Polaris RZR 900, EPS, XC, and RZR S 900 (2015) - Repair, Workshop Manual, Wiring Diagrams and Owners Manual

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POLARIS RZR 900, EPS, XC, & RZR S 900 (2015) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Workshop Manual / Repair Manual, Wiring Diagrams and Owners Manual, for UTV Polaris RZR 900, EPS, XC, & RZR S 900 (2015).

CONTENTS:

WORKSHOP MANUAL

2015 Rzr 900
Trademarks
Vehicle Identification
- Model Number Designation
- Vehicle Identification Number (Vin) Designation (2015+)
- Vehicle And Engine Serial Number Location
Misc. Information
- Publication Numbers
- Replacement Keys
- Special Tools
General Specifications
- Rzr 900 / Rzr 900 Eps Specifications
- Rzr 900 Xc Specifications
- Rzr S 900 Specifications
Misc. Specifications And Charts
- Master Torque Table
- Conversion Table
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- Sae Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
Periodic Maintenance Chart
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 50 Hour Maintenance Interval
- 50 - 500 Hour Maintenance Interval
- Maintenance Quick Reference
- Grease Lubrication Points
General Vehicle Inspection And Maintenance
- Pre-Ride / Daily Inspection
- Shift Cable Inspection / Adjustment
Fuel System
- Fuel System
- Fuel Tank Vent Line
- Fuel Pump / Fuel Filter
- Fuel Lines
- Throttle Pedal Inspection
Engine System
- 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
Transmission And Front Gearcase
- Specification Chart
- Transmission Lubrication
- Front Gearcase Lubrication
Cooling System
- Cooling System Overview
- Coolant Strength
- Coolant Level Inspection
- Cooling System Pressure Test
- Cooling System Hose Inspection
- Radiator Inspection / Cleaning
- Coolant Drain / Fill
Pvt System
- Drive Clutch / Driven Clutch / Belt Service
- Pvt Duct Cleaning
- Pvt Drying
Final Drive / Wheel And Tire
- Drive Shaft Boot Inspection
- Wheel And Hub Torque Table
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
Electrical / Ignition System
- Battery Maintenance
- Battery Off Season Storage
- Battery Charging
- Battery Removal
- Battery Installation
- Engine / Chassis Ground
- Spark Plug Service
Steering System
- Steering Inspection
- Steering Wheel Free-Play
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
Suspension System
- Spring Adjustment
- Spring Adjustment (Fox)
- Shock Compression Adjustment (Fox)
Brake System
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose And Fitting Inspection
General Information
- Special Tools
- Lubrication Specifications
- Main Engine Components - Torque Specification And Sequence
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
- Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
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
- Engine Specifications
- Accessible Engine Components
- Top End Service
- Engine Mounts
- Engine Removal
- Engine Installation
- Engine Break-In
Engine Disassembly / Inspection - Top End
- 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
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-Way Clutch Disassembly
- Starter One-Way Clutch Assembly
- Crankcase Disassembly / Inspection
- 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
- 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
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Clearance Adjustment
- Intake Valve Lash - Tappet Selection Matrix
- Exhaust Valve Lash - Shim Selection Matrix
- Valve Cover Installation
Troubleshooting
- Engine / Cooling System
General Information
- Special Tools
- Torque Specifications
- Efi Service Notes
- Fuel System Assembly View
- Fuel System Component Locations
Electronic Fuel Injection
- Principal Components
- Efi Operation Overview
- Initial Priming / Starting Procedure
Electronic Control Unit (Ecu)
- Operation Overview
- Ecu Service
- Ecu Replacement
Fuel Injectors
- Operation Overview
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement
Fuel Tank
- 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
T-Map Sensor
- 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
Pedal Position Sensor (Pps)
- Operation Overview
- Pps Location
- Pps Test
- Pps Replacement
Efi Diagnostics
- Data Display Definitions
- Trouble Code Display (Etc)
- Efi Troubleshooting
Digital Wrench
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Also Refer To The Beginning Of This Chapter)
- 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
- Ecu Reprogramming (Reflash)
