Polaris 2015 RZR 900 Service Manual

1.16
9925723 R01 - 2015 RZR 900 Service Manual
© Copyright 2014 Polaris Industries Inc.
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

Polaris 2015 RZR 900 Specifications

General

Brand	Polaris
Model	2015 RZR 900
Category	Utility Vehicle
Language	English