Polaris 2015 RZR 900 Service Manual

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 2014 (PN 9925723 R01)

© Copyright 2014 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.

2015 RZR 900

Service Manual

UNDERSTANDING SAFETY LABELS AND DIRECTIONS

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.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

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.

GENERAL INFORMATION

MAINTENANCE

ENGINE / COOLING SYSTEM

FUEL SYSTEM

PVT SYSTEM

TRANSMISSION

FINAL DRIVE

STEERING / SUSPENSION

BRAKE SYSTEM

BODY / FRAME

ELECTRICAL

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9925723 R01 - 2015 RZR 900 Service Manual

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . 1.2

MODEL NUMBER DESIGNATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

MISC. INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

REPLACEMENT KEYS. . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . 1.5

SPECIAL TOOLS . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . 1.6

GENERAL SPECIFICATIONS.. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

RZR 900 / RZR 900 EPS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

RZR 900 XC SPECIFICATIONS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

RZR S 900 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . .1.16

MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .1.16

CONVERSION TABLE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19

STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.20

METRIC BOLT TORQUE SPECIFICATION ... . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .1.20

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . .1.21

METRIC TAP / DRILL SIZES .. . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

DECIMAL EQUIVALENTS.. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

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9925723 R01 - 2015 RZR 900 Service Manual

VEHICLE IDENTIFICATION

Model Number Designation

Example: A15SEA57AD

GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION

1st 2nd 3rd

4th* 5th* 6th* 7th* 8th* 9th 10th**

A 1

S E A

A D

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

Vehicle Identification Number (VIN) Designation (2015+)

Example: 4XARH57A0F3000000

WORLD MFG. ID

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

CHASSIS

DRIVELINE

ENGINE SIZE

ENGINE MODIFIER

CATEGORY

CHECK DIGIT

MODEL YEAR *

MFG. LOCATION

INDIVIDUAL SERIAL NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R H 5 7 A 0 F 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

Vehicle and Engine Serial Number Location

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on a portion of the left rear upper frame and also on a decal on the front frame

support behind the lower shock mounting location ①.

The engine serial number can be found on a decal applied to the front of the engine crankcase ② or

stamped into the crankcase on the PTO side of the engine.

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

MISC. INFORMATION

Publication Numbers

MODEL OWNER’S MANUAL PARTS MANUAL

2015 RZR 900 / EPS (50″)

9925322 9925324

2015 RZR 900 XC 9925631 9925324

2015 RZR S 900 / EPS (60″)

9925322 9925792

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.

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

Replacement Keys

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

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.

Bosch Automotive Service Solutions:

1-800-345-2233 or http://polaris.service-solutions.com/

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

2200421

Gas Shock Recharging Kit

2460761

Hall Sensor Probe Harness

2870341-A

Drive Clutch Spider Remover/Installer

2870386

Piston Pin Puller

2870630

Timing Light

2870910-A

Roller Pin Tool

2870975

Mity-Vac Pressure Test Tool

2871056

Driven Clutch Puller

2871226

Clutch Bushing Replacement Tool Kit

2871282

Transmission Seal Driver (50 MM)

2871351

IFP Depth Tool

2871358-B

Drive Clutch Holding Fixture

2871702

Shaft Drive Transmission and Front Gearcase Tool Kit

2871745

Static Timing Light Harness

2872085

Drive Clutch Puller

2872608

Roll Pin Removal Tool (27″)

2876389

Combination Pliers

2877408

Spanner Wrench / Clutch Spreader

8700226

CV Boot Clamp Pliers (ear)

9314177-A

Drive Clutch Holding Tool

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

PA-49316

Water Pump Drive & Rotor Removal Tool

PA-50231

Snorkel Driver

PS-45908

T-Handle Tool

PU-43506-A

Fuel Pressure Gauge Kit

PU-45281–A

Shock Body Holding Tool

PU-47471

Smartlink Module Kit

PU-48951

CV Boot Clamp Pliers (Stepless)

PU-49466

Relay Bypass

PU-50105

Oil Filter Wrench

PU-50296

Battery Tester

PU-50338

Hydrometer

PU-50518

Clutch Compressor

PU-50562

Engine Stand Adapter

PU-50563

Cylinder Holding & Camshaft Timing Plate

PU-50564

Water Pump Seal Installer

PU-50565

Oil Pressure Gauge Adapter (1/2 NPT)

PU-50566

Transmission Nut Socket

PU-50578

Clutch Spider Nut Socket

PU-50624

Rolling Engine Stand

PU-50625

Engine Stand Adapter Sleeve (2″)

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

PU-50658

Clutch Center Distance Tool

PU-50931

Shock Rod Holding Tool (3/4″)

PU-50939

Shock Seal Protector Sleeve (5/8″)

PU-51024

Shock Rod Holding Tool

PU-51039

Gas Shock Fill Tool

PV-1253

Valve Spring Compressor

PV-43513-A

Valve Spring Compressor Adapter

PV-43526

Connector Test Kit

PV-43531

Oil Presure gauge

PV-43568

Fluke Multimeter

PV-43570

Piston Ring Compressor Pliers

PV-48656

Fuel Pressure Gauge Adapter

PW-47053

Bench Mount Engine Stand

PW-47054

Engine Stand Adapter Sleeve (2 3/8″)

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

GENERAL SPECIFICATIONS

RZR 900 / RZR 900 EPS Specifications

CATEGORY DIMENSION / CAPACITY

Length

107″ / 271.8 cm

Width 50″ / 127cm

Height

69.5″ / 176.5cm

Wheel Base 79″ / 200 cm

Ground Clearance 10-11″ / 25.4-27.9 cm

Dry Weight 1148 lbs. / 521 kg

Gross Vehicle Weight 1969 lbs. / 893 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

740 lbs. / 336.4 kg (Includes riders, cargo and accessories)

Hitch Towing Capacity 1500 lbs (680 kg)

Hitch Tongue Capacity 150 lbs (68 kg)

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

ENGINE

Platform

Domestic Twin Cyl., 4–Stroke, DOHC

Engine Displacement

875 cc

Number of Cylinders

Bore & Stroke 93 x 64.4 mm Compression Ratio

10.5:1

Engine Idle Speed

1250 +/- 100 RPM

Engine Max Speed

8300 RPM

Engine Hot Light

Instrument Cluster Indicator

Lubrication

Wet Sump

Oil Requirements

PS4

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5.0 qt (4.7 L)

FUEL SYSTEM

Type

Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure

58 ± 2 PSI (400 ± 14 kPa)

Fuel Capacity / Requirement

9.5 gal. (36 L) 87 Octane (minimum)

ELECTRICAL

Alternator Max Output 560 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam 55/60W Halogen

Taillights

0.2 Watt LED cluster

Brake Lights

2.9 Watt LED cluster

Ignition System

ME17 ECU

Spark Plug / Gap

NGK MR7F/ 0.7–0.8 mm

Battery / Amp Hr

12v Flooded, 575 CCA

DC Outlet Standard 12 Volt

Relays

Fan, EFI, Fuel Pump, Chassis, EPS (if appl.)

Circuit Breaker

20A Cooling Fan

Fuses

10A EFI 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.)

DRIVETRAIN

Transmission Type

Polaris Automatic PVT

Shift Sequence

In Line Shift - P / R / N / L / H

Transmission Gear Ratios: High Low Reverse

10.4:1

18.8:1

22.92:1

Front Gearcase Lubricant Requirement

Demand Drive

7.5 oz. (222 ml)

Transmission Lubricant Requirement

Full Synthetic AGL 44 oz. (1300 mL)

STEERING / SUSPENSION

Toe Out

1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension

Independent Dual A-arm Sachs Shocks

Front Travel

10″ (25.4 cm)

Rear Suspension

Independent Dual A-arm Sachs Shocks

Rear Travel

10″ (25.4 cm)

Spring Adjustment

Threaded Spanner Wrench Adjustment

WHEELS / BRAKES

Front Rim / Size

Steel 12 x 6

Rear Rim / Size

Steel 12 x 8

Front Tire Make / Model / Size

PXT 26 x 8 R12

Rear Tire Make / Model / Size

PXT 26 x 9 R12

Tire Air Pressure

Front

10 psi (69 kPa)

Rear

12 psi (83 kPa)

Brake System Front & Rear

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

Brake Fluid DOT 4

For clutch specifications / High Altitude setup, see PVT System chapter – Clutch Charts, page 5.3

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

RZR 900 XC Specifications

CATEGORY DIMENSION / CAPACITY

Length

108″ / 274.3 cm

Width 55″ / 139.7 cm

Height

70.5″ / 179 cm

Wheel Base 79″ / 200 cm

Ground Clearance 12.5″ / 31.75 cm

Dry Weight 1247 lbs. / 566 kg

Gross Vehicle Weight 2068 lbs. / 938 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

740 lbs. / 336 kg (Includes riders, cargo and accessories)

Hitch Towing Capacity 1500 lbs (680 kg)

Hitch Tongue Capacity 150 lbs (68 kg)

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

ENGINE

Platform

Domestic Twin Cyl., 4–Stroke, DOHC

Engine Displacement

875 cc

Number of Cylinders

Bore & Stroke 93 x 64.4 mm Compression Ratio

10.5:1

Engine Idle Speed

1250 +/- 100 RPM

Engine Max Speed

8300 RPM

Engine Hot Light

Instrument Cluster Indicator

Lubrication

Wet Sump

Oil Requirements

PS4

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5.0 qt (4.7 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)

Fuel Capacity / Requirement

9.5 gal. (36 L) 87 Octane (minimum)

ELECTRICAL

Alternator Max Output 560 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam 55/60W Halogen

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap NGK MR7F/ 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 575 CCA

DC Outlet Standard 12 Volt Relays Fan, EFI, Fuel Pump, Chassis,

EPS

Circuit Breaker 20A Cooling Fan

Fuses 10A EFI

10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS

DRIVETRAIN

Transmission Type

Polaris Automatic PVT

Shift Sequence

In Line Shift - P / R / N / L / H

Transmission Gear Ratios: High Low Reverse

10.4:1

18.8:1

22.92:1

Front Gearcase Lubricant Requirement

Demand Drive

7.5 oz. (222 ml)

Transmission Lubricant Requirement

Full Synthetic AGL 44 oz. (1300 mL)

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

FOX 2.0″

Front Travel 10″ (25.4 cm)

Rear Suspension Independent Dual A-arm

FOX 2.0″

Rear Travel 10″ (25.4 cm)

Spring Adjustment Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 7 Rear Rim / Size Aluminum 14 x 8 Front Tire Make / Model /

Size

GBC Dirt Commander 27 x 9 R14

Rear Tire Make / Model / Size

GBC Dirt Commander 27 x 11 R14

Tire Air Pressure

Front 10 psi (69 kPa)

Rear 12 psi (83 kPa)

Brake System Front & Rear

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

Brake Fluid DOT 4

For clutch specifications / High Altitude setup, see PVT System chapter – Clutch Charts, page 5.3

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

RZR S 900 Specifications

CATEGORY DIMENSION / CAPACITY

Length

108″ / 274.3 cm

Width 60″ / 152.4 cm

Height

72″ / 182.9 cm

Wheel Base 79″ / 200 cm

Ground Clearance 12.5″ / 31.75 cm

Dry Weight 1208 lbs. / 548 kg

Gross Vehicle Weight 2029 lbs. / 920 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

740 lbs. / 336 kg (Includes riders, cargo and accessories)

Hitch Towing Capacity 1500 lbs (680 kg)

Hitch Tongue Capacity 150 lbs (68 kg)

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

ENGINE

Platform

Domestic Twin Cyl., 4–Stroke, DOHC

Engine Displacement

875 cc

Number of Cylinders

Bore & Stroke 93 x 64.4 mm Compression Ratio

10.5:1

Engine Idle Speed

1250 +/- 100 RPM

Engine Max Speed

8300 RPM

Engine Hot Light

Instrument Cluster Indicator

Lubrication

Wet Sump

Oil Requirements

PS4

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5.0 qt (4.7 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)

Fuel Capacity / Requirement

9.5 gal. (36 L) 87 Octane (minimum)

ELECTRICAL

Alternator Max Output 560 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam 55/60W Halogen

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap NGK MR7F / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 575 CCA

DC Outlet Standard 12 Volt Relays Fan, EFI, Fuel Pump, Chassis,

EPS (if appl.)

Circuit Breaker 20A Cooling Fan

Fuses 10A EFI

10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS (if appl.)

