Polaris RZR 900 2017 Service Manual
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Polaris RZR 900 2017 Service Manual

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2017-2020 RZR 900 900/S 900/S4 1000/S 1000/
S4
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2019 (PN 9930588 R02)
© Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RZR 900 2017

  • Page 1 Publication Printed September 2019 (PN 9930588 R02) © Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
  • 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 4 REVISION INDEX DATE CHANGES 9/10/2019 Initial release Revised PVT System Chapter 2/6/2020...
  • Page 5 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
  • Page 7 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING SYSTEM CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION...

  • Page 9: Table Of Contents

    ..............1.44 2019 RZR S 900 SPECIFICATIONS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 10 .................1.66 DECIMAL EQUIVALENTS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 11: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018; K=2019; L=2020 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 12: Vehicle And Engine Serial Number Location

    The engine serial number can be found on a decal applied to the front of the engine crankcase NUMBER LOCATION stamped into the crankcase on the PTO side of the Whenever corresponding about a Polaris ORV, refer to engine. the vehicle identification number (VIN) and the engine serial number.

  • Page 13: Reference Information

    NOTICE 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 14: Replacement Keys

    (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.) SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 15: 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 16 8700226 9314177-A Roll Pin Removal Tool Combination Pliers Spanner Wrench / CV Boot Clamp Pliers Drive Clutch Holding (27″) Clutch Spreader (ear) Tool 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 17 PU-50624 Water Pump Seal Oil Pressure Gauge Clutch Spider Nut Rolling Engine Stand Oil Pressure Gauge Installer Adapter (1/2 NPT) Socket Adapter (M20) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 18 Piston Ring Fuel Pressure Gauge Bench Mount Engine Engine Stand Adapter Compressor Pliers Adapter Stand Sleeve (2 3/8″) PU-50566 Transmission Nut Socket 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.10 © Copyright Polaris Industries Inc.

  • Page 19: Master Torque Table

    89 in-lb (10 Nm) Coolant Bleed Screw Engine Mount to Frame Coolant Temperature 22 ft-lb (30 Nm) 17 ft-lb (23 Nm) Fasteners Sensor 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 20 9 ft-lb (12 Nm) Parking Brake Caliper Screws 37 ft-lb (50 Nm) Assembly Bolts Starter Solenoid Cable 35 in-lb (4 Nm) Fasteners 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 21 7 ft-lb (10 Nm) (Apply Loctite® Water Pump Cover Bolts 204™ to bolt threads) Aluminum: 120 ft-lbs (163 Wheel Lug Nuts Steel: 60 ft-lb (81 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 22: General Specifications

    Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.14 © Copyright Polaris Industries Inc.

  • Page 23: Rzr 900 Clutch Chart

    Black / Red / (0-6000) (5633319) Meters 10A Drive White White (Feet) 1800-3700 29-54 15A Lights (7044504) (7044505) (6000 - 12000) (5633320) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 24: 2017 Rzr 900 Eps Specifications

    Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 25: Rzr 900 Clutch Chart

    (5633319) Meters Fuses 10A Accessory White White (Feet) 1800-3700 29-54 10A Drive (7044504) (7044505) (6000 - 12000) (5633320) 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.17 © Copyright Polaris Industries Inc.

  • Page 26: 2017 Rzr 900 Xc Specifications

    Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.18 © Copyright Polaris Industries Inc.
  • Page 27 10A Key White White (Feet) 1800-3700 29-54 10A Term (7044504) (7044505) (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.19 © Copyright Polaris Industries Inc.
  • Page 28 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.20 © Copyright Polaris Industries Inc.
  • Page 29 Meters 10A Key White White (Feet) 1800-3700 29-54 10A Term (7044504) (7044505) (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.21 © Copyright Polaris Industries Inc.
  • Page 30 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.22 © Copyright Polaris Industries Inc.
  • Page 31 White (Feet) 1800-3700 29-54 10A Key (7044504) (7044505) (6000 - 12000) (5633320) 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.23 © Copyright Polaris Industries Inc.
  • Page 32 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.24 © Copyright Polaris Industries Inc.
  • Page 33 White (Feet) 10A Key 1800-3700 29-54 (7044465) (7044505) 10A Term (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.25 © Copyright Polaris Industries Inc.
  • Page 34 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.26 © Copyright Polaris Industries Inc.
  • Page 35 10A Key White (Feet) 10A Term 1800-3700 29-59 (7044263) (7044505) 10A Accessory (6000 - 12000) (5633319) 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.27 © Copyright Polaris Industries Inc.
  • Page 36 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.28 © Copyright Polaris Industries Inc.
  • Page 37 Black / Red / (0-6000) (5633319) Meters 10A Drive White White (Feet) 1800-3700 29-54 15A Lights (7044504) (7044505) (6000 - 12000) (5633320) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.29 © Copyright Polaris Industries Inc.
  • Page 38 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.30 © Copyright Polaris Industries Inc.
  • Page 39 (5633319) Meters Fuses 10A Accessory White White (Feet) 1800-3700 29-54 10A Drive (7044504) (7044505) (6000 - 12000) (5633320) 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.31 © Copyright Polaris Industries Inc.
  • Page 40 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.32 © Copyright Polaris Industries Inc.
  • Page 41 Meters 10A Key White White (Feet) 1800-3700 29-54 10A Term (7044504) (7044505) (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.33 © Copyright Polaris Industries Inc.
  • Page 42 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.34 © Copyright Polaris Industries Inc.
  • Page 43 White (Feet) 1800-3700 29-54 10A Key (7044504) (7044505) (6000 - 12000) (5633320) 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.35 © Copyright Polaris Industries Inc.
  • Page 44 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.36 © Copyright Polaris Industries Inc.
  • Page 45 White (Feet) 10A Key 1800-3700 29-54 (7044465) (7044505) 10A Term (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.37 © Copyright Polaris Industries Inc.
  • Page 46 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.38 © Copyright Polaris Industries Inc.
  • Page 47 10A Key White (Feet) 10A Term 1800-3700 29-59 (7044263) (7044505) 10A Accessory (6000 - 12000) (5633319) 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.39 © Copyright Polaris Industries Inc.
  • Page 48 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.40 © Copyright Polaris Industries Inc.
  • Page 49 Black / Red / (0-6000) (5633319) Meters 10A Drive White White (Feet) 1800-3700 29-54 15A Lights (7044504) (7044505) (6000 - 12000) (5633320) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.41 © Copyright Polaris Industries Inc.
  • Page 50 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.42 © Copyright Polaris Industries Inc.
  • Page 51 (5633319) Meters Fuses 10A Accessory White White (Feet) 1800-3700 29-54 10A Drive (7044504) (7044505) (6000 - 12000) (5633320) 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.43 © Copyright Polaris Industries Inc.
  • Page 52 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.44 © Copyright Polaris Industries Inc.
  • Page 53 Meters 10A Key White White (Feet) 1800-3700 29-54 10A Term (7044504) (7044505) (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.45 © Copyright Polaris Industries Inc.
  • Page 54 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.46 © Copyright Polaris Industries Inc.
  • Page 55 10A Key White (Feet) 10A Term 1800-3700 29-59 (7044263) (7044505) 10A Accessory (6000 - 12000) (5633319) 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.47 © Copyright Polaris Industries Inc.
  • Page 56 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.48 © Copyright Polaris Industries Inc.
  • Page 57 10A Key White (Feet) 10A Term 1800-3700 29-59 (7044263) (7044505) 10A Accessory (6000 - 12000) (5633319) 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.49 © Copyright Polaris Industries Inc.
  • Page 58 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.50 © Copyright Polaris Industries Inc.
  • Page 59 White (Feet) 10A Key 1800-3700 29-5 (7044465) (7044506) 10A Term (6000 - 12000) (5633319) 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.51 © Copyright Polaris Industries Inc.
  • Page 60 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.52 © Copyright Polaris Industries Inc.
  • Page 61 Black / Red / (0-6000) (5633319) Meters 10A Drive White White (Feet) 1800-3700 29-54 15A Lights (7044504) (7044505) (6000 - 12000) (5633320) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.53 © Copyright Polaris Industries Inc.
  • Page 62 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.54 © Copyright Polaris Industries Inc.
  • Page 63 (5633319) Meters Fuses 10A Accessory White White (Feet) 1800-3700 29-54 10A Drive (7044504) (7044505) (6000 - 12000) (5633320) 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.55 © Copyright Polaris Industries Inc.
  • Page 64 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.56 © Copyright Polaris Industries Inc.
  • Page 65 Meters 10A Key White White (Feet) 1800-3700 29-54 10A Term (7044504) (7044505) (6000 - 12000) (5633320) 10A Accessory 10A Drive 15A Lights 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.57 © Copyright Polaris Industries Inc.
  • Page 66 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.58 © Copyright Polaris Industries Inc.
  • Page 67 DIMENSION / CAPACITY Length 106″ / 269.2 cm Width 60″ / 152.4 cm Height 71.5″ / 181.6 cm Wheel Base 79″ / 200.7 cm 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.59 © Copyright Polaris Industries Inc.
  • Page 68 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.60 © Copyright Polaris Industries Inc.
  • Page 69 10A Key White (Feet) 10A Term 1800-3700 29-59 (7044263) (7044505) 10A Accessory (6000 - 12000) (5633319) 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.61 © Copyright Polaris Industries Inc.
  • Page 70 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.62 © Copyright Polaris Industries Inc.
  • Page 71 White (Feet) 10A Key 1800-3700 29-5 (7044465) (7044506) 10A Term (6000 - 12000) (5633319) 10A Accessory 10A Drive 15A Lights 20A EPS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.63 © Copyright Polaris Industries Inc.
  • Page 72 π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.64 © Copyright Polaris Industries Inc.
  • Page 73 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 3–4 7/16–14 2 3/4 7/16–20 25/64 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.65 © Copyright Polaris Industries Inc.
  • Page 74 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 0.5938″ 19/32 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 1.66 © Copyright Polaris Industries Inc.
  • Page 75 ..............2.44 WHEEL AND HUB TORQUE TABLE 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 76 ................. . .2.59 SPARK PLUG SERVICE 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 77: Maintenance

    When inspection reveals the need for the oil level begins to rise. Monitor the oil level, and if it replacement parts, use genuine Pure Polaris parts continues to rise, discontinue use and determine the available from your Polaris dealer.

  • Page 78: Pre-Ride Inspection

    Wheels / Lug Nuts • Verify proper lug nut torque • Inspect cable / line and switch Winch (if equipped) • Ensure operation 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 79: Maintenance Intervals

    Initial fluid level inspection; add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual...
  • Page 80 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual...
  • Page 81 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual...
  • Page 82 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual...
  • Page 83 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual...
  • Page 84 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.10...
  • Page 85 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.11...
  • Page 86 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.12...
  • Page 87 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.13...
  • Page 88 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.14...
  • Page 89 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.15...
  • Page 90 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.16...
  • Page 91 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.17...
  • Page 92 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.18...
  • Page 93 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.19...
  • Page 94 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.20...
  • Page 95 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.21...
  • Page 96 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.22...
  • Page 97 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.23...
  • Page 98 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.

