Page 1 Publication Printed September 2014 (PN 9925723 R01) © Copyright 2014 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.
Page 2 UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 5 GENERAL INFORMATION MAINTENANCE ENGINE / COOLING SYSTEM FUEL SYSTEM PVT SYSTEM TRANSMISSION FINAL DRIVE STEERING / SUSPENSION BRAKE SYSTEM BODY / FRAME ELECTRICAL...
Page 8: Vehicle Identification
WORLD MFG. ID INDIVIDUAL SERIAL NO. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 9: Vehicle And Engine Serial Number Location
The VIN can be found stamped on a portion of the left rear upper frame and also on a decal on the front frame support behind the lower shock mounting location ①. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 10: Misc. Information
9925792 NOTE: When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 11: Replacement Keys
SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 12: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier.
Page 13 2872608 2876389 2877408 8700226 9314177-A Roll Pin Removal Tool Combination Pliers Spanner Wrench / CV Boot Clamp Pliers Drive Clutch Holding (27″) Clutch Spreader (ear) Tool 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 14 PU-50565 PU-50566 PU-50578 PU-50624 PU-50625 Oil Pressure Gauge Transmission Nut Clutch Spider Nut Rolling Engine Stand Engine Stand Adapter Adapter (1/2 NPT) Socket Socket Sleeve (2″) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 15 Fluke Multimeter Compressor Compressor Adapter PV-43570 PV-48656 PW-47053 PW-47054 Piston Ring Fuel Pressure Gauge Bench Mount Engine Engine Stand Adapter Compressor Pliers Adapter Stand Sleeve (2 3/8″) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 16: General Specifications
740 lbs. / 336.4 kg Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 1.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 17 For clutch specifications / High Altitude setup, see PVT 10A Term System chapter – Clutch Charts, page 5.3 10A Accessory Fuses 10A Drive 15A Lights 20A EPS (if appl.) 1.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 18: Rzr 900 Xc Specifications
740 lbs. / 336 kg Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 1.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 19 For clutch specifications / High Altitude setup, see PVT Fuses 10A EFI 10A Key System chapter – Clutch Charts, page 5.3 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS 1.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 20: Rzr S 900 Specifications
740 lbs. / 336 kg Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 1.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 21 For clutch specifications / High Altitude setup, see PVT Fuses 10A EFI System chapter – Clutch Charts, page 5.3 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.) 1.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 22: Misc. Specifications And Charts
Step 2: 21 ft-lb (28 Nm) Step 3: Tighten add’n 90° Front Gearcase Cover 11 ft-lbs (15 Nm) Plate Screws 26 ft-lb (35 Nm) Crankcase Bolts M8 1.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 23 33 ft-lb (45 Nm) 4 ft-lb (5 Nm) Seat Fasteners (rear) Seat Frame Fasteners Transmission Rear Mount 14 ft-lb (19 Nm) 22 ft-lb (30 Nm) (front) Bracket Fasteners 1.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 24 7 ft-lb (10 Nm) (Apply Loctite® 204™ to bolt Water Pump Cover Bolts threads) Aluminum: 120 ft-lbs (163 Nm) Wheel Lug Nuts Steel: 60 ft-lb (81 Nm) 1.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 25: Conversion Table
π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 1.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 26: Standard Bolt Torque Specification
103 (140) 151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 27: Sae Tap / Drill Sizes
2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 1.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 28: Decimal Equivalents
17/32 0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 0.6094″ 39/64 0.625″ 16 mm = 0.6299″ 1.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 31: Periodic Maintenance Chart
▶ = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.
Page 32: Pre-Ride - 50 Hour Maintenance Interval
▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 33: 50 - 500 Hour Maintenance Interval
▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 34: Maintenance Quick Reference
Coolant Radiator bottle and radiator. * More often under severe use, such as operation in water or under severe loads. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 35 Add lubricant until it is visible at first Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 36: Grease Lubrication Points
Polaris All Season these areas. Bushings plate access holes on each side Grease *There is no grease point on the front upper control arm rear mount. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 37: General Vehicle Inspection And Maintenance
• Excessive gear lash (noise) shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will • Gear selector moving out of desired range require service. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 38: Fuel System
Refer to Chapter 4 for Fuel Pump Replacement, NOTE: Make sure vent line is not kinked or page 4.22 and all other information related to the EFI pinched. System. 2.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 39: Fuel Lines
The throttle pedal should move freely and always return to its idle state (no throttle) when released. Check throttle pedal periodically. 2.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 40: Engine System
2. Check the area for debris. 3. Pull cover rearward far enough to remove air filter . 3. Remove the air box cover and clean out any debris. 2.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 41: Air Box / Filter Assembly View
Air Box / Filter Assembly View Intake Airbox Hose Airbox Clips Drain Cap Vent Hose Airbox Intake Tubes Air Filter Engine Intake Housing Airbox Cover 2.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 42: Engine Oil Level
Access the oil fill cap through the cargo box access oil level within the SAFE range on dipstick. Do not panel. overfill (see NOTE below). Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. Recommended Engine Oil: PS-4 (PN 2876244) Ambient Temp Range: -35°...
Page 43: Engine Oil And Filter Change
5. Remove the seats and engine service panel to access the oil filter. Engine Oil Drain Plug: 12 ft-lbs (16 Nm) 2.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 44: Crankcase Breather Hose Inspection
2. Remove the engine access panel. panel and seats. 3. Remove eight screws retaining the outer clutch cover. 21. Dispose of used oil and filter properly. 2.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 45 The timing chain may jump teeth and 6. Remove the four T40 bolts retaining the valve cover. lead to poor performance. 9. Measure the valve clearance using a feeler gauge. 2.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 46 NOTE: The engine will misfire if the spark plug wires are installed incorrectly. The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder. 2.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 47: Transmission And Front Gearcase
9. Reinstall the drain plug and torque to specification. 3. If lubricant level is not even with bottom threads add recommended lubricant as needed. Do not overfill. 2.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 48: Front Gearcase Lubrication
1. Position vehicle on a level surface. 8. Clean the drain plug magnetic surface. 9. Reinstall the drain plug and torque to specification. 2.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 49 11. Reinstall the fill plug and torque to specification. Front Gearcase Fill / Drain Plug Torque: 10 ft-lbs (14 Nm) 12. Check for leaks. Dispose of used fluid properly. 2.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 50: Cooling System
Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2880514) (Quart) 5. Remove recovery bottle cap and add coolant using a funnel. (PN 2880513) (Gallon) 2.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 51: Cooling System Pressure Test
3. Check tightness and condition of all hose spring clamps. Replace if necessary. Recovery Bottle Engine Hoses Radiator Hoses To Thermostat Housing To Water Pump To Radiator 2.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 52: Radiator Inspection / Cleaning
MAX level. 8. Refer to Chapter 3 – Cooling System Bleeding, page 3.15. Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2880514) (Quart) (PN 2880513) (Gallon) 2.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 53: Pvt System
PVT system components for water damage. IMPORTANT: The PVT intake and exhaust ducts MUST be checked for debris in the event of a belt failure. 2.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 54: Final Drive / Wheel And Tire
4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 2.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 55: Tire Inspection
12 psi (83 kPa) RZR 900 10 psi (69 kPa) 12 psi (83 kPa) RZR XC 900 10 psi (69 kPa) 14 psi (97 kPa) RZR S 900 2.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 56: Electrical / Ignition System
NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging once a WARNING month to make up for normal discharge. Battery tenders can be left connected during the storage...
