Polaris RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020) - Service Manual / Repair Manual

POLARIS RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for UTV Polaris RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020).

 
CONTENTS:


CHAPTER 1 : GENERAL INFORMATION

VEHICLE IDENTIFICATION
- Model Number Designation (2015 +)
- Vehicle Identification Number (VIN) Designation (2015+)
- Vehicle and Engine Serial Number Location

REFERENCE INFORMATION
- Publication Numbers
- Replacement Keys
- SPECIAL TOOLS
- Master Torque Table

GENERAL SPECIFICATIONS
- 2017 RZR 900 Specifications
- RZR 900 Clutch Chart
- 2017 RZR 900 EPS Specifications
- RZR 900 Clutch Chart
- 2017 RZR 900 XC Specifications
- RZR 900 XC Clutch Chart
- 2017 RZR S 900 Specifications
- RZR S 900 Clutch Chart
- 2017 RZR S 900 EPS
- RZR S 900 Clutch Chart
- 2017 RZR S4 900 Specifications
- RZR S4 900 Clutch Chart
- 2017 RZR S 1000 Specifications
- RZR S 1000 Clutch Chart
- 2018 RZR 900 Specifications
- RZR 900 Clutch Chart
- 2018 RZR 900 EPS Specifications
- RZR 900 Clutch Chart
- 2018 RZR S 900 Specifications
- RZR S 900 Clutch Chart
- 2018 RZR S 900 EPS Specifications
- RZR S 900 Clutch Chart
- 2018 RZR S4 900 Specifications
- RZR S4 900 Clutch Chart
- 2018 RZR S 1000 Specifications
- RZR S 1000 Clutch Chart
- 2019 RZR 900 Specifications
- 2019 RZR 900 Clutch Chart
- 2019 RZR 900 EPS Specifications
- 2019 RZR 900 EPS Clutch Chart
- 2019 RZR S 900 Specifications
- 2019 RZR S 900 Clutch Chart
- 2019 RZR S 1000 Specifications
- 2019 RZR S 1000 Clutch Chart
- 2019 RZR S 1000 EPS Specifications
- 2019 RZR S 1000 EPS Clutch Chart
- 2019 RZR S4 1000 Specifications
- 2019 RZR S4 1000 Clutch Chart
- 2020 RZR 900 Specifications
- RZR 900 Clutch Chart
- 2020 RZR 900 EPS Specifications
- RZR 900 Clutch Chart
- 2020 RZR S 900 Specifications
- RZR S 900 Clutch Chart
- 2020 RZR S 1000 Specifications
- RZR S 1000 Clutch Chart
- 2020 RZR S 1000 EPS Specifications
- 2019 RZR S 1000 EPS Clutch Chart
- 2020 RZR S4 1000 Specifications
- 2019 RZR S4 1000 Clutch Chart

Misc. Specifications and Charts
- Conversion Table
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

CHAPTER 2 : MAINTENANCE

PERIODIC MAINTENANCE CHART
- Periodic Maintenance Overview
- Break-In Period
- Pre-Ride Inspection
- Maintenance Intervals
- Maintenance Quick Reference
- Grease Lubrication Points

GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Lubricants / Service Products
- Shift Cable Inspection / Adjustment

ENGINE / AIR INTAKE
- Engine Air Filter Service
- Intake Duct Inspection
- Air Box / Filter Assembly View
- Engine Oil Level
- Engine Oil and Filter Change
- Crankcase Breather Hose Inspection
- Engine Cylinder Leak-down Test
- Valve Clearance Inspection
- Cam Chain Tensioner Inspection

COOLING SYSTEM
- Cooling System Overview
- Coolant Strength
- Coolant Level Inspection
- Cooling System Pressure Test
- Cooling System Hose Inspection
- Radiator Inspection / Cleaning
- Coolant Drain / Fill

FUEL SYSTEM
- Fuel System Warning
- Fuel Tank Vent Line
- Fuel Pump / Fuel Filter
- Fuel Lines
- Throttle Pedal Inspection

PVT SYSTEM
- Drive Clutch / Driven Clutch / Belt Service
- PVT Duct Cleaning
- PVT Drying

