts.

1. Complete the New Operator Driving Procedures.

2. Perform the pre-ride inspection.

3. Do not carry more than one passenger in this vehicle. Additional passengers can affect the operator’s ability to steer and operate the controls.

4. Make sure the passenger is at least 12 years of age and is tall enough to comfortably and safely sit in the passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

5. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye protection.

6. Make sure the passenger secures the seat belt.

7. Make sure all cab nets are properly secured.

8. Allow a passenger to ride only in the passenger seat.

9. Slow down. Always travel at a speed appropriate for your skills, your passenger’s skills and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger.

10. Vehicle handling may change with a passenger and/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.

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 climb hills with excessively slippery or loose surfaces.

5. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

6. Avoid unnecessary changes in speed or direction.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

8. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

3. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill.

4. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.

5. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Slow down. Never travel down a hill at high speed.

3. Always check the terrain carefully before descending a hill.

4. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral.

5. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill.

6. Apply the brakes lightly to aid in slowing.

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land.

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter.

3. Dry the spark plug wells with a clean cloth, then remove the spark plugs.

4. Turn the engine over several times.

5. Dry the spark plugs 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 for drying.

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use. Items not listed in the chart should be lubricated at the general lubrication interval.

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart. Hot oil can cause burns; do not allow hot oil to contact skin.

1. Position the vehicle on a level surface. Place the transmission in PARK.

2. Clean the areas around the oil tank and crankcase drain plugs.

3. Place a drain pan under the oil tank (accessed through the left rear wheel well) and remove the drain plug. Allow the oil to drain completely.

4. Place a drain pan under the engine crankcase (accessed through the hole under the crankcase) and remove the drain plug. Allow the oil to drain completely.

5. Locate the oil catch tool in the tool kit. Position it below the oil filter to catch spills.

6. Using an oil filter wrench, turn the filter counter-clockwise to remove it.

7. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

8. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

9. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 1/2 turn.

10. Reinstall the oil tank and crankcase drain plugs. Torque both drain plugs to 12 ft. lbs. (16 Nm).

11. Remove the dipstick and fill the oil tank with 3.5 quarts (3.3 l) of recommended oil.

12. Start the engine and allow it to idle for 30 seconds.

13. Stop the engine and wait 15 seconds before removing the dipstick.

14. Remove the dipstick from the oil tank. Wipe it dry with a clean cloth.

15. Reinstall the dipstick completely. Remove the dipstick and check the oil level.

16. Add oil as necessary to bring the level to the upper mark on the dipstick. Do not overfill.

17. Reinstall the dipstick.

18. Dispose of used filter and oil properly.

Gearcase Specification Chart

Spark Plug Gap/Torque

Spark Plug Removal and Replacement

1. Remove the cargo box access panel.

2. Clean the area around the spark plugs before removing the plugs.

3. Remove the spark plug caps.

4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counter-clockwise.

5. Reverse the procedure for spark plug installation. Torque to specification (10 ft. lbs / 13.5 Nm).

Spark Plug Condition Inspection

• Normal Plug: The insulator tip is gray, tan or light brown. There 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. The tip should not be white, as this indicates overheating.

• Wet Fouled Plug: The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather.

The main fuse box is located under the dash. The power fuse box is located under the driver’s seat.

Main Fuse

Power Fuse

Belt Replacement/Debris Removal

If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt.

1. Remove the engine access cover and thoroughly clean all debris from the aluminum debris basket and from the engine compartment.

2. Remove the clutch cover screws and open the clutch cover. Remove all debris wrapped in and around the PVT system. Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation.

3. Remove all debris from the entire clutch air duct passage.

4. Check for signs of damage to seals on the transmission and engine.

PVT Drying

If water is ingested into the PVT system, use the following instructions to dry it out before operating.

1. Remove the clutch cover drain plug.

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

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

4. Start the engine.

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

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

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

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

Front/Rear Spring Preload Adjustment

The factory setting is appropriate for nearly all riding conditions. It can be adjusted to maintain vehicle clearance height when carrying loads. Use the shock/clutch tool from the tool kit for adjustments.

1. Elevate the vehicle to allow the suspension to fully extend.

2. Loosen the jam nut and back it away from the adjusting ring.

3. Turn the adjusting ring to the left to increase preload for a stiffer ride. Turn the adjusting ring to the right to decrease preload for a softer ride.

4. Tighten the jam nut firmly against the adjuster ring.

Front/Rear Shock Compression Adjustment

The compression damping clicker knob is located on top of the shock reservoir.

1. Turn the clicker clockwise to increase compression damping.

2. Turn the clicker counter-clockwise to decrease compression damping.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Place the transmission in PARK.

2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

3. Attach the wheel nuts and washers and finger tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification (30 ft. lbs. (41 Nm) PLUS 1/4 TURN).

A sealed battery must always be maintained with a full charge. Use a voltmeter or multimeter to measure DC voltage.

1. Check the battery voltage. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using a constant current charger, use the guidelines below.

Clean the Exterior: Make any necessary repairs and clean the vehicle.

Stabilize the Fuel:

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

Oil and Filter: Change the oil and filter.

Air Filter / Air Box: Replace the air filter. Clean the air box. Drain the sediment tube.

Fluid Levels: Inspect the fluid levels. Add or change fluids as recommended.

Inspect and Lubricate: Inspect all cables and lubricate all areas of the vehicle as recommended.

Fog the Engine:

1. Treat the fuel system with POLARIS Carbon Clean. Start the engine and let it idle for several minutes. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil into the plug holes.

3. Reinstall the spark plugs and torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall the caps onto the plugs at this step.

5. Turn the engine over several times to coat the cylinder with oil.

6. If fuel system additive is not used, drain the fuel system completely.

7. Reinstall the spark plug caps to the spark plugs.

Battery Maintenance: See instructions for battery storage and charging procedures.

Storage Area/Covers: Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover.