Polaris RZR XP 4 1000 EPS 2020 User manual

2020
OWNER’S MANUAL
RZR® XP / XP 4 1000 EPS
RZR® XP 1000 TRAILS AND ROCKS EDITION

WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road
vehicle can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of California
to cause cancer and birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the engine except as
necessary, service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
!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.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
!

2020 RZR Owner’s Manual
1000 XP / XP 4 EPS
1000 XP Trails and Rocks Edition

POLARIS® and RZR® are trademarks of POLARIS Industries Inc.
Copyright 2019 Polaris Industries Inc. All information contained within this
publication is based on the latest product information at the time of
publication. Due to constant improvements in the design and quality of
production components, some minor discrepancies may result between the
actual vehicle and the information presented in this publication. Depictions
and/or procedures in this publication are intended for reference use only. No
liability can be accepted for 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 instructions.
Printed in U.S.A.
9929976

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide
family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for
the latest news, new product introductions, upcoming events, career
opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational
products. We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience
have gone into the engineering, design, and development of your POLARIS
vehicle, making it the finest machine we’ve ever produced.
• Snowmobiles
• SPORTSMAN® All-terrain vehicles
• Low emission vehicles (LEVs)
•RANGER® utility vehicles
• BRUTUS® work vehicles
• SLINGSHOT® three wheel
motorcycles
• RZR® sport vehicles
• GEM® vehicles
• INDIAN® motorcycles
• POLARIS POWER® generators
• POLARIS DEFENSE® combat
vehicles
• Timbersled® Snow Bikes
For safe and enjoyable 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 can be performed by a factory
certified Master Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total
satisfaction. Your POLARIS dealership can perform all of your service needs
during, and after, the warranty period.
3
WELCOME

The following signal words and symbols appear throughout this manual and on
your vehicle. Your safety is involved when these words and symbols are used.
Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation that, if not avoided, will result in
death to the operator, bystanders or person(s) inspecting or servicing the
vehicle.
WARNING
WARNING indicates a hazardous situation that, if not avoided, may result in
death to the operator, bystanders or person(s) inspecting or servicing the
vehicle.
CAUTION
CAUTION indicates a potential hazard that may result in minor personal injury
or damage to the vehicle.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
The Prohibition Safety Sign indicates an action NOT to take in
order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to
be taken to avoid a hazard.
4
SAFETY SYMBOLS AND SIGNAL WORDS

Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . 11
Features and Controls . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . 69
Winch Guide. . . . . . . . . . . . . . . . . . . 87
Emission Control Systems . . . . . . . . . . . . . 97
Maintenance . . . . . . . . . . . . . . . . . . 99
Specifications . . . . . . . . . . . . . . . . . . 169
Polaris Products . . . . . . . . . . . . . . . . . 175
Troubleshooting . . . . . . . . . . . . . . . . . 177
Warranty . . . . . . . . . . . . . . . . . . . . 183
Maintenance Log . . . . . . . . . . . . . . . . 193
5
TABLE OF CONTENTS

6

INTRODUCTION
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your
local POLARIS dealer. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with
the vehicle.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16
and have a valid driver’s license to operate this vehicle.
• All riders must be able to sit with backs against the seat, both feet flat on the
floor and both hands on the steering wheel (if driving) or on a passenger
hand hold.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.
• Always wear a seat belt when riding in this vehicle. Always wear a helmet,
eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the steps described in the New Operator Driving Procedures
section. Never allow a guest to operate this vehicle until the guest has
completed the New Operator Driving Procedures.
7
INTRODUCTION

EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per EN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as
indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many
factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
8
INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS
Record your vehicle’s identification number q, engine
serial number w, and key number ein 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 your existing keys.
The ignition switch must be replaced if all keys are
lost.
Vehicle Model Number:
Vehicle Identification Number:
Engine Serial Number:
Key Number:
9
INTRODUCTION

10

SAFETY
SAFETY TRAINING
Safety training is a top priority for POLARIS. POLARIS strongly encourages you
and any family members who will be riding this vehicle to take a training course
ROHVA (Recreational Off-Highway Vehicle Association) provides both an online
safety e-course and a hands-on safety course. To access this valuable training,
visit www.rohva.org.
Your POLARIS vehicle is considered an off-road vehicle. Familiarize yourself
with all laws and regulations concerning the operation of this vehicle in your
area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance program
is designed to ensure that all critical components on your vehicle are thoroughly
inspected at specific intervals.
For more information about recreational off-road vehicle safety in the
United States, visit www.rohva.org or call POLARIS at 1-800-342-3764.
11
SAFETY

