IX
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
IX.3
Operation .............................................................. 5.5
Drive Shaft
Boot Inspection ......................................................2.24
CV Joint Handling...................................................7.14
Installation (Front) ..................................................7.11
Installation (rear) ....................................................7.13
Removal (Front) .....................................................7.10
Removal (rear).......................................................7.12
Driven Clutch
Assembly ..................................................... 5.31, 5.37
Assembly View .............................................. 5.34–5.35
Bushing Service .....................................................5.28
Disassembly .........................................................5.26
Operation .............................................................. 5.6
Slider Inspection ....................................................5.26
Driveshaft / CV Joint
CV Joint Replacement (Outer) ..................................7.14
DTC .......................................................................4.33
E
ECU ........................................................................ 4.5
ETC Learn Procedure ............................... 4.6, 4.25, 4.46
Replacement.........................................................4.46
EFI
Operation Overview ................................................. 4.4
Electrical
12v Receptacle .................................................... 11.33
AWD Coil............................................................ 11.33
Chassis Ground Point ........................................... 11.35
Diagnostic Plug.................................................... 11.35
Fuse Box ............................................................ 11.30
Ignition Coil ......................................................... 11.34
Service Notes ........................................................ 11.3
Special Tools......................................................... 11.3
Stator ................................................................ 11.15
Terminal Block ..................................................... 11.33
Torque Specifications .............................................. 11.3
Voltage Regulator................................................. 11.15
Electronic Control Unit
Replacement.......................................................... 4.5
Service ................................................................. 4.5
Electronic Control Unit (ECU)........................................ 4.5
Electronic Throttle Body
Learn Procedure ...................................... 4.6, 4.25, 4.46
Engine
Balance Shaft Removal / Inspection .................. 3.55, 3.111
Bearing Selection Identification ........................3.66, 3.121
Break-in ...............................................................3.33
Breather Hose Inspection.........................................2.15
Camshaft Installation / Timing ..........................3.82, 3.137
Camshaft Removal ......................................... 3.38, 3.94
Camshaft Sprocket Inspection........................... 3.40, 3.96
Camshaft Timing - Quick Reference ...........................3.86
Connecting Rod Bearing Selection ....................3.67, 3.122
Connecting Rod Inspection.......................................3.64
Cooling System Troubleshooting ...............................3.35
Crankcase Assembly .....................................3.74, 3.130
Crankcase Disassembly / Inspection .................3.53, 3.109
Crankcase Inspection..............................................3.59
Crankshaft Installation ....................................3.71, 3.127
Crankshaft Main Bearing Selection ...................3.67, 3.122
Crankshaft Removal / Inspection ......................3.56, 3.112
Cylinder / Piston Installation.............................3.70, 3.126
Cylinder / Piston Removal ...............................3.60, 3.116
Cylinder Head Assembly.................................3.79, 3.135
Cylinder Head Disassmebly......................................3.99
Cylinder Head Inspection .........................................3.42
Cylinder Head Installation ...............................3.81, 3.136
Cylinder Head Removal ................................... 3.42, 3.98
Cylinder Head Warp........................................ 3.42, 3.99
Cylinder Inspection ........................................3.60, 3.115
Cylinder Leak-down Test..........................................2.15
Engine / Chassis Ground .........................................2.36
Exploded Views ............................................... 3.7–3.10
Flywheel Installation ......................................3.78, 3.134
Flywheel Removal .........................................3.50, 3.107
Installation ............................................................3.28
Lower Crankcase Preparation ...................................3.73
Lubrication Specifications .................................. 3.5, 3.22
Mount Replacement................................................3.24
Oil and Filter Change ..............................................2.14
Oil Flow Chart........................................................3.23
Oil Level ...............................................................2.13
Oil Pressure Test....................................................3.22
Piston / Connecting Rod Assembly....................3.69, 3.125
Piston Disassembly / Inspection ................................3.61
Piston Disassembly / Inspection (1000) ..................... 3.117
Piston Ring Installation ...................................3.68, 3.123
Piston Ring Installed Gap .........................................3.63
Piston Ring Installed Gap (1000) ............................. 3.119
Piston Ring Removal / Inspection......................3.62, 3.118
Piston-to-Cylinder Clearance ....................................3.64
Removal...............................................................3.24
Service Panel Removal ......................................... 10.19
Specifications (900) ................................................3.36
Specifications (RZR 1000)........................................3.92
Starter Drive Installation..................................3.78, 3.134
Stator Cover Installation..................................3.78, 3.134
Top End Service.....................................................3.24
Torque Sequence .................................................... 3.6
Troubleshooting .....................................................3.34
Upper Crankcase Preparation ...................................3.68
Valve Clearance Adjustment .....................................3.87
Valve Cover Installation ...........................................3.91
Valve Cover Removal...................................... 3.38, 3.94
Valve Inspection............................................3.44, 3.100
Valve Lash - Tappet Selection ..........................3.90, 3.144
Valve Sealing Test .........................................3.80, 3.102
Valve Seat Reconditioning........................................3.45
Valve Seat Reconditioning (1000) ............................ 3.102
Engine, Camshaft Timing - Quick Reference ................. 3.141
Engine, Valve Cover Installation ................................. 3.145
EPS
Break-Out Diagram............................................... 11.39
Operation ........................................................... 11.28
Torque Offset Procedure ........................................ 11.28
ETC
Replacement.........................................................4.24
Test .....................................................................4.24
ETC Learn Procedure .................................. 4.6, 4.25, 4.46
Exhaust
Assembly View ...................................................... 3.11
Removal / Installation ..............................................3.12
Torque Table ......................................................... 3.11
F
Fan
Replacement.........................................................3.14
Fender
Removal (rear)..................................................... 10.20
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