DRIVESHAFT / WHEEL AND TIRE
- Drive Shaft Boot Inspection
- Wheel and Hub Torque Table
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure

TRANSMISSION AND FRONT GEARCASE
- Specification Chart
- Transmission Lubrication
- Front Gearcase Lubrication

STEERING SYSTEM
- Steering Inspection
- Steering Wheel Free-play
- Tie Rod End / Wheel Bearing Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment

SUSPENSION SYSTEM
- Spring Adjustment (non-Fox)
- Spring Adjustment (FOX)
- Shock Compression Adjustment (FOX)
- Spring Adjustment (Walker Evans)
- Shock Compression Adjustment (Walker Evans)

BRAKE SYSTEM
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose and Fitting Inspection

ELECTRICAL / IGNITION SYSTEM
- Battery Maintenance
- Battery Off Season Storage
- Battery Charging
- Engine / Chassis Ground
- Spark Plug Service

CHAPTER 3 : ENGINE / COOLING SYSTEM

Engine - General
- General Information
- Lubrication Specifications
- Main Engine Components - Torque Specification and Sequence
- Exhaust System
- Exhaust Assembly View / Torque Values
- Exhaust Removal / Installation
- Engine Cooling System
- Cooling System Specifications
- Cooling System Pressure Test
- Radiator Cap Pressure Test
- Radiator Removal / Installation
- Thermostat Replacement
- Cooling System Bleeding
- Water Pump Removal
- Water Pump Service
- Water Pump Installation
- Engine Service
- Lubrication Specifications
- Engine Oil Pressure Test
- Engine Oil Flow Chart
- Accessible Engine Components
- Top End Service
- Engine Mounts
- Crankshaft PTO Seal Replacement
- Engine Removal
- Engine Installation
- Engine Break-In
- Troubleshooting
- Engine
- Cooling System

900 Engine
- Engine Specifications (900)
- Engine Specifications
- Engine Disassembly / Inspection - Top End (900)
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Seat Reconditioning
- Engine Disassembly / Inspection - Lower End (900)
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-Way Clutch Disassembly
- Starter One-Way Clutch Assembly
- Crankcase Disassembly
- Balance Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Inspection
- Cylinder / Piston Removal
- Cylinder Inspection
- Piston Disassembly / Inspection
- Piston Ring Removal
- Piston Ring to Groove Clearance Inspection
- Piston Ring Installed Gap
- Piston-to-Cylinder Clearance
- Connecting Rod Inspection
- Engine Assembly - Lower End (900)
- Bearing Selection Identification Letters and Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- Upper Crankcase Preparation
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Cylinder / Piston Installation
- Crankshaft Installation
- Balance Shaft Installation
- Lower Crankcase Preparation
- Crankcase Assembly
- Flywheel Installation
- Stator Cover Installation
- Engine Assembly - Top End (900)
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Clearance Adjustment
- Valve Lash - Tappet Selection
- Valve Cover Installation

1000 Engine
- Engine Specifications (1000)
- Engine Specifications (1000)
- ENGINE DISASSEMBLY / INSPECTION - TOP END (1000)
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection (1000)
- Cylinder Head Removal
- Cylinder Head Warp Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Sealing Test
- Valve Seat Reconditioning (1000)
- ENGINE DISASSEMBLY / INSPECTION - LOWER END (1000)
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-Way Clutch Disassembly
- Crankcase Disassembly / Inspection
- Balance Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Inspection
- Cylinder Inspection
- Cylinder / Piston Removal
- Piston Disassembly / Inspection (1000)
- Piston Ring Removal
- Piston Ring to Groove Clearance Inspection
- Piston Ring Installed Gap (1000)
- Piston-to-Cylinder Clearance
- Connecting Rod Inspection
- ENGINE ASSEMBLY - LOWER END (1000)
- Bearing Selection Identification Letters and Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- Upper Crankcase Preparation
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Cylinder / Piston Installation
- Crankshaft Installation
- Balance Shaft Installation
- Lower Crankcase Preparation
- Crankcase Assembly
- Starter One-Way Clutch Assembly
- Flywheel Installation
- Stator Cover Installation
- ENGINE ASSEMBLY - TOP END (1000)
- Cylinder Head Assembly
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Clearance Adjustment
- Valve Lash - Tappet Selection
- Valve Cover Installation

