Polaris RZR 900 2015 Service Manual
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Polaris RZR 900 2015 Service Manual

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Table of Contents

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2015-2016 RZR 900
2016 RZR S 1000
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 2015 (PN 9926814 R08)
© Copyright 2017 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 2015

  • Page 1 Publication Printed September 2015 (PN 9926814 R08) © Copyright 2017 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 Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX DATE...
  • Page 5 2015-2016 RZR 900 2016 RZR S 1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM...

  • Page 7: Table Of Contents

    ................1.33 DECIMAL EQUIVALENTS 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 8: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 9: Vehicle And Engine Serial Number Location

    The engine serial number can be found on a decal applied to the front of the engine crankcase 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 10: Misc. Information

    2016 RZR S 1000 9926384 9926385 NOTE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual...

  • Page 11: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 12: Special Tools

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier.
  • Page 13 8700226 9314177-A Roll Pin Removal Tool Combination Pliers Spanner Wrench / CV Boot Clamp Pliers Drive Clutch Holding (27″) Clutch Spreader (ear) Tool 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 PU-50566 PU-50578 PU-50624 Water Pump Seal Oil Pressure Gauge Transmission Nut Clutch Spider Nut Rolling Engine Stand Installer Adapter (1/2 NPT) Socket Socket 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 PV-48656 PW-47053 PW-47054 Fluke Multimeter Piston Ring Fuel Pressure Gauge Bench Mount Engine Engine Stand Adapter Compressor Pliers Adapter Stand Sleeve (2 3/8″) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 16: General Specifications

    Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.10 Manual © Copyright Polaris Industries Inc.
  • Page 17 For clutch specifications / High Altitude setup, see PVT 10A Term System chapter – Clutch Charts, page 5.4 10A Accessory Fuses 10A Drive 15A Lights 20A EPS (if appl.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.11 Manual © Copyright Polaris Industries Inc.

  • Page 18: 2015 Rzr 900 Xc Specifications

    Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.12 Manual © Copyright Polaris Industries Inc.
  • Page 19 Fuses 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.13 Manual © Copyright Polaris Industries Inc.

  • Page 20: 2015 Rzr S 900 Specifications

    Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.14 Manual © Copyright Polaris Industries Inc.
  • Page 21 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.15 Manual © Copyright Polaris Industries Inc.
  • Page 22 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.16 Manual © Copyright Polaris Industries Inc.
  • Page 23 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.17 Manual © Copyright Polaris Industries Inc.
  • Page 24 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.18 Manual © Copyright Polaris Industries Inc.
  • Page 25 For clutch specifications / High Altitude setup, see PVT 10A Term System chapter – Clutch Charts, page 5.4 10A Accessory Fuses 10A Drive 15A Lights 20A EPS (if appl.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.19 Manual © Copyright Polaris Industries Inc.
  • Page 26 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.20 Manual © Copyright Polaris Industries Inc.
  • Page 27 Fuses 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.21 Manual © Copyright Polaris Industries Inc.
  • Page 28 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.22 Manual © Copyright Polaris Industries Inc.
  • Page 29 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.23 Manual © Copyright Polaris Industries Inc.
  • Page 30 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.24 Manual © Copyright Polaris Industries Inc.
  • Page 31 Fuses 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.25 Manual © Copyright Polaris Industries Inc.
  • Page 32 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) Hitch Towing Capacity 1500 lbs (680 kg) Hitch Tongue Capacity 150 lbs (68 kg) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.26 Manual © Copyright Polaris Industries Inc.
  • Page 33 10A EFI System chapter – Clutch Charts, page 5.4 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.27 Manual © Copyright Polaris Industries Inc.

  • Page 34: Misc. Specifications And Charts

    Engine Mount to Frame 22 ft-lb (30 Nm) Fasteners 89 in-lb (10 Nm) Coolant Bleed Screw Engine Oil Plug 12 ft-lbs (16 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.28 Manual © Copyright Polaris Industries Inc.
  • Page 35 35 in-lb (4 Nm) Parking Brake Caliper Fasteners 37 ft-lb (50 Nm) Mount Bracket Bolts 9 ft-lb (12 Nm) Stator Cover Screws 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.29 Manual © Copyright Polaris Industries Inc.
  • Page 36 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.30 Manual © Copyright Polaris Industries Inc.

  • Page 37: Conversion Table

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.31 Manual © Copyright Polaris Industries Inc.

  • Page 38: Sae Tap / Drill Sizes

    5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.32 Manual © Copyright Polaris Industries Inc.

  • Page 39: Decimal Equivalents

    0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.33 Manual © Copyright Polaris Industries Inc.
  • Page 40 GENERAL INFORMATION NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 1.34 Manual © Copyright Polaris Industries Inc.
  • Page 41 ..............2.24 WHEEL AND HUB TORQUE TABLE 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 42 ................. . .2.36 SPARK PLUG SERVICE 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 43: Maintenance

    Have an authorized Polaris dealer perform these services. Severe Use Definition • Frequent immersion in mud, water or sand •...

  • Page 44: Maintenance Intervals

    Front / Rear Suspension 500 (800) Lubricate (if applicable) 50 H Inspect coolant strength seasonally; pressure test ■ Cooling System 500 (800) 50 H system yearly 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 45 Adjust as needed ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual ©...

  • Page 46: Maintenance Quick Reference

    Coolant Radiator bottle and radiator. * More often under severe use, such as operation in water or under severe loads. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 47 Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 48: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 49: General Vehicle Inspection And Maintenance

    U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 2870652 16 oz (12) Fuel Stabilizer 2.5 gal (2) 2872280 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 50: Pre-Ride / Daily Inspection

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.10 Manual © Copyright Polaris Industries Inc.

  • Page 51: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.11 Manual © Copyright Polaris Industries Inc.

  • Page 52: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.12 Manual © Copyright Polaris Industries Inc.

  • Page 53: 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:...

  • Page 54: Engine Oil And Filter Change

    TORQUE 5. Remove the seats and engine service panel to Engine Oil Drain Plug: access the oil filter. 12 ft-lbs (16 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.14 Manual © Copyright Polaris Industries Inc.

  • Page 55: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.15 Manual © Copyright Polaris Industries Inc.
  • Page 56 IMPORTANT Do not rotate the engine backwards. The timing chain may jump teeth and lead to poor performance. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.16 Manual © Copyright Polaris Industries Inc.
  • Page 57 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.17 Manual © Copyright Polaris Industries Inc.

  • Page 58: 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...

  • Page 59: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.19 Manual © Copyright Polaris Industries Inc.

  • Page 60: Radiator Inspection / Cleaning

    8. Refer to Chapter 3 – Cooling System Bleeding, page 3.16. Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2880514) (Quart) (PN 2880513) (Gallon) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.20 Manual © Copyright Polaris Industries Inc.

  • Page 61: Fuel System

    1. Remove the seats and the engine service panel. 2. Check the fuel tank vent line for signs of wear, deterioration or damage. Replace vent line if necessary. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.21 Manual © Copyright Polaris Industries Inc.

  • Page 62: Fuel Pump / Fuel Filter

    Refer to Chapter 4 for Fuel Pump Replacement, page 4.18 and all other information related to the EFI System. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.22 Manual © Copyright Polaris Industries Inc.

  • Page 63: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.23 Manual © Copyright Polaris Industries Inc.

  • Page 64: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.24 Manual © Copyright Polaris Industries Inc.

  • Page 65: Tire Pressure

    16 psi (110 kPa) 20 psi (138 kPa) RZR 4 900 10 psi (69 kPa) 14 psi (97 kPa) RZR S 1000 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.25 Manual © Copyright Polaris Industries Inc.

  • Page 66: Transmission And Front Gearcase

    Capacity (without Turf mode): 44 oz. (1300 ml) 4. Reinstall the fill plug and torque to specification. Capacity (with Turf mode): 40.5 oz. (1200 ml) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.26 Manual © Copyright Polaris Industries Inc.

  • Page 67: Front Gearcase Lubrication

    4. Reinstall the fill plug and torque to specification. 10 ft-lbs (14 Nm) 12. Check for leaks. Dispose of used fluid properly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.27 Manual © Copyright Polaris Industries Inc.

  • Page 68: 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 69: Wheel Toe Alignment Inspection

    This will tell you which tie rod needs adjusting. NOTE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.29 Manual © Copyright Polaris Industries Inc.
  • Page 70 • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.30 Manual © Copyright Polaris Industries Inc.

  • Page 71: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.31 Manual © Copyright Polaris Industries Inc.

  • Page 72: Spring Adjustment (Fox)

    1. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend. Shock Spanner Wrench: 2877408 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.32 Manual © Copyright Polaris Industries Inc.

  • Page 73: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.33 Manual © Copyright Polaris Industries Inc.

  • Page 74: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.34 Manual © Copyright Polaris Industries Inc.

  • Page 75: Electrical / Ignition System

    NOTE 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 76: Engine / Chassis Ground

    4. Rinse plug wells with water and dry with compressed air. NOTE Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.36 Manual © Copyright Polaris Industries Inc.
  • Page 77 Ensure wires are pushed down all the way so they engage onto the spark plugs. 13. Reinstall the cargo box access panel. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.37 Manual © Copyright Polaris Industries Inc.
  • Page 78 MAINTENANCE NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 2.38 Manual © Copyright Polaris Industries Inc.
  • Page 79 ............3.40 CAMSHAFT SPROCKET INSPECTION 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 80 ..............3.90 VALVE LASH - TAPPET SELECTION 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 81 ..............3.134 STATOR COVER INSTALLATION 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 82 ..............3.145 VALVE COVER INSTALLATION 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 83: Engine - General

    220° F: 60 PSI * Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 84: Main Engine Components - Torque Specification And Sequence

    ENGINE / COOLING SYSTEM MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 85: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

    ENGINE / COOLING SYSTEM BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 86: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

    ENGINE / COOLING SYSTEM CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 87: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 88: Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover

    ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THERMOSTAT HOUSING / TRANS JOINT / VALVE COVER 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.10 Manual © Copyright Polaris Industries Inc.