  • Page 99: Maintenance Quick Reference

    Radiator bottle and radiator. * More often under severe use, such as operation in water or under severe loads. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.25 © Copyright Polaris Industries Inc.
  • Page 100 Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 101: Grease Lubrication Points

    Polaris All Season Grease top and bottom fittings Pivot Grease *There is no grease point on the front upper control arm rear mount. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 102: General Vehicle Inspection And Maintenance

    U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 16 oz (12) 2870652 Fuel Stabilizer 2872280 2.5 gal (2) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 103: Shift Cable Inspection / Adjustment

    4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 104: Engine / Air Intake

    2. Check the area for debris. 3. Remove the air box cover and clean out any debris. 3. Pull cover rearward far enough to remove air filter 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 105: 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 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 106: Engine Oil Level

    Access the oil dipstick through the opening in front of the passenger rear tire. Access the oil fill cap through the cargo box access panel. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. FLUID CAPACITY Recommended Engine Oil: PS-4 (PN 2876244) Ambient Temp Range: -35°...

  • Page 107: Engine Oil And Filter Change

    TORQUE Engine Oil Drain Plug: 5. Remove the seats and engine service panel to 12 ft-lbs (16 Nm) access the oil filter. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 108: Crankcase Breather Hose Inspection

    21. Dispose of used oil and filter properly. IMPORTANT Do not rotate the engine backwards. The timing chain may jump teeth and lead to poor performance. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.34 © Copyright Polaris Industries Inc.
  • Page 109 IMPORTANT Do not rotate the engine backwards. The timing chain may jump teeth and lead to poor performance. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 110: Cam Chain Tensioner Inspection

    15. Install the spark plug wires back into their correct location. 16. Install the push rivet that retains the heat shield to the frame cross member. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.36 © Copyright Polaris Industries Inc.
  • Page 111 Tensioner Mounting Bolts: 7 ft-lb (10 Nm) 7. Install the plunger bolt. Torque fastener to specification. TORQUE Plunger Bolt: 15 ft-lb (20 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 112: Cooling System

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Antifreeze is premixed and ready to use. Do not dilute with water. With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle.

  • Page 113: 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 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 114: Radiator Inspection / Cleaning

    8. Refer to Chapter 3 – Cooling System Bleeding page 3.12. Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2880514) (Quart) (PN 2880513) (Gallon) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 115: Fuel System

    1. Remove the seats and the engine service panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 116: Fuel Pump / Fuel Filter

    Refer to Chapter 4 for Fuel Pump Replacement page 5.25 and all other information related to the EFI System. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 117: Pvt System

    PVT system components The PVT intake and exhaust ducts MUST be checked for water damage. for debris in the event of a belt failure. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 118: Driveshaft / 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.44 © Copyright Polaris Industries Inc.

  • Page 119: Tire Pressure

    14 psi (97 kPa) 16 psi (110 kPa) RZR S4 900 14 psi (97 kPa) 16 psi (110 kPa) RZR S 1000 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.45 © Copyright Polaris Industries Inc.

  • Page 120: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.46 © Copyright Polaris Industries Inc.

  • Page 121: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.47 © Copyright Polaris Industries Inc.
  • Page 122 11. Reinstall the fill plug and torque to specification. TORQUE Front Gearcase Fill / Drain Plug Torque: 10 ft-lbs (14 Nm) 12. Check for leaks. Dispose of used fluid properly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.48 © Copyright Polaris Industries Inc.

  • Page 123: Steering System

    Check front end alignment whenever steering components are replaced. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized • Replace any worn steering components. Steering Polaris MSD certified technician.

  • Page 124: Wheel Toe Alignment Inspection

    This will tell you which tie rod needs adjusting. NOTICE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.50 © Copyright Polaris Industries Inc.
  • Page 125 • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.51 © Copyright Polaris Industries Inc.

  • Page 126: Suspension System

    Shock Spanner Wrench: 2877408 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.52 © Copyright Polaris Industries Inc.

  • Page 127: Spring Adjustment (Fox)

    2. Loosen the upper jam nut adjustment ring using the spanner wrench included in the vehicle’s tool kit. Shock Spanner Wrench: 2877408 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.53 © Copyright Polaris Industries Inc.

  • Page 128: Shock Compression Adjustment (Fox)

    Always return the spring to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.54 © Copyright Polaris Industries Inc.

  • Page 129: Spring Adjustment (Walker Evans)

    The recommended factory setting for the front and rear spanner wrench included in the vehicle’s tool kit. shocks are provided in the following compression adjustment tables. Shock Spanner Wrench: 2877408 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.55 © Copyright Polaris Industries Inc.
  • Page 130 WALKER EVANS™ 2.0" SHOCK: COMPRESSION ADJUSTMENT TABLE SETTING COMPRESSION DAMPING Full counter-clockwise position Softest Factory 8 clicks from full clockwise position Full clockwise position Firmest 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.56 © Copyright Polaris Industries Inc.

  • Page 131: Brake System

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.57 © Copyright Polaris Industries Inc.

  • Page 132: Electrical / Ignition System

    NOTICE WARNING Battery charge can be maintained by using a Polaris CALIFORNIA PROPOSITION 65 WARNING: battery tender charger or by charging once a month to Batteries, battery posts, terminals and related make up for normal discharge.

  • Page 133: Engine / Chassis Ground

    Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 5. Remove spark plugs using a 5/8” spark plug socket with an extension. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.59 © Copyright Polaris Industries Inc.
  • Page 134 Ensure wires are pushed down all the way so they engage onto the spark plugs. 13. Reinstall the cargo box access panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 2.60 © Copyright Polaris Industries Inc.
  • Page 135 ..............3.40 CYLINDER HEAD INSPECTION 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 136 1000 ENGINE....................3.89 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 137 ..............3.132 CYLINDER HEAD ASSEMBLY 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 138 ..............3.142 VALVE COVER INSTALLATION 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 139: Engine - General

    220° F: 60 PSI * Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 140: Main Engine Components - Torque Specification And Sequence

    ENGINE / COOLING SYSTEM MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 141: Exhaust System

    Head Pipe Bolts / 18 ft-lb (24 Nm) Muffler Shield Fasteners / 10 ft-lb (14 Nm) Push Rivet Muffler Rubber Mounts Muffler Exhaust Spring 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 142: 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 143: Engine Cooling System

    If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, clamps and water pump seal for signs of leaking. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 144: Radiator Cap Pressure Test

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 145: Thermostat Replacement

    Escaping stead can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 146: Cooling System Bleeding

    9. Install the thermostat cover bolts. Torque bolts to 4. Remove the radiator pressure cap and add the specification. necessary amount of Polaris Premium Antifreeze to the radiator. TORQUE 5. Remove the cargo box engine access panel. Thermostat Cover Bolts: 6.

  • Page 147: Water Pump Removal

    9. Allow engine and coolant system to completely cool down. 10. Remove the radiator pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator. 11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.
  • Page 148 9. Clean and inspect water pump shaft for excessive wear or damage. Replace water pump housing if necessary as shaft cannot be purchased separately. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.14 © Copyright Polaris Industries Inc.
  • Page 149 21. Install water pump assembly into the engine. (see Chapter 3 – Water Pump Installation page 3.16) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 150: Water Pump Installation

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.16 © Copyright Polaris Industries Inc.
  • Page 151 7. Slide water pump into engine crankcase. CAUTION The water pump drive tab and slot must be aligned properly or severe engine damage will occur. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 152: Engine Service

    -35° F to 100° F Test results are based on the use of the recommended Oil Type PS-4 Extreme Duty engine oil (Polaris PS-4 or PS-4 Extreme Duty) at Ambient Temp Range: Synthetic Engine Oil operating temperature, and may vary considerably if 0°...

  • Page 153: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.19 © Copyright Polaris Industries Inc.

  • Page 154: Accessible Engine Components

    To service the top-end of the engine, refer to Chapter 2 – Valve Clearance Inspection page 2.34 which provides detailed steps to remove the valve cover. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.20 © Copyright Polaris Industries Inc.

  • Page 155: Crankshaft Pto Seal Replacement

    3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 156 5. Test drive the vehicle and recheck for leaks before putting back into service. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.22 © Copyright Polaris Industries Inc.

  • Page 157: Engine Removal

    ECU leads to the panel. Remove the panel from the vehicle. 4. Remove the seat and ECU cover panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.23 © Copyright Polaris Industries Inc.
  • Page 158 12. Remove the two bolts mounting the air box to the frame bracket and loosen the clamp on the air box duct. Remove the air box from vehicle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 159 18. Disconnect the two fuel rail mounting bolts and move the fuel rail off to the driver’s side. CAUTION Be careful not to pinch or kink the fuel rail. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 160 21. Remove the belt and driven clutch. 27. Remove the four bolts retaining the engine to the front engine mount. 28. Remove the engine from the frame. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.26 © Copyright Polaris Industries Inc.

  • Page 161: Engine Installation

    2016-19 RZR 1000 2016–19 ACE 900 2016–19 GENERAL 2015-18 RANGER Diesel i.e. 2015 RZR 900 uses the holes marked with a 4 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.27 © Copyright Polaris Industries Inc.
  • Page 162 7. Install the seven bolts retaining the inner clutch cover. Fuel Rail Mounting Fasteners Torque bolts to specification. 5 ft-lb (7 Nm) TORQUE Inner Clutch Cover Fasteners 10 ft-lb (14 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 163 16. Install the ignition coil. Connect the wiring leads and spark plug caps. Torque mounting bolts to specification. TORQUE Ignition Coil Mounting Bolts: 75 in-lb (9 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.29 © Copyright Polaris Industries Inc.
  • Page 164 19. Install the four screws mounting the engine and PVT intake vents. Torque screws to specification. TORQUE PVT and Engine Air Intake Screen Screws: 35 in-lb (4 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 165: Engine Break

    CAUTION Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

  • Page 166: Troubleshooting

    • Spark plug fouled/weak spark • Cylinder head gasket leak • Broken throttle cable • No valve clearance (cam wear) • Obstruction in air intake 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.32 © Copyright Polaris Industries Inc.

  • Page 167: Cooling System

    Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 168: 900 Engine

    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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 169 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 170: Engine Disassembly / Inspection - Top End (900)

    3. Remove the spark plugs . Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.36 © Copyright Polaris Industries Inc.
  • Page 171 9. Using a paperclip or other tool, hold cam chain up. NOTICE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 172: Camshaft Sprocket Inspection

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.38 © Copyright Polaris Industries Inc.
  • Page 173 O. D. s from camshaft carrier bore I. D. s. Compare to specification. MEASUREMENT Calculated Camshaft Oil Clearance: 0.0009" - 0.0028" (.022 - .072 mm) Service Limit: .0039" (.10 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 174: Cylinder Head Removal

    Plate (PU-50563). Refer to Cylinder / Piston Removal page 3.58. CYLINDER HEAD INSPECTION Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.40 © Copyright Polaris Industries Inc.
  • Page 175 7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 176: Valve Inspection

    0.2165 - 0.2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 177: Combustion Chamber Cleaning

    2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to areas around spark plug and valve seats. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.43 © Copyright Polaris Industries Inc.
  • Page 178 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTICE Remove only the amount of material necessary to repair the seat surface. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.44 © Copyright Polaris Industries Inc.
  • Page 179 Service Limit: 0.075" (1.9 mm) 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.45 © Copyright Polaris Industries Inc.
  • Page 180 12. Thoroughly clean cylinder head and valves. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 181: Engine Disassembly / Inspection - Lower End

    . If replacement is required, refer to Chapter 10. 4. Inspect the ball bearing that supports the starter motor shaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.47 © Copyright Polaris Industries Inc.