Page 58: Battery Installation
60 in-lb (7 Nm) 5. Connect and tighten the black (negative) cable (s) last. 6. Verify that cables are properly routed and reinstall the driver’s seat. 2.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 59: Spark Plug Service
4. Rinse plug wells with water and dry with compressed air. NOTE: Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 2.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 60: Steering System
(loose wheel nuts or loose front hub nut). • Refer to Chapter 7 “Final Drive” for front hub service procedures. 2.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 61: Wheel Toe Alignment Inspection
1/8 to 3/16" (3.2 to 4.8 mm) 4. Rotate the tires 180° to position by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line. 2.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 62: Wheel Toe Adjustment
• After alignment is complete, torque jam nuts to specification. Tie Rod Jam Nut: 14 ft-lbs (19 Nm) 2.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 63: Suspension System
Shock Spanner Wrench: PN 2877408 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 2.35 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 64: Shock Compression Adjustment (Fox)
(25.4 mm) over SETTING COMPRESSION DAMPING the factory setting. Full counter-clockwise position Softest FACTORY 12 clicks from closed Firmest 2 clicks from closed 2.36 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 65: Brake System
Brake Hose and Fitting Inspection Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 2.37 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 69: General Information
Valve Spring Compressor Adapter PV-43531 Oil Pressure Gauge PV-43570–1 Piston Ring Compressor Pliers PW-47053 Bench Mount Engine Stand Adapter Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 70: Main Engine Components - Torque Specification And Sequence
ENGINE / COOLING SYSTEM Main Engine Components - Torque Specification and Sequence 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 71: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
ENGINE / COOLING SYSTEM Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 72: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
ENGINE / COOLING SYSTEM Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 73: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
ENGINE / COOLING SYSTEM Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 74: Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
ENGINE / COOLING SYSTEM Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 76: Exhaust System
Spark Arrestor Fastener / 8 ft-lb (11 Nm) Head Pipe Bolts / 18 ft-lb (24 Nm) Muffler Shield Fasteners / 10 ft-lb (14 Nm) Push Rivet Muffler Rubber Mounts Muffler Exhaust Spring 3.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 77: Exhaust Removal / Installation
Exhaust Head Pipe Fasteners: 18 ft-lb (24 Nm) Body Screws: 8 ft-lb (11 Nm) Air Box Mounting Fasteners: 8 ft-lb (11 Nm) 3.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 78: Cooling System Specifications
If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, clamps and water pump seal for signs of leaking. 3.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 79: Thermostat Replacement
Tilt top of radiator outward and remove the radiator from the vehicle. 8. Separate the fan motor assembly from the radiator. Inspect fan blades for damage. 3.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 80 9. Install the thermostat cover bolts. Torque bolts to specification. Thermostat Cover Bolts: 7 ft-lb (10 Nm) 10. Install coolant hose back on the thermostat cover and securely tighten the hose clamp. 3.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 81: Cooling System Bleeding
13. Fill the recovery bottle to the MAX line. the radiator. 14. Reinstall the cargo box engine access panel and the 5. Remove the cargo box engine access panel. hood. 3.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 82: Water Pump Removal
5. Remove impeller from water pump shaft. 6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 3.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 83 (Apply Loctite® 204™ to bolt threads) 14. Rotate the water pump shaft after seal installation to verify free movement. 15. Place impeller onto the water pump shaft. 3.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 84: Water Pump Installation
NOTE: Always use NEW o-rings each time the water pump is removed. 3. Remove the shop towel from the water pump drive access hole in the engine block. 3.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 85 7. Slide water pump into engine crankcase. Be sure water pump is fully seated and the drive tab and slot are properly aligned. 3.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 86: Engine Service
Standard @ 1200 RPM: 60 PSI Minimum: 15 PSI 5. Upon assembly, torque the crankcase gallery plug to specification. Crankcase Gallery Plug: 11 ft-lb (15 Nm) 3.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 88: Engine Specifications
Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.0014" - 0.0026" (0.035 - 0.065 mm) 3.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 89 4.9527" ± 0.0078" (125.8 ± 0.2 mm) Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm) Balance Shaft Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm) 3.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 90: Accessible Engine Components
Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to the vehicle. 3.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 91: Fuel System
5. Remove the four screws mounting the ECU to the divider panel and disconnect the harness plugs from the ECU 8. Remove the five bolts retaining the frame support bar above the engine 3.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 94: Engine Installation
26. Remove the six engine-to-transmission mounting bolts. 27. Remove the four bolts retaining the engine to the front engine mount. 28. Remove the engine from the frame. 3.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 95 6. Install the positive and negative cables going to the starter. Torque fasteners to specification. Starter Cable Fasteners 30 in-lb (4 Nm) 3.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 96 Fuel Rail Mounting Fasteners 7 ft-lb (10 Nm) 13. Route the harness and install the three harness clamps on the intake manifold 3.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 97 Duct Clamp: 35 in-lb (4 Nm) Air Box Mounting Bolts: Ignition Coil Mounting Bolts: 8 ft-lb (11 Nm) 75 in-lb (9 Nm) 3.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 98 ECU to the divider panel. Torque screws to specification. ECU Mounting Screws: 24 in-lb (3 Nm) 25. Install the ECU cover panel and the seat. 3.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 99: Engine Break
CAUTION Battery Terminal Fasteners: Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic 60 in-lb (7 Nm) 4-Cycle Engine Oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
Page 100: Engine Disassembly / Inspection - Top End
. 3. Remove the spark plugs . Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber. 3.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 101: Camshaft Sprocket Inspection
, and remove the top bolt from the camshaft sprockets 6. Rotate the engine to allow access to the remaining bolt on each camshaft sprocket 3.35 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 102: Camshaft / Camshaft Bore Inspection
Service Limit: 1.5220" (38.66 mm) Exhaust: 1.4961" ± .0015" (38.00 ± .040 mm) Service Limit: 1.4925" (37.91 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 3.36 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 103: Cylinder Head Removal
NOT rotate the engine without using the Cylinder Service Limit: 0.9072" (23.044 mm) Holding & Camshaft Timing Plate (PU-50563). xrefRefer to “Cylinder / Piston Removal”. 3.37 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 104: Cylinder Head Inspection
If warp exceeds the service limit, replace the cylinder head. Cylinder Head Warp Limit: .0039" (0.10 mm) 3.38 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 105: Valve Inspection
7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 3.39 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 106: Combustion Chamber Cleaning
0.2165 - 0.2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTE: The valve guides cannot be replaced. 3.40 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 107: Valve Seat Reconditioning
75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface. 3.41 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 109 Exhaust Seat Cutter Diameter: 1.260″ (32.00 mm) Valve Seat Width: Intake: 0.039" (1.00 mm) Service Limit: 0.055" (1.4 mm) Exhaust: 0.059" (1.50 mm) Service Limit: 0.075" (1.9 mm) 3.43 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 110: Engine Disassembly / Inspection - Lower End
3. Inspect the condition of the stator windings output wires . If replacement is required, refer to Chapter 10. 4. Inspect the ball bearing that supports the starter motor shaft. 3.44 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 111: Water Pump Housing Removal
Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 3.45 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 112: Starter One-Way Clutch Disassembly
Grasp clutch gear and rotate clockwise. It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 3.46 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 113: Starter One-Way Clutch Assembly
5. If starter gear was replaced, inspect the torque limit 1. Install one-way clutch in clutch hub with flange of gear. clutch engaged in recess. 3.47 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 114: Crankcase Disassembly / Inspection
2. Remove the crankcase drain plug to drain any oil remaining in the engine. 7. Remove the sump cover from the crankcase. 3.48 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 116: Balance Shaft Removal / Inspection
17. Tap on the lower crankcase in reinforced areas with a soft faced hammer to loosen. Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 3.50 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 117: Crankshaft Removal / Inspection
4. Loosen, remove and discard the four connecting rod bolts . Remove the end caps from the crankshaft. 8. If the crankshaft gear is damaged, the crankshaft assembly must be replaced. 3.51 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 118 4.9527 ± .0078″ (125.8 ± 0.2 mm) MAG End PTO Rod Journal Main Journal 1 Main Journal 3 MAG Rod Journal Main Journal 4 Main Journal 2 PTO End 3.52 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 119 16. Whether installing a new crankshaft or re-installing the original, refer to the bearing selection chart provided in the “Crankshaft Main Bearing Selection” and “Connecting Rod Bearing Selection” procedures. 3.53 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 120: Crankcase Inspection
(see Chapter 3 – Engine Oil Flow Chart, page 3.21. NOTE: Always replace plain bearings when the crankcase connecting rods have been disassembled. Refer “Bearing Selection Chart”. 3.54 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 121: Cylinder / Piston Removal
.002" (0.05 mm) 2. Inspect cylinder for wear, scratches, or damage. NOTE: DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 3.55 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 122: Piston Disassembly / Inspection
DO NOT apply heat to piston rings or a loss of Standard Bore Size: radial tension could result. 3.6614 ± .0003" (93 mm ± .008 mm) 3.56 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 123: Piston Ring Removal
Remove top rail first, then bottom rail, then the expander. Piston Pin O.D.: 0.7872" - 0.7874" (19.995 - 20.000 mm) Service Limit: 0.7866" (19.98 mm) 3.57 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 124: Piston Ring To Groove Clearance Inspection
Oil Control Rails: .010 - .040" (.25 - 1.02 mm) Service Limit: .059" (1.50 mm) NOTE: Always check piston ring installed gap when installing new rings and/or a new cylinder. 3.58 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 125: Piston-To-Cylinder Clearance
(12 Nm) Step 2: 22 ft-lb (30 Nm) .0014 - .0026" (.035 - .065 mm) Step 3: Tighten add’n 90° prior to taking any measurements. 3.59 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 126 8. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided in the “Connecting Rod Bearing Selection” procedure in this chapter. 3.60 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 127: Engine Assembly - Lower End
Bearing Selection Identification Letters and Numbers Connecting Rod Bearing Identification Number (1 digit) Crankcase Bearing Identification Number (6 digits) Crankshaft Bearing Identification Letters (6 letters) 3.61 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 128: Connecting Rod Bearing Selection
Yellow bearing for Main #2 CRANKSHAFT Green bearing for Main #3 Code Yellow bearing for Main #4 Blue Blue Green Blue Green Yellow Green Yellow Yellow 3.62 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 129: Upper Crankcase Preparation
2. Install lower rail with end gap positioned on the intake side of piston 3. Install upper rail with end gap positioned on the exhaust side of piston 3.63 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 130: Piston / Connecting Rod Assembly
Do not compress the new clip more than necessary to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation. 3.64 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 131: Cylinder / Piston Installation
10. Carefully place the cylinder and pistons into the upper crankcase. NOTE: Orientation arrow is also located on the bottom side of piston as an additional reference. 3.65 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 132: Crankshaft Installation
(PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft & . Crankshaft Installation...
