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RZR S 1000 2016
Polaris RZR S 1000 2016 User Manual
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4
9926814
R08
-
2015-2016
RZR
900
2016
RZR
S
1000
Service
Manual
©
Copyright
Polaris
Industries
Inc.
4.1
1
FUEL
T
ANK
FUEL
T
ANK
ASSEMBL
Y
VIEW
q
PF
A
Nut
70
ft-lbs
(95
Nm)
t
Preliminary
Filter
w
Fuel
Sender
Float
Arm
y
Fuel
T
ank
V
ent
e
PF
A
Gasket
(*replace
if
removed)
u
Fuel
T
ank
Assembly
r
Fuel
Pump/Regulator
FUEL
SYSTEM
234
236
Table of Contents
Chapter 1 1 General Information
7
Table of Contents
7
Vehicle Identification
8
Model Number Designation (2015 +)
8
Vehicle Identification Number (Vin) Designation (2015+)
8
Vehicle and Engine Serial Number Location
9
Misc. Information
10
Publication Numbers
10
Replacement Keys
11
Special Tools
12
General Specifications
16
2015 Rzr 900 / Rzr 900 Eps Specifications
16
2015 Rzr 900 XC Specifications
18
2015 Rzr S 900 Specifications
20
Misc. Specifications and Charts
34
Master Torque Table
34
Conversion Table
37
Sae Tap / Drill Sizes
38
Metric Tap / Drill Sizes
38
Decimal Equivalents
39
Maintenance Chapter 2 Maintenance 2
41
Break-In Period
43
Maintenance
43
Maintenance Chart Key
43
Periodic Maintenance Chart
43
Periodic Maintenance Overview
43
Maintenance Intervals
44
Maintenance Quick Reference
46
Grease Lubrication Points
48
General Vehicle Inspection and Maintenance
49
Lubricants / Service Products
49
Pre-Ride / Daily Inspection
50
Shift Cable Inspection / Adjustment
50
Engine / Air Intake
51
Engine Air Filter Service
51
Intake Duct Inspection
51
Air Box / Filter Assembly View
52
Engine Oil Level
53
Engine Oil and Filter Change
54
Crankcase Breather Hose Inspection
55
Engine Cylinder Leak-Down Test
55
Valve Clearance Inspection
55
Coolant Level Inspection
58
Coolant Strength
58
Cooling System
58
Cooling System Overview
58
Cooling System Hose Inspection
59
Cooling System Pressure Test
59
Coolant Drain / Fill
60
Radiator Inspection / Cleaning
60
Fuel System
61
Fuel System Warning
61
Fuel Tank Vent Line
61
Fuel Lines
62
Fuel Pump / Fuel Filter
62
Throttle Pedal Inspection
62
Drive Clutch / Driven Clutch / Belt Service
63
Pvt Drying
63
Pvt Duct Cleaning
63
Pvt System
63
Drive Shaft Boot Inspection
64
Driveshaft / Wheel and Tire
64
Tire Inspection
64
Wheel and Hub Torque Table
64
Wheel Installation
64
Wheel Removal
64
Tire Pressure
65
Specification Chart
66
Transmission and Front Gearcase
66
Transmission Lubrication
66
Front Gearcase Lubrication
67
Steering Inspection
68
Steering System
68
Steering Wheel Free-Play
68
Tie Rod End / Wheel Bearing Inspection
68
Wheel Toe Adjustment
69
Wheel Toe Alignment Inspection
69
Spring Adjustment (Non-Fox)
71
Suspension System
71
Spring Adjustment (Fox)
72
Shock Compression Adjustment (Fox)
73
Brake Fluid Inspection
74
Brake Hose and Fitting Inspection
74
Brake Pad / Disc Inspection
74
Brake System
74
Battery Charging
75
Battery Maintenance
75
Battery off Season Storage
75
Electrical / Ignition System
75
Engine / Chassis Ground
76
Spark Plug Service
76
Chapter 3 Engine / Cooling System
79
Engine - General
83
General Information
83
Lubrication Specifications
83
Main Engine Components - Torque Specification and Sequence
84
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
85
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
86
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
87
Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
88
Exhaust Assembly View / Torque Values
89
Exhaust System
89
Engine Cooling System
90
Exhaust Removal / Installation
90
