Attachment 2- 2016 Polaris RZR 4 Owners Manual.pdf

MAINTENANCE

Periodic Maintenance Chart Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s manual.

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Frequent short trip operation in cold weather (engine frequently does not operate long enough to reach full operating temperature) Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise.

Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your POLARIS dealer can assist.

Periodic Maintenance Chart Maintenance Chart Key

Perform these operations more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.

Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.

Record maintenance and service in the Maintenance Log beginning on page 148.

Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Steering - Pre-Ride - Make adjustments as need

ed. See Pre-Ride Checklist on page 51.Front suspension - Pre-Ride -

Rear suspension - Pre-Ride - Tires - Pre-Ride - Brake fluid level - Pre-Ride - Brake pedal travel Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - Frame fasteners - Pre-Ride - Engine oil level - Pre-Ride - PVT intake - Daily - Inspect; clean often Coolant - Daily - Check coolant level Power steering unit (if equipped)

- Daily - Inspect daily; clean often

Headlight/taillight - Daily - Check operation Air filter - Weekly - Inspect; replace as needed Front gearcase (demand drive) fluid

25 H 1 M - Perform a break-in oil level check

Transmission (main gearcase) oil

25 H 1 M - Perform a break-in oil level check

D Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 25 H Monthly 250 (400) Check terminals; clean;

test

Engine breather filter (if equipped)

25 H Monthly 250 (400) Inspect; replace as needed

Fuel System 25 H Monthly - Inspect; cycle key to pressurize fuel pump;

check lines and fittings for leaks and abrasion

Air filter 25 H - 500 (800) Replace filter Engine oil change (break-in)

25 H 6 M - Perform a break-in oil change

Periodic Maintenance Chart

Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

D Throttle pedal 50 H 6 M 500 (800) Inspect for free movement;

replace pedal as needed

Throttle body air intake ducts/flange

50 H 6 M 500 (800) Inspect duct for proper sealing/air leaks

Shift Linkage 50 H 6 M 500 (800) Inspect, adjust Front Suspension 50 H 6 M 500 (800) Lubricate and inspect bushings Rear Suspension 50 H 6 M 500 (800) Lubricate and inspect bushings Cooling system (if applicable)

50 H 6 M 500 (800) Inspect coolant strength seasonally; pressure test system yearly

Oil lines, fasteners 50 H 6 M 1000 (1600) Inspect for leaks and loose fittings

Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter Front gearcase (demand drive) fluid

100 H 12 M 1000 (1600) Change fluid

Transmission (main gearcase) oil

100 H 12 M 1000 (1600) Change fluid

D Fuel system 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

Spark plugs 100 H 12 M 1000 (1600) Inspect; replace as needed, torque to specification

Periodic Maintenance Chart

Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer or other qualified person perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces

Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler/ pipe

100 H 12 M 1000 (1600) Inspect

Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

D Clutches (drive and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

Drive belt 100 H 12 M 1000 (1600) Inspect; replace as needed Shock Seals 100 H - - Inspect shock seals

D Shocks - 12 M 1500 (2400) See your dealer for oil change/seal inspection.

D Front wheel bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

D Brake fluid 200 H 24 M 2000 (3200) Change every two years Spark arrester 200 H 24 M 2000 (3200) Clean daily when driving in mud and water; replace a cracked or damaged arrester before operating (see page 107)

Suspension bushings

250 H 24 M 2000 (3200) Inspect; replace if necessary

Valve clearance 500 H - 5000 (8000) Check; adjust as needed Coolant - 60 M - Replace coolant

D Toe adjustment - Inspect periodically; adjust when parts are replaced

Headlight aim - Adjust as needed

Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, 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 interval.

Item Lube Method Engine Oil PS-4 5W-50 4-Cycle Oil and

PS-4 Extreme Duty 10W-50 4-Cycle Oil

See page 88.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines.

See page 110.

Transmission Oil (Main Gearcase)

AGL Gearcase Lubricant & Transmission Fluid

See page 92.

Front Gearcase Fluid (Demand Drive)

Demand Drive Fluid See page 94.

Prop Shaft U-Joint Grease Grease middle and rear fittings.

Control Arm Bushings All Season Grease or grease conforming to NLGI No. 2 Grease fittings

Stabilizer Bar Bushings All Season Grease or grease conforming to NLGI No. 2

Grease front and rear fittings

Middle Prop Shaft Grease Fitting

Rear Prop Shaft Grease Fitting

Fitting Access