Polaris RZR 900 2015 User 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.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
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

SAFETY WARNINGS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE
NOTE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX
REV DATE CHANGES
R01 9/11/15 Initial Release. RZR S 1000 added for 2016
R02 10/27/2015
Add PU-50658-A matrix to transmission section.
Rear Axle Nut torque changed to 180 ft-lb
Lower rear bearing carrier torque changed to 40 ft-lb + 180°
R03 2/29/2016 Clarified CAN system testing
R04
3/30/2016 Updated Driven Clutch Service procedures with new graphics
4/7/2016 Updated Shock preload information and images. Added mono shock
information
R05 12/06/2016 • Updated Exhaust valve clearance matrix
• Updated intake hose clamp torque
R06 04/25/2017
Increased Oil Filter torque specification
Added new process for selecting/calculating valve tappets
R07 05/11/2017 Corrected CAN System Testing topic
R08 11/21/2017 Added door latch and door adjustment procedures

2015-2016 RZR 900 2016 RZR S 1000
Service Manual
Chapter Summary
CHAPTER 1: GENERAL INFORMATION
CHAPTER 2: MAINTENANCE
CHAPTER 3: ENGINE / COOLING SYSTEM
CHAPTER 4: FUEL SYSTEM
CHAPTER 5: PVT SYSTEM
CHAPTER 6: TRANSMISSION
CHAPTER 7: FINAL DRIVE
CHAPTER 8: STEERING / SUSPENSION
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL

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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MISC. INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2015 RZR 900 / RZR 900 EPS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2015 RZR 900 XC SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2015 RZR S 900 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
2015 RZR 4 900 EPS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2016 RZR 900 / RZR 900 EPS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
2016 RZR 900 XC SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2016 RZR S 900 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
2016 RZR 900 S4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
2016 RZR S 1000 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.31
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33

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VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5R U E 57A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)
Example: 4XARUE573FG000000
WORLD MFG. ID
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
CHASSIS
DRIVELINE
CHASSIS
MODIFIER
ENGINE SIZE
ENGINE MODIFIER
CHECK DIGIT
MODEL YEAR *
MFG. LOCATION
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A R U E 5 7 3 F G 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018
GENERAL INFORMATION

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VEHICLE AND ENGINE SERIAL NUMBER
LOCATION
Whenever corresponding about a Polaris ORV, refer to
the vehicle identification number (VIN) and the engine
serial number.
The VIN can be found stamped on a portion of the left
rear upper frame and also on a decal on the front frame
support behind the lower shock mounting location q.
The engine serial number can be found on a decal
applied to the front of the engine crankcase wor
stamped into the crankcase on the PTO side of the
engine.
GENERAL INFORMATION
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MISC. INFORMATION
PUBLICATION NUMBERS
MODEL OWNER’S MANUAL PARTS MANUAL
2015 RZR 900 / EPS (50″) 9925892 9925324
2015 RZR 900 XC 9925892 9925324
2015 RZR S 900 / EPS (60″) 9925892 9925792
2015 RZR 4 900 EPS (60″) 9925892 9925792
2016 RZR 900 / EPS (50″) 9926378 9926379
2016 RZR 900 XC 9926378 9926379
2016 RZR INT’L 9926381 9926382
2016 RZR S 900 / EPS (60″) 9926378 9926380
2016 RZR S4 900 9926378 9926386
2016 RZR S 1000 9926384 9926385
NOTE
When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.
GENERAL INFORMATION

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REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.
SERIES# PART NUMBER
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
GENERAL INFORMATION
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SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier.
Bosch Automotive Service Solutions:
1-800-345-2233 or http://polaris.service-solutions.com/
GENERAL INFORMATION

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2200421
Gas Shock
Recharging Kit
2460761
Hall Sensor Probe
Harness
2870341-A
Drive Clutch Spider
Remover/Installer
2870386
Piston Pin Puller
2870630
Timing Light
2870910-A
Roller Pin Tool
2870975
Mity-Vac Pressure
Test Tool
2871056
Driven Clutch Puller
2871226
Clutch Bushing
Replacement Tool Kit
2871282
Transmission Seal
Driver (50 MM)
2871351
IFP Depth Tool
2871358-B
Drive Clutch Holding
Fixture
2871702
Shaft Drive
Transmission and
Front Gearcase Tool
Kit
2871745
Static Timing Light
Harness
2872085
Drive Clutch Puller
2872608
Roll Pin Removal Tool
(27″)
2876389
Combination Pliers
2877408
Spanner Wrench /
Clutch Spreader
8700226
CV Boot Clamp Pliers
(ear)
9314177-A
Drive Clutch Holding
Tool
GENERAL INFORMATION
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PA-48838
Fuel Pressure Adapter
PA-49316
Water Pump Drive &
Rotor Removal Tool
PA-50231
Snorkel Driver
PS-45908
T-Handle Tool
PU-43506-A
Fuel Pressure Gauge
Kit
PU-45281–A
Shock Body Holding
Tool
PU-47471
Smartlink Module Kit
PU-48951
CV Boot Clamp Pliers
(Stepless)
PU-49466
Relay Bypass
PU-50105
Oil Filter Wrench
PU-50296
Battery Tester
PU-50338
Hydrometer
PU-50518
Clutch Compressor
PU-50562
Engine Stand Adapter
PU-50563
Cylinder Holding &
Camshaft Timing
Plate
PU-50564
Water Pump Seal
Installer
PU-50565
Oil Pressure Gauge
Adapter (1/2 NPT)
PU-50566
Transmission Nut
Socket
PU-50578
Clutch Spider Nut
Socket
PU-50624
Rolling Engine Stand
GENERAL INFORMATION