DRIVETRAIN

Transmission Type

Polaris Automatic PVT

Shift Sequence

In Line Shift - P / R / N / L / H

Transmission Gear Ratios: High Low Reverse

10.4:1

18.8:1

22.92:1

Front Gearcase Lubricant Requirement

Demand Drive

7.5 oz. (222 ml)

Transmission Lubricant Requirement

Full Synthetic AGL 44 oz. (1300 mL)

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

FOX 2.0″

Front Travel 10″ (25.4 cm)

Rear Suspension Independent Dual A-arm

FOX 2.0″

Rear Travel 10″ (25.4 cm)

Spring Adjustment Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 12 x 6 Rear Rim / Size Aluminum 12 x 8 Front Tire Make / Model /

Size

GBC Dirt Commander 27 x 9 R12

Rear Tire Make / Model / Size

GBC Dirt Commander 27 x 11 R12

Tire Air Pressure

Front 12 psi (83 kPa)

Rear 14 psi (97 kPa)

Brake System Front & Rear

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

Brake Fluid DOT 4

For clutch specifications / High Altitude setup, see PVT System chapter – Clutch Charts, page 5.3

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

MISC. SPECIFICATIONS AND CHARTS

Master Torque Table

ITEM

TORQUE

A-Arm Mounting Fasteners 42 ft-lb (57 Nm)

Air Box Mounting

Fasteners

8 ft-lb (11 Nm)

Ball Joint Fasteners

42 ft-lb (57 Nm)

Battery Bracket

Fasteners

8 ft-lb (11 Nm)

Battery Terminal Fasteners 60 in-lb (7 Nm)

Bearing Carrier Mounting

Fasteners (rear)

42 ft-lb (57 Nm)

Body / Floor Screws (T-40) 8 ft-lb (11 Nm)

Brake Disc Mounting Bolts 18 ft-lb (24 Nm)

Brake Bleed Screws

48 in-lb (5 Nm)

Brake Caliper Mounting

Bolts (front)

30 ft-lb (42 Nm)

Brake Caliper Mounting

Bolts (rear)

46 ft-lb (62 Nm)

Brake Disc Scraper 7 ft-lb (11 Nm)

Brake Junction Block

35 in-lb (4 Nm)

Brake Line Banjo Bolts 15 ft-lb (20 Nm)

Brake Line Flare Fittings 15 ft-lb (20 Nm)

Brake Pedal Mount Bracket

Bolts

18 ft-lb (24 Nm)

Brake Switch

15 ft-lb (20 Nm)

Cab Frame Bolts

40 ft-lb (54 Nm)

Cam Chain Tensioner

29 ft-lb (40 Nm)

Camshaft Carrier Bolts

7 ft-lb (10 Nm)

Camshaft Sprocket Bolts 11 ft-lb (15 Nm)

Clutch Cover(inner) Screws 10 ft-lb (14 Nm)

Clutch Cover (outer)

Screws

54 in-lb (5 Nm)

Connecting Rod Bolts

Step 1: 9 ft-lb (12 Nm)

Step 2: 22 ft-lb (30 Nm)

Step 3: Tighten add’n 90°

Coolant Bleed Screw

89 in-lb (10 Nm)

Coolant Temperature

Sensor

17 ft-lb (23 Nm)

CPS Retaining Bolt 9 ft-lb (12 Nm)

Crankcase Bolts M10

Torque in sequence

Step 1: 9 ft-lb (12 Nm)

Step 2: 21 ft-lb (28 Nm)

Step 3: Tighten add’n 90°

Crankcase Bolts M8

26 ft-lb (35 Nm)

ITEM

TORQUE

Crankcase Bolts M6

9 ft-lb (12 Nm)

Crankcase Oil Gallery Plug 11 ft-lbs (15 Nm)

Cylinder Head Bolts

Torque in sequence 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)

Differential Cover Screws

22 ft-lb (30 Nm)

Door Fasteners

8 ft-lb (11 Nm)

Drive Clutch Retaining Bolt 96 ft-lb (130 Nm)

Drive Clutch Cover Plate

Screw

8 ft-lb (11 Nm)

Drive Clutch Shift Weight

Fasteners

20 in-lb (2 Nm)

Drive Clutch Spider

290 ft-lb (393 Nm)

(Apply 0.4 mL Loctite® 620™)

Drive Clutch Spider Jam

Nut

250 ft-lb (339 Nm)

(Apply 0.1 mL Loctite® 620™)

Driven Clutch Retaining

Bolt

38 ft-lb (52 Nm)

Driven Clutch Spring

Retainer Screws (non-

EBS)

12 ft-lb (16 Nm)

Driven Clutch Helix Screws

(EBS)

48 in-lb (5 Nm)

ECU Mounting Screws 24 in-lb (3 Nm)

Engine Mount / Isolator

(front)

40 ft-lbs (54 Nm)

Engine Mount to Frame

Fasteners

22 ft-lb (30 Nm)

Engine Oil Plug 12 ft-lbs (16 Nm)

Engine/Transmission

Mounting Bolts

Step 1-2: 64 ft-lb (87 Nm)

Step 3: 5 ft-lb (7 Nm)

Step 4-7: 44 ft-lb (60 Nm)

*see procedure for illustration

ETC Mounting Bolts 7 ft-lb (10 Nm)

Exhaust Head Pipe Bolts 18 ft-lb (24 Nm)

Flywheel Bolt 133 ft-lbs (180 Nm)

Frame Support (above

engine)

22 ft-lb (30 Nm)

Front Bumper / Fender

Screws

8 ft-ln (11 Nm)

Front Gearcase Cover

Plate Screws

11 ft-lbs (15 Nm)

GENERAL INFORMATION

1.17

9925723 R01 - 2015 RZR 900 Service Manual

ITEM

TORQUE

Front Gearcase Drain/Fill

Plugs

10 ft-lbs (14 Nm)

Front Gearcase Mounting

Bolts

33 ft-lbs (45 Nm)

Fuel Pump PFA Nut 70 ft-lbs (95 Nm)

Fuel Rail Mounting Screws 7 ft-lb (10 Nm)

Fuel Tank Block-off Panel

8 ft-lbs (11 Nm)

Fuel Tank Strap Screw 8 ft-lbs (11 Nm)

Harness Bracket Screws

35 in-lb (4 Nm)

Hip Bolster Bolts 16 ft-lb (22 Nm)

Hose Clamp 35 in-lb (4 Nm)

Hub Castle Nut (front and

rear)

110 ft-lbs (149 Nm)

Ignition Coil Mounting

Fasteners

75 in-lb (9 Nm)

Intake Manifold Mount

Screw (lower)

22 ft-lb (30 Nm)

Intake Manifold to Engine

Fasteners

17 ft-lb (23 Nm)

Master Cylinder Mount

Bolts

23 ft-lbs (31 Nm)

Oil Cooler Bolts

7 ft-lb (10 Nm)

Oil Pump Mounting Bolts 7 ft-lbs (10 Nm)

Oil Pump Pickup Fastener 7 ft-lb (10 Nm)

Oil Sump Cover M8 Bolts 26 ft-lb (35 Nm)

Oil Sump Cover M6 Bolts 9 ft-lb (12 Nm)

Parking Brake Caliper

Assembly Bolts

37 ft-lb (50 Nm)

Parking Brake Caliper

Mount Bracket Bolts

37 ft-lb (50 Nm)

Parking Brake Disc

Mounting Bolt

14 ft-lb (20 Nm)

Power Steering Cover

Screws

15 ft-lb (20 Nm)

Power Steering Bracket to

Frame Nuts

16 ft-lb (22 Nm)

Power Steering Unit to

Mount Bracket

30 ft-lb (41 Nm)

Prop Shaft Support Bearing

Fasteners

33 ft-lb (45 Nm)

Radiator Mounting Bracket

(Upper)

8 ft-lb (11 Nm)

Seat Belt Mounting

Fasteners

40 ft-lbs (54 Nm)

Seat Fasteners

4 ft-lb (5 Nm)

Seat Frame Fasteners

(front)

14 ft-lb (19 Nm)

ITEM

TORQUE

Seat Frame Fasteners

(rear)

30 ft-lb (41 Nm)

Shift Cable Bracket Bolts

17 ft-lb (23 Nm)

Shift Cable Jam Nut

18 ft-lb (24 Nm)

Shift Cable Mounting

Fasteners

13 ft-lb (18 Nm)

Shock Mounting Fasteners 42 ft-lb (57 Nm)

Skid Plate Fasteners

8 ft-lbs (11 Nm)

Spark Plug 7 ft-lbs (10 Nm)

Speed Sensor Screw 12 ft-lb (16 Nm)

Stabilizer Bar Linkage

(front)

40 ft-lb (54 Nm)

Stabilizer Bar Mounting

Bracket Bolts (front)

16 ft-lb (22 Nm)

Stabilizer Bar Linkage

(rear)

40 ft-lbs (54 Nm)

Stabilizer Bar Mounting

Bracket Bolts (rear)

17 ft-lb (23 Nm)

Starter Cable Nuts

30 in-lb (4 Nm)

Starter Mounting Bolts 7 ft-lb (10 Nm)

Starter One-Way Clutch

Screws

9 ft-lb (12 Nm)

Stator Cover Screws

9 ft-lb (12 Nm)

Steering Tilt Shock

Fastener

7 ft-lb (10 Nm)

Steering Pivot Fasteners 40 ft-lb (54 Nm)

Steering Rack Mounting

Bolts

16 ft-lbs (22 Nm)

Steering Shaft to EPS Unit 15 ft-lbs (20 Nm)

Steering Shaft to Steering

Rack

48 ft-lb (65 Nm)

Steering Wheel Nut

65 ft-lbs (88 Nm)

Thermostat Cover Bolts

7 ft-lb (10 Nm)

Throttle Pedal Mounting

Fasteners

8 ft-lb (11 Nm)

Tie Rod End to Knuckle

30 ft-lbs (41 Nm) + 90°

Tie Rod Jam Nuts

14 ft-lbs (19 Nm)

Transmission Bell Crank

Nut

18 ft-lb (24 Nm)

Transmission Case Screws

20 ft-lbs (27 Nm)

Transmission Drain / Fill

Plugs

14 ft-lbs (19 Nm)

Transmission Isolator Bolt

(rear)

33 ft-lb (45 Nm)

Transmission Rear Mount

Bracket Fasteners

22 ft-lb (30 Nm)

GENERAL INFORMATION

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9925723 R01 - 2015 RZR 900 Service Manual

ITEM

TORQUE

Transmission Joint Bracket

Bolts

44 ft-lb (60 Nm)

Transmission Park Flange

Screws

10 ft-lb (14 Nm)

Transmission Sector Gear

Cover

12 ft-lb (16 Nm)

Transmission Shift Fork

Screws

10 ft-lb (14 Nm)

Transmission Snorkel Tube

Locking Screw

10 ft-lb (14 Nm)

Valve Cover Bolts

7 ft-lbs (10 Nm)

Visor Mounting Screws 8 ft-lb (11 Nm)

Voltage Regulator

Fasteners

5 ft-lb (7 Nm)

Water Pump Impeller

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt

threads)

Water Pump Cover Bolts

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt

threads)

Wheel Lug Nuts

Aluminum: 120 ft-lbs (163 Nm)

Steel: 60 ft-lb (81 Nm)

GENERAL INFORMATION

1.19

9925723 R01 - 2015 RZR 900 Service Manual

Conversion Table

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs x 12 = in-lbs

in-lbs x 0.0833 = ft-lbs

ft-lbs

x 1.356 = Nm

in-lbs x 0.0115 = kg-m

Nm x 0.7376

= ft-lbs

kg-m x 7.233

= ft-lbs

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

= mm

x 0.03937 = inch

inch x 2.54

= cm

mile (mi)

x 1.6 = km

km x 0.6214 = mile

ounces (oz)

x 28.35

= grams (g)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

x .03381

= fluid ounces

grams (g)

x 0.035

= ounces

pounds (lb) x 0.454 = kg

kilogram (kg)

x 2.2046 = lbs

cubic inches (cu in)

x 16.387

= cc

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

x 0.946

= liters (L)

liters (L) x 1.057 = US quarts

US gallons x 3.785 = liters (L)

liters (L)

x 0.264

= US gallons

PSI x 6.895 = kilopascals (kPa)

kilopascals (kPa)

x 0.145

PSI

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

GENERAL INFORMATION

1.20

9925723 R01 - 2015 RZR 900 Service Manual

Standard Bolt Torque Specification

BOLT SIZE

GRADE 2

FT. LBS. (NM)

