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9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual
© Copyright Polaris Industries Inc.
FUEL TANK INSTALLATION
1. Carefully install the fuel tank assembly. Install the
inner tank bracket with the fuel tank to ensure the
bracket is inserted properly into the lower fuel tank
mount.
2. Reinstall the fuel tank bracket and fasteners.
3. Install the vent line onto the tank fitting.
4. Reinstall the block-off panel. Secure with plastic
rivets and torque screws to specification.
TORQUE
Block-off Panel Screws:
8 ft-lb (11 Nm)
5. Install the seat base frame and torque fasteners to
specification.
TORQUE
Seat Base Frame Fasteners:
8 ft-lb (11 Nm)
6. Install regulator and fuse box to the block-off panel.
Torque fasteners to specification.
TORQUE
Regulator / Fuse Box Fasteners:
5 ft-lb (7 Nm)
7. Install fuel tank strap screw. Torque screw to
specification.
TORQUE
Fuel Tank Strap Screw:
8 ft-lbs (11 Nm)
8. Install center console and secure the shifter boot to
the console.
9. Install seat belt mechanism. Torque bolt to
specification.
TORQUE
Seat Belt Mechanism Bolt:
40 ft-lbs (54 Nm)
10.Install right rocker panel and all body fasteners.
11. Connect the fuel line and fuel pump electrical
harness. Verify connections are secure.
12.On S 1000 models only, install the rubber fuel pump
cover.
13.On S 1000 models only, install the fuel pump close off
panel.
14.Install the battery and battery bracket. Torque
fasteners to specification.
TORQUE
Battery Bracket Fasteners:
8 ft-lb (11 Nm)
15.Install both seats and test the fuel pump by turning
the ignition key ON and listening for the fuel pump to
activate. Check fuel line fittings for leaks.
FUEL SYSTEM
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