Polaris RZR 900 2016 Service Manual

3.92
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
1000 ENGINE
ENGINE SPECIFICATIONS (1000)
ENGINE SPECIFICATIONS (1000)
CAMSHAFT / CYLINDER HEAD / CYLINDER
ITEM
STANDARD SERVICE LIMIT
Camshaft
Cam Lobe Height - Intake 1.5390 - 1.5429" (39.09 - 39.19 mm) 1.5370" (39.04 mm)
Cam Lobe Height - Exhaust 1.5142 - 1.5181" (38.46 - 38.56 mm) 1.5122" (38.41 mm)
Camshaft Journal O.D. - All
.9036 - .9055" (22.954 - 22.999 mm) .9033" (22.944 mm)
Camshaft Carrier Bore I.D. - All
.9055 - .9063" (23.000 - 23.021 mm) .9072" (23.044 mm)
Camshaft Oil Clearance
.0000 - .0026" (0.001 - 0.067 mm) .0039" (0.1 mm)
Camshaft End Play .0040 - .0100" (0.101 - 0.254 mm) .0157" (0.4 mm)
Cylinder
Cylinder - Surface Warp Limit (cylinder head
surface)
-
.002″ (0.05 mm)
Cylinder Bore - Standard 3.6614 ± .0003" (93 mm ± 0.008 mm)
-
Cylinder Out of Round Limit
-
.001″ (0.025 mm)
Cylinder Taper Limit
-
.001″ (0.025 mm)
Cylinder to Piston Clearance .0009 - .0019" (0.025 - 0.050 mm)
-
Cylinder
Head
Cylinder Head - Surface Warp Limit
-
.0039″ (0.1 mm)
Cylinder Head - Standard Height 4.717 ± .0019" (119.82 ± 0.05 mm)
-
Valve
Valve Lash (Cold) - Intake .006 ± .002" (0.15 ± 0.05 mm)
-
Valve Lash (Cold) - Exhaust .010 ± .002" (0.25 ± 0.05 mm)
-
Valve Stem Diameter - Intake
.2155 - .2161" (5.475 - 5.490 mm)
-
Valve Stem Diameter - Exhaust
.2147 - .2153" (5.455 - 5.470 mm)
-
Valve Stem Oil Clearance - Intake
.0003 - .0015" (0.010 - 0.040 mm)
-
Valve Stem Oil Clearance - Exhaust
.0011 - .0023" (0.030 - 0.060 mm)
-
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
-
Valve Stem Overall Length - Exhaust 3.8023" (96.58 mm)
-
Valve
Guide
Valve Guide Inner Diameter
.2165 - .2171" (5.500 - 5.515 mm)
-
Valve Seat
Valve Seat - Contacting Width - Intake .0393 ± .0039" (1.0 ± 0.10 mm) .0551" (1.4 mm)
Valve Seat - Contacting Width - Exhaust .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm)
Valve Seat Angles
30.0° ± 1.5°
45.0° ± 0.5°
60.0° ± 1.5°
-
ENGINE / COOLING SYSTEM

Polaris RZR 900 2016 Specifications

General

Brand	Polaris
Model	RZR 900 2016
Category	Offroad Vehicle
Language	English

Summary

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION

Describes VIN and model number designation.

GENERAL SPECIFICATIONS

CHAPTER 2 MAINTENANCE

PERIODIC MAINTENANCE CHART

Outlines inspection, adjustment, and lubrication schedule.

COOLING SYSTEM

Covers system overview, testing, and fluid procedures.

FUEL SYSTEM

PVT SYSTEM

Outlines service for clutches, belt, and ducting.

TRANSMISSION AND FRONT GEARCASE

SUSPENSION SYSTEM

BRAKE SYSTEM

Covers fluid, pad/disc, and hose/fitting inspection.

ELECTRICAL / IGNITION SYSTEM

CHAPTER 3 ENGINE / COOLING SYSTEM

ENGINE - GENERAL

Covers general info and lubrication specs.

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE

Details torque values for key components.

ENGINE COOLING SYSTEM

Includes specifications, testing, and bleeding.

