Polaris RZR 900 2016 Service Manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
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Publication Printed September 2015 (PN 9926814 R08)
© Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2015-2016 RZR 900
2016 RZR S 1000

Polaris RZR 900 2016 Specifications

General

Brand	Polaris
Model	RZR 900 2016
Category	Offroad Vehicle
Language	English

Summary

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION

Describes VIN and model number designation.

GENERAL SPECIFICATIONS

CHAPTER 2 MAINTENANCE

PERIODIC MAINTENANCE CHART

Outlines inspection, adjustment, and lubrication schedule.

COOLING SYSTEM

Covers system overview, testing, and fluid procedures.

FUEL SYSTEM

PVT SYSTEM

Outlines service for clutches, belt, and ducting.

TRANSMISSION AND FRONT GEARCASE

SUSPENSION SYSTEM

BRAKE SYSTEM

Covers fluid, pad/disc, and hose/fitting inspection.

ELECTRICAL / IGNITION SYSTEM

CHAPTER 3 ENGINE / COOLING SYSTEM

ENGINE - GENERAL

Covers general info and lubrication specs.

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE

Details torque values for key components.

ENGINE COOLING SYSTEM

Includes specifications, testing, and bleeding.

ENGINE SERVICE

ENGINE REMOVAL

Instructions for removing the engine from the vehicle.

ENGINE BREAK-IN

Outlines the procedure for breaking in a new engine.

CHAPTER 4 FUEL SYSTEM

EFI OVERVIEW

Explains EFI system components and operation.

ELECTRONIC CONTROL UNIT (ECU)

Details ECU operation, service, and replacement.

FUEL INJECTORS

Covers operation, testing, and replacement.

FUEL TANK

FUEL PUMP

Explains operation, testing, and sender test.

FUEL PUMP REPLACEMENT

Procedure for replacing the fuel pump assembly.

CRANKSHAFT POSITION SENSOR (CPS)

ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE BODY

Explains operation, testing, replacement, and learn procedure.

EFI DIAGNOSTICS

Data display definitions for EFI diagnosis.

TROUBLE CODE DISPLAY (DTC)

How to display and interpret diagnostic trouble codes.

POLARIS DIGITAL WRENCH

Diagnostic software overview and special tools.

CHAPTER 5 PVT SYSTEM

PVT SYSTEM OVERVIEW

Explains general operation and break-in.

PVT DISASSEMBLY

PVT ASSEMBLY

DRIVE BELT

Belt removal and installation.

DRIVE CLUTCH SERVICE

Assembly view and disassembly.

DRIVEN CLUTCH DISASSEMBLY

DRIVEN CLUTCH ASSEMBLY

CHAPTER 6 TRANSMISSION

SHIFT LEVER / CABLE

TRANSMISSION SERVICE

Procedure for transmission removal.

TRANSMISSION INSTALLATION

Procedure for installing transmission.

TRANSMISSION DISASSEMBLY

Steps for disassembling transmission.

GEAR / SHAFT / BEARING INSPECTION

TROUBLESHOOTING

Diagnosing shifting difficulties.

CHAPTER 7 FINAL DRIVE

BEARING CARRIER

Front bearing carrier removal and inspection.

REAR BEARING CARRIER REMOVAL / INSPECTION

Removing and inspecting rear bearing carrier.

DRIVE SHAFT

FRONT GEARCASE / CENTRALIZED HILLIARD

AWD DIAGNOSIS

Diagnosing AWD system issues.

CHAPTER 8 STEERING / SUSPENSION

STEERING SYSTEM

General info, rack, tie rod replacement.

STEERING ASSEMBLY (NON-EPS)

STEERING ASSEMBLY (EPS)

POWER STEERING UNIT REMOVAL

Removing power steering unit.

FRONT SUSPENSION

FRONT CONTROL ARM REPLACEMENT

Replacing front control arms.

REAR SUSPENSION

SHOCK REMOVAL / INSTALLATION

SHOCK SERVICE

Shock specifications and disassembly/assembly.

FOX SHOCK DISASSEMBLY

Disassembling FOX shocks.

CHAPTER 9 BRAKE SYSTEM

BRAKE SYSTEM SERVICE NOTES

Important notes for brake service.

HYDRAULIC BRAKE SYSTEM OPERATION

MASTER CYLINDER

BRAKE BLEEDING / FLUID CHANGE

Procedures for bleeding brakes and changing fluid.

PARKING BRAKE (INT'L)

FRONT BRAKES

FRONT DISC REPLACEMENT

REAR BRAKES

REAR CALIPER DISASSEMBLY

REAR DISC REPLACEMENT

TROUBLESHOOTING

Common brake system issues like noise, poor performance, and locking.

CHAPTER 10 BODY / FRAME

DOORS

HOOD / FRONT BODY

CHASSIS / MAIN FRAME

BODY COMPONENT REMOVAL

FRONT FENDER / BODY REMOVAL

CHAPTER 11 ELECTRICAL

GENERAL INFORMATION

INSTRUMENT CLUSTER

SWITCHES

CHARGING SYSTEM

BATTERY

LIGHTING SYSTEM

COOLING SYSTEM

STARTING SYSTEM

ELECTRONIC POWER STEERING

EPS operation, diagnosis, software.

FUSES / RELAYS

CAN SYSTEM