Cooling System Pressure Test
91
Cooling System Specifications
91
Radiator Cap Pressure Test
92
Radiator Removal / Installation
92
Thermostat Replacement
93
Cooling System Bleeding
94
Water Pump Removal
95
Water Pump Service
95
Water Pump Installation
99
Engine Oil Pressure Test
100
Engine Service
100
Lubrication Specifications
100
Engine Oil Flow Chart
101
Accessible Engine Components
102
Engine Mounts
102
Engine Removal
102
Top End Service
102
Engine Installation
106
Engine Break
111
Engine
112
Troubleshooting
112
Cooling System
113
900 Engine
114
Engine Specifications
114
Engine Specifications (900)
114
Camshaft Removal
116
Engine Disassembly / Inspection - Top End (900)
116
Valve Cover Removal
116
Camshaft / Camshaft Bore Inspection
118
Camshaft Sprocket Inspection
118
Cylinder Head Inspection
120
Cylinder Head Removal
120
Cylinder Head Warp Inspection
120
Cylinder Head Disassembly
121
Valve Inspection
122
Combustion Chamber Cleaning
123
Valve Seat Reconditioning
123
Engine Disassembly / Inspection - Lower End (900)
127
Stator Cover Removal / Inspection
127
Flywheel Removal
128
Water Pump Housing Removal
128
Starter One-Way Clutch Disassembly
129
Starter One-Way Clutch Assembly
130
Crankcase Disassembly
131
Balance Shaft Removal / Inspection
133
Crankshaft Removal / Inspection
134
Crankcase Inspection
137
Cylinder / Piston Removal
138
Cylinder Inspection
138
Piston Disassembly / Inspection
139
Piston Ring Removal
140
Piston Ring Installed Gap
141
Piston Ring to Groove Clearance Inspection
141
Connecting Rod Inspection
142
Piston-To-Cylinder Clearance
142
Bearing Selection Identification Letters and Numbers
144
Engine Assembly - Lower End (900)
144
Connecting Rod Bearing Selection
145
Crankshaft Main Bearing Selection
145
Piston Ring Installation
146
Upper Crankcase Preparation
146
Piston / Connecting Rod Assembly
147
Cylinder / Piston Installation
148
Crankshaft Installation
149
Balance Shaft Installation
150
Lower Crankcase Preparation
151
Crankcase Assembly
152
Flywheel Installation
156
Stator Cover Installation
156
Cylinder Head Assembly
157
Engine Assembly - Top End (900)
157
Valve Sealing Test
158
Cylinder Head Installation
159
Camshaft Installation / Timing
160
Camshaft Timing - Quick Reference
164
Valve Clearance Adjustment
165
Valve Lash - Tappet Selection
168
Valve Cover Installation
169
Engine Specifications (1000)
170
Camshaft Removal
172
Engine Disassembly / Inspection - Top End (1000)
172
Valve Cover Removal
172
Camshaft Sprocket Inspection
174
Camshaft / Camshaft Bore Inspection (1000)
175
Cylinder Head Removal
176
Cylinder Head Disassembly
177
Cylinder Head Warp Inspection
177
Valve Inspection
178
Combustion Chamber Cleaning
179
Valve Sealing Test
180
Valve Seat Reconditioning (1000)
180
Engine Disassembly / Inspection - Lower End (1000)
183
Stator Cover Removal / Inspection
183
Water Pump Housing Removal
184
Flywheel Removal
185
Starter One-Way Clutch Disassembly
186
Crankcase Disassembly / Inspection
187
Balance Shaft Removal / Inspection
189
Crankshaft Removal / Inspection
190
Crankcase Inspection
192
Cylinder Inspection
193
Cylinder / Piston Removal
194
Piston Disassembly / Inspection (1000)
195
Piston Ring Removal
196
Piston Ring to Groove Clearance Inspection
196
Connecting Rod Inspection
197
Piston Ring Installed Gap (1000)
197
Piston-To-Cylinder Clearance
197
Bearing Selection Identification Letters and Numbers
199
Engine Assembly - Lower End (1000)
199
Connecting Rod Bearing Selection
200
Crankshaft Main Bearing Selection
200
Piston Ring Installation
201
Upper Crankcase Preparation
201