Page 133: Balance Shaft Installation
MAG end gear is visible. 12. Install matching rod cap on connecting rod using markings made upon disassembly. 4. Apply Polaris PS-4 engine oil to both balance shaft journals. 13. Install new bolts and tighten evenly until snug. 14. Torque connecting rod bolts to specification...
Page 134: Lower Crankcase Preparation
Lower Crankcase Preparation NOTE: Always replace plain bearings when the crankcase connecting rods have been 3. Apply Polaris PS-4 engine oil to the new bearings disassembled. Refer bearing selection installed in the lower crankcase half. procedures. 4. Clean crankcase mating surfaces to remove any oil.
Page 135 11. Rotate the engine so the cylinder is facing up. 12. Install the two M8 and eleven M6 upper crankcase bolts. Tighten all bolts lightly by hand. NOTE: Install new M10 lower crankcase bolts. 3.69 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 137 23. Install the thirteen M6 and three M8 bolts that 26. Rotate the engine so the cylinder is facing up. retain the oil sump cover to the crankcase. 3.71 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 138: Flywheel Installation
Flywheel Installation, page 3.72 and then Cylinder Head Installation, page 3.76. Flywheel Retaining Bolt: 133 ft-lbs (180 Nm) 6. Install the starter torque limit gear as an assembly. 3.72 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 139: Stator Cover Installation
/ installation process or injury could result. 3. Install stator cover and thirteen screws. Torque screws in sequence to specification. Stator Cover Screws: 9 ft-lb (12 Nm) 3.73 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 140: Engine Assembly - Top End
9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 3.74 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 141: Valve Sealing Test
3. Repeat for exhaust valves by pouring fluid into each exhaust port NOTE: Oil the tappet prior to installing. If any valve train components were replaced, refer to Valve Clearance Adjustment, page 3.82. 3.75 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 142: Cylinder Head Installation
Torque in sequence Step 1: 9 ft-lbs (12 Nm) Step 2: 26 ft-lb (35 Nm) Step 3: Additional 180° Step 4: M6 bolts: 7 ft-lb (10 Nm) 3.76 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 143: Camshaft Installation / Timing
Intake Camshaft - PN 1204583 Exhaust Camshaft - PN 1204584 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3.77 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 144 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 3.78 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 145 15. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 3.79 9925723 R01 - 2015 RZR 900 Service Manual...
Page 146 22. Torque the camshaft carriers bolts in sequence to specification. Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 23. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 3.80 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 147: Camshaft Timing - Quick Reference
Camshaft Timing - Quick Reference Intake Cam Align Exhaust Marks With Surface Exhaust Cam CPS Mounting Hole Align Intake Marks With Surface Align Flywheel Mark in Mounting Hole 3.81 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 148: Valve Clearance Adjustment
Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes should face out as shown. 3.82 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 150: Intake Valve Lash - Tappet Selection Matrix
0.926-0.950 520 522 525 528 530 532 535 538 540 542 545 0.951-0.975 522 525 528 530 532 535 538 540 542 545 0.976-1.000 525 528 530 532 535 538 540 542 545 3.84 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 151: Exhaust Valve Lash - Shim Selection Matrix
0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 3.85 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 152: Valve Cover Installation
6. Install the four valve cover shoulder bolts isolators using a T40 driver. 7. Torque valve cover bolts to specification. Valve Cover Bolts: 7 ft-lbs (10 Nm) 3.86 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 153: Troubleshooting
• Restricted breather Engine Idles But Will Not Accelerate • Air filter dirty or contaminated • Spark plug fouled/weak spark • Obstruction in air intake Low Compression 3.87 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 154 • Cooling fan inoperative or turning too slowly (perform current draw test) • Low oil level • Spark plug incorrect heat range • Faulty hot light circuit 3.88 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 157: General Information
Fasteners (lower) cable, USB serial adapter cable and Smartlink Intake Manifold to Engine 17 ft-lb (23 Nm) Module Kit) Fasteners Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 158: Efi Service Notes
• Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 159: Fuel System Assembly View
Fuel Level Sender Engine Coolant Temperature Sensor (ECT) Fuel Filter Throttle Body/Electronic Throttle Control (ETC) Fuel Supply Line Fuel Injectors TMAP Sensor Fuel Rail/Regulator Engine Coolant Temp Sensor 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 160: Fuel System Component Locations
Located on the top of the intake manifold, retained • Temperature and Manifold Absolute Pressure by the fuel rail. (TMAP) Sensor Located on top of the intake manifold 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 161 FUEL SYSTEM • Fuel Rail Located on top of the intake manifold. • Fuel Pump / Fuel Regulator / Fuel Sender Located under the passenger seat. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 162: Electronic Fuel Injection
4- stroke cycle. When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 163: Electronic Control Unit (Ecu)
For the purpose of troubleshooting, a known-good ECU requirements for the immediate operating conditions. from another Polaris RZR 900 of the same model and The ECU then sends output signals to set injector year may be used without system or engine component duration and ignition timing.
Page 164 ECU Mounting Screws: 24 in-lb (3 Nm) NOTE: Upon installing the ECU connectors, you should hear a “click” when the connectors are fully closed. 4.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 165: Fuel Injectors
Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 166: Fuel Injector Test
NOTE: Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation. 4.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 167 17. Reconnect the negative battery cable and reinstall the driver’s seat. 18. Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks. 4.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 168 20. Reinstall the breather into the air box and tighten the hose clamps retaining the air box to the throttle body assembly. 21. Reinstall the two screws retaining the air box assembly. 4.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 169: Fuel Tank
Fuel Tank Assembly View PFA Nut Preliminary Filter Fuel Sender Float Arm Fuel Tank Vent PFA Gasket (*replace if removed) Fuel Tank Assembly Fuel Pump/Regulator 4.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 170: Fuel Line Removal / Installation
4. Disconnect the fuel pump electrical harness 3. Pull on the fuel line to remove. 4. To install, verify the connections are clean and undamaged. 4.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 171 10. Remove the Torx screws and plastic rivets the console. Remove the console from the vehicle. retaining the block-off panel using a T40 Torx bit. 4.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 172: Fuel Tank Installation
7. Install fuel tank strap screw. Torque screw to specification. Fuel Tank Strap Screw: 8 ft-lbs (11 Nm) 8. Install center console and secure the shifter boot to the console. 4.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 173 13. Install both seats and test the fuel pump by turning the ignition key ON and listening for the fuel pump to activate. Check fuel line fittings for leaks. 4.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 174: Fuel Pump
• If the key switch is not promptly turned to the "start" position. • If the engine fails to start. 4.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 175: Fuel Pump Test
ECU operation by plugging in a known-good ECU of the same model. NOTE: If the pump still does not operate, replace the fuel pump assembly. 4.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 176: Fuel Pump Replacement
NOTE: Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 4.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 177 IMPORTANT: Failure to align the orientation marks may lead to interferences with the fuel level float arm and cause incorrect function. 4.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 178 23. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 24. Install the seat. 4.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 179: T-Map Sensor
4. Install the engine access cover. programming for determining the fuel and ignition requirements during engine operation. The T-MAP provides the ECU with engine load data. 4.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 180: Crankshaft Position Sensor (Cps)
If the sensor fails or becomes disconnected for any reason, the engine will stop running. CPS Resistance Specification: 1000Ω ± 10% 4.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 181: Cps Replacement
6. Torque CPS retaining bolt to specification. CPS Retaining Bolt: 9 ft-lb (12 Nm) 7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 4.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 182: Electronic Throttle Control (Etc) / Throttle Body
ETC housing to performed. If a problem is encountered, and you intake plenum. determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization. Use Digital Wrench® to perform all troubleshooting of this component.
