3.24
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
ACCESSIBLE ENGINE COMPONENTS
The following components can be serviced or removed
with the engine installed:
• Camshaft(s)
• Camshaft Sprocket(s)
• Cylinder Head
• Flywheel
• Oil Cooler
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
• Water Pump
The following components require engine removal for
service:
• Camshaft Timing Chain
• Connecting Rod(s)
• Counterbalance Shaft / Bearings
• Crankcase
• Crankshaft / Main Bearings
• Crankshaft Seal (PTO)
• Cylinder
• Oil Pump / Oil Pump Sprocket or Chain
• Piston / Rings
TOP END SERVICE
Some top-end engine components can be service while
the engine is mounted in the chassis.
To service the top-end of the engine, refer to Chapter 2 –
Valve Clearance Inspection, page 2.15 which provides
detailed steps to remove the valve cover.
ENGINE MOUNTS
The engine is mounted to the frame on the front only.
The rear of the engine is mounted to the transmission. To
replace the isolators:
1. Slightly lift and secure the engine using an engine lift.
2. Remove the engine isolator bolts securing the mount
to the engine bracket.
3. Remove the fasteners retaining the isolator bracket to
the frame and remove the isolator.
4. To install, reverse the procedure. Tighten fasteners to
specification.
TORQUE
Engine Mount to Frame Fasteners:
22 ft-lb (30 Nm)
Engine Isolator Fasteners:
40 ft-lbs (54 Nm)
ENGINE REMOVAL
IMPORTANT
Do NOT rotate the engine backwards. The timing chain
may jump teeth and lead to poor performance.
NOTE
Some engine repair procedures can be performed
without removing the engine assembly from the vehicle.
See Accessible Engine Components, page 3.24 for
further information.The use of an overhead or portable
engine hoist is the only recommended method for
removing and installing the engine.Have an assistant
help guide the engine in and out of the vehicle while
using an engine hoist to prevent personal injury or
damage to the vehicle.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this service manual.
Failing to do so may lead to injury.
1. Disconnect the battery.
2. Drain the coolant from the engine.
3. Depressurize the fuel system at the valve
q
on the
fuel rail while holding a clean rag over the valve.
4. Remove the seat and ECU cover panel.
ENGINE / COOLING SYSTEM
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