  • Page 182: Flywheel Removal

    Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 183: Starter One-Way Clutch Disassembly

    It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 184: Starter One-Way Clutch Assembly

    Torque Limit Gear Flywheel Starter Gear One-Way Clutch Screws Torque Limit Gear Bolt 5. If starter gear was replaced, inspect the torque limit gear. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.50 © Copyright Polaris Industries Inc.

  • Page 185: Crankcase Disassembly

    2. Remove the crankcase drain plug to drain any oil 7. Remove the sump cover from the crankcase. remaining in the engine. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.51 © Copyright Polaris Industries Inc.
  • Page 186 Access the sprocket bolt by removing the case plug. 13. Rotate the engine so the cylinder is facing up. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 187: Balance Shaft Removal / Inspection

    Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 188: Crankshaft Removal / Inspection

    . Remove the end caps from the crankshaft. 8. If the crankshaft gear is damaged, the crankshaft assembly must be replaced. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.54 © Copyright Polaris Industries Inc.
  • Page 189 MAG End PTO Rod Journal Main Journal 1 Main Journal 3 MAG Rod Journal Main Journal 4 Main Journal 2 PTO End 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.55 © Copyright Polaris Industries Inc.
  • Page 190 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 191: Crankcase Inspection

    NOTICE Always replace plain bearings when the crankcase or connecting rods have been disassembled. Refer to Crankshaft Main Bearing Selection page 3.65. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 192: Cylinder / Piston Removal

    Inspect cylinder for wear, scratches, or damage. NOTICE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 193: Piston Disassembly / Inspection

    3.6614 ± .0003" (93 mm ± .008 mm) CAUTION DO NOT apply heat to piston rings or a loss of radial tension could result. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 194: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. MEASUREMENT Piston Pin O.D.: 0.7872" - 0.7874" (19.995 - 20.000 mm) Service Limit: 0.7866" (19.98 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 195: Piston Ring To Groove Clearance Inspection

    Measure piston outside diameter at a point 13 mm up from the bottom of the piston, at a right angle to piston pin bore. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.61 © Copyright Polaris Industries Inc.

  • Page 196: Connecting Rod Inspection

    TORQUE Connecting Rod Bolts: Step 1: 9 ft-lb (12 Nm) Step 2: 22 ft-lb (30 Nm) Step 3: Tighten add’n 90° 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.62 © Copyright Polaris Industries Inc.
  • Page 197 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 198: Engine Assembly - Lower End (900)

    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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 199: Connecting Rod Bearing Selection

    Yellow bearing for Main #2 Code Green bearing for Main #3 Blue Blue Green Blue Green Yellow Yellow bearing for Main #4 Green Yellow Yellow 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 200: 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 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.66 © Copyright Polaris Industries Inc.

  • Page 201: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 202: Cylinder / Piston Installation

    10. Carefully place the cylinder and pistons into the upper crankcase. NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 203: 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 204: 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 205: Lower Crankcase Preparation

    Rinse with clear, warm water and dry with compressed air. 7. Be sure passages are clean and dry before assembling the crankcase. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 206: Crankcase Assembly

    8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 3. Apply Polaris PS-4 engine oil to the new bearings installed in the lower crankcase half. 9. Install the eight M10 , one M6 and two M8 lower crankcase bolts.
  • Page 207 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.73 © Copyright Polaris Industries Inc.
  • Page 208 NOTICE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.74 © Copyright Polaris Industries Inc.
  • Page 209 26. Rotate the engine so the cylinder is facing up. 27. Reinstall the oil cooler , if previously removed. Use new O-rings upon installation 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 210: Flywheel Installation

    TORQUE 9 ft-lb (12 Nm) Flywheel Retaining Bolt: 133 ft-lbs (180 Nm) 6. Install the starter torque limit gear as an assembly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.76 © Copyright Polaris Industries Inc.
  • Page 211 9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 212 NOTICE Oil the tappet prior to installing. If any valve train components were replaced, refer to Valve Clearance Adjustment page 3.85. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.78 © Copyright Polaris Industries Inc.
  • Page 213 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.79 © Copyright Polaris Industries Inc.
  • Page 214 (PU-50563) into the end of camshafts as shown. Use an open-end wrench to rotate camshafts slightly if 3. Lubricate all camshaft lobes and bearing journal needed. surfaces with Polaris PS-4 engine oil prior to installation. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.80...
  • Page 215 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.81...
  • Page 216 TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 22. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. Use a new tensioner sealing washer. 23. HYDRAULIC TENSIONER ONLY: Install the cam chain tensioner into the cylinder and torque to specification.
  • Page 217 • Install the plunger bolt. Torque fastener to specification. TORQUE Plunger Bolt: 15 ft-lb (20 Nm) 25. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.83 © Copyright Polaris Industries Inc.
  • Page 218 Intake Cam Align Exhaust Marks With Surface Exhaust Cam CPS Mounting Hole Align Intake Marks With Surface Align Flywheel Mark in Mounting Hole 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.84 © Copyright Polaris Industries Inc.
  • Page 219 - PN 1204583 Exhaust Camshaft - PN 1204584 2. Lubricate the camshaft bearing journal surfaces with 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.
  • Page 220 11. Record the 3 digit number on the bottom of the tappet 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.86 © Copyright Polaris Industries Inc.
  • Page 221 5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.87 © Copyright Polaris Industries Inc.
  • Page 222 6. Install the four valve cover shoulder bolts isolators using a T40 driver. 7. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.88 © Copyright Polaris Industries Inc.

  • Page 223: Engine Specifications (1000)

    .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.89 © Copyright Polaris Industries Inc.
  • Page 224 Crankshaft Runout Limit (PTO and MAG) (0.025 mm) Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm) Shaft 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.90 © Copyright Polaris Industries Inc.

  • Page 225: Engine Disassembly / Inspection - Top End (1000)

    3. Remove the spark plugs . Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.91 © Copyright Polaris Industries Inc.
  • Page 226 NOTICE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.92 © Copyright Polaris Industries Inc.

  • Page 227: Camshaft Sprocket Inspection

    Replace timing chain and sprockets if worn or damaged. 10. Mark the intake and exhaust camshafts to ensure proper assembly. 11. Carefully remove camshafts from the cylinder head. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.93 © Copyright Polaris Industries Inc.

  • Page 228: Camshaft / Camshaft Bore Inspection (1000)

    1.5122" (38.41 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.94 © Copyright Polaris Industries Inc.

  • Page 229: Cylinder Head Removal

    Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal Service Limit: page 3.113. .0039" (0.1 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.95 © Copyright Polaris Industries Inc.

  • Page 230: Cylinder Head Warp Inspection

    Note the tappet size engraved on the underside of the bucket. MEASUREMENT Cylinder Head Warp Limit: .0039″ (0.1 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.96 © Copyright Polaris Industries Inc.

  • Page 231: Valve Inspection

    8. Clean the combustion chamber and head gasket surface. 9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.97 © Copyright Polaris Industries Inc.

  • Page 232: Combustion Chamber Cleaning

    .2165 - .2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.98 © Copyright Polaris Industries Inc.

  • Page 233: Valve Sealing Test

    1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.99 © Copyright Polaris Industries Inc.
  • Page 234 6. Insert valve into guide and tap valve lightly into place a few times. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.100 © Copyright Polaris Industries Inc.
  • Page 235 12. Thoroughly clean cylinder head and valves. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.101 © Copyright Polaris Industries Inc.

  • Page 236: Engine Disassembly / Inspection - Lower End (1000)

    Tap cover on a soft work surface to remove the bearing from the housing. A blind bearing puller can also be used. Replace bearing if removed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.102 © Copyright Polaris Industries Inc.

  • Page 237: Water Pump Housing Removal

    Water Pump Service page 2. Remove the three long gold colored bolts retaining the water pump housing to the engine. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.103 © Copyright Polaris Industries Inc.

  • Page 238: Flywheel Removal

    5. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel (left hand thread - turn flywheel puller counterclockwise to install). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.104 © Copyright Polaris Industries Inc.

  • Page 239: Starter One-Way Clutch Disassembly

    3. Remove the one-way clutch and inspect both sides of drive rollers . Inspect the roller contact surface inside the hub for wear, damage or uneven surface. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.105 © Copyright Polaris Industries Inc.

  • Page 240: Crankcase Disassembly / Inspection

    The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 5. Rotate engine to access the crankcase sump cover. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.106 © Copyright Polaris Industries Inc.
  • Page 241 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.107 © Copyright Polaris Industries Inc.

  • Page 242: Balance Shaft Removal / Inspection

    3. Carefully rotate the balance shaft and remove it from the crankcase. 4. Inspect the balance shaft gear teeth for damage. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.108 © Copyright Polaris Industries Inc.

  • Page 243: Crankshaft Removal / Inspection

    5. Carefully lift the crankshaft out of the crankcase. 6. Remove the cam chain , oil pump drive chain and PTO main seal from the crankshaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.109 © Copyright Polaris Industries Inc.
  • Page 244 If worn past the service limit, replace the crankshaft assembly. CRANKSHAFT BEARING JOURNAL DIAMETERS 1.6140 - 1.6143" Main (40.996 - 41.004 Standard Bearing 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.110 © Copyright Polaris Industries Inc.

  • Page 245: Crankcase Inspection

    Crankshaft Main Bearing Selection page 3.119 and Connecting Rod Bearing Selection page 3.119 procedures. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.111 © Copyright Polaris Industries Inc.

  • Page 246: Cylinder Inspection

    Inspect cylinder for wear, scratches, or damage. NOTICE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.112 © Copyright Polaris Industries Inc.

  • Page 247: Cylinder / Piston Removal

    (MAG / PTO). 4. Carefully lift the cylinder and pistons from the upper crankcase. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.113 © Copyright Polaris Industries Inc.

  • Page 248: Piston Disassembly / Inspection (1000)

    DO NOT apply heat to piston rings or a loss of radial Piston Pin O.D.: tension could result. .7873 - .7875" (20.000 - 20.005 mm) Service Limit: .7866" (19.98 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.114 © Copyright Polaris Industries Inc.

  • Page 249: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.115 © Copyright Polaris Industries Inc.

  • Page 250: Piston Ring Installed Gap (1000)

    Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.116 © Copyright Polaris Industries Inc.
  • Page 251 5. Install matching rod cap on connecting rod (without bearings) and install the bolts. 6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.117 © Copyright Polaris Industries Inc.

  • Page 252: Engine Assembly - Lower End (1000)

    *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.118 © Copyright Polaris Industries Inc.

  • Page 253: Connecting Rod Bearing Selection

    9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.119 © Copyright Polaris Industries Inc.

  • Page 254: Upper Crankcase Preparation

    Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.120 © Copyright Polaris Industries Inc.
  • Page 255 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.121 © Copyright Polaris Industries Inc.

  • Page 256: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.122 © Copyright Polaris Industries Inc.

  • Page 257: Cylinder / Piston Installation

    NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.123 © Copyright Polaris Industries Inc.