Piston / Connecting Rod Assembly
203
Cylinder / Piston Installation
204
Crankshaft Installation
205
Balance Shaft Installation
207
Lower Crankcase Preparation
207
Crankcase Assembly
208
Starter One-Way Clutch Assembly
211
Flywheel Installation
212
Stator Cover Installation
212
Cylinder Head Assembly
213
Engine Assembly - Top End (1000)
213
Cylinder Head Installation
214
Camshaft Installation / Timing
215
Camshaft Timing - Quick Reference
219
Valve Clearance Adjustment
220
Valve Lash - Tappet Selection
222
Valve Cover Installation
223
Chapter 4 Fuel System
225
General Information
227
Special Tools
227
Torque Specifications
227
Efi Operation Overview
228
Efi Overview
228
Initial Priming / Starting Procedure
228
Principal Components
228
Ecu Replacement
229
Ecu Service
229
Electronic Control Unit (Ecu)
229
Operation Overview
229
Etc Learn Procedure
230
Fuel Injector Troubleshooting
231
Fuel Injectors
231
Operation Overview
231
Fuel Injector Replacement
232
Fuel Injector Test
232
Fuel Tank
235
Fuel Tank Assembly View
235
Fuel Line Removal / Installation
236
Fuel Tank Removal
236
Fuel Tank Installation
238
Fuel Pump
240
Fuel Pump Test
240
Fuel Sender Test
240
Operation Overview
240
Fuel Pump Replacement
242
Operation Overview
245
Temperature and Manifold Absolute Pressure Sensor (T-Map)
245
Tmap Test / Replacement
245
Cps Test
246
Crankshaft Position Sensor (Cps)
246
Operation Overview
246
Cps Replacement
247
Electronic Throttle Control (Etc) / Throttle Body
248
Etc Replacement
248
Etc Test
248
Throttle Body Operation Overview
248
Etc Learn Procedure
249
Operation Overview
250
Pedal Position Sensor (Pps)
250
Pps Location
250
Pps Replacement
250
Pps Test
250
Oxygen Sensor (Rzr S 1000)
252
Oxygen Sensor Information
252
Oxygen Sensor Replacement
252
Data Display Definitions
254
Efi Diagnostics
254
Trouble Code Display (Dtc)
257
Efi Troubleshooting
264
Digital Wrench® Diagnostic Software Overview
265
Polaris Digital Wrench
265
Special Tools (Digital Wrench)
265
Digital Wrench Software Version and Update
266
Digital Wrench® Updates
266
Digital Wrench® - Diagnostic Connector
267
Digital Wrench® Communication Errors
267
Guided Diagnostics
267
Digital Wrench® Serial Number Location
268
Digital Wrench® Feature Map
269
Ecu Replacement
270
Ecu Reprogramming (Reflash)
270
Etc Learn Procedure
270
Polaris Mobile Digital Wrench (Pmdw)
273
Chapter 5 Pvt System
275
General Information
277
Special Tools
277
Torque Specifications
277
Clutch Charts
278
Drive Clutch Operation
279
General Operation
279
Pvt Break-In (Drive Belt / Clutches)
279
Pvt System Overview
279
Driven Clutch Operation
280
Maintenance / Inspection
280
Pvt Covers and Ducting Components
281
Pvt System Service
281
Rzr 4 900 / S 1000 Pvt Covers and Ducting Components
282
Pvt Disassembly
283
Pvt Assembly
284
Belt Removal (Ebs)
285
Drive Belt
285
Belt Removal (Non-Ebs)
286
Belt Inspection
287
Belt Installation (Ebs)
287
Belt Installation (Non-Ebs)
287
Pvt Break-In (Drive Belt / Clutches)
288
Drive Clutch Assembly View
289
Drive Clutch Service
289
Drive Clutch Disassembly
290
Bearing Inspection
291
Button to Tower Clearance
292
Shift Weight Inspection
292
Roller, Pin and Thrust Washer Inspection
293
Spider Removal
293
Drive Clutch Inspection
294
Bushing Service
295
Moveable Sheave Bushing Inspection
295
Drive Clutch Assembly
297
Driven Clutch Disassembly
300
Driven Clutch Service (Ebs)
300
Driven Clutch Slider Inspection
300
Driven Clutch Bushing Service
302
Clutch Bushing Removal
303
Clutch Bushing Installation
304
Driven Clutch Assembly
305
Chapter 6 Transmission
317
General Information