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PU-50625
Engine Stand Adapter
Sleeve (2″)
PU-50658-A
Clutch Center
Distance Tool
PU-50931
Shock Rod Holding
Tool (3/4″)
PU-50939
Shock Seal Protector
Sleeve (5/8″)
PU-51024
Shock Rod Holding
Tool
PU-51039
Gas Shock Fill Tool
PV-1253
Valve Spring
Compressor
PV-43513-A
Valve Spring
Compressor Adapter
PV-43526
Connector Test Kit
PV-43531
Oil Presure gauge
PV-43568
Fluke Multimeter
PV-43570
Piston Ring
Compressor Pliers
PV-48656
Fuel Pressure Gauge
Adapter
PW-47053
Bench Mount Engine
Stand
PW-47054
Engine Stand Adapter
Sleeve (2 3/8″)
GENERAL INFORMATION
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GENERAL SPECIFICATIONS
2015 RZR 900 / RZR 900 EPS
SPECIFICATIONS
CATEGORY DIMENSION / CAPACITY
Length 107″ / 271.8 cm
Width 50″ / 127cm
Height 69.5″ / 176.5cm
Wheel Base 79″ / 200 cm
Ground Clearance 10-11″ / 25.4-27.9 cm
Dry Weight 1148 lbs. / 521 kg
Gross Vehicle Weight 1969 lbs. / 893 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity (Payload)
740 lbs. / 336.4 kg
(Includes riders, cargo and
accessories)
Hitch Towing Capacity 1500 lbs (680 kg)
Hitch Tongue Capacity 150 lbs (68 kg)
GENERAL INFORMATION

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ENGINE
Platform Domestic Twin Cyl., 4–Stroke,
DOHC
Engine Displacement 875 cc
Number of Cylinders 2
Bore & Stroke 93 x 64.4 mm
Compression Ratio 10.5:1
Engine Idle Speed 1250 +/- 100 RPM
Engine Max Speed 8300 RPM
Engine Hot Light Instrument Cluster Indicator
Lubrication Wet Sump
Oil Requirements PS4
Oil Capacity 2.5 qts. (2.4 L)
Coolant Capacity 5.0 qt (4.7 L)
FUEL SYSTEM
Type Bosch ME17 EFI
Fuel Delivery Electronic Fuel Pump (in-tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Fuel Capacity /
Requirement
9.5 gal. (36 L)
87 Octane (minimum)
ELECTRICAL
Alternator Max Output 560 Watts @ 3000 RPM
Lights: Main Headlights Dual Beam 55/60W Halogen
Taillights 0.2 Watt LED cluster
Brake Lights 2.9 Watt LED cluster
Ignition System ME17 ECU
Spark Plug / Gap NGK MR7F/ 0.7–0.8 mm
Battery / Amp Hr 12v Flooded, 575 CCA
DC Outlet Standard 12 Volt
Relays Fan, EFI, Fuel Pump, Chassis,
EPS (if appl.)
Circuit Breaker 20A Cooling Fan
Fuses
10A EFI
10A Key
10A Term
10A Accessory
10A Drive
15A Lights
20A EPS (if appl.)
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Sequence In Line Shift - P / R / N / L / H
Transmission Gear Ratios:
High
Low
Reverse
10.4:1
18.8:1
22.92:1
Front Gearcase Lubricant
Requirement
Demand Drive
7.5 oz. (222 ml)
Transmission Lubricant
Requirement
Full Synthetic AGL
44 oz. (1300 mL)
STEERING / SUSPENSION
Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)
Front Suspension Independent Dual A-arm
Sachs Shocks
Front Travel 10″ (25.4 cm)
Rear Suspension Independent Dual A-arm
Sachs Shocks
Rear Travel 10″ (25.4 cm)
Spring Adjustment Threaded Spanner Wrench
Adjustment
WHEELS / BRAKES
Front Rim / Size Steel
12 x 6
Rear Rim / Size Steel
12 x 8
Front Tire Make / Model /
Size
PXT
26 x 8 R12
Rear Tire Make / Model /
Size
PXT
26 x 9 R12
Tire Air Pressure Front 10 psi (69 kPa)
Rear 12 psi (83 kPa)
Brake System
Front & Rear
Foot Actuated 4 Wheel
Hydraulic – Dual Bore Caliper
Brake Fluid DOT 4
For clutch specifications / High Altitude setup, see PVT
System chapter – Clutch Charts, page 5.4
GENERAL INFORMATION
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2015 RZR 900 XC SPECIFICATIONS
CATEGORY DIMENSION / CAPACITY
Length 108″ / 274.3 cm
Width 55″ / 139.7 cm
Height 70.5″ / 179 cm
Wheel Base 79″ / 200 cm
Ground Clearance 11″ / 28 cm
Dry Weight 1247 lbs. / 566 kg
Gross Vehicle Weight 2068 lbs. / 938 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity (Payload)
740 lbs. / 336 kg
(Includes riders, cargo and
accessories)
Hitch Towing Capacity 1500 lbs (680 kg)
Hitch Tongue Capacity 150 lbs (68 kg)
GENERAL INFORMATION