  • Page 258: Crankshaft Installation

    Press bearing insert firmly into place. is rotated. Repeat for the other connecting rod. 5. Install oil drain diverter into the upper crankcase. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.124 © Copyright Polaris Industries Inc.
  • Page 259 ENGINE / COOLING SYSTEM 6. Apply Polaris PS-4 engine oil to each rod bearing 11. Clean bolt hole threads in connecting rod to remove journal and main bearing journal of crankshaft. all oil. 12. Install matching rod cap on connecting rod with 3 digit serial number stampings aligned &...

  • Page 260: Balance Shaft Installation

    3. Apply Polaris PS-4 engine oil to both balance shaft 6. Flush all oil passages with solvent and then warm journals soapy water. Rinse with clear, warm water and dry with compressed air.

  • Page 261: Crankcase Assembly

    8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 3. Apply Polaris PS-4 engine oil to the new bearings installed in the lower crankcase half. 9. Install the eight M10 , two M8 and one M6 lower crankcase bolts.
  • Page 262 11. Rotate the engine so the cylinder is facing up. and two M8 upper 12. Install the eleven M6 crankcase bolts. Tighten all bolts lightly by hand. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.128 © Copyright Polaris Industries Inc.
  • Page 263 NOTICE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.129 © Copyright Polaris Industries Inc.

  • Page 264: Starter One-Way Clutch Assembly

    6. After assembly, be sure the starter gear rotates in the clockwise direction only. 27. Proceed to Flywheel Installation page 3.131 and then Cylinder Head Installation page 3.133. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.130 © Copyright Polaris Industries Inc.

  • Page 265: Flywheel Installation

    NOTICE Loctite cures with time, the longer the unit is let stand before engine starting the better the joint will be. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.131 © Copyright Polaris Industries Inc.

  • Page 266: Engine Assembly - Top End (1000)

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.132 © Copyright Polaris Industries Inc.
  • Page 267 5. Carefully set the cylinder head in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder head bolts evenly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.133 © Copyright Polaris Industries Inc.

  • Page 268: Camshaft Installation / Timing

    3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head.
  • Page 269 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.135 © Copyright Polaris Industries Inc.
  • Page 270 18. Install the front camshaft carrier and two outer retaining bolts. 19. Install the fixed cam chain guide and two retaining bolts. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.136 © Copyright Polaris Industries Inc.
  • Page 271 Camshaft Carrier Bolts: • Install the two mounting bolts. Torque fasteners to 7 ft-lbs (10 N·m) specification. 21. Apply Polaris PS-4 engine oil to the cam chain TORQUE tensioner bore prior to assembly. Use a new Tensioner Mounting Bolts: tensioner sealing washer 7 ft-lb (10 Nm) 22.

  • Page 272: Camshaft Timing - Quick Reference

    DO NOT use the “V” mark located on the flywheel opposite of the “I” mark. Only the “I” mark should be used as a TDC reference 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.138 © Copyright Polaris Industries Inc.

  • Page 273: Valve Clearance Adjustment

    2. Lubricate the camshaft bearing journal surfaces with 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.
  • Page 274 16. Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification. TORQUE Camshaft Carrier Bolts: 7 ft-lbs (10 N·m) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.140 © Copyright Polaris Industries Inc.

  • Page 275: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.141 © Copyright Polaris Industries Inc.

  • Page 276: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts to specification. TORQUE Spark Plugs: 7 ft-lbs (10 N·m) Valve Cover Bolts: 7 ft-lbs (10 N·m) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 3.142 © Copyright Polaris Industries Inc.
  • Page 277 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........

  • Page 278: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU requirements for the immediate operating conditions. from another Polaris RZR of the same model and year The ECU then sends output signals to set injector may be used without system or engine component duration and ignition timing.

  • Page 279: Etc Learn Procedure

    ECU will write values into memory and then completely shut down. 3. Turn key back on and start the vehicle. The vehicle should operate normally. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 280: Temperature And Manifold Absolute Pressure Sensor (T-Map)

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 281: Crankshaft Position Sensor (Cps)

    • Check the sensor mounting, flywheel encoder ring for damage or runout, and flywheel key. 4. If the resistance is incorrect, follow the CPS Replacement page 4.6 procedure. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 282: Cps Replacement

    6. Torque CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 ft-lb (12 Nm) 7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 283: Electronic Throttle Control (Etc) / Throttle Body

    No internal servicing or adjustments may be performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization.

  • Page 284: Etc Learn Procedure

    3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 285: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 286 6. Install the negative (-) battery cable. Torque fastener to specification. TORQUE Battery Terminal Fasteners 60 in-lb (7 Nm) 7. Connect the PPS harness to the throttle pedal. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 287: Oxygen Sensor (Rzr S 1000)

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 288: Polaris Digital Wrench

    • Perform guided diagnostic procedures provided in the Digital Wrench® Diagnostic Kit to install • Create customer service account records the Polaris Digital Wrench® diagnostic software on your computer. • Perform output state control tests (some models) The Digital Wrench® diagnostic software allows the...

  • Page 289: 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. NOTICE You must already have the current version installed before adding an update.

  • Page 290: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 4.14 © Copyright Polaris Industries Inc.

  • Page 291: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 292: Digital Wrench® Feature Map

    Run the Help System. and adjustment functions service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 4.16 © Copyright Polaris Industries Inc.

  • Page 293: Ecu Replacement

    (see Chapter 4 – Digital Wrench® Updates page 4.13. 1. After the reflash / ECU replacement / throttle body • CLOSE NON-ESSENTIAL PROGRAMS: Polaris change, leave the key on (engine not running) for 60 recommends that you DO NOT install non-essential seconds.
  • Page 294 ENGINE ELECTRICAL • Proceed to http://polaris.diagsys.com for specific 6. Select “Engine Controller Reprogramming”. information and FAQs on how to troubleshoot communication problems. • DON’T DISTURB THE PC: While reprogramming is in progress, don’t move the mouse and don’t touch the 7.
  • Page 295 ‘Finish’ button on the screen. Turn the key off, wait 30 seconds, and then turn the key on to verify the reflash was successful. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 4.19 © Copyright Polaris Industries Inc.

  • Page 296: Polaris Mobile Digital Wrench (Pmdw)

    PMDW app and the WVL. See the user’s guide for a complete list of compatible vehicles. You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download.
  • Page 297 ................5.40 EFI TROUBLESHOOTING 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 298: General Information

    Software (includes CD w/ serial number, interface cable, USB serial adapter cable and Smartlink Module Kit) Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 299: Efi Overview

    4- stroke cycle. When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 300: Fuel Injectors

    IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 301: Fuel Injector Troubleshooting

    MAG harness lead to the MAG injector been a problem. to ensure proper engine operation. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 302: Fuel Injector Replacement

    5 mm Allen wrench. 4. Remove the driver’s seat and disconnect the negative battery cable. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 303 21. Reinstall the two screws retaining the air box assembly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 304 FUEL SYSTEM 22. Position the intake hose onto the air box and tighten the hose clamp. 23. Reinstall the cargo box access panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 305: Fuel Lines

    4. Route the vent line upwards along the outside of the fuel line. Attach it to the cross brace with a hinge clip 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 306 5. Attach the fuel vent line to the supply line with a harness clip 6. Attach the fuel vent line to the fitting in the frame 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 307: Fuel Vent Line Routing (Evap Models)

    3. Secure vent line to top of canister. Route vent line up to the horizontal frame rail and secure with a hinge clip. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.11 © Copyright Polaris Industries Inc.
  • Page 308 FUEL SYSTEM 4. Attach vent line to the termination fitting in the vertical support tube. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 309: Fuel Supply Line Routing

    2. Retain fuel supply line to the frame with a hinge clip 4. Route fuel supply line vertically along fuel vent line and secure to fuel vent line with a harness clip 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.13 © Copyright Polaris Industries Inc.
  • Page 310 5. Route fuel supply line towards the rear of the vehicle and secure to the transmission vent line with a harness clip 6. Attach fuel supply line to the fuel rail 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 311: Fuel Supply Line Routing (Evap Models)

    1. Retain fuel line to frame, behind fuel tank with two 2. Route fuel line up to the purge valve mounting panduit straps. bracket. Retain fuel line with three panduit straps. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.15 © Copyright Polaris Industries Inc.
  • Page 312 FUEL SYSTEM 3. Attach fuel line to fuel rail. Retain fuel line to purge line with two panduit straps. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 313: Vent Line Termination Fitting

    If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 314: Fuel Tank / Pump

    Preliminary Filter 70 ft-lbs (95 Nm) Fuel Sender Float Arm Fuel Tank Vent PFA Gasket (*replace if removed) Fuel Tank Assembly Fuel Pump/Regulator 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 315: Fuel Line Removal / Installation

    3. Pull on the fuel line to remove. 4. To install, verify the connections are clean and undamaged. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.19 © Copyright Polaris Industries Inc.
  • Page 316 Properly drain fuel into a suitable the console. Remove the console from the vehicle. container. 6. Disconnect the fuel pump electrical harness 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.20 © Copyright Polaris Industries Inc.
  • Page 317 12. Remove the Torx screws and plastic rivets retaining the block-off panel using a T40 Torx bit. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.21 © Copyright Polaris Industries Inc.

  • Page 318: Fuel Tank Installation

    10. Install right rocker panel and all body fasteners. 11. Connect the fuel line and fuel pump electrical harness. Verify connections are secure. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 319: Fuel Pump

    The ECU switches off the pump preventing the continued delivery of fuel in these instances: • Loose float • Float contact with tank • Bent float rod 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.23 © Copyright Polaris Industries Inc.

  • Page 320: Fuel Pump Test

    If the pump starts, repeat steps 3, 4 and 5 to verify correct pressure. NOTICE If the fuel pressure is out of specification, replace the fuel pump assembly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.24 © Copyright Polaris Industries Inc.

  • Page 321: Fuel Pump Replacement

    6. Ensure that static has been discharged by touching a ground source such as the engine or frame. 4. On S 1000 models only, remove the rubber fuel pump cover. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.25 © Copyright Polaris Industries Inc.
  • Page 322 Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 8. Disconnect the fuel pump electrical harness 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.26 © Copyright Polaris Industries Inc.
  • Page 323 Do not use water or any other chemicals to remove debris. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.27 © Copyright Polaris Industries Inc.
  • Page 324 25. 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.28 © Copyright Polaris Industries Inc.

  • Page 325: 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.29 © Copyright Polaris Industries Inc.
  • Page 326 ECU control of the crank when key is turned to START Start Enable Driver start solenoid ECU is not grounding the start solenoid Inactive 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.30 © Copyright Polaris Industries Inc.
  • Page 327 On or Off Inactive AWD or 2WD mode How fast the transmission output Vehicle Speed — varies is turning (calculated to wheel speed) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.31 © Copyright Polaris Industries Inc.

  • Page 328: Misfire Detection (S 1000 Only)

    Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.32 © Copyright Polaris Industries Inc.

