Polaris 2015 RZR 900 XC Edition Manuals

Manuals and User Guides for Polaris 2015 RZR 900 XC Edition. We have 5 Polaris 2015 RZR 900 XC Edition manuals available for free PDF download: Service Manual, Owner's Manual, Instructions Manual

Polaris 2015 RZR 900 XC Edition Service Manual (543 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 36.33 MB

Chapter 1 1 General Information

7
- Table of Contents
  7
- Vehicle Identification
  8
- Model Number Designation (2015 +)
  8
- Vehicle Identification Number (Vin) Designation (2015+)
  8
- Vehicle and Engine Serial Number Location
  9
- Misc. Information
  10
- Publication Numbers
  10
- Replacement Keys
  11
- Special Tools
  12
- General Specifications
  16
- 2015 Rzr 900 / Rzr 900 Eps Specifications
  16
- 2015 Rzr 900 XC Specifications
  18
- 2015 Rzr S 900 Specifications
  20
- Misc. Specifications and Charts
  34
- Master Torque Table
  34
- Conversion Table
  37
- Sae Tap / Drill Sizes
  38
- Metric Tap / Drill Sizes
  38
- Decimal Equivalents
  39
Maintenance Chapter 2 Maintenance 2

41
- Break-In Period
  43
- Maintenance
  43
- Maintenance Chart Key
  43
- Periodic Maintenance Chart
  43
- Periodic Maintenance Overview
  43
- Maintenance Intervals
  44
- Maintenance Quick Reference
  46
- Grease Lubrication Points
  48
- General Vehicle Inspection and Maintenance
  49
- Lubricants / Service Products
  49
- Pre-Ride / Daily Inspection
  50
- Shift Cable Inspection / Adjustment
  50
- Engine / Air Intake
  51
- Engine Air Filter Service
  51
- Intake Duct Inspection
  51
- Air Box / Filter Assembly View
  52
- Engine Oil Level
  53
- Engine Oil and Filter Change
  54
- Crankcase Breather Hose Inspection
  55
- Engine Cylinder Leak-Down Test
  55
- Valve Clearance Inspection
  55
- Coolant Level Inspection
  58
- Coolant Strength
  58
- Cooling System
  58
- Cooling System Overview
  58
- Cooling System Hose Inspection
  59
- Cooling System Pressure Test
  59
- Coolant Drain / Fill
  60
- Radiator Inspection / Cleaning
  60
- Fuel System
  61
- Fuel System Warning
  61
- Fuel Tank Vent Line
  61
- Fuel Lines
  62
- Fuel Pump / Fuel Filter
  62
- Throttle Pedal Inspection
  62
- Drive Clutch / Driven Clutch / Belt Service
  63
- Pvt Drying
  63
- Pvt Duct Cleaning
  63
- Pvt System
  63
- Drive Shaft Boot Inspection
  64
- Driveshaft / Wheel and Tire
  64
- Tire Inspection
  64
- Wheel and Hub Torque Table
  64
- Wheel Installation
  64
- Wheel Removal
  64
- Tire Pressure
  65
- Specification Chart
  66
- Transmission and Front Gearcase
  66
- Transmission Lubrication
  66
- Front Gearcase Lubrication
  67
- Steering Inspection
  68
- Steering System
  68
- Steering Wheel Free-Play
  68
- Tie Rod End / Wheel Bearing Inspection
  68
- Wheel Toe Adjustment
  69
- Wheel Toe Alignment Inspection
  69
- Spring Adjustment (Non-Fox)
  71
- Suspension System
  71
- Spring Adjustment (Fox)
  72
- Shock Compression Adjustment (Fox)
  73
- Brake Fluid Inspection
  74
- Brake Hose and Fitting Inspection
  74
- Brake Pad / Disc Inspection
  74
- Brake System
  74
- Battery Charging
  75
- Battery Maintenance
  75
- Battery off Season Storage
  75
- Electrical / Ignition System
  75
- Engine / Chassis Ground
  76
- Spark Plug Service
  76
Chapter 3 Engine / Cooling System