CHAPTER 4 : ENGINE ELECTRICAL

Electronic Control Unit (ECU)
- Operation Overview
- ECU Service
- ECU Replacement
- ETC Learn Procedure

Temperature and Manifold Absolute Pressure Sensor (T-MAP)
- Operation Overview
- TMAP Test / Replacement

Crankshaft Position Sensor (CPS)
- Operation Overview
- CPS Test
- CPS Replacement

Electronic Throttle Control (ETC) / Throttle Body
- Throttle Body Operation Overview
- ETC Test
- ETC Replacement
- ETC Learn Procedure

Pedal Position Sensor (PPS)
- Operation Overview
- PPS Location
- PPS Test
- PPS Replacement

Oxygen Sensor (RZR S 1000)
- Oxygen Sensor Information
- Oxygen Sensor Replacement

Polaris Digital Wrench
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Digital Wrench)
- Digital Wrench Software Version and Update ID
- Digital Wrench® Updates
- Digital Wrench® Communication Errors
- Digital Wrench® - Diagnostic Connector
- Guided Diagnostics
- Digital Wrench® Serial Number Location
- Digital Wrench® Feature Map
- ECU Replacement
- ETC Learn Procedure
- ECU Reprogramming (Reflash)

Polaris Mobile Digital Wrench (PMDW)
- Polaris Mobile Digital Wrench® (PMDW)

CHAPTER 5 : FUEL SYSTEM

General Information
- Special Tools

EFI Overview
- Principal Components
- EFI Operation Overview
- Initial Priming / Starting Procedure

Fuel Injectors
- Operation Overview
- Fuel Injector O-rings
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement

Fuel Lines
- Fuel Vent Line Routing
- Fuel Vent Line Routing (EVAP Models)
- Fuel Supply Line Routing
- Fuel Supply Line Routing (EVAP Models)
- Vent Line Termination Fitting

Fuel Tank / Pump
- Fuel Tank Assembly View
- Fuel Line Removal / Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Pump
- Operation Overview
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump Replacement

EFI Diagnostics
- Data Display Definitions
- Misfire Detection (S 1000 ONLY)
- Cylinder Misfire Detection
- Trouble Code Display (DTC)
- EFI Troubleshooting

CHAPTER 6 : PVT SYSTEM

General Information
- Special Tools
- Clutch Charts
- RZR 900 Clutch Chart
- RZR 900 XC Clutch Chart
- RZR S 900 Clutch Chart
- RZR S 1000 Clutch Chart
- RZR S4 1000 Clutch Chart

PVT System Overview
- General Operation
- PVT Break-In (Drive Belt / Clutches)
- Drive Clutch Operation
- Driven Clutch Operation
- Maintenance / Inspection

PVT System Service
- PVT Covers and Ducting Components
- RZR S 1000 / S4 1000 PVT Covers and Ducting Components
- PVT Disassembly
- PVT Assembly

Drive Belt
- Belt Removal (EBS)
- Belt Removal (non-EBS)
- Belt Inspection
- Belt Installation (EBS)
- Belt Installation (non-EBS)
- PVT Break-In (Drive Belt / Clutches)

Drive Clutch Service
- Drive Clutch Assembly View
- Drive Clutch Disassembly
- Bearing Inspection
- Shift Weight Inspection
- Button to Tower Clearance
- Spider Removal
- Roller, Pin and Thrust Washer Inspection
- Drive Clutch Inspection
- Moveable Sheave Bushing Inspection
- Bushing Service
- Drive Clutch Assembly

Driven Clutch Service (EBS)
- Driven Clutch Assembly View
- Driven Clutch Slider Inspection
- Driven Clutch Disassembly
- Driven Clutch Assembly

Driven Clutch Service (non-EBS)
- Driven Assembly View
- Driven Clutch Disassembly
- Driven Clutch Assembly

Troubleshooting
- PVT Troubleshooting
- PVT Overheating / Diagnosis

CHAPTER 7 : TRANSMISSION

General Information
- Special Tools
- Lubrication Specifications
- Transmission Mounting View