  • Page 329: Trouble Code Display (Dtc)

    MODE button or turn the ignition key OFF once the 2. Press and hold the MODE button to enter the codes are recorded. diagnostics code menu. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.33 © Copyright Polaris Industries Inc.
  • Page 330 P0112 MAP) Abnormal rate of Change P0114 Valid But Above Normal P0127 (least severe) Engine Temperature Sensor Engine Overheat Shutdown P1217 (ECT) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.34 © Copyright Polaris Industries Inc.
  • Page 331 P1262 Driver Circuit Open P0261 P0265 Driver Circuit Short to B+ Injector 2 (PTO) Driver Circuit Grounded P1265 Driver Circuit Open P0264 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.35 © Copyright Polaris Industries Inc.
  • Page 332 3599 Valid But Above Normal P17AD (least severe) Valid But Below Normal P17AF (least severe) Cylinder Not Identified Misfire Detected 65590 P0314 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.36 © Copyright Polaris Industries Inc.
  • Page 333 EPS Power Save Condition 520231 C1071 Power Save/Timeout Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520268 P1519 M17; IAC Stepper Pin 3 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.37 © Copyright Polaris Industries Inc.
  • Page 334 Repeated Adaptation Failed Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.38 © Copyright Polaris Industries Inc.
  • Page 335 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.39 © Copyright Polaris Industries Inc.

  • Page 336: Efi Troubleshooting

    • Throttle stop screw tampering Symptom: Erratic Idle. • Throttle cable incorrectly adjusted • Air Leaks, dirty injector • TMAP damaged (check with Digital Wrench®) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 5.40 © Copyright Polaris Industries Inc.
  • Page 337 .............6.25 DRIVEN CLUTCH SLIDER INSPECTION 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 338 ............... .6.35 PVT OVERHEATING / DIAGNOSIS 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 339: General Information

    WEIGHT SPRING SPRING 0-1800 29–59 Black / Red / (0-6000) (5633319) Meters White White (Feet) 1800-3700 29-54 (7044504) (7044505) (6000 - 12000) (5633320) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 340: 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 and the vehicle’s intended usage. Therefore, modifications or variations of components at random are never recommended.

  • Page 341: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 342: Pvt System Service

    Cover Assembly, Outer Screw O-Ring Nut, Nylok Drain Plug, Cover Bracket, Belt Screen Seal, Cover Hose, Air Outlet Screw Seal, Cover Cover Assembly 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 343: Rzr S 1000 / S4 1000 Pvt Covers And Ducting Components

    Inner Cover Screws Outlet Duct Outer Cover Drain Screw Outer Clutch Cover Outer Cover Screws Inner Clutch Cover Intake Hose Bracket Inner Cover Seal 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 344: Pvt Disassembly

    7. Remove the seven fasteners retaining the inner clutch cover to the engine and transmission. 8. Remove the inner clutch cover from the vehicle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 345: Pvt Assembly

    TORQUE Outer Clutch Cover Screws: 54 in-lb (5 Nm) 8. Install second intake hose onto PVT cover and tighten hose clamp until taught. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 346: Drive Belt

    4. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 347: Belt Inspection

    Be sure to install belt in the same direction as it was removed. 4. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 348: Belt Installation (Non-Ebs)

    RPM during the break-in period. In addition, when operating in sand/dune environments, avoid extended low speed operation at high throttle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.12 © Copyright Polaris Industries Inc.

  • Page 349: Drive Clutch Service

    290 ft-lb (393 Nm) (Apply 0.4 mL Loctite® 620™) Shift Weight Cover Bolt Cover Bolt 20 in-lb (2 Nm) 8 ft-lb (11 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.13 © Copyright Polaris Industries Inc.

  • Page 350: Drive Clutch Disassembly

    DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 351: Bearing Inspection

    If problems are noted continue with disassembly. NOTICE Excessive drag in the bearing may cause difficult shifting or vehicle creep at idle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 352: Shift Weight Inspection

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.16 © Copyright Polaris Industries Inc.

  • Page 353: Spider Removal

    Clutch Spider Removal / Installation Tool (PN 2870341). Spider Removal / Installation Tool: 2870341 Clutch Holding Fixture: 2871358-A 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.17 © Copyright Polaris Industries Inc.

  • Page 354: Drive Clutch Inspection

    Measure the thickness and compare to specification. Replace if worn or damaged. MEASUREMENT Thrust Washer Thickness: Standard: .030″ (.76 mm) Service Limit: .025″ (.64 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 355: Moveable Sheave Bushing Inspection

    /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 356 16. Install nut on puller rod and hand tighten. Turn barrel 3. Remove nut from puller rod and set aside. to apply additional tension if needed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 357 32. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 33. Turn clutch cover counterclockwise on puller rod until bushing is seated. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 358: Drive Clutch Assembly

    4. Apply 0.4 mL of Loctite® 620™ and 0.4 mL of Loctite® 7088™ Primer in 90° apart in vertical stripes to the shaft threads. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.22 © Copyright Polaris Industries Inc.
  • Page 359 12. Install cover bolts and torque in a cross pattern evenly to specification. TORQUE Drive Clutch Cover Bolts: 8 ft-lb (11 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.23 © Copyright Polaris Industries Inc.

  • Page 360: Driven Clutch Service (Ebs)

    Bearing Spider Spring Pin Roller Slider Washer E-clip Slider Pin Stationary Sheave Helix (Cam) Helix Screws Moveable Sheave 48 in-lb (5 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 361: Driven Clutch Slider Inspection

    Universal Clutch Compressor. Slider to Sheave Clearance Service Limit: 0.175″ (4.5 mm) Slider Width Service Limit: 0.975″ (24.8 mm) Universal Clutch Compressor: PU-50518-A 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.25 © Copyright Polaris Industries Inc.
  • Page 362 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTICE Spring is compression only and has no torsional wind. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.26 © Copyright Polaris Industries Inc.
  • Page 363 1. Align the X’s on the moveable and stationary sheaves. 4. If removed, install the rollers , washers and E- clips onto the spider. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.27 © Copyright Polaris Industries Inc.
  • Page 364 The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 365 Driven Clutch Spring Fixed Sheave Thrust Washer Spring Cup 1.189 x 0.838 x 0.12 Rollers Plate Screws Washers 12 ft-lbs (16 Nm) E-Clips 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.29 © Copyright Polaris Industries Inc.

  • Page 366: Driven Clutch Disassembly

    6. Turn the compression tool handle counter-clockwise to relieve spring pressure and remove the compressor tool from the clutch assembly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.30 © Copyright Polaris Industries Inc.

  • Page 367: Driven Clutch Assembly

    14. Lube splines with a light film of grease. Do not lubricate the bearings! 3. Install the spring pins to retain the slider pins. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.31 © Copyright Polaris Industries Inc.
  • Page 368 10. Install the drive clutch on the vehicle. See PVT 6. Align the X’s on the spider and moveable sheave. Assembly page 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.32 © Copyright Polaris Industries Inc.

  • Page 369: Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.33 © Copyright Polaris Industries Inc.
  • Page 370 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.34 © Copyright Polaris Industries Inc.

  • Page 371: Pvt Overheating / Diagnosis

    PVT system. 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 certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty Poor engine performance.
  • Page 372 PVT SYSTEM NOTES 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 6.36 © Copyright Polaris Industries Inc.
  • Page 373 ................7.33 SHIFTING DIFFICULTY 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 374: General Information

    LUBRICATION SPECIFICATIONS FLUID CAPACITY Recommended Transmission Lubricant: AGL (PN 2878068) (Quart) Capacity (Standard): 44 oz. (1300 ml) Capacity (INT’L): 40.5 oz. (1200 ml) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 375: Transmission Mounting View

    *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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 376: Shift Lever / Cable

    4. Remove both bushings from the shift lever and service as needed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 377: Shift Cable Adjustment

    6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 378: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 379 13. Remove rear wheels from the vehicle. CAUTION Be careful not to pinch or kink the fuel rail 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 380 Discard nuts and replace with new upon assembly. Allow the radius rods swing downward. 19. Remove the PVT outer cover. 20. Remove the belt and driven clutch. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 381 27. Using a 15mm socket, remove the four bolts from the 23. Remove vent hose from transmission. left side and two from the right side , securing the transmission to the engine. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 382: Transmission Installation

    Rear Transmission Isolator Fasteners: 33 ft-lb (45 Nm) 5. Install the two rear exhaust springs securing the muffler to the rear transmission mounting bracket. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.10 © Copyright Polaris Industries Inc.
  • Page 383 2016-19 RZR 1000 2016–19 ACE 900 2016–19 GENERAL 2015-18 RANGER Diesel i.e. 2015 RZR 900 uses the holes marked with a 4 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.11 © Copyright Polaris Industries Inc.
  • Page 384 , shift cable clevis pin and washer onto the transmission. 18. Lubricate the transmission splines and mid prop shaft joint splines with Polaris All Purpose Grease. Install the propshaft onto the transmission output shaft (see Chapter 7 – Prop Shaft Installation page 8.20).
  • Page 385 23. Install the stabilizer bar link mounting bolts and new nuts . Torque to specification. 30. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris AGL (see Chapter 2 – Transmission Lubrication page 2.46. FLUID CAPACITY...

  • Page 386: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 387 18. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. Gear Cluster Disassembly 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.15 © Copyright Polaris Industries Inc.
  • Page 388 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.16 © Copyright Polaris Industries Inc.
  • Page 389 Snorkel Tool: PA-50231 31. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.17 © Copyright Polaris Industries Inc.

  • Page 390: Differential Operation

    4WD and Differential Unlock in Turf mode. Differential lock is beneficial in low traction and rough terrain conditions. Differential unlock makes maneuvering easier and minimizes damage to terrain. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 391 This locks the rear differential as a solid rear axle, increasing traction. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.19 © Copyright Polaris Industries Inc.
  • Page 392 Differential Cover Assembly Planetary Differential Assembly Fasteners Engagement Dog Bearing Shift Fork Retainer Fastener Torsion Spring Retainer Shift Fork Solenoid Spring Solenoid 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.20 © Copyright Polaris Industries Inc.

  • Page 393: Planetary Differential Disassembly (Turf Mode Models Only)

    Planetary Differential Bushing Replacement (Turf Mode Models Only) page 7.22. 2. Remove the six screws retaining the differential cover and remove the cover. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.21 © Copyright Polaris Industries Inc.

  • Page 394: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 395 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 396: Planetary Differential Assembly (Turf Mode Models Only)

    3. Align and install the differential cover using the previously made scribe marks. 4. Apply Loctite® 2760™ to cover screws. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.24 © Copyright Polaris Industries Inc.
  • Page 397 10.9. Torque the screws according to their corresponding grade. TORQUE Differential Cover Screws (8.8 Fastener): 22 ft-lbs (30 N·m) TORQUE Differential Cover Screws (10.9 Fastener):28 ft-lbs (38 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 398: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 399: Transmission Assembly / Snorkel Gear Backlash Procedure

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.27 © Copyright Polaris Industries Inc.
  • Page 400 8. Apply Loctite ® ™ to the threads of the bearing and may have some tight spots. cover retaining screws. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.28 © Copyright Polaris Industries Inc.
  • Page 401 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.29 © Copyright Polaris Industries Inc.
  • Page 402 Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.30 © Copyright Polaris Industries Inc.
  • Page 403 20 ft-lbs (27 N·m) shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 404 Install and torque the bolts to specification. TORQUE Transmission Gear Sector Cover Bolts: 12 ft-lbs (16 N·m) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.32 © Copyright Polaris Industries Inc.

