User Manuals: Polaris RZR S 900 2016 Off-road vehicle

Manuals and User Guides for Polaris RZR S 900 2016 Off-road vehicle. We have 1 Polaris RZR S 900 2016 Off-road vehicle manual available for free PDF download: Service Manual

Polaris RZR S 900 2016 Service Manual

Polaris RZR S 900 2016 Service Manual (543 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 36 MB

Table of Contents

Chapter 1 1 General Information

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

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

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

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

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

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

355
- Bearing Carrier
  357
- Front Bearing Carrier Removal / Inspection
  357
- Front Bearing Carrier Installation
  358
- Front Bearing Replacement
  358
- Rear Bearing Carrier Removal / Inspection
  360
- Rear Carrier Bearing Replacement
  361
- Rear Bearing Carrier Installation
  362
- Drive Shaft
  364
- Front Half Shaft Removal
  364
- Front Half Shaft Installation
  365
- Rear Half Shaft Removal
  366
- Rear Half Shaft Installation
  367
- Drive Shaft / CV Joint Handling Tips
  368
- Outer CV Joint / Boot Replacement
  368
- Inner Plunging Joint / Boot Replacement
  371
- Prop Shaft Removal
  373
- Prop Shaft Installation
  374
- Rear Prop Shaft Removal (4 Seater)
  375
- Rear Prop Shaft Installation (4 Seater)
  376
- All Wheel Drive Operation
  377
- Front Gearcase / Centralized Hilliard
  377
- Front Gearcase Assembly View
  377
- Awd Diagnosis
  378
- Front Gearcase Disassembly / Inspection
  379
- Front Gearcase Removal
  379
- Front Gearcase Assembly
  383
- Front Gearcase Installation
  385
- Front Hub Assembly View
  387
- Wheel Hubs
  387
- Rear Hub Assembly View
  388
Chapter 8 Steering / Suspension

389
- General Information
  390
- Special Tools
  390
- Torque Specifications
  390
- Steering - General
  391
- Steering Rack Replacement
  391
- Steering System
  391
- Tie Rod Replacement
  391
- Steering Assembly (Non-Eps)
  393
- Steering Assembly View
  393
- Steering Shaft Bearing Replacement
  394
- Steering Shaft Removal (Non-Eps)
  394
- Steering Wheel Removal (Non-Eps)
  394
- Steering Assembly (Eps)
  396
- Steering Assembly View (Eps)
  396
- Upper Steering Shaft Removal
  397
- Power Steering Unit Removal
  398
- Steering Wheel Removal (Eps)
  398
- Lower Steering Shaft Installation
  400
- Lower Steering Shaft Removal
  400
- Power Steering Unit Installation
  401
- Upper Steering Shaft Installation
  402
- Front Suspension
  403
- Front Suspension Assembly View
  403
- Front Control Arm Replacement
  404
- Ball Joint Installation
  406
- Ball Joint Removal
  406
- Front Stabilizer Bar Replacement (50
  407
- Rear Control Arm Removal
  408
- Rear Suspension
  408
- Rear Control Arm Installation
  409
- Rear Stabilizer Bar Replacement
  409
- Front Shock Assembly View
  411
- Rear Shock Assembly View
  411
- Shocks / Springs
  411
- Shock / Spring Replacement
  412
- Shock Removal / Installation
  412
- Shock Service
  413
- Shock Specifications (Fox)
  413
- Fox Shock Disassembly
  415
- Fox Shock Assembly
  424
Chapter 9 Brake System

433
- General Information
  435
- General Specifications
  435
- Special Tools
  435
- Torque Specifications
  435
- Brake System Service Notes
  436
- Hydraulic Brake System Operation
  436
- Rzr 900 / 1000
  437
- Master Cylinder
  438
- Master Cylinder Installation
  438
- Master Cylinder Removal
  438
- Brake Bleeding / Fluid Change
  440
- Brake Pedal
  440
- Brake Pedal Installation
  440
- Brake Pedal Lever Removal
  440
- Parking Brake (Int
  442
- Parking Brake Assembly View
  442
- Parking Brake Cable Adjustment
  443
- Parking Brake Inspection
  443
- Parking Brake Caliper
  445
- Parking Brake Disc
  448
- Front Brakes
  449
- Front Caliper / Pad Removal
  449
- Front Caliper Assembly View
  450
- Front Caliper Disassembly
  451
- Front Caliper Assembly
  452
- Front Caliper Inspection
  452
- Front Brake Disc Inspection
  453
- Front Pad Inspection
  453
- Front Brake Disc Runout
  454
- Front Disc Replacement
  454
- Front Caliper / Pad Installation
  455
- Brake Burnishing Procedure
  456
- Rear Brakes
  457
- Rear Caliper / Brake Pad Removal
  457
- Rear Caliper Assembly View
  458
- Rear Caliper Disassembly
  459
- Rear Caliper Inspection
  459
- Rear Brake Pad Inspection
  460
- Rear Caliper Assembly
  460
- Rear Disc Inspection
  461
- Rear Disc Replacement
  461
Chapter 10 Body / Frame

