Polaris RZR 900 2019 Manuals

Manuals and User Guides for Polaris RZR 900 2019. We have 1 Polaris RZR 900 2019 manual available for free PDF download: Service Manual

Polaris RZR 900 2019 Service Manual

Polaris RZR 900 2019 Service Manual (611 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 37.75 MB

Table of Contents

Chapter 1 1 General Information

9
- Table of Contents
  9
- Vehicle Identification
  11
- Model Number Designation (2015 +)
  11
- Vehicle Identification Number (Vin) Designation (2015+)
  11
- Vehicle and Engine Serial Number Location
  12
- Reference Information
  13
- Publication Numbers
  13
- Replacement Keys
  14
- Special Tools
  15
- Master Torque Table
  19
- General Specifications
  22
- 2017 Rzr 900 Specifications
  22
- Rzr 900 Clutch Chart
  23
- 2017 Rzr 900 Eps Specifications
  24
- Rzr 900 Clutch Chart
  25
- 2017 Rzr 900 XC Specifications
  26
Maintenance Chapter 2 Maintenance 2

75
- Break-In Period
  77
- Maintenance
  77
- Periodic Maintenance Chart
  77
- Periodic Maintenance Overview
  77
- Pre-Ride Inspection
  78
- Maintenance Intervals
  79
- Maintenance Quick Reference
  99
- Grease Lubrication Points
  101
- General Vehicle Inspection and Maintenance
  102
- Lubricants / Service Products
  102
- Shift Cable Inspection / Adjustment
  103
- Engine / Air Intake
  104
- Engine Air Filter Service
  104
- Intake Duct Inspection
  104
- Air Box / Filter Assembly View
  105
- Engine Oil Level
  106
- Engine Oil and Filter Change
  107
- Crankcase Breather Hose Inspection
  108
- Engine Cylinder Leak-Down Test
  108
- Valve Clearance Inspection
  108
- Cam Chain Tensioner Inspection
  110
- Coolant Level Inspection
  112
- Coolant Strength
  112
- Cooling System
  112
- Cooling System Overview
  112
- Cooling System Hose Inspection
  113
- Cooling System Pressure Test
  113
- Coolant Drain / Fill
  114
- Radiator Inspection / Cleaning
  114
- Fuel System
  115
- Fuel System Warning
  115
- Fuel Tank Vent Line
  115
- Fuel Lines
  116
- Fuel Pump / Fuel Filter
  116
- Throttle Pedal Inspection
  116
- Drive Clutch / Driven Clutch / Belt Service
  117
- Pvt Drying
  117
- Pvt Duct Cleaning
  117
- Pvt System
  117
- Drive Shaft Boot Inspection
  118
- Driveshaft / Wheel and Tire
  118
- Tire Inspection
  118
- Wheel and Hub Torque Table
  118
- Wheel Installation
  118
- Wheel Removal
  118
- Tire Pressure
  119
- Specification Chart
  120
- Transmission and Front Gearcase
  120
- Transmission Lubrication
  120
- Front Gearcase Lubrication
  121
- Steering Inspection
  123
- Steering System
  123
- Steering Wheel Free-Play
  123
- Tie Rod End / Wheel Bearing Inspection
  123
- Wheel Toe Adjustment
  124
- Wheel Toe Alignment Inspection
  124
- Spring Adjustment (Non-Fox)
  126
- Suspension System
  126
- Spring Adjustment (Fox)
  127
- Shock Compression Adjustment (Fox)
  128
- Shock Compression Adjustment (Walker Evans)
  129
- Spring Adjustment (Walker Evans)
  129
- Brake Fluid Inspection
  131
- Brake Hose and Fitting Inspection
  131
- Brake Pad / Disc Inspection
  131
- Brake System
  131
- Battery Charging
  132
- Battery Maintenance
  132
- Battery off Season Storage
  132
- Electrical / Ignition System
  132
- Engine / Chassis Ground
  133
- Spark Plug Service
  133
Chapter 3 Engine / Cooling System