  • Page 89: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.11 Manual © Copyright Polaris Industries Inc.

  • Page 90: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.12 Manual © Copyright Polaris Industries Inc.

  • Page 91: Cooling System Specifications

    If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, clamps and water pump seal for signs of leaking. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.13 Manual © Copyright Polaris Industries Inc.

  • Page 92: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.14 Manual © Copyright Polaris Industries Inc.

  • Page 93: Thermostat Replacement

    Fan Motor Control Radiator THERMOSTAT REPLACEMENT 1. Remove the hood. 2. Remove the pressure cap to relieve any system pressure. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.15 Manual © Copyright Polaris Industries Inc.

  • Page 94: Cooling System Bleeding

    7. Clean the thermostat mating surfaces on the engine and thermostat cover. 4. Remove the radiator pressure cap and add the necessary amount of Polaris Premium Antifreeze to 8. Install a new thermostat and seal into the cover and the radiator. install the cover onto the engine.

  • Page 95: 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 96 14. Rotate the water pump shaft after seal installation to verify free movement. 15. Place impeller onto the water pump shaft. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.18 Manual © Copyright Polaris Industries Inc.
  • Page 97 21. Install water pump assembly into the engine. (see Chapter 3 – Water Pump Installation, page 3.21) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.19 Manual © Copyright Polaris Industries Inc.
  • Page 98 ENGINE / COOLING SYSTEM Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.20 Manual © Copyright Polaris Industries Inc.

  • Page 99: Water Pump Installation

    Be sure orientation and routing are correct. 10. Connect the (-) negative battery cable. 11. Fill and bleed the cooling system. (see Cooling System Bleeding, page 3.16) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.21 Manual © Copyright Polaris Industries Inc.

  • Page 100: Engine Service

    2.5 Quarts (2.4 L) Test results are based on the use of the recommended PU-50105 or 2.5″ (64 engine oil (Polaris PS-4 or PS-4 Extreme Duty) at Oil Filter Wrench operating temperature, and may vary considerably if any other oil is used or if the engine is not up to...

  • Page 101: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.23 Manual © Copyright Polaris Industries Inc.

  • Page 102: Accessible Engine Components

    4. To install, reverse the procedure. Tighten fasteners to specification. 4. Remove the seat and ECU cover panel. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.24 Manual © Copyright Polaris Industries Inc.
  • Page 103 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.25 Manual © Copyright Polaris Industries Inc.
  • Page 104 Differential Relay (if equipped) 14. Remove the ignition coil by disconnecting the wiring leads and removing the two mounting bolts. Remove the spark plug caps. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.26 Manual © Copyright Polaris Industries Inc.
  • Page 105 (PN 2872085). CAUTION Be careful not to pinch or kink the fuel rail. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.27 Manual © Copyright Polaris Industries Inc.

  • Page 106: Engine Installation

    26. Remove the six engine-to-transmission mounting bolts. 27. Remove the four bolts retaining the engine to the front engine mount. 28. Remove the engine from the frame. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.28 Manual © Copyright Polaris Industries Inc.
  • Page 107 Torque bolts to specification. i.e. 2015 RZR 900 uses the holes marked with a 4 TORQUE Inner Clutch Cover Fasteners 10 ft-lb (14 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.29 Manual © Copyright Polaris Industries Inc.
  • Page 108 Lower: 22 ft-lb (30 Nm) 12. Install the two fuel rail mounting fasteners. Torque fasteners to specification. TORQUE Fuel Rail Mounting Fasteners 5 ft-lb (7 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.30 Manual © Copyright Polaris Industries Inc.
  • Page 109 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.31 Manual © Copyright Polaris Industries Inc.
  • Page 110 See Chapter 3 – Cooling System Bleeding, page 3.16 27. Connect battery. Torque fasteners specification. TORQUE Battery Terminal Fasteners: 60 in-lb (7 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.32 Manual © Copyright Polaris Industries Inc.

  • Page 111: 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 112: Troubleshooting

    • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring • Lack of lubrication 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.34 Manual © Copyright Polaris Industries Inc.

  • Page 113: Cooling System

    Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.35 Manual © Copyright Polaris Industries Inc.

  • Page 114: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.36 Manual © Copyright Polaris Industries Inc.
  • Page 115 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.37 Manual © Copyright Polaris Industries Inc.

  • Page 116: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.38 Manual © Copyright Polaris Industries Inc.
  • Page 117 9. Using a paperclip or other tool, hold cam chain up. NOTE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.39 Manual © Copyright Polaris Industries Inc.

  • Page 118: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.40 Manual © Copyright Polaris Industries Inc.
  • Page 119 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.41 Manual © Copyright Polaris Industries Inc.

  • Page 120: Cylinder Head Removal

    DO NOT rotate the engine without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal, page 3.60. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.42 Manual © Copyright Polaris Industries Inc.

  • Page 121: Cylinder Head Disassembly

    7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.43 Manual © Copyright Polaris Industries Inc.

  • Page 122: Valve Inspection

    0.2165 - 0.2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.44 Manual © Copyright Polaris Industries Inc.

  • Page 123: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.45 Manual © Copyright Polaris Industries Inc.
  • Page 124 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE Remove only the amount of material necessary to repair the seat surface. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.46 Manual © Copyright Polaris Industries Inc.
  • Page 125 Service Limit: 0.075" (1.9 mm) 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.47 Manual © Copyright Polaris Industries Inc.
  • Page 126 12. Thoroughly clean cylinder head and valves. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.48 Manual © Copyright Polaris Industries Inc.

  • Page 127: Engine Disassembly / Inspection - Lower End (900)

    . If replacement is required, refer to Chapter 10. 4. Inspect the ball bearing that supports the starter motor shaft. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.49 Manual © Copyright Polaris Industries Inc.

  • Page 128: Water Pump Housing Removal

    Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.50 Manual © Copyright Polaris Industries Inc.

  • Page 129: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.51 Manual © Copyright Polaris Industries Inc.

  • Page 130: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.52 Manual © Copyright Polaris Industries Inc.

  • Page 131: Crankcase Disassembly

    2. Remove the crankcase drain plug to drain any oil 7. Remove the sump cover from the crankcase. remaining in the engine. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.53 Manual © Copyright Polaris Industries Inc.
  • Page 132 Access the sprocket bolt by removing the case plug. 13. Rotate the engine so the cylinder is facing up. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.54 Manual © Copyright Polaris Industries Inc.

  • Page 133: Balance Shaft Removal / Inspection

    Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.55 Manual © Copyright Polaris Industries Inc.

  • Page 134: Crankshaft Removal / Inspection

    . Remove the end caps from the crankshaft. 8. If the crankshaft gear is damaged, the crankshaft assembly must be replaced. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.56 Manual © Copyright Polaris Industries Inc.
  • Page 135 MAG End PTO Rod Journal Main Journal 1 Main Journal 3 MAG Rod Journal Main Journal 4 Main Journal 2 PTO End 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.57 Manual © Copyright Polaris Industries Inc.
  • Page 136 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.58 Manual © Copyright Polaris Industries Inc.

  • Page 137: Crankcase Inspection

    NOTE Always replace plain bearings when the crankcase or connecting rods have been disassembled. Refer to Crankshaft Main Bearing Selection, page 3.67. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.59 Manual © Copyright Polaris Industries Inc.

  • Page 138: Cylinder / Piston Removal

    Inspect cylinder for wear, scratches, or damage. NOTE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.60 Manual © Copyright Polaris Industries Inc.

  • Page 139: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.61 Manual © Copyright Polaris Industries Inc.

  • Page 140: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.62 Manual © Copyright Polaris Industries Inc.

  • Page 141: Piston Ring To Groove Clearance Inspection

    Oil Control Rails: .010 - .040" (.25 - 1.02 mm) Service Limit: .059" (1.50 mm) NOTE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.63 Manual © Copyright Polaris Industries Inc.

  • Page 142: Piston-To-Cylinder Clearance

    TORQUE Connecting Rod Bolts: Step 1: 9 ft-lb (12 Nm) Step 2: 22 ft-lb (30 Nm) Step 3: Tighten add’n 90° 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.64 Manual © Copyright Polaris Industries Inc.
  • Page 143 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.65 Manual © Copyright Polaris Industries Inc.

  • Page 144: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.66 Manual © Copyright Polaris Industries Inc.

  • Page 145: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.67 Manual © Copyright Polaris Industries Inc.

  • Page 146: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.68 Manual © Copyright Polaris Industries Inc.

  • Page 147: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.69 Manual © Copyright Polaris Industries Inc.

  • Page 148: Cylinder / Piston Installation

    10. Carefully place the cylinder and pistons into the upper crankcase. NOTE Orientation arrow is also located on the bottom side of piston as an additional reference. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.70 Manual © Copyright Polaris Industries Inc.

  • Page 149: 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 150: 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 151: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.73 Manual © Copyright Polaris Industries Inc.

  • Page 152: 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 9. Install the eight M10 , one M6 and two M8 installed in the lower crankcase half.
  • Page 153 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.75 Manual © Copyright Polaris Industries Inc.
  • Page 154 NOTE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.76 Manual © Copyright Polaris Industries Inc.
  • Page 155 26. Rotate the engine so the cylinder is facing up. 27. Reinstall the oil cooler , if previously removed. Use new O-rings upon installation 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.77 Manual © Copyright Polaris Industries Inc.

  • Page 156: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.78 Manual © Copyright Polaris Industries Inc.

  • Page 157: Engine Assembly - Top End (900)

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.79 Manual © Copyright Polaris Industries Inc.

