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RZR S 1000 2019
Polaris RZR S 1000 2019 User Manual
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10.24
9930588
R02
-
2017-2020
RZR
900
900/S
900/S4
1000/S
1000/S4
Service
Manual
©
Copyright
Polaris
Industries
Inc.
REAR
CALIPER
ASSEMBL
Y
VIEW
q
Socket
Set
Screw
t
Pistons
w
Bleeder
Screw
48
in-lb
(5
Nm)
y
Boots
e
Caliper
Assembly
u
Caliper
Mount
r
Square
O-Rings
i
Brake
Pad
BRAKE
SYSTEM
523
525
Table of Contents
Chapter 1 1 General Information
9
Table of Contents
9
Vehicle Identification
11
Model Number Designation (2015 +)
11
Vehicle Identification Number (Vin) Designation (2015+)
11
Vehicle and Engine Serial Number Location
12
Reference Information
13
Publication Numbers
13
Replacement Keys
14
Special Tools
15
Master Torque Table
19
General Specifications
22
2017 Rzr 900 Specifications
22
Rzr 900 Clutch Chart
23
2017 Rzr 900 Eps Specifications
24
Rzr 900 Clutch Chart
25
2017 Rzr 900 XC Specifications
26
Maintenance Chapter 2 Maintenance 2
75
Break-In Period
77
Maintenance
77
Periodic Maintenance Chart
77
Periodic Maintenance Overview
77
Pre-Ride Inspection
78
Maintenance Intervals
79
Maintenance Quick Reference
99
Grease Lubrication Points
101
General Vehicle Inspection and Maintenance
102
Lubricants / Service Products
102
Shift Cable Inspection / Adjustment
103
Engine / Air Intake
104
Engine Air Filter Service
104
Intake Duct Inspection
104
Air Box / Filter Assembly View
105
Engine Oil Level
106
Engine Oil and Filter Change
107
Crankcase Breather Hose Inspection
108
Engine Cylinder Leak-Down Test
108
Valve Clearance Inspection
108
Cam Chain Tensioner Inspection
110
Coolant Level Inspection
112
Coolant Strength
112
Cooling System
112
Cooling System Overview
112
Cooling System Hose Inspection
113
Cooling System Pressure Test
113
Coolant Drain / Fill
114
Radiator Inspection / Cleaning
114
Fuel System
115
Fuel System Warning
115
Fuel Tank Vent Line
115
Fuel Lines
116
Fuel Pump / Fuel Filter
116
Throttle Pedal Inspection
116
Drive Clutch / Driven Clutch / Belt Service
117
Pvt Drying
117
Pvt Duct Cleaning
117
Pvt System
117
Drive Shaft Boot Inspection
118
Driveshaft / Wheel and Tire
118
Tire Inspection
118
Wheel and Hub Torque Table
118
Wheel Installation
118
Wheel Removal
118
Tire Pressure
119
Specification Chart
120
Transmission and Front Gearcase
120
Transmission Lubrication
120
Front Gearcase Lubrication
121
Steering Inspection
123
Steering System
123
Steering Wheel Free-Play
123
Tie Rod End / Wheel Bearing Inspection
123
Wheel Toe Adjustment
124
Wheel Toe Alignment Inspection
124
Spring Adjustment (Non-Fox)
126
Suspension System
126
Spring Adjustment (Fox)
127
Shock Compression Adjustment (Fox)
128
Shock Compression Adjustment (Walker Evans)
129
Spring Adjustment (Walker Evans)
129
Brake Fluid Inspection
131
Brake Hose and Fitting Inspection
131
Brake Pad / Disc Inspection
131
Brake System
131
Battery Charging
132
Battery Maintenance
132
Battery off Season Storage
132
Electrical / Ignition System
132
Engine / Chassis Ground
133
Spark Plug Service
133
Chapter 3 Engine / Cooling System
135
Engine - General
139
Lubrication Specifications
139
Main Engine Components - Torque Specification and Sequence
140
Exhaust Assembly View / Torque Values
141
Exhaust System
141
Exhaust Removal / Installation
142
Cooling System Pressure Test
143
Cooling System Specifications
143
Engine Cooling System
143
Radiator Cap Pressure Test
144
Radiator Removal / Installation
144
Thermostat Replacement
145
Cooling System Bleeding
146
Water Pump Removal
147
Water Pump Service
147
Water Pump Installation
150
Engine Oil Pressure Test
152
Engine Service
152
Lubrication Specifications
152
Engine Oil Flow Chart
153
Accessible Engine Components
154
Engine Mounts
154
Top End Service
154
Crankshaft Pto Seal Replacement
155
Engine Removal
157
Engine Installation
161
Engine Break
165
Engine
166
Troubleshooting
166
Cooling System
167
900 Engine
168
Engine Specifications
168
Engine Specifications (900)
168
Camshaft Removal
170
Engine Disassembly / Inspection - Top End (900)
170
Valve Cover Removal
170
Camshaft / Camshaft Bore Inspection
172
Camshaft Sprocket Inspection
172
Cylinder Head Inspection
174
Cylinder Head Removal
174
Cylinder Head Warp Inspection
174
Valve Inspection
176
Combustion Chamber Cleaning
177
Valve Seat Reconditioning
177
Engine Disassembly / Inspection - Lower End
181
Flywheel Removal
182
Starter One-Way Clutch Disassembly
183
Starter One-Way Clutch Assembly
184
Crankcase Disassembly
185
Balance Shaft Removal / Inspection
187
Crankshaft Removal / Inspection
188
Crankcase Inspection
191
Cylinder / Piston Removal
192
Cylinder Inspection
192
Piston Disassembly / Inspection
193
Piston Ring Removal
194
Piston Ring Installed Gap
195
Piston Ring to Groove Clearance Inspection
195
Piston-To-Cylinder Clearance
195
Connecting Rod Inspection
196
Bearing Selection Identification Letters and Numbers
198
Engine Assembly - Lower End (900)
198
Connecting Rod Bearing Selection
199
Crankshaft Main Bearing Selection
199
Piston Ring Installation
200
Upper Crankcase Preparation
200
Piston / Connecting Rod Assembly
201
Cylinder / Piston Installation
202
Crankshaft Installation
203
Balance Shaft Installation
204
Lower Crankcase Preparation
205
Crankcase Assembly
206
Flywheel Installation
210
Stator Cover Installation
210
Engine Specifications (1000)
223
Camshaft Removal
225
Engine Disassembly / Inspection - Top End (1000)
225
Valve Cover Removal
225
Camshaft Sprocket Inspection
227
Camshaft / Camshaft Bore Inspection (1000)
228
Cylinder Head Removal
229
Cylinder Head Disassembly
230
Cylinder Head Warp Inspection
230
Valve Inspection
231
Combustion Chamber Cleaning
232
Valve Sealing Test
233
Valve Seat Reconditioning (1000)
233
Engine Disassembly / Inspection - Lower End (1000)
236
Stator Cover Removal / Inspection
236
Water Pump Housing Removal
237
Flywheel Removal
238
Starter One-Way Clutch Disassembly
239
Crankcase Disassembly / Inspection
240
Balance Shaft Removal / Inspection
242
Crankshaft Removal / Inspection
243
Crankcase Inspection
245
Cylinder Inspection
246
Cylinder / Piston Removal
247
Piston Disassembly / Inspection (1000)
248
Piston Ring Removal
249
Piston Ring to Groove Clearance Inspection
249
Connecting Rod Inspection
250
Piston Ring Installed Gap (1000)
250
Piston-To-Cylinder Clearance
250
Bearing Selection Identification Letters and Numbers
252
Engine Assembly - Lower End (1000)
252
Connecting Rod Bearing Selection
253
Crankshaft Main Bearing Selection
253
Piston Ring Installation
254
Upper Crankcase Preparation
254
Piston / Connecting Rod Assembly
256
Cylinder / Piston Installation
257
Crankshaft Installation
258
Balance Shaft Installation
260
Lower Crankcase Preparation
260
Crankcase Assembly
261
Starter One-Way Clutch Assembly
264
Flywheel Installation
265
Stator Cover Installation
265
Cylinder Head Assembly
266
Engine Assembly - Top End (1000)
266
Camshaft Installation / Timing
268
Camshaft Timing - Quick Reference
272
Valve Clearance Adjustment
273
Valve Lash - Tappet Selection
275
Valve Cover Installation
276