135
- Engine - General
  139
- Lubrication Specifications
  139
- Main Engine Components - Torque Specification and Sequence
  140
- Exhaust Assembly View / Torque Values
  141
- Exhaust System
  141
- Exhaust Removal / Installation
  142
- Cooling System Pressure Test
  143
- Cooling System Specifications
  143
- Engine Cooling System
  143
- Radiator Cap Pressure Test
  144
- Radiator Removal / Installation
  144
- Thermostat Replacement
  145
- Cooling System Bleeding
  146
- Water Pump Removal
  147
- Water Pump Service
  147
- Water Pump Installation
  150
- Engine Oil Pressure Test
  152
- Engine Service
  152
- Lubrication Specifications
  152
- Engine Oil Flow Chart
  153
- Accessible Engine Components
  154
- Engine Mounts
  154
- Top End Service
  154
- Crankshaft Pto Seal Replacement
  155
- Engine Removal
  157
- Engine Installation
  161
- Engine Break
  165
- Engine
  166
- Troubleshooting
  166
- Cooling System
  167
- 900 Engine
  168
- Engine Specifications
  168
- Engine Specifications (900)
  168
- Camshaft Removal
  170
- Engine Disassembly / Inspection - Top End (900)
  170
- Valve Cover Removal
  170
- Camshaft / Camshaft Bore Inspection
  172
- Camshaft Sprocket Inspection
  172
- Cylinder Head Inspection
  174
- Cylinder Head Removal
  174
- Cylinder Head Warp Inspection
  174
- Valve Inspection
  176
- Combustion Chamber Cleaning
  177
- Valve Seat Reconditioning
  177
- Engine Disassembly / Inspection - Lower End
  181
- Flywheel Removal
  182
- Starter One-Way Clutch Disassembly
  183
- Starter One-Way Clutch Assembly
  184
- Crankcase Disassembly
  185
- Balance Shaft Removal / Inspection
  187
- Crankshaft Removal / Inspection
  188
- Crankcase Inspection
  191
- Cylinder / Piston Removal
  192
- Cylinder Inspection
  192
- Piston Disassembly / Inspection
  193
- Piston Ring Removal
  194
- Piston Ring Installed Gap
  195
- Piston Ring to Groove Clearance Inspection
  195
- Piston-To-Cylinder Clearance
  195
- Connecting Rod Inspection
  196
- Bearing Selection Identification Letters and Numbers
  198
- Engine Assembly - Lower End (900)
  198
- Connecting Rod Bearing Selection
  199
- Crankshaft Main Bearing Selection
  199
- Piston Ring Installation
  200
- Upper Crankcase Preparation
  200
- Piston / Connecting Rod Assembly
  201
- Cylinder / Piston Installation
  202
- Crankshaft Installation
  203
- Balance Shaft Installation
  204
- Lower Crankcase Preparation
  205
- Crankcase Assembly
  206
- Flywheel Installation
  210
- Stator Cover Installation
  210
- Engine Specifications (1000)
  223
- Camshaft Removal
  225
- Engine Disassembly / Inspection - Top End (1000)
  225
- Valve Cover Removal
  225
- Camshaft Sprocket Inspection
  227
- Camshaft / Camshaft Bore Inspection (1000)
  228
- Cylinder Head Removal
  229
- Cylinder Head Disassembly
  230
- Cylinder Head Warp Inspection
  230
- Valve Inspection
  231
- Combustion Chamber Cleaning
  232
- Valve Sealing Test
  233
- Valve Seat Reconditioning (1000)
  233
- Engine Disassembly / Inspection - Lower End (1000)
  236
- Stator Cover Removal / Inspection
  236
- Water Pump Housing Removal
  237
- Flywheel Removal
  238
- Starter One-Way Clutch Disassembly
  239
- Crankcase Disassembly / Inspection
  240
- Balance Shaft Removal / Inspection
  242
- Crankshaft Removal / Inspection
  243
- Crankcase Inspection
  245
- Cylinder Inspection
  246
- Cylinder / Piston Removal
  247
- Piston Disassembly / Inspection (1000)
  248
- Piston Ring Removal
  249
- Piston Ring to Groove Clearance Inspection
  249
- Connecting Rod Inspection
  250
- Piston Ring Installed Gap (1000)
  250
- Piston-To-Cylinder Clearance
  250
- Bearing Selection Identification Letters and Numbers
  252
- Engine Assembly - Lower End (1000)
  252
- Connecting Rod Bearing Selection
  253
- Crankshaft Main Bearing Selection
  253
- Piston Ring Installation
  254
- Upper Crankcase Preparation
  254
- Piston / Connecting Rod Assembly
  256
- Cylinder / Piston Installation
  257
- Crankshaft Installation
  258
- Balance Shaft Installation
  260
- Lower Crankcase Preparation
  260
- Crankcase Assembly
  261
- Starter One-Way Clutch Assembly
  264
- Flywheel Installation
  265
- Stator Cover Installation
  265
- Cylinder Head Assembly
  266
- Engine Assembly - Top End (1000)
  266
- Camshaft Installation / Timing
  268
- Camshaft Timing - Quick Reference
  272
- Valve Clearance Adjustment
  273
- Valve Lash - Tappet Selection
  275
- Valve Cover Installation
  276
Chapter 4 Engine Electrical