  • Page 158: Valve Sealing Test

    NOTE Oil the tappet prior to installing. If any valve train components were replaced, refer to Valve Clearance Adjustment, page 3.87. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.80 Manual © Copyright Polaris Industries Inc.

  • Page 159: Cylinder Head Installation

    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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.81 Manual © Copyright Polaris Industries Inc.

  • Page 160: Camshaft Installation / Timing

    Exhaust Camshaft - PN 1204584 an open-end wrench to rotate camshafts slightly if needed. 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.82...
  • Page 161 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.83...
  • Page 162 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 163 • 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.85 Manual © Copyright Polaris Industries Inc.

  • Page 164: Camshaft Timing - Quick Reference

    Intake Cam Align Exhaust Marks With Surface Exhaust Cam CPS Mounting Hole Align Intake Marks With Surface Align Flywheel Mark in Mounting Hole 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.86 Manual © Copyright Polaris Industries Inc.

  • Page 165: Valve Clearance Adjustment

    Intake Camshaft - PN 1204583 Exhaust Camshaft - PN 1204584 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. TORQUE Camshaft Carrier Bolts: 89 in-lbs (10 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.87...
  • Page 166 3-digit tappet number. 13. Refer to the appropriate tappet selection matrix (Intake or Exhaust) on the following pages and select the proper tappet. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.88 Manual © Copyright Polaris Industries Inc.
  • Page 167 19. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to Camshaft Installation / Timing, page 3.82. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.89 Manual © Copyright Polaris Industries Inc.

  • Page 168: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.90 Manual © Copyright Polaris Industries Inc.

  • Page 169: Valve Cover Installation

    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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.91 Manual © Copyright Polaris Industries Inc.

  • Page 170: 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° 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.92 Manual © Copyright Polaris Industries Inc.
  • Page 171 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.93 Manual © Copyright Polaris Industries Inc.

  • Page 172: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.94 Manual © Copyright Polaris Industries Inc.
  • Page 173 NOTE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.95 Manual © Copyright Polaris Industries Inc.

  • Page 174: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.96 Manual © Copyright Polaris Industries Inc.

  • Page 175: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.97 Manual © Copyright Polaris Industries Inc.

  • Page 176: Cylinder Head Removal

    Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal, Service Limit: page 3.116. .0039" (0.1 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.98 Manual © Copyright Polaris Industries Inc.

  • Page 177: Cylinder Head Warp Inspection

    Note the tappet size engraved on the underside of the bucket. MEASUREMENT Cylinder Head Warp Limit: .0039″ (0.1 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.99 Manual © Copyright Polaris Industries Inc.

  • Page 178: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.100 Manual © Copyright Polaris Industries Inc.

  • Page 179: Combustion Chamber Cleaning

    .2165 - .2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.101 Manual © Copyright Polaris Industries Inc.

  • Page 180: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.102 Manual © Copyright Polaris Industries Inc.
  • Page 181 6. Insert valve into guide and tap valve lightly into place a few times. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.103 Manual © Copyright Polaris Industries Inc.
  • Page 182 .0393 ± .0039" (1.0 ± 0.10 mm) Service Limit: .0551" (1.4 mm) Exhaust: .0590 ± .0039" (1.5 ± 0.10 mm) Service Limit: .0748" (1.9 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.104 Manual © Copyright Polaris Industries Inc.

  • Page 183: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.105 Manual © Copyright Polaris Industries Inc.

  • Page 184: Water Pump Housing Removal

    Water Pump Service, page 2. Remove the three long gold colored bolts retaining the water pump housing to the engine. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.106 Manual © Copyright Polaris Industries Inc.

  • Page 185: Flywheel Removal

    5. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel (left hand thread - turn flywheel puller counterclockwise to install). 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.107 Manual © Copyright Polaris Industries Inc.

  • Page 186: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.108 Manual © Copyright Polaris Industries Inc.

  • Page 187: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.109 Manual © Copyright Polaris Industries Inc.
  • Page 188 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.110 Manual © Copyright Polaris Industries Inc.

  • Page 189: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.111 Manual © Copyright Polaris Industries Inc.

  • Page 190: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.112 Manual © Copyright Polaris Industries Inc.
  • Page 191 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.113 Manual © Copyright Polaris Industries Inc.

  • Page 192: Crankcase Inspection

    Crankshaft Main Bearing Selection, page 3.122 and Connecting Rod Bearing Selection, page 3.122 procedures. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.114 Manual © Copyright Polaris Industries Inc.

  • Page 193: Cylinder Inspection

    Inspect cylinder for wear, scratches, or damage. NOTE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.115 Manual © Copyright Polaris Industries Inc.

  • Page 194: Cylinder / Piston Removal

    (MAG / PTO). 4. Carefully lift the cylinder and pistons from the upper crankcase. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.116 Manual © Copyright Polaris Industries Inc.

  • Page 195: Piston Disassembly / Inspection (1000)

    DO NOT apply heat to piston rings or a loss of radial MEASUREMENT tension could result. Piston Pin O.D.: .7873 - .7875" (20.000 - 20.005 mm) Service Limit: .7866" (19.98 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.117 Manual © Copyright Polaris Industries Inc.

  • Page 196: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.118 Manual © Copyright Polaris Industries Inc.

  • Page 197: Piston Ring Installed Gap (1000)

    Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.119 Manual © Copyright Polaris Industries Inc.
  • Page 198 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). 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.120 Manual © Copyright Polaris Industries Inc.

  • Page 199: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.121 Manual © Copyright Polaris Industries Inc.

  • Page 200: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings Blue Blue Green Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.122 Manual © Copyright Polaris Industries Inc.

  • Page 201: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.123 Manual © Copyright Polaris Industries Inc.
  • Page 202 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.124 Manual © Copyright Polaris Industries Inc.

  • Page 203: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.125 Manual © Copyright Polaris Industries Inc.

  • Page 204: Cylinder / Piston Installation

    NOTE Orientation arrow is also located on the bottom side of piston as an additional reference. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.126 Manual © Copyright Polaris Industries Inc.

  • Page 205: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.127 Manual © Copyright Polaris Industries Inc.
  • Page 206 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 207: 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 208: 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 9. Install the eight M10 , two M8 and one M6 installed in the lower crankcase half.
  • Page 209 11. Rotate the engine so the cylinder is facing up. 12. Install the eleven M6 and two M8 upper crankcase bolts. Tighten all bolts lightly by hand. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.131 Manual © Copyright Polaris Industries Inc.
  • Page 210 NOTE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.132 Manual © Copyright Polaris Industries Inc.

  • Page 211: 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 3.134 and then Cylinder Head Installation, page 3.136. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.133 Manual © Copyright Polaris Industries Inc.

  • Page 212: Flywheel Installation

    9 ft-lb (12 Nm) NOTE Loctite cures with time, the longer the unit is let stand before engine starting the better the joint will be. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.134 Manual © Copyright Polaris Industries Inc.

  • Page 213: Engine Assembly - Top End (1000)

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.135 Manual © Copyright Polaris Industries Inc.

  • Page 214: Cylinder Head Installation

    5. Carefully set the cylinder head in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder head bolts evenly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.136 Manual © Copyright Polaris Industries Inc.

  • Page 215: 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 216 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.138 Manual © Copyright Polaris Industries Inc.
  • Page 217 18. Install the front camshaft carrier and two outer retaining bolts. 19. Install the fixed cam chain guide and two retaining bolts. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.139 Manual © Copyright Polaris Industries Inc.
  • Page 218 • Install the two mounting bolts. Torque fasteners to Camshaft Carrier Bolts: specification. 7 ft-lb (10 Nm) TORQUE 21. Apply Polaris PS-4 engine oil to the cam chain Tensioner Mounting Bolts: tensioner bore prior to assembly. Use a new 7 ft-lb (10 Nm) tensioner sealing washer 22.

  • Page 219: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.141 Manual © Copyright Polaris Industries Inc.

  • Page 220: 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 221 NOTE Lubricate the outer portion of the valve tappet upon installation. 15. Repeat steps 10-14 until all necessary valves have been adjusted. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.143 Manual © Copyright Polaris Industries Inc.

  • Page 222: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.144 Manual © Copyright Polaris Industries Inc.

  • Page 223: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts to specification. TORQUE Spark Plugs: 7 ft-lbs (10 Nm) Valve Cover Bolts: 7 ft-lbs (10 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.145 Manual © Copyright Polaris Industries Inc.
  • Page 224 ENGINE / COOLING SYSTEM NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 3.146 Manual © Copyright Polaris Industries Inc.
  • Page 225 ................4.26 OPERATION OVERVIEW 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 226 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........

  • Page 227: 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/ 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 228: Efi Overview

    ECU computer chip, and the ECU adjusts the fuel delivery and ignition timing based on these values. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 229: Electronic Control Unit (Ecu)

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

  • Page 230: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 231: Fuel Injectors

    Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 232: Fuel Injector Test

    MAG harness lead to the MAG injector to ensure proper engine operation. FUEL INJECTOR REPLACEMENT CAUTION Be sure the engine has cooled enough to work on. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 233 Take care not to damage the fuel injector ends during removal. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 234 20. Reinstall the breather into the air box and tighten the hose clamps retaining the air box to the throttle body assembly. 21. Reinstall the two screws retaining the air box assembly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.10 Manual © Copyright Polaris Industries Inc.

  • Page 235: Fuel Tank

    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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.11 Manual © Copyright Polaris Industries Inc.

  • Page 236: Fuel Line Removal / Installation

    4. Disconnect the fuel pump electrical harness 3. Pull on the fuel line to remove. 4. To install, verify the connections are clean and undamaged. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.12 Manual © Copyright Polaris Industries Inc.
  • Page 237 10. Remove the Torx screws and plastic rivets the console. Remove the console from the vehicle. retaining the block-off panel using a T40 Torx bit. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.13 Manual © Copyright Polaris Industries Inc.