SAFE RIDING GEAR
Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-
the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces
the chance of injury.
RIDER COMFORT
Under certain operating conditions, heat generated by the engine and exhaust
system can elevate temperatures in the rider cab area.
The condition occurs most frequently
when a vehicle is being operated in high
ambient temperatures at low speeds
and/or high load conditions for an
extended period of time. The use of
certain windshield, roof and/or cab
systems may contribute to this condition
by restricting airflow. Any discomfort
due to heat buildup in this area can be
minimized by wearing proper riding
apparel and by varying speeds to
increase airflow.
qHelmet
wEye Protection
eLong Sleeves
rGloves
tLong Pants
yOver-the-Ankle Boots
12
SAFETY

HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds established
safety standards. Clasp the buckle and pull each strap tight to ensure the helmet
is properly secured to the head.
Parents should verify that young operators have a helmet that fits, and should
obtain one of proper size if it does not fit before allowing operation.
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. The ECE mark consists of a
circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding
this POLARIS vehicle, 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. Make sure protective eye wear is kept clean.
GLOVES
Wear gloves for comfort and for protection from sun, cold weather and other
elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a
POLARIS vehicle with bare feet or sandals.
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
13
SAFETY

SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and
follow the instructions 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 to purchase a replacement. Replacement safety labels are
provided by POLARIS at no charge. The part number is printed on the label.
qWarning Labels
wPayload Warning
PROPER USE WARNING
WARNING
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway
vehicle access) - collisions with cars and trucks can occur.
•RZR: Do not exceed seating capacity: 1 passenger.
•RZR 4: Do not exceed seating capacity: 3 passengers.
14
SAFETY

PAYLOAD WARNING
WARNING
RZR Never Exceed If Total Payload Exceeds
XP 1000 68 MPH (109 km/h) 330 lbs. (150 kg)
XP4 1000 68 MPH (109 km/h) 860 lbs. (390 kg)
SEAT BELT WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
Be Prepared
• Fasten seat belts.
• Wear an approved helmet and protective gear.
• ALWAYS use cab nets and/or doors.
• Each rider must be able to sit with back against
seat, feet flat on the floor, and hands on steering
wheel or hand holds. Stay completely inside the
vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA
TRAINING (rohva.org).
RIDERS WARNING
Be Sure Riders Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
• Keep a firm grip on the steering wheel or hand holds and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
15
SAFETY

FUEL TRANSPORT WARNING
NEVER carry fuel or other flammable liquids on this
vehicle.
Failure to follow this instruction could lead to serious
burn injuries or death.
DRIVE RESPONSIBLY WARNING
WARNING:
Drive Responsibly
Rollovers have caused severe injuries and death, even on flat, open areas.
Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways
sliding, skidding or fishtailing, and
never do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when
turning, even from a stop.
• Plan for hills, rough terrain, ruts and
other changes in traction and terrain.
• Avoid paved surfaces.
• Avoid sidehilling (riding across
slopes).
16
SAFETY

AIR BOX CAUTION
CAUTION:
Use a Polaris approved air filter. The
use of a non-Polaris approved air filter
may cause engine damage. Before
installing filter, ensure there is no dirt or
debris in the clean side of the intake
tube. The air filter must be properly
seated before the lid is reinstalled.
Please reference your owner’s manual
for additional information regarding air
filter service.
qAir Box Caution
BELT DEBRIS WARNING
WARNING
Improper service or maintenance of this PVT system can result in vehicle
damage, SEVERE INJURY or DEATH.
Always look for and remove debris inside and around the clutch and vent
system when replacing the belt.
Read owner’s manual or see authorized POLARIS dealer or other authorized
person.
qBelt Debris Warning
17
SAFETY

LOAD / PASSENGER / TIRE PRESSURE WARNING
The Load / Passenger / Tire Pressure
Warning qis located at the rear of the
vehicle in the cargo box.
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
• Reduce speed and allow greater distance for braking when carrying cargo.
• Overloading or carrying tall, off-center, or unsecured loads will increase your
risk of losing control. Loads should be centered and carried as low as
possible in box.
• For stability on rough or hilly terrain, reduce speed and cargo.
• Be careful if load extends over the side of the box.
• Never carry passengers in cargo box.
• Passengers can be thrown off. This can cause serious injury or death.
RZR XP 1000 RZR XP 4 1000
RZR XP 1000
Trails and Rocks
Edition
MAXIMUM
CARGO BOX
LOAD
300 lbs. (136 kg) 300 lbs. (136 kg) 300 lbs. (136 kg)
TIRE
PRESSURE
IN PSI (KPa)
FRONT 16 (110)
REAR 16 (110)
FRONT 19 (131)
REAR 20 (138)
FRONT 12 (83)
REAR 16 (110)
MAXIMUM
WEIGHT
CAPACITY*
740 lbs. (336 kg) 900 lbs. (408 kg) 740 lbs (336 kg)
*INCLUDES WEIGHT OF OPERATOR, PASSENGERS, CARGO AND
ACCESSORIES
Read Operation and Maintenance Manual for more detailed loading
information.
18
SAFETY