277
- Ecu Replacement
  278
- Ecu Service
  278
- Electronic Control Unit (Ecu)
  278
- Operation Overview
  278
- Etc Learn Procedure
  279
- Operation Overview
  280
- Temperature and Manifold Absolute Pressure Sensor (T-Map)
  280
- Tmap Test / Replacement
  280
- Cps Test
  281
- Crankshaft Position Sensor (Cps)
  281
- Operation Overview
  281
- Cps Replacement
  282
- Electronic Throttle Control (Etc) / Throttle Body
  283
- Etc Replacement
  283
- Etc Test
  283
- Throttle Body Operation Overview
  283
- Etc Learn Procedure
  284
- Operation Overview
  285
- Pedal Position Sensor (Pps)
  285
- Pps Location
  285
- Pps Replacement
  285
- Pps Test
  285
- Oxygen Sensor (Rzr S 1000)
  287
- Oxygen Sensor Information
  287
- Oxygen Sensor Replacement
  287
- Digital Wrench® Diagnostic Software Overview
  288
- Polaris Digital Wrench
  288
- Special Tools (Digital Wrench)
  288
- Digital Wrench Software Version and Update
  289
- Digital Wrench® Updates
  289
- Digital Wrench® - Diagnostic Connector
  290
- Digital Wrench® Communication Errors
  290
- Guided Diagnostics
  290
- Digital Wrench® Serial Number Location
  291
- Digital Wrench® Feature Map
  292
- Ecu Replacement
  293
- Ecu Reprogramming (Reflash)
  293
- Etc Learn Procedure
  293
- Polaris Mobile Digital Wrench (Pmdw)
  296
Chapter 5 Fuel System

297
- Special Tools
  298
- Efi Operation Overview
  299
- Efi Overview
  299
- Initial Priming / Starting Procedure
  299
- Principal Components
  299
- Fuel Injector O-Rings
  300
- Fuel Injectors
  300
- Operation Overview
  300
- Fuel Injector Test
  301
- Fuel Injector Troubleshooting
  301
- Fuel Injector Replacement
  302
- Fuel Lines
  305
- Fuel Vent Line Routing
  305
- Fuel Vent Line Routing (Evap Models)
  307
- Fuel Supply Line Routing
  309
- Fuel Supply Line Routing (Evap Models)
  311
- Vent Line Termination Fitting
  313
- Fuel Tank / Pump
  314
- Fuel Tank Assembly View
  314
- Fuel Line Removal / Installation
  315
- Fuel Tank Removal
  315
- Fuel Tank Installation
  318
- Fuel Pump
  319
- Fuel Sender Test
  319
- Operation Overview
  319
- Fuel Pump Test
  320
- Fuel Pump Replacement
  321
- Data Display Definitions
  325
- Efi Diagnostics
  325
- Cylinder Misfire Detection
  328
- Misfire Detection (S 1000 Only)
  328
- Trouble Code Display (Dtc)
  329
- Efi Troubleshooting
  336
Chapter 6 Pvt System