  • Page 238: Fuel Tank Installation

    11. Connect the fuel line and fuel pump electrical harness. Verify connections are secure. 12. Install the battery and battery bracket. Torque fasteners to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.14 Manual © Copyright Polaris Industries Inc.
  • Page 239 13. Install both seats and test the fuel pump by turning the ignition key ON and listening for the fuel pump to activate. Check fuel line fittings for leaks. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.15 Manual © Copyright Polaris Industries Inc.

  • Page 240: Fuel Pump

    • If the engine is stopped with the key switch "on" (as in 1. Remove the passenger seat from the vehicle. the case of an accident). 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.16 Manual © Copyright Polaris Industries Inc.
  • Page 241 ECU operation by plugging in a known-good ECU of the same model. NOTE If the pump still does not operate, replace the fuel pump assembly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.17 Manual © Copyright Polaris Industries Inc.

  • Page 242: Fuel Pump Replacement

    5. While holding a shop towel over the fuel line connectors, disconnect the fuel supply line from the pump. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.18 Manual © Copyright Polaris Industries Inc.
  • Page 243 Do not use water or any other chemicals to remove debris. NOTE Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.19 Manual © Copyright Polaris Industries Inc.
  • Page 244 IMPORTANT Failure to align the orientation marks may lead to interferences with the fuel level float arm and cause incorrect function. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.20 Manual © Copyright Polaris Industries Inc.

  • Page 245: Temperature And Manifold Absolute Pressure Sensor (T-Map)

    ECU and compared to its programming for determining the fuel and ignition requirements during engine operation. The T-MAP provides the ECU with engine load data. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.21 Manual © Copyright Polaris Industries Inc.

  • Page 246: 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 4.23 procedure. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.22 Manual © Copyright Polaris Industries Inc.

  • Page 247: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.23 Manual © Copyright Polaris Industries Inc.

  • Page 248: Electronic Throttle Control (Etc) / Throttle Body

    ETC housing performed. If a problem is encountered, and you to intake plenum. determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization. Use Digital Wrench® to perform all troubleshooting of this component.

  • Page 249: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.25 Manual © Copyright Polaris Industries Inc.

  • Page 250: Pedal Position Sensor (Pps)

    The PPS is calibrated to the throttle pedal. If the PPS is faulty, the throttle pedal assembly must be replaced. 6. Install the negative (-) battery cable. Torque fastener to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.26 Manual © Copyright Polaris Industries Inc.
  • Page 251 FUEL SYSTEM TORQUE Battery Terminal Fasteners 60 in-lb (7 Nm) 7. Connect the PPS harness to the throttle pedal. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.27 Manual © Copyright Polaris Industries Inc.

  • Page 252: Oxygen Sensor (Rzr S 1000)

    1. Disconnect the harness going to the oxygen sensor. 2. Remove the oxygen sensor from the exhaust pipe. 3. Install new oxygen sensor. Torque sensor to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.28 Manual © Copyright Polaris Industries Inc.
  • Page 253 FUEL SYSTEM TORQUE Oxygen Sensor: 13 ft-lb (18 Nm) 4. Connect the harness going to the oxygen sensor. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.29 Manual © Copyright Polaris Industries Inc.

  • Page 254: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.30 Manual © Copyright Polaris Industries Inc.
  • Page 255 ECU control of the crank when key is turned to START Start Enable Driver start solenoid ECU is not grounding the start solenoid Inactive 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.31 Manual © Copyright Polaris Industries Inc.
  • Page 256 On or Off Inactive AWD or 2WD mode How fast the transmission output Vehicle Speed — varies is turning (calculated to wheel speed) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.32 Manual © Copyright Polaris Industries Inc.

  • Page 257: Trouble Code Display (Dtc)

    MODE button or turn the ignition key OFF once the codes are recorded. 2. Press and hold the MODE button to enter the diagnostics code menu. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.33 Manual © Copyright Polaris Industries Inc.
  • Page 258 P0112 MAP) Abnormal rate of Change P0114 Valid But Above Normal P0127 (least severe) Engine Temperature Sensor Engine Overheat Shutdown P1217 (ECT) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.34 Manual © Copyright Polaris Industries Inc.
  • Page 259 P1262 Driver Circuit Open P0261 P0265 Driver Circuit Short to B+ Injector 2 (PTO) Driver Circuit Grounded P1265 Driver Circuit Open P0264 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.35 Manual © Copyright Polaris Industries Inc.
  • Page 260 3599 Valid But Above Normal P17AD (least severe) Valid But Below Normal P17AF (least severe) Cylinder Not Identified Misfire Detected 65590 P0314 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.36 Manual © Copyright Polaris Industries Inc.
  • Page 261 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.37 Manual © Copyright Polaris Industries Inc.
  • Page 262 Repeated Adaptation Failed Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.38 Manual © Copyright Polaris Industries Inc.
  • Page 263 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.39 Manual © Copyright Polaris Industries Inc.

  • Page 264: Efi Troubleshooting

    • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.40 Manual © Copyright Polaris Industries Inc.

  • Page 265: Polaris Digital Wrench

    Refer to Section 2, 3 and 4 in the Instruction Manual • Perform output state control tests (some models) provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the...

  • Page 266: Digital Wrench Software Version And Update

    4. The Digital Wrench® portal website should appear in a new web browser. 5. Click on “Digital Wrench Version Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. NOTE You must already have the current version installed before adding an update.

  • Page 267: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.43 Manual © Copyright Polaris Industries Inc.

  • Page 268: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.44 Manual © Copyright Polaris Industries Inc.

  • Page 269: Digital Wrench® Feature Map

    Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.45 Manual © Copyright Polaris Industries Inc.

  • Page 270: Ecu Replacement

    ECU. • Proceed to http://polaris.diagsys.com for specific The Digital Wrench® Engine Controller Reprogramming information and FAQs on how to troubleshoot (or “Reflash”) feature allows reprogramming of the ECU communication problems.
  • Page 271 EXACTLY as they appear on the screen. 9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop- down menu. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.47 Manual © Copyright Polaris Industries Inc.
  • Page 272 12. An “Authorization Key” will appear in the upper left corner of the screen. Copy this key exactly as it appears. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.48 Manual © Copyright Polaris Industries Inc.

  • Page 273: Polaris Mobile Digital Wrench (Pmdw)

    To access the user’s guide, launch the app, and then (PMDW) click on the “Help” button in the Settings/Preferences Polaris Mobile Digital Wrench (PMDW) is a diagnostic menu. software application (app) designed specifically for • Only CAN-based vehicles are compatible with PMDW Android™...
  • Page 274 FUEL SYSTEM NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 4.50 Manual © Copyright Polaris Industries Inc.
  • Page 275 ............... .5.31 DRIVEN CLUTCH ASSEMBLY 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 276 ............... .5.41 PVT OVERHEATING / DIAGNOSIS 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 277: General Information

    1-800-345-2233 or http://polaris.service-solutions.com/ Shift Weight Fasteners 20 in-lb (2 Nm) Spring/Helix Cover Screws (EBS) 48 in-lb (5 Nm) 12 ft-lb (16 Spring Cover Screws (non-EBS) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 278: Clutch Charts

    ALTITUDE WEIGHT SPRING SPRING 0-1800 29–66 Black / Red / (0-6000) (5633496) Meters White (Feet) 1800-3700 29-59 (7044263) (7044505) (6000 - 12000) (5633319) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 279: Pvt System Overview

    The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage.

  • Page 280: Driven Clutch Operation

    PVT area. This is especially critical on units subjected to frequent water forging. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 281: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 282: Rzr 4 900 / S 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 283: Pvt Disassembly

    8. Remove the inner clutch cover from the vehicle. 4. Remove the drive belt. (see Chapter 5 – Belt Removal (EBS), page 5.11) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 284: Pvt Assembly

    Outer Clutch Cover Screws: 54 in-lb (5 Nm) 8. Install second intake hose onto PVT cover and tighten hose clamp until taught. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.10 Manual © Copyright Polaris Industries Inc.

  • Page 285: Drive Belt

    4. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.11 Manual © Copyright Polaris Industries Inc.

  • Page 286: Belt Removal (Non-Ebs)

    4. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.12 Manual © Copyright Polaris Industries Inc.

  • Page 287: Belt Inspection

    TORQUE Outer Clutch Cover Retaining Screws: 54 in-lb (5 Nm) 6. Install the grease fitting on the left rear upper control arm. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.13 Manual © Copyright Polaris Industries Inc.

  • Page 288: Pvt Break-In (Drive Belt / Clutches)

    RPM during the break-in period. In addition, when operating in sand/dune environments, avoid extended low speed operation at high throttle. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.14 Manual © Copyright Polaris Industries Inc.

  • Page 289: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.15 Manual © Copyright Polaris Industries Inc.

  • Page 290: Drive Clutch Disassembly

    MUST be replaced. spacer. Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.16 Manual © Copyright Polaris Industries Inc.

  • Page 291: Bearing Inspection

    Excessive drag in the bearing may cause difficult shifting or vehicle creep at idle. Color Black / Red Free Length 3.219″ (81.76 mm) Spring Wire Diameter 0.177″ (4.50 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.17 Manual © Copyright Polaris Industries Inc.

  • Page 292: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.18 Manual © Copyright Polaris Industries Inc.

  • Page 293: Spider Removal

    Clutch Spider Removal / Installation Tool (PN 2870341). Spider Removal / Installation Tool: 2870341 Clutch Holding Fixture: 2871358-A 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.19 Manual © Copyright Polaris Industries Inc.

  • Page 294: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.20 Manual © Copyright Polaris Industries Inc.