Page 183 6. Reverse these steps for installation. Torque the ETC housing retaining bolts and intake boot clamp to specification. ETC Housing Retaining Bolts: 7 ft-lb (10 Nm) Intake Boot Clamp: 35 in-lb (4 Nm) 4.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 184: Pedal Position Sensor (Pps)
• Pedal fully depressed ≈ 99.6% The PPS is calibrated to the throttle pedal. If the PPS is faulty, the throttle pedal assembly must be replaced. 4.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 185: Efi Diagnostics
70° F (21° C) Room temperature Engine Temperature Coolant temperature 195° to 210° F (92° at the ECT sensor Cooling fan running to 99° C) 4.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 186 Active ECU control of the crank when key is turned to START Start Enable Driver start solenoid ECU is not grounding the start solenoid Inactive 4.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 187 On or Off Inactive AWD or 2WD mode How fast the transmission output Vehicle Speed — varies is turning (calculated to wheel speed) 4.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 188: Trouble Code Display (Etc)
5. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded. 4.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 189: Diagnostic Trouble Code Table
Driver Circuit Short to B+ P0265 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 4.35 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 190 Driver Circuit Open / Grounded P1515 Idle Air Control Valve (IAC) 520268 Driver Circuit Short to B+ P1519 M17; IAC Stepper Pin 3 Driver Circuit Grounded P1518 4.36 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 191 Cut Off (Level 1) ECU Monitoring of Injection Condition Exists 520289 P1543 Cut Off (Level 2) Controller Option Setting Not Out of Calibration 520290 P1544 Programmed 4.37 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 192 P0032 to High Source Voltage Below Normal or Shorted Oxygen Sensor Heater 1 520209 P0031 to Low Source Current below Normal or Open P0030 Circuit 4.38 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 193: Efi Troubleshooting
• Throttle cable incorrectly adjusted • Air Leaks, dirty injector • TMAP damaged (check with Digital Wrench®) • Tight valves (low compression or high leakdown) 4.39 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 194: Digital Wrench
NOTE: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
Page 195: Digital Wrench Software Version And Update
4. The Digital Wrench® portal website should appear in a new web browser. 5. Click on “Digital Wrench Version Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. NOTE: You must already have the current version installed before adding an update.
Page 196: Digital Wrench® Communication Errors
Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 4.42 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 197: Digital Wrench® Serial Number Location
Digital Wrench® Serial Number Location Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 4.43 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 198: Digital Wrench® Feature Map
Perform specialized testing and Run the Help System. adjustment functions service reports. Prints the current screen as a Open the ASSERT ASK form. formatted printout. 4.44 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 199: Ecu Replacement
(see 2. Connect SmartLink Module cables to PC and Chapter 4 – Digital Wrench® Updates, page 4.41. vehicle. See 3. Open the Digital Wrench® program. 4.45 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 200 7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 4.46 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 201 13. Enter or paste the Authorization Key in the box located on the Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 4.47 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 202: Polaris Mobile Digital Wrench (Pmdw)
• Rear facing camera with minimum 3.0 mega pixel resolution with auto/continuous focus • Video, Microphone and Voice-to-text capable • Internet Bluetooth wireless technology capable 4.48 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 204: General Information
(Apply 0.1 mL 9314177 Clutch Holding Wrench Loctite® 620™) PU-50518 Driven Clutch Compression Tool PU-50578 Spider Jam Nut Socket Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 205: Clutch Charts
(7044263) Meters (Feet) Black / 1800-3700 26-49 Black** (6000 - 12000) (1323271) (7044318) (7044263) **EBS Driven Spring has white letters on it that start with 210499... 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 206: Pvt System Overview
The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage.
Page 207: Driven Clutch Operation
PVT system changes engine load requirements by either the PVT area. This is especially critical on units upshifting or backshifting. subjected to frequent water forging. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 208: Pvt System Service
Bolt and Washer Screw Cover Assembly, Outer Screw O-Ring Nut, Nylok Drain Plug, Cover Bracket, Belt Screen Seal, Cover Hose, Air Outlet Screw Seal, Cover Cover Assembly 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 209: Pvt Disassembly
3. Remove the drive belt. (see Chapter 5 – Belt Removal, page 5.9) 4. Remove the Driven Clutch retaining bolt 5. Remove the Drive Clutch retaining bolt 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 210: Pvt Assembly
12 ft-lb (16 Nm) 7. Install the eight screws retaining the outer clutch cover. Torque screws to specification. Outer Clutch Cover Screws: 54 in-lb (5 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 211: Drive Belt
NOTE: Removal of left rear wheel or left rear shock is NOT necessary for belt replacement. 4. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 212: Belt Inspection
Chapter 3 Engine Break-In Period, page for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break- in period. 5.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 213: Drive Clutch Service
290 ft-lb (393 Nm) Cover Bushing (Apply 0.4 mL Loctite® 620™) Shift Weight Cover Bolt Cover Bolt 20 in-lb (2 Nm) 8 ft-lb (11 Nm) 5.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 214: Drive Clutch Disassembly
DO NOT reassemble the drive clutch without the limiter 3. Remove cover bolts evenly in a cross pattern and spacer. Belt life will be greatly reduced. remove cover plate. 5.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 215: Bearing Inspection
Part Number 7044263 Color Black / Red Free Length 3.219″ (81.76 mm) Spring Wire Diameter 0.177″ (4.50 mm) 5.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 216: Shift Weight Inspection
Button to Tower Clearance: 0.000-.012″ (.000-.304 mm) 2. Inspect the tower sheave surfaces that the buttons slide on. Replace the drive clutch if worn, damaged or cracked. 5.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 217: Spider Removal
2. Loosen and remove the spider (counterclockwise) using Clutch Spider Removal / Installation Tool (PN 2870341). Spider Removal / Installation Tool: 2870341 Clutch Holding Fixture: 2871358-A 5.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 218: Drive Clutch Inspection
5. Visually inspect the thrust washers for damage. Measure the thickness and compare to specification. Replace if worn or damaged. Thrust Washer Thickness: Standard: .030″ (.76 mm) Service Limit: .025″ (.64 mm) 5.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 219: Moveable Sheave Bushing Inspection
5020629 Bushing Removal /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 5.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 220 Piston Pin Puller: PN 2870386 seated. 18. Remove nut from puller rod and set aside. 3. Remove nut from puller rod and set aside. 19. Remove sheave from puller. 5.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 221: Drive Clutch Assembly
33. Turn clutch cover counterclockwise on puller rod until bushing is seated. 34. Remove nut from puller rod. Take installation tool and clutch cover off rod. 5.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 222 Socket (PU-50578). Torque jam nut to specification. Spider Jamb Nut: 250 ft-lb (339 Nm) (Apply 0.1 mL Loctite® 620™) in 90° apart to the threads of the spider jamb nut. 5.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 223 8 ft-lb (11 Nm) CAUTION DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 5.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 224: Driven Clutch Service (Ebs)
Snap Ring Spring Bearing Spider Insert Stationary Sheave Spider Dampener E-Clip Roller Washer Helix (Cam) Moveable Sheave Helix Screws Clutch Shaft 48 in-lb (5 Nm) 5.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 225: Clutch Disassembly
2. It is important to mark the position of the shaft, cam cover and sheave before disassembly or use the X’s on the components for reference. This will aid in assembly and maintains clutch balance. 5.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 226 NOTE: Spring is compression only and has no torsional wind. 9. Remove the clutch assembly from the holding tool. 10. Press out the spring pins in the inner sheave. 5.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 227 To replace the bearing, remove the snap ring from the end of the shaft and press the bearing off the shaft. 5.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 228: Bushing Service
Turn puller barrel for further tension if needed. 7. Turn clutch sheave counterclockwise until bushing is removed and sheave comes free. 5.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 229: Clutch Assembly
18. Remove nut (C) from puller rod and set aside. 19. Remove installation tool and clutch sheave from puller. 5.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 230 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 5.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 231 (helix) side down. Press down on the moveable sheave belt face with both hands and the helix will release. 5.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 232 PVT SYSTEM 15. Use a T25 Torx driver to install the four helix retaining screws and torque to specification. Helix Retaining Screws: 48 in-lb (5 Nm) 5.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 233: Driven Clutch Service (Non-Ebs)
Driven Clutch Assembly View (non-EBS) Stationary Sheave Moveable Sheave Thrust Washer Spring Roller Spring Cup Washer Retaining Ring Torx Screw E-clip 12 ft-lb (16 Nm) 5.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 234: Driven Clutch Disassembly
Note if there is a thrust washer between the sheaves. 6. Turn the compression tool handle counter-clockwise relieve spring pressure remove compressor tool from the clutch assembly. 5.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 235: Driven Clutch Assembly
Apply and hold downward pressure on the spring cup. Torque the retaining ring bolts to specification. Clutch Spring Retaining Ring Bolts: 12 ft-lb (16 Nm) 5. Install driven clutch assembly and drive belt. 5.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 236: Troubleshooting
Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 5.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 237 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 5.35 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 238: Overheating / Diagnosis
PVT system. full position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD Clutch malfunction. certified technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or Poor engine performance.