337
- Clutch Charts
  339
- Rzr 900 Clutch Chart
  339
- Rzr 900 XC Clutch Chart
  339
- Rzr S 1000 Clutch Chart
  339
- Rzr S 900 Clutch Chart
  339
- Rzr S4 1000 Clutch Chart
  339
- Special Tools
  339
- Drive Clutch Operation
  340
- General Operation
  340
- Pvt Break-In (Drive Belt / Clutches)
  340
- Pvt System Overview
  340
- Driven Clutch Operation
  341
- Maintenance / Inspection
  341
- Pvt Covers and Ducting Components
  342
- Pvt System Service
  342
- Rzr S 1000 / S4 1000 Pvt Covers and Ducting Components
  343
- Pvt Disassembly
  344
- Pvt Assembly
  345
- Belt Removal (Ebs)
  346
- Belt Removal (Non-Ebs)
  346
- Drive Belt
  346
- Belt Inspection
  347
- Belt Installation (Ebs)
  347
- Belt Installation (Non-Ebs)
  348
- Pvt Break-In (Drive Belt / Clutches)
  348
- Drive Clutch Assembly View
  349
- Drive Clutch Service
  349
- Drive Clutch Disassembly
  350
- Bearing Inspection
  351
- Button to Tower Clearance
  352
- Shift Weight Inspection
  352
- Roller, Pin and Thrust Washer Inspection
  353
- Spider Removal
  353
- Drive Clutch Inspection
  354
- Bushing Service
  355
- Moveable Sheave Bushing Inspection
  355
- Drive Clutch Assembly
  358
- Driven Clutch Assembly View
  360
- Driven Clutch Service (Ebs)
  360
- Driven Clutch Slider Inspection
  361
- Driven Clutch Disassembly
  366
- Driven Clutch Assembly
  367
- Pvt Troubleshooting
  369
- Troubleshooting
  369
- Pvt Overheating / Diagnosis
  371
Chapter 7 Transmission

373
- Lubrication Specifications
  374
- Special Tools
  374
- Transmission Mounting View
  375
- Shift Cable Inspection
  376
- Shift Lever / Cable
  376
- Shift Lever Installation
  376
- Shift Lever Removal
  376
- Shift Cable Adjustment
  377
- Transmission Removal
  378
- Transmission Service
  378
- Transmission Installation
  382
- Transmission Disassembly
  386
- Differential Operation
  390
- Planetary Differential Disassembly (Turf Mode Models Only)
  393
- Planetary Differential Bushing Replacement (Turf Mode Models Only)
  394
- Planetary Differential Assembly (Turf Mode Models Only)
  396
- Gear / Shaft / Bearing Inspection
  398
- Transmission Assembly / Snorkel Gear Backlash Procedure
  399
- Shifting Difficulty
  405
- Troubleshooting
  405
Chapter 8 Final Drive

407
- Special Tools
  408
- Bearing Carrier
  409
- Front Bearing Carrier Removal / Inspection
  409
- Front Bearing Replacement
  410
- Front Bearing Carrier Installation
  411
- Rear Bearing Carrier Removal / Inspection
  412
- Rear Carrier Bearing Replacement
  413
- Rear Bearing Carrier Installation
  414
- Drive Shaft
  416
- Front Half Shaft Removal
  416
- Front Half Shaft Installation
  417
- Rear Half Shaft Removal
  418
- Rear Half Shaft Installation
  419
- Drive Shaft / CV Joint Handling Tips
  420
- Outer CV Joint / Boot Replacement
  420
- Inner Plunging Joint / Boot Replacement
  423
- Prop Shaft Removal
  425
- Prop Shaft Installation
  426
- Front Gearcase / Centralized Hilliard
  431
- Front Gearcase Assembly View
  431
- All Wheel Drive Operation
  432
- Awd Diagnosis
  433
- Front Gearcase Disassembly / Inspection
  434
- Front Gearcase Removal
  434
- Front Gearcase Assembly
  437
- Front Gearcase Installation
  440
- Front Hub Assembly View
  441
- Wheel Hubs
  441
- Rear Hub Assembly View
  442
Chapter 9 Steering / Suspension