79
- Engine - General
  83
- General Information
  83
- Lubrication Specifications
  83
- Main Engine Components - Torque Specification and Sequence
  84
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
  85
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
  86
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
  87
- Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
  88
- Exhaust Assembly View / Torque Values
  89
- Exhaust System
  89
- Engine Cooling System
  90
- Exhaust Removal / Installation
  90
- Cooling System Pressure Test
  91
- Cooling System Specifications
  91
- Radiator Cap Pressure Test
  92
- Radiator Removal / Installation
  92
- Thermostat Replacement
  93
- Cooling System Bleeding
  94
- Water Pump Removal
  95
- Water Pump Service
  95
- Water Pump Installation
  99
- Engine Oil Pressure Test
  100
- Engine Service
  100
- Lubrication Specifications
  100
- Engine Oil Flow Chart
  101
- Accessible Engine Components
  102
- Engine Mounts
  102
- Engine Removal
  102
- Top End Service
  102
- Engine Installation
  106
- Engine Break
  111
- Engine
  112
- Troubleshooting
  112
- Cooling System
  113
- 900 Engine
  114
- Engine Specifications
  114
- Engine Specifications (900)
  114
- Camshaft Removal
  116
- Engine Disassembly / Inspection - Top End (900)
  116
- Valve Cover Removal
  116
- Camshaft / Camshaft Bore Inspection
  118
- Camshaft Sprocket Inspection
  118
- Cylinder Head Inspection
  120
- Cylinder Head Removal
  120
- Cylinder Head Warp Inspection
  120
- Cylinder Head Disassembly
  121
- Valve Inspection
  122
- Combustion Chamber Cleaning
  123
- Valve Seat Reconditioning
  123
- Engine Disassembly / Inspection - Lower End (900)
  127
- Stator Cover Removal / Inspection
  127
- Flywheel Removal
  128
- Water Pump Housing Removal
  128
- Starter One-Way Clutch Disassembly
  129
- Starter One-Way Clutch Assembly
  130
- Crankcase Disassembly
  131
- Balance Shaft Removal / Inspection
  133
- Crankshaft Removal / Inspection
  134
- Crankcase Inspection
  137
- Cylinder / Piston Removal
  138
- Cylinder Inspection
  138
- Piston Disassembly / Inspection
  139
- Piston Ring Removal
  140
- Piston Ring Installed Gap
  141
- Piston Ring to Groove Clearance Inspection
  141
- Connecting Rod Inspection
  142
- Piston-To-Cylinder Clearance
  142
- Bearing Selection Identification Letters and Numbers
  144
- Engine Assembly - Lower End (900)
  144
- Connecting Rod Bearing Selection
  145
- Crankshaft Main Bearing Selection
  145
- Piston Ring Installation
  146
- Upper Crankcase Preparation
  146
- Piston / Connecting Rod Assembly
  147
- Cylinder / Piston Installation
  148
- Crankshaft Installation
  149
- Balance Shaft Installation
  150
- Lower Crankcase Preparation
  151
- Crankcase Assembly
  152
- Flywheel Installation
  156
- Stator Cover Installation
  156
- Cylinder Head Assembly
  157
- Engine Assembly - Top End (900)
  157
- Valve Sealing Test
  158
- Cylinder Head Installation
  159
- Camshaft Installation / Timing
  160
- Camshaft Timing - Quick Reference
  164
- Valve Clearance Adjustment
  165
- Valve Lash - Tappet Selection
  168
- Valve Cover Installation
  169
- Engine Specifications (1000)
  170
- Camshaft Removal
  172
- Engine Disassembly / Inspection - Top End (1000)
  172
- Valve Cover Removal
  172
- Camshaft Sprocket Inspection
  174
- Camshaft / Camshaft Bore Inspection (1000)
  175
- Cylinder Head Removal
  176
- Cylinder Head Disassembly
  177
- Cylinder Head Warp Inspection
  177
- Valve Inspection
  178
- Combustion Chamber Cleaning
  179
- Valve Sealing Test
  180
- Valve Seat Reconditioning (1000)
  180
- Engine Disassembly / Inspection - Lower End (1000)
  183
- Stator Cover Removal / Inspection
  183
- Water Pump Housing Removal
  184
- Flywheel Removal
  185
- Starter One-Way Clutch Disassembly
  186
- Crankcase Disassembly / Inspection
  187
- Balance Shaft Removal / Inspection
  189
- Crankshaft Removal / Inspection
  190
- Crankcase Inspection
  192
- Cylinder Inspection
  193
- Cylinder / Piston Removal
  194
- Piston Disassembly / Inspection (1000)
  195
- Piston Ring Removal
  196
- Piston Ring to Groove Clearance Inspection
  196
- Connecting Rod Inspection
  197
- Piston Ring Installed Gap (1000)
  197
- Piston-To-Cylinder Clearance
  197
- Bearing Selection Identification Letters and Numbers
  199
- Engine Assembly - Lower End (1000)
  199
- Connecting Rod Bearing Selection
  200
- Crankshaft Main Bearing Selection
  200
- Piston Ring Installation
  201
- Upper Crankcase Preparation
  201
- Piston / Connecting Rod Assembly
  203
- Cylinder / Piston Installation
  204
- Crankshaft Installation
  205
- Balance Shaft Installation
  207
- Lower Crankcase Preparation
  207
- Crankcase Assembly
  208
- Starter One-Way Clutch Assembly
  211
- Flywheel Installation
  212
- Stator Cover Installation
  212
- Cylinder Head Assembly
  213
- Engine Assembly - Top End (1000)
  213
- Cylinder Head Installation
  214
- Camshaft Installation / Timing
  215
- Camshaft Timing - Quick Reference
  219
- Valve Clearance Adjustment
  220
- Valve Lash - Tappet Selection
  222
- Valve Cover Installation
  223
Chapter 4 Fuel System