GRADE 5

FT. LBS. (NM)

GRADE 8

FT. LBS. (NM)

1/4-20

5 (7) 8 (11) 12 (16)

1/4-28

6 (8) 10 (14) 14 (19)

5/16-18

11 (15) 17 (23) 25 (35)

5/16-24

12 (16) 19 (26) 29 (40)

3/8-16

20 (27) 30 (40) 45 (62)

3/8-24

23 (32) 35 (48) 50 (69)

7/16-14

30 (40) 50 (69) 70 (97)

7/16-20

35 (48) 55 (76) 80 (110)

1/2-13

50 (69) 75 (104) 110 (152)

1/2-20

55 (76) 90 (124) 120 (166)

Metric Bolt Torque Specification

BOLT

SIZE

GRADE

4.6 4.8 8.8 / 8.9 10.9 12.9

FT.— LBS. (NM) DRY THREADS

0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)

0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

M10

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

M12

26 (35) 33 (45) 63 (85) 97 (130) 11 (150)

M14

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

M16

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

M18

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

GENERAL INFORMATION

1.21

9925723 R01 - 2015 RZR 900 Service Manual

SAE Tap / Drill Sizes

THREAD SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

1/2–20 29/64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64

5/8–11 17/32

#3–48 5/64 5/8–18 37/64

#3–56

3/4–10 21/32

#4–40

3/4–16 11/16

#4–48

7/8–9 49/64

#5–40 38 7/8–14 13/16

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

1 1/8–7 63/64

#8–32

1 1/8–12 1 3/64

#8–36

1 1/4–7 1 7/64

#10–24

1 1/4–12 1 11/64

#10–32

1 1/2–6 1 11/32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1 3/4–12 1 43/64

1/4–28

2–4 1/2 1 25/32

5/16–18

F 2–12

1 59/64

5/16–24

2 1/4–4 1/2 2 1/32

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

U 3–4

2 3/4

7/16–20 25/64

Metric Tap / Drill Sizes

TAP SIZE DRILL SIZE DECIMAL

NEAREST

FRACTION

3 x .50

#39

0.0995

3/32

3 x .60

3/32

0.0937

3/32

4 x .70 #30 0.1285 1/8

4 x .75

1/8 0.125 1/8

5 x .80 #19 0.166 11/64

5 x .90

#20

0.161

5/32

6 x 1.00

0.196

13/64

7 x 1.00

16/64

0.234

15/64

8 x 1.00 J 0.277

9/32

8 x 1.25 17/64 0.265 17/64

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

5/16

0.3125

5/16

10 x 1.25

11/32

0.3437

11/32

10 x 1.50 R 0.339

11/32

11 x 1.50

3/8

0.375

3/8

12 x 1.50

13/32

0.406

13/32

12 x 1.75 13/32 0.406 13/32

GENERAL INFORMATION

1.22

9925723 R01 - 2015 RZR 900 Service Manual

Decimal Equivalents

FRACTION DECIMAL MM TO INCHES

1/64 0.0156″

1/32

0.0312″ 1 mm = 0.0394″

3/64

0.0469″

1/16 0.0625″

5/64 0.0781″ 2 mm = 0.0787″

3/32

0.0938″

7/64

0.1094″ 3 mm = 0.1181″

1/8 0.1250″

9/64

0.1406″

5/32

0.1563″ 4 mm = 0.1575″

11/64 0.1719″

3/16

0.1875″ 5 mm = 0.1969″

13/64

0.2031″

7/32 0.2188″

15/64 0.2344″ 6 mm = 0.2362″

1/4

0.25″

17/64 0.2656″ 7 mm = 0.2756″

9/32 0.2813″

19/64

0.2969″

5/16

0.3125″ 8 mm = 0.3150″

21/64 0.3281″

11/32

0.3438″ 9 mm = 0.3543″

23/64

0.3594″

3/8 0.375″

25/64

0.3906″ 10 mm = 0.3937″

13/32

0.4063″

27/64

0.4219″ 11 mm = 0.4331″

7/16 0.4375″

29/64

0.4531″

15/32 0.4688″ 12 mm = 0.4724″

31/64 0.4844″

1/2

0.500″ 13 mm = 0.5118″

33/64

0.5156″

17/32 0.5313″

35/64

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″

5/8

0.625″ 16 mm = 0.6299″

FRACTION DECIMAL MM TO INCHES

41/64 0.6406″

21/32

0.6563″ 17 mm = 0.6693″

43/64

0.6719″

11/16 0.6875″

45/64 0.7031″ 18 mm = 0.7087″

23/32

0.7188″

47/64

0.7344″ 19 mm = 0.7480″

3/4 0.750″

49/64

0.7656″

25/32

0.7813″ 20 mm = 0.7874″

51/64 0.7969″

13/16

0.8125″ 21 mm = 0.8268″

53/64

0.8281″

27/32

0.8438″

55/64 0.8594″ 22 mm = 0.8661″

7/8

0.875″

57/64

0.8906″ 23 mm = 0.9055″

29/32 0.9063″

59/64

0.9219″

15/16

0.9375″ 24 mm = 0.9449″

61/64 0.9531″

31/32

0.9688″ 25 mm = 0.9843″

63/64

0.9844″

1 1.000″

GENERAL INFORMATION

2.1

9925723 R01 - 2015 RZR 900 Service Manual

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . 2.3

BREAK-IN PERIOD .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 2.3

PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL .... . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . 2.4

50 - 500 HOUR MAINTENANCE INTERVAL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 2.6

GREASE LUBRICATION POINTS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

GENERAL VEHICLE INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . 2.9

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . .. . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . 2.9

SHIFT CABLE INSPECTION / ADJUSTMENT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

FUEL SYSTEM . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .2.10

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . .2.10

FUEL TANK VENT LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

FUEL PUMP / FUEL FILTER . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . 2.10

FUEL LINES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

THROTTLE PEDAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

ENGINE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 2.12

ENGINE AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

INTAKE DUCT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

AIR BOX / FILTER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

ENGINE OIL LEVEL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .2.14

ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .2.15

CRANKCASE BREATHER HOSE INSPECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE CYLINDER LEAK-DOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

TRANSMISSION AND FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

SPECIFICATION CHART... . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . .2.19

TRANSMISSION LUBRICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

FRONT GEARCASE LUBRICATION. . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . .2.20

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

COOLING SYSTEM OVERVIEW . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

COOLANT STRENGTH .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .2.22

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .2.22

COOLING SYSTEM PRESSURE TEST... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

COOLING SYSTEM HOSE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

RADIATOR INSPECTION / CLEANING . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . .2.24

COOLANT DRAIN / FILL . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .2.24

PVT SYSTEM . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . .2.25

DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .2.25

PVT DUCT CLEANING. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

PVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .2.25

2.2

9925723 R01 - 2015 RZR 900 Service Manual

FINAL DRIVE / WHEEL AND TIRE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . .2.26

WHEEL AND HUB TORQUE TABLE. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .2.26

WHEEL REMOVAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . .2.26

WHEEL INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .2.27

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

ELECTRICAL / IGNITION SYSTEM.. . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .2.28

BATTERY MAINTENANCE . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

BATTERY OFF SEASON STORAGE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

BATTERY CHARGING ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BATTERY INSTALLATION. . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

ENGINE / CHASSIS GROUND . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .2.30

SPARK PLUG SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

STEERING SYSTEM . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . .2.32

STEERING INSPECTION ... . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .2.32

STEERING WHEEL FREE-PLAY .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .2.32

TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

WHEEL TOE ADJUSTMENT .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .2.34

SUSPENSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

SPRING ADJUSTMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

SPRING ADJUSTMENT (FOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

SHOCK COMPRESSION ADJUSTMENT (FOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .2.36

BRAKE SYSTEM.. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . .2.37

BRAKE PAD / DISC INSPECTION . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .2.37

MAINTENANCE

2.3

9925723 R01 - 2015 RZR 900 Service Manual

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Break-In Period

The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 25 hours or one month.

• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

■ = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an

authorized Polaris dealer.

▶ = SEVERE USE ITEM: See information provided above.

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

MAINTENANCE

2.4

9925723 R01 - 2015 RZR 900 Service Manual

Pre-Ride - 50 Hour Maintenance Interval

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

REMARKS

HOURS CALENDAR

MILES

(KM)

Steering

Pre-Ride

Inspect or adjust as needed. See Pre-Ride Checklist on Page 2.10.

Front / Rear Suspension

- -

Tires

- -

Brake Fluid Level

- -

Brake Pedal Travel

- -

Brake System

- -

Wheels / Fasteners

- -

Frame Fasteners

- -

Engine Oil Level

- -

▶

Intake Baffle Box Drain

Daily

Inspect drain at the bottom of the air intake baffle box for obstructions

Coolant Level

Daily

Check level daily

Suspension Bushings

Daily

Lubricate daily or after each use in mud or water

Spark Arrestor

Daily

Clean daily when driving in mud and water; replace a cracked or damaged arrestor before operating

Head Lights / Tail Lights

Daily

Check operation

▶

Power Steering (if equipped)

Daily

Turn key on, check for smooth operation

▶

■

Brake Pad Wear / Inspect Parking Brake Pads (INT’L)

10 H

Monthly 100 (160) Inspect periodically

Fuel System

25 H

Monthly

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

▶

■

Parking Brake Cable Adjustment (INT’L)

25 H

- -

Inspect; adjust tension after first 25 hours

▶

Air Filter

Weekly

Inspect; replace as needed

▶-

Engine Breather

25 H

Monthly 150 (250) Inspect;clean

Battery

25 H

Monthly 250 (400)

Check terminals; clean; test

▶

Engine Oil & Filter Change (Break-In Period)

25 H 1 M

Perform a break-in oil and filter change at 25 hours or one month; perform every 50 hours or 6 months thereafter

▶

Front Gearcase Lubricant (Demand Drive)

25 H 1 M

250 (400) Initial fluid level inspection; add lubricant if needed

▶

Transmission Lubricant (AGL)

25 H 1 M

250 (400) Initial fluid level inspection; add lubricant if needed

▶

General Lubrication 50 H 3 M

500 (800) Lubricate all fittings, pivots, cables, etc.

■

Throttle Cable / Throttle Pedal

50 H 6 M

500 (800) Inspect; adjust; replace if necessary

Throttle Body Intake Ducts/ Flange

50 H 6 M

500 (800) Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage

50 H 6 M

500 (800) Inspect; adjust as needed

■

Steering

50 H 6 M

500 (800) Lubricate (if applicable)

▶

Front / Rear Suspension

50 H 6 M

500 (800) Lubricate (if applicable)

▶ 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.

MAINTENANCE

2.5

9925723 R01 - 2015 RZR 900 Service Manual

50 - 500 Hour Maintenance Interval

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

REMARKS

HOURS CALENDAR

MILES

(KM)

■

Cooling System

50 H 6 M

500 (800)

Inspect coolant strength seasonally; pressure test system yearly

■

Drive Belt 50 H 6 M

1000 (1600) Inspect; replace as needed

▶

Engine Oil Lines/Fasteners

50 H 6 M

1000 (1600) Inspect for leaks and loose fittings

▶

Engine Oil/Filter Change

100 H 6 M

1000 (1600)

Perform a break-in oil change at 25 hours or one month

▶

■

Parking Brake Cable Adjustment (INT’L)

100 H 6 M

1000 (1600) Inspect; adjust tension as needed

▶

Front Gearcase Lubricant (Demand Drive)

100 H 12 M

1000 (1600) Change lubricant

▶

Transmission Lubricant (AGL)

100 H 12 M

1000 (1600) Change lubricant

■

Fuel System

100 H 12 M

1000 (1600)

Check for leaks at fill cap, fuel line / rail, and fuel pump.

■

Spark Plug Inspection

100 H 12 M

1000 (1600) Inspect; replace as needed; torque to specification

▶

Radiator 100 H 12 M

1000 (1600) Inspect; clean external surfaces

▶

Cooling Hoses

100 H 12 M

1000 (1600) Inspect for leaks; pressure test system

▶

Engine Mounts

100 H 12 M

1000 (1600) Inspect, torque to specification

Exhaust Silencer / Pipe

100 H 12 M

1000 (1600) Inspect

▶

Wiring

100 H 12 M

1000 (1600)

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

■

Clutches (Drive and Driven)

100 H 12 M

1000 (1600) Inspect; clean; replace worn parts

■

Front Wheel Bearings

100 H 12 M

1000 (1600) Inspect; replace as needed

▶

Shocks 100 H

- -

Visually inspect shock seals

▶

■

Shocks

12 M

1500 (2400) Change shock oil and inspect seals

■

Brake Fluid 200 H 24 M

2000 (3200) Change every two years (DOT 4)

Spark Arrestor

200 H 24 M

2000 (3200)

Clean daily when driving in mud and water; replace a cracked or damaged arrestor before operating

■

Valve Clearance 500 H

5000 (8000) Inspect; adjust as needed

■

Spark Plug Replacement

500 H 36 M

5000 (8000) Replace; torque to specification

▶

Coolant

60 M

Replace coolant

■

Toe Adjustment

Inspect periodically; adjust when parts are replaced

Headlight Aim

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.