ENGINE SERVICE

ENGINE REMOVAL

Instructions for removing the engine from the vehicle.

ENGINE BREAK-IN

Outlines the procedure for breaking in a new engine.

CHAPTER 4 FUEL SYSTEM

EFI OVERVIEW

Explains EFI system components and operation.

ELECTRONIC CONTROL UNIT (ECU)

Details ECU operation, service, and replacement.

FUEL INJECTORS

Covers operation, testing, and replacement.

FUEL TANK

FUEL PUMP

Explains operation, testing, and sender test.

FUEL PUMP REPLACEMENT

Procedure for replacing the fuel pump assembly.

CRANKSHAFT POSITION SENSOR (CPS)

ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE BODY

Explains operation, testing, replacement, and learn procedure.

EFI DIAGNOSTICS

Data display definitions for EFI diagnosis.

TROUBLE CODE DISPLAY (DTC)

How to display and interpret diagnostic trouble codes.

POLARIS DIGITAL WRENCH

Diagnostic software overview and special tools.

CHAPTER 5 PVT SYSTEM

PVT SYSTEM OVERVIEW

Explains general operation and break-in.

PVT DISASSEMBLY

PVT ASSEMBLY

DRIVE BELT

Belt removal and installation.

DRIVE CLUTCH SERVICE

Assembly view and disassembly.

DRIVEN CLUTCH DISASSEMBLY

DRIVEN CLUTCH ASSEMBLY

CHAPTER 6 TRANSMISSION

SHIFT LEVER / CABLE

TRANSMISSION SERVICE

Procedure for transmission removal.

TRANSMISSION INSTALLATION

Procedure for installing transmission.

TRANSMISSION DISASSEMBLY

Steps for disassembling transmission.

GEAR / SHAFT / BEARING INSPECTION

TROUBLESHOOTING

Diagnosing shifting difficulties.

CHAPTER 7 FINAL DRIVE

BEARING CARRIER

Front bearing carrier removal and inspection.

REAR BEARING CARRIER REMOVAL / INSPECTION

Removing and inspecting rear bearing carrier.

DRIVE SHAFT

FRONT GEARCASE / CENTRALIZED HILLIARD

AWD DIAGNOSIS

Diagnosing AWD system issues.

CHAPTER 8 STEERING / SUSPENSION

STEERING SYSTEM

General info, rack, tie rod replacement.

STEERING ASSEMBLY (NON-EPS)

STEERING ASSEMBLY (EPS)

POWER STEERING UNIT REMOVAL

Removing power steering unit.

FRONT SUSPENSION

FRONT CONTROL ARM REPLACEMENT

Replacing front control arms.

REAR SUSPENSION

SHOCK REMOVAL / INSTALLATION

SHOCK SERVICE

Shock specifications and disassembly/assembly.

FOX SHOCK DISASSEMBLY

Disassembling FOX shocks.

CHAPTER 9 BRAKE SYSTEM

BRAKE SYSTEM SERVICE NOTES

Important notes for brake service.

HYDRAULIC BRAKE SYSTEM OPERATION

MASTER CYLINDER

BRAKE BLEEDING / FLUID CHANGE

Procedures for bleeding brakes and changing fluid.

PARKING BRAKE (INT'L)

FRONT BRAKES

FRONT DISC REPLACEMENT

REAR BRAKES

REAR CALIPER DISASSEMBLY

REAR DISC REPLACEMENT

TROUBLESHOOTING

Common brake system issues like noise, poor performance, and locking.

CHAPTER 10 BODY / FRAME

DOORS

HOOD / FRONT BODY

CHASSIS / MAIN FRAME

BODY COMPONENT REMOVAL

FRONT FENDER / BODY REMOVAL

CHAPTER 11 ELECTRICAL

GENERAL INFORMATION

INSTRUMENT CLUSTER

SWITCHES

CHARGING SYSTEM

BATTERY

LIGHTING SYSTEM

COOLING SYSTEM

STARTING SYSTEM

ELECTRONIC POWER STEERING

EPS operation, diagnosis, software.

FUSES / RELAYS

CAN SYSTEM