225
- General Information
  227
- Special Tools
  227
- Torque Specifications
  227
- Efi Operation Overview
  228
- Efi Overview
  228
- Initial Priming / Starting Procedure
  228
- Principal Components
  228
- Ecu Replacement
  229
- Ecu Service
  229
- Electronic Control Unit (Ecu)
  229
- Operation Overview
  229
- Etc Learn Procedure
  230
- Fuel Injector Troubleshooting
  231
- Fuel Injectors
  231
- Operation Overview
  231
- Fuel Injector Replacement
  232
- Fuel Injector Test
  232
- Fuel Tank
  235
- Fuel Tank Assembly View
  235
- Fuel Line Removal / Installation
  236
- Fuel Tank Removal
  236
- Fuel Tank Installation
  238
- Fuel Pump
  240
- Fuel Pump Test
  240
- Fuel Sender Test
  240
- Operation Overview
  240
- Fuel Pump Replacement
  242
- Operation Overview
  245
- Temperature and Manifold Absolute Pressure Sensor (T-Map)
  245
- Tmap Test / Replacement
  245
- Cps Test
  246
- Crankshaft Position Sensor (Cps)
  246
- Operation Overview
  246
- Cps Replacement
  247
- Electronic Throttle Control (Etc) / Throttle Body
  248
- Etc Replacement
  248
- Etc Test
  248
- Throttle Body Operation Overview
  248
- Etc Learn Procedure
  249
- Operation Overview
  250
- Pedal Position Sensor (Pps)
  250
- Pps Location
  250
- Pps Replacement
  250
- Pps Test
  250
- Oxygen Sensor (Rzr S 1000)
  252
- Oxygen Sensor Information
  252
- Oxygen Sensor Replacement
  252
- Data Display Definitions
  254
- Efi Diagnostics
  254
- Trouble Code Display (Dtc)
  257
- Efi Troubleshooting
  264
- Digital Wrench® Diagnostic Software Overview
  265
- Polaris Digital Wrench
  265
- Special Tools (Digital Wrench)
  265
- Digital Wrench Software Version and Update
  266
- Digital Wrench® Updates
  266
- Digital Wrench® - Diagnostic Connector
  267
- Digital Wrench® Communication Errors
  267
- Guided Diagnostics
  267
- Digital Wrench® Serial Number Location
  268
- Digital Wrench® Feature Map
  269
- Ecu Replacement
  270
- Ecu Reprogramming (Reflash)
  270
- Etc Learn Procedure
  270
- Polaris Mobile Digital Wrench (Pmdw)
  273
Chapter 5 Pvt System