Chapter 4 Engine Electrical
277
Ecu Replacement
278
Ecu Service
278
Electronic Control Unit (Ecu)
278
Operation Overview
278
Etc Learn Procedure
279
Operation Overview
280
Temperature and Manifold Absolute Pressure Sensor (T-Map)
280
Tmap Test / Replacement
280
Cps Test
281
Crankshaft Position Sensor (Cps)
281
Operation Overview
281
Cps Replacement
282
Electronic Throttle Control (Etc) / Throttle Body
283
Etc Replacement
283
Etc Test
283
Throttle Body Operation Overview
283
Etc Learn Procedure
284
Operation Overview
285
Pedal Position Sensor (Pps)
285
Pps Location
285
Pps Replacement
285
Pps Test
285
Oxygen Sensor (Rzr S 1000)
287
Oxygen Sensor Information
287
Oxygen Sensor Replacement
287
Digital Wrench® Diagnostic Software Overview
288
Polaris Digital Wrench
288
Special Tools (Digital Wrench)
288
Digital Wrench Software Version and Update
289
Digital Wrench® Updates
289
Digital Wrench® - Diagnostic Connector
290
Digital Wrench® Communication Errors
290
Guided Diagnostics
290
Digital Wrench® Serial Number Location
291
Digital Wrench® Feature Map
292
Ecu Replacement
293
Ecu Reprogramming (Reflash)
293
Etc Learn Procedure
293
Polaris Mobile Digital Wrench (Pmdw)
296
Chapter 5 Fuel System
297
Special Tools
298
Efi Operation Overview
299
Efi Overview
299
Initial Priming / Starting Procedure
299
Principal Components
299
Fuel Injector O-Rings
300
Fuel Injectors
300
Operation Overview
300
Fuel Injector Test
301
Fuel Injector Troubleshooting
301
Fuel Injector Replacement
302
Fuel Lines
305
Fuel Vent Line Routing
305
Fuel Vent Line Routing (Evap Models)
307
Fuel Supply Line Routing
309
Fuel Supply Line Routing (Evap Models)
311
Vent Line Termination Fitting
313
Fuel Tank / Pump
314
Fuel Tank Assembly View
314
Fuel Line Removal / Installation
315
Fuel Tank Removal
315
Fuel Tank Installation
318
Fuel Pump
319
Fuel Sender Test
319
Operation Overview
319
Fuel Pump Test
320
Fuel Pump Replacement
321
Data Display Definitions
325
Efi Diagnostics
325
Cylinder Misfire Detection
328
Misfire Detection (S 1000 Only)
328
Trouble Code Display (Dtc)
329
Efi Troubleshooting
336
Chapter 6 Pvt System
337
Clutch Charts
339
Rzr 900 Clutch Chart
339
Rzr 900 XC Clutch Chart
339
Rzr S 1000 Clutch Chart
339
Rzr S 900 Clutch Chart
339
Rzr S4 1000 Clutch Chart
339
Special Tools
339
Drive Clutch Operation
340
General Operation
340
Pvt Break-In (Drive Belt / Clutches)
340
Pvt System Overview
340
Driven Clutch Operation
341
Maintenance / Inspection
341
Pvt Covers and Ducting Components
342
Pvt System Service
342
Rzr S 1000 / S4 1000 Pvt Covers and Ducting Components
343
Pvt Disassembly
344
Pvt Assembly
345
Belt Removal (Ebs)
346
Belt Removal (Non-Ebs)
346
Drive Belt
346
Belt Inspection
347
Belt Installation (Ebs)
347
Belt Installation (Non-Ebs)
348
Pvt Break-In (Drive Belt / Clutches)
348
Drive Clutch Assembly View
349
Drive Clutch Service
349
Drive Clutch Disassembly
350
Bearing Inspection
351
Button to Tower Clearance
352
Shift Weight Inspection
352
Roller, Pin and Thrust Washer Inspection
353
Spider Removal
353
Drive Clutch Inspection
354
Bushing Service
355
Moveable Sheave Bushing Inspection
355
Drive Clutch Assembly
358
Driven Clutch Assembly View
360
Driven Clutch Service (Ebs)
360
Driven Clutch Slider Inspection
361
Driven Clutch Disassembly
366
Driven Clutch Assembly
367
Pvt Troubleshooting
369
Troubleshooting
369
Pvt Overheating / Diagnosis
371
Chapter 7 Transmission
373
Lubrication Specifications
374
Special Tools
374
Transmission Mounting View
375
Shift Cable Inspection
376
Shift Lever / Cable
376