443
- Special Tools
  445
- Steering - General
  446
- Steering Rack Replacement
  446
- Steering System
  446
- Tie Rod Replacement
  446
- Steering Assembly (Non-Eps)
  448
- Steering Assembly View
  448
- Steering Shaft Bearing Replacement
  449
- Steering Shaft Removal (Non-Eps)
  449
- Steering Wheel Removal (Non-Eps)
  449
- Steering Assembly (Eps)
  451
- Steering Assembly View (Eps)
  451
- Upper Steering Shaft Removal
  452
- Power Steering Unit Removal
  453
- Steering Wheel Removal (Eps)
  453
- Lower Steering Shaft Removal
  454
- Lower Steering Shaft Installation
  455
- Power Steering Unit Installation
  456
- Upper Steering Shaft Installation
  457
- Front Suspension
  458
- Front Suspension Assembly View
  458
- Front Control Arm Replacement
  459
- Ball Joint Installation
  461
- Ball Joint Removal
  461
- Front Stabilizer Bar Replacement (50" & XC)
  462
- Rear Control Arm Removal
  463
- Rear Suspension
  463
- Rear Control Arm Installation
  464
- Rear Stabilizer Bar Replacement
  464
- Front Shock Assembly View
  466
- Rear Shock Assembly View
  466
- Shocks / Springs
  466
- Shock / Spring Replacement
  467
- Shock Removal / Installation
  467
- Shock Service (Fox)
  468
- Shock Specifications (Fox)
  468
- Fox Shock Disassembly
  470
- Fox Shock Assembly
  479
- Shock Service (Walker Evans)
  489
- Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
  489
- Shock Compression Adjustment (Walker Evans)
  490
- Spring Adjustment (Walker Evans)
  490
- Shock Piston Orientation
  492
- Special Tools
  492
- Valve Shim Arrangement
  492
- Walker Evans™ Shock Rebuild Information
  492
- Walker Evans™ Shock Disassembly
  493
- Walker Evans™ Shock Assembly
  496
Chapter 10 Brake System

501
- General Specifications
  503
- Special Tools
  503
- Brake System Service Notes
  504
- Hydraulic Brake System Operation
  504
- Rzr 900 / 1000
  505
- Master Cylinder
  506
- Master Cylinder Installation
  506
- Master Cylinder Removal
  506
- Brake Bleeding / Fluid Change
  508
- Brake Pedal
  508
- Brake Pedal Installation
  508
- Brake Pedal Lever Removal
  508
- Parking Brake (Int'l)
  510
- Parking Brake Assembly View
  510
- Parking Brake Cable Adjustment (Intl)
  511
- Parking Brake Inspection (Intl)
  511
- Caliper Installation
  513
- Caliper Removal
  513
- Disc Inspection / Replacement
  513
- Front Brakes
  515
- Front Caliper / Pad Removal
  515
- Front Caliper Assembly View
  516
- Front Caliper Disassembly
  517
- Front Caliper Assembly
  518
- Front Caliper Inspection
  518
- Front Brake Disc Inspection
  519
- Front Pad Inspection
  519
- Front Brake Disc Runout
  520
- Front Disc Replacement
  520
- Front Caliper / Pad Installation
  521
- Brake Burnishing Procedure
  522
- Rear Brakes
  523
- Rear Caliper / Brake Pad Removal
  523
- Rear Caliper Assembly View
  524
- Rear Caliper Disassembly
  525
- Rear Caliper Inspection
  525
- Rear Brake Pad Inspection
  526
- Rear Caliper Assembly
  526
- Rear Disc Inspection
  527
- Rear Disc Replacement
  527
- Rear Caliper / Pad Installation
  528
- Brake Burnishing Procedure
  529
- Brake Noise Troubleshooting
  530
- Brake Vibration
  530
- Poor Brake Performance
  530
- Troubleshooting
  530
- Brakes Lock
  531
- Caliper Overheats (Brakes Drag)
  531
- Brake Pedal Switch Inspection
  532
- Brake Warning System Inspection (Intl Models)
  532
Chapter 11 Body / Frame