MAINTENANCE

2.6

9925723 R01 - 2015 RZR 900 Service Manual

Maintenance Quick Reference

ITEM LUBE REC. METHOD

FREQUENCY*

Oil Fill Cap

Oil Filter

/ Dipstick3:

- Behind Engine Access Panel

Polaris PS-4 or Polaris PS-4 Extreme Duty

Remove cargo box panel and add oil to proper level on dipstick

Perform a break-in oil and filter change at 25 hrs or one month; perform every 50 hrs thereafter

Engine Coolant Reservoir

Radiator Cap

Radiator

Polaris 50/50 Coolant

Remove hood panel. Maintain coolant level in coolant reservoir bottle and radiator.

Check level daily; change coolant every two years

* More often under severe use, such as operation in water or under severe loads.

MAINTENANCE

2.7

9925723 R01 - 2015 RZR 900 Service Manual

ITEM LUBE REC. METHOD

FREQUENCY*

Brake Fluid

Polaris DOT 4 Brake Fluid

Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir

Check level during pre-ride inspection; change fluid every two years

Front Gearcase

Polaris Demand Drive

Add lubricant until it is visible at the fill hole threads

≈ 7.5 oz. (222 mL)

Initial level check at 25 hours or 1 month; Change lubricant at 100 hours or every 12 months, whichever comes first

Transmission Polaris AGL

Add lubricant until it is visible at the fill hole threads

* More often under severe use, such as operation in water or under severe loads.

MAINTENANCE

2.8

9925723 R01 - 2015 RZR 900 Service Manual

Grease Lubrication Points

ITEM METHOD LUBE

FREQUENCY

Control Arm Pivot Bushings

Grease 3 fittings

on each side

Polaris All Season Grease

Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle. Apply grease until all traces of water has been purged out at each of these areas.

Prop Shaft Yokes

Grease middle and rear fittings

Polaris Premium UJoint Grease

Front Stabilizer Bar Bushings (50″ and XC)

Grease the fitting on each side

Polaris All Season Grease

Rear Stabilizer Bar Bushings

Grease 2 fittings

through the skid

plate access holes on each side

Polaris All Season Grease

*There is no grease point on the front upper control arm rear mount.

MAINTENANCE

2.9

9925723 R01 - 2015 RZR 900 Service Manual

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Engine Oil - Check for proper level on dipstick (see Chapter 2 – Engine Oil Level, page 2.14)

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation and fluid level and adjustment (includes parking brake on INT’L Model)

• Headlights/Taillights/Brakelights - also check operation of all indicator lights, instrument cluster and switches

• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Engine Intake Pre-Filter - Inspect pre-filter and clean with soapy water and low pressure compressed air if necessary

• PVT Intake Pre-Filter - Inspect pre-filter and clean with soapy water and low pressure compressed air if necessary

• Steering - check for free operation noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

• Drive Shaft Boots - Inspect inner and outer boots for tears or damage on both front and rear drive shafts

• Check all front and rear suspension components for wear or damage.

Shift Cable Inspection / Adjustment

Shift cable adjustment may be necessary if symptoms include:

• No gear position or AWD display on instrument cluster

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear lash (noise)

• Gear selector moving out of desired range

1. Locate the shift cable

attached to the transmission

case in the right rear wheel well area.

2. Inspect shift cable, clevis pin, pivot bushings

, and

dust boot

. Replace if worn or damaged.

3. If adjustment is required, loosen the lower jam nut

and pull the cable out of the mount6to move the upper jam nut

4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK.

5. Thread the upper or lower jam nut as required to obtain proper cable adjustment.

NOTE: This procedure may require a few attempts to obtain the proper adjustment.

6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount.

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.

MAINTENANCE

2.10

9925723 R01 - 2015 RZR 900 Service Manual

FUEL SYSTEM

Fuel System

WARNING

Gasoline is extremely flammable and explosive under

certain conditions.

Always stop the engine and refuel outdoors or in a well

ventilated area.

Do not smoke or allow open flames or sparks in or near

the area where refueling is performed or where

gasoline is stored.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow

gasoline, seek medical attention immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water

and change clothing.

Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result in

loss of consciousness or

death in a short time.

Never drain the fuel when the engine is hot.

Severe burns may result.

Fuel Tank Vent Line

Symptoms of a restricted fuel tank vent include the following: collapsing fuel tank, engine miss or hesitation, loss of engine performance or high exhaust temperatures.

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.

3. Be sure the vent line is routed properly and secured with cable tie(s).

NOTE: Make sure vent line is not kinked or pinched.

Fuel Pump / Fuel Filter

The fuel pump assembly1is located in the fuel tank under the passenger seat.

The RZR 900 EFI engine uses a serviceable, highvolume, high-pressure, fuel pump that includes a preliminary filter

and an internal fine filter3located

before the pump regulator.

NOTE: Neither filter is serviceable individually. Must replace the fuel pump as an assembly.

Refer to Chapter 4 for Fuel Pump Replacement, page 4.22 and all other information related to the EFI System.

MAINTENANCE

2.11

9925723 R01 - 2015 RZR 900 Service Manual

Fuel Lines

1. Check the quick connect fuel line1at the fuel tank

for signs of wear, deterioration, damage or leakage. Replace line if necessary.

2. Locate the fuel supply fitting

going to the fuel rail by removing the cargo box access panel. Check the line and quick-connect fitting for signs of wear, deterioration, damage or leakage. Replace line if necessary.

3. Be sure fuel lines are routed and retained properly.

IMPORTANT: Lines should not be kinked or pinched.

Throttle Pedal Inspection

This vehicle is equipped with a Pedal Position Sensor

used to detect when the throttle pedal2is pushed or released.

The throttle pedal should move freely and always return to its idle state (no throttle) when released.

Check throttle pedal periodically.

MAINTENANCE

2.12

9925723 R01 - 2015 RZR 900 Service Manual

ENGINE SYSTEM

Engine Air Filter Service

Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often.

1. Remove the cargo box access panel

2. Disengage the two cover straps2.

3. Pull cover rearward far enough to remove air filter3.

4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean shop towel.

NOTE: If the filter has been soaked with fuel or oil it must be replaced.

5. Inspect the air filter and replace if necessary.

NOTE: DO NOT attempt to clean the air filter.

6. Place the air filter into the air box and reinstall the air box cover.

NOTE: Be sure the lower tabs on the air box cover are properly engaged into the airbox.

7. Engage the cover straps.

8. Reinstall the cargo box access panel.

Intake Duct Inspection

It is recommended that the intake be inspected daily.

1. Access the air intake duct

underneath the intake

doghouse cover 2.

2. Check the area for debris.

3. Remove the air box cover and clean out any debris.

MAINTENANCE

2.13

9925723 R01 - 2015 RZR 900 Service Manual

Air Box / Filter Assembly View

Intake Airbox Hose

Airbox Clips

Drain Cap

Vent Hose

Airbox

Intake Tubes

Air Filter

Engine Intake Housing

Airbox Cover

MAINTENANCE

2.14

9925723 R01 - 2015 RZR 900 Service Manual

Engine Oil Level

The RZR 900 engine has a wet-sump design, meaning the engine oil is contained in the bottom of the crankcase. To check the oil level, follow the procedure listed below:

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.

Recommended Engine Oil:

PS-4 (PN 2876244)

Ambient Temp Range: -35° F to 100° F

PS-4 Extreme Duty (PN 2878920)

Ambient Temp Range: 0° F to 120° F

Capacity: 2.5 Quarts (2.4 L)

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down before removing the dipstick.

3. Remove the access panel between the seats to access the dipstick.

4. Unlock the dipstick lever

. Remove the dipstick and

wipe it dry with a clean cloth.

5. Reinstall the dipstick and push it into place. Do not lock the dipstick.

NOTE: Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.

6. Remove the dipstick and check the oil level.

7. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill (see NOTE below).

NOTE: A rising oil level between checks during cold weather operation can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the upper mark, change the oil immediately.

8. Add engine oil through the oil fill cap

located on top

of the valve cover, under the cargo box access panel.

9. When finished, reinstall dipstick and lock the lever.

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Engine Oil and Filter Change

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

The engine oil dipstick is located on the front side of the engine. Access the dipstick through the engine service panel.

The engine oil fill cap is located on top of the valve cover. Access the oil fill cap through the cargo box access panel.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase.

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down.

3. Clean the area around the crankcase drain plug.

CAUTION

Use caution when performing this procedure.

Do not allow hot engine oil to come into contact with

skin, as serious burns may result.

4. Place a drain pan under the engine crankcase and remove the drain plug

. Allow the oil to drain

completely.

5. Remove the seats and engine service panel to access the oil filter.

6. Using the Oil Filter Wrench (PU-50105), turn the oil filter

counter-clockwise to remove it.

Oil Filter Wrench:

PU-50105: 2.5″ (64 mm)

7. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase.

8. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it by hand until the O-ring contacts the sealing surface, then turn an additional 1/2 turn.

Oil Filter Torque:

Turn by hand until filter O-ring contacts sealing surface,

then turn an additional 1/2 turn.

9. Replace the sealing washer on drain plug.

NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.

10.Reinstall the engine crankcase drain plug. Torque drain plug to specification.

Engine Oil Drain Plug:

12 ft-lbs (16 Nm)

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11.Remove oil fill cap (see Chapter 2 – Engine Oil Level, page 2.14). Fill engine with 2.5 quarts (2.4 L) of recommended engine oil.

Recommended Engine Oil:

PS-4 (PN 2876244)

Ambient Temp Range: -35° F to 100° F

PS-4 Extreme Duty (PN 2878920)

Ambient Temp Range: 0° F to 120° F

Capacity: 2.5 Quarts (2.4 L)

12.Verify the transmission is still in PARK.

13.Start the engine and allow it to idle for 30 seconds.

14.Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.

15.Unlock the dipstick lever. Remove the dipstick and wipe it dry with a clean cloth (see Chapter 2 – Engine Oil Level, page 2.14).

16.Reinstall the dipstick and push it into place. Do not lock the dipstick.

NOTE: Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.

17.Remove the dipstick and check the oil level.

18.Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

19.When finished, reinstall the oil fill cap, oil dipstick and lock the lever.

20.Reinstall the cargo box access panel, engine service panel and seats.

21.Dispose of used oil and filter properly.

Crankcase Breather Hose Inspection

The engine crankcase is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is form fitted for proper fit.

Follow the breather hose

from the crankcase to the

engine intake duct.

NOTE: Make sure hoses are not kinked or pinched.

Engine Cylinder Leak-down Test

A cylinder leak-down test is the best indication of engine condition. Follow tester manufacturer’s instructions to perform a cylinder leak-down test. Never use high pressure leakage testers as crankshaft seals may dislodge and leak.

Cylinder Leakage Service Limit: 20%

If leakage exceeds service limit, inspect the engine

for the cause.

Valve Clearance Inspection

NOTE: Valve clearance inspection should be performed on a cold engine, at room temperature.

IMPORTANT: Do not rotate the engine backwards. The timing chain may jump teeth and lead to poor performance.

1. Remove the driver’s seat. Disconnect the negative (-) battery cable.

2. Remove the engine access panel.

3. Remove eight screws retaining the outer clutch cover.

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4. Maneuver the outer clutch cover to allow access to the drive clutch, in order to rotate the engine.

NOTE: Removal of left rear wheel or left rear shock is NOT necessary to perform this procedure.

5. Remove the spark plug wires to gain access to valve cover as shown below.

6. Remove the four T40 bolts retaining the valve cover.

7. The engine will need to be rotated four times to inspect all eight valve clearances

. Two valves can

be measured at each camshaft lobe position.

8. Rotate the drive clutch counter-clockwise until the cam lobes

above the valves you are inspecting are

facing up.

IMPORTANT: Do not rotate the engine backwards. The timing chain may jump teeth and lead to poor performance.