  • Page 295: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.21 Manual © Copyright Polaris Industries Inc.
  • Page 296 3. Remove nut from puller rod and set aside. 19. Remove sheave from puller. 4. Install puller adapter from kit. Puller Adapter: PN 2871226 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.22 Manual © Copyright Polaris Industries Inc.

  • Page 297: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.23 Manual © Copyright Polaris Industries Inc.
  • Page 298 7. Apply 0.1mL of Loctite® 620™ and 0.1mL of Loctite® 7088™ Primer in 90° apart to the threads of the spider jamb nut. Install spider jamb nut onto stationary shaft threads. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.24 Manual © Copyright Polaris Industries Inc.
  • Page 299 12. Install cover bolts and torque in a cross pattern evenly to specification. TORQUE Drive Clutch Cover Bolts: 8 ft-lb (11 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.25 Manual © Copyright Polaris Industries Inc.

  • Page 300: Driven Clutch Service (Ebs)

    X’s on the components for reference. This will aid in assembly and maintains Slider Width clutch balance. Service Limit: 0.975″ (24.8 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.26 Manual © Copyright Polaris Industries Inc.
  • Page 301 . Inspect the rollers for wear; replace if worn. 9. Remove the clutch assembly from the holding tool. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.27 Manual © Copyright Polaris Industries Inc.

  • Page 302: Driven Clutch Bushing Service

    TOOL DESCRIPTION Clutch Bushing Tool Kit (see breakdown 2201379 below) 2870386 Piston Pin Puller Clutch Bushing Replacement Tool Kit 2871226 (see breakdown below) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.28 Manual © Copyright Polaris Industries Inc.

  • Page 303: Clutch Bushing Removal

    Removal/Installation Tool P-90 Driven Clutch Cover 5020631 Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller Adapter 5020633 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.29 Manual © Copyright Polaris Industries Inc.

  • Page 304: Clutch Bushing Installation

    2. Install the Adapter Reducer onto puller. 3. Apply Loctite® 648 evenly to bushing bore inside moveable sheave. 4. Install sheave face down on puller. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.30 Manual © Copyright Polaris Industries Inc.

  • Page 305: Driven Clutch Assembly

    The flat side of the roller pin faces towards the sheaves. NOTE Press only on the outer race of the bearing during installation to prevent damaging the bearing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.31 Manual © Copyright Polaris Industries Inc.
  • Page 306 9. Install the spider dampener inside the spider and install the inside spider plate 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.32 Manual © Copyright Polaris Industries Inc.
  • Page 307 15. Use a T25 Torx driver to install the four helix retaining screws and torque to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.33 Manual © Copyright Polaris Industries Inc.
  • Page 308 Spider Insert Stationary Sheave Spider Dampener E-Clip Slider / Roller Washer Helix (Cam) Moveable Sheave Helix Screws Clutch Shaft 48 in-lb (5 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.34 Manual © Copyright Polaris Industries Inc.
  • Page 309 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.35 Manual © Copyright Polaris Industries Inc.
  • Page 310 Note if there is a thrust washer between the sheaves. 6. Turn the compression tool handle counter-clockwise relieve spring pressure remove compressor tool from the clutch assembly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.36 Manual © Copyright Polaris Industries Inc.
  • Page 311 14. Lube splines with a light film of grease. Do not lubricate the bearings! 3. Install the spring pins to retain the slider pins. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.37 Manual © Copyright Polaris Industries Inc.
  • Page 312 6. Align the X’s on the spider and moveable sheave. 7. Install the universal clutch compressor on the clutch and compress the helix cover. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.38 Manual © Copyright Polaris Industries Inc.
  • Page 313 Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.39 Manual © Copyright Polaris Industries Inc.
  • Page 314 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.40 Manual © Copyright Polaris Industries Inc.
  • Page 315 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 316 PVT SYSTEM NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 5.42 Manual © Copyright Polaris Industries Inc.
  • Page 317 ................6.37 SHIFTING DIFFICULTY 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 318: General Information

    Transmission Drain / Fill Plug Capacity (INT’L): 40.5 oz. (1200 ml) Transmission Isolator Fasteners 33 ft-lb (45 (rear) Transmission Mount Bracket 22 ft-lb (30 Fasteners (rear) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 319: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 320: Shift Lever / Cable

    4. Remove both bushings from the shift lever and service as needed. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 321: Shift Cable Adjustment

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 322: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 323 CAUTION Be careful not to pinch or kink the fuel rail 13. Remove rear wheels from the vehicle. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 324 21. Remove the drive clutch from the vehicle using the 17. Pivot the control arms downward and maneuver the correct drive clutch puller (PN 2872085). drive shafts out of the vehicle frame. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 325 27. Using a 15mm socket, remove the four bolts from the left side and two from the right side , securing the transmission to the engine. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 326: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.10 Manual © Copyright Polaris Industries Inc.
  • Page 327 RZR 900 2016-18 RZR 1000 2016–18 ACE 900 2015-18 RANGER Diesel i.e. 2015 RZR 900 uses the holes marked with a 4 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.11 Manual © Copyright Polaris Industries Inc.
  • Page 328 , 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 7.20).
  • Page 329 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 2.26. FLUID CAPACITY...

  • Page 330: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.14 Manual © Copyright Polaris Industries Inc.
  • Page 331 18. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. Gear Cluster Disassembly 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.15 Manual © Copyright Polaris Industries Inc.
  • Page 332 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.16 Manual © Copyright Polaris Industries Inc.
  • Page 333 Snorkel Tool: PA-50231 31. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.17 Manual © Copyright Polaris Industries Inc.

  • Page 334: Differential Operation

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.18 Manual © Copyright Polaris Industries Inc.
  • Page 335 This locks the rear differential as a solid rear axle, increasing traction. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.19 Manual © Copyright Polaris Industries Inc.
  • Page 336 Differential Cover Assembly Planetary Differential Assembly Fasteners Engagement Dog Bearing Shift Fork Retainer Fastener Torsion Spring Retainer Shift Fork Solenoid Spring Solenoid 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.20 Manual © Copyright Polaris Industries Inc.

  • Page 337: Planetary Differential Disassembly (Turf Mode Models Only)

    Planetary Differential Bushing Replacement (Turf Mode Models Only), page 6.22. 2. Remove the six screws retaining the differential cover and remove the cover. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.21 Manual © Copyright Polaris Industries Inc.

  • Page 338: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.22 Manual © Copyright Polaris Industries Inc.
  • Page 339 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.23 Manual © Copyright Polaris Industries Inc.

  • Page 340: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.24 Manual © Copyright Polaris Industries Inc.
  • Page 341 10.9. Torque the screws according to their corresponding grade. TORQUE Differential Cover Screws (8.8 Fastener): 22 ft-lb (30 Nm) TORQUE Differential Cover Screws (10.9 Fastener):28 ft-lbs (38 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.25 Manual © Copyright Polaris Industries Inc.

  • Page 342: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.26 Manual © Copyright Polaris Industries Inc.

  • Page 343: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.27 Manual © Copyright Polaris Industries Inc.
  • Page 344 8. Apply Loctite ® ™ to the threads of the bearing and may have some tight spots. cover retaining screws. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.28 Manual © Copyright Polaris Industries Inc.
  • Page 345 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.29 Manual © Copyright Polaris Industries Inc.
  • Page 346 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.30 Manual © Copyright Polaris Industries Inc.
  • Page 347 Be sure to install the detent star with Transmission Case Bolts: the raised edge facing outward and skip-tooth 20 ft-lbs (27 Nm) aligned. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.31 Manual © Copyright Polaris Industries Inc.
  • Page 348 TORQUE Sector Gear Cover Bolts: 12 ft-lb (16 Nm) 34. Install the transmission drain plug and torque to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.32 Manual © Copyright Polaris Industries Inc.

  • Page 349: Transmission Assembly View (No Turf Mode)

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW (NO TURF MODE) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.33 Manual © Copyright Polaris Industries Inc.
  • Page 350 Tube, Snorkel Bearing, Ball Cover, Sector Gears Case, RH Spring, Wave Case, LH Bracket, Wire Harness Drum, Shift Collar Sleeve, Input Shaft 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.34 Manual © Copyright Polaris Industries Inc.

  • Page 351: Transmission Assembly View (Turf Mode Models)

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW (TURF MODE MODELS) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.35 Manual © Copyright Polaris Industries Inc.
  • Page 352 Shift Dog, Park Bearing, Plain Bearing, Ball Gear, 44T Collar Sleeve, Input Shaft Bearing, Ball Fork, Shift Bearing, Needle Cage Sprocket, 48T, 6-Face 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.36 Manual © Copyright Polaris Industries Inc.

  • Page 353: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.37 Manual © Copyright Polaris Industries Inc.
  • Page 354 TRANSMISSION NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 6.38 Manual © Copyright Polaris Industries Inc.
  • Page 355 ............... .7.34 REAR HUB ASSEMBLY VIEW 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 356 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/ 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 357: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 358: Front Bearing Replacement

    Use an arbor and press only on the outer race, otherwise bearing damage may occur. Ball Joint Pinch Bolts: 42 ft-lb (57 Nm) 4. Apply Anti-Seize to drive shaft axle splines. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 359 11. Rotate wheel and check for smooth operation. 8. Torque the tie rod end fastener to specification and install a new cotter pin. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 360: Rear Bearing Carrier Removal / Inspection

    Do NOT hang the caliper by the brake like. Use wire or between inner and outer race. rope to hang the caliper to prevent brake line damage. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 361: Rear Carrier Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race or bearing damage may occur. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 362: Rear Bearing Carrier Installation

    46 ft-lb (62 Nm) Rear Bearing Carrier Mounting Fasteners: 42 ft-lb (57 Nm) 3. Apply a small amount of anti-seize to the drive shaft splines. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 363 Steel: 60 ft-lb (81 Nm) 8. Rotate wheel and check for smooth operation. Bend both ends of the cotter pin around the end of the spindle. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 364: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.10 Manual © Copyright Polaris Industries Inc.