Shift Lever / Cable
- Shift Lever Removal
- Shift Lever Installation
- Shift Cable Inspection
- Shift Cable Adjustment

Transmission Service
- Transmission Removal
- Transmission Installation
- Transmission Disassembly
- Differential Operation
- Planetary Differential Disassembly (Turf Mode Models Only)
- Planetary Differential Bushing Replacement (Turf Mode Models Only)
- Planetary Differential Assembly (Turf Mode Models Only)
- Gear / Shaft / Bearing Inspection
- Transmission Assembly / Snorkel Gear Backlash Procedure

Troubleshooting
- Shifting Difficulty

CHAPTER 8 : FINAL DRIVE

General Information
- Special Tools

Bearing Carrier
- Front Bearing Carrier Removal / Inspection
- Front Bearing Replacement
- Front Bearing Carrier Installation
- Rear Bearing Carrier Removal / Inspection
- Rear Carrier Bearing Replacement
- Rear Bearing Carrier Installation

Drive Shaft
- Front Half Shaft Removal
- Front Half Shaft Installation
- Rear Half Shaft Removal
- Rear Half Shaft Installation
- Drive Shaft / CV Joint Handling Tips
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Prop Shaft Removal
- Prop Shaft Installation
- Rear Prop Shaft Removal 4 1000
- Rear Prop Shaft Installation 4 1000

Front Gearcase / Centralized Hilliard
- Front Gearcase Assembly View
- All Wheel Drive Operation
- AWD Diagnosis
- Front Gearcase Removal
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- Front Gearcase Installation

Wheel Hubs
- Front Hub Assembly View
- Rear Hub Assembly View

CHAPTER 9 : STEERING / SUSPENSION

General Information
- Special Tools

Steering System
- Steering - General
- Steering Rack Replacement
- Tie Rod Replacement
- Steering Assembly (non-EPS)
- Steering Assembly View
- Steering Wheel Removal (non-EPS)
- Steering Shaft Removal (non-EPS)
- Steering Shaft Bearing Replacement
- Steering Assembly (EPS)
- Steering Assembly View (EPS)
- Upper Steering Shaft Removal
- Steering Wheel Removal (EPS)
- Power Steering Unit Removal
- Lower Steering Shaft Removal
- Lower Steering Shaft Installation
- Power Steering Unit Installation
- Upper Steering Shaft Installation

Front Suspension
- Front Suspension Assembly View
- Front Control Arm Replacement
- Ball Joint Removal
- Ball Joint Installation
- Front Stabilizer Bar Replacement (50" & XC)

Rear Suspension
- Rear Control Arm Removal
- Rear Control Arm Installation
- Rear Stabilizer Bar Replacement

Shocks / Springs
- Front Shock Assembly View
- Rear Shock Assembly View
- Shock Removal / Installation
- Shock / Spring Replacement

Shock Service (FOX)
- Shock Specifications (FOX)
- FOX Shock Disassembly
- FOX Shock Assembly

Shock Service (Walker Evans)
- Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
- Spring Adjustment (Walker Evans)
- Shock Compression Adjustment (Walker Evans)
- Walker Evans™ Shock Rebuild Information
- Special Tools
- Valve Shim Arrangement
- Shock Piston Orientation
- Walker Evans™ Shock Disassembly
- Walker Evans™ Shock Assembly

CHAPTER 10 : BRAKE SYSTEM

GENERAL INFORMATION
- SPECIAL TOOLS
- GENERAL SPECIFICATIONS
- BRAKE SYSTEM SERVICE NOTES
- HYDRAULIC BRAKE SYSTEM OPERATION
- RZR 900 / 1000

MASTER CYLINDER
- Master Cylinder Removal
- Master Cylinder Installation

BRAKE PEDAL
- Brake Pedal Lever Removal
- Brake Pedal Installation
- BRAKE BLEEDING / FLUID CHANGE

PARKING BRAKE (INT'L)
- Parking Brake Assembly View
- Parking Brake Inspection (INTL)
- Parking Brake Cable Adjustment (INTL)
- Caliper Removal
- Caliper Installation
- Disc Inspection / Replacement