  • Page 405: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 406 TRANSMISSION NOTES 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 407 ............... .8.36 REAR HUB ASSEMBLY VIEW 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 408: General Information

    CV Boot Clamp Pliers (earless type) 2872608 Roll Pin Removal Tool PU-48951 Axle Boot Clamp Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 409: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 410: Front Bearing Replacement

    4. Inspect the bearing carrier housing for scratches, wear or damage. Replace front bearing carrier if damaged. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 411: Front Bearing Carrier Installation

    8. Torque the tie rod end fastener to specification and install a new cotter pin. TORQUE Tie Rod End Fastener: 30 ft-lbs (41 Nm) + 90° 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 412: Rear Bearing Carrier Removal / Inspection

    CAUTION Do NOT hang the caliper by the brake like. Use wire or rope to hang the caliper to prevent brake line damage. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 413: Rear Carrier Bearing Replacement

    6. Support the bottom of the bearing carrier housing. between inner and outer race. CAUTION Use an arbor and press only on the outer race or bearing damage may occur. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 414: Rear Bearing Carrier Installation

    TORQUE Rear Bearing Carrier Mounting Fasteners: 42 ft-lb (57 Nm) 3. Apply a small amount of anti-seize to the drive shaft splines. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 415 8. Rotate wheel and check for smooth operation. Bend both ends of the cotter pin around the end of the spindle. TORQUE Brake Caliper Mounting Bolts: 46 ft-lb (62 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 416: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 417: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 418: Rear Half Shaft Removal

    Steel: 60 ft-lb (81 Nm) 5. Completely remove the four wheel nuts and the wheel. 11. Rotate wheel and check for smooth operation. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 419: Rear Half Shaft Installation

    9. With a quick, short jerk outward, remove the half shaft Bearing Carrier Mounting Fasteners: from the transmission. 42 ft-lb (57 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 420: Drive Shaft / Cv Joint Handling Tips

    OUTER CV JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps TORQUE Hub Castle Nut: 180 ft-lbs (244 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.14 © Copyright Polaris Industries Inc.
  • Page 421 IMPORTANT Tap on inner race only! 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.15 © Copyright Polaris Industries Inc.
  • Page 422 14. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 423: Inner Plunging Joint / Boot Replacement

    INNER PLUNGING JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps IMPORTANT Tap on inner race only! 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.17 © Copyright Polaris Industries Inc.
  • Page 424 10. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined in the shaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 425: Prop Shaft Removal

    7. Remove the two fasteners retaining the prop shaft support bearing to the frame. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 426: Prop Shaft Installation

    6. Install and torque the support bearing fasteners to specification. TORQUE Prop Shaft Support Bearing Fasteners: 33 ft-lb (45 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.20 © Copyright Polaris Industries Inc.
  • Page 427 2. Remove four Torx T40 screws and five push rivets retaining the front console to the floor. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.21 © Copyright Polaris Industries Inc.
  • Page 428 10. Remove two fasteners retaining the voltage regulator to the back of the lower rear close off panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.22 © Copyright Polaris Industries Inc.
  • Page 429 Reference these marks during installation if still visible. 5. Torque the support bearing fasteners to specification. TORQUE Support Bearing Fasteners: 33 ft-lb (45 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.23 © Copyright Polaris Industries Inc.
  • Page 430 FINAL DRIVE 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 431: Front Gearcase / Centralized Hilliard

    10 ft-lbs (14 N·m) Fill / Check Plug Roller Cage 10 ft-lbs (14 N·m) Roller Pinion Gear Spring Retainer Snap Ring O-ring Cover Plate Screws 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 432: All Wheel Drive Operation

    “over-running” condition. The vehicle is now back to rear wheel drive until the next loss of rear wheel traction occurs. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.26 © Copyright Polaris Industries Inc.

  • Page 433: Awd Diagnosis

    The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 434: Front Gearcase Removal

    Lift and remove the gearcase from the front LH wheel well area and slide it out of the vehicle above the upper A-arm. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 435 AWD Diagnosis page 8.27 for detailed inspection process. 6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.29 © Copyright Polaris Industries Inc.
  • Page 436 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.30 © Copyright Polaris Industries Inc.

  • Page 437: Front Gearcase Assembly

    Bearing Roller Surface Spacer Thrust Bearing 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.31 © Copyright Polaris Industries Inc.
  • Page 438 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.32 © Copyright Polaris Industries Inc.
  • Page 439 Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. TORQUE Cover Plate Screws: 9 ft-lbs (12 N·m) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.33 © Copyright Polaris Industries Inc.

  • Page 440: Front Gearcase Installation

    (fill on a level surface to bottom of threads on the fill 33 ft-lbs (45 Nm) hole) 5. Install the vent line 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 441: Wheel Hubs

    Steel: 60 ft-lb (81 Nm) Front Rim (Aluminum shown) Studs Retaining Ring Cotter Pin Castle Nut Sealed Bearing 180 ft-lbs (244 Nm) Bearing Carrier Cone Washer 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.35 © Copyright Polaris Industries Inc.

  • Page 442: Rear Hub Assembly View

    Steel: 60 ft-lb (81 Nm) Rear Rim (Aluminum shown) Studs Retaining Ring Cotter Pin Castle Nut Sealed Bearing 180 ft-lbs (244 Nm) Bearing Carrier Cone Washer 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 8.36 © Copyright Polaris Industries Inc.
  • Page 443 ........9.47 WALKER EVANS™ 2.0" FRONT SHOCK / 2.5" REAR SHOCK 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 444 ..............9.54 WALKER EVANS™ SHOCK ASSEMBLY 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 445: General Information

    Shock Rod Holding Tool PU-51039 Gas Shock Fill Tool commercially Shock Bearing Cap Removal Tool available Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 446: Steering System

    1. Safely lift the vehicle. 2. Remove the four wheel nuts. 3. Remove the fastener retaining the tie rod end to the knuckle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 447 7. Install the wheel and four wheel nuts. Tighten lug nuts to specification. TORQUE Wheel Lug Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 448: Steering Assembly (Non-Eps)

    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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 449: Steering Wheel Removal (Non-Eps)

    5. Refer to steps 11-16 of the Steering Shaft Bearing Replacement page 9.7 procedure for installation. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.
  • Page 450 Steering Shaft to Rack Pinch Bolt: TORQUE 48 ft-lb (65 Nm) Steering Wheel Nut: 65 ft-lbs (88 Nm) 15. Install steering wheel cap and test steering operation. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 451: Steering Assembly (Eps)

    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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual © Copyright Polaris Industries Inc.

  • Page 452: Upper Steering Shaft Removal

    3. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 453: Steering Wheel Removal (Eps)

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 454: Lower Steering Shaft Removal

    3. Remove the power steering unit (see Chapter 8 – Power Steering Unit Removal page 9.11). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 455: Lower Steering Shaft Installation

    (see Chapter 8 – Power Steering Unit Installation page 9.14). 5. Lift up on the shaft and remove it through the floor panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 456: Power Steering Unit Installation

    3. Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 457: Upper Steering Shaft Installation

    Torque the nut to specification and reinstall the plastic wheel cover. TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 458: Front Suspension

    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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 459: Front Control Arm Replacement

    5. Remove the front bumper to allow A-arm bolt removal. TORQUE Front Ball Joint Pinch Bolts: 42 ft-lb (57 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.17 © Copyright Polaris Industries Inc.
  • Page 460 17. Examine A-arm bushings and pivot tube. Replace if worn. Discard hardware. 18. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 461: Ball Joint Removal

    11. Carefully press the ball joint out of the A-arm and discard the ball joint. 30 ft-lb (42 Nm) Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 462: Front Stabilizer Bar Replacement (50" & Xc)

    5. To install, reverse procedure and torque fasteners to specification TORQUE Stabilizer Bar Link Fasteners: 40 ft-lb (54 Nm) Stabilizer Bar Mount Fasteners: 17 ft-lb (23 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 463: Rear Suspension

    A-arm and remove the upper A-arm from the vehicle. 5. Examine bushings and pivot tubes. Replace if worn. Discard hardware. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 464: Rear Control Arm Installation

    5. To Install, carefully install the stabilizer bar in the Shock Mounting Bolts: vehicle. 42 ft-lb (57 Nm) Upper Rear Bearing Carrier M10 Bolts: 42 ft-lb (57 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.22 © Copyright Polaris Industries Inc.
  • Page 465 Stabilizer Bar Linkage Fasteners: 40 ft-lbs (54 Nm) 8. Lubricate the stabilizer bar bushings. See Maintenance chapter – Grease Lubrication Points page 2.27 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.23 © Copyright Polaris Industries Inc.

  • Page 466: Shocks / Springs

    SHOCKS / SPRINGS FRONT SHOCK ASSEMBLY VIEW REAR SHOCK ASSEMBLY VIEW 50″ Model 50″ Model XC & 60″ Model XC & 60″ Model 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 467: Shock Removal / Installation

    1. (see Shock Specifications (FOX) page for factory settings. 6. Reinstall the shock onto the vehicle 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 468: Shock Service (Fox)

    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 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.26 © Copyright Polaris Industries Inc.
  • Page 469 1.250 x .015 1.250 x .015 1.100 x .015 1.100 x .008 1.570 x .128 Top Out 1.570 x .128 Top Out 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 470: Fox Shock Disassembly

    3. Once nitrogen pressure has been released, depress reservoir cap and remove retaining ring. Typically a valve shim can be used. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.28 © Copyright Polaris Industries Inc.
  • Page 471 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.29 © Copyright Polaris Industries Inc.
  • Page 472 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). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.30 © Copyright Polaris Industries Inc.
  • Page 473 CAUTION Body Cap will be hot. 21. Discard all O-rings and clean Loctite® residue completely out of threads of the body. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.31 © Copyright Polaris Industries Inc.
  • Page 474 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.) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.32 © Copyright Polaris Industries Inc.
  • Page 475 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.33 © Copyright Polaris Industries Inc.
  • Page 476 41. Remove Jet/Check Valve with Hex T-handle wrench. 38. Remove eyelet using an adjustable wrench or Body Cap socket. CAUTION Eyelet will be Hot. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.34 © Copyright Polaris Industries Inc.
  • Page 477 44. Back out rebound adjuster with flat head screw driver. 47. Remove both retaining rings from the eyelet and press out bearing. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.35 © Copyright Polaris Industries Inc.
  • Page 478 DX Bushing style eyelets have larger bore diameters than conventional eyelets. 5. Remove U-Cup seal from bearing assembly. Note the direction seal was installed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.36 © Copyright Polaris Industries Inc.