275
- General Information
  277
- Special Tools
  277
- Torque Specifications
  277
- Clutch Charts
  278
- Drive Clutch Operation
  279
- General Operation
  279
- Pvt Break-In (Drive Belt / Clutches)
  279
- Pvt System Overview
  279
- Driven Clutch Operation
  280
- Maintenance / Inspection
  280
- Pvt Covers and Ducting Components
  281
- Pvt System Service
  281
- Rzr 4 900 / S 1000 Pvt Covers and Ducting Components
  282
- Pvt Disassembly
  283
- Pvt Assembly
  284
- Belt Removal (Ebs)
  285
- Drive Belt
  285
- Belt Removal (Non-Ebs)
  286
- Belt Inspection
  287
- Belt Installation (Ebs)
  287
- Belt Installation (Non-Ebs)
  287
- Pvt Break-In (Drive Belt / Clutches)
  288
- Drive Clutch Assembly View
  289
- Drive Clutch Service
  289
- Drive Clutch Disassembly
  290
- Bearing Inspection
  291
- Button to Tower Clearance
  292
- Shift Weight Inspection
  292
- Roller, Pin and Thrust Washer Inspection
  293
- Spider Removal
  293
- Drive Clutch Inspection
  294
- Bushing Service
  295
- Moveable Sheave Bushing Inspection
  295
- Drive Clutch Assembly
  297
- Driven Clutch Disassembly
  300
- Driven Clutch Service (Ebs)
  300
- Driven Clutch Slider Inspection
  300
- Driven Clutch Bushing Service
  302
- Clutch Bushing Removal
  303
- Clutch Bushing Installation
  304
- Driven Clutch Assembly
  305
Chapter 6 Transmission

317
- General Information
  318
- Transmission Mounting View
  319
- Shift Cable Inspection
  320
- Shift Lever / Cable
  320
- Shift Lever Installation
  320
- Shift Lever Removal
  320
- Shift Cable Adjustment
  321
- Transmission Removal
  322
- Transmission Service
  322
- Transmission Installation
  326
- Transmission Disassembly
  330
- Differential Operation
  334
- Planetary Differential Disassembly (Turf Mode Models Only)
  337
- Planetary Differential Bushing Replacement (Turf Mode Models Only)
  338
- Planetary Differential Assembly (Turf Mode Models Only)
  340
- Gear / Shaft / Bearing Inspection
  342
- Transmission Assembly / Snorkel Gear Backlash Procedure
  343
- Transmission Assembly View (no Turf Mode)
  349
- Transmission Assembly View (Turf Mode Models)
  351
- Shifting Difficulty
  353
- Troubleshooting
  353
Chapter 7 Final Drive

355
- Bearing Carrier
  357
- Front Bearing Carrier Removal / Inspection
  357
- Front Bearing Carrier Installation
  358
- Front Bearing Replacement
  358
- Rear Bearing Carrier Removal / Inspection
  360
- Rear Carrier Bearing Replacement
  361
- Rear Bearing Carrier Installation
  362
- Drive Shaft
  364
- Front Half Shaft Removal
  364
- Front Half Shaft Installation
  365
- Rear Half Shaft Removal
  366
- Rear Half Shaft Installation
  367
- Drive Shaft / CV Joint Handling Tips
  368
- Outer CV Joint / Boot Replacement
  368
- Inner Plunging Joint / Boot Replacement
  371
- Prop Shaft Removal
  373
- Prop Shaft Installation
  374
- Rear Prop Shaft Removal (4 Seater)
  375
- Rear Prop Shaft Installation (4 Seater)
  376
- All Wheel Drive Operation
  377
- Front Gearcase / Centralized Hilliard
  377
- Front Gearcase Assembly View
  377
- Awd Diagnosis
  378
- Front Gearcase Disassembly / Inspection
  379
- Front Gearcase Removal
  379
- Front Gearcase Assembly
  383
- Front Gearcase Installation
  385
- Front Hub Assembly View
  387
- Wheel Hubs
  387
- Rear Hub Assembly View
  388

Polaris 2015 RZR 900 XC Edition Service Manual (457 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 37.03 MB