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ENGINE
Platform Domestic Twin Cyl., 4–Stroke,
DOHC
Engine Displacement 875 cc
Number of Cylinders 2
Bore & Stroke 93 x 64.4 mm
Compression Ratio 10.5:1
Engine Idle Speed 1250 +/- 100 RPM
Engine Max Speed 8300 RPM
Engine Hot Light Instrument Cluster Indicator
Lubrication Wet Sump
Oil Requirements PS4
Oil Capacity 2.5 qts. (2.4 L)
Coolant Capacity 5.0 qt (4.7 L)
FUEL SYSTEM
Type Bosch ME17 EFI
Fuel Delivery Electronic Fuel Pump (in-tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Fuel Capacity /
Requirement
9.5 gal. (36 L)
87 Octane (minimum)
ELECTRICAL
Alternator Max Output 560 Watts @ 3000 RPM
Lights: Main Headlights Dual Beam 55/60W Halogen
Taillights 0.2 Watt LED cluster
Brake Lights 2.9 Watt LED cluster
Ignition System ME17 ECU
Spark Plug / Gap NGK MR7F/ 0.7–0.8 mm
Battery / Amp Hr 12v Flooded, 575 CCA
DC Outlet Standard 12 Volt
Relays Fan, EFI, Fuel Pump, Chassis,
EPS
Circuit Breaker 20A Cooling Fan
Fuses 10A EFI
10A Key
10A Term
10A Accessory
10A Drive
15A Lights
20A EPS
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Sequence In Line Shift - P / R / N / L / H
Transmission Gear Ratios:
High
Low
Reverse
10.4:1
18.8:1
22.92:1
Front Gearcase Lubricant
Requirement
Demand Drive
7.5 oz. (222 ml)
Transmission Lubricant
Requirement
Full Synthetic AGL
44 oz. (1300 mL)
STEERING / SUSPENSION
Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)
Front Suspension Independent Dual A-arm
FOX 2.0″
Front Travel 10″ (25.4 cm)
Rear Suspension Independent Dual A-arm
FOX 2.0″
Rear Travel 10″ (25.4 cm)
Spring Adjustment Threaded Spanner Wrench
Adjustment
WHEELS / BRAKES
Front Rim / Size Aluminum 14 x 7
Rear Rim / Size Aluminum 14 x 8
Front Tire Make / Model /
Size
GBC Dirt Commander
27 x 9 R14
Rear Tire Make / Model /
Size
GBC Dirt Commander
27 x 11 R14
Tire Air Pressure Front 10 psi (69 kPa)
Rear 12 psi (83 kPa)
Brake System
Front & Rear
Foot Actuated 4 Wheel
Hydraulic – Dual Bore Caliper
Brake Fluid DOT 4
For clutch specifications / High Altitude setup, see PVT
System chapter – Clutch Charts, page 5.4
GENERAL INFORMATION
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1.14 9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
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2015 RZR S 900 SPECIFICATIONS
CATEGORY DIMENSION / CAPACITY
Length 108″ / 274.3 cm
Width 60″ / 152.4 cm
Height 72″ / 182.9 cm
Wheel Base 79″ / 200 cm
Ground Clearance 12.5″ / 31.75 cm
Dry Weight 1208 lbs. / 548 kg
Gross Vehicle Weight 2029 lbs. / 920 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity (Payload)
740 lbs. / 336 kg
(Includes riders, cargo and
accessories)
Hitch Towing Capacity 1500 lbs (680 kg)
Hitch Tongue Capacity 150 lbs (68 kg)
GENERAL INFORMATION