Page 240: General Information
Transmission Mount Bracket Fasteners 22 ft-lb (30 Nm) (rear) Transmission Mount 33 ft-lb (45 Nm) Isolator Bolt (rear) Transmission Snorkel 10 ft-lb (14 Nm) Tube Locking Screw 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 241: Transmission Mounting View
Step 4-7: 44 ft-lb (60 Nm) *See sequence in illustrations below *See sequence in illustrations below Transmission Isolator Fasteners Transmission Mount Bracket Fasteners 33 ft-lb (45 Nm) 22 ft-lb (30 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 243: Shift Cable Inspection
7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 244: Transmission Service
6. Remove the 22 cargo box mounting screws. 3. Loosen the clamp for the PVT intake. 4. Remove the four screws mounting the engine and PVT intake vents. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 245 Move the main harness out of the way towards the driver’s seat. 10. Disconnect the two fuel rail mounting bolts and move the fuel rail off to the driver’s side. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 246 15. Remove the stabilizer bar mounting bolt and nut from both sides. Discard nuts and replace with new upon assembly. Be careful not to stretch the brake line when pivoting the bearing carrier downward. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 247 25. Remove wire ties retaining harness transmission and mounts. 26. Remove the six engine-to-transmission mounting bolts. 22. Remove seven bolts retaining the inner clutch cover. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 248 Remove the mount assembly from upper control arm and the differential solenoid (if the vehicle. equipped) if there is trouble removing the transmission. 6.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 249: Transmission Installation
9. Loosely install the two longer bolts into left side mounting holes and two shorter bolts with washers into right side mounting holes. Rear Transmission Mount Bracket Fasteners: 22 ft-lb (30 Nm) 6.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 250 Step 4-7: 44 ft-lb (60 Nm) 12. Remove the clutch center distance tool. 13. Remove the spacer or support between the vehicle frame and engine. 6.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 251 Chapter (see Chapter 4 – ETC Replacement, page 4.28. 27. Install the rear bumper and cargo box as an assembly (see Chapter 5 – Rear Cargo Box / Fenders, page 10.10). 6.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 252: Transmission Disassembly
7. Remove the detent star . Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly. 8. Remove the spacer 6.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 253 Do not pry on case sealing surfaces. opposite side. Use only the designated pry points on the transmission. 6.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 254 Gear Cluster Disassembly 22. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 6.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 255 CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 6.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 257 When “Differential-Lock” is selected, power is removed from the electrical solenoid allowing the solenoid plunger 6.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 258: Planetary Differential Disassembly (Turf Mode Models Only)
Planetary Differential Bushing Replacement (Turf Mode Models Only), page 6.21. 2. Remove the six screws retaining the differential cover and remove the cover. 6.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 259: Planetary Differential Bushing Replacement (Turf Mode Models Only)
5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 6.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 261: Planetary Differential Assembly (Turf Mode Models Only)
4. Apply Loctite® 2760™ to cover screws. 5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification. Differential Cover Screws: 22 ft-lb (30 Nm) 6.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 263: Transmission Assembly / Snorkel Gear Backlash Procedure
NOTE: Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 6.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 264 'zero' backlash position, you should still be able to turn the snorkel shaft using your fingers, but it will feel rough and may have some tight spots. 6.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 265 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 6.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 266 Lift up on the shift shaft rail and move the rail assembly towards the shift drum to allow the shift fork ends to be installed into the shift drum. 6.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 267 28. Install the spacer and then the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 6.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 268 33. Install the sector cover and align the transmission case dowel with the alignment hole. Install and torque the bolts to specification. Sector Gear Cover Bolts: 12 ft-lb (16 Nm) 6.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 271 Spring, Compression, Detent Tube, Snorkel Sensor, Speed Cover, Sector Gears Bearing, Ball Case, RH Spring, Wave Case, LH Bracket, Wire Harness Drum, Shift Collar Sleeve, Input Shaft 6.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 272: Transmission Assembly View (Turf Mode Models)
TRANSMISSION TRANSMISSION ASSEMBLY VIEW (Turf Mode Models) 6.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 273 Shift Dog, Park Bearing, Plain 108. Bearing, Ball Gear, 44T Collar Sleeve, Input Shaft 109. Bearing, Ball Fork, Shift Bearing, Needle Cage Sprocket, 48T, 6-Face 6.35 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 274: Troubleshooting
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 6.36 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 276: General Information
Hub Castle Nut 110 ft-lbs (149 Tie Rod End Fastener 30 ft-lbs (41 Nm) + 90° Wheel Lug Nuts Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 277: Bearing Carrier
12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 278: Front Bearing Replacement
2. Support the bottom of the bearing carrier housing. CAUTION Ball Joint Pinch Bolts: 42 ft-lb (57 Nm) Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 279 Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 11. Rotate wheel and check for smooth operation. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 280: Rear Bearing Carrier Removal / Inspection
Do NOT hang the caliper by the brake like. Use wire or rope to hang the caliper to prevent brake line damage. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 281: Rear Carrier Bearing Replacement
6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race or bearing damage may occur. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 282: Rear Bearing Carrier Installation
Brake Caliper Mounting Bolts: 46 ft-lb (62 Nm) Rear Bearing Carrier Mounting Fasteners: 42 ft-lb (57 Nm) 3. Apply a small amount of anti-seize to the drive shaft splines. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 283 Steel: 60 ft-lb (81 Nm) 8. Rotate wheel and check for smooth operation. Bend both ends of the cotter pin around the end of the spindle. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 284: Drive Shaft
Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 7.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 285: Front Half Shaft Installation
3. Install drive shaft into the front bearing carrier. 4. Install the upper and lower ball joint ends into the front bearing carrier. 7.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 286: Rear Half Shaft Removal
5. Completely remove the four wheel nuts and the wheel. Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 11. Rotate wheel and check for smooth operation. 7.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 287: Rear Half Shaft Installation
9. With a quick, short jerk outward, remove the half shaft from the transmission. Bearing Carrier Mounting Fasteners: 42 ft-lb (57 Nm) 7.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 288: Drive Shaft / Cv Joint Handling Tips
• The drive shaft is not to be used as a lever arm to position other suspension components. • Never use a hammer or sharp tools to remove or to install boot clamps. 7.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 289: Outer Cv Joint / Boot Replacement
2. Remove the large end of the boot from the CV joint and slide the boot down the shaft. 3. Clean the grease from the face of the joint. 7.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 291: Inner Plunging Joint / Boot Replacement
3. Clean the grease from the face of the joint and place the drive shaft in a soft-jawed vise. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 293 Axle Boot Clamp Tool: PU-48951 into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. CV Boot Clamp Pliers: 8700226 7.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 295: Prop Shaft Installation
9. Install the center console. NOTE: Paint marks are applied to the front and rear prop shafts to aid in shaft alignment and installation. Reference these marks during installation. 7.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 296 Fill / Check Plug Roller Cage 10 ft-lbs (14 Nm) Roller Pinion Gear Spring Retainer Snap Ring Cover Plate Screws O-ring 11 ft-lbs (15 Nm) 7.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 297: All Wheel Drive Operation
Torsion Spring Operation: The torsion spring acts as a return mechanism to help disengage the coupling of 7.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 298: Awd Diagnosis
Should have a minimum of 11 Vdc. 3. If electrical tests are within specification, remove gearcase (see Chapter 7 – Front Gearcase Removal, page ) and inspect components. 7.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 299: Front Gearcase Removal
6. Remove the vent line from the front gearcase and plug vent line fitting. 7. Remove the four bolts securing the front gearcase to the frame. 7.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 300 4. Remove and inspect the armature plate. Refer to AWD Diagnosis, page 7.24 for detailed inspection process. 6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. 7.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 301 NOTE: Rollers are spring loaded. Take care not to allow them to fall out or lose them upon removal of the roll cage. 7.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 302 14. Inspect the roll cage assembly (B) sliding surfaces and H-springs. The sliding surfaces must be clean and free of nicks, burrs or scratches. If damaged, replace the roll cage assembly. 7.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 303: Front Gearcase Assembly