318
Transmission Mounting View
319
Shift Cable Inspection
320
Shift Lever / Cable
320
Shift Lever Installation
320
Shift Lever Removal
320
Shift Cable Adjustment
321
Transmission Removal
322
Transmission Service
322
Transmission Installation
326
Transmission Disassembly
330
Differential Operation
334
Planetary Differential Disassembly (Turf Mode Models Only)
337
Planetary Differential Bushing Replacement (Turf Mode Models Only)
338
Planetary Differential Assembly (Turf Mode Models Only)
340
Gear / Shaft / Bearing Inspection
342
Transmission Assembly / Snorkel Gear Backlash Procedure
343
Transmission Assembly View (no Turf Mode)
349
Transmission Assembly View (Turf Mode Models)
351
Shifting Difficulty
353
Troubleshooting
353
Chapter 7 Final Drive
355
Bearing Carrier
357
Front Bearing Carrier Removal / Inspection
357
Front Bearing Carrier Installation
358
Front Bearing Replacement
358
Rear Bearing Carrier Removal / Inspection
360
Rear Carrier Bearing Replacement
361
Rear Bearing Carrier Installation
362
Drive Shaft
364
Front Half Shaft Removal
364
Front Half Shaft Installation
365
Rear Half Shaft Removal
366
Rear Half Shaft Installation
367
Drive Shaft / CV Joint Handling Tips
368
Outer CV Joint / Boot Replacement
368
Inner Plunging Joint / Boot Replacement
371
Prop Shaft Removal
373
Prop Shaft Installation
374
Rear Prop Shaft Removal (4 Seater)
375
Rear Prop Shaft Installation (4 Seater)
376
All Wheel Drive Operation
377
Front Gearcase / Centralized Hilliard
377
Front Gearcase Assembly View
377
Awd Diagnosis
378
Front Gearcase Disassembly / Inspection
379
Front Gearcase Removal
379
Front Gearcase Assembly
383
Front Gearcase Installation
385
Front Hub Assembly View
387
Wheel Hubs
387
Rear Hub Assembly View
388
Chapter 8 Steering / Suspension
389
General Information
390
Special Tools
390
Torque Specifications
390
Steering - General
391
Steering Rack Replacement
391
Steering System
391
Tie Rod Replacement
391
Steering Assembly (Non-Eps)
393
Steering Assembly View
393
Steering Shaft Bearing Replacement
394
Steering Shaft Removal (Non-Eps)
394
Steering Wheel Removal (Non-Eps)
394
Steering Assembly (Eps)
396
Steering Assembly View (Eps)
396
Upper Steering Shaft Removal
397
Power Steering Unit Removal
398
Steering Wheel Removal (Eps)
398
Lower Steering Shaft Installation
400
Lower Steering Shaft Removal
400
Power Steering Unit Installation
401
Upper Steering Shaft Installation
402
Front Suspension
403
Front Suspension Assembly View
403
Front Control Arm Replacement
404
Ball Joint Installation
406
Ball Joint Removal
406
Front Stabilizer Bar Replacement (50
407
Rear Control Arm Removal
408
Rear Suspension
408
Rear Control Arm Installation
409
Rear Stabilizer Bar Replacement
409
Front Shock Assembly View
411
Rear Shock Assembly View
411
Shocks / Springs
411
Shock / Spring Replacement
412
Shock Removal / Installation
412
Shock Service
413
Shock Specifications (Fox)
413
Fox Shock Disassembly
415
Fox Shock Assembly
424
Chapter 9 Brake System
433
General Information
435
General Specifications
435
Special Tools
435
Torque Specifications
435
Brake System Service Notes
436
Hydraulic Brake System Operation
436
Rzr 900 / 1000
437
Master Cylinder
438
Master Cylinder Installation
438
Master Cylinder Removal
438
Brake Bleeding / Fluid Change
440
Brake Pedal
440
Brake Pedal Installation
440
Brake Pedal Lever Removal
440
Parking Brake (Int
442
Parking Brake Assembly View
442
Parking Brake Cable Adjustment
443
Parking Brake Inspection
443
Parking Brake Caliper
445
Parking Brake Disc
448
Front Brakes
449
Front Caliper / Pad Removal