  • Page 479: Fox Shock Assembly

    If internal bearing is damaged, replace with complete 2. Press bearing into the eyelet using Bearing Press or bearing assembly. proper sized socket. 3. Install second retaining ring. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.37 © Copyright Polaris Industries Inc.
  • Page 480 11. Place shock shaft in clamp blocks and insert needle into shock shaft. 7. Put the steel ball on the spring with a dab of shock oil. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.38 © Copyright Polaris Industries Inc.
  • Page 481 360° around shock shaft threads. 17. Install wiper seal in body cap (if equipped). 18. Apply thin layer of shock oil to seal. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.39 © Copyright Polaris Industries Inc.
  • Page 482 20. Install U-Cup seal. 24. Install piston O-ring if applicable. 21. Install back-up washer. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.40 © Copyright Polaris Industries Inc.
  • Page 483 29. Apply a thin layer of float fluid to the threads, nut, or BOC post and torque to 22 ft-lbs (30 Nm). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.41 © Copyright Polaris Industries Inc.
  • Page 484 32. Apply Loctite® primer to the body cap threads. 36. Place body in clamp blocks and torque body cap to 100 ft-lbs (136 Nm) using body cap socket. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.42 © Copyright Polaris Industries Inc.
  • Page 485 43. Apply thin layer of shock oil to O-ring. (16 Nm). 44. Thread down reservoir with strap wrench and torque to specification. 40. Apply Loctite® to LSC screw (if equipped). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.43 © Copyright Polaris Industries Inc.
  • Page 486 48. Ensure oil is 0.250″ above IFP and install bleed screw with O-ring. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.44 © Copyright Polaris Industries Inc.
  • Page 487 56. Use IFP tool to push down on IFP and fully extend the shock shaft assembly. 60. Install reservoir cap and retaining ring. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.45 © Copyright Polaris Industries Inc.
  • Page 488 NOTICE Check for any leaks or faults in the shock absorber’s functionality. 63. Tap body cap into position. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.46 © Copyright Polaris Industries Inc.

  • Page 489: Shock Service (Walker Evans)

    Piston Wear Band (1.750" OD) 36. Shaft, Chrome Clicker Bolt Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.47 © Copyright Polaris Industries Inc.

  • Page 490: Spring Adjustment (Walker Evans)

    The recommended factory setting for the front and rear shocks are provided in the following compression spanner wrench included in the vehicle’s tool kit. adjustment tables. Shock Spanner Wrench: 2877408 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.48 © Copyright Polaris Industries Inc.
  • Page 491 WALKER EVANS™ 2.0" SHOCK: COMPRESSION ADJUSTMENT TABLE SETTING COMPRESSION DAMPING Full counter-clockwise position Softest Factory 8 clicks from full clockwise position Full clockwise position Firmest 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.49 © Copyright Polaris Industries Inc.

  • Page 492: Walker Evans™ Shock Rebuild Information

    The rebound and compression valve stacks will always be positioned as shown in the illustration, regardless of how the shock assembly is installed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.50 © Copyright Polaris Industries Inc.

  • Page 493: Walker Evans™ Shock Disassembly

    Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.51 © Copyright Polaris Industries Inc.
  • Page 494 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.52 © Copyright Polaris Industries Inc.
  • Page 495 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.53 © Copyright Polaris Industries Inc.

  • Page 496: Walker Evans™ Shock Assembly

    NOTICE If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.54 © Copyright Polaris Industries Inc.
  • Page 497 15. Screw IFP Tool (PS-45908) onto the floating piston. FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.55 © Copyright Polaris Industries Inc.
  • Page 498 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.56 © Copyright Polaris Industries Inc.
  • Page 499 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.57 © Copyright Polaris Industries Inc.
  • Page 500 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTICE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 9.58 © Copyright Polaris Industries Inc.
  • Page 501 ............... 10.27 REAR DISC REPLACEMENT 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.1 © Copyright Polaris Industries Inc.
  • Page 502 ..............10.32 BRAKE PEDAL SWITCH INSPECTION 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 503: General Information

    .298 ± .007" (7.57 ± .178 mm) .180" (4.6 mm) Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm) Rear Brake Disc Runout .010" (.254 mm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 504: 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 505: Rzr 900 / 1000

    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 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 506: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.6 © Copyright Polaris Industries Inc.
  • Page 507 7. Perform the BRAKE BLEEDING / FLUID CHANGE page 10.8 procedure. TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 N·m) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 508: Brake Pedal

    2. If changing fluid, remove old fluid from reservoir with a Mity Vac™ pump or similar tool. Brake Pedal Free-play: 1/4-3/8″ (6.35-9.53 mm) Mity Vac™: 2870975 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 509 8. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to specification. Polaris DOT 4 Brake Fluid 2872189 TORQUE Bleeder Screw: 4.

  • Page 510: Parking Brake (Int'l)

    Parking Brake Lever Fasteners Parking Brake Caliper/Pad Assembly 30 ft-lbs (42 Nm) Parking Brake Switch Clip Cable Adjuster Parking Brake Lever Assembly 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 511: Parking Brake Inspection (Intl)

    5. Place the vehicle in neutral on a flat level surface. 6. Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.11 © Copyright Polaris Industries Inc.
  • Page 512 10. If additional adjustment is needed, the cable can be adjust on the parking brake handle side jam nut 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 513: Caliper Removal

    2. Using a 1/2” socket and ratchet, remove the brake disc retaining bolt and flat washer. 3. Remove the disc from the transmission shaft. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.13 © Copyright Polaris Industries Inc.
  • Page 514 4. Install the new brake disc. Install the flat washer and mounting bolt . Torque the mounting bolt to specification. TORQUE Parking Brake Disc Mounting Bolt: 26 lb-ft (35 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 515: Front Brakes

    NOTICE When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 516: Front Caliper Assembly View

    Socket Set Screw Pistons Bleeder Screw 48 in-lb (5 Nm) Caliper Mount Caliper Assembly Brake Pads Brake Scraper Boots Square O-Rings Bolts 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 517: Front Caliper Disassembly

    Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 518: Front Caliper Inspection

    Replace if damaged or worn beyond may drag upon assembly. service limit. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. MEASUREMENT Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore Front Caliper Piston Bore I.D.:...

  • Page 519: Front Pad Inspection

    Brake Disc Thickness New: .0188″ (4.78 mm) Service Limit: 0.170″ (4.32 mm) Brake Disc Thickness Variance Service Limit: 0.002″ (.051 mm) difference between measurements 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 520: Front Brake Disc Runout

    18 ft-lb (24 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 521: Front Caliper / Pad Installation

    Maintain at least 1/2" (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.21 © Copyright Polaris Industries Inc.

  • Page 522: Brake Burnishing Procedure

    7. Install wheel and torque wheel nuts to specification. TORQUE Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 523: Rear Brakes

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 524: Rear Caliper Assembly View

    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 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.24 © Copyright Polaris Industries Inc.

  • Page 525: Rear Caliper Disassembly

    Rear Caliper Piston O.D.: Standard: 1.500″ (38.10 mm) Service Limit: 1.498″ (38.05 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.25 © Copyright Polaris Industries Inc.

  • Page 526: Rear Caliper Assembly

    2. Measure the thickness of the pad material. Replace may drag upon assembly. pads if worn beyond the service limit. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN MEASUREMENT 2872189). Install piston with a twisting motion while pushing inward.

  • Page 527: Rear Disc Inspection

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Brake Disc Mounting Bolts: 18 ft-lb (24 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.27 © Copyright Polaris Industries Inc.

  • Page 528: Rear Caliper / Pad Installation

    Maintain at least 1/2″, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.28 © Copyright Polaris Industries Inc.

  • Page 529: Brake Burnishing Procedure

    7. Install wheel and torque wheel nuts to specification. TORQUE Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.29 © Copyright Polaris Industries Inc.

  • Page 530: Troubleshooting

    • Brake Disc worn (runout or thickness variance • Brake Pad wear (uneven / unusual wear) exceeds service limit) • Brake Disc damaged 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.30 © Copyright Polaris Industries Inc.

  • Page 531: Caliper Overheats (Brakes Drag)

    • For this system to operate correctly. The Brake Pressure Switch and Brake pedal switch need to close within an acceptable amount of time. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.31 © Copyright Polaris Industries Inc.

  • Page 532: Brake Warning System Inspection (Intl Models)

    ECU. for mechanical damage, and check for free play. NOTICE A sticking brake pedal may also cause false brake warning alarms. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 10.32 © Copyright Polaris Industries Inc.
  • Page 533 ................11.26 DOOR ADJUSTMENT 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.1 © Copyright Polaris Industries Inc.

  • Page 534: General Information

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.2 © Copyright Polaris Industries Inc.

  • Page 535: 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.3 © Copyright Polaris Industries Inc.
  • Page 536 M6 x 1.0 x 25 Screw 8 ft-lb (11 Nm) Hoop, ROPS - Rear M6 x 1.5 x 65 Screw 30 ft-lb (41 Nm) Hip Bolster M10 x 1.5 Nut 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 537: 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.5 © Copyright Polaris Industries Inc.
  • Page 538 DOORS - 4 1000 Hinge Pin Door Panel 8 ft-lb (11 Nm) Door Frame Latch Release Latch Striker Latch 8 ft-lb (11 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 539: Dash / Instruments

    BODY / FRAME DASH / INSTRUMENTS Instrument Cluster Headlight Switch Key Switch AWD Switch 12V Accessory Port Bezel 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 540: Hood / Front Body

    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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 541: Chassis / Main 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.9 © Copyright Polaris Industries Inc.
  • Page 542 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) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 543: Seats

    Seat Latch Screw Spring 4 ft-lb (5 Nm) Shoulder Belt Seat Slider Lever Spring Lock Washer Seat Bottom Flat Washer Seat Back 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 544: Seats - Rear

    4 ft-lb (5 Nm) Seat Base Bolt Seat Base 4 ft-lb (5 Nm) Seat Latch Lever Seat Bottom Spring Seat Latch Seat Back 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 545: Floor / Rocker Panels

    RH Rocker T27 Screw Push Rivots LH Rocker Console Cover U-Type Nuts Seat Belt Boot Block Off Flap Shifter Boot Lower Floor 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.13 © Copyright Polaris Industries Inc.
  • Page 546 Seat Belt Boot Lower Floor - Front Shifter Boot Lower Floor - Rear B-Pillar - Left Closeoff Panel - Rear Lower B-Pillar - Right 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 547: Rear Cargo Box / Fenders

    LH Fender T27 Torx Screws LH Fender Flair (50″ model has smaller flair) 8 ft-lb (11 Nm) Rear Bumper Plastic Rivets Cargo Box 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 548: Rear Bumper

    BODY / FRAME REAR BUMPER Screw Mounting Brackets 8 ft-lb (11 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 549: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 550: Hood Removal

    3. Remove the dash assembly from the vehicle. NOTICE The lower dash is also held by clips. Pull the dash straight out to disengage the clips.. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 551: Front Fender / Body Removal

    Do NOT let the reservoir hang by the hose. Use a wire or string to restrain the reservoir. 5. Remove the front fender. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 552: Rocker Panel / Console / Floor

    5. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 553: Rocker Panels / Rear Console / Floor - 4 900

    Panel / Console / Floor page 11.20). 2. Remove four Torx T40 screws and five push rivets retaining the front console to the floor. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.21 © Copyright Polaris Industries Inc.
  • Page 554 10. Remove two fasteners retaining the voltage regulator to the back of the lower rear close off panel. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.22 © Copyright Polaris Industries Inc.
  • Page 555 2. Remove the four Torx T40 rear door mounting fasteners and remove door. Console and Lower Floor Removal 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.23 © Copyright Polaris Industries Inc.
  • Page 556 6. Remove two M10x1.25x20 bolts from the rear seat frame and two M10x1.50x55 bolts from the rear seat frame assembly. 7. Remove the seat frame. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.24 © Copyright Polaris Industries Inc.
  • Page 557 15. Remove the Torx screws retaining the main floor and remove the main floor from the vehicle. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 558: Doors

    Door Panel Fasteners: 22 in-lb (2 Nm) 5. Adjust the door so it properly opens and latches. Refer to Door Adjustment page 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.26 © Copyright Polaris Industries Inc.
  • Page 559 5. Holding the door in position, tighten the top hinge bracket M8 fasteners and then bottom fasteners . Torque to specification. TORQUE Door Hinge Fasteners: 8 ft-lb (11 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.27 © Copyright Polaris Industries Inc.
  • Page 560 BODY / FRAME NOTES 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 11.28 © Copyright Polaris Industries Inc.
  • Page 561 LIGHTING SYSTEM................. . . 12.28 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.1 © Copyright Polaris Industries Inc.
  • Page 562 ................. 12.40 CAN SYSTEM TESTING 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.2 © Copyright Polaris Industries Inc.