6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 4. Install the RH output hub into the gearcase housing. 7.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 304 11. Install a new O-ring on the cover plate assembly. NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 7.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 305: Front Gearcase Installation
Front Gearcase Mounting Bolts: 33 ft-lbs (45 Nm) 5. Install the vent line Cover Plate Screws: 11 ft-lbs (15 Nm) 7.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 306 Recommended Front Gearcase Fluid: Polaris Demand Drive (PN 2877922) (Quart) Capacity:≈ 7.5 oz. (222 mL) (fill on a level surface to bottom of threads on the fill hole) 7.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 307: Wheel Hubs
Steel: 60 ft-lb (81 Nm) Front Rim (Aluminum shown) Studs Retaining Ring Cotter Pin Castle Nut Sealed Bearing 110 ft-lbs (149 Nm) Bearing Carrier Cone Washer 7.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 308 Steel: 60 ft-lb (81 Nm) Rear Rim (Aluminum shown) Studs Retaining Ring Cotter Pin Castle Nut Sealed Bearing 110 ft-lbs (149 Nm) Bearing Carrier Cone Washer 7.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 310: General Information
Steering Wheel Nut 65 ft-lbs (88 Nm) Tilt Shock Bolts 7 ft-lb (10 Nm) Wheel Lug Nuts Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 311: Steering - General
Tie Rod End to Knuckle: 30 ft-lbs (41 Nm) + 90° Wheel Lug Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 312: Tie Rod Replacement
7. Install the wheel and four wheel nuts. Tighten lug nuts to specification. Wheel Lug Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 313: Steering Assembly (Non-Eps)
30 ft-lbs (41 Nm) + 90° Tie Rod Jam Nut Bushing Steering Shaft 14 ft-lbs (19 Nm) Shaft to Rack Fasteners Bearing Tie Rod End 48 ft-lb (65 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 314: Steering Wheel Removal (Non-Eps)
Be sure the lower washers and spacers are still 5. Refer to steps 11-16 of the Steering Shaft Bearing on the steering shaft. Replacement, page 8.6 procedure for installation. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 315 15. Wipe the pivot tube clean of any excess Loctite ® 16. Install steering wheel cap and field test steering operation. Pivot Tube Bolts: 40 ft-lb (54 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 316: Steering Assembly (Eps)
EPS Cover 16 ft-lbs (22 Nm) Pivot Fasteners EPS Mounting Bracket Tie Rod End 40 ft-lb (54 Nm) Bracket Fasteners Tilt Locking Shock 30 ft-lb (41 Nm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 317: Upper Steering Shaft Removal
8.10 shaft to the power steering unit 3. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 318: Steering Wheel Removal (Eps)
6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 8.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 319 IMPORTANT: Electronic Power Steering (EPS) units are programmed to be vehicle specific and are not interchangeable between product lines. 8.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 321: Power Steering Unit Installation
8.14 to complete the installation procedure. 3. Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts. 8.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 322: Upper Steering Shaft Installation
Pivot Tube Fasteners: 40 ft-lb (54 Nm) 3. Install the tilt shock and torque fastener to specification. Tilt Shock Fastener: 7 ft-lb (10 Nm) 8.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 323: Front Suspension
Shock Fasteners Lower A-arm 42 ft-lb (57 Nm) Ball Joint Fasteners Bushings 42 ft-lb (57 Nm) Control Arm Bolt Ball Joint 42 ft-lb (57 Nm) 8.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 324: Front Control Arm Replacement
Install upper ball joint pinch bolt into the bearing carrier and torque bolt to specification. Front Ball Joint Pinch Bolts: 42 ft-lb (57 Nm) 8.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 325 . Remove the lower control arm from the vehicle. 17. Examine A-arm bushings and pivot tube. Replace if worn. Discard hardware. 8.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 326: Ball Joint Removal
42 ft-lb (57 Nm) Front Caliper Mounting Bolts: 30 ft-lb (42 Nm) Wheel Nuts (Alum): Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 8.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 327: Front Stabilizer Bar Replacement (50
5. To install, reverse procedure and torque fasteners to specification Stabilizer Bar Link Fasteners: 40 ft-lb (54 Nm) Stabilizer Bar Mount Fasteners: 17 ft-lb (23 Nm) 8.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 328: Rear Suspension
Discard hardware. 6. If not replacing the A-arm, thoroughly clean the a-arm and pivot tubes. 5. Examine bushings and pivot tubes. Replace if worn. Discard hardware. 8.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 329: Rear Control Arm Installation
9. Install wheel and torque wheel nuts to specification. Stabilizer Linkage Fasteners: 40 ft-lbs (54 Nm) Shock Mounting Bolts: 42 ft-lb (57 Nm) Upper Rear Bearing Carrier Bolts: 42 ft-lb (57 Nm) 8.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 330: Rear Stabilizer Bar Replacement
6. Fully install the stabilizer bar, bushings, bracket and fasteners. Center stabilizer bar in the frame. Torque mounting fasteners to specification. Stabilizer Bar Mounting Bolts: 16 ft-lb (22 Nm) 8.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 331: Shocks / Springs
STEERING / SUSPENSION SHOCKS / SPRINGS Front Shock Assembly View Rear Shock Assembly View 50″ Model 50″ Model XC & 60″ Model XC & 60″ Model 8.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 332: Shock Removal / Installation
42 ft-lb (57 Nm) height distance as instructed in step 1. (see Shock Specifications (FOX), page 8.25 for factory settings. 6. Reinstall the shock onto the vehicle 8.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 333 0.750 x .100 Back Up 1.250 x .012 0.750 x .100 Back Up 1.570 x .128 Top Out 1.100 x .012 0.900 x .012 1.570 x .128 Top Out 8.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 334 1.350 x .015 1.230 x .082 Top Out 1.350 x .015 1.250 x .015 1.250 x .015 1.100 x .015 1.570 x .128 Top Out 8.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 335: Fox Shock Disassembly
6. Tap bearing cap removal tool up with dead blow hammer. 3. Once nitrogen pressure has been released, depress reservoir cap and remove retaining ring. Typically a valve shim can be used. 8.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 336 12. Using a 9/16” open end wrench and a 1/8” Hex Tee handle wrench, remove the bleed screw. 9. Remove retaining ring with a valve shim. 8.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 337 15. Remove the LSC using a 5/8” wrench. partially insert an old or used bearing assembly in the body ( This will prevent over tightening and deforming the body). 8.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 338 22. Clean body cap using a wire brush and pick. 23. Remove both retaining rings in the body cap using a sharp pick. 8.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 339 26. Place shock shaft assembly in clamp blocks and remove nut from non-BOC equipped shaft assembly. (Valving laid out in order removed from post.) 8.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 340 31. Note the side of the piston as it comes off the shock shaft. Compression side down. 32. Remove the piston bearing if it shows any signs of damage or wear. 8.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 341 40. Remove Loctite® residue from shock shaft. 38. Remove eyelet using an adjustable wrench or Body Cap socket (398-00-626). 41. Remove Jet/Check Valve with Hex T-handle wrench. 8.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 342 46. Remove dust boot. 44. Back out rebound adjuster with flat head screw driver. 47. Remove both retaining rings from the eyelet and press out bearing. 8.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 343 3. Remove dust seal from bearing cap. NOTE: If internal bearing is damaged, replace with complete bearing assembly. NOTE: On some models the seal may be in the bearing assembly. 8.35 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 344: Fox Shock Assembly
2. Press bearing into the eyelet using Bearing Press (803-00-569). 6. Insert spring. 3. Install second retaining ring. 7. Put the steel ball on the spring with a dab of shock oil. 8.36 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 345 14. Apply specified Loctite® two threads down and two threads wide 360° around shock shaft threads. 11. Place shock shaft in clamp blocks and insert needle into shock shaft. 8.37 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 346 20. Install U-Cup seal. 17. Install wiper seal in body cap (if equipped). 21. Install back-up washer. 18. Apply thin layer of shock oil to seal. 8.38 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 347 26. Place installation tool assembly on top of the piston tool. and push down to install bearing. 24. Install piston O-ring if applicable. NOTE: Bearing will be fully seated around piston when done correctly. 8.39 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 348 29. Apply a thin layer of float fluid to the threads, nut, or 32. Apply Loctite® primer to the body cap threads. BOC post and torque to 22 ft-lbs (30 Nm). 8.40 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 349 36. Place body in clamp blocks and torque body cap to 100 ft-lbs (136 Nm) using body cap socket. 40. Apply Loctite® to LSC screw (if equipped). 8.41 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 350 44. Thread down reservoir with strap wrench and torque to specification. 48. Ensure oil is 0.250″ above IFP and install bleed screw with O-ring. 8.42 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 351 56. Use IFP tool to push down on IFP and fully extend the shock shaft assembly. 52. Slowly compress the bearing assembly to release any air that may be trapped below the bearing assembly. 8.43 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 352 NOTE: Check for any leaks or faults in the shock absorber’s functionality. 63. Tap body cap into position. 60. Install reservoir cap and retaining ring. 8.44 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 355: General Information
Park Brake Pad Thickness Outboard - 0.250” (6.35 mm) 0.190" (4.83 mm) Park Brake Disc Thickness 0.175” - 0.185” (4.44 - 4.70 mm) 0.150" (3.81 mm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 356: Brake System Service Notes
HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.