General Information Chapter 1 General Information

7
- Table of Contents
  7
- Chapter 1
  8
- Model Number Designation
  8
- Vehicle Identification
  8
- Vehicle Identification Number (Vin) Designation (2015+)
  8
- Vehicle and Engine Serial Number Location
  9
- Misc. Information
  10
  - Publication Numbers
    10
  - Replacement Keys
    11
  - Special Tools
    12
- General Specifications
  16
- Misc. Specifications and Charts
  22
  - Master Torque Table
    22
  - Conversion Table
    25
  - Standard Bolt Torque Specification
    26
  - Metric Bolt Torque Specification
    26
  - Sae Tap / Drill Sizes
    27
  - Metric Tap / Drill Sizes
    27
  - Decimal Equivalents
    28
Maintenance Chapter 2 Maintenance

29
- Break-In Period
  31
- Chapter 2
  31
- Maintenance Chart Key
  31
- Periodic Maintenance Chart
  31
- Periodic Maintenance Overview
  31
- Pre-Ride - 50 Hour Maintenance Interval
  32
- 50 - 500 Hour Maintenance Interval
  33
- Maintenance Quick Reference
  34
- Grease Lubrication Points
  36
- General Vehicle Inspection and Maintenance
  37
  - Pre-Ride / Daily Inspection
    37
  - Shift Cable Inspection / Adjustment
    37
- Fuel System
  38
  - Fuel Tank Vent Line
    38
  - Fuel Pump / Fuel Filter
    38
  - Fuel Lines
    39
  - Throttle Pedal Inspection
    39
- Engine System
  40
  - Engine Air Filter Service
    40
  - Intake Duct Inspection
    40
  - Air Box / Filter Assembly View
    41
  - Engine Oil Level
    42
  - Engine Oil and Filter Change
    43
  - Crankcase Breather Hose Inspection
    44
  - Engine Cylinder Leak-Down Test
    44
  - Valve Clearance Inspection
    44
- Transmission and Front Gearcase
  47
  - Specification Chart
    47
  - Transmission Lubrication
    47
  - Front Gearcase Lubrication
    48
- Cooling System
  50
  - Cooling System Overview
    50
  - Coolant Strength
    50
  - Coolant Level Inspection
    50
  - Maintenance
    50
  - Cooling System Pressure Test
    51
  - Cooling System Hose Inspection
    51
  - Radiator Inspection / Cleaning
    52
  - Coolant Drain / Fill
    52
- Pvt System
  53
  - Drive Clutch / Driven Clutch / Belt Service
    53
  - Pvt Duct Cleaning
    53
  - Pvt Drying
    53
- Final Drive / Wheel and Tire
  54
  - Drive Shaft Boot Inspection
    54
  - Wheel and Hub Torque Table
    54
  - Wheel Removal
    54
  - Wheel Installation
    54
  - Transmission
    54
  - Tire Inspection
    55
  - Tire Pressure
    55
- Electrical / Ignition System
  56
  - Battery Maintenance
    56
  - Battery off Season Storage
    56
  - Battery Charging
    57
  - Battery Removal
    57
  - Battery Installation
    58
  - Engine / Chassis Ground
    58
  - Spark Plug Service
    59
  - Electrical
    59
- Steering System
  60
  - Steering Inspection
    60
  - Steering Wheel Free-Play
    60
  - Tie Rod End / Wheel Hub Inspection
    60
  - Final Drive
    60
  - Wheel Toe Alignment Inspection
    61
  - Wheel Toe Adjustment
    62
- Suspension System
  63
- Brake System
  65
Engine / Cooling System Chapter 3 Engine / Cooling System