  • Page 563: General Information

    • The headlights, taillights, switches and LED light will stay on for approximately 20 seconds after the key has been switched OFF. This is a normal occurrence. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.3 © Copyright Polaris Industries Inc.

  • Page 564: Break-Out Diagram Viewing

    2. If the wiring diagram does not open the Adobe navigation bars, click on the Adobe Icon. 3. Click on the Layers Icon. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.4 © Copyright Polaris Industries Inc.
  • Page 565 5. Click on the Wiring Diagram (black & white) box to get a shadow of the full diagram behind the break-out diagram. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.5 © Copyright Polaris Industries Inc.

  • Page 566: Instrument Cluster

    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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.6 © Copyright Polaris Industries Inc.
  • Page 567 Hours Indicator - Illuminates when Hours are being displayed on the Information Display Mode Button - Used to move through the menu features. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.7 © Copyright Polaris Industries Inc.

  • Page 568: Information Display Area

    Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.8 © Copyright Polaris Industries Inc.
  • Page 569 5 hour increments to a maximum of 100 hours. 4. To turn off the service interval function, toggle the MODE button until “OFF” is displayed. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.9 © Copyright Polaris Industries Inc.
  • Page 570 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.10 © Copyright Polaris Industries Inc.

  • Page 571: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.11 © Copyright Polaris Industries Inc.
  • Page 572 CAN Low Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input International Models Only Turn Signal Input, LH Turn Signal Input, RH 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.12 © Copyright Polaris Industries Inc.

  • Page 573: Switches / Controls

    Brake Switch: 15 ft-lb (20 Nm) 4. Bleed the brake system. See Chapter 9 – BRAKE BLEEDING / FLUID CHANGE page 10.8 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.13 © Copyright Polaris Industries Inc.

  • Page 574: Ignition (Key) Switch

    • Move the switch to 2WD (NONE / OFF). There should continuity between switch pins A and B; C and D. ONLY be continuity between pins 3 and 7. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.14 © Copyright Polaris Industries Inc.

  • Page 575: Awd/2Wd/Turf Switch (Models With Turf)

    2. Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.15 © Copyright Polaris Industries Inc.

  • Page 576: Seat Belt Switch

    SWITCH TERMINALS A AND B HAZARD SWITCH (INT'L / TRACTOR) HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.16 © Copyright Polaris Industries Inc.

  • Page 577: Turn/Lights/Horn Switch (Int'l/Tractor)

    • Turn on the Right Turn Signal. There should be continuity between switch pins 1 and 7. • Depress the Horn. There should be continuity between switch pins 3 and 4. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.17 © Copyright Polaris Industries Inc.

  • Page 578: Horn

    The rear turn lights are integrated into the rear taillight. If the taillights are functioning properly but there is no blinker, check the wiring connections and the flasher module. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.18 © Copyright Polaris Industries Inc.

  • Page 579: Parking Brake Switch (Int'l/Tractor)

    1. Disconnect the harness connector at the parking brake switch (Orange/Red and Red/Blue wires). 2. Place the ohmmeter leads onto the switch terminals. The reading should be infinite (OL). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.19 © Copyright Polaris Industries Inc.

  • Page 580: Differential Solenoid Overview

    • Check the AWD / 2WD / TURF Switch wires for loose connections. • Remove solenoid from rear differential and ensure the solenoid plunger is actuating. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.20 © Copyright Polaris Industries Inc.

  • Page 581: Charging System

    Be sure to thoroughly clean the area around the stator cover prior to removal. VOLTAGE REGULATOR The regulator / rectifier is located in front of the radiator. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.21 © Copyright Polaris Industries Inc.

  • Page 582: Charging System "Break Even" Test

    2. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.22 © Copyright Polaris Industries Inc.
  • Page 583 (Y1 to Y2, Y1 to Y3, Y2 to Y3). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.23 © Copyright Polaris Industries Inc.

  • Page 584: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.24 © Copyright Polaris Industries Inc.

  • Page 585: 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. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.25 © Copyright Polaris Industries Inc.

  • Page 586: Current Draw - Key Off

    Damage will occur to electrical components. IMPORTANT Charging system damage will occur if incompatible components are installed. Always reference the Polaris Electronic Parts Catalog for the proper part numbers. NOTICE Wait ten minutes with the key off for the ECU to power down.

  • Page 587: Ocv - Open Circuit Voltage Test

    If the battery is stored or Authorized Polaris dealers/distributors are required to used at a low state of charge, hard crystal sulfation will use the conductance analyzer when testing 12V Polaris form on the plates, reducing the efficiency and service batteries.

  • Page 588: Lighting System

    Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.28 © Copyright Polaris Industries Inc.

  • Page 589: Taillights

    6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlamp Adjustment” procedure as shown in this chapter. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.29 © Copyright Polaris Industries Inc.

  • Page 590: Cooling System

    (see Chapter 3 – Cooling System Bleeding page 3.12). 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). 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.30...

  • Page 591: Radiator Fan

    For radiator fan replacement, refer to the Radiator Removal / Installation page 3.10. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.31 © Copyright Polaris Industries Inc.

  • Page 592: Starting System

    (bendix) with the flywheel. This helps prevent binding and starter damage. Voltage should not exceed 0.1 volts per connection 6. Torque upper starter mount screw to specification. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.32 © Copyright Polaris Industries Inc.

  • Page 593: Starter Solenoid

    See “ELECTRICAL SYSTEM BREAKOUTS: Starter- Interlock” provided in this chapter for starter solenoid operation. TORQUE Starter Solenoid Cable Fasteners: 35 in-lb (4 Nm) 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.33 © Copyright Polaris Industries Inc.

  • Page 594: Electronic Power Steering

    Electronic Power Steering (EPS) units are not to a normal mechanically coupled steering system. The interchangeable between ATV, RZR and RANGER system is Polaris Digital Wrench® compatible for product lines. simplified diagnostics and system troubleshooting through the vehicle’s diagnostic port.
  • Page 595 ELECTRICAL 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.35 © Copyright Polaris Industries Inc.
  • Page 596 Insr 10A Fuse Power Out Coil High Power In EFI Relay Power Out Coil Low Coil High Fuel Pump Power In Relay Power Out 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.36 © Copyright Polaris Industries Inc.

  • Page 597: Fuse Box (Rzr S 4 1000)

    Power Out Coil High Power In EFI Relay Power Out Coil Low Coil High Fuel Pump Power In Relay Power Out Coil Low 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.37 © Copyright Polaris Industries Inc.

  • Page 598: Misc. Electrical

    80% of all electrical issues are caused by bad/failed connections and grounds. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.38 © Copyright Polaris Industries Inc.

  • Page 599: Ignition Coil

    PRIMARY COIL TESTING TEST Ω RESISTANCE 0.4 Ω 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.39 © Copyright Polaris Industries Inc.

  • Page 600: Diagnostic Plug

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual 12.40 © Copyright Polaris Industries Inc.
  • Page 601 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams 2017 Click Here for 2017 RZR 900 / S 900 (non-EPS) Wiring Diagrams Click Here for 2017 RZR 900 / S 900 (EPS) Wiring Diagrams Click Here for 2017 RZR XC 900 Wiring Diagrams Click Here for 2017 RZR 900 LE (Turf) Wiring Diagrams Click Here for 2017 RZR S4 Wiring Diagrams Click Here for 2017 RZR S 1000 Wiring Diagrams...
  • Page 602 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Click Here for RZR S4 900 wiring diagrams. Click Here for RZR 900 INT’L wiring diagrams. Click Here for RZR S 1000 wiring diagrams 2019 Click Here for RZR 900 / S 900 (EPS and non-EPS) / S 1000 / S4 1000 wiring diagrams. A.4.1 Break-Out Diagram viewing Break-Out Diagrams The main wiring diagram(s) maybe found in the back of the paper manual.
  • Page 603 Break-Out Diagram viewing Break-Out diagrams for this model may be found in the online service manual in with the main wiring diagrams. To access the interactive break-out diagrams: 1. Open the wiring diagram PDF and open the left side menu. 2.
  • Page 604 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 4. Click on the box next to the breakout diagram you want to see. Deselect any other diagram that may be selected. 5. Click on the Wiring Diagram (black & white) box to get a shadow of the full diagram behind the break-out diagram.
  • Page 605 Cab Frame Assembly — 4 1000 ........ 11.4 Removal (front) ............ 10.15 Brake Removal (rear)............. 10.23 Brake Warning System .......... 10.31 Caliper. 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 606 Pressure Test ..........2.39, 3.9 Serial Number ............4.15 Radiator Cap Test...........3.10 Updates ...............4.13 Digital Wrench® Specification ............3.9 CPS ................ 4.5 Polaris Mobile Digital Wrench® (PMDW) .....4.20 Crankcase Disc Inspection (front) ..........10.19 Assembly ............3.72, 3.127 Disassembly ............3.51 Replacement (Front) ..........10.20 Disassembly / Inspection ........
  • Page 607 Crankshaft Main Bearing Selection ....3.65, 3.119 Replacement............3.10 Crankshaft Removal / Inspection ......3.54, 3.109 Fender Cylinder / Piston Installation......3.68, 3.123 Removal (rear)............. 11.19 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 608 Half Shaft Model Numbers ............1.5 Installation (rear) ............8.13 Module Removal (rear)............8.12 Flasher .............. 12.18 Hazard Switch ............12.16 Headlight Switch ............. 12.13 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 609 Installation ............8.23 Seat - Rear ............11.12 Removal...............8.21 Seat Belt Publication Numbers ........... 1.5 Switch..............12.16 Sensor Intake Cleaning............2.43 Crankshaft Position ..........4.5 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 610 One-Way Clutch Assembly ........3.130 Brake Light ............12.13 One-Way Clutch Disassembly ......... 3.105 One-Way Clutch Inspection ........3.104 Removal............. 12.32 Troubleshooting ........... 12.32 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 611 Misfire Detection ............5.32 PVT..............6.33 Transmission Shifting Difficulty ........7.33 Turn Lights............. 12.18 Turn/Lights/Horn Switch..........12.17 Upper Dash Removal............. 11.18 Valve Clearance Adjustment ........... 3.139 9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual IX.7 © Copyright Polaris Industries Inc.

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