  • Page 365: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.11 Manual © Copyright Polaris Industries Inc.

  • Page 366: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.12 Manual © Copyright Polaris Industries Inc.

  • Page 367: Rear Half Shaft Installation

    9. With a quick, short jerk outward, remove the half shaft TORQUE from the transmission. Bearing Carrier Mounting Fasteners: 42 ft-lb (57 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.13 Manual © Copyright Polaris Industries Inc.

  • Page 368: Drive Shaft / Cv Joint Handling Tips

    7. Install two washers and castle nut over the spindle. Torque castle nut to specification. TORQUE Hub Castle Nut: 180 ft-lbs (244 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.14 Manual © Copyright Polaris Industries Inc.
  • Page 369 IMPORTANT Tap on inner race only! 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.15 Manual © Copyright Polaris Industries Inc.
  • Page 370 14. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.16 Manual © Copyright Polaris Industries Inc.

  • Page 371: 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! 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.17 Manual © Copyright Polaris Industries Inc.
  • Page 372 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.18 Manual © Copyright Polaris Industries Inc.

  • Page 373: Prop Shaft Removal

    7. Remove the two fasteners retaining the prop shaft support bearing to the frame. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.19 Manual © Copyright Polaris Industries Inc.

  • Page 374: Prop Shaft Installation

    6. Install and torque the support bearing fasteners to specification. TORQUE Prop Shaft Support Bearing Fasteners: 33 ft-lb (45 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.20 Manual © Copyright Polaris Industries Inc.

  • Page 375: Rear Prop Shaft Removal (4 Seater)

    6. Move the prop shaft support bearing assembly to the drivers side to slide the rear prop shaft yoke off the transmission output shaft. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.21 Manual © Copyright Polaris Industries Inc.

  • Page 376: Rear Prop Shaft Installation (4 Seater)

    3. Lubricate the front and rear prop shaft mid joint with Polaris All Purpose Grease. 4. Align the front and rear prop shafts and slide them together. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.22 Manual © Copyright Polaris Industries Inc.

  • Page 377: Front Gearcase / Centralized Hilliard

    Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.23 Manual © Copyright Polaris Industries Inc.

  • Page 378: Awd Diagnosis

    Step 5. A wear band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.24 Manual © Copyright Polaris Industries Inc.

  • Page 379: Front Gearcase Removal

    2. Place gear selector in neutral. 3. Remove both front half shafts from the front gearcase. See Chapter 7 – Front Half Shaft Removal, page 7.10 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.25 Manual © Copyright Polaris Industries Inc.
  • Page 380 3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. NOTE Nylon spacer is non-serviceable and should not be removed. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.26 Manual © Copyright Polaris Industries Inc.
  • Page 381 Rollers are spring loaded. Take care not to allow them to fall out or lose them upon removal of the roll cage. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.27 Manual © Copyright Polaris Industries Inc.
  • Page 382 H-springs . The sliding surfaces must be clean and free of nicks, burrs or scratches. If damaged, replace the roll cage assembly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.28 Manual © Copyright Polaris Industries Inc.

  • Page 383: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.29 Manual © Copyright Polaris Industries Inc.
  • Page 384 NOTE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.30 Manual © Copyright Polaris Industries Inc.

  • Page 385: Front Gearcase Installation

    TORQUE Front Gearcase Mounting Bolts: 33 ft-lbs (45 Nm) 5. Install the vent line TORQUE Cover Plate Screws: 9 ft-lbs (12 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.31 Manual © Copyright Polaris Industries Inc.
  • Page 386 S 1000 / 4 900 Capacity:≈ 8.5 oz. (250 mL) (fill on a level surface to bottom of threads on the fill hole) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.32 Manual © Copyright Polaris Industries Inc.

  • Page 387: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.33 Manual © Copyright Polaris Industries Inc.

  • Page 388: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 7.34 Manual © Copyright Polaris Industries Inc.
  • Page 389 ................8.36 FOX SHOCK ASSEMBLY 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 390: General Information

    Tie Rod End Fasteners 90° 14 ft-lbs (19 Nm) Tie Rod End Jam Nuts 7 ft-lb (10 Nm) Tilt Shock Fasteners Wheel Lug Nuts 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 391: Steering System

    2. Remove the four wheel nuts. 3. Remove the fastener retaining the tie rod end to the knuckle. 5. Reverse procedure for installation. Torque NEW fasteners to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 392 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 393: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 394: Steering Wheel Removal (Non-Eps)

    5. Refer to steps 11-16 of the Steering Shaft Bearing Replacement, page 8.6 procedure for installation. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 395 Steering Shaft to Rack Pinch Bolt: 48 ft-lb (65 Nm) TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 15. Install steering wheel cap and test steering operation. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 396: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 397: Upper Steering Shaft Removal

    8.10 shaft to the power steering unit 3. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 398: Steering Wheel Removal (Eps)

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.10 Manual © Copyright Polaris Industries Inc.
  • Page 399 IMPORTANT Electronic Power Steering (EPS) units are programmed to be vehicle specific and are not interchangeable between product lines. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.11 Manual © Copyright Polaris Industries Inc.

  • Page 400: Lower Steering Shaft Removal

    5. Lift up on the shaft and remove it through the floor panel. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.12 Manual © Copyright Polaris Industries Inc.

  • Page 401: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.13 Manual © Copyright Polaris Industries Inc.

  • Page 402: Upper Steering Shaft Installation

    Torque the nut to specification and reinstall the plastic wheel cover. TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.14 Manual © Copyright Polaris Industries Inc.

  • Page 403: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.15 Manual © Copyright Polaris Industries Inc.

  • Page 404: Front Control Arm Replacement

    Front Ball Joint Pinch Bolts: 42 ft-lb (57 Nm) 13. Attach shock to control arm with fastener. Torque lower shock bolt to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.16 Manual © Copyright Polaris Industries Inc.
  • Page 405 Joint Replacement” section. 20. Insert new control arm bushings and pivot tube into new control arm. A light press force may be needed. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.17 Manual © Copyright Polaris Industries Inc.

  • Page 406: Ball Joint Removal

    Front Caliper Mounting Bolts: discard the ball joint. 30 ft-lb (42 Nm) Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.18 Manual © Copyright Polaris Industries Inc.

  • Page 407: Front Stabilizer Bar Replacement (50

    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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.19 Manual © Copyright Polaris Industries Inc.

  • Page 408: Rear Suspension

    5. Examine bushings and pivot tubes. Replace if worn. and pivot tubes. Discard hardware. 6. If not replacing the A-arm, thoroughly clean the A-arm and pivot tubes. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.20 Manual © Copyright Polaris Industries Inc.

  • Page 409: Rear Control Arm Installation

    Center stabilizer bar in the frame. Torque mounting fasteners to specification. NOTE Refer to bolt head to determine which class bolt has been installed during manufacturing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.21 Manual © Copyright Polaris Industries Inc.
  • Page 410 TORQUE Stabilizer Bar Linkage Fasteners: 40 ft-lbs (54 Nm) 8. Lubricate stabilizer bushings. Maintenance chapter – Grease Lubrication Points, page 2.8 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.22 Manual © Copyright Polaris Industries Inc.

  • Page 411: Shocks / Springs

    SHOCKS / SPRINGS FRONT SHOCK ASSEMBLY VIEW REAR SHOCK ASSEMBLY VIEW 50″ Model 50″ Model XC & 60″ Model XC & 60″ Model 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.23 Manual © Copyright Polaris Industries Inc.

  • Page 412: Shock Removal / Installation

    1. (see Shock Specifications (FOX), page for factory settings. 6. Reinstall the shock onto the vehicle 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.24 Manual © Copyright Polaris Industries Inc.

  • Page 413: Shock Service

    1.250 x .012 0.750 x .100 Back Up 1.100 x .012 1.570 x .128 Top Out 0.900 x .012 1.570 x .128 Top Out 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.25 Manual © Copyright Polaris Industries Inc.
  • Page 414 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.26 Manual © Copyright Polaris Industries Inc.

  • Page 415: Fox Shock Disassembly

    3. Once nitrogen pressure has been released, depress reservoir cap and remove retaining ring. Typically a valve shim can be used. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.27 Manual © Copyright Polaris Industries Inc.
  • Page 416 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.28 Manual © Copyright Polaris Industries Inc.
  • Page 417 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). 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.29 Manual © Copyright Polaris Industries Inc.
  • Page 418 22. Clean body cap using a wire brush and pick. 23. Remove both retaining rings in the body cap using a sharp pick. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.30 Manual © Copyright Polaris Industries Inc.
  • Page 419 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.) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.31 Manual © Copyright Polaris Industries Inc.
  • Page 420 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.32 Manual © Copyright Polaris Industries Inc.
  • Page 421 40. Remove Loctite® residue from shock shaft. 38. Remove eyelet using an adjustable wrench or Body 41. Remove Jet/Check Valve with Hex T-handle wrench. Cap socket. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.33 Manual © Copyright Polaris Industries Inc.
  • Page 422 44. Back out rebound adjuster with flat head screw driver. 47. Remove both retaining rings from the eyelet and press out bearing. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.34 Manual © Copyright Polaris Industries Inc.
  • Page 423 6. Remove external O-ring from bearing assembly. 3. Remove dust seal from bearing cap. NOTE If internal bearing is damaged, replace with complete bearing assembly. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.35 Manual © Copyright Polaris Industries Inc.

  • Page 424: Fox Shock Assembly

    6. Insert spring. 3. Install second retaining ring. 7. Put the steel ball on the spring with a dab of shock oil. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.36 Manual © Copyright Polaris Industries Inc.
  • Page 425 15. Place shaft back in clamp blocks, apply loctite® primer to eyelet, and Torque eyelet to shock shaft. See specifications. 12. Thread in the damping jet and torque to specification. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.37 Manual © Copyright Polaris Industries Inc.
  • Page 426 18. Apply thin layer of shock oil to seal. 21. Install back-up washer. 19. Install body cap. 22. Apply thin layer of shock oil to washer. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.38 Manual © Copyright Polaris Industries Inc.
  • Page 427 Bearing will be fully seated around piston when done correctly. 25. Install piston bearing on installation tool. 27. Install compression side valve stack. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.39 Manual © Copyright Polaris Industries Inc.
  • Page 428 BOC post and torque to 22 ft-lbs (30 Nm). 33. Install appropriate O-ring and apply a thin layer of shock oil to the O-ring ONLY. 30. Install BOC post valving. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.40 Manual © Copyright Polaris Industries Inc.
  • Page 429 37. Place body in block clamps parallel to the ground. 41. Install LSC knob and torque screw to specification. 38. Replace both O-rings on DSC or LSC. 42. Install reservoir O-ring. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.41 Manual © Copyright Polaris Industries Inc.
  • Page 430 46. Install IFP bearing and O-ring on the IFP and apply a thin layer of shock oil to bearing and O-ring. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.42 Manual © Copyright Polaris Industries Inc.
  • Page 431 59. Install reservoir cap O-ring on cap and apply a thin layer of shock oil to side and O-ring. 55. Install retaining ring. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.43 Manual © Copyright Polaris Industries Inc.
  • Page 432 NOTE Check for any leaks or faults in the shock absorber’s functionality. 63. Tap body cap into position. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 8.44 Manual © Copyright Polaris Industries Inc.
  • Page 433 ............... . .9.29 REAR DISC REPLACEMENT 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 434 ................... .9.32 BRAKES LOCK 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 435: General Information

    Park Brake Pad Thickness Outboard - .250″ (6.35 mm) .190" (4.83 mm) Park Brake Disc Thickness .175 - .185″ (4.44 - 4.70 mm) .150" (3.81 mm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 436: 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 437: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 438: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 439 30° 7. Perform the BRAKE BLEEDING / FLUID CHANGE, page 9.8 procedure. TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 440: Brake Pedal

    2. If changing fluid, remove old fluid from reservoir Brake Pedal Free-play: with a Mity Vac™ pump or similar tool. 1/4-3/8″ (6.35-9.53 mm) Mity Vac™: 2870975 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 441 TORQUE Bleeder Screw: 48 in-lb (5 Nm) 9. Repeat steps 5 - 8 for the remaining calipers. Polaris DOT 4 Brake Fluid 10. Add brake fluid to MAX level on reservoir. 2872189 Master Cylinder Fluid Level Between MIN and MAX lines on reservoir.

  • Page 442: Parking Brake (Int

    BRAKE SYSTEM PARKING BRAKE (INT'L) PARKING BRAKE ASSEMBLY VIEW 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.10 Manual © Copyright Polaris Industries Inc.

  • Page 443: Parking Brake Inspection

    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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.11 Manual © Copyright Polaris Industries Inc.
  • Page 444 NOTE See Chapter 10 – Parking Brake Switch (INT’L/Tractor), page for more information on the parking brake switch. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.12 Manual © Copyright Polaris Industries Inc.

  • Page 445: Parking Brake Caliper

    BRAKE SYSTEM PARKING BRAKE CALIPER 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.13 Manual © Copyright Polaris Industries Inc.
  • Page 446 Caliper Disassembly / Inspection NOTE Refer to the “Electronic Parts Catalog” for parking brake caliper replacement parts information. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.14 Manual © Copyright Polaris Industries Inc.
  • Page 447 5. Ensure the parking brake assembly functions properly by actuating the lever. Install the mounting sleeves (D) before installation. Brake Caliper Installation 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.15 Manual © Copyright Polaris Industries Inc.

  • Page 448: Parking Brake Disc

    4. Install the new brake disc. Install the mounting bolt and flat washer. Torque the mounting bolt to specification. TORQUE Parking Brake Disc Mounting Bolt: 14 ft-lb (20 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.16 Manual © Copyright Polaris Industries Inc.

  • Page 449: Front Brakes

    NOTE When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.17 Manual © Copyright Polaris Industries Inc.

  • Page 450: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.18 Manual © Copyright Polaris Industries Inc.

  • Page 451: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.19 Manual © Copyright Polaris Industries Inc.

  • Page 452: 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 453: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.21 Manual © Copyright Polaris Industries Inc.

  • Page 454: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.22 Manual © Copyright Polaris Industries Inc.

  • Page 455: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.23 Manual © Copyright Polaris Industries Inc.

  • Page 456: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.24 Manual © Copyright Polaris Industries Inc.

  • Page 457: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.25 Manual © Copyright Polaris Industries Inc.

  • Page 458: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.26 Manual © Copyright Polaris Industries Inc.

  • Page 459: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.27 Manual © Copyright Polaris Industries Inc.

  • Page 460: 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 461: Rear Disc Inspection

    18 ft-lb (24 Nm) 6. Install wheel hub assembly, washers, and castle nut. Torque castle nut to specification and install a new cotter pin. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.29 Manual © Copyright Polaris Industries Inc.

  • Page 462: 2015-2016 Rzr 900

    Maintain at least 1/2″, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.30 Manual © Copyright Polaris Industries Inc.
  • Page 463 7. Install wheel and torque wheel nuts to specification. than 3 stops per 1 mile (1.6 km). TORQUE Wheel Nuts: Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.31 Manual © Copyright Polaris Industries Inc.
  • Page 464 • Improper assembly of brake system components PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds service limit) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 9.32 Manual © Copyright Polaris Industries Inc.
  • Page 465 ................10.25 DOOR ADJUSTMENT 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.1 Manual © Copyright Polaris Industries Inc.

  • Page 466: General Information

    1-800-345-2233 or http://polaris.service-solutions.com/ Included in the tool kit, the multi-function pliers assists in removing the plastic push rivets used to fasten body components. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.2 Manual © Copyright Polaris Industries Inc.

  • Page 467: Decal Replacement

    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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.3 Manual © Copyright Polaris Industries Inc.

  • Page 468: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.4 Manual © Copyright Polaris Industries Inc.

  • Page 469: Cab Frame Assembly - 4 900

    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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.5 Manual © Copyright Polaris Industries Inc.

  • Page 470: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.6 Manual © Copyright Polaris Industries Inc.

  • Page 471: Doors - 4 900

    DOORS - 4 900 Hinge Pin Door Panel 8 ft-lb (11 Nm) Door Frame Latch Release Latch Striker Latch 8 ft-lb (11 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.7 Manual © Copyright Polaris Industries Inc.

  • Page 472: Dash / Instruments

    BODY / FRAME DASH / INSTRUMENTS Instrument Cluster Headlight Switch Key Switch AWD Switch 12V Accessory Port Bezel 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.8 Manual © Copyright Polaris Industries Inc.

  • Page 473: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.9 Manual © Copyright Polaris Industries Inc.

  • Page 474: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.10 Manual © Copyright Polaris Industries Inc.

  • Page 475: Chassis / Main Frame - 4 900

    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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.11 Manual © Copyright Polaris Industries Inc.

  • Page 476: Seats

    Seat Latch Screw Spring 4 ft-lb (5 Nm) Shoulder Belt Seat Slider Lever Spring Lock Washer Seat Bottom Flat Washer Seat Back 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.12 Manual © Copyright Polaris Industries Inc.

  • Page 477: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.13 Manual © Copyright Polaris Industries Inc.

  • Page 478: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.14 Manual © Copyright Polaris Industries Inc.

  • Page 479: Floor / Rocker Panels - 4 900

    Seat Belt Boot Lower Floor - Front Shifter Boot Lower Floor - Rear B-Pillar - Left Closeoff Panel - Rear Lower B-Pillar - Right 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.15 Manual © Copyright Polaris Industries Inc.

  • Page 480: 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 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.16 Manual © Copyright Polaris Industries Inc.

  • Page 481: Rear Bumper

    BODY / FRAME REAR BUMPER Screw Mounting Brackets 8 ft-lb (11 Nm) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.17 Manual © Copyright Polaris Industries Inc.

  • Page 482: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.18 Manual © Copyright Polaris Industries Inc.

  • Page 483: Engine Service Panel

    2. Lift rear of hood and slide forward to disengage the front tabs and remove the hood from the vehicle. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.19 Manual © Copyright Polaris Industries Inc.

  • Page 484: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.20 Manual © Copyright Polaris Industries Inc.

  • Page 485: Rocker Panel / Console / Floor

    1. Remove rear fender flare and rear fender. (Refer to Rear Fender / Fender Flair Removal, page 10.20). 9. Remove the cargo box half from the vehicle. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.21 Manual © Copyright Polaris Industries Inc.
  • Page 486 4. Remove the Torx T40 screws and push rivets retaining the rear console to the rear floor. 5. Remove the rear console. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.22 Manual © Copyright Polaris Industries Inc.
  • Page 487 14. Remove four Torx T40 screws retaining the rear floor and remove the rear floor. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.23 Manual © Copyright Polaris Industries Inc.
  • Page 488 BODY / FRAME 15. Remove the Torx screws retaining the main floor and remove the main floor from the vehicle. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.24 Manual © Copyright Polaris Industries Inc.

  • Page 489: Doors

    Door Panel Fasteners: 22 in-lb (2 Nm) 5. Adjust the door so it properly opens and latches. Refer to Door Adjustment, page 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.25 Manual © Copyright Polaris Industries Inc.
  • Page 490 4. 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 10.26 Manual © Copyright Polaris Industries Inc.
  • Page 491 ................11.26 VOLTAGE DROP TEST 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.1 Manual © Copyright Polaris Industries Inc.
  • Page 492 ........... . 11.45 KEY ON BATTERY POWER BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.2 Manual © Copyright Polaris Industries Inc.

  • Page 493: General Information

    1-800-345-2233 or http://polaris.service-solutions.com/ • Speedometer • AWD Switch • Headlamp Switch • 12 Vdc Accessory Power Point • Ignition Switch • LED Ambiance Light 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.3 Manual © Copyright Polaris Industries Inc.

  • Page 494: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.4 Manual © Copyright Polaris Industries Inc.
  • Page 495 Hours Indicator - Illuminates when Hours are being displayed on the Information Display Mode Button - Used to move through the menu features. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.5 Manual © Copyright Polaris Industries Inc.

  • Page 496: Information Display Area

    Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. Engine Hours 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.6 Manual © Copyright Polaris Industries Inc.
  • Page 497 4. To turn off the service interval function, toggle the 2. Press and hold the MODE button while turning the MODE button until “OFF” is displayed. key to the ON position. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.7 Manual © Copyright Polaris Industries Inc.
  • Page 498 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.8 Manual © Copyright Polaris Industries Inc.

  • Page 499: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.9 Manual © Copyright Polaris Industries Inc.
  • Page 500 CAN Low Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input International Models Only Turn Signal Input, LH Turn Signal Input, RH 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.10 Manual © Copyright Polaris Industries Inc.

  • Page 501: Switches

    Brake Switch: 15 ft-lb (20 Nm) 4. Bleed the brake system. See Chapter 9 – BRAKE BLEEDING / FLUID CHANGE, page 9.8 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.11 Manual © Copyright Polaris Industries Inc.

  • Page 502: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.12 Manual © Copyright Polaris Industries Inc.

  • Page 503: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.13 Manual © Copyright Polaris Industries Inc.

  • Page 504: Seat Belt Switch

    GEAR WHEN MEASURED AT POSITION SWITCH TERMINALS A AND B HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.14 Manual © Copyright Polaris Industries Inc.

  • Page 505: Charging System

    VOLTAGE REGULATOR The regulator / rectifier is located in front of the left rear wheel. It is mounted behind the left panel divider. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.15 Manual © Copyright Polaris Industries Inc.

  • Page 506: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.16 Manual © Copyright Polaris Industries Inc.
  • Page 507 (Y1 to Y2, Y1 to Y3, Y2 to Y3). 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.17 Manual © Copyright Polaris Industries Inc.

  • Page 508: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.18 Manual © Copyright Polaris Industries Inc.

  • Page 509: 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. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.19 Manual © Copyright Polaris Industries Inc.

  • Page 510: Current Draw - Key Off

    At 14 seconds into the test, check battery voltage. A good 12V battery will have at least 10.5 volts. If the reading is low, charge the battery and retest. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.20 Manual © Copyright Polaris Industries Inc.

  • Page 511: Battery Conductance Analyzer

    Conductance testing is more accurate than voltage, specific gravity, or load testing. Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries. Polaris MDX-610P PU-50296 9926814 R08 -...

  • Page 512: Lighting System

    Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.22 Manual © Copyright Polaris Industries Inc.

  • Page 513: Taillights

    6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlamp Adjustment” procedure as shown in this chapter. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.23 Manual © Copyright Polaris Industries Inc.

  • Page 514: Cooling System

    (see Chapter 3 – Cooling System Bleeding, page 3.16). 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). 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.24...

  • Page 515: Radiator Fan

    For radiator fan replacement, refer to the Radiator Removal / Installation, page 3.14. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.25 Manual © Copyright Polaris Industries Inc.

  • Page 516: Starting System

    Starter Mounting Bolts and Nut: 7 ft-lb (10 Nm) 3. Remove RH rear wheel. 4. Remove (+) positive wire from starter motor terminal. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.26 Manual © Copyright Polaris Industries Inc.

  • Page 517: 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) 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.27 Manual © Copyright Polaris Industries Inc.

  • Page 518: Electronic Power Steering

    EPS system is detected, the system will illuminate a fault indicator and transition CAN High Signal YELLOW to a normal mechanically coupled steering system. The CAN Low Signal system is Polaris Digital Wrench® compatible for GREEN simplified diagnostics system troubleshooting through the vehicle’s diagnostic port.

  • Page 519: Eps System Diagnosis

    Digital Wrench, update the software to the latest version and follow guided diagnostic procedures available for any Digital Wrench codes found. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.29 Manual © Copyright Polaris Industries Inc.

  • Page 520: Fuses / Relays

    EFI system, drive system and EPS. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.30 Manual © Copyright Polaris Industries Inc.

  • Page 521: Relay Circuits

    High side power from EFI fuse High side output to Red / Dark Blue EFI B+ Splice Dark Green / ECU controlled Yellow ground 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.31 Manual © Copyright Polaris Industries Inc.

  • Page 522: Fuse / Circuit Breaker Circuits

    Lights – 15A Fuse WIRE COLOR FUNCTION Red / Dark Green Power from Chassis Splice Red / Yellow Power to Lights B+ Splice 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.32 Manual © Copyright Polaris Industries Inc.

  • Page 523: Misc. Electrical

    80% of all electrical issues are caused by bad/failed connections and grounds. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.33 Manual © Copyright Polaris Industries Inc.

  • Page 524: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Retaining Bolt: 75 in-lb (9 Nm) COIL TESTING Primary Coil Testing TEST Ω RESISTANCE 0.4 Ω 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.34 Manual © Copyright Polaris Industries Inc.

  • Page 525: Chassis Ground Point

    DIAGNOSTIC PLUG The diagnostic plug is located under the hood near the coolant reservoir 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.35 Manual © Copyright Polaris Industries Inc.

  • Page 526: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.36 Manual © Copyright Polaris Industries Inc.

  • Page 527: Break-Out Diagrams

    ELECTRICAL BREAK-OUT DIAGRAMS AWD BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.37 Manual © Copyright Polaris Industries Inc.

  • Page 528: Cooling System Break-Out Diagram

    ELECTRICAL COOLING SYSTEM BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.38 Manual © Copyright Polaris Industries Inc.

  • Page 529: Eps Break-Out Diagram

    ELECTRICAL EPS BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.39 Manual © Copyright Polaris Industries Inc.

  • Page 530: Lighting Break-Out Diagram

    ELECTRICAL LIGHTING BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.40 Manual © Copyright Polaris Industries Inc.

  • Page 531: Starting System Break-Out Diagram

    ELECTRICAL STARTING SYSTEM BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.41 Manual © Copyright Polaris Industries Inc.

  • Page 532: Differential Circuit Break-Out Diagram

    ELECTRICAL DIFFERENTIAL CIRCUIT BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.42 Manual © Copyright Polaris Industries Inc.

  • Page 533: Vehicle Speed Sensor Break-Out Diagram

    ELECTRICAL VEHICLE SPEED SENSOR BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.43 Manual © Copyright Polaris Industries Inc.

  • Page 534: Unswitched Chassis Power Break-Out Diagram

    ELECTRICAL UNSWITCHED CHASSIS POWER BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.44 Manual © Copyright Polaris Industries Inc.

  • Page 535: Key On Battery Power Break-Out Diagram

    ELECTRICAL KEY ON BATTERY POWER BREAK-OUT DIAGRAM 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.45 Manual © Copyright Polaris Industries Inc.
  • Page 536 ELECTRICAL NOTES 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service 11.46 Manual © Copyright Polaris Industries Inc.
  • Page 537 Brake Disassembly (front)..........9.19 Light Switch ............11.11 Disassembly (rear) ..........9.27 Brake System Inspection (rear).............9.27 Brake Hose and Fitting Inspection......2.34 Installation (front) ...........9.23 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service IX.1 Manual © Copyright Polaris Industries Inc.
  • Page 538 Disassembly / Inspection ........3.109 Doors (2 seat)............10.6 Inspection.............3.59 Doors (4 seat)............10.7 Crankcase Preparation Drive Clutch Lower ..............3.73 Upper ..............3.68 Cover Bushing ............5.21 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service IX.2 Manual © Copyright Polaris Industries Inc.
  • Page 539 Crankshaft Removal / Inspection ......3.56, 3.112 Cylinder / Piston Installation......3.70, 3.126 Replacement............3.14 Cylinder / Piston Removal .......3.60, 3.116 Fender Cylinder Head Assembly.........3.79, 3.135 Removal (rear)............. 10.20 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service IX.3 Manual © Copyright Polaris Industries Inc.
  • Page 540 Headlight Switch ............. 11.11 Headlights ............. 11.22 Hood ..............10.9 Valve Clearance Adjustment ........3.142 Removal............. 10.19 Hydraulic Brake System Operation......... 9.4 Oil Change...............2.14 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service IX.4 Manual © Copyright Polaris Industries Inc.
  • Page 541 Installation ............7.22 Piston to Cylinder Clearance.......3.64, 3.119 Removal...............7.21 Plunging Joint / Boot Reflash Authorization ..........4.46 Replacement (Inner) ..........7.17 Regulator .............. 11.15 Polaris Mobile Digital Wrench (PMDW) ......4.49 Relay Circuits ............11.31 PPS ...............4.26 Relays ..............11.30 Location ...............4.26 Rocker Panel Replacement............4.26 Removal.............
  • Page 542 Body / Frame............10.2 Steering Shaft Removal (non-EPS) ......8.6 Brakes ..............9.3 Steering Wheel Removal (EPS).........8.10 Steering Wheel Removal (non-EPS)......8.6 Electrical .............. 11.3 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service IX.6 Manual © Copyright Polaris Industries Inc.
  • Page 543 Valve Spring Free Length ............3.43 Removal............3.43, 3.99 Vehicle Identification Model Number Designation ........1.2 Vehicle Identification Number........1.2 VIN ................. 1.2 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service IX.7 Manual © Copyright Polaris Industries Inc.

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