FRONT BRAKES
- Front Caliper / Pad Removal
- Front Caliper Assembly View
- Front Caliper Disassembly
- Front Caliper Inspection
- Front Caliper Assembly
- Front Pad Inspection
- Front Brake Disc Inspection
- Front Brake Disc Runout
- Front Disc Replacement
- Front Caliper / Pad Installation
- Brake Burnishing Procedure

REAR BRAKES
- Rear Caliper / Brake Pad Removal
- Rear Caliper Assembly View
- Rear Caliper Disassembly
- Rear Caliper Inspection
- Rear Caliper Assembly
- Rear Brake Pad Inspection
- Rear Disc Inspection
- Rear Disc Replacement
- Rear Caliper / Pad Installation
- Brake Burnishing Procedure

TROUBLESHOOTING
- BRAKE NOISE TROUBLESHOOTING
- Poor Brake Performance
- Brake Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
- Brake Warning System (INTL Models)
- Brake Warning System Inspection (INTL Models)
- Brake Pedal Switch Inspection

CHAPTER 11 : BODY / FRAME

General Information
- Special Tools
- DECAL REPLACEMENT

Body Assembly Views
- Cab Frame Assembly
- Cab Frame Assembly - 4 1000
- Doors
- Doors - 4 1000
- Dash / Instruments
- Hood / Front Body
- Chassis / Main Frame
- Chassis / Main Frame - 4 1000
- Seats
- Seats - Rear
- Floor / Rocker Panels
- Floor / Rocker Panels - 4 1000
- Rear Cargo Box / Fenders
- Rear Bumper

Body Component Removal
- Seat Removal
- Front Bumper Removal
- Rear Bumper Removal
- Engine Service Panel
- Hood Removal
- Upper Dash Removal
- Lower Dash Removal
- Front Fender / Body Removal
- Rear Fender / Fender Flair Removal
- Cargo Box Removal
- Rocker Panel / Console / Floor
- Rocker Panels / Rear Console / Floor - 4 900
- Rocker Panels / Rear Console / Floor - 4 1000

Doors
- Door Panel / Latch Replacement
- Door Adjustment

CHAPTER 12 : ELECTRICAL

General Information
- Special Tools
- Service Notes
- Under Dash Components
- Break-Out Diagram viewing

Instrument Cluster
- Overview
- Information Display Area
- Diagnostic Mode
- Instrument Cluster Pinouts

Switches / Controls
- Brake Light Switch
- Headlamp Switch
- Ignition (Key) Switch
- AWD / 2WD Switch (no Turf mode)
- AWD/2WD/Turf Switch (models with Turf)
- Transmission (Gear Position) Switch
- Seat Belt Switch
- Hazard Switch (INT'L / Tractor)
- Turn/Lights/Horn Switch (INT'L/Tractor)
- Horn
- Turn Lights
- Flasher Module (INT'L/Tractor)
- Brake Alarm (INT'L/Tractor)
- Parking Brake Switch (INT’L/Tractor)
- Differential Solenoid Overview
- Differential Solenoid Circuit Operation

Charging System
- Stator
- Voltage Regulator
- Charging System “Break Even” Test
- Charging System Stator (Alternator) Tests
- Charging System Testing Flow Chart

Battery
- Battery Removal
- Battery Installation
- Current Draw - Key Off
- OCV - Open Circuit Voltage Test
- Load Test
- Battery Conductance Analyzer

Lighting System
- Headlights
- Taillights
- Dash LED Light

Cooling System
- Coolant Temperature Sensor
- Radiator Fan

Starting System
- Starter Troubleshooting
- Voltage Drop Test
- Starter Removal
- Starter Installation
- Starter Solenoid

Electronic Power Steering
- EPS Operation
- EPS System Diagnosis

Fuses / Relays
- Fuse Box (900 / 900 XC / S 900 / S 1000)
- Fuse Box (RZR S 4 1000)

Misc. Electrical
- 12v Receptacle
- AWD Coil
- Speed Sensor
- Terminal Block
- Ignition Coil
- Chassis Ground Point
- Diagnostic Plug
- CAN System Overview
- CAN System Testing