67
- Chapter 3
  69
- General Information
  69
- Lubrication Specifications
  69
- Special Tools
  69
- Main Engine Components - Torque Specification and Sequence
  70
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
  71
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
  72
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
  73
- Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
  74
- Exhaust System
  76
  - Exhaust Assembly View / Torque Values
    76
  - Exhaust Removal / Installation
    77
- Engine Cooling System
  77
  - Cooling System Specifications
    78
  - Cooling System Pressure Test
    78
  - Radiator Cap Pressure Test
    78
  - Radiator Removal / Installation
    78
  - Thermostat Replacement
    79
  - Cooling System Bleeding
    81
  - Water Pump Removal
    82
  - Water Pump Service
    82
  - Water Pump Installation
    84
- Engine Service
  86
  - Lubrication Specifications
    86
  - Engine Oil Pressure Test
    86
  - Engine Oil Flow Chart
    87
  - Engine Specifications
    88
  - Accessible Engine Components
    90
  - Top End Service
    90
  - Engine Mounts
    90
  - Engine Removal
    90
  - Fuel System
    91
  - Engine Installation
    94
  - Engine Break
    99
- Engine Disassembly / Inspection - Top End
  100
  - Valve Cover Removal
    100
  - Camshaft Removal
    100
  - Camshaft Sprocket Inspection
    101
  - Camshaft / Camshaft Bore Inspection
    102
  - Cylinder Head Removal
    103
  - Cylinder Head Inspection
    104
  - Cylinder Head Warp Inspection
    104
  - Cylinder Head Disassembly
    104
  - Valve Inspection
    105
  - Combustion Chamber Cleaning
    106
  - Valve Seat Reconditioning
    107
- Engine Disassembly / Inspection - Lower End
  110
  - Stator Cover Removal / Inspection
    110
  - Water Pump Housing Removal
    111
  - Flywheel Removal
    111
  - Starter One-Way Clutch Disassembly
    112
  - Starter One-Way Clutch Assembly
    113
  - Crankcase Disassembly / Inspection
    114
  - Balance Shaft Removal / Inspection
    116
  - Crankshaft Removal / Inspection
    117
  - Crankcase Inspection
    120
  - Cylinder / Piston Removal
    121
  - Cylinder Inspection
    121
  - Piston Disassembly / Inspection
    122
  - Piston Ring Removal
    123
  - Piston Ring to Groove Clearance Inspection
    124
  - Piston Ring Installed Gap
    124
  - Piston-To-Cylinder Clearance
    125
  - Connecting Rod Inspection
    125
- Engine Assembly - Lower End
  127
  - Bearing Selection Identification Letters and Numbers
    127
  - Connecting Rod Bearing Selection
    128
  - Crankshaft Main Bearing Selection
    128
  - Upper Crankcase Preparation
    129
  - Piston Ring Installation
    129
  - Piston / Connecting Rod Assembly
    130
  - Cylinder / Piston Installation
    131
  - Crankshaft Installation
    132
  - Balance Shaft Installation
    133
  - Lower Crankcase Preparation
    134
  - Crankcase Assembly
    134
  - Flywheel Installation
    138
  - Stator Cover Installation
    139
- Engine Assembly - Top End
  140
  - Cylinder Head Assembly
    140
  - Valve Sealing Test
    141
  - Cylinder Head Installation
    142
  - Camshaft Installation / Timing
    143
  - Camshaft Timing - Quick Reference
    147
  - Valve Clearance Adjustment
    148
  - Intake Valve Lash - Tappet Selection Matrix
    150
  - Exhaust Valve Lash - Shim Selection Matrix
    151
  - Valve Cover Installation
    152
- Troubleshooting
  153
  - Engine / Cooling System
    153
Fuel System Chapter 4 Fuel System

155
- Chapter 4
  157
- General Information
  157
- Special Tools
  157
- Torque Specifications
  157
- Efi Service Notes
  158
- Fuel System Assembly View
  159
- Fuel System Component Locations
  160
- Electronic Fuel Injection
  162
  - Principal Components
    162
  - Efi Operation Overview
    162
  - Initial Priming / Starting Procedure
    162
- Electronic Control Unit (Ecu)
  163
  - Operation Overview
    163
  - Ecu Service
    163
  - Ecu Replacement
    163
- Fuel Injectors
  165
  - Operation Overview
    165
  - Fuel Injector Troubleshooting
    165
  - Fuel Injector Test
    166
  - Fuel Injector Replacement
    166
- Fuel Tank
  169
  - Fuel Tank Assembly View
    169
  - Fuel Line Removal / Installation
    170
  - Fuel Tank Removal
    170
  - Fuel Tank Installation
    172
- Fuel Pump
  174
  - Operation Overview
    174
  - Fuel Sender Test
    174
  - Fuel Pump Test
    175
  - Fuel Pump Replacement
    176
- T-Map Sensor
  179
  - Operation Overview
    179
  - Tmap Test / Replacement
    179
- Crankshaft Position Sensor (Cps)
  180
  - Operation Overview
    180
  - Cps Test
    180
  - Cps Replacement
    181
- Electronic Throttle Control (Etc) / Throttle Body
  182
  - Throttle Body Operation Overview
    182
  - Etc Test
    182
  - Etc Replacement
    182
- Pedal Position Sensor (Pps)
  184
  - Operation Overview
    184
  - Pps Location
    184
  - Pps Test
    184
  - Pps Replacement
    184
- Efi Diagnostics
  185
  - Data Display Definitions
    185
  - Trouble Code Display (Etc)
    188
  - Diagnostic Trouble Code Table
    189
  - Efi Troubleshooting
    193
- Digital Wrench
  194
Pvt System Chapter 5 Pvt System