449
Front Caliper Assembly View
450
Front Caliper Disassembly
451
Front Caliper Assembly
452
Front Caliper Inspection
452
Front Brake Disc Inspection
453
Front Pad Inspection
453
Front Brake Disc Runout
454
Front Disc Replacement
454
Front Caliper / Pad Installation
455
Brake Burnishing Procedure
456
Rear Brakes
457
Rear Caliper / Brake Pad Removal
457
Rear Caliper Assembly View
458
Rear Caliper Disassembly
459
Rear Caliper Inspection
459
Rear Brake Pad Inspection
460
Rear Caliper Assembly
460
Rear Disc Inspection
461
Rear Disc Replacement
461
Chapter 10 Body / Frame
465
General Information
466
Special Tools
466
Torque Specifications
466
Decal Replacement
467
Body Assembly Views
468
Cab Frame Assembly
468
Cab Frame Assembly - 4 900
469
Doors
470
Doors - 4 900
471
Dash / Instruments
472
Hood / Front Body
473
Chassis / Main Frame
474
Chassis / Main Frame - 4 900
475
Seats
476
Seats - Rear
477
Floor / Rocker Panels
478
Floor / Rocker Panels - 4 900
479
Rear Cargo Box / Fenders
480
Rear Bumper
481
Body Component Removal
482
Front Bumper Removal
482
Rear Bumper Removal
482
Seat Removal
482
Engine Service Panel
483
Hood Removal
483
Lower Dash Removal
483
Upper Dash Removal
483
Cargo Box Removal
484
Front Fender / Body Removal
484
Rear Fender / Fender Flair Removal
484
Rocker Panel / Console / Floor
485
Rocker Panels / Rear Console / Floor - 4
485
Door Adjustment
489
Door Panel / Latch Replacement
489
Doors
489
Chapter 11 Electrical
491
General Information
493
Service Notes
493
Special Tools
493
Torque Specifications
493
Under Dash Components
493
Instrument Cluster
494
Overview
494
Information Display Area
496
Diagnostic Mode
499
Brake Light Switch
501
Headlamp Switch
501
Switches
501
Awd / 2Wd Switch (no Turf Mode)
502
Ignition (Key) Switch
502
Awd/2Wd/Turf Switch (Models with Turf)
503
Transmission (Gear Position) Switch
503
Seat Belt Switch
504
Charging System
505
Stator
505
Voltage Regulator
505
Charging System "Break Even" Test
506
Charging System Stator (Alternator) Tests
506
Charging System Testing Flow Chart
508
Battery
509
Battery Installation
509
Battery Removal
509
Current Draw - Key off
510
Load Test
510
Ocv - Open Circuit Voltage Test
510
Battery Conductance Analyzer
511
Headlights
512
Lighting System
512
Dash Led Light
513
Taillights
513
Coolant Temperature Sensor
514
Cooling System
514
Radiator Fan
515
Starter Installation
516
Starter Removal
516
Starter Troubleshooting
516
Starting System
516
Voltage Drop Test
516
Starter Solenoid
517
Electronic Power Steering
518
Eps Operation
518
Eps Torque Offset Procedure
518
Eps System Diagnosis
519
Fuse Box
520
Fuses / Relays
520
Relay Circuits
521
Fuse / Circuit Breaker Circuits
522
12V Receptacle
523
Awd Coil
523
Misc. Electrical
523
Speed Sensor
523
Terminal Block
523
Coil Testing
524
Ignition Coil
524
Ignition Coil / Plug Wire Replacement
524
Operation Overview
524
Chassis Ground Point
525
Diagnostic Plug
525
Can System
526
Can System Overview
526
Can System Testing
526
Awd Break-Out Diagram
527
Break-Out Diagrams
527
Cooling System Break-Out Diagram
528
Eps Break-Out Diagram
529
Lighting Break-Out Diagram
530
Starting System Break-Out Diagram
531
Differential Circuit Break-Out Diagram
532
Vehicle Speed Sensor Break-Out Diagram
533
Unswitched Chassis Power Break-Out Diagram
534
Key on Battery Power Break-Out Diagram
535
4
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Polaris RZR S 1000 2016 Specifications
General
Brand
Polaris
Model
RZR S 1000 2016
Category
Offroad Vehicle
Language
English
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