Polaris RZR 900, 1000S
POLARIS RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020) - WORKSHOP MANUAL
POLARIS RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020) - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop Manual / Repair Manual, for UTV Polaris RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020). INDEX: CHAPTER 1 : GENERAL INFORMATION VEHICLE IDENTIFICATION - Model Number Designation (2015 +) - Vehicle Identification Number (VIN) Designation (2015+) - Vehicle and Engine Serial Number Location REFERENCE INFORMATION - Publication Numbers - Replacement Keys - SPECIAL TOOLS - Master Torque Table GENERAL SPECIFICATIONS - 2017 RZR 900 Specifications - RZR 900 Clutch Chart - 2017 RZR 900 EPS Specifications - RZR 900 Clutch Chart - 2017 RZR 900 XC Specifications - RZR 900 XC Clutch Chart - 2017 RZR S 900 Specifications - RZR S 900 Clutch Chart - 2017 RZR S 900 EPS - RZR S 900 Clutch Chart - 2017 RZR S4 900 Specifications - RZR S4 900 Clutch Chart - 2017 RZR S 1000 Specifications - RZR S 1000 Clutch Chart - 2018 RZR 900 Specifications - RZR 900 Clutch Chart - 2018 RZR 900 EPS Specifications - RZR 900 Clutch Chart - 2018 RZR S 900 Specifications - RZR S 900 Clutch Chart - 2018 RZR S 900 EPS Specifications - RZR S 900 Clutch Chart - 2018 RZR S4 900 Specifications - RZR S4 900 Clutch Chart - 2018 RZR S 1000 Specifications - RZR S 1000 Clutch Chart - 2019 RZR 900 Specifications - 2019 RZR 900 Clutch Chart - 2019 RZR 900 EPS Specifications - 2019 RZR 900 EPS Clutch Chart - 2019 RZR S 900 Specifications - 2019 RZR S 900 Clutch Chart - 2019 RZR S 1000 Specifications - 2019 RZR S 1000 Clutch Chart - 2019 RZR S 1000 EPS Specifications - 2019 RZR S 1000 EPS Clutch Chart - 2019 RZR S4 1000 Specifications - 2019 RZR S4 1000 Clutch Chart - 2020 RZR 900 Specifications - RZR 900 Clutch Chart - 2020 RZR 900 EPS Specifications - RZR 900 Clutch Chart - 2020 RZR S 900 Specifications - RZR S 900 Clutch Chart - 2020 RZR S 1000 Specifications - RZR S 1000 Clutch Chart - 2020 RZR S 1000 EPS Specifications - 2019 RZR S 1000 EPS Clutch Chart - 2020 RZR S4 1000 Specifications - 2019 RZR S4 1000 Clutch Chart Misc. Specifications and Charts - Conversion Table - SAE Tap / Drill Sizes - Metric Tap / Drill Sizes - Decimal Equivalents CHAPTER 2 : MAINTENANCE PERIODIC MAINTENANCE CHART - Periodic Maintenance Overview - Break-In Period - Pre-Ride Inspection - Maintenance Intervals - Maintenance Quick Reference - Grease Lubrication Points GENERAL VEHICLE INSPECTION AND MAINTENANCE - Lubricants / Service Products - Shift Cable Inspection / Adjustment ENGINE / AIR INTAKE - Engine Air Filter Service - Intake Duct Inspection - Air Box / Filter Assembly View - Engine Oil Level - Engine Oil and Filter Change - Crankcase Breather Hose Inspection - Engine Cylinder Leak-down Test - Valve Clearance Inspection - Cam Chain Tensioner Inspection COOLING SYSTEM - Cooling System Overview - Coolant Strength - Coolant Level Inspection - Cooling System Pressure Test - Cooling System Hose Inspection - Radiator Inspection / Cleaning - Coolant Drain / Fill FUEL SYSTEM - Fuel System Warning - Fuel Tank Vent Line - Fuel Pump / Fuel Filter - Fuel Lines - Throttle Pedal Inspection PVT SYSTEM - Drive Clutch / Driven Clutch / Belt Service - PVT Duct Cleaning - PVT Drying DRIVESHAFT / WHEEL AND TIRE - Drive Shaft Boot Inspection - Wheel and Hub Torque Table - Wheel Removal - Wheel Installation - Tire Inspection - Tire Pressure TRANSMISSION AND FRONT GEARCASE - Specification Chart - Transmission Lubrication - Front Gearcase Lubrication STEERING SYSTEM - Steering Inspection - Steering Wheel Free-play - Tie Rod End / Wheel Bearing Inspection - Wheel Toe Alignment Inspection - Wheel Toe Adjustment SUSPENSION SYSTEM - Spring Adjustment (non-Fox) - Spring Adjustment (FOX) - Shock Compression Adjustment (FOX) - Spring Adjustment (Walker Evans) - Shock Compression Adjustment (Walker Evans) BRAKE SYSTEM - Brake Fluid Inspection - Brake Pad / Disc Inspection - Brake Hose and Fitting Inspection ELECTRICAL / IGNITION SYSTEM - Battery Maintenance - Battery Off Season Storage - Battery Charging - Engine / Chassis Ground - Spark Plug Service CHAPTER 3 : ENGINE / COOLING SYSTEM Engine - General - General Information - Lubrication Specifications - Main Engine Components - Torque Specification and Sequence - Exhaust System - Exhaust Assembly View / Torque Values - Exhaust Removal / Installation - Engine Cooling System - Cooling System Specifications - Cooling System Pressure Test - Radiator Cap Pressure Test - Radiator Removal / Installation - Thermostat Replacement - Cooling System Bleeding - Water Pump Removal - Water Pump Service - Water Pump Installation - Engine Service - Lubrication Specifications - Engine Oil Pressure Test - Engine Oil Flow Chart - Accessible Engine Components - Top End Service - Engine Mounts - Crankshaft PTO Seal Replacement - Engine Removal - Engine Installation - Engine Break-In - Troubleshooting - Engine - Cooling System 900 Engine - Engine Specifications (900) - Engine Specifications - Engine Disassembly / Inspection - Top End (900) - Valve Cover Removal - Camshaft Removal - Camshaft Sprocket Inspection - Camshaft / Camshaft Bore Inspection - Cylinder Head Removal - Cylinder Head Inspection - Cylinder Head Warp Inspection - Cylinder Head Disassembly - Valve Inspection - Combustion Chamber Cleaning - Valve Seat Reconditioning - Engine Disassembly / Inspection - Lower End (900) - Stator Cover Removal / Inspection - Water Pump Housing Removal - Flywheel Removal - Starter One-Way Clutch Disassembly - Starter One-Way Clutch Assembly - Crankcase Disassembly - Balance Shaft Removal / Inspection - Crankshaft Removal / Inspection - Crankcase Inspection - Cylinder / Piston Removal - Cylinder Inspection - Piston Disassembly / Inspection - Piston Ring Removal - Piston Ring to Groove Clearance Inspection - Piston Ring Installed Gap - Piston-to-Cylinder Clearance - Connecting Rod Inspection - Engine Assembly - Lower End (900) - Bearing Selection Identification Letters and Numbers - Connecting Rod Bearing Selection - Crankshaft Main Bearing Selection - Upper Crankcase Preparation - Piston Ring Installation - Piston / Connecting Rod Assembly - Cylinder / Piston Installation - Crankshaft Installation - Balance Shaft Installation - Lower Crankcase Preparation - Crankcase Assembly - Flywheel Installation - Stator Cover Installation - Engine Assembly - Top End (900) - Cylinder Head Assembly - Valve Sealing Test - Cylinder Head Installation - Camshaft Installation / Timing - Camshaft Timing - Quick Reference - Valve Clearance Adjustment - Valve Lash - Tappet Selection - Valve Cover Installation 1000 Engine - Engine Specifications (1000) - Engine Specifications (1000) - ENGINE DISASSEMBLY / INSPECTION - TOP END (1000) - Valve Cover Removal - Camshaft Removal - Camshaft Sprocket Inspection - Camshaft / Camshaft Bore Inspection (1000) - Cylinder Head Removal - Cylinder Head Warp Inspection - Cylinder Head Disassembly - Valve Inspection - Combustion Chamber Cleaning - Valve Sealing Test - Valve Seat Reconditioning (1000) - ENGINE DISASSEMBLY / INSPECTION - LOWER END (1000) - Stator Cover Removal / Inspection - Water Pump Housing Removal - Flywheel Removal - Starter One-Way Clutch Disassembly - Crankcase Disassembly / Inspection - Balance Shaft Removal / Inspection - Crankshaft Removal / Inspection - Crankcase Inspection - Cylinder Inspection - Cylinder / Piston Removal - Piston Disassembly / Inspection (1000) - Piston Ring Removal - Piston Ring to Groove Clearance Inspection - Piston Ring Installed Gap (1000) - Piston-to-Cylinder Clearance - Connecting Rod Inspection - ENGINE ASSEMBLY - LOWER END (1000) - Bearing Selection Identification Letters and Numbers - Connecting Rod Bearing Selection - Crankshaft Main Bearing Selection - Upper Crankcase Preparation - Piston Ring Installation - Piston / Connecting Rod Assembly - Cylinder / Piston Installation - Crankshaft Installation - Balance Shaft Installation - Lower Crankcase Preparation - Crankcase Assembly - Starter One-Way Clutch Assembly - Flywheel Installation - Stator Cover Installation - ENGINE ASSEMBLY - TOP END (1000) - Cylinder Head Assembly - Cylinder Head Installation - Camshaft Installation / Timing - Camshaft Timing - Quick Reference - Valve Clearance Adjustment - Valve Lash - Tappet Selection - Valve Cover Installation CHAPTER 4 : ENGINE ELECTRICAL Electronic Control Unit (ECU) - Operation Overview - ECU Service - ECU Replacement - ETC Learn Procedure Temperature and Manifold Absolute Pressure Sensor (T-MAP) - Operation Overview - TMAP Test / Replacement Crankshaft Position Sensor (CPS) - Operation Overview - CPS Test - CPS Replacement Electronic Throttle Control (ETC) / Throttle Body - Throttle Body Operation Overview - ETC Test - ETC Replacement - ETC Learn Procedure Pedal Position Sensor (PPS) - Operation Overview - PPS Location - PPS Test - PPS Replacement Oxygen Sensor (RZR S 1000) - Oxygen Sensor Information - Oxygen Sensor Replacement Polaris Digital Wrench - Digital Wrench? Diagnostic Software Overview - Special Tools (Digital Wrench) - Digital Wrench Software Version and Update ID - Digital Wrench? Updates - Digital Wrench? Communication Errors - Digital Wrench? - Diagnostic Connector - Guided Diagnostics - Digital Wrench? Serial Number Location - Digital Wrench? Feature Map - ECU Replacement - ETC Learn Procedure - ECU Reprogramming (Reflash) Polaris Mobile Digital Wrench (PMDW) - Polaris Mobile Digital Wrench? (PMDW) CHAPTER 5 : FUEL SYSTEM General Information - Special Tools EFI Overview - Principal Components - EFI Operation Overview - Initial Priming / Starting Procedure Fuel Injectors - Operation Overview - Fuel Injector O-rings - Fuel Injector Troubleshooting - Fuel Injector Test - Fuel Injector Replacement Fuel Lines - Fuel Vent Line Routing - Fuel Vent Line Routing (EVAP Models) - Fuel Supply Line Routing - Fuel Supply Line Routing (EVAP Models) - Vent Line Termination Fitting Fuel Tank / Pump - Fuel Tank Assembly View - Fuel Line Removal / Installation - Fuel Tank Removal - Fuel Tank Installation - Fuel Pump - Operation Overview - Fuel Sender Test - Fuel Pump Test - Fuel Pump Replacement EFI Diagnostics - Data Display Definitions - Misfire Detection (S 1000 ONLY) - Cylinder Misfire Detection - Trouble Code Display (DTC) - EFI Troubleshooting CHAPTER 6 : PVT SYSTEM General Information - Special Tools - Clutch Charts - RZR 900 Clutch Chart - RZR 900 XC Clutch Chart - RZR S 900 Clutch Chart - RZR S 1000 Clutch Chart - RZR S4 1000 Clutch Chart PVT System Overview - General Operation - PVT Break-In (Drive Belt / Clutches) - Drive Clutch Operation - Driven Clutch Operation - Maintenance / Inspection PVT System Service - PVT Covers and Ducting Components - RZR S 1000 / S4 1000 PVT Covers and Ducting Components - PVT Disassembly - PVT Assembly Drive Belt - Belt Removal (EBS) - Belt Removal (non-EBS) - Belt Inspection - Belt Installation (EBS) - Belt Installation (non-EBS) - PVT Break-In (Drive Belt / Clutches) Drive Clutch Service - Drive Clutch Assembly View - Drive Clutch Disassembly - Bearing Inspection - Shift Weight Inspection - Button to Tower Clearance - Spider Removal - Roller, Pin and Thrust Washer Inspection - Drive Clutch Inspection - Moveable Sheave Bushing Inspection - Bushing Service - Drive Clutch Assembly Driven Clutch Service (EBS) - Driven Clutch Assembly View - Driven Clutch Slider Inspection - Driven Clutch Disassembly - Driven Clutch Assembly Driven Clutch Service (non-EBS) - Driven Assembly View - Driven Clutch Disassembly - Driven Clutch Assembly Troubleshooting - PVT Troubleshooting - PVT Overheating / Diagnosis CHAPTER 7 : TRANSMISSION General Information - Special Tools - Lubrication Specifications - Transmission Mounting View Shift Lever / Cable - Shift Lever Removal - Shift Lever Installation - Shift Cable Inspection - Shift Cable Adjustment Transmission Service - Transmission Removal - Transmission Installation - Transmission Disassembly - Differential Operation - Planetary Differential Disassembly (Turf Mode Models Only) - Planetary Differential Bushing Replacement (Turf Mode Models Only) - Planetary Differential Assembly (Turf Mode Models Only) - Gear / Shaft / Bearing Inspection - Transmission Assembly / Snorkel Gear Backlash Procedure Troubleshooting - Shifting Difficulty CHAPTER 8 : FINAL DRIVE General Information - Special Tools Bearing Carrier - Front Bearing Carrier Removal / Inspection - Front Bearing Replacement - Front Bearing Carrier Installation - Rear Bearing Carrier Removal / Inspection - Rear Carrier Bearing Replacement - Rear Bearing Carrier Installation Drive Shaft - Front Half Shaft Removal - Front Half Shaft Installation - Rear Half Shaft Removal - Rear Half Shaft Installation - Drive Shaft / CV Joint Handling Tips - Outer CV Joint / Boot Replacement - Inner Plunging Joint / Boot Replacement - Prop Shaft Removal - Prop Shaft Installation - Rear Prop Shaft Removal 4 1000 - Rear Prop Shaft Installation 4 1000 Front Gearcase / Centralized Hilliard - Front Gearcase Assembly View - All Wheel Drive Operation - AWD Diagnosis - Front Gearcase Removal - Front Gearcase Disassembly / Inspection - Front Gearcase Assembly - Front Gearcase Installation Wheel Hubs - Front Hub Assembly View - Rear Hub Assembly View CHAPTER 9 : STEERING / SUSPENSION General Information - Special Tools Steering System - Steering - General - Steering Rack Replacement - Tie Rod Replacement - Steering Assembly (non-EPS) - Steering Assembly View - Steering Wheel Removal (non-EPS) - Steering Shaft Removal (non-EPS) - Steering Shaft Bearing Replacement - Steering Assembly (EPS) - Steering Assembly View (EPS) - Upper Steering Shaft Removal - Steering Wheel Removal (EPS) - Power Steering Unit Removal - Lower Steering Shaft Removal - Lower Steering Shaft Installation - Power Steering Unit Installation - Upper Steering Shaft Installation Front Suspension - Front Suspension Assembly View - Front Control Arm Replacement - Ball Joint Removal - Ball Joint Installation - Front Stabilizer Bar Replacement (50" & XC) Rear Suspension - Rear Control Arm Removal - Rear Control Arm Installation - Rear Stabilizer Bar Replacement Shocks / Springs - Front Shock Assembly View - Rear Shock Assembly View - Shock Removal / Installation - Shock / Spring Replacement Shock Service (FOX) - Shock Specifications (FOX) - FOX Shock Disassembly - FOX Shock Assembly Shock Service (Walker Evans) - Walker Evans? 