Shift Lever Installation
376
Shift Lever Removal
376
Shift Cable Adjustment
377
Transmission Removal
378
Transmission Service
378
Transmission Installation
382
Transmission Disassembly
386
Differential Operation
390
Planetary Differential Disassembly (Turf Mode Models Only)
393
Planetary Differential Bushing Replacement (Turf Mode Models Only)
394
Planetary Differential Assembly (Turf Mode Models Only)
396
Gear / Shaft / Bearing Inspection
398
Transmission Assembly / Snorkel Gear Backlash Procedure
399
Shifting Difficulty
405
Troubleshooting
405
Chapter 8 Final Drive
407
Special Tools
408
Bearing Carrier
409
Front Bearing Carrier Removal / Inspection
409
Front Bearing Replacement
410
Front Bearing Carrier Installation
411
Rear Bearing Carrier Removal / Inspection
412
Rear Carrier Bearing Replacement
413
Rear Bearing Carrier Installation
414
Drive Shaft
416
Front Half Shaft Removal
416
Front Half Shaft Installation
417
Rear Half Shaft Removal
418
Rear Half Shaft Installation
419
Drive Shaft / CV Joint Handling Tips
420
Outer CV Joint / Boot Replacement
420
Inner Plunging Joint / Boot Replacement
423
Prop Shaft Removal
425
Prop Shaft Installation
426
Front Gearcase / Centralized Hilliard
431
Front Gearcase Assembly View
431
All Wheel Drive Operation
432
Awd Diagnosis
433
Front Gearcase Disassembly / Inspection
434
Front Gearcase Removal
434
Front Gearcase Assembly
437
Front Gearcase Installation
440
Front Hub Assembly View
441
Wheel Hubs
441
Rear Hub Assembly View
442
Chapter 9 Steering / Suspension
443
Special Tools
445
Steering - General
446
Steering Rack Replacement
446
Steering System
446
Tie Rod Replacement
446
Steering Assembly (Non-Eps)
448
Steering Assembly View
448
Steering Shaft Bearing Replacement
449
Steering Shaft Removal (Non-Eps)
449
Steering Wheel Removal (Non-Eps)
449
Steering Assembly (Eps)
451
Steering Assembly View (Eps)
451
Upper Steering Shaft Removal
452
Power Steering Unit Removal
453
Steering Wheel Removal (Eps)
453
Lower Steering Shaft Removal
454
Lower Steering Shaft Installation
455
Power Steering Unit Installation
456
Upper Steering Shaft Installation
457
Front Suspension
458
Front Suspension Assembly View
458
Front Control Arm Replacement
459
Ball Joint Installation
461
Ball Joint Removal
461
Front Stabilizer Bar Replacement (50" & XC)
462
Rear Control Arm Removal
463
Rear Suspension
463
Rear Control Arm Installation
464
Rear Stabilizer Bar Replacement
464
Front Shock Assembly View
466
Rear Shock Assembly View
466
Shocks / Springs
466
Shock / Spring Replacement
467
Shock Removal / Installation
467
Shock Service (Fox)
468
Shock Specifications (Fox)
468
Fox Shock Disassembly
470
Fox Shock Assembly
479
Shock Service (Walker Evans)
489
Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
489
Shock Compression Adjustment (Walker Evans)
490
Spring Adjustment (Walker Evans)
490
Shock Piston Orientation
492
Special Tools
492
Valve Shim Arrangement
492
Walker Evans™ Shock Rebuild Information
492
Walker Evans™ Shock Disassembly
493
Walker Evans™ Shock Assembly
496
Chapter 10 Brake System
501
General Specifications
503
Special Tools
503
Brake System Service Notes
504
Hydraulic Brake System Operation
504
Rzr 900 / 1000
505
Master Cylinder
506
Master Cylinder Installation
506
Master Cylinder Removal
506
Brake Bleeding / Fluid Change
508
Brake Pedal
508
Brake Pedal Installation
508
Brake Pedal Lever Removal
508
Parking Brake (Int'l)
510
Parking Brake Assembly View
510
Parking Brake Cable Adjustment (Intl)
511
Parking Brake Inspection (Intl)
511
Caliper Installation
513