203
- Chapter 5
  204
- General Information
  204
- Special Tools
  204
- Torque Specifications
  204
- Clutch Charts
  205
- Pvt System Overview
  206
  - General Operation
    206
  - Drive Clutch Operation
    206
  - Driven Clutch Operation
    207
  - Maintenance / Inspection
    207
- Pvt System Service
  208
  - Pvt Disassembly
    209
  - Pvt Assembly
    210
- Drive Belt
  211
  - Belt Removal
    211
  - Belt Inspection
    212
  - Belt Installation
    212
  - Pvt Break-In (Drive Belt / Clutches)
    212
- Drive Clutch Service
  213
  - Drive Clutch Assembly View
    213
  - Drive Clutch Disassembly
    214
  - Bearing Inspection
    215
  - Shift Weight Inspection
    216
  - Button to Tower Clearance
    216
  - Spider Removal
    217
  - Roller, Pin and Thrust Washer Inspection
    217
  - Drive Clutch Inspection
    218
  - Moveable Sheave Bushing Inspection
    219
  - Bushing Service
    219
  - Drive Clutch Assembly
    221
- Driven Clutch Service (Ebs)
  224
  - Assembly View
    224
  - Clutch Disassembly
    225
  - Bushing Service
    228
  - Clutch Assembly
    229
- Driven Clutch Service (Non-Ebs)
  233
  - Driven Clutch Assembly View (Non-Ebs)
    233
  - Driven Clutch Disassembly
    234
  - Driven Clutch Assembly
    235
- Troubleshooting
  236
  - Pvt Troubleshooting
    236
  - Overheating / Diagnosis
    238
Transmission Chapter 6 Transmission

239
- Chapter 6
  240
- General Information
  240
- Lubrication Specifications
  240
- Special Tools
  240
- Torque Specifications
  240
- Transmission Mounting View
  241
- Shift Lever / Cable
  242
  - Shift Lever Removal
    242
  - Shift Lever Installation
    242
  - Shift Cable Inspection
    243
  - Shift Cable Adjustment
    243
- Transmission Service
  244
- Troubleshooting
  274
  - Shifting Difficulty
    274
Final Drive Chapter 7 Final Drive

275
- Chapter 7
  276
- General Information
  276
- Special Tools
  276
- Torque Specifications
  276
- Bearing Carrier
  277
- Drive Shaft
  284
  - Front Half Shaft Removal
    284
  - Front Half Shaft Installation
    285
  - Rear Half Shaft Removal
    286
  - Rear Half Shaft Installation
    287
  - Drive Shaft / CV Joint Handling Tips
    288
  - Outer CV Joint / Boot Replacement
    289
  - Inner Plunging Joint / Boot Replacement
    291
  - Prop Shaft Removal
    294
  - Prop Shaft Installation
    295
  - All Wheel Drive Operation
    297
  - Awd Diagnosis
    298
  - Front Gearcase Removal
    299
  - Front Gearcase Disassembly / Inspection
    299
  - Front Gearcase Assembly
    303
  - Front Gearcase Installation
    305
- Wheel Hubs
  307
  - Front Hub Assembly View
    307
Steering / Suspension Chapter 8 Steering / Suspension