Page 357: Brake System Assembly View
Brake Line Retainers 15 ft-lb (20 Nm) 35 in-lb (4 Nm) Master Cylinder Mounting Fasteners Rear Caliper Bolts 23 ft-lbs (31 Nm) 46 ft-lb (62 Nm) Master Cylinder 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 358: Master Cylinder
15 ft-lb (20 Nm) Master Cylinder Mounting Fasteners 23 ft-lbs (31 Nm) 2. After installing the foot brake check pedal free-play. Pedal free-play should not exceed .090″ (2.286 mm). 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 359: Brake Pedal
The difference in the two numbers will give you the free-play. Brake Pedal Free-play: 1/4-3/8″ (6.35-9.53 mm) 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 360: Brake Bleeding / Fluid Change
11. Install master cylinder reservoir cover. clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 361 Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 363: Parking Brake Inspection
4. Adjust the parking brake cable where it attaches to the caliper mount / shift cable bracket. The mount bracket is located on the right-hand side of the transmission. 9.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 365 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. Caliper Disassembly / Inspection NOTE: Refer to the “Electronic Parts Catalog” for parking brake caliper replacement parts information. 9.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 366 Parking Brake Caliper - Assembly Bolts: 37 ft-lb (50 Nm) 5. Ensure the parking brake assembly functions properly by actuating the lever. Install the mounting sleeves (D) before installation. 9.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 367: Parking Brake Disc
4. Install the new brake disc. Install the mounting bolt and flat washer. Torque the mounting bolt to specification. Parking Brake Disc Mounting Bolt: 14 ft-lb (20 Nm) 9.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 368: Front Brake Pads
Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 369: Front Pad Inspection
Use only new, clean pads. 3. Install caliper onto front hub and torque mounting bolts to specification. Front Caliper Mount Bolt: 30 ft-lb (42 Nm) 9.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 370: Brake Burnishing Procedure
Up to MAX line inside reservoir 7. Install wheel and torque wheel nuts to specification. Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 371: Front Caliper Service
Front Caliper Assembly View Socket Set Screw Pistons Bleeder Screw 48 in-lb (5 Nm) Caliper Mount Caliper Assembly Brake Pads Boots Brake Scraper Square O-Rings Bolts 9.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 372: Front Caliper Disassembly
NOTE: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 373: Front Caliper Inspection
Measure piston diameter and replace if damaged or worn beyond service limit. Front Caliper Piston O.D.: Std: 1.370″ (34.80 mm) Service Limit: 1.368″ (34.75 mm) 9.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 374: Front Caliper Assembly
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 375: Front Brake Disc
Service Limit: 0.170″ (4.32 mm) Brake Disc Thickness Variance Service Limit: 0.002″ (.051 mm) difference between measurements Brake Disc Runout: Service Limit: 0.010″ (0.254 mm) 9.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 376: Front Disc Replacement
If the brake drags, re-check assembly and disc on wheel hub. installation. 5. Install new brake disc bolts and torque to specification. Brake Disc Mounting Bolts: 18 ft-lb (24 Nm) 9.24 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 377: Rear Caliper / Brake Pads
7. Remove the inner brake pad. CAUTION When removing caliper, be careful not to damage brake line. Support caliper to avoid kinking or bending brake line. 9.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 378: Rear Brake Pad Inspection
Use only new clean pads. 3. Install the caliper and torque the new mounting bolts to specification. Rear Caliper Mount Bolt : 46 ft-lb (62 Nm) 9.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 379: Brake Burnishing Procedure
Up to MAX line inside reservoir 7. Install wheel and torque wheel nuts to specification. Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 380: Rear Caliper Service
REAR CALIPER SERVICE Rear Caliper Assembly View Socket Set Screw Pistons Bleeder Screw 48 in-lb (5 Nm) Boots Caliper Assembly Caliper Mount Square O-Rings Brake Pad 9.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 381: Rear Caliper Disassembly
2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit. Rear Caliper Piston O.D.: Standard: 1.500″ (38.10 mm) Service Limit: 1.498″ (38.05 mm) 9.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 382 . Be sure groove is clean and free of residue or brakes may drag upon assembly. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 383: Rear Brake Disc
Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications. Brake Disc Runout: Service Limit: 0.010″ (0.254 mm) 9.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 384 Inspect for fluid leaks and firm brakes. Make sure brakes do not drag when pedal is released. If the brakes drag, re-check assembly and installation. 9.32 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 385: Troubleshooting
If noise does not change when brake is applied check Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary 9.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 386: Poor Brake Performance
• Residue build up under caliper seals • Operator riding brakes Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.34 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 388: General Information
30 ft-lb (41 Nm) Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm) 8 ft-lbs (11 Nm) Skid Plate Fasteners 8 ft-lb (11 Nm) Visor Screws 10.2 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 389: Body Assembly Views
M10 x 1.5 x 20 Screw 40 ft-lb (54 Nm) M8 x 1.25 x 55 Screw 16 ft-lb (22 Nm) M6 x 1.0 x 25 Screw 8 ft-lb (11 Nm) 10.3 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 390: Doors
BODY / FRAME Doors Hinge Pin Door Panel 8 ft-lb (11 Nm) Door Frame Latch Release Latch Striker Latch 8 ft-lb (11 Nm) 10.4 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 391: Dash / Instruments
BODY / FRAME Dash / Instruments Instrument Cluster Headlight Switch Key Switch AWD Switch 12V Accessory Port Bezel 10.5 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 392: Hood / Front Body
Left Front Fender 8 ft-lb (11 Nm) Bolt Left Front Fender Flair (50″ model has smaller flair) 7 ft-lb (10 Nm) Screw Hood 8 ft-lb (11 Nm) 10.6 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 393: Chassis / Main Frame
Dash Frame 8 ft-lbs (11 Nm) Seat Frame Bolt (rear) Upper Frame Support 30 ft-lb (41 Nm) Frame Support Bracket Front Tiedown 22 ft-lb (30 Nm) 10.7 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 394: Seats
Plate Seat Latch Seat Latch Screw Spring 4 ft-lb (5 Nm) Shoulder Belt Seat Slider Lever Spring Lock Washer Seat Bottom Flat Washer Seat Back 10.8 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 395: Floor / Rocker Panels
Floor / Rocker Panels Upper Floor RH Rocker T27 Screw Push Rivots LH Rocker Console Cover U-Type Nuts Seat Belt Boot Block Off Flap Shifter Boot Lower Floor 10.9 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 396: Rear Cargo Box / Fenders
Bumper Bracket LH Fender T27 Torx Screws LH Fender Flair (50″ model has smaller flair) 8 ft-lb (11 Nm) Rear Bumper Plastic Rivets Cargo Box 10.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 398: Body Component Removal
4. Pull out on the front bumper to remove the bumper, headlights and radiator deflector as an assembly. 5. If replacing the front bumper, remove both headlights and the radiator deflector. 10.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 399: Rear Bumper Removal
2. Lift rear of hood and slide forward to disengage the front tabs and remove the hood from the vehicle. 10.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 400: Front Fender / Body Removal
NOTE: Do NOT let the reservoir hang by the hose. Use a wire or string to restrain the reservoir. 5. Remove the front fender. 10.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 401: Rocker Panel / Console / Floor
8. Remove the seven T-40 Torx screws on the cab side of cargo box. 5. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 10.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 402: Decals
2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 10.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 405: General Information
(K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 11.3 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 406: Instrument Cluster
NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 11.4 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 407 Hours Indicator - Illuminates when Hours are being displayed on the Information Display Mode Button - Used to move through the menu features. 11.5 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 408: Information Display Area
To reset the trip meter: 1. Toggle the MODE button to TRIP 1. Engine hours are logged anytime the engine is running. Total hours can not be reset. 11.6 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 409 Refer to “Units of Measurement” to change the format (Standard 12-hour / Metric-24 hour). To set the clock, follow these steps: 7. Toggle the MODE button until the odometer is displayed. 11.7 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 410 15. Press and hold the MODE button to save the setting LCD backlighting and icons will turn off. and advance to the next display option. 11.8 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 411: Diagnostic Mode
MIL will illuminate and blink in place of the check engine MIL. 2. Press and hold the MODE button to enter the diagnostics code menu. 11.9 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 412: Instrument Cluster Pinouts
Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input Fuel Level Sensor Ambient Air Temperature International Models Only Turn Signal Input, LH Turn Signal Input, RH 11.10 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 413: Switches
3. Install new brake switch. Torque brake switch to specifications. Brake Switch: 15 ft-lb (20 Nm) 4. Bleed the brake system. See Chapter 9 – BRAKE BLEEDING / FLUID CHANGE, page 9.8 11.11 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 414: Ignition (Key) Switch
• Turn the ignition key to START. There should be should be no continuity between any pins. continuity between switch pins A and B; C and D. 11.12 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 415: Awd/2Wd/Turf Switch (Models With Turf)
1 and 2; 4 and 5. 2. Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring. 11.13 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 416: Seat Belt Switch
RESISTANCE VALUE GEAR WHEN MEASURED AT POSITION SWITCH TERMINALS A AND B HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 11.14 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 417: Charging System
Voltage Regulator The regulator / rectifier is located in front of the left rear wheel. It is mounted behind the left panel divider. 11.15 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 418: Charging System "Break Even" Test
TEST 2: Resistance Value of Each Stator Leg to Ground 2. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 11.16 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 419 ‘leg’ of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3). 11.17 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 420: Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 11.18 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 421: Battery
4. Remove the battery hold-down bracket 6. Verify that cables are properly routed and reinstall the driver’s seat. 5. Lift the battery out of the vehicle. 11.19 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 422: Current Draw - Key Off
At 14 seconds into the test, check battery voltage. A good 12V battery will have at least 10.5 volts. If the reading is low, charge the battery and retest. 11.20 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 423: Battery Conductance Analyzer
Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries. Polaris MDX-610P Bosch PN: PU-50296 11.21 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 424: Lighting System
Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. Headlamp Replacement 11.22 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 425: Taillights
5. Install the front bumper as shown in Chapter 5 if previously removed. 6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlamp Adjustment” procedure as shown in this chapter. 11.23 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 426: Cooling System
(see Chapter 3 – Cooling System Bleeding, page 3.15). Refer to Chapter 3 and 10 for additional ECT sensor information. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). 11.24 9925723 R01 - 2015 RZR 900 Service Manual...
Page 427: Radiator Fan
ELECTRICAL Radiator Fan The radiator fan is located on the radiator, accessible through the hood access panel. 11.25 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 428: Starting System
Refer to the voltage drop tests on the starter system in 6. Torque upper starter mount screw to specification. this chapter. Voltage should not exceed 0.1 volts per connection 11.26 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 429: Starter Solenoid
12V power to reach the starter motor. NOTE: “ELECTRICAL SYSTEM BREAKOUTS: Starter-Interlock” provided in this chapter for starter solenoid operation. 11.27 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 430: Electronic Power Steering
ATV, RZR and RANGER product lines. NOTE: See Chapter 5 – Power Steering Unit Removal, page 8.10 for power steering unit removal and installation procedures. 11.28 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 431: Fuses / Relays
Red / Dark High side output to Orange / Black High side output to Green Chassis Splice Grey ECU controlled Orange / Black ECU controlled ground ground 11.29 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 432: Fuse / Circuit Breaker Circuits
Orange / White Power to Key Acc Splice Accessory – 10A Fuse WIRE COLOR FUNCTION Power from Solenoid B+ Orange / White Power to 12V Receptacle 11.30 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 433: Differential Circuit (Turf Models Only)
Turf Solenoid Driver (Turf Mode models only) The Turf Solenoid Driver is located between the clutch cover and the exhaust muffler. 11.31 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 435: Ignition Coil
(s), remove the other end of the lead (s) from the spark plug. 4. Install the new ignition coil and/or high tension lead (s). Ignition Coil Retaining Bolt: 75 in-lb (9 Nm) 11.33 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 445 Removal (front) ..........9.16 Brake Light Switch ..........11.11 Removal (rear) ........... 9.25 Brakes Camshaft Bleeding / Fluid Change........9.8 Specifications ............ 3.36 Brake Burnishing Procedure .......9.18, 9.27 IX.1 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 446 Ignition Coil............11.33 Cylinder Head Warp..........3.38 Service Notes ............ 11.3 Cylinder Removal ..........3.55 Special Tools ............. 11.3 Stator .............. 11.15 Terminal Block ..........11.32 IX.2 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 447 Test ..............4.21 Valve Sealing Test ..........3.75 Fuel System ............2.10 Valve Seat Reconditioning ........3.41 Component Locations........... 4.6 Engine Bearing Selection Identification....3.61 IX.3 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 448 Grease Points ............2.8 Covers and Ducting Components ......5.6 Transmission ..........2.19, 6.2 Disassembly ............5.7 Drive Belt Inspection........... 5.10 Drive Belt Installation .......... 5.10 IX.4 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 449 Upper Steering Shaft Installation ......8.14 Service .............. 2.31 Upper Steering Shaft Removal ......8.9 Special Tools............1.6 Wheel Free-play..........2.32 Brakes..............9.3 Steering / Suspension Electrical ............11.3 IX.5 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 450 Steering / Suspension........... 8.2 Removal ............3.16 Transmission ............6.2 Service .............. 3.16 Transmission Water Pump Housing Removal ....... 3.45 Assembly............6.25 Wheel Alignment ........... 2.33 IX.6 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.
Page 451 Wheel and Hub Torque Table ............2.26 Wheel Installation..........2.26 Wheel Removal..........2.26 Wheel Hub Assembly View (front)......... 7.33 Assembly View (rear).......... 7.34 IX.7 9925723 R01 - 2015 RZR 900 Service Manual © Copyright 2014 Polaris Industries Inc.

Polaris 2015 RZR 900 Service Manual

General Information Chapter 1 General Information

Maintenance Chapter 2 Maintenance

Engine / Cooling System Chapter 3 Engine / Cooling System

Fuel System Chapter 4 Fuel System

Pvt System Chapter 5 Pvt System

Transmission Chapter 6 Transmission

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris 2015 RZR 900

Summary of Contents for Polaris 2015 RZR 900