9. Measure the valve clearance using a feeler gauge.

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10.If the valve clearance is out of specification, proceed to Chapter 3 – Valve Clearance Adjustment, page

3.82.

Intake Valve Clearance (cold):

.006 ± .002″ (0.15 ± 0.05 mm)

Exhaust Valve Clearance (cold):

.008 ± .002″ (0.20 ± 0.05 mm)

11.Repeat steps 18-20 until all eight valves have been inspected.

12.If previously removed, apply anti-seize compound to the spark plug threads and reinstall the spark plugs. Torque spark plugs to specification.

Spark Plug Torque:

7 ft-lbs (10 Nm)

13.Inspect the valve cover seal and replace if necessary.

14.Install NEW isolators on the valve cover bolts. Install the valve cover and the four T40 bolts. Torque bolts to specification.

Valve Cover Bolts:

7 ft-lbs (10 Nm)

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.

17.Install the spark plug wires. Ensure wires are installed on their proper cylinder spark plug and pushed down all the way so they engage onto the spark plugs.

NOTE: The engine will misfire if the spark plug wires are installed incorrectly. The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder.

18.Install outer clutch cover and eight retaining screws. Torque screws to specification.

Outer Clutch Cover Screws:

54 in-lb (5 Nm)

19.Connect the negative (-) battery cable to the battery and install the seat.

20.Start the engine to ensure proper operation.

21.Install the engine access panel.

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TRANSMISSION AND FRONT GEARCASE

Specification Chart

GEARCASE LUBRICANT CAPACITY

FILL / DRAIN PLUG TORQUE

Transmission AGL

without turf mode:

44 oz. (1300 ml)

14 ft-lbs (19 Nm)

with turf mode:

40.5 oz. (1200 mL)

Front Gearcase Demand Drive

8.5oz. (250 ml) 10 ft-lbs (14 Nm)

Transmission Lubrication

NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart. Regular lubricant level inspections should be performed as well.

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the lubricant.

• Check vent hose to be sure it is routed properly and unobstructed.

Transmission Lubricant Level Check

The fill plug is located on the rear portion of the transmission gearcase. Access the fill plug at the rear of the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug

and check the lubricant level.

3. If lubricant level is not even with bottom threads2, add recommended lubricant as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

Transmission Fill / Drain Plug Torque:

14 ft-lbs (19 Nm)

Transmission Lubricant Change

The drain plug is located on the bottom of the transmission gearcase. Access the drain plug through the drain hole in the skid plate.

5. Remove the fill plug.

6. Place a drain pan under the transmission drain plug.

7. Remove drain plug

and allow lubricant to drain

completely.

8. Clean the drain plug magnetic surface.

9. Reinstall the drain plug and torque to specification.

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10.Add the recommended amount of lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

Recommended Transmission Lubricant:

AGL (PN 2878068) (Quart)

Capacity (without Turf mode): 44 oz. (1300 ml)

Capacity (with Turf mode): 40.5 oz. (1200 ml)

11.Reinstall the fill plug and torque to specification.

Transmission Fill / Drain Plug Torque:

14 ft-lbs (19 Nm)

12.Check for leaks. Dispose of used lubricant properly.

Front Gearcase Lubrication

NOTE: It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well.

The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Front Gearcase Fluid Level Check

The fill plug is located on the bottom right side of the front gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug

and check the fluid level.

3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

Front Gearcase Fill / Drain Plug Torque:

10 ft-lbs (14 Nm)

Front Gearcase Fluid Change:

The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase.

5. Remove the fill plug.

6. Place a drain pan under the front gearcase drain plug.

7. Remove the drain plug

and allow fluid to drain

completely.

8. Clean the drain plug magnetic surface.

9. Reinstall the drain plug and torque to specification.

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10.Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.

Recommended Front Gearcase Fluid:

Polaris Demand Drive

(PN 2877922) (Quart)

Capacity:  7.5 oz. (222 mL)

11.Reinstall the fill plug and torque to specification.

Front Gearcase Fill / Drain Plug Torque:

10 ft-lbs (14 Nm)

12.Check for leaks. Dispose of used fluid properly.

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COOLING SYSTEM

Cooling System Overview

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during break-in period.

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.

Coolant Strength

Test the strength of the coolant using an antifreeze hydrometer.

• A 50/50 mixture of antifreeze and distilled water

will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze or straight

water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system

to freeze, corrode, or overheat.

Recommended Coolant:

Polaris Premium Pre-Mixed Antifreeze

(PN 2880514) (Quart)

(PN 2880513) (Gallon)

Coolant Level Inspection

The pressure cap1and recovery bottle2are located under the front hood of the vehicle. The coolant level must be maintained between the minimum and maximum levels indicated on the recovery bottle.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle. If not, perform the following procedure:

1. Position the vehicle on a level surface.

2. If the coolant level is below the MIN line, inspect the coolant level in the radiator.

NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.

WARNING

Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure

cap.

3. Remove the pressure cap. Using a funnel, add coolant to the top of the filler neck.

4. Reinstall the pressure cap.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.

5. Remove recovery bottle cap and add coolant using a funnel.

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6. Fill recovery bottle to MAX level with recommended coolant or 50/50 mixture of antifreeze and distilled water.

Recommended Coolant:

Polaris Premium Pre-Mixed Antifreeze

(PN 2880514) (Quart)

(PN 2880513) (Gallon)

7. Reinstall the recovery bottle cap.

8. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating.

Cooling System Pressure Test

Refer to ENGINE COOLING SYSTEM, page .

Cooling System Hose Inspection

1. Inspect all vehicle hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

Recovery Bottle

Engine Hoses

Radiator Hoses

To Thermostat Housing

To Water Pump

To Radiator

2. Inspect all engine hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

Bypass Hose

Water Pump Outlet Hose

Oil Cooler Inlet Hose

Oil Cooler Outlet Hose

3. Check tightness and condition of all hose spring clamps. Replace if necessary.

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Radiator Inspection / Cleaning

1. Check radiator air passages for restrictions or damage.

Radiator

Shroud

Fan

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with low pressure compressed air or low pressure water.

CAUTION

Washing the vehicle with a high-pressure washer could

damage the radiator fins and impair the radiators

effectiveness. Use of a high-pressure washer is not

recommended.

Coolant Drain / Fill

1. Remove the front hood.

WARNING

Never drain the coolant when the engine and radiator

are warm or hot. Hot coolant can cause severe burns.

Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling system pressure.

3. Place a suitable drain pan underneath the radiator fitting on the front right side of the vehicle.

4. Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown

5. Allow coolant to drain completely. Properly dispose of the used coolant.

6. Reinstall coolant hose and reposition the spring clamp.

7. Remove the pressure cap. Using a funnel, add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level.

8. Refer to Chapter 3 – Cooling System Bleeding, page

3.15.

Recommended Coolant:

Polaris Premium Pre-Mixed Antifreeze

(PN 2880514) (Quart)

(PN 2880513) (Gallon)

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PVT SYSTEM

Drive Clutch / Driven Clutch / Belt Service

Refer to Chapter 5 – PVT System for servicing the belt and drive/driven clutches.

PVT Duct Cleaning

It is recommended that the PVT intake be inspected occasionally. The PVT ducts should be inspected using the following procedure:

1. The PVT intake screen

is located just above the left

rear wheel fender.

2. Remove the two screws retaining the screen and inspect inside for signs of debris.

3. Inspect the PVT exhaust duct and grate

, found near the exhaust head pipe. Clean the grate so air can flow through unrestricted.

IMPORTANT: The PVT intake and exhaust ducts MUST be checked for debris in the event of a belt failure.

PVT Drying

NOTE: After operating in water, the vehicle’s PVT system should be checked immediately. Use the following instructions to dry it out before operating.

The PVT drain plug is located at the bottom of the outer clutch cover. Access the drain plug through the left rear wheel well.

1. Using a flat blade screwdriver, remove the PVT drain plug

and O-ring from the outer clutch cover.

2. Allow the water to drain out completely.

3. Reinstall the drain plug and O-ring.

4. Place the transmission in PARK, apply the brake and start the engine.

5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.

NOTE: Do not hold the throttle pedal wide open for more than 5 seconds.

6. Allow the engine RPM to return to idle, then shift the transmission into low gear.

7. Test the PVT system for belt slippage. If the belt slips, repeat the process or remove the outer clutch cover to inspect the PVT system.

NOTE: If the vehicle has ingested a large amount of water into the PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage.

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FINAL DRIVE / WHEEL AND TIRE

Drive Shaft Boot Inspection

Inspect the front and rear drive shaft boots

for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Check to see the boot clamps

are properly positioned. Refer to DRIVE SHAFT CV JOINT / BOOT REPLACEMENT , page for drive shaft boot replacement.

Wheel and Hub Torque Table

ITEM SPECIFICATION

Wheel Nuts

Aluminum: 120 ft-lbs (163 Nm) Steel: 60 ft-lb (81 Nm)

Hub Retaining Nuts (Front and Rear)

110 ft-lbs (149 Nm)

NOTE: Do not lubricate the stud or the lug nut.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK and stop the engine.

3. Loosen the wheel nuts slightly. If wheel hub removal

is required, remove the wheel cap, cotter pin and loosen the hub nut slightly.

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.

Wheel Installation

1. Verify the transmission is still in PARK.

2. Place the wheel in the correct position on the wheel hub

. Be sure the valve stem

is toward the outside and rotation arrows on the tire point toward forward rotation.

3. Attach the wheel nuts

and finger tighten them.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts and/or hub nut

to the proper torque specification. Wheel and Hub Torque Table, page 2.26

6. If hub nut was removed, install a new cotter pin

after the hub nut has been tightened. If the holes do not line up, turn the hub nut counter-clockwise until the cotter pin can be installed.

CAUTION

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered wheel

nuts, make sure tapered end of nut goes into taper on

wheel.

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Tire Inspection

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect vehicle handling.

WARNING

Operating with worn tires will increase the possibility of

the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the usable tread depth has

worn out.

Tire Pressure

Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle’s tool kit.

CAUTION

Maintain proper tire pressure. Refer to the warning tire

pressure decal applied to the vehicle.

Tire Pressure (cold)

FRONT REAR

RZR 900

10 psi (69 kPa) 12 psi (83 kPa)

RZR XC 900

10 psi (69 kPa) 12 psi (83 kPa)

RZR S 900

10 psi (69 kPa) 14 psi (97 kPa)

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ELECTRICAL / IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related

accessories contain lead and lead compounds, and

other chemicals known to the State of California to

cause cancer and birth defects or other reproductive

harm.

WASH HANDS AFTER HANDLING.

WARNING

Battery electrolyte is poisonous. It contains sulfuric

acid. Serious burns can result from contact with skin,

eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow

with milk of magnesia, beaten egg, or vegetable oil. Call

physician immediately.

Eyes: Flush with water for 15 minutes and get prompt

medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc. away. Ventilate

when charging or using in an enclosed space. Always

shield eyes when

working near batteries.

KEEP OUT OF REACH OF CHILDREN.

NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery according to “Charging Procedure”, page . Do not use the vehicle’s stator/ alternator to charge a new battery.

Battery Off Season Storage

Whenever the vehicle is not used for a period of two months or more, remove the battery from the vehicle, ensure that it is fully charged and store it out of the sun in a cool, dry place. Check battery voltage each month during storage or and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal discharge. Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre-determined point.

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Battery Charging

If battery voltage is less than 12.6 Vdc, the battery may need recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging.

Do not exceed 6 amps when charging the battery.

NOTE: Charge the battery using an automatic charger that will not exceed 14.6 Vdc. An automatic charger will signal when charging is complete. Allow the battery to stand disconnected for at least 1-2 hours after being properly charged. If the voltage drops below 12.6 volts, charging was ineffective or the battery needs to be replaced.

WARNING

An overheated battery could explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the

touch. Allow it to cool before resuming charging.

STATE OF CHARGE

VOLTAGE (DC)

ACTION

CHARGE TIME

100%

12.8 or more

None, check again in 3 months

None Required

75% 100%

12.6 - 12.8

May need slight charge

3 - 6 hrs

50% - 75% 12.3 - 12.6

Needs Charge

5 - 11 hrs

25% - 50% 12.0 - 12.3

Needs Charge

At least 13 hrs

0% - 25% 12.0 or less

Needs Charge

At least 20 hrs

NOTE: Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet.

Battery Removal

1. Remove the driver’s seat to access the battery1.

2. Disconnect the black (negative) battery cable.

CAUTION

To reduce the chance of sparks: Whenever removing

the battery, disconnect the black (negative) cable first.