2.0" Front Shock / 2.5" Rear Shock - Spring Adjustment (Walker Evans) - Shock Compression Adjustment (Walker Evans) - Walker Evans? Shock Rebuild Information - Special Tools - Valve Shim Arrangement - Shock Piston Orientation - Walker Evans? Shock Disassembly - Walker Evans? Shock Assembly CHAPTER 10 : BRAKE SYSTEM GENERAL INFORMATION - SPECIAL TOOLS - GENERAL SPECIFICATIONS - BRAKE SYSTEM SERVICE NOTES - HYDRAULIC BRAKE SYSTEM OPERATION - RZR 900 / 1000 MASTER CYLINDER - Master Cylinder Removal - Master Cylinder Installation BRAKE PEDAL - Brake Pedal Lever Removal - Brake Pedal Installation - BRAKE BLEEDING / FLUID CHANGE PARKING BRAKE (INT'L) - Parking Brake Assembly View - Parking Brake Inspection (INTL) - Parking Brake Cable Adjustment (INTL) - Caliper Removal - Caliper Installation - Disc Inspection / Replacement FRONT BRAKES - Front Caliper / Pad Removal - Front Caliper Assembly View - Front Caliper Disassembly - Front Caliper Inspection - Front Caliper Assembly - Front Pad Inspection - Front Brake Disc Inspection - Front Brake Disc Runout - Front Disc Replacement - Front Caliper / Pad Installation - Brake Burnishing Procedure REAR BRAKES - Rear Caliper / Brake Pad Removal - Rear Caliper Assembly View - Rear Caliper Disassembly - Rear Caliper Inspection - Rear Caliper Assembly - Rear Brake Pad Inspection - Rear Disc Inspection - Rear Disc Replacement - Rear Caliper / Pad Installation - Brake Burnishing Procedure TROUBLESHOOTING - BRAKE NOISE TROUBLESHOOTING - Poor Brake Performance - Brake Vibration - Caliper Overheats (Brakes Drag) - Brakes Lock - Brake Warning System (INTL Models) - Brake Warning System Inspection (INTL Models) - Brake Pedal Switch Inspection CHAPTER 11 : BODY / FRAME General Information - Special Tools - DECAL REPLACEMENT Body Assembly Views - Cab Frame Assembly - Cab Frame Assembly - 4 1000 - Doors - Doors - 4 1000 - Dash / Instruments - Hood / Front Body - Chassis / Main Frame - Chassis / Main Frame - 4 1000 - Seats - Seats - Rear - Floor / Rocker Panels - Floor / Rocker Panels - 4 1000 - Rear Cargo Box / Fenders - Rear Bumper Body Component Removal - Seat Removal - Front Bumper Removal - Rear Bumper Removal - Engine Service Panel - Hood Removal - Upper Dash Removal - Lower Dash Removal - Front Fender / Body Removal - Rear Fender / Fender Flair Removal - Cargo Box Removal - Rocker Panel / Console / Floor - Rocker Panels / Rear Console / Floor - 4 900 - Rocker Panels / Rear Console / Floor - 4 1000 Doors - Door Panel / Latch Replacement - Door Adjustment CHAPTER 12 : ELECTRICAL General Information - Special Tools - Service Notes - Under Dash Components - Break-Out Diagram viewing Instrument Cluster - Overview - Information Display Area - Diagnostic Mode - Instrument Cluster Pinouts Switches / Controls - Brake Light Switch - Headlamp Switch - Ignition (Key) Switch - AWD / 2WD Switch (no Turf mode) - AWD/2WD/Turf Switch (models with Turf) - Transmission (Gear Position) Switch - Seat Belt Switch - Hazard Switch (INT'L / Tractor) - Turn/Lights/Horn Switch (INT'L/Tractor) - Horn - Turn Lights - Flasher Module (INT'L/Tractor) - Brake Alarm (INT'L/Tractor) - Parking Brake Switch (INT?L/Tractor) - Differential Solenoid Overview - Differential Solenoid Circuit Operation Charging System - Stator - Voltage Regulator - Charging System ?Break Even? Test - Charging System Stator (Alternator) Tests - Charging System Testing Flow Chart Battery - Battery Removal - Battery Installation - Current Draw - Key Off - OCV - Open Circuit Voltage Test - Load Test - Battery Conductance Analyzer Lighting System - Headlights - Taillights - Dash LED Light Cooling System - Coolant Temperature Sensor - Radiator Fan Starting System - Starter Troubleshooting - Voltage Drop Test - Starter Removal - Starter Installation - Starter Solenoid Electronic Power Steering - EPS Operation - EPS System Diagnosis Fuses / Relays - Fuse Box (900 / 900 XC / S 900 / S 1000) - Fuse Box (RZR S 4 1000) Misc. Electrical - 12v Receptacle - AWD Coil - Speed Sensor - Terminal Block - Ignition Coil - Chassis Ground Point - Diagnostic Plug - CAN System Overview - CAN System Testing
Polaris RZR 900, 900S, 900S4, 1000S, 1000S4, (2017-2020) - Workshop Manual / Repair Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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