- Polaris Mobile Digital Wrench (Pmdw)
General Information
- Special Tools
- Torque Specifications
- Clutch Charts
Pvt System Overview
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- Maintenance / Inspection
Pvt System Service
- Pvt Covers And Ducting Components
- Pvt Disassembly
- Pvt Assembly
Drive Belt
- Belt Removal
- Belt Inspection
- Belt Installation
- 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)
- Assembly View
- Clutch Disassembly
- Bushing Service
- Clutch Assembly
Driven Clutch Service (Non-Ebs)
- Driven Clutch Assembly View (Non-Ebs)
- Driven Clutch Disassembly
- Driven Clutch Assembly
Troubleshooting
- Pvt Troubleshooting
- Overheating / Diagnosis
General Information
- Torque Specifications
- 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 (Turf Mode Models Only)
- 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
- Transmission Assembly View (No Turf Mode)
- Transmission Assembly View (Turf Mode Models)
Troubleshooting
- Shifting Difficulty
General Information
- Torque Specifications
- 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
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
General Information
- Special Tools
- Torque Specifications
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
Fox Shock Service
- Shock Specifications (Fox)
- Fox Shock Disassembly
- Fox Shock Assembly
General Information
- Special Tools
- Torque Specifications
- General Specifications
- Brake System Service Notes
- Hydraulic Brake System Operation
Brake System Assembly View
- Rzr 900
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
- Parking Brake Cable Adjustment
- Parking Brake Caliper
- Parking Brake Disc
Front Brake Pads
- Front Caliper / Pad Removal
- Front Pad Inspection
- Front Caliper / Pad Installation
- Brake Burnishing Procedure
Front Caliper Service
- Front Caliper Assembly View
- Front Caliper Disassembly
- Front Caliper Inspection
- Front Caliper Assembly
Front Brake Disc
- Front Brake Disc Inspection
- Front Brake Disc Runout
- Front Disc Replacement
Rear Caliper / Brake Pads
- Rear Caliper / Brake Pad Removal
- Rear Brake Pad Inspection
- Rear Caliper / Pad Installation
- Brake Burnishing Procedure
Rear Caliper Service
- Rear Caliper Assembly View
- Rear Caliper Disassembly
- Rear Caliper Inspection
- Rear Caliper Assembly
Rear Brake Disc
- Rear Disc Inspection
- Rear Disc Replacement
Troubleshooting
- Brake Noise Troubleshooting
- Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
General Information
- Special Tools
- Torque Specifications
Body Assembly Views
- Cab Frame Assembly
- Doors
- Dash / Instruments
- Hood / Front Body
- Chassis / Main Frame
- Seats
- Floor / Rocker Panels
- Rear Cargo Box / Fenders
- Rear Bumper
Body Component Removal
- Seat Removal
- Engine Service Panel
- Front Bumper Removal
- Rear Bumper Removal
- Hood Removal
- Upper Dash Removal
- Lower Dash Removal
- Front Fender / Body Removal
- Rear Fender / Fender Flair Removal
- Cargo Box Removal
- Rocker Panel / Console / Floor
Decals
- Decal Replacement
General Information
- Special Tools
- Service Notes
- Under Dash Components
Instrument Cluster
- Overview
- Information Display Area
- Diagnostic Mode
- Instrument Cluster Pinouts
Switches
- Brake Light Switch
- Headlamp Switch
- Ignition (Key) Switch
- Awd / 2wd Switch (Models Without Turf)
- Awd/2wd/Turf Switch (Models With Turf)
- Transmission (Gear Position) Switch
- Seat Belt Switch
Charging System
- Stator
- Voltage Regulator
- Charging System “Break Even” Test
- Charging System Stator (Alternator) Tests
- Charging System Testing Flow Chart
Battery
- Battery Specifications
- 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
- Relay Circuits
- Fuse / Circuit Breaker Circuits
Differential Circuit (Turf Models Only)
- Turf Solenoid (Turf Mode Models Only)
- Turf Solenoid Driver (Turf Mode Models Only)
Misc. Electrical
- 12v Receptacle
- Awd Coil
- Speed Sensor
- Terminal Block
- Ignition Coil
- Chassis Ground Point
- Diagnostic Plug
Break-Out Diagrams
- Awd Break-Out Diagram
- Cooling System Break-Out Diagram
- Eps Break-Out Diagram
- Lighting Break-Out Diagram
- Starting System Break-Out Diagram
- Differential Circuit Break-Out Diagram
- Vehicle Speed Sensor Break-Out Diagram
- Unswitched Chassis Power Break-Out Diagram
- Key On Battery Power Break-Out Diagram
2015_RZR_900_Wiring_Diagrams
2015 Rzr 900 & Rzr S 900 (Chassis)
2015 Rzr S 900 Eps (Chassis)
2015 Rzr 900 & Rzr Xc, Eps, Turf (Chassis)

OWNERS MANUAL