When reinstalling the battery, install the black (negative)

cable last.

3. Disconnect the red (positive) battery cable.

4. Remove the battery hold-down bracket

5. Lift the battery out of the vehicle.

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Battery Installation

NOTE: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Refer to Battery Charging, page 2.29 before installing the battery.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with hold-down bracket. Torque bracket fastener to specification.

Battery Hold-Down Bracket:

8 ft-lb (11 Nm)

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Connect and tighten the red (positive) cable (s) first. Torque fasteners to specification.

Battery Terminal Fasteners:

60 in-lb (7 Nm)

5. Connect and tighten the black (negative) cable (s) last.

6. Verify that cables are properly routed and reinstall the driver’s seat.

Engine / Chassis Ground

Inspect the ground cable connections. Remove ground terminals and clean if necessary.

The chassis ground connection

, located below the

start solenoid

, can be accessed through the left rear

wheel area.

Inspect the chassis ground terminals. Be sure the grounds are clean and tight.

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Spark Plug Service

Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart.

1. Remove the cargo box access panel

WARNING

A hot engine can cause serious burns. Allow engine to

cool or wear protective gloves when removing the spark

plugs.

2. Remove both spark plug caps

NOTE: Use MAG and PTO reference decals on spark plug wires for reassembly.

3. Clean out plug wells with compressed air to remove any loose dirt or debris.

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.

5. Remove spark plugs using a 5/8” spark plug socket with an extension.

6. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

7. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode.

9. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

Recommended Spark Plug:

Champion RG4YCX

10.Apply anti-seize compound to the spark plug threads.

11.Install spark plugs and torque to specification.

Spark Plug Torque:

7 ft-lbs (10 Nm)

12.Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals. Ensure wires are pushed down all the way so they engage onto the spark plugs.

13.Reinstall the cargo box access panel.

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STEERING SYSTEM

Steering Inspection

The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must be replaced.

Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: 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

Polaris MSD certified technician.

Steering Wheel Free-play

Check steering wheel for specified free-play and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8-1.0″ (20-25 mm) of free-play.

4. If there is excessive free-play or the steering feels rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints

• Steering Rack

Tie Rod End / Wheel Hub Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Replace any worn steering components. Steering should move freely through entire range of travel without binding.

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front wheel/hub assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).

• Refer to Chapter 7 “Final Drive” for front hub service procedures.

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Wheel Toe Alignment Inspection

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires at position

approximately 10″ (25.4 cm) from the floor or as close to the hub/axle center line as possible.

NOTE: It is important the height of both marks be equally positioned to get an accurate measurement.

3. Measure the distance between the marks at position

and record the measurement. Call this

measurement A.

4. Rotate the tires 180° to position2by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks at position

and record. Call this measurement B.

6. Subtract measurement B from measurement A. The difference between measurements A and B is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8 to 3/16″ (3.2 to 4.8 mm) toe out. This means the measurement at the front of the tire (A) is 1/8 to 3/16″ (3.2 to 4.8 mm) wider than the measurement at the rear (B).

Wheel Toe-Out:

1/8 to 3/16" (3.2 to 4.8 mm)

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Wheel Toe Adjustment

If toe alignment is incorrect, repeat steps 3-5 of “Wheel Toe Alignment Inspection”, but instead measure the distance between each wheel and the vehicle center. This will tell you which tie rod needs adjusting.

NOTE: Be sure steering wheel is straight ahead before determining which tie rod needs adjustment.

CAUTION

During tie rod adjustment, it is very important that the

following precautions be taken when tightening tie rod

end jam nuts.

If the rod end is positioned incorrectly it will not pivot,

and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”.

• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

• After alignment is complete, torque jam nuts to specification.

Tie Rod Jam Nut:

14 ft-lbs (19 Nm)

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SUSPENSION SYSTEM

Spring Adjustment

The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change ride height.

WARNING

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and serious

injury or death. Always adjust both the left and right

springs equally.

1. Position the vehicle on a level surface and stop the

engine.

2. Raise and safely support front or rear of vehicle off

the ground to allow the suspension to fully extend.

NOTE: The tires should not be touching the ground.

3. To adjust the suspension, rotate the adjustment cam

clockwise to increase spring tension or counter-

clockwise to decrease spring tension.

Shock Spanner Wrench:

PN 2877408

4. Each notch of the adjustment will add 6% - 8% more

preload to the spring over the primary position.

Spring Adjustment (FOX)

The front and rear shocks have a spring adjustment. Suspension springs may be adjusted to suit different riding conditions or vehicle payloads.

WARNING

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and serious

injury or death. Always adjust both the left and right

springs equally.

SPRING ADJUSTMENT - FACTORY

SETTING

Front Rear

4.41″ (11.20 cm) 0.56″ (1.42 cm)

60″

7.39″ (18.77 cm) 2.80″ (7.11 cm)

NOTE: Refer to the shock illustrations within this procedure for spring measurement location.

The factory setting is appropriate for nearly all riding conditions. Since this vehicle is equipped with full skid plates, adjustment is not necessary.

If desired, the spring setting may be adjusted to maintain vehicle clearance height when carrying loads.

1. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend.

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2. Loosen the upper jam nut adjustment ring using the spanner wrench (PN 2877408) included in the vehicle’s tool kit.

Shock Spanner Wrench:

PN 2877408

3. Turn the lower adjustment ring

clockwise to increase ride height or counter-clockwise to decrease ride height.

IMPORTANT: DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting.

4. Once you have obtained the correct ride height, hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place.

IMPORTANT: 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.

Shock Compression Adjustment (FOX)

The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each shock.

Turn the clicker adjuster knob to make damping adjustments.

NOTE: When clicker adjuster is turned clockwise until it stops, damping is in the fully closed position.

Turn the clicker clockwise to increase compression damping. Turn the clicker counter-clockwise to decrease compression damping.

NOTE: The factory setting is 12 clicks from closed. Refer to the “Compression Adjustment Table”.

Compression Adjustment Table

SETTING COMPRESSION DAMPING

Softest

Full counter-clockwise position

FACTORY 12 clicks from closed

Firmest 2 clicks from closed

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BRAKE SYSTEM

Brake Fluid Inspection

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. View the brake fluid level in the reservoir

. The level

should be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches the MAX level line.

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material

is worn to 0.040″ (1 mm).

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

6. The disc (s) should be replaced if thickness is less than 0.170″ (4.32 mm).

Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

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NOTES

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ENGINE / COOLING SYSTEM

CHAPTER 3

ENGINE / COOLING SYSTEM

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . 3.3

SPECIAL TOOLS . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . 3.3

LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 3.3

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE. . . . . . . . . . . . . . . . . . . . . 3.4

BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS . . . . . . . . . . . . . 3.5

CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP .... . . . . . . . . . . . . . . 3.6

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER. . . . . . . . . . . . .. . . . 3.7

SPARK PLUGS / STARTER / THERMOSTAT HOUSING / TRANS JOINT / VALVE COVER.. . . . . . . . . . 3.8

EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

EXHAUST ASSEMBLY VIEW / TORQUE VALUES ... . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 3.10

EXHAUST REMOVAL / INSTALLATION . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 3.11

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .3.12

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

COOLING SYSTEM PRESSURE TEST... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12

RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . .3.12

RADIATOR REMOVAL / INSTALLATION. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .3.12

THERMOSTAT REPLACEMENT ... . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . .3.13

COOLING SYSTEM BLEEDING... . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

WATER PUMP SERVICE.. . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . .3.16

WATER PUMP INSTALLATION. . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . .3.18

ENGINE SERVICE .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .3.20

LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .3.20

ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . .3.20

ENGINE OIL FLOW CHART .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .3.21

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

TOP END SERVICE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.24

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

ENGINE BREAK-IN .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34

VALVE COVER REMOVAL . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .3.34

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . 3.34

CAMSHAFT SPROCKET INSPECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

CYLINDER HEAD DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

VALVE INSPECTION. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .3.39

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COMBUSTION CHAMBER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . .3.44

STATOR COVER REMOVAL / INSPECTION. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .3.44

WATER PUMP HOUSING REMOVAL.. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .3.45

FLYWHEEL REMOVAL. . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45

STARTER ONE-WAY CLUTCH DISASSEMBLY. . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . .3.46

STARTER ONE-WAY CLUTCH ASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .3.48

BALANCE SHAFT REMOVAL / INSPECTION. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . .3.50

CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .3.51

CRANKCASE INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54

CYLINDER / PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . .3.55

CYLINDER INSPECTION . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . .3.55

PISTON DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.56

PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57

PISTON RING TO GROOVE CLEARANCE INSPECTION . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.58

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . .3.59

CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61

BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . .3.61

CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .3.62

CRANKSHAFT MAIN BEARING SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62

UPPER CRANKCASE PREPARATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63

PISTON RING INSTALLATION . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .3.63

PISTON / CONNECTING ROD ASSEMBLY. .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . .3.64

CYLINDER / PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65

CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66

BALANCE SHAFT INSTALLATION .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67

LOWER CRANKCASE PREPARATION. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .3.68

CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72

STATOR COVER INSTALLATION ... . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .3.73

ENGINE ASSEMBLY - TOP END. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74

CYLINDER HEAD ASSEMBLY . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .3.74

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . .3.75

CYLINDER HEAD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 3.76

CAMSHAFT INSTALLATION / TIMING. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77

CAMSHAFT TIMING - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81

VALVE CLEARANCE ADJUSTMENT ... . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . .3.82

INTAKE VALVE LASH - TAPPET SELECTION MATRIX . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . .3.84

EXHAUST VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .3.85

VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

ENGINE / COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.87

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9925723 R01 - 2015 RZR 900 Service Manual

GENERAL INFORMATION

Special Tools

PART NUMBER

TOOL DESCRIPTION

2870975 Mity Vac Pressure Tester

PA-49316 Flywheel Puller

PU-50105

Oil Filter Wrench

PU-50562 Engine Stand Adapter (Mounts to

Engine)

PU-50563 Cylinder Holding & Camshaft

Timing Plate

PU-50564 Water Pump Mechanical Seal

Installer

PU-50565 Oil Pressure Gauge Adapter

PU-50624

Engine Stand (2″ Bore)

PU-50625

Engine Stand Sleeve Adapter

PU-50658 Clutch Center Distance Tool

PV-1253 or PV4019

Valve Spring Compressor

PV-43513–A

Valve Spring Compressor Adapter

PV-43531 Oil Pressure Gauge

PV-43570–1

Piston Ring Compressor Pliers

PW-47053

Bench Mount Engine Stand Adapter

Bosch Automotive Service Solutions:

1-800-345-2233 or http://polaris.service-solutions.com/

Lubrication Specifications

Oil Capacity* ≈ 2.5 Quarts (2.4 L)

Oil Filter Wrench PU-50105 or 2.5″ (64

mm)

Oil Filter 2540086

Oil Type

Ambient Temp Range:

-35° F to 100° F

PS-4 Synthetic Engine Oil 2876244 – Qt

Oil Type

Ambient Temp Range: 0° F to 120° F

PS-4 Extreme Duty Synthetic Engine Oil 2878920 – Qt

Oil Pressure (idle)

at 70° F: 72 PSI

at 220° F: 60 PSI

* Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

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Main Engine Components - Torque Specification and Sequence

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Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

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Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

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Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

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Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover

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EXHAUST SYSTEM

Exhaust Assembly View / Torque Values

ITEM / TORQUE ITEM / TORQUE

Exhaust Head Pipe

Exhaust Gasket

Head Pipe Gasket

Spark Arrestor

Heat Shields

Spark Arrestor Fastener / 8 ft-lb (11 Nm)

Head Pipe Bolts / 18 ft-lb (24 Nm)

Muffler Shield Fasteners / 10 ft-lb (14 Nm)

Push Rivet

Muffler Rubber Mounts

Muffler

Exhaust Spring

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Exhaust Removal / Installation

1. Remove the engine access panel1and the air intake housing cover

2. Remove the seats.

3. Disconnect and remove the ECU

4. Remove the four plastic rivets retaining the bottom of the engine / cab divider panel

5. Disconnect both taillights and remove ten Torx fasteners

retaining the rear fascia.

6. Remove the three springs6, two retaining the muffler to the head pipe and one spring retaining the muffler to the chassis.