465
- General Information
  466
- Special Tools
  466
- Torque Specifications
  466
- Decal Replacement
  467
- Body Assembly Views
  468
- Cab Frame Assembly
  468
- Cab Frame Assembly - 4 900
  469
- Doors
  470
- Doors - 4 900
  471
- Dash / Instruments
  472
- Hood / Front Body
  473
- Chassis / Main Frame
  474
- Chassis / Main Frame - 4 900
  475
- Seats
  476
- Seats - Rear
  477
- Floor / Rocker Panels
  478
- Floor / Rocker Panels - 4 900
  479
- Rear Cargo Box / Fenders
  480
- Rear Bumper
  481
- Body Component Removal
  482
- Front Bumper Removal
  482
- Rear Bumper Removal
  482
- Seat Removal
  482
- Engine Service Panel
  483
- Hood Removal
  483
- Lower Dash Removal
  483
- Upper Dash Removal
  483
- Cargo Box Removal
  484
- Front Fender / Body Removal
  484
- Rear Fender / Fender Flair Removal
  484
- Rocker Panel / Console / Floor
  485
- Rocker Panels / Rear Console / Floor - 4
  485
- Door Adjustment
  489
- Door Panel / Latch Replacement
  489
- Doors
  489
Chapter 11 Electrical

491
- General Information
  493
- Service Notes
  493
- Special Tools
  493
- Torque Specifications
  493
- Under Dash Components
  493
- Instrument Cluster
  494
- Overview
  494
- Information Display Area
  496
- Diagnostic Mode
  499
- Brake Light Switch
  501
- Headlamp Switch
  501
- Switches
  501
- Awd / 2Wd Switch (no Turf Mode)
  502
- Ignition (Key) Switch
  502
- Awd/2Wd/Turf Switch (Models with Turf)
  503
- Transmission (Gear Position) Switch
  503
- Seat Belt Switch
  504
- Charging System
  505
- Stator
  505
- Voltage Regulator
  505
- Charging System "Break Even" Test
  506
- Charging System Stator (Alternator) Tests
  506
- Charging System Testing Flow Chart
  508
- Battery
  509
- Battery Installation
  509
- Battery Removal
  509
- Current Draw - Key off
  510
- Load Test
  510
- Ocv - Open Circuit Voltage Test
  510
- Battery Conductance Analyzer
  511
- Headlights
  512
- Lighting System
  512
- Dash Led Light
  513
- Taillights
  513
- Coolant Temperature Sensor
  514
- Cooling System
  514
- Radiator Fan
  515
- Starter Installation
  516
- Starter Removal
  516
- Starter Troubleshooting
  516
- Starting System
  516
- Voltage Drop Test
  516
- Starter Solenoid
  517
- Electronic Power Steering
  518
- Eps Operation
  518
- Eps Torque Offset Procedure
  518
- Eps System Diagnosis
  519
- Fuse Box
  520
- Fuses / Relays
  520
- Relay Circuits
  521
- Fuse / Circuit Breaker Circuits
  522
- 12V Receptacle
  523
- Awd Coil
  523
- Misc. Electrical
  523
- Speed Sensor
  523
- Terminal Block
  523
- Coil Testing
  524
- Ignition Coil
  524
- Ignition Coil / Plug Wire Replacement
  524
- Operation Overview
  524
- Chassis Ground Point
  525
- Diagnostic Plug
  525
- Can System
  526
- Can System Overview
  526
- Can System Testing
  526
- Awd Break-Out Diagram
  527
- Break-Out Diagrams
  527
- Cooling System Break-Out Diagram
  528
- Eps Break-Out Diagram
  529
- Lighting Break-Out Diagram
  530
- Starting System Break-Out Diagram
  531
- Differential Circuit Break-Out Diagram
  532
- Vehicle Speed Sensor Break-Out Diagram
  533
- Unswitched Chassis Power Break-Out Diagram
  534
- Key on Battery Power Break-Out Diagram
  535

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