309
- Chapter 8
  310
- General Information
  310
- Special Tools
  310
- Torque Specifications
  310
- Steering - General
  311
  - Steering Rack Replacement
    311
  - Tie Rod Replacement
    312
- Steering Assembly (Non-Eps)
  313
  - Steering Assembly View
    313
  - Steering Wheel Removal (Non-Eps)
    314
  - Steering Shaft Removal (Non-Eps)
    314
  - Steering Shaft Bearing Replacement
    314
- Steering Assembly (Eps)
  316
  - Steering Assembly View (Eps)
    316
  - Upper Steering Shaft Removal
    317
  - Steering Wheel Removal (Eps)
    318
  - Power Steering Unit Removal
    318
  - Lower Steering Shaft Removal
    320
  - Lower Steering Shaft Installation
    320
  - Power Steering Unit Installation
    321
  - Upper Steering Shaft Installation
    322
- Front Suspension
  323
  - Front Suspension Assembly View
    323
  - Front Control Arm Replacement
    324
  - Ball Joint Removal
    326
  - Ball Joint Installation
    326
  - Front Stabilizer Bar Replacement (50
    327
- Rear Suspension
  328
  - Rear Control Arm Removal
    328
  - Rear Control Arm Installation
    329
  - Rear Stabilizer Bar Replacement
    330
- Shocks / Springs
  331
  - Front Shock Assembly View
    331
  - Rear Shock Assembly View
    331
  - Shock Removal / Installation
    332
  - Shock / Spring Replacement
    332
  - Fox Shock Disassembly
    335
  - Fox Shock Assembly
    344

Polaris 2015 RZR 900 XC Edition Owner's Manual (154 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 4.28 MB

Table of Contents
5
Introduction
6
- Vehicle Identification Numbers
  8
Safety
9
- Safe Riding Gear
  10
- Operating Without Instruction
  16
- Safety Warnings
  16
  - Using Alcohol or Drugs
    16
  - Protective Apparel
    17
- Seat Belts
  17
- Operating on Pavement
  19
- Operating on Public Roads
  19
- Operating at Excessive Speeds
  19
- Descending Hills Improperly
  20
- Jumps and Stunts
  20
- Turning Improperly
  20
- Improper Hill Climbing
  20
- Crossing Hillsides
  21
- Stalling While Climbing a Hill
  21
- Operating in Unfamiliar Terrain
  21
- Improper Tire Maintenance
  22
- Skidding or Sliding
  22
- Operating a Damaged Vehicle
  23
- Improper Cargo Loading
  24
- Exposure to Exhaust
  25
- Hot Exhaust Systems
  25
- Equipment Modifications
  26
- Component Locations
  27
Features and Controls
27
- Auxiliary Outlets
  28
- Ignition Switch
  28
- Headlight Switch
  29
- Seat Removal
  30
- Steering Wheel
  30
  - Cargo Box Access Panel
    33
  - Fuel Cap
    33
- Service Access Panels
  33
  - Seat Belt Inspection
    35
  - Gear Selector
    36
  - Brake Pedal
    37
- Throttle Pedal
  37
  - Engaging Awd
    38
  - Disengaging Awd
    39
  - Instrument Cluster
    40
- Mode Button
  40
- Indicator Lamps
  41
- Rider Information Center
  42
- Clock Mode
  45
- Engine Error Codes
  48
- Instrument Cluster
  48
Operation
49
- Brake System Break-In
  50
- Vehicle Break-In Period
  50
- Safe Operation Practices
  52
- Starting the Engine
  53
- Stopping the Engine
  53
- Parking the Vehicle
  54
- Trail Etiquette
  54
- Driving with Passengers
  57
- Driving on Slippery Surfaces
  58
- Driving Uphill
  59
- Driving Downhill
  61
- Driving through Water
  62
- Driving over Obstacles
  63
- Driving in Reverse
  64
- Parking on an Incline
  65
- Hauling Cargo
  66
- Belt Life
  67
Winch Guide
69
- Winch Safety Precautions
  70
- Winch Operation
  72
- Winch Cable Care
  77
- Winch Maintenance and Service Safety
  79
- Crankcase Emission Control System
  80
Emission Control Systems
80

Polaris 2015 RZR 900 XC Edition Owner's Manual (160 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 3.79 MB

Polaris 2015 RZR 900 XC Edition Instructions Manual (14 pages)

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Brand: Polaris | Category: Automobile Accessories | Size: 0.61 MB

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