7. Remove the six exhaust head pipe fasteners7.

8. Remove the exhaust from the vehicle.

9. To install, reverse procedure. Torque fasteners to specification.

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)

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ENGINE COOLING SYSTEM

Cooling System Specifications

CONDITION COOLANT TEMP

Thermostat Starts to Open

180° F (82° C)

Fan Shuts Off 192° F (89° C)

Fan Turns On 198° F (92° C)

Thermostat Fully Open 203° F (95° C)

Engine Temperature Overheat Indicator

232° F (111° C)

Engine Protection Level 1 – Power Limit

232° F (111° C)

Engine Protection – Ignition Misfire

237° F (114° C)

Engine Protection Level 2 – Power Limit

244° F (118° C)

Engine Shutdown Protection

252° F (122° C)

ITEM

SPECIFICATION

Cooling System Capacity 4.9 qts (4.6 L)

Pressure Cap Relief 13 PSI

PolarisAntifreeze

2880514 – Quart

2880513 – Gallon

Cooling System Pressure Test

1. Remove the hood from the front cab.

WARNING

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

2. Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available tester.

3. The system must maintain 10 PSI for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, clamps and water pump seal for signs of leaking.

Radiator Cap Pressure Test

1. Open the front hood.

WARNING

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

2. Remove radiator pressure cap and test using a commercially available pressure cap tester.

3. Replace cap if it does not meet the specification.

Radiator Cap Pressure Relief

13 PSI

Radiator Removal / Installation

NOTE: This procedure should also be followed for radiator fan replacement.

1. Remove the hood and front bumper. (see Chapter 10 – Front Bumper Removal, page 10.12)

2. Remove the four fasteners retaining the front bumper support to the main frame.

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3. Drain radiator by removing the lower radiator hose1. Be sure to catch and dispose of coolant properly.

WARNING

The cooling system is under pressure. Allow engine to

cool before servicing or serious burns may result.

4. Disconnect the cooling fan electrical connector.

5. Remove the upper radiator hose from the radiator.

6. Remove the four upper radiator support fasteners

and disconnect the coolant reservoir hose3.

7. Lift radiator up to disengage it from its lower mounting points. 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.

9. Reverse this procedure for installation. Be sure to properly fill and bleed cooling system. (see Chapter 3 – Cooling System Bleeding Procedure, page

Upper Radiator Hose

Lower Radiator Hose

Coolant Reservoir

Reservoir Hose (to radiator)

Fan Motor Control

Radiator

Thermostat Replacement

1. Remove the hood.

2. Remove the pressure cap

to relieve any system

pressure.

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WARNING

Escaping stead can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

3. Remove the lower radiator hose

and drain coolant

to a level below the thermostat housing.

4. Loosen the hose clamp3and remove the coolant hose from the thermostat cover.

5. Remove the two bolts4that retain the thermostat cover to the engine.

6. Remove the thermostat cover, seal5and thermostat

from the engine.

NOTE: Thermostat has a pop-off relief to allow the bypass system to operate until the thermostat opens.

7. Clean the thermostat mating surfaces on the engine and thermostat cover.

8. Install a new thermostat and seal into the cover and install the cover onto the engine.

9. Install the thermostat cover bolts. Torque bolts to specification.

Thermostat Cover Bolts:

7 ft-lb (10 Nm)

10.Install coolant hose back on the thermostat cover and securely tighten the hose clamp.

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11.Fill cooling system and proceed to bleed the cooling system (see Chapter 3 – Cooling System Bleeding Procedure, page ).

Cooling System Bleeding

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this manual. Failing

to do so may lead to injury or death.

NOTE: If the coolant level is LOW in the radiator or if there are leaks in the system, the cooling system will not draw coolant from the reservoir tank.

1. Allow engine and cooling system to cool down.

CAUTION

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

2. Remove the hood.

3. Remove the cap from the Coolant Reservoir

and fill

the reservoir to the MAX line.

4. Remove the radiator pressure cap2and add the necessary amount of Polaris Premium Antifreeze to the radiator.

5. Remove the cargo box engine access panel.

6. Open the bleed screw

to allow any trapped air to

escape.

7. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

Coolant Bleed Screw:

89 in-lb (10 Nm)

8. Start the engine and allow it to idle until the cooling fan has cycled two times.

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.

12.Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

Coolant Bleed Screw:

89 in-lb (10 Nm)

13.Fill the recovery bottle to the MAX line.

14.Reinstall the cargo box engine access panel and the hood.

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Water Pump Removal

1. Allow engine and cooling system to cool down.

WARNING

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be hot and could cause severe

injury / burns.

2. Disconnect the (-) negative battery cable.

3. Remove all debris and thoroughly clean the area around the water pump.

4. Remove the hood and remove the pressure cap from the radiator.

5. Place a drain pan under the water pump and drain the cooling system.

6. Disconnect the three coolant hoses that are attached to the water pump. Note the location and routing for installation.

7. Remove the three bolts

retaining the water pump to the engine. Note the different lengths of the bolts for installation.

8. Remove the water pump from the engine by gently twisting and rocking the water pump housing while pulling outward.

9. Plug the water pump drive access hole in the engine block with a clean shop towel.

Water Pump Service

NOTE: The water pump cover gasket can be replaced while the water pump housing is still installed in the engine.

1. Remove water pump assembly. (see Chapter 3 – Water Pump Removal, page 3.16)

2. Remove the three bolts retaining the water pump

cover to the water pump housing2. Discard the gasket

3. Place the water pump drive tab4vertically into a soft jaw vice.

4. Remove the bolt and washer retaining the water pump impeller to the shaft. Inspect the impeller vanes and water pump housing for damage.

NOTE: The water pump impeller bolt

is left

hand threaded (reverse thread).

5. Remove impeller from water pump shaft.

6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side.

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7. Extract the mechanical seal and the oil seal from the water pump housing.

NOTE: A 5/32″ (4 mm ) diameter punch will fit in the lubrication slot to aid in the removal of the oil seal. Do not damage the water pump shaft bearing surface.

8. Inspect the water pump shaft bore for damage. Replace water pump housing if necessary.

9. Clean and inspect water pump shaft for excessive wear or damage. Replace water pump housing if necessary as shaft cannot be purchased separately.

10.Thoroughly clean mechanical seal and oil seal bores.

11.Install a NEW oil seal into the water pump housing until fully seated.

12.Fully install the water pump shaft and two washers into the housing.

13.Place water pump drive tab vertically into a soft jaw vice. Install a NEW mechanical seal into the water pump housing using special tool PU-50564. Press the new mechanical seal in until it is flush with the housing.

14.Rotate the water pump shaft after seal installation to verify free movement.

15.Place impeller onto the water pump shaft.

16.Apply Loctite® 204™ to the threads of the impeller bolt. Install washer and impeller bolt and torque to specification.

Water Pump Impeller Bolt:

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt threads)

17.Clean water pump cover and housing gasket surfaces.

18.Install a new water pump cover gasket.

19.Install the water pump cover and three retaining bolts

. Torque bolts in sequence to specification.

Water Pump Cover Bolts:

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt threads)

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20.Install two new water pump o-rings and lubricate them with clean engine oil.

21.Install water pump assembly into the engine. (see Chapter 3 – Water Pump Installation, page 3.18)

Bolt

Washers

Oil Seal

Loctite 204

Drive Tab

Impeller

Mechanical Seal

Water Pump Shaft

Washer

O-Rings

Water Pump Housing

Water Pump Installation

1. Replace the two sealing o-rings1on the water pump housing.

NOTE: Always use NEW o-rings each time the water pump is removed.

2. Lubricate new o-rings

with clean engine oil.

3. Remove the shop towel from the water pump drive access hole in the engine block.

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4. Clean the o-ring sealing surface2in the engine block using a clean shop towel.

5. Use a shop light to illuminate the water pump drive access hole in the engine crankcase. Note the orientation of the water pump drive slot

6. Rotate the water pump drive tab

so it matches the

angle of the drive slot in the engine.

CAUTION

The water pump drive tab and slot must be aligned

properly during installation or severe engine or water

pump damage will occur.

7. Slide water pump into engine crankcase. Be sure water pump is fully seated and the drive tab and slot are properly aligned.

8. Install the three water pump mounting bolts

, noting location of the shorter bolt. Torque bolts to specification.

Water Pump Mounting Bolts:

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt threads)

9. Install the three coolant hoses that attach to the water pump. Be sure orientation and routing are correct.

10.Connect the (-) negative battery cable.

11.Fill and bleed the cooling system. (see Chapter 3 – Cooling System Bleeding, page 3.15)

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ENGINE SERVICE

Lubrication Specifications

Oil Capacity* ≈ 2.5 Quarts (2.4 L)

Oil Filter Wrench PU-50105 or 2.5″ (64

mm)

Oil Filter 2540086

Oil Type

Ambient Temp Range:

-35° F to 100° F

PS-4 Synthetic Engine Oil 2876244 – Qt

Oil Type

Ambient Temp Range: 0° F to 120° F

PS-4 Extreme Duty Synthetic Engine Oil 2878920 – Qt

Oil Pressure (idle)

at 70° F: 72 PSI

at 220° F: 60 PSI

* Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

Engine Oil Pressure Test

1. Attach the Oil Pressure Gauge Adapter (PU-50565) to the Oil Pressure Gauge (PV-43531).

Oil Pressure Gauge: PV-43531

Oil Pressure Gauge Adapter: PU-50565

2. Clean the area around the main oil gallery plug

, located in the upper crankcase on the MAG side of the engine.

3. Remove the plug and insert the oil pressure adapter.

4. Start engine and allow it to reach operating temperature. Monitor the gauge.

NOTE: Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if the engine is not up to operating temperature.

Oil Pressure (engine at operating temp)

Standard @ 1200 RPM: 60 PSI

Minimum: 15 PSI

5. Upon assembly, torque the crankcase gallery plug to specification.

Crankcase Gallery Plug:

11 ft-lb (15 Nm)

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Engine Oil Flow Chart

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Engine Specifications

CAMSHAFT / CYLINDER HEAD / CYLINDER

Camshaft

Cam Lobe Height - Intake (Standard) 1.5256" ± 0.0015" (38.75 ± 0.04 mm)

Cam Lobe Height - Intake (Service Limit) 1.5220" (38.66 mm)

Cam Lobe Height - Exhaust (Standard) 1.4961" ± 0.0015" (38.00 ± 0.04 mm)

Cam Lobe Height - Exhaust (Service Limit) 1.4925" (37.91 mm)

Camshaft Journal O.D. - All (Standard) 0.9035" - 0.9046" (22.949 - 22.978 mm)

Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)

Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)

Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)

Camshaft Oil Clearance (Standard) 0.0009" - 0.0028" (0.022 - 0.072 mm)

Camshaft Oil Clearance (Service Limit) 0.0039" (0.1 mm)

Camshaft End Play (Standard) 0.0040" - 0.0100" (0.101 - 0.254 mm)

Camshaft End Play (Service Limit) 0.0157" (0.4 mm)

Cylinder Head

Cylinder Head - Surface Warp Limit 0.0039" (0.1 mm)

Cylinder Head - Standard Height 4.717" ± 0.0019" (119.8 ± 0.05 mm)

Valve Seat

Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)

Valve Seat - Contacting Width - Intake (Service Limit) 0.0551" (1.4 mm)

Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)

Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)

Valve Seat Angles

30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°

Valve Guide Valve Guide Inner Diameter

0.2165" - 0.2171" (5.500 - 5.515 mm)

Valve

Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.15 ± 0.5 mm)

Valve Lash (Cold) - Exhaust 0.008" ± 0.002" (0.20 ± 0.5 mm)

Valve Stem Diameter - Intake

0.2155" - 0.2161" (5.475 - 5.490 mm)

Valve Stem Diameter - Exhaust

0.2147" - 0.2153" (5.455 - 5.470 mm)

Valve Stem Oil Clearance - Intake

0.0003" - 0.0015" (0.010 - 0.040 mm)

Valve Stem Oil Clearance - Exhaust

0.0011" - 0.0023" (0.030 - 0.060 mm)

Valve Overall Length - Intake 3.7704" (95.77 mm)

Valve Overall Length - Exhaust 3.8023" (96.58 mm)

Valve Spring

Valve Spring Free Length (Standard) 1.7213" (43.72 mm)

Valve Spring Free Length (Service Limit) 1.6830" (42.75 mm)

Cylinder

Cylinder - Surface Warp Limit (mating with cylinder head)

0.002" (0.05 mm)

Cylinder Bore - Standard 3.6614" ± 0.0003" (93 mm ± 0.008 mm)

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)

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PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT

Piston

Piston - Standard O.D. - Measured 90 degrees to pin,

0.51 in. (13 mm) up from piston skirt. See text.