533
- Decal Replacement
  534
- Special Tools
  534
- Body Assembly Views
  535
- Cab Frame Assembly
  535
- Doors
  537
- Dash / Instruments
  539
- Hood / Front Body
  540
- Chassis / Main Frame
  541
- Seats
  543
- Seats - Rear
  544
- Floor / Rocker Panels
  545
- Rear Cargo Box / Fenders
  547
- Rear Bumper
  548
- Body Component Removal
  549
- Engine Service Panel
  549
- Front Bumper Removal
  549
- Rear Bumper Removal
  549
- Seat Removal
  549
- Hood Removal
  550
- Lower Dash Removal
  550
- Upper Dash Removal
  550
- Cargo Box Removal
  551
- Front Fender / Body Removal
  551
- Rear Fender / Fender Flair Removal
  551
- Rocker Panel / Console / Floor
  552
- Rocker Panels / Rear Console / Floor - 4 900
  553
- Door Adjustment
  558
- Door Panel / Latch Replacement
  558
- Doors
  558
Chapter 12 Electrical

561
- Service Notes
  563
- Special Tools
  563
- Under Dash Components
  563
- Break-Out Diagram Viewing
  564
- Instrument Cluster
  566
- Overview
  566
- Information Display Area
  568
- Diagnostic Mode
  571
- Brake Light Switch
  573
- Headlamp Switch
  573
- Switches / Controls
  573
- Awd / 2Wd Switch (no Turf Mode)
  574
- Ignition (Key) Switch
  574
- Awd/2Wd/Turf Switch (Models with Turf)
  575
- Transmission (Gear Position) Switch
  575
- Hazard Switch (Int'l / Tractor)
  576
- Seat Belt Switch
  576
- Turn/Lights/Horn Switch (Int'l/Tractor)
  577
- Brake Alarm (Int'l/Tractor)
  578
- Flasher Module (Int'l/Tractor)
  578
- Horn
  578
- Turn Lights
  578
- Parking Brake Switch (Int'l/Tractor)
  579
- Differential Solenoid Circuit Operation
  580
- Differential Solenoid Overview
  580
- Charging System
  581
- Stator
  581
- Voltage Regulator
  581
- Charging System "Break Even" Test
  582
- Charging System Stator (Alternator) Tests
  582
- Charging System Testing Flow Chart
  584
- Battery
  585
- Battery Installation
  585
- Battery Removal
  585
- Current Draw - Key off
  586
- Battery Conductance Analyzer
  587
- Load Test
  587
- Ocv - Open Circuit Voltage Test
  587
- Headlights
  588
- Lighting System
  588
- Dash Led Light
  589
- Taillights
  589
- Coolant Temperature Sensor
  590
- Cooling System
  590
- Radiator Fan
  591
- Starter Installation
  592
- Starter Removal
  592
- Starter Troubleshooting
  592
- Starting System
  592
- Voltage Drop Test
  592
- Starter Solenoid
  593
- Electronic Power Steering
  594
- Eps Operation
  594
- Eps System Diagnosis
  594
- Fuse Box (Rzr S 4 1000)
  597
- 12V Receptacle
  598
- Awd Coil
  598
- Misc. Electrical
  598
- Speed Sensor
  598
- Terminal Block
  598
- Chassis Ground Point
  599
- Ignition Coil
  599
- Can System Overview
  600
- Can System Testing
  600
- Diagnostic Plug
  600

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