Caliper Removal
513
Disc Inspection / Replacement
513
Front Brakes
515
Front Caliper / Pad Removal
515
Front Caliper Assembly View
516
Front Caliper Disassembly
517
Front Caliper Assembly
518
Front Caliper Inspection
518
Front Brake Disc Inspection
519
Front Pad Inspection
519
Front Brake Disc Runout
520
Front Disc Replacement
520
Front Caliper / Pad Installation
521
Brake Burnishing Procedure
522
Rear Brakes
523
Rear Caliper / Brake Pad Removal
523
Rear Caliper Assembly View
524
Rear Caliper Disassembly
525
Rear Caliper Inspection
525
Rear Brake Pad Inspection
526
Rear Caliper Assembly
526
Rear Disc Inspection
527
Rear Disc Replacement
527
Rear Caliper / Pad Installation
528
Brake Burnishing Procedure
529
Brake Noise Troubleshooting
530
Brake Vibration
530
Poor Brake Performance
530
Troubleshooting
530
Brakes Lock
531
Caliper Overheats (Brakes Drag)
531
Brake Pedal Switch Inspection
532
Brake Warning System Inspection (Intl Models)
532
Chapter 11 Body / Frame
533
Decal Replacement
534
Special Tools
534
Body Assembly Views
535
Cab Frame Assembly
535
Doors
537
Dash / Instruments
539
Hood / Front Body
540
Chassis / Main Frame
541
Seats
543
Seats - Rear
544
Floor / Rocker Panels
545
Rear Cargo Box / Fenders
547
Rear Bumper
548
Body Component Removal
549
Engine Service Panel
549
Front Bumper Removal
549
Rear Bumper Removal
549
Seat Removal
549
Hood Removal
550
Lower Dash Removal
550
Upper Dash Removal
550
Cargo Box Removal
551
Front Fender / Body Removal
551
Rear Fender / Fender Flair Removal
551
Rocker Panel / Console / Floor
552
Rocker Panels / Rear Console / Floor - 4 900
553
Door Adjustment
558
Door Panel / Latch Replacement
558
Doors
558
Chapter 12 Electrical
561
Service Notes
563
Special Tools
563
Under Dash Components
563
Break-Out Diagram Viewing
564
Instrument Cluster
566
Overview
566
Information Display Area
568
Diagnostic Mode
571
Brake Light Switch
573
Headlamp Switch
573
Switches / Controls
573
Awd / 2Wd Switch (no Turf Mode)
574
Ignition (Key) Switch
574
Awd/2Wd/Turf Switch (Models with Turf)
575
Transmission (Gear Position) Switch
575
Hazard Switch (Int'l / Tractor)
576
Seat Belt Switch
576
Turn/Lights/Horn Switch (Int'l/Tractor)
577
Brake Alarm (Int'l/Tractor)
578
Flasher Module (Int'l/Tractor)
578
Horn
578
Turn Lights
578
Parking Brake Switch (Int'l/Tractor)
579
Differential Solenoid Circuit Operation
580
Differential Solenoid Overview
580
Charging System
581
Stator
581
Voltage Regulator
581
Charging System "Break Even" Test
582
Charging System Stator (Alternator) Tests
582
Charging System Testing Flow Chart
584
Battery
585
Battery Installation
585
Battery Removal
585
Current Draw - Key off
586
Battery Conductance Analyzer
587
Load Test
587
Ocv - Open Circuit Voltage Test
587
Headlights
588
Lighting System
588
Dash Led Light
589
Taillights
589
Coolant Temperature Sensor
590
Cooling System
590
Radiator Fan
591
Starter Installation
592
Starter Removal
592
Starter Troubleshooting
592
Starting System
592
Voltage Drop Test
592
Starter Solenoid
593
Electronic Power Steering
594
Eps Operation
594
Eps System Diagnosis
594
Fuse Box (Rzr S 4 1000)
597
12V Receptacle
598
Awd Coil
598
Misc. Electrical
598
Speed Sensor
598
Terminal Block
598
Chassis Ground Point
599
Ignition Coil
599
Can System Overview
600
Can System Testing
600
Diagnostic Plug
600
5
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Polaris RZR S 1000 2019 Specifications
General
Brand
Polaris
Model
RZR S 1000 2019
Category
Offroad Vehicle
Language
English
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