3.6592 ± 0.0003" (92.950 ± 0.008 mm)

Piston Pin Bore I.D. (Standard) 0.7876" - 0.7878" (20.004 - 20.009 mm)

Piston Pin Bore I.D. (Service Limit) 0.7893" (20.05 mm)

Piston Pin

Piston Pin O.D. (Standard) 0.7872" - 0.7874" (19.995 - 20.000 mm)

Piston Pin O.D. (Service Limit) 0.7866" (19.98 mm)

Piston Ring

Installed Gap

Top Ring (Standard) 0.008" - 0.014" (0.20 - 0.36 mm)

Top Ring (Service Limit) 0.020" (0.5 mm)

Second Ring (Standard) 0.015" - 0.025" (0.37 - 0.63 mm)

Second Ring (Service Limit) 0.028" (0.70 mm)

Oil Control Rails (Standard) 0.010" - 0.040" (0.25 - 1.02 mm)

Oil Control Rails (Service Limit) 0.059" (1.50 mm)

Ring to Groove Clearance

Top Ring (Standard) 0.0012" - 0.0037" (0.030 - 0.095 mm)

Second Ring (Standard) 0.0012" - 0.0030" (0.030 - 0.076 mm)

Service Limit

0.0047" (0.12 mm)

Connecting Rod

Connecting Rod Small End I.D. (Standard) 0.7879" - 0.7884" (20.015 - 20.025 mm)

Connecting Rod Small End I.D. (Service Limit) 0.7897" (20.06 mm)

1 - Marking Connecting Rod Big End Bore I.D. 1.7318" - 1.7321" (43.989 - 43.996 mm)

2 - Marking Connecting Rod Big End Bore I.D. 1.7321" - 1.7323" (43.996 - 44.003 mm)

3 - Marking Connecting Rod Big End Bore I.D. 1.7323" - 1.7326" (44.003 - 44.010 mm)

Crankshaft

B - Marking Main Journal O.D. (Standard) 1.6140" - 1.6143" (40.996 - 41.004 mm)

G - Marking Main Journal O.D. (Standard) 1.6137" - 1.6140" (40.988 - 40.995 mm)

Y - Marking Main Journal O.D. (Standard) 1.6134" - 1.6137" (40.980 - 40.987 mm)

Main Journal O.D. (Service Limit) 1.6126" (40.960 mm)

B - Marking Rod Journal O.D. (Standard) 1.6118" - 1.6122" (40.942 - 40.950 mm)

G - Marking Rod Journal O.D. (Standard) 1.6115" - 1.6118" (40.934 - 40.941 mm)

Y - Marking Rod Journal O.D. (Standard) 1.6112" - 1.6115" (40.926 - 40.933 mm)

Rod Journal O.D. (Service Limit) 1.6104" (40.906 mm)

Crankshaft Runout Limit (PTO and MAG) Less than 0.001" (0.025 mm)

Auxiliary Sprocket Installed Depth 4.9527" ± 0.0078" (125.8 ± 0.2 mm)

Balance Shaft

Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm)

Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm)

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Accessible Engine Components

The following components can be serviced or removed with the engine installed:

• Camshaft(s)

• Camshaft Sprocket(s)

• Cylinder Head

• Flywheel

• Oil Cooler

• Starter Motor / Idler Gear Asm

• Stator (Alternator)

• Thermostat

• Valve Cover

• Water Pump

The following components require engine removal for service:

• Camshaft Timing Chain

• Connecting Rod(s)

• Counterbalance Shaft / Bearings

• Crankcase

• Crankshaft / Main Bearings

• Crankshaft Seal (PTO)

• Cylinder

• Oil Pump / Oil Pump Sprocket or Chain

• Piston / Rings

Top End Service

Some top-end engine components can be service while the engine is mounted in the chassis. To service the top-end of the engine, refer to Chapter 2 – Valve Clearance Inspection, page 2.16 which provides detailed steps to remove the valve cover.

Engine Mounts

The engine is mounted to the frame on the front only. The rear of the engine is mounted to the transmission. To replace the isolators:

1. Slightly lift and secure the engine using an engine lift.

2. Remove the engine isolator bolts securing the mount to the engine bracket.

3. Remove the fasteners retaining the isolator bracket to the frame and remove the isolator.

4. To install, reverse the procedure. Tighten fasteners to specification.

Engine Mount to Frame Fasteners:

22 ft-lb (30 Nm)

Engine Isolator Fasteners:

40 ft-lbs (54 Nm)

Engine Removal

IMPORTANT: Do NOT rotate the engine backwards. The timing chain may jump teeth and lead to poor performance.

NOTE: Some engine repair procedures can be performed without removing the engine assembly from the vehicle. See Accessible Engine Components, page 3.24 for further information.

The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine.

Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to the vehicle.

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WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this service manual.

Failing to do so may lead to injury.

1. Disconnect the battery.

2. Drain the coolant from the engine.

3. Depressurize the fuel system at the valve

on the

fuel rail while holding a clean rag over the valve.

4. Remove the seat and ECU cover panel.

5. Remove the four screws mounting the ECU to the divider panel

and disconnect the harness plugs

from the ECU

6. Remove the nine screws4for the air intake housing cover over the air box.

7. Remove the six plastic rivets5retaining the engine divider panel and push the clamp retaining the main harness ECU leads to the panel. Remove the panel from the vehicle.

8. Remove the five bolts retaining the frame support bar above the engine

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9. Remove the six exhaust head pipe fasteners7and the two springs

retaining the pipe to the muffler.

10.Remove the four screws retaining the engine and PVT intake vents.

11.Loosen the PVT intake clamp.

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.

13.Remove the 22 screws retaining the cargo box panel.

14.Remove the ignition coil by disconnecting the wiring leads and removing the two mounting bolts. Remove the spark plug caps.

15.Disconnect the following electrical components:

TMAP

Electronic Throttle Control

Taillight Harness

Engine Temp Sensor

Speed Sensor

CPS

Transmission Switch

Differential Relay (if equipped)

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16.Remove the three fasteners retaining the harness to the intake manifold

and two fasteners retaining the

harness by the transmission switch

17.Remove the three harness clamps on the intake manifold

. Move the main harness out of the way

towards the driver’s seat.

18.Disconnect the two fuel rail mounting bolts and move the fuel rail off to the driver’s side.

CAUTION

Be careful not to pinch or kink the fuel rail

19.Remove the four fasteners retaining the intake manifold to the engine

and the one retaining the bottom of the intake manifold to the transmission bracket

20.Remove the PVT outer cover.

21.Remove the belt and driven clutch.

22.Remove the drive clutch from the vehicle using the correct drive clutch puller (PN 2872085).

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CAUTION

Correct Drive Clutch Puller P/N 2872085

Using the incorrect puller may result in a damaged

crankshaft.

23.Remove seven bolts retaining the inner clutch cover.

24.Remove the positive and negative cables going to the starter.

25.Put a thin block of wood under the engine assembly to assist with engine mounting fastener removal.

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.

Engine Installation

1. Carefully install the engine in the frame.

2. Install the four bolts retaining the engine to the front engine mount. Torque bolts to specification.

Engine Mounting Bolts (front)

40 ft-lbs (54 Nm)

3. Install the Clutch Center Distance tool (PU-50658) onto the crankshaft and transmission input shaft to properly position the clutch center distance.

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4. Install the six engine-to-transmission mounting bolts. Torque bolts in sequence to specification.

Engine-to-Transmission Mounting Bolts

Step 1-2: 64 ft-lb (87 Nm)

Step 3: 5 ft-lb (7 Nm)

Step 4-7: 44 ft-lb (60 Nm)

5. Remove the thin block of wood under the engine assembly if you placed on there for engine removal.

6. Install the positive and negative cables going to the starter. Torque fasteners to specification.

Starter Cable Fasteners

30 in-lb (4 Nm)

7. Install the seven bolts retaining the inner clutch cover. Torque bolts to specification.

Inner Clutch Cover Fasteners

10 ft-lb (14 Nm)

8. Install the drive clutch on the vehicle. Torque mounting bolt to specification.

Drive Clutch Bolt

96 ft-lb (130 Nm)

9. Install the driven clutch and the belt. Torque bolt to specification.

Driven Clutch Bolt

38 ft-lb (52 Nm)

10.Install the PVT outer cover screws. Torque screws to specification.

Inner Clutch Cover Fasteners

54 in-lb (5 Nm)

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11.Install the four fasteners retaining the intake manifold to the engine

and the one to retain the bottom of

the intake manifold to the transmission bracket.

Intake Manifold Mounting Fasteners:

To Engine: 17 ft-lb (23 Nm)

Lower: 22 ft-lb (30 Nm)

12.Install the two fuel rail mounting fasteners. Torque fasteners to specification.

Fuel Rail Mounting Fasteners

7 ft-lb (10 Nm)

13.Route the harness and install the three harness clamps on the intake manifold

14.Install the three fasteners retaining the harness to the intake manifold

and two fasteners retaining the

harness by the transmission

switch.

Harness Mounting Bracket Screws:

35 in-lb (4 Nm)

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15.Connect the following electrical components:

TMAP

Electronic Throttle Control

Taillight Harness

Engine Temp Sensor

CPS

Transmission Switch

Speed Sensor

Differential Relay (if equipped)

16.Install the ignition coil. Connect the wiring leads and spark plug caps. Torque mounting bolts to specification.

Ignition Coil Mounting Bolts:

75 in-lb (9 Nm)

17.Install the 22 Torx screws retaining the cargo box panel. Torque screws to specification.

Cargo Box Screws:

8 ft-lb (11 Nm)

18.Install the two bolts mounting the air box to the frame bracket

and tighten the clamp on the air box duct

. Also tighten the PVT intake clamp

. Torque

fasteners to specification.

Duct Clamp:

35 in-lb (4 Nm)

Air Box Mounting Bolts:

8 ft-lb (11 Nm)

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19.Install the four screws mounting the engine and PVT intake vents. Torque screws to specification.

PVT and Engine Air Intake Screen Screws:

35 in-lb (4 Nm)

20.Install the six exhaust head pipe fasteners

and the

two springs retaining the pipe to the muffler

. Torque

screws to specification.

Exhaust Head Pipe Screws:

18 ft-lb (24 Nm)

21.Install the five bolts retaining the frame support bar above the engine. Torque Bolts to Specification.

Frame Support Bolts:

22 ft-lb (30 Nm)

22.Install the six plastic rivets retaining the engine divider panel

and install the clamp retaining the main

harness ECU leads

to the panel.

23.Install the nine screws for the air intake housing cover over the air box

. Torque fasteners to specification.

Intake Housing Cover Screws:

8 ft-lb (11 Nm)

24.Connect the harness plugs to the ECU and install the four screws mounting the ECU to the divider panel. Torque screws to specification.

ECU Mounting Screws:

24 in-lb (3 Nm)

25.Install the ECU cover panel and the seat.

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26.Fill the cooling system with coolant and bleed the system. See Chapter 3 – Cooling System Bleeding, page 3.15

27.Connect the battery. Torque fasteners to specification.

Battery Terminal Fasteners:

60 in-lb (7 Nm)

Engine Break-In

The break-in period consists of the first 25 hours of operation, or the time it takes to use 15 gallons (57 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

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.

Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

1. Fill fuel tank with unleaded fuel which has a minimum pump octane number of 87 = (R + M)/2.

2. Refer to Chapter 2 – Engine Oil Level, page 2.14. Check oil level indicated on dipstick. Add oil if necessary.

3. Drive slowly at first to gradually bring engine up to operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important bolt torques.

6. Change oil and oil filter after 25 hour break-in period.

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ENGINE DISASSEMBLY / INSPECTION - TOP END

Valve Cover Removal

NOTE: The valve cover can be removed with the engine installed in the chassis.

1. Remove the four valve cover shoulder bolts

and

isolators

using a T40 driver.

NOTE: Replace rubber isolators upon assembly.

2. Remove valve cover and valve cover seal. Replace isolators and valve cover seal

if oil leaks are

evident.

3. Remove the spark plugs

. Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber.

Camshaft Removal

NOTE: The camshafts can be removed with the engine installed in the chassis.

1. Rotate the engine so the PTO cylinder is at Top Dead Center (TDC) to relieve most of the valve spring pressure. The camshaft lobes should face out and the slots on the end of the camshafts should line up

2. Remove the hydraulic cam chain tensioner2from the cylinder. Use a new tensioner gasket upon assembly

ENGINE / COOLING SYSTEM

Polaris 2015 RZR 900 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual