Polaris Ranger RZR XP 900 2011 Service Manual Download

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Summary of Contents for Ranger RZR XP 900 2011

Page 1: ... PDLRRIS The Way Out 2011 RANGER RZR XP 900 SERVICE MANUAL PN 9923144 ...

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Page 3: ...e 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 Publications Question Consumers please pro...

Page 4: ... 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 TIllS MANUAL Loctite Registered Trademark ofthe Loctite Corporation Nyogel Trademark ofWm F Nye Co Fluke Registered Trademark ofJohn Fluke Mfg Co Mity Vac Registered Trademark ofNeward Ent...

Page 5: ...GENERAL INFORMATION II MAINTENANCE IfI ENGINE I COOLING II ELECTRONIC FUEL INJECTION II BODY I STEERING I SUSPENSION II CLUTCHING PVT FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL II II II II III ...

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Page 7: ...ION NUMBERS 1 3 REPLACEMENT KEYS 1 3 SPECIAL TOOLS 1 3 GENERAL SPECIFICATIONS 1 4 GENERAL 2011 RANGER RZR XP 900 1 4 DETAILED 2011 RANGER RZR XP 900 1 5 MISC SPECIFICATIONS AND CHARTS 1 6 CONVERSION TABLE 1 6 STANDARD TORQUE SPECIFICATIONS 1 7 SAE TAP I DRILL SIZES 1 8 METRIC TAP I DRILL SIZES 1 8 DECIMAL EQUIVALENTS 1 8 GLOSSARY OF TERMS 1 9 9923144 2011 RANGER RZR XP 900 Service Manual Copyright...

Page 8: ...ndividual Serial No World Mfg 10 Vehicle Description 123456789 4XA J H 87A I E e Body Style Emissions Plant No Powerlrain Check Digit Vehicle and Engine Serial Number Location This could be either a number or a letter Whenever corresponding about a Polaris ORV refer to the vehicle identification number YIN and the engine serial number The VIN can be found stamped on a portion ofthe left rear frame...

Page 9: ...art to the right for the proper part number KEY COVER PIN 5533534 I C 1x 1 ies SPECIAL TOOLS Series Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Special tools may be required while servicing this vehicle Some ofthe tools listed or depicted are mandatory while othertools maybe substituted with a similar tool ifavailable Po...

Page 10: ...3cm Dry Weight 1190 Ibs 1540 kg Gross Vehicle Weight 1930 Ibs 1875 kg Cargo Box Capacity 300 Ibs 1136 kg Maximum Weight 740 Ibs 1335 6 kg Includes driver passenger cargo Capacity Payload and accessories Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads Do not use Hitch Tongue Capacity this vehicle for towing Do not modify the vehicle by adding a hitch 1 4 9923144 201...

Page 11: ...T4 MODEL 2011 RANGER RZR XP 900 MODEL NUMBER R11JH87AA AD ENGINE NUMBER 1204098 1 i Platform 4 Stroke DOHC Twin Cylinder Liquid Cooled Electric Start Engine Number 1204098 ES0870LE011 Engine Displacement 875cc Number of Cylinders 2 Bore Stroke mm 93 x 64 4 mm Compression Ratio 10 5 1 Engine Idle Speed 1250 100 RPM Engine Max Operating RPM 8750 RPM Lubrication Dry Sump Oil Requirements PS 4 Plus Sy...

Page 12: ...timeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters I Liters I x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters I Liters I xO 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters I Liters I x 1 057 US quarts US qt US gallons US gal x 3 785 Liters I Liters I x ...

Page 13: ...ade 2 Grade 5 Grade 8 Torgue in Ibs INm 24 27 3 1 43 5 0 60 6 9 32 31 3 6 49 5 6 68 7 8 Torgue ft Ibs Nm 20 5 7 8 11 12 16 28 6 8 10 14 14 19 18 11 15 17 23 25 35 24 12 16 19 26 29 40 16 20 27 30 40 45 62 24 23 32 35 48 50 69 14 30 40 50 69 70 97 20 35 48 55 76 80 110 13 50 69 75 104 110 152 20 55 76 90 124 120 166 72 78 In Ibs 14 18 ft Ibs 26 30 ft Ibs To convert ft Ibs to Nm multiply foot pounds...

Page 14: ...4 2 64 50 5 8 11 17 32 3 48 5 64 5 8 18 37 64 3 56 45 4 40 43 3 4 10 21 32 4 48 42 3 4 16 11 16 5 40 38 7 8 9 49 64 5 44 37 7 8 14 13 16 6 32 36 1 8 7 8 6 40 33 1 12 59 64 8 32 29 1 1 8 7 63 64 8 36 29 1 1 8 12 13 64 10 24 24 1 1 4 7 17 64 10 32 21 12 24 17 1 1 4 12 1 11 64 12 28 4 6mm 1 1 2 6 1 11 32 1 4 20 7 1 1 2 12 1 27 64 1 4 28 3 1 3 4 5 1 9 16 5 16 18 F 1 3 4 12 1 43 64 5 16 24 I 2 41 2 1 2...

Page 15: ...n a rotational direction g Gram Unit ofweight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm2 Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end ofa lever one meter in length applied in a rotational direction I or ltr Liter Ibs in2 Pounds per square inch Left or Right Side Always referre...

Page 17: ... ENGINE OIL LEVEll OIL AND FILTER CHANGE 2 16 ENGINE OIL TANK BREATHER HOSE INSPECTION 2 18 ENGINE CYLINDER LEAKDOWN TEST 2 18 VALVE CLEARANCE INSPECTION 2 18 EXHAUST SPARK ARRESTOR 2 21 TRANSMISSION AND FRONT GEARCASE 2 22 TRANSMISSION LUBRICATION 2 22 FRONT GEARCASE LUBRICATION 2 23 COOLING SYSTEM 2 24 COOLANT STRENGTH 2 24 COOLANT LEVEL INSPECTION 2 25 COOLING SYSTEM PRESSURE TEST HOSES 2 25 RA...

Page 18: ...ECTION 2 33 WHEEL TOE ADJUSTMENT 2 33 SUSPENSION FOXTM 2 34 SPRING PRELOAD ADJUSTMENT 2 34 SHOCK COMPRESSION ADJUSTMENT 2 35 BRAKE SYSTEM 2 36 BRAKE FLUID INSPECTION 2 36 BRAKE PAD DISC INSPECTION 2 36 BRAKE HOSE AND FITTING INSPECTION 2 36 MAINTENANCE LOG 2 37 2 2 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 19: ... to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists ofthe first 25 hours ofoperation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Drive vehicle slowly at first while val ing the throttle position Do n...

Page 20: ...ter 25 H Monthly 250 400 Inspect replace as needed E Battery 25 H Monthly 250 400 Check terminals clean test Front Gearcase Lubricant 25 H Monthly 250 400 Inspect level add lubricant if needed Demand Drive Plus Transmission Lubricant 25 H Monthly 250 400 Inspect level add lubricant if needed AGL Gearcase Lubricant Engine Breather Filter 25 H Monthly 250 400 Inspect replace if necessary E if equipp...

Page 21: ...orque to specification Exhaust Silencer Pipe 100 H 12 M 1000 1600 Inspect Inspect for wear routing security apply Wiring 100 H 12 M 1000 1600 dielectric grease to connectors subjected to water mud etc Clutches Drive and Driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive Belt 100 H 12 M 1000 1600 Inspect replace as needed Front Wheel Bearings 100 H 12 M 1000 1600 Inspect replace as ...

Page 22: ... coolant every two years More often under severe use such as operated in water or under severe loads IMPORTANT Refer to Engine Oil and Filter Service procedure for proper method to check the engine oiL MAX MIN Recovery Bottle Maintain oil level between Min and Max range r Dipstick i I Engine Oil Dipstick Radiator Cap 2 Engine Coolant Under Front Hood 1 Engine Oil Dipstick Under Oil Tank Access Pan...

Page 23: ... level every 25 hours or at the fill hole threads 250 mi 400 km Change fluid 5 Transmission Polaris AGL Plus Add lubricant until it is visible yearly or every 2500 mi 4000 Gearease Lubricant at the fill hole threads km whichever comes first More often under severe use such as operated in water or under severe loads 3 Brake Fluid Front LH Wheel Well 4 Front Gearcase Front RH Wheel Well Reservoir Ma...

Page 24: ...tings on each Polaris All Season Grease 800 km Grease before long Pivot Bushings side of the vehicle periods of storage and after Grease 2 fittings through thoroughly washing or Rear Torsion Bar the skid plate access holes Polaris All Season Grease submerging the vehicle Bushings on each side of the vehicle Grease Access through left rear wheel well I U Rear Propshafts Grease Access through skid p...

Page 25: ...23 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871329 Dielectric Grease NyogeI Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count MAINTENANCE NOTE Each item can be purchased separately at your local Polaris dealer Part No Description Ad...

Page 26: ...ar or damage Frame Nuts Bolts and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter Shift Cable Inspection I Adjustment Shift cable adjustment may be necessary if symptoms include No gear position or AWD display on instrument cluster Ratcheting nois...

Page 27: ... or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result S...

Page 28: ...uick connect fitting for signs of wear deterioration damage or leakage Replace line ifnecessary 4 Be sure fuel lines are routed and retained properly IMPORTANT Make sure lines are not kinked or pinched Throttle Pedal Inspection If the throttle pedal has excessive play due to cable stretch or cable misadjustment it will cause a delay in throttle reaction Also the throttle may not open fully Ifthe t...

Page 29: ... a 12 mm open end wrench move the cable adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal NOTE While adjusting lightly move the throttle pedal in and out 5 Apply Thread Sealant with Teflon to the adjuster threads 6 Re tighten the jam nut after final adjustment is made 7 Slide the cable adjuster boot over the cable adjuster to its original position and reinstall the ...

Page 30: ...with fuel or oil it must be replaced 5 Inspect the air filter and replace ifnecessary IMPORTANT DO NOT attempt to clean the air filter 6 Place the air filter into the air box and reinstall the air box cover NOTE Be sure the lower tabs on the air box cover are properly engaged into the airbox 7 Engage the cover latches and tighten the retaining knobs 8 Reinstall the cargo box access panel Intake Ba...

Page 31: ...dView Flter Explo e Air Box I Air I Drain Cap Intake Pre Filter Snap Bushing Clamps Clamps Intake Tubes Air Filter Clamp Air Box Cover 2 15 ER RZR XP 900 Service Manual 9923144 2011 R Nh 2011 Polaris Sales Inc Copyng ...

Page 32: ... Remove the oil tank access panel Remove the dipstick from the oil tank and wipe it dry with a clean cloth 5 Reinstall the dipstick completely fully threaded Remove the dipstick and check the oil level 2 16 7 When finished reinstall dipstick and oil tank access panel Engine Oil and Filter Change Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart Always ...

Page 33: ...urface on the drain plug should be clean and free of burrs nicks or scratches 11 Reinstall the oil tank and engine crankcase drain plugs Torque drain plugs to specification C T Drain Plugs 12 ft Ibs 16 Nm 12 Remove the engine oil dipstick see Engine Oil Level Fill the oil tank with 3 5 quarts 3 3 L of recommended engine oil Recommended Engine Oil PS 4 Plus Synthetic 4 Cycle Engine Oil PN 2876244 Q...

Page 34: ...the air intake baffle box Valve Cover Oil Tank Breather Hose Oil Tank 3 Remove the rear bumper and cargo box as an assembly s e Chapter 5 4 Remove the 8 screws that retain the outer clutch cover 5 Maneuver the outer clutch cover for drive clutch access NOTE Removal of left rear wheel or left rear shock is NOT necessary to perform this procedure NOTE Make sure hoses are not kinked or pinched Engine...

Page 35: ...vets that retain the heat shield to the frame cross members Remove the heat shield Heat i 8 Shield Y 10 Support the oil tank in position prior to removing the rear cross member MAINTENANCE 11 Remove the 4 bolts that attach the rear cross member to the vehicle frame Raise and slide the cross member towards the rear ofthe vehicle to gain access to valve cover as shown below 12 Remove the 4 T40 bolts...

Page 36: ...e cold 011 013 in 0 275 0 325 mm 17 Repeat steps 14 16 until all 8 valves have been inspected 18 Inspect the valve cover seal and replace ifnecessary 19 Install valve cover and the 4 T40 bolts Torque bolts to specification C T Valve Cover Bolts 7 ft Ibs 10 Nm 20 Slide rear cross member back into position and install the 4 selftapping mounting bolts Be sure oil tank mounting bracket is correctly su...

Page 37: ...t from contact with the exhaust components Allow components to cool SUfficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time 1 Remove the retaining screw and nut 2 Remove the spark arrestor from the end ofthe silencer I 24 Install the wire ...

Page 38: ...eck Fill Drain Plug Torque 10 14ft lbs 14 19 Nm Transmission Lubricant Change The drain plug is located on the bottom of the transmission gearcase Access the drain plugthrough the drain hole inthe skid plate The fill plug is located on the rear portion of the transmission gearcase Access the fill plug at the rear ofthe vehicle Maintain lubricant level even with the bottom ofthe fill plug hole 1 Re...

Page 39: ...level should be checked and changed in accordance with the maintenance schedule Be sure vehicle is positioned on a level surface when checking or changing the fluid Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located on the bottom right side of the front gearcase Access the fill plug through the right front wheel well Maintain...

Page 40: ...diator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank pastthe pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels often during the break in period NOTE Overheating of engine could occur ...

Page 41: ...sure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly 7 Remove recovery bottle cap and add coolantusing a funnel MAINTENANCE 8 Fill recovery bottle to MAX level with recommended coolant or 50 50 or60 40 mixture ofantifreeze and distilled water as required for freeze protection in your area Recommended Coolant Polaris Premium Pre Mixed Antifreeze P...

Page 42: ... to relieve any cooling system pressure 1 Remove the front hood Coolant Drain I Fill Oil Cooler Inlet Hose Oil Cooler Outlet Hose Waterpump Outlet Hose Bypass Hose Flush radiator fins in this direction Engine Coolant Hose Inspection Radiator Inspection I Cleaning 1 Check radiator air passages for restrictions or damage 3 Inspect all engine hoses for cracks deterioration abrasion or leaks Replace i...

Page 43: ... through the left rear wheel well 1 Using a flat blade screwdriver remove the PVT drain plug and G ring from the outer clutch cover 2 Allow the water to drain out completely 3 Reinstall the drain plug and G ring 4 Place the transmission in PARK apply the brake and start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold th...

Page 44: ...ropriate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel 2 28 Wheel Installation 1 Verify the transmission is still in PARK 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Attach the wheel nuts and finger tighten them 4...

Page 45: ...from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed sp...

Page 46: ...e installing the battery 1 Ensure the battery is fully charged 2 30 2 Place the battery in the battery holder and secure with hold down strap 3 Coatthe terminals with dielectric grease or petroleumjelly 4 Connect and tighten the red positive cables first 5 Connect and tighten the black negative cables last 6 VerifY that cables are properly routed and reinstall the driver s seat Battery Charging I ...

Page 47: ... a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 8 Measure gap with a wire gauge Adjust gap ifnecessary by carefully bending the side electrode 9 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the inc...

Page 48: ... certified technician Use only genuine Polaris replacement parts Steering Wheel Freeplay Replace any worn steering components Steering should move freely through entire range oftravel without binding Elevate front end of machine so front wheels are offthe ground Check for any looseness in front wheel hub assembly by grasping the tire firmly at top and bottom first and then at front and rear Try to...

Page 49: ...rward Position chalk marks facing rearward even with the hub axle center line 5 Again measure the distance between the marks and record Call this measurement B Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 3 16 3 2 to 4 8 mm toe out This means the measurement at the front ofthe tire...

Page 50: ...death Always adjust both the left and right spring preloads equally Spring Preload Adjustment Factory Setting Front 7 625 in 19 37 cm Rear 3 625 in 9 21 cm 2 34 NOTE Refer to the shock illustrations within this procedure for spring preload measurement location The factory preload setting is appropriate for nearly all riding conditions Since this vehicle is equipped with full skid plates adjustment...

Page 51: ...icle The increased suspension height will negatively impact vehicle stability when operating without a load MAINTENANCE Shock Compression Adjustment The compression damping adjustment is located on top of the shock Piggyback reservoir of each shock Use a flat blade screwdriver to make damping adjustments 2 NOTE When the adjuster screw is turned clockwise until it stops the damping is in the fully ...

Page 52: ...e 2 Place the transmission in PARK 3 View the brake fluid level in the reservoir The level should be between the MAX and J tlIN level lines Measure Pad Material Thickness 1 Service Limit 040 1 mm 4 Ifthe fluid level is lower than the J tlIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for...

Page 53: ...MAINTENANCE MAINTENANCE LOG Service Date Hours I Miles km Service Performed I Comments Dealer I Technician r 111 2 37 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 55: ...NSPECTION TOP END 3 31 VALVE COVER REMOVAL 3 31 CAMSHAFT REMOVAL 3 31 CAMSHAFT SPROCKET INSPECTION 3 33 CAMSHAFT CAMSHAFT BORE INSPECTION 3 33 CYLINDER HEAD REMOVAL 3 34 CYLINDER HEAD INSPECTION WARP INSPECTION 3 35 CYLINDER HEAD DISASSEMBLY 3 35 VALVE INSPECTION 3 36 COMBUSTION CHAMBER CLEANING 3 37 VALVE SEAT RECONDITIONING 3 38 ENGINE DISASSEMBLY I INSPECTION LOWER END 3 40 STATOR COVER REMOVAL...

Page 56: ...nd insert the oil pressure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 Plus at operating temperature and may vary considerably if any other oil is used or if engine is not up to temperature 3 4 6 Upon assembly torque the crankcase gallery plug to specification C T Cr...

Page 57: ... I I I Cylinder Head y Cam Cyl head Heat Coolant in bearings drains Exchanger Coolant ou Cylinder unit Chain Cam chain tensioner chest Balancer bearing Starter gear bearing S 1 Main Stator bolt jet feed U MAG 1 M bearing 1 P Main Oil Main Gallery 1 CENTER Piston spray jet 1 Piston small f bearing 2 end bearings 1 Crank big end 1 I Main PT01 bearing 3 Piston spray jet 2 r Piston small end bearings ...

Page 58: ...e Seat Contacting Width Intake Service Limit 0 0551 1 4 mm Valve Seat Valve Seat Contacting Width Exhaust Standard 0 0590 0 0039 1 5 0 10 mm Valve Seat Contacting Width Exhaust Service Limit 0 0748 1 9 mm Valve Seat Angles 30 0 1 5 45 0 0 5 60 0 1 50 Valve Guide Valve Guide Inner Diameter 0 2165 0 2171 5 500 5 515 mm Valve Lash Cold Intake 0 005 0 007 0 125 0 175 mm Valve Lash Cold Exhaust 0 011 0...

Page 59: ...ting Rod Small End LD Service Limit 0 7897 20 06 mm Connecting Rod 1 Marking Connecting Rod Big End Bore LD 1 7318 1 7321 43 989 43 996 mm 2 Marking Connecting Rod Big End Bore LD 1 7321 1 7323 43 996 44 003 mm 3 Marking Connecting Rod Big End Bore LD 1 7323 1 7326 44 003 44 010 mm B Marking Main Journal O D Standard 1 6144 1 6147 41 006 41 014 mm G Marking Main Journal O D Standard 1 6140 1 6143 ...

Page 60: ...UE SEQUENCE 10 Nm 18 5 CYLINDER HEAD TORQUE SEQUENCE Step 1 21 ft Ibs 28 Nm Step 2 26 ft Ibs 35 Nm Step 3 180 0 1 2 turn STATOR COVER 9 ft Ibs TORQUE SEQUENCE 12 Nm 3 11 5 9 ft Ibs 12 Nm 10 26 ft Ibs 35 Nm 21 ft Ibs 28 Nm 90 0 1 4 turn CRANKCASE SPLlT L1NE 6 TORQUE SEQUENCE 5 7 3 4 8 SUMP COVER TORQUE SEQUENCE 9 ft Ibs 12 Nm 15 3 8 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polar...

Page 61: ...1 L DROUL IN SfQULNCL PER CRANKCIISE SPII I IINf VIEW SELECT PROPlR BEAR INSS PER CHART ill TORQUE IN SEQUENCE PER CRANKCASE SPLIT LINE VIEW TORQUE TO 28 3 N m PLUS 90 DEGREfS APPLY ENGINE OIL TO iNTERNAL BEARING SURF Cr INSTAL CIRCllP WITH OPLN LNO TOWARDS TOP OF PISTON Al PLY OIL TO PlsrON PIN BOfiE I ill INSURE THAT OIL DEfLECTOR IS PROPERLY POSIT OfIED IN UPPER CRMilICASE INS SUR ACES SEAL MUS...

Page 62: ... 00 10 00 N m 120 00 12 00 I m ffi INSURE O R ING SEAlS ARE SEATED EEFORE ASSEMBl Y NOTE S LJ LUBRICATE SEAL WITH ENGIHE OIL PRIOR TO FILTER INSTALLATIOII Ii1SUHE 11 8 IS VISIBLE TO VUll Y ASSEMBLY APPLY ENGINE OIL TO TEHSIONER BORE PRIOR TO ASSEMBLY INSURE SEALING WASHER IS IN PLACE PRIOR TO TOHQIJING 2250 2 50 Nm i IL 40 00 4 OON APPLY ENGINE OIL TO CYLINDER BORES PRIOR TO ASSEMBLY 3 10 9923144 ...

Page 63: ...i2 00 N NOTE S L INSURE TAB IS VISIBLE TO VERIFY ASSEMBLY 1 ili TOROUE IN SEOUENCE SHOWN IN STATOR COVER VIEW THE MOUNTING SURFACE ON BOTH THE CRANKSHAFT AND FLYWHEEL SHOULD BE FREE FROM 01 L OR GREASE TORQUE IN SEGUEI CE SHOWII FOR CYLiNDER HEAD STEP I TORQUE IN SEQUENCE TQ 28 0 3 0 Nm STEP 2 rORQVE IN SEOUENCETO 35 0 3 5 N m STEP 3 TORQUE IN SEQUENCE TO 180 DEGREES TORGUE IN SEOLIENCE SHOWN FOR ...

Page 64: ...HTElI LOWER SCREW AND TORGUE HLN rORGUL lOP INSERT NS I DE GASKU APPLY SEALANT TO CORNERS OF VAl VE flOES F1 5TEf ER TOf l E TABLE i I QiJO 00 N L I IG OO 200 N m 800 I OO N 28 00 300 N m r 1200 2 00 N c Ir 35 00 2 00 N m 0 IOO OO iOOO N rn 1 22 50 2 50 N m L 10 00 4 00 N II OO 2 00 N IT L 15 00 2 00 N m 120 00 1200 N 3 12 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales ...

Page 65: ...s recommended for use in all cooling systems and comes pre mixed ready to use Cooling System Pressure Test 1 Remove the hood from the front cab A WARNING Never remove pressure cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing ENGINE I COOLING 2 Remove pressure cap and pressure test the cooling system using a c...

Page 66: ... servicing 3 14 4 Drain radiator by removing lower radiator hose Be sure to catch and dispose of coolant properly 5 Disconnect cooling fan electrical connector 6 Remove the upper radiator hose from the radiator 7 Disconnect the small radiator bypass hose and remove the 2 upper radiator support bolts 8 Lift radiator up to disengage it from its lower mounting points Tilt top ofradiator outward and r...

Page 67: ...d from the front cab A WARNING The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 2 Remove the pressure cap to relieve any system pressure see Pressure Cap Test 3 Drain coolant to a level below the thermostat housing 4 Remove upper coolant hose from thermostat housing A 5 Remove the rear bolt B retaining the thermostat cover 9 Install a new ...

Page 68: ... Waterpump I I 1 A ReCOVeryBOttie r Pressure cap r c I Filler Neck 0 Engine OJ 0 H oses V t Radiator Hoses Coolant Flow Diagram Outlet active when thermostat open 3 16 1 _ _ 1 Filler Neck IRecovery Bottle I Bypass active when thermostat closed Radiator 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 69: ...move the seats and engine service panel to access the coolant bleed screw ENGINE I COOLING 6 Open the bleed screw C to allow any trapped airto escape Close the bleed screw once a steady stream of coolant begins to drain out I 7 Tighten the bleed screwto specification top offcoolant and properly install the pressure cap e T Coolant Bleed Screw 89 9 in Ibs 10 1 Nm 8 Start the engine and allow it to ...

Page 70: ...tallation Be sure to catch and dispose of coolant properly 11 Remove the 3 bolts holding the water pump to the engine block Make note of different bolt lengths for installation 12 Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward 13 Maneuver water pump downward and remove it through the access hole in the skid plate 14 Plug the water pump dri...

Page 71: ...into engine crankcase 10 Be sure waterpump is fully seated and the drive tab and slot are properly engaged 11 Install the 3 water pump mounting bolts and torque to specification C T Water Pump Mounting Bolts 89 9 in Ibs 10 1 Nm 13 Install the right rear lower shock bolt and new nut Torque mounting bolt to specification C T Rear Shock Mounting Bolts 70 ft Ibs 95 Nm 14 Install the right rear wheel T...

Page 72: ...e Replace water pump housing assembly if necessary as shaft can not be purchased separately 4 Remove the bolt and washer retaining the water pump impeller to the shaft Inspect impeller veins for damage replace water pump housing assembly ifneeded NOTE The water pump impeller bolt is left hand thread reverse thread 5 Remove impeller from water pump shaft 6 Using an appropriate arbor press properly ...

Page 73: ...aces 19 Install a new water pump cover gasket 20 Install the water pump cover and 3 retaining bolts Torque 2 bolts in sequence to specification Bolt LH Thread NEW Gasket C T Water Pump Cover Bolts 89 18 in Ibs 10 2 Nm Apply Loctite 204 to bolt threads 21 Install 2 new water pump O rings and lubricate them with fresh engine oil 22 Install water pump assembly into engine as shown in the Water Pump I...

Page 74: ...cover 3 22 Engine Removal IMPORTANT Some engine repair procedures can be performed without removing the engine assembly from the vehicle Refer to Accessible Engine Components for further information NOTE The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine NOTE Have an assistant help guide the engine in and out of the vehicle while u...

Page 75: ... mounting bolt A from the left rear shock and discard the nut Install a new nut upon assembly 10 Remove the outer clutch cover screws B and remove the cover from the vehicle 11 Remove the drive belt drive clutch driven clutch inner clutch cover and clutch outlet duct see Chapter 6 IMPORTANT Be sure to use the correct Drive Clutch Puller PN 2872085 to prevent damage to crankshaft ENGINE I COOLING 1...

Page 76: ...d 4 nuts that attach the front and rear cross memberto the vehicle frame 23 Remove the 6 fasteners that attach the exhaust head pipe to the engine Remove the 2 exhaust springs that attach the head pipe to the muffler Remove exhaust head pipe towards the front ofthe vehicle Discard exhaust gaskets 20 Disconnect the oil lines at the engine crankcase Make note ofrouting and orientation 21 Remove the ...

Page 77: ...the LH side ofthe vehicle Discard the through bolt 27 To remove through bolt B Hold through bolt B firmly in position with an open ended wrench from the LH side ofthe engine From the RH side ofthe engine remove the nut that secures through bolt B Be sure that through bolt B does not rotate while removing the nut from the RH side of the engine Remove the through bolt from the LH side ofthe vehicle ...

Page 78: ...follow torque procedure outlined in Service Manual will result In damage to the engine case 1 Clean all dirt and debris out of the rear engine mount threads 3 75 ft Ibs bolt 2 33 ft Ibs jam nut 1 10 ft Ibs threaded spacer 34 Place engine onto the engine stand pU 50624 for service 2 Attach engine with suitable lifting straps to an overhead or portable engine hoist 3 Remove the engine stand adapter ...

Page 79: ...PU 50658 properly installed ENGINE I COOLING 8 Apply anti seize to the threaded spacers and fully thread the inner jam nuts onto the threaded spacers I 9 Install threaded spacers into the engine crankcase by hand approximately 3 turns 10 Install new engine through bolts and nut Loosely assemble by hand 11 Lightly tighten both threaded spacers by hand Be sure innerjam nuts are fully threaded onto t...

Page 80: ... torque the inner jam nut to 33 ft lbs 45 Nm 17 Install the 2 coolant hoses onto the engine 15 Torque the 2 new through bolts and new nut to 75 ft lbs 102 Nm IMPORTANT Hold the threaded spacer firmly in position while tightening the top through bolt 18 Replace exhaust gaskets seals Install exhaust head pipe Install the 6 fasteners that attach the exhaust head pipe to the engine and torque to speci...

Page 81: ...tch outlet duct see Chapter 6 ENGINE I COOLING 33 Install the left rear shock lower mounting bolt and new nut Torque to specification C T Rear Shock Mounting Bolts 70 ft Ibs 95 Nm 34 rIn_s_t_al_l_t_h_e_l_e_ft_re_ar_w_h_ee_l_an_d_t_or_q_u_e_w_h_e_el_n uts to 3 specification C T Wheel Nuts 30 ft Ibs 41 Nm 90 1 4 turn 35 Install the rear bumper and cargo box as an assembly see Chapter 5 NOTE Be sure ...

Page 82: ...n fluid levels controls and all important bolt torques Use only Polaris PS 4 PLUS Synthetic Engine Oil Never substitute or mix oil brands Serious engine damage and voiding of warrantycan result Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unlead...

Page 83: ...mbly 1 Rotate the engine so the PTO cylinder is at Top Dead Center IDe to relieve most ofthe valve spring pressure The camshaft lobes should face out and the slots on the end 3 ofthe camshafts should line up 2 Replace isolators B and valve cover seal C if oil leaks are evident 1 Remove the 4 valve cover shoulder bolts A and isolators B using a T40 driver 3 Remove the spark plugs D Stuff spark plug...

Page 84: ...heel and remove the remaining bolt from each camshaft sprocket 1 3 32 7 Lift the chain and sprockets offthe camshafts to allow each sprocket to be removed 8 Using a paperclip 1 or other tool hold the cam chain up NOTE The crankcase has a built in lower guide to prevent the chain from falling off the crankshaft 9 Evenly loosen the 4 bolts retaining each rear camshaft carrier K and carefully lift th...

Page 85: ... camshaft carriers to measure the camshaft bore Torque bolts in sequence to specification Replace cylinder head ifworn Camshaft Lobe Height Intake 0 9499 0015 24 13 040 mm Service Limit 0 9464 24 04 mm In I mm NOTE Replace camshafts if damaged or if any part is worn past the service limit Camshaft I Camshaft Bore Inspection Inspect all main journals and cam lobes as described below and compare to ...

Page 86: ...ed in the chassis 1 Remove the 2 outer M6 bolts A that retain the cylinder head B to the cylinder 2 Loosen the 6 cylinder head bolts C evenly 1 8 turn at a time until all are loose 3 Remove and discard the cylinder head bolts C 4 Tap cylinder head lightly with a soft faced hammer until loose 3 34 5 Tap only in reinforced areas or onthick parts ofthe cylinder head casting 6 Remove the cylinder head...

Page 87: ...en the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head V Jv In mm Cylinder Head Warp Limit 004 0 10 mm ENGINE I COOLING Cylinder Head Disassembly A WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs IMPORTANT Keep mated parts together and in order 3 with respect to their location...

Page 88: ...mm Service Limit 1 683 42 75 mm 2 Check valve face for runout pitting and burnt spots To check for bentvalve stems mountvalve in a drill oruse V blocks and a dial indicator 1 Remove all carbon from valves with a soft wire wheel or brush Valve Inspection n _ _ M Push down on the spring and remove the split keepers H NOTE Replace valve seals whenever cylinder head is disassembled Hardened cracked or...

Page 89: ...e stem with a micrometer in three places then rotate 90 and measure again take six measurements total Compare to specifications In 1mm Valve Guide 1 0 0 2165 0 2171 5 500 5 515 mm I v c ln mm Valve Stem Diameter Intake 0 2155 0 2161 5 475 5 490 mm Exhaust 0 2147 0 2153 5 455 5 470 mm 7 Be sure to measure each guide and valve combination individually NOTE The valve guides cannot be replaced Combust...

Page 90: ...valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area ofthe seat Ifthe contact area is less than 75 ofthe circumference ofthe seat rotate the pilot 180 and make another light cut Ifthe cutter now c...

Page 91: ...e Limit 055 1 4 mm Exhaust 059 1 50 mm Service Limit 075 1 9 mm 8 Clean all filings from the area with hot soapy water Rinse and dry with compressed air 9 Lubricate valve guides with clean engine oil and apply oil or water based lapping compound to the face ofthe valve NOTE Lapping is not required if an interference angle reconditioning method is used 10 Insert the valve into its respective guide ...

Page 92: ...ury could result 2 Carefully pry the stator cover offthe engine using the two pry areas as shown below 3 Inspect the condition ofthe stator windings A and output wires B Ifreplacement is required refer to Chapter 10 4 Inspect the ball bearing C that supports the starter motor shaft 5 If bearing replacement is required remove the retaining ring and heat the stator cover around the bearing evenly wi...

Page 93: ... engine by using a twisting motion as you pull out on the housing I 4 Ifwater pump service is required impeller or mechanical seal refer to ENGINE COOLING SYSTEM Flywheel Removal NOTE The flywheel can be serviced with the engine installed in the chassis 1 Remove the stator cover assembly 2 Remove the starter torque limit gear as an assembly 3 Inspect gear teeth for damage Inspect fit of shaft insi...

Page 94: ...talled in the chassis 1 Remove the stator cover and flywheel see Stator Cover Removal Inspection and Flywheel Removal 2 Place flywheel on a work bench with the one way clutch facing up Grasp clutch gear and rotate clockwise It should turn smoothly without binding 3 Rotate one way gear counterclockwise The gear should immediately lock in position and not slip 4 Inspect the one way gear bushing A fo...

Page 95: ...mbly ENGINE I COOLING Starter One Way Clutch Assembly 1 Install one way clutch in clutch hub with flange of clutch F engaged in recess I 2 Clean screw threads in flywheel to remove all oil or grease 3 Place one way clutch on flywheel and install the 3 screws Torque screws to specification C T One Way Clutch Retaining Screws 106 18 in Ibs 12 2 Nm 4 Reassemble starter one way clutch and gear using t...

Page 96: ...ngine 3 44 3 Locate the Oil Catch Tool PN 5438829 in the vehicle s tool kit Position the tool below the oil filter to catch the oil when the filter is removed Remove the oil filter 4 Installthe CylinderHolding Camshaft TimingPlate PU 50563 onto the cylinder The cylinder holding tool retains the cylinder and pistons when the engine is rotated 5 Rotate the engine to access the crankcase sump cover 6...

Page 97: ...l pins from the oil pump the oil pump sprocket must be removed Access the sprocket bolt by removing the case plug 12 Visually inspect the oil pump and drive sprocket 1 for wear or damage Replace oil pump drive chain and sprocket ifwom or damaged Ifany part ofthe oil pump is damaged the entire assembly must be replaced Replace the oil pump seal J during crankcase assembly NOTE Oil pump assembly is ...

Page 98: ...nspection procedure 2 Note timing marks K on balance shaft and crankshaft drive gears Shafts must be properly timed upon assembly 3 Carefully rotate the balance shaft L and remove it from the crankcase 4 Inspect the balance shaft gear teeth for damage 5 Measure each bearing journal in two locations 90 degrees apart Replace balance shaft ifeitherjournal is worn below the service limit specification...

Page 99: ... a new balance shaft or re installing the original refer to the bearing selection chart provided in the Balance Shaft Bearing Selection procedure in this chapter 3 For ease of assembly mark each connecting rod and end cap 7 Use the table below to see if the balance shaft bearing journals are within specification If worn past the service limit replace the balance shaft assembly Crankshaft Removal I...

Page 100: ...he following illustration o l4 9527 0078 in 125 8 0 2 mm 3 48 v In mm Auxiliary Sprocket Installed Depth 4 9527 0078 in 125 8 0 2 mm 11 Support crankshaft on V blocks or on centers in a crankshaft stand or lathe Measure crankshaft ronout and replace ifrunout exceeds maximum listed below J j In I mm Crankshaft Maximum Runout 001 in 0 025 mm 12 Visually inspect surface ofcrankshaft main and connecti...

Page 101: ...fthe crankshaft bearingjournals are within specification If worn past the service limit replace the crankshaft assembly Journal 5 Main Bearing Journal 1 Main Bearing Journal 6 Main Bearing PTO MAG 16 Whether installing a new crankshaft or re installing the original refer to the bearing selection chart provided in the Crankshaft Main Bearing Selection and Connecting Rod Bearing Selection procedure ...

Page 102: ...eaning solvent see Engine Oil Flow Chart 3 50 5 Remove and discard the plain bearings located in the upper crankcase B lower crankcase C and connecting rods D Replace the crankcase assembly if a bearing bore is galled or ifbearing inserts have rotated in the case Refer to bearing selection procedures upon assembly IMPORTANT Always replace plain bearings when the crankcase or connecting rods have b...

Page 103: ...late PU 50563 from the cylinder 4 Carefully lift the cylinder and pistons from the upper crankcase ENGINE I COOLING 5 Remove the piston connecting rod assemblies from the cylinder NOTE If the pistons are to be reused mark the pistons so they are reassembled in the same cylinder bore and direction from which they were removed MAG I PTO Cylinder Inspection 1 Lay a straight edge E across the top surf...

Page 104: ...p From Bottom J JV t In mm Cylinder Taper Service Limit 001 025 mm Cylinder Out of Round Service Limit 001 025 mm In mm Standard Bore Size 3 6614 0003 93 mm 008 mm 3 52 Piston Disassembly I Inspection NOTE New pistons are directional intake vs exhaust but can be placed in either cylinder 1 Note location ofthe piston circlip gap A at the top 12 00 position or bottom 6 00 position 2 Remove piston ci...

Page 105: ...ion Remove top rail first then bottom rail then the expander 1 Carefully remove top compression ring B by hand or using a ring removal pliers Piston Ring Removal v In I mm Piston Pin Bore 1 0 0 7877 0 7881 20 009 20 018 mm Service Limit 0 7893 20 05 mm 4 Measure piston pin O D in two directions 900 apart at three locations on the length Replace piston and piston pin ifout of specification 3 Measur...

Page 106: ...The cylinder should be measured for taper and out of round 0 59 in 15mm Head Gasket Surface C 8 Measure I f Here Measure Here r J 7 In mm Piston Ring to Groove Clearance 3 lfthe installed gap measurement exceeds the service limit replace the rings Top Ring 0007 0023 020 060 mm Second Ring 0007 0023 020 060 mm v In mm Service Limit 0047 12 mm Piston Ring Installed Gap Top Ring 010 014 25 35 mm Serv...

Page 107: ... Side of Rod EXHAUST Side of Rod Matching 5 Digit Serial Numbers I 0 39 in 10mm In mm Piston 0 0 Standard 3 6597 0003 92 959 008 mm I I n mm Piston to Cylinder Clearance 0009 0019 025 050 mm Measure piston outside diameter at a point 10 mm up from the bottom ofthe piston at a right angle to piston pin bore Subtract measurement from maximum measurement obtained in Step 4 of Cylinder Inspection proc...

Page 108: ...s and compare to specifications Remove bearings when taking measurements 3 56 8 Refer to the number stamped onto the exhaust side of the connecting rod This number represents the bore diameter EXHAUST Side of Rod Number Bore Diameter 9 The table below lists the big end bore diameter specifications Connecting Rod Big End Bore Diameters 1 2 3 1 7318 1 7321 in 1 7321 1 7323 in 1 7323 1 7326 in 43 989...

Page 109: ... Letters and Numbers Connecting Rod Bearing Identification Number Balance Shaft Bearing Identification Letters Crankcase Bearing Identification Numbers Crankshaft Bearing Identification Letters 3 57 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 110: ...this example you would use the number Z as the crankcase codes casejournals 1 2 3 4 You would use letters X y as the crankshaft codes crank journals 1 3 5 and 6 Based offthe bearing selection chart you would use Green bearing for Main 1 Yellow bearing for Main 2 Green bearing for Main 3 Yellow bearing for Main 4 Reference number on conn rod cap This Example 2 Reference number on conn rod cap This ...

Page 111: ...olt hole threads to remove any oil or crankcaseI sealant 3 Inspect crankcase bearing bores Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case 1 Remove all traces of crankcase sealer from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 7 Be sure passages are clean and dry before assembling the PTO upper cran...

Page 112: ...l Spring Expander I l1 LowerRail Upper Rail Gap Position I I I I I I I I Spring Expander Gap Position I I I I I 1 Place oil control ring expander in oil ring groove Rotate expander in groove until butt ends are on PTO side of piston see illustration below IMPORTANT Ends must butt squarely together and must not overlap 2 Install lower rail with end gap positioned on the intake side ofpiston 3 60 4 ...

Page 113: ...ton pin circlip NOTE If reinstalling the original connecting rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is recommended they be installed with rods facing the same direction 3 Place piston A on connecting rod B Push piston pin C 3 through rod and piston until it seat...

Page 114: ...iston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side Arrow to Point Toward Exhaust Side NOTE Orientation arrow is also located on the bottom side of piston as an additional reference 3 62 4 Carefully compress the piston rings with your fingers and install the piston connecting rod assemblies into the cylinder from the bottom side NOTE Use a slight fr...

Page 115: ... procedures in this chapter 1 Rotate the engine so the cylinder is facing down Clean the bearing bore surfaces of upper crankcase main 3 bearings connecting rods and connecting rod caps 3 Align tab of new main bearing A with the slot in main bearing bore of crankcase Press bearing insert firmly into place Repeat for all main bearings 4 Align tab ofnew connecting rod bearings B with the slot in the...

Page 116: ... end of the crankshaft 3 64 9 Carefully lower the crankshaft into upper crankcase Guide connecting rods onto the rod journals of crankshaft as necessary 10 Adjust the PTO crankshaft seal so it rests properly in the upper crankcase 11 Clean bolt hole threads in connecting rod to remove all oil 12 Install matching rod cap on connecting rod with 5 digit serial number stampings aligned INTAKE Side of ...

Page 117: ...rankcase balance shaft bearing bore surfaces 2 Align tab of new balance shaft bearings A with the slot in each bearing bore of crankcase Press bearing insert firmly into place ENGINE I COOLING 3 Rotate the crankshaft until the alignment dot B on the crankshaft MAG end gear is visible 4 Apply Polaris PS 4 Plus engine oil to both balance shaft journals Apply Engine Oil t Apply Engine Oil 5 Install t...

Page 118: ...es are clean and dry before assembling the crankcase Crankcase Assembly 1 Check to be sure the PTa crankshaft seal is resting properly in the upper crankcase 2 Align tab ofnew main bearings A and new balance shaft bearings B with the slot in each bearing bore ofthe lower crankcase Press bearing inserts firmly into place 3 66 3 Apply Polaris PS 4 Plus engine oil to the new bearings installed in the...

Page 119: ...tall the 11 M6 and 2 M8 upper crankcase bolts Tighten all bolts lightly by hand I 13 Torque the upper crankcase bolts in sequence to specification startwith 12 Repeatthe sequence to verify final torque T Lower Crankcase Bolts M10 Bolts Step 1 21 2 ft Ibs 28 3 Nm Step 2 Tighten an additional 90 1 4 turn M8 Bolts 26 1 ft Ibs 35 2 Nm Me Bolts 106 18 in Ibs 12 2 Nm T Upper Crankcase Bolts M8 Bolts 26 ...

Page 120: ... Pump Pick Up Retaining Screws 89 9 in Ibs 10 1 Nm 20 Clean the gasket sealing surfaces on oil sump cover and crankcase to remove old gasket material and any oil NOTE Gasket surfaces must be DRY and oil free Use care upon assembly to keep oil away 21 Install a new oil sump cover gasket 22 Install the oil sump cover G onto the crankcase 23 Install the 15 M6 bolts that retain the oil sump cover H to...

Page 121: ...n taper Crankcase Drain Plug 12 1 ft Ibs 16 2 Nm 6 Install the flywheel retaining bolt Using a commercially available strap wrench D hold the flywheel and torque the flywheel retaining bolt E to specification 26 Reinstall the oil cooler J ifpreviously removed Use new O rings upon installation IMPORTANT If the Cylinder Holding Camshaft Timing Plate PU 50563 is installed remove it before tightening ...

Page 122: ...ON The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result 3 Install stator cover and 13 screws Torque screws in sequence to specification 13 C T Stator Cover Screws 106 18 in Ibs 12 2 Nm 3 70 9923144 2011 RANGER RZR XP 900 Service Man...

Page 123: ...ated in retaining groove and square with the guide IMPORTANT Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the seat C valve spring D and retainer E in clean engine oil 6 Install the valve spring seat C NOTE Valve springs to be installed with yellow paint mark facing up 8 Place the valve retainer E on the spring 9 Compress the valve spring by hand...

Page 124: ...k for leakage around the valves The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into each exhaust port C Cylinder Head Installation 1 Rotate the engine so the cylinder is facing up 2 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 from the cylinder IMPORTANT Once the cylinder head is removed nothing retains the cylinder to the engine DO NOT...

Page 125: ...ins 6 Install new bolts and finger tighten the 6 cylinder head bolts G evenly 7 Install and finger tighten the 2 outer M6 bolts H evenly I Cylinder Head Torque Procedure Step 4 Torque Outer M6 Head Bolts 89 9 in Ibs 10 1 Nm Step 1 Torque in Sequence 21 ft Ibs 28 Nm 5 e T Step 2 Torque in Sequence 26 ft Ibs 35 Nm Step 3 Torque in Sequence Additional 180 1 2 turn 3 r Ii i i G IMPORTANT Install new c...

Page 126: ...ace each other when installed properly 6 Install the 4 bolts that retain eachrear camshaft carrier C and tighten the bolts evenly until snug EXHAUST Part Number INTAKE Part Number 2 Reference the intake and exhaust markings made during disassembly If installing new camshafts or if camshafts were not marked you can reference the part number stamped on the end ofthe shafts Camshaft Installation I Ti...

Page 127: ...aust cam sprocket should have E marks aligned with gasket surface IMPORTANT Install the exhaust cam sprocket first opposite the cam chain tensioner to ensure proper cam timing 12 Use new camshaft sprocket retaining bolts upon assembly Apply Loctite 272 to bolt threads Install the top bolt in each camshaft sprocket D Do not torque the bolts at this time IMPORTANT Use new sprocket retaining bolts up...

Page 128: ...ll the front camshaft carrier E and 2 outer retaining bolts 19 Install the fixed cam chain guide F and 2 retaining bolts 3 76 20 Torque the camshaft carriers bolts in sequence to specification 3 5 C T Camshaft Carrier Bolts 89 9 in Ibs 10 1 Nm 21 Apply Polaris PS 4 Plus engine oil to the cam chain tensioner bore prior to assembly Insure the sealing washer G is in place 22 Install the hydraulic cam...

Page 130: ...olaris PS 4 Plus engine oil prior to installation 3 Carefully install the camshafts into the cylinder head The PTO camshaft lobes should face out as shown 4 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when installed properly Camshaft Carrier Bolts 89 9 in Ibs 10 1 Nm 6 Rotate the camshaft until the cam lobes above the valves you are inspe...

Page 131: ...E I COOLING 11 Record the 3 digit adjustment shim number B I NOTE Shim 240 is shown for reference only 12 Reference the valve clearance measurement recorded for that valve along with the 3 digit shim number 13 Refer to the appropriate shim selection matrix Intake or Exhaust on the following pages and selectthe proper shim 14 Install the new adjustment shim and valve bucket NOTE Lubricate the outer...

Page 132: ...5238240242245248250252255258260262265268 10 025 0 049 1801821185188190192 951982002022052082101 212215218 220 222 2 232235238240242245248250252255258260262265268270 235 238 240 242 245 248 250 252 255 258 260 262 285 268 270 272 10 075 0 0991185118811901192195198 208210212215218220222225228230232235238240242245 248 250 252 255 258 260 262 265 268270272 275 I 98 200 202 2051208 210 212 215 218 220 ...

Page 133: ...asured clearance is 0 007 in 0 18 mm Replace 240 shim with 230 shim Shim Thickness Example 240 equals thickness of 2 40 mm Plart_N_u_m_b_elr4 8 4 i i XXX 20 04 28 21 hX 8 S S J 2 i S if 2i2 h 5 2 8 23 0 2 3 2 2 35 2g3 8 Ig4Q I 2 4 2 2 5 sh2 i4m 8r 2 50 2 5 2 2 55 2h5 8 2460 2 6 2 2 65 1 2 8 12 701 2 7 2 2 75 27 84 2 8do I i i i onShimj 0 551 0 575 215 218 220 222 225 228 230 232 235 238 240 242 24...

Page 134: ...r sealing surfaces by cleaning thoroughly to remove all residue 3 Install a new valve cover seal B 4 Install the 4 valve cover shoulder bolts C and isolators D using a T40 driver A 5 Torque valve cover bolts to specification C T Valve Cover Bolts 89 9 in Ibs 10 1 Nm 3 82 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 135: ...es But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Cam worn excessivel...

Page 136: ...gnition timing incorrect Sheared flywheel key 3 84 Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or fuel valve Fuel pump output weak El...

Page 137: ...T 4 18 DUAL THROTTLE BODY ASSEMBLY 4 20 THROTTLE BODY SERVICE I REMOVAL 4 20 FUEL INJECTORS 4 22 FUEL INJECTOR TROUBLESHOOTING 4 22 FUEL INJECTOR TEST I REPLACEMENT 4 23 FUEL PUMP 4 26 FUEL SENDER TEST 4 26 FUEL PUMP TEST 4 27 FUEL PUMP REPLACEMENT 4 28 IGNITION COIL 4 31 IGNITION COIL I HT LEAD REPLACEMENT 4 31 IGNITION COIL TESTS 4 31 EFI DIAGNOSTICS 4 32 INSTRUMENT CLUSTER TROUBLE CODE DiSPLAy ...

Page 138: ...tic Software PU 47063 A Includes most recent version of software w serial number standard interfacecable and SmartLink Module Kit PU 47471 Digital Wrench SmartLink Module Kit PU 47470 PU 47469 PU 47468 PU 47470 Digital Wrench PC Interface Cable PU 47469 Digital Wrench Vehicle Interface Cable PU 47468 Digital Wrench SmartLink Module 4 2 Fuel Pressure Gauge Kit PU 43506 A IMPORTANT The EFI fuel syst...

Page 139: ... and the Digital Wrench diagnostic software Polaris dealers can also order the following kit components separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pin connector based Polaris EFI systems This kit is available to Polaris dealers through our tool supplier SPX at 1 800 328 6657 or http polaris spx com Located ...

Page 140: ...uld be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with t...

Page 141: ...lant Temperature Sensor ECT 6 Dual Throttle Body Assembly 7 Fuel Injectors 8 Fuel Rail Regulator ELECTRONIC FUEL INJECTION 9 Fuel Pump Regulator 10 Fuel Level Sender 11 Fuel Filter 12 Fuel Supply Line 13 Fuel Return Line 14 Ignition Coil 15 Spark Plug Wires 16 Spark Plugs 13 1 12 II 4 5 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 142: ...n top ofthe stator cover 4 6 4 Idle Air Control Valve lAC Located above the engine underneath the cargo box access panel 5 Engine Coolant Temperature Sensor ECT Located on the left side of the thermostat housing The sensor can be accessed with the air box assembly removed 6 Dual Throttle Body Assembly Located betweenthe air box assembly and rubber cylinder head adapters 9923144 2011 RANGER RZR XP ...

Page 143: ...er s side ofthe vehicle 9 Fuel Pump Regulator Fuel Gauge Sender Assembly Located under the passenger seat 8 Fuel Rail Regulator Located on the throttle body on top ofthe fuel injectors 7 Fuel Injectors Located on the top ofthe throttle body in the intake track retained on top by the fuel rail 4 7 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 144: ...m Fuel Sender Float Arm PFAGasket replace if removed Refer to Fuel Pump Replacement for service procedure Fuel Flow I Fuel Return Line i Pressure Regulator I Fuel Rail I Fuel Injectors 1 I j Ir Fuel Tank I Pressure Regulator I I Fuel Filters I Fuel Pump Assembly I Fuel Supply Line I I r L 4 8 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 145: ...onnector tabs snap back into place 6 Be sure fuel line is routed and retained properly Fuel Return Line Removal 1 Place a shop towel around the fuel line to catch any dripping fuel 2 Ifremoving either end ofreturn line squeeze the connector 4 tabs together and push the white locking slide back to release the line 3 Pull on the fuel line for removal 4 To install the line verify the connections are ...

Page 146: ...gs for specific removal procedures NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 4 Remove the fuel tank vent line C from the tank fitting 5 Disconnect the fuel pump electrical harness D 4 10 6 Remove the push rivets and Torx screws retaining the right hand rocker panel using the multi function pliers and a T27 Torx driver R...

Page 147: ...ng the tank brackets clear ofthe fuel tank for removal 12 Lift the rear ofthe fuel tank up first 2 Reinstall the 2 fuel tank brackets and fasteners 3 Reinstall the right rear fender well and secure with screws 4 Reinstall the center console shift knob and screws 5 Reinstall the rear seat base assembly and secure with bolts 6 Reinstall the seat belt mechanism Torque bolt to 40 ft lbs 54 Nm 7 Reinst...

Page 148: ...ction ofthe fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned 4 12 The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake air temperature manifold absolute pressure load engine temperature engine...

Page 149: ...ed and possible failure an RPM limiting feature is programmed into the ECU Ifthe maximum RPM limit is exceeded the ECU suppresses the injection signals cutting offthe fuel flow and retards the ignition timing This process repeats it self in rapid succession limiting operation to the preset maximum ELECTRONIC FUEL INJECTION ECU Service Never attempt to disassemble the ECU It is sealed to prevent da...

Page 150: ...S performs three functions in one unit The MAQS detects intake air temperature manifold absolute pressure and throttle position These sensor signals comprised of separate intake air temperature manifold absolute pressure readings and throttle plate position are processed by the ECU and compared to its programming for determining the fuel and ignition requirements during engine operation The MAQS p...

Page 151: ...r ring During rotation an AC pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive pulses Mounted on top of the stator cover the crankshaft position sensor is essential to engine operation constantly monitoring the rotational speed RPM and position ofthe crankshaft CRANKSHAFT POSITION SENSOR CPS Operation Overview C...

Page 152: ...he shield 3 Using an 8mm socket remove the CPS retaining bolt and remove the sensor from the stator cover 4 Install new sensor using a light coating ofoil on the O ring to aid installation 5 Torque the CPS and heat shield retaining bolts to specification C T CPS Stator Cover Retaining Bolt Torque 106 in Ibs 12 Nm 4 16 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 153: ...ktheresistancevalues at each ofthe following pin locations ofthe lAC Ifany ofthe readings are out ofspecification replace the lAC The lAC contains 1 stepper motor which receives varying voltage signal pulses from the ECD These pulses determine the lAC plunger setting thereby controlling the amount of air bypassing the closed throttle body plates for idle control Ifthe lAC is disconnected or inoper...

Page 154: ...disconnect the harness from the ECT sensor and start the engine After a few seconds the fan should tum on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly ECTSensor Refer to Chapter 10 for additional ECT sensor information Polaris dealers can test the sensor by using Digital Wrench Diagnostic Software dealer only 4 18 ...

Page 155: ...e air box assembly 12 Position the intake hose onto the air box and tighten the hose clamp 13 Reinstall the cargo box access panel 14 Add the required amount of coolant and bleed the system see Chapter 3 Cooling System Bleeding Procedure 7 Using a wrench remove and replace the sensor applying a light coating ofthread sealant to aid installation 6 Drain the coolant so the level is below the sensor ...

Page 156: ...lity Sensor MAQS attached to the end ofthe throttle body is non serviceable If the sensor is faulty the entire throttle body assembly must be replaced Refer to Throttle Body Removal procedure Throttle Body Removal 1 Remove the cargo box access panel 4 20 2 Be sure the engine has cooled enough to work on 3 Remove the breather hose from the air box and loosen the hose clamps retaining the air box to...

Page 157: ...able removal 11 Slid book th c ble mj t boot U fig a 14 nun wrench I loosenthejamnut Using a 12mm wrench tumthe adjuster in and count the number ofturns it take to fully seat it Note the number ofturns so it can be setthe same upon assembly 12 Unscrew the throttle cable adjuster and jam nut from the throttle body Remove the throttle body from the vehicle 13 Reverse the previous steps to reinstall ...

Page 158: ...closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel injector s Excessive voltage will burn out the injector ...

Page 159: ...el Injector Replacement IMPORTANT Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation The fuel injectors are non serviceable If diagnosis indicates a problem with either injector test the resistance of the fuel injector s by measuring between the two pin terminals Fuel Injector Test IMPORTANT Take note of PTO an...

Page 160: ...l Remove the 2 screws that mount the fuel rail to the throttle body using a 5 mm Allen wrench 4 24 9 Carefully pull up on the fuel rail and injectors and remove them from the throttle body as an assembly Take care not to damage the fuel injector ends during removal 10 Pull out on the fuel injector retaining clip and pull the injector out of the fuel rail Repeat on the other injector if removal is ...

Page 161: ...dy 15 Install the fuel rail mounting screws and torque to specification 13 Thoroughly clean the area around the fuel injector ports on the throttle body IMPORTANT Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation 17 Connect the harness leads to the fuel injectors NOTE Be sure the retaining clip is positioned o...

Page 162: ...ons the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on Fuel Sender Test If the fuel gauge reading on the instrument cluster is not working or ifthe display reading differs in large comparison to the fuel in the tank perform a resistance test on the fuel sender Disconnectthe fuel pump sending ...

Page 163: ...L LEVEL SENSOR 3 FUEL PUMP 4 FUEL PUMP I 4 Connect the hose from the Fuel Pressure Gauge Kit pU 43506 A to the test valve on the Fuel Pressure Gauge Adapter pV 48656 Route the clear hose into a portable gasoline container or the vehicle s fuel tank 5 Tum on the key switch to activate the pump and check the system pressure on the gauge Ifsystem pressure of 43 5 2 psi is observed the ignition switch...

Page 164: ... While holding a shop towel over the fuel line connectors disconnect the fuel supply line A from the pump and the fuel return line B from the tank see Fuel Lines Quick Connect Fittings for specific removal procedures A CAUTION It is possible for pressurized fuel to be present when disconnecting the fuel line It is recommended to allow the vehicle to sit for a period of one hour after shutting off ...

Page 165: ... and rinse it with a small amount of clean fuel Do not use water or any other chemicals to remove debris 10 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 11 Inspect the inside of the fuel tank for debris may require flashlight and mirror Ifdebris like mud or sand is present fuel tank should be flushed and cleaned out prior to inst...

Page 166: ...rks are still aligned between fuel pump and fuel tank 4 30 19 Torque PFA nut to specification using the Fuel Pump Service Tool pU 50326 and a calibrated torque wrench C T Fuel Pump PFA Nut 70 5 ft Ibs 95 7 Nm 20 Verify alignment offuel pump and tank orientation marks 21 Connect the fuel supply line to the pump and the fuel return line to the tank see Fuel Lines Quick Connect Fittings for specific ...

Page 167: ... the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plugs Operation Overview Ignition Coil I HT Lead Replacement IMPORTANT The engine will misfire if the spark plug wires are installed incorrectly The spark ...

Page 168: ...ink in place of the check engine MIL 1 If the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area 11 f LI Error Code Number 0 9 SPN Suspect Parameter Number FMI Failure Mode Identifier 2 Press and hold the MODE button to enter the diagnostics code menu 4 If more than one code exists press the MODE button to advance to the next troubl...

Page 169: ...if equipped wITURF Driver Circuit Grounded 4 P1693 Driver Circuit Open I Grounded 5 P1481 Fan Relay Driver Circuit Driver Circuit Short to B 1071 3 P1482 Driver Circuit Grounded 4 P1483 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 P1353 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 P1354 Driver Circuit Open I Grounded 5 P0230 Fuel Pump Driver Circuit Dr...

Page 170: ...re Error Software Error 520229 12 C1070 if equipped w EPS IC CAN Communication with EPS EPS Off Line EPS DM1 not seen 520230 31 U0131 if equipped w EPS Driver Circuit Open I Grounded 5 P1505 Idle Air Control Valve lAC Driver Circuit Short to B 520267 3 P1509 M17 lAC Stepper Pin 1 Driver Circuit Grounded 4 P1508 Driver Circuit Open I Grounded 5 P1515 Idle Air Control Valve lAC Driver Circuit Short ...

Page 171: ...ucts air box cover Rich Mixture Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug Injector failure Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw t...

Page 172: ...ntial data contained within the original ECU is transferred to the replacement ECD Refer to procedure and carefully follow all instructions provided in Digital Wrench Guided Diagnostic Available Guided diagnostics are available within Digital Wrench for all supported Trouble Codes that is any fault that will tum on the Check Engine indicator In addition guided diagnostics are also available for ma...

Page 173: ... from the Digital Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic connector 4 Tum the ignition key to the ON position select the appropriate vehicle and wait for the status to display Connected in the lower left comer ofthe screen 5 Once connected proceed with using Digital Wrench Digital Wrench Serial Number Location Open the configuration screen by clickin...

Page 174: ...on 3 3 installed before adding these updates They will not install if you have version 3 0 or older on your PC 4 38 6 If the update file date listed is newer than your current version and update see Digital Wrench Version and Update ill download the file 7 Click on the link shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or ope...

Page 175: ...me Page Exit The Diagnostic System Open the Software Configu ration Screen Prints the current screen as a formatted printout Vehicle Selection Custome r Info rmatio n Exit View information from the main ECU Sensors System Help Digital Wrench Home Page Digital Wrench Knowledge Base View or clear trouble codes in the Engine Controller memoty Product Utilities System Config uratio n SmartLink Setup S...

Page 176: ...B THE PC While reprogramming is in progress don t move the mouse and don t touch the keyboard The process only takes a few minutes and is best left alone until complete No Senal Port Needa USB Adapter for your ne Posted bvmike on Monday August 20 1 3 04 17 eDT TOpic L IMPORTANT Failure to follow the reprogramming instructions completely and correctly can result in an engine that does not run Repla...

Page 177: ...to proceed to the Integrity Check 6 Select Engine Controller Reprogramming GI Um _ _ol _ Ji f 1 t mtI t po Wron n_ l _ b w n l 2 Connect the SmartLink Module cables to the PC and vehicle See Digital Wrench Diagnostic Connector on page 4 37 5 Select the Special Tests icon 4 Select the model year product line and vehicle description by selecting the Change Vehicle Type icon 3 Open the Digital Wrench...

Page 178: ...tW 6 M t Codef r Enter the Request Code 4 42 12 Select the same file type from the list that you selected previously while in Digital WrenchTM Enter the VIN along with the customer s name and address When completed click the Authorize button ill to proceed Enter ALL the information and click on the Authorize button 13 An AuthorizationKey will appear inthe upper left comer of the screen Copy CTRL C...

Page 179: ...not touch the vehicle or PC during the process 16 Once the ECU reprogramming procedure is complete click the Finish button on the screen Verify the reflash was a success by starting the vehicle I 4 43 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 180: ...EFI Relay out to Splice ECM A9 8 Unswitched EFI Relay Coil B4 Fuel Pump Relay Coil Control B5 8 Fuel Pump Relay B8 EFI Relay Coil Control B9 8 Unswitched to EFI Relay D4 8 Splice Unswitched D6 8 out to Fuel Pump Relay INSTi1iY1ENT CLUSTEf RELAY FUSE BLOCK 2 t o 4 44 COOL ANT TEMP SUJson IDLE A j fl CONTHCL 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc CPS ...

Page 181: ...EERING SHAFT BEARING REPLACEMENT 5 18 FRONT A ARMS 5 19 REMOVAL REPLACEMENT 5 19 BALL JOINT SERVICE 5 20 REMOVAL 5 20 INSTALLATION 5 21 REAR RADIUS RODS 5 22 REMOVAL INSTALLATION 5 22 REAR TRAILING ARM 5 23 TRAILING ARM REMOVAL INSTALLATION 5 23 TRAILING ARM SPHERICAL BEARING REPLACEMENT 5 25 REAR SUSPENSION EXPLODED VIEW 5 25 REAR STABILIZER BAR 5 26 REMOVAL INSTALLATION 5 26 DECAL REPLACEMENT 5 ...

Page 182: ...lizer Bar Linkage 31 34 ft Ibs 42 46 Nm Stabilizer Bar 17 ft Ibs 23 Nm Bushing Bracket Bolts Stabilizer Bar 10ft Ibs 13 5 Nm Locating Clamp Bolts Seat Belt to Seat Base 40 ft Ibs 54 Nm Tilt Shock Upper Fastener 7 ft Ibs 10 Nm Tilt Shock Lower Fastener 12 ft Ibs 16 Nm Steering Pivot Tube Fasteners 23 ft Ibs 31 Nm Steering Wheel to Shaft 65 ft Ibs 88 Nm Lower Steering Shaft to Box 30 ft Ibs 41 Nm St...

Page 183: ... 2 Place the assembled cab frame onto the vehicle and align the rear mount holes Fasten the rear cab frame brackets to vehicle with four MI0x1 5x25 bolts and MI0x1 5 nuts Tighten bolts to 30 ft lbs 41 Nm Fasten the two self tapping screws to the rear inner portion ofthe bracket on each side Tighten screws to 15 ft lbs 20 Nm 3 Place the straps from the safety net over the front coupler posts 4 Fast...

Page 184: ...Washers BODY I STEERING I SUSPENSION BODY EXPLODED VIEWS Side Safety Nets Mount Screw Y ti r Nyloc Nut 5 4 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc Side Net Screw ...

Page 185: ...atch Pin Seal I I I I Screws I I Cover I I I I Hinge Pin veboxii I _ Catch Plate I Grommet I L _ _ _ J A Instrument ClusterI Speedo B Headlight Switch C AWD 2WD Switch D 12 Volt Accessory Receptacle E Key Switch 5 5 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 186: ...s Grill Winch Pocket Cover Push Rivet i 1 I 17 Deflector Panel Center Access Hood 1 4 Turn Latch k Washer 11 CJ ________ i Grommet T25 Screws Hood Retention Panel Ij fi _ a Hood Dash a Mud Shield Front Fender Flair 5 6 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 187: ...crew Grill II Ii Deflector Panel T25 Screw 4 Headlight _ _ T25 Screws Front Bumper Support 1 W Screws Side Panel 1 0 1 4 7 ft Ibs i 23 Nm o 0 J C J Spring Rear Bumper Tail Light Socket T27 Screws Rear Bumper p 5 7 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 188: ... PI t C 1 ae_ It Cap Ii l 41 57 in lbs 41 57 in lbs 4 6 6 4 Nm 4 6 6 4 Nm Grommets Rear Seat Base Shoulder Bolt Retainer I 40 ft Ibs J 54Nm Washer 40 ft Ibs _ _ 54 Nm t I l 3 Point Seat Belt Drivers Side Shown Seat Belts I Mounting 5 8 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 189: ...f Tapping Screw Console Cover I T27 Screws Push Rivets T27 LH Rocker RH Rocker Seal T27 Screws U Self Tapping Screws Rear Support Bracket D Rear Support Bracket Lower Floor 5 9 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 190: ...nel Intake Grill Cover Foam Filter Rear LH Panel Divider Rear Cargo Box RearLH Fender Flair I Oil Tank Access Panel 1 4 Turn Latch Asm Tie Down Screw _ Rear RH Fender Flair Cargo Box Access Panel 5 10 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 191: ... Rear Bumper Support Screws 17 ft Ibs 23Nm Skid Plate 40 ft Ibs 54 Nm t lnBracel o Front Cross Member Washer Screws 6 5 ft Ibs 8 5Nm Main Frame Screws 17 ft Ibs 23Nm I 5 11 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 192: ...ver and remove the seat from the vehicle 1 To remove the seats lift upward on the latch lever located behind the seat bottom Engine Service Panel 1 Remove driver and passenger seats 2 Tum both latches 1 4 tum to disengage the panel Rear Bumper 1 Disconnect the harness connectors at the taillights 1 4 Turn Latches r t fiiN Service Panel 2 Remove the 10 T 27 Torx screws retaining rear bumper to the ...

Page 193: ... disengage the front tabs and remove the hood from the vehicle Hood Removal Hood and Front Body Work 2 Remove the front bumper see BODY COMPONENT REMOVAL Front Bumper 6 Disconnect all electrical dash components noting their location and wire routing 3 Remove the front portion of the cab frame assembly to allow dash removal Refer to appropriate CAB FRAME Assembly Removal procedure for assembly torq...

Page 194: ... ofthe vehicle 5 Remove the 4 Torx screws C from both the RR and LH side ofthe vehicle 6 Remove the 2 Torx screws D from both the RR and LH side ofthe vehicle 7 Remove the 6 Torx screws E from the rear cargo box area 5 14 8 Remove the 4 Torx screws that attach the rear bumper to the vehicle frame 9 Disconnect the wire harness connectors at the taillights 10 Loosen the hose clamp F and disconnect t...

Page 195: ...ve the push rivets and Torx screws retaining the rocker panel and remove panel from the vehicle Rocker Panel Removal 14 With the aid of an assistant carefully lift and guide the cargo box assembly up and off the vehicle frame Make note ofwire and hose routings for reassembly 13 Remove the vent hose from the top ofthe oil tame 4 Remove the Torx screws retaining the upper floor to the lower floor 5 ...

Page 196: ...l 7 ft Ibs i Bushin 42 5 ft Ibs 10 Nm e 23 ft Ibs 58 Nm 1 A Y iil 31 27 33 ft Ibs l Bushing 37 45 N O AI 23 ft Ibs Y 0 31 Nm LH Boot Oil Locking Bearing 12 14 ft Ibs Gear Box 16 19 Nm __ ro Shock Asm iLl Asm 12 ft Ibs RH Boot 475 m_ __ e _3 J _ f Boot 17 ft Ibs EJ 23 Nm 17 ft Ibs 23Nm 12 14 ft Ibs 16 19 Nm Nut Tie Rod Cotter Pin Rod End 5 16 9923144 2011 RANGER RZR XP 900 Service Manual Copyright ...

Page 197: ...e steering wheel pops loose completely remove the nut and lift the steering wheel offthe shaft BODY I STEERING I SUSPENSION Steering Shaft Removal 1 Remove the pinch bolt retaining the lower portion of the steering shaft to the steering gear box assembly _ _ steering Shaft Pinch Bolt o Figure 5 16 2 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube ...

Page 198: ... onto the steering shaft and press it into the pivot tube by hand NOTE Use care not to allow any of the Loctite to get in the bearing NOTE Bearings will be seated in the pivot housing upon tightening the steering wheel nut in step 14 5 18 9 Reinstall the upper washers and spacers in the order in which they were removed 10 Install the steering wheel and hand tighten the nut Apply Loctite 271TM 11 R...

Page 199: ...l upper balljointpinch bolt B into the bearing carrier and torque bolt to specification 13 Attach shock to A arm with fastener A Torque lower shock bolt to specification 14 Remove lowerballjointpinch bolt E from bearing carrier 15 Using a soft face hammer tap on bearing carrier to loosen the lower A arm balljoint end while pushing downward on the lower A arm Completely remove the ball joint end fr...

Page 200: ...l joint if it has been removed for any reason If removed it must be replaced Use this removal procedure only when replacing the ball joint Picture For Reference Only 2 Remove the retaining ring from the ball joint 3 A driver must be used for the removal ofthe ball joint Use the dimensions below to fabricate or locate the correct size driver to use in the following process Driver Dimensions 1 375 i...

Page 201: ...ll joint is installed into the A arm install a NEW retaining ring Picture For Reference Only Upper A arm Press into the A arm in this direction Upper A Arm Shown Ball Joint I I NEW 0 Retaining Ring Picture For Reference Only 3 Reinstall the A arm see FRONT A ARMS Removal Replacement 4 Repeat the ball joint service procedure for any additional A arm ball joint replacements 5 21 9923144 2011 RANGER ...

Page 202: ...t and washer A and B attaching the upper and lower radius rod to the bearing carrier Discard the nuts 5 22 5 Remove bolts C and D attaching radius rods to the vehicle frame Discard the nuts 6 Remove radius rods from vehicle 7 Examine radius rod shafts boots and spherical bearings Replace entire radius rod if any excessive wear is evident 8 Reverse this procedure to reinstall the radius rods 9 Torq...

Page 203: ...ng the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 8 Remove the bearing carrier from the rear drive shaft and trailing arm 6 Remove the rear wheel hub and brake disk assembly 5 7 Remove the 5 remaining bolts that attach the rear bearing carrier to trailing arm Discard the nuts 4 Remove the lowerradius rod mounting bolt nut and washer from the bearing carr...

Page 204: ...rm Spherical Bearing Replacement 16 Replace trailing arm ifphysically damaged 17 Reverse this procedure to reinstall the rear trailing arm NOTE Use new fastener nuts upon installation of the rear trailing arm and bearing carrier 5 24 18 Torque all fasteners to specification C T Trailing Arm to Main Frame Bolt Trailing arm spherical bearing bolt 50 ft Ibs 67 7 Nm C T Rear Shock Mounting Bolts 70 ft...

Page 205: ...ring race do not press on the center spherical bearing 6 Inspect trailing ann bearing housing for wear or damage Replace trailing arm if damaged 7 Press bearing in until fully seated into trailing ann casting 8 Install spherical bearing and new snap ring Rear Suspension Exploded View Bearing Carrier 31 34 ft lbs 42 46 Nm Stabilizer Bar Bushing 50 ft Ibs 67 7 Nm Spherical Bearing 31 34 ft Ibs 42 46...

Page 206: ...rease fitting fittings are accessible through skid plate 15 Install rear wheels and wheel nuts Torque wheel nuts to 30 ft lbs 41 Nm 1 4 turn 5 Remove the 4 fasteners retaining the stabilizer bar to the vehicle frame see below 6 Remove the bushing brackets and bushings for ease of removal 7 Carefully remove the stabilizer from the LH wheel well area ofthe vehicle 8 Mark the location and remove the ...

Page 207: ...nate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted plastic components Painted plastic surfaces should only be wiped clean prior to decal adhesion To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slight...

Page 208: ... the vehicle Discard nuts and replace with new upon installation Preload Ring 50 ft lbs 67 7Nm O p O Rings Spring Retainer R la should be 1800 from spring end Spring Retainer gap should be 1800 from spring end Rear Shock Exploded View I Bushings I P j I II 7 I fJ4J A I I II I I I I _______ I Shock J 70 ft Ibs II 95 Nm Spring Retainer e J i C tJ j 70 ft Ibs IiJ 95 Nm 5 f O Rings Guard Shock Spring ...

Page 209: ...g Ring 4 1 Eyelet 19 1 Pellet Retainer Set Screw Air Valve 5 1 Shaft 20 1 Nylon Ball Air Valve 6 1 Bearing Cap Asm 2I 1 Preload Ring Jam Nut 7 1 Bearing Asm 22 1 Preload Ring 8 1 Spacer 23 1 Damping Adjust Asm Piston 9 1 Plate Top Out 24 1 Damping Adjust Asm Concentric Adjuster 10 1 Valving Asm 25 2 Bearing External II 1 Piston Damping 26 1 Bumper 12 2or3 Plate Back Up 27 2 Bearing Spherical 13 1 ...

Page 210: ...FP Location 3 40 Nitrogen Pressure 200 psi 5 Gas Shock Oil 2870995 qt SHOCK VALVING COMPRESSION REBOUND 1 600 x 0 0080 1 425 x 0 012 1 600 x 0 0060 1 350 x 0 012 1 600 x 0 012 1 250 x 0 015 1 425 x 0 012 1 100 x 0 015 1 350 x 0 012 0 950 x 0 015 1 250 x 0 012 0 800 x 0 010 1 100 x 0 012 0 800 x 0 015 0 950 x 0 012 0 875 x 100 Back Up 1 570 x 0 128 Top Out 0 875 x 100 Back Up 0 875 x 100 Back Up Pi...

Page 211: ...oves 3 Lint Free Towels 4 Assembly Lube lithium based grease 5 Loctite 271 6 12 Tie Wrap Zip Tie 7 MAPP Gas or Propane Torch 8 1 834 TC Seal Kit 9 5wt Shock Fluid Special Tools Required Body Holding Tool PN 2871071 Charging Needle PN 7052069 A Gas Shock Recharging Kit PN 2200421 FOXTM Shock IFP Tool PN 2871351 Seal Installation Bullet Tool PN 2201640 PN 2201639 10 IFP Depth Setting Tool 11 Seal In...

Page 212: ...urethane bushings and sleeves remove them from both ends of the shock Fig 1 5 Note and record the setting on the Compression Adjuster Screw Using the Flat Blade Screwdriver count the clicks as you turn the adjuster clockwise until it stops Fig 2 Once you have written this number down tum the screw all the way counterclockwise until it stops 5 32 6 Clean the entire shock assembly with soapy water T...

Page 213: ...etting Tool and place it on a clean lint free towel Remove the shock from the vise and pour shock oil from body and reservoir tubes into a proper disposal container DO NOT RE USE OLD SHOCKOlL 18 Using the 1 8 Hex Tool remove the IFP bleed screw from the IFP 19 Clean the body tube reservoir tube and the IFP using solvent Dry with compressed air in a well ventilated area Ifcompressed air is not avai...

Page 214: ...ir is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate 3 Use a scribe or dental pick to remove the a ring seal from the IFP 4 Use a scribe or dental pick to remove the a ring seals from the reservoir end cap 5 Install the new well lubricated a rings into the bearing housing Correct placement ofthe shaft sea...

Page 215: ...shaft with the scraper facing the eyelet Fig 11 This should be done in a single smooth motionto avoid damagingthe seals I 3 Insert the shaft of a Phillips head screwdriver through the center of the piston assembly The pointed end of the screwdriver should be on the same side as the top out plate Cut and remove the tie wrap that was holding the piston assembly together 4 Hold the piston assembly fr...

Page 216: ...e ofthe oil during this process 19 Bring the damping piston up until it is approximately 114 below the surface of the oil Using the mallet give 2 3 sharp blows to the eyelet driving the damping piston down into the shock body This opens the valves on the damping piston You will see the released air bubbles come to the surface ofthe oil 5 36 20 Add oil to the body tube until the surface ofthe oil i...

Page 217: ...using a smooth straight motion Keep the reservoir as straight as possible to prevent the safety needle from bending As the safety needle is pulled free from the FOXTM air valve a popping sound should be heard A WARNING CHARGE THE SHOCK USING NITROGEN GAS ONLY DO NOT FILL WITH ANY OTHER GASES Doing so compromises the performance of the shock and may be EXTREMELY DANGEROUS 35 Install the nylon valve...

Page 219: ...BREAK IN DRIVE BELT CLUTCHES 6 9 DRIVE CLUTCH SERVICE 6 1 0 6 DRIVE CLUTCH EXPLODED VIEW 6 10 DRIVE CLUTCH DISASSEMBLY INSPECTION 6 11 DRIVE CLUTCH SPRING INSPECTION 6 12 NEEDLE BEARING INSPECTION 6 12 SHIFT WEIGHT INSPECTION 6 12 BUTTON TO TOWER CLEARANCE INSPECTION 6 13 SPIDER REMOVAL 6 13 ROLLER PIN AND THRUST WASHER INSPECTION 6 14 CLUTCH INSPECTION 6 15 MOVEABLE SHEAVE BUSHING INSPECTION 6 16...

Page 220: ...thorized special tools and service procedures The Polaris Variable Transmission PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of the Polaris vehicle the PVT system is matched first to the engin...

Page 221: ... drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hours as recommended see Chapter 3 Engine Break In Period for break in example Avoid aggressive acceleration and high speed operation during the break in period CLUTCHING PVT Maintenance I Inspection Under normal use the PVT system will provide years oftroub...

Page 222: ...or snow application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a Shift the transmission to Low carefully use fast aggressive brief throttle stopped position application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Remove the PVT drain plug Shift the transmission to neutral...

Page 223: ...d engine service panel see chapter 5 A CAUTION 2 Place transmission in neutral 3 Raise and support the vehicle Correct Drive Clutch Puller PIN 2872085 2872085 Correct Drive Clutch Puller For RZR XP 900 A CAUTION PA 48595 Incorrect Drive Clutch Puller Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 4 Remove the left rear wheel 5 R...

Page 224: ...872085 to prevent damage to crankshaft 6 6 12 Remove the 4 pushrivets that secure the upper guard plate to the top ofthe inner PVT cover Make note ofthe routing ofthe fuel lines vent line battery cable and wire harness for proper assembly 13 Loosen hose clamp attachingthe PVT inlet ductto the inner clutch cover Disengage hose from the inner clutch cover 14 Loosen the hose clamps that attach the cl...

Page 225: ...otective cover to the top ofthe inner PVT cover 4 Install and properly align the inner clutch cover Be sure the fuel line vent line and battery cables are properly routed through the guard plate as shown 1 Inspect inner clutch cover Replace ifcracked or damaged 2 Inspect the seal on the transmission input shaft Replace if damaged 3 Inspect inner clutch cover seal engine side Replace if cracked tom...

Page 226: ...e fasteners to specification e T Rear Shock Mounting Bolt 70 ft Ibs 95 Nm e T Wheel Nuts 30 ft Ibs 41 Nm 90 1 4 turn 18 Install engine service panel and both seats 6 8 DRIVE BELT Belt Removal IMPORTANT Inspect the entire clutch outlet duct including the outlet duct screen when replacing a drive belt Remove any debris found in the outlet duct or outlet duct screen 1 Remove the 8 screws that retain ...

Page 227: ...for possible causes CLUTCHING PVT Belt Installation NOTE Be sure to install belt in the same direction as it was removed 1 With the belt removal tool installed PN 2877408 loop the belt over the drive clutch and over the driven clutch 2 Rotate the driven clutch and walk the belt into the clutch 3 Remove the belt removal tool from driven clutch 6 4 Rotate spin the driven clutch and belt approximatel...

Page 228: ...m Retaining Ring Washer Clutch Washer Bolt 96 ft lbs 130 Nm Limiter Spring Spacer BUSh Washers o1 Roller tf i0 I Shift R et oJ Button Nut Bolt N Moveable Sheave Spider Apply 263 Loctite 280 300 ft Ibs 379 406 Nm Bushing Non braking Needle Bearing Stationary Sheave 6 10 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 229: ...gnment the clutch will not be in balance and the assembly MUST be replaced 3 Remove cover bolts evenly in a cross pattern and remove cover plate CLUTCHING PVT 4 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is detennined by the amount of Teflon remaining on the bushing A 5 Inspect area on shaft where bushing rides for wear galling I nicks or scratches R...

Page 230: ...n 43 kg mm Wire Diameter 0 187 4 75mm 6 12 Needle Bearing Inspection 1 Rotate the clutch bearing in both clockwise and counter clockwise directions The non braking needle bearing should rotate in both directions on the shaft with only a slight amount of drag 2 Verify there is no binding or rough spots Ifproblems are noted continue with disassembly Shift Weight Inspection 1 Remove shift weight bolt...

Page 231: ...ixture 2871358 A and secure in bench vice Loosen and remove the spider jam nut counterclockwise using the Clutch Spider Nut Socket PU 50578 Spider Removal 2 Inspect the tower sheave surfaces Replace the drive clutch ifworn damaged or cracked 1 Inspect the button to tower clearance as shown Replace the drive clutch if clearance is beyond specification Button To Tower Clearance Inspection 6 13 99231...

Page 232: ... a flat metal rod across the roller 2 TUrn roller with your finger If you notice resistance galling or flat spots replace the drive clutch NOTE Rollers pins thrust washers and buttons are not serviceable at the time of this publication 6 14 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 233: ...r damaged c ln mm 27 94 152 mm 71 In I mm Shaft Diameter I Standard 1 3725 1 3712 34 8615 34 8488 mm Service Limit 1 3704 34 8088 mm 5 Visually inspect the thrust washers for damage Measure the thickness and compare to specification Replace ifworn or damaged I 44 399 025 mm 32 004 076 mm r 2 Remove the moveable clutch sheave 3 Lift the bearing and thrust washers off the shaft Replace as an assembl...

Page 234: ... 5 P 90 Driven Clutch Cover 5020631 Bushing Removal Tool 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller 5020633 Adapter Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemoval Tool 5132028 I Instructions 9915111 Additional Special Tools EBS Clutch Bushing Tool Kit 2201379 Bushing ...

Page 235: ...pear CLUTCHING PVT 9 Tum sheave counterclockwise on puller rod until it comes free Lift sheave offpuller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Moveable Sheave Bushing Installation 1 Place main adapter Item 8 on puller 2 Apply Loctite 609 evenly to bushing bore inSidel moveable sheave 3 Set bushing i...

Page 236: ...adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Tum puller barrel to apply more tension ifneeded 5 Tum clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover offrod 6 18 Drive Clutch Assembly A CAUTION Do not apply oil or grease to the bushings...

Page 237: ...he marks illustrated below are not in alignment upon assembly the clutch will not be in balance and the drive clutch assembly must be replaced 8 Tighten the spiderjam nut using Clutch SpiderNut Socket PU 50578 Torque jam nut to specification Jam Nut C J Align All Marks 2871358 A Spider Assembly 280 300 ft Ibs 379 406 Nm Apply Loctite 263 to threads Moveable Sheave Assembly 6 Install clutch onto ho...

Page 238: ...ter spacer Belt life will be greatly reduced 11 Install the drive clutch cover C Be sure all alignment marts are in alignment 12 Install cover bolts and torque in a cross pattern evenly to specification C T Drive Clutch Cover Bolts 100 in Ibs 12 Nm 6 20 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 239: ...PU 50518 5 Press down on the top ofthe spider assembly pushing the spider onto the shaft Remove snap ring A and slowly release the assembly 2 It is important to mark the position ofthe shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four screws that secure the...

Page 240: ...d rollers K 8 Remove the E clips F washers G and the clutch rollers E Inspect the rollers for wear replace ifwom 7 Remove the inside spider plate D and spider dampener E Inspect the spider dampener E for wear and replace ifneeded NOTE Spring is compression only and has no torsional wind 9 Remove the clutch assembly from the holding tool 6 22 9923144 2011 RANGER RZR XP 900 Service Manual Copyright ...

Page 241: ... 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemoval Tool 5132028 I Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool Kit 2871226 1 Piston Pin Puller 2870386 Clutch Bushing Replacement Tool Kit PN 2871226 Part Description 2 P 90 DrivelDriven Clutch 5020628 Bushing Install Tool Drive Clutch Cover 3 Bushing Removal 5020629 Installation T...

Page 242: ...e 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing 6 24 Clutch Bushing Installation 1 Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller 3 Apply Loctite 609 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller 5 Install new bushing on installation tool Item 2 and install assembly into sheave 6 ...

Page 243: ...shaft and bearing assembly into the outer sheave 1 Install a new bearing onto the clutch shaft using an arbor press Once bearing is fully seated install a new snap ring Clutch Assembly NOTE Press only on the outer race of the bearing during installation to prevent from damaging the bearing 4 Install the roller A onto the roller pin B on both sides 6 25 9923144 2011 RANGER RZR XP 900 Service Manual...

Page 244: ... washers E and E clips F to secure the rollers The rollers should spin freely 6 26 9 Install the spider dampener G inside the outer spider and install the inside spider plate H D I E F I I JLl 10 Install the spider assembly onto the shaft with the retaining ring on top ofthe spider NOTE Use the marks previously made to align the skip tooth spider or use the X on top ofthe spider and align it with ...

Page 245: ... aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveable sheave belt face with both hands and the helix will release Q i 13 Slowly compress the spider into place Ifthe spider appears to bind while compressing stop and make sure the skip tooth onthe shaft andthe spiderare aligned Once the spider passes the retaining r...

Page 246: ...Ibs 4 75 5 88 Nm I Retaining Ring Outer Spider E Clips Thrust Washer Roller Spider Dampener Compression Spring Slotted Spring Pin Moveable Sheave Roller Yilo I Retaining Ring 6 28 Stationary Sheave Ball Bearing RZR XP 900 Service Manual 99 23144 2011 R 1 Polaris Sales Inc Copyng ...

Page 247: ...iftweights incorrectfor application Install correct recommended shift weights too light Drive clutch binding Disassemble and clean clutch inspecting shift weights Engine RPM above and rollers Reassemble without the spring and move specified operating sheaves through entire range to further determine range probable cause Driven clutch binding Disassemble clean and inspect driven clutch noting worn ...

Page 248: ...ts leaking Find leak and repair as necessary Water ingestion Operator error Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt worn out Replace belt Belt slippage Water ingestion Inspect and seal PVT system Belt contaminated with oil or grease Inspect and clean Belt worn or separated thin spots loose belt Replace belt PVTnoise Bro...

Page 249: ...ILLIARD EXPLODED VIEW 7 13 ALL WHEEL DRIVE OPERATION 7 14 AWD DIAGNOSIS 7 15 GEARCASE REMOVAL DISASSEMBLY INSPECTION 7 16 GEARCASEASSEMBLY 7 19 GEARCASE INSTALLATION 7 21 REAR BEARING CARRIER 7 22 BEARING CARRIER INSPECTION REMOVAL 7 22 BEARING REPLACEMENT 7 24 7 BEARING CARRIER INSTALLATION 7 25 REAR DRIVE SHAFT 7 26 DRIVE SHAFT REMOVAL 7 26 DRIVE SHAFT INSTALLATION 7 27 DRIVE SHAFT CV JOINT I BO...

Page 250: ...s Radius Rod to 50 ft Ibs 67 7 Nm Bearing Carrier Bolts Rear Brake Caliper 30 ft lbs 41 Nm Mounting Bolts 7 2 FRONT BEARING CARRIER Bearing Carrier Inspection I Removal 1 Elevate front ofvehicle and safely support machine under the frame area A CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when remov...

Page 251: ...arings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 12 Replace bearing if moisture dirt corrosion or roughness is evident FINAL DRIVE Bearing Replacement Bearing Removal 1 Remove...

Page 252: ...d to get in the bearing 8 Wipe the housing clean ofany excess compound and install the snap ring 7 4 Bearing Carrier Installation 1 Install drive shaft axle through the backside ofthe bearing carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install new pinch bolts and nuts Torque to specification C T Ball Joint Pinch Bolts 23 ft Ibs 31 Nm 4 Apply Anti Seize to...

Page 253: ...os below to ensure proper placement of the tie rod end 8 Torque the tie rod end fastener to specification and install a new cotter pin C T Tie Rod End Fastener 42 5 ft Ibs 58 Nm 9 Torque wheel hub nut to specification and install a new cotter pin Tighten nut slightly if necessary to align cotter pin holes Bend both ends of cotter pin around end of spindle in different directions C T Wheel Nuts 30 ...

Page 254: ...t wheel hub assembly 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 7 6 6 Remove and discard the upper and lower ball joint pinch bolts and nuts 7 Using a softfaced hammer light...

Page 255: ... Nm 7 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 6 Apply Anti Seize to drive shaft axle splines Cone Washers Wheel Hub Out I 3 Install drive shaft into the front bearing carrier 4 Install the upper and lower ball joint ends into the front bearing carrier 8 Torque wheel hub nut to specification and install a new cotter pin Tight...

Page 256: ...Ibs 41 Nm 90 1 4 turn e T Front Caliper Mounting Bolts 31 34 ft Ibs 42 46 Nm A CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 11 Rotate wheel and check for smooth operation 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification 9 Install new brake caliper mounting bolts and torque to specifi...

Page 257: ...ront portion of the propshaft use a new roll pin 15 Torque the support bearing fasteners to specification y er rril1 11nl1 I WTT J Support Bearing Rear Shaft Slide shaft back on transmission shaft 7 Slide the front portion ofthe propshaft back and away from the front gearcase to remove it 8 If removing the rear portion of the propshaft remove the bearing support upper lower half from the shaft 9 P...

Page 258: ...ssing Tooth for Alignment nro NOTE If bearing is seized on the shaft remove the rear portion of the shaft from the vehicle Refer to Removal Installation 4 Clean the mounting surface ofthe shaft and install the new bearing 5 Install a new retaining ring and slide the bearing tight against the retaining ring 7 10 8 Install the rubber isolator over the bearing 9 Install the upper and lower halves of ...

Page 259: ...nvise as shown and drive inneryoke down to remove remaining bearing caps Always wear eye protection A CAUTION 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer Disassembly 1 Remove internal or external snap ring from bearing caps NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting and mark inner and oute...

Page 260: ...e aligning marks made at disassembly and repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete yokes must pivot freely in all directions without binding Ifthejoint is stiffor binding tap the yoke lightly to center the joint until it pivots freely 7 12 9923144 20...

Page 261: ...le Row 1 23 Torsion Spring 7 Bushing 1 24 H Clip Spring 8 Bushing 1 26 Nylon Spacer 9 Oil Seal 2 27 Backlash Spacer 10 Oil Seal 1 28 Ring Gear Spacer 11 Retaining Ring Internal 1 29 Torsion Spring Retainer 12 Retaining Ring 1 30 Pinion Gear 13 Cover Screws M6 T30 Torx 7 31 Armature Plate 14 Cover Plate Assembly 1 32 AWD Coil 15 Gearcase Housing 35 Fill Plug 16 Clutch Housing Ring Gear 36 Drain Plu...

Page 262: ...t gearcase damage could result 7 14 AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts an armature plate that is keyed to the roll cage When the ring gear and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers insid...

Page 263: ...system Ifthis is found replace the cover plate assembly Tum the ignition and AWD switches on and place gear selector in High or Low gear Check for minimum battery voltage at the Gray and Brown White chassis wires that power the coil A minimum of 11 Vdc should be present Ifelectrical tests are within specification remove gearcase see Gearcase Removal and inspect components 3 4 Inspect the armature ...

Page 264: ... line from the front gearcase and plug vent line fitting 7 Remove the 4 bolts securing the front gearcase to the frame 7 16 8 Rotate front ofgearcase up so the input shaft is facing down Lift and remove the gearcase from the front LH wheel well area and slide it out ofthe vehicle above the upper A arm Gearcase Disassembly I Inspection 1 Drain and properly dispose ofgearcase fluid Remove any metal ...

Page 265: ...from the top ofthe ring gear NOTE Nylon spacer is non serviceable and should not be removed 6 Remove the clutch housing ring assembly from the gearcase housing I gear and roll cage 4 Remove and inspect the armature plate Refer to AWD Diagnosis for detailed inspection process 7 17 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 266: ...ing 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in order to retain all the rollers NOTE Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 12 Thoroughly clean all parts and inspect the rollers A for nicks and scratches The rollers must slide up and down and in and out freely wit...

Page 267: ...age 15 Inspect both output hub assemblies Inspect the bearings and replace ifneeded I 2 Install pinion shaft assembly and install internal snap ring 4 Install the RH output hub into the gearcase housing 3 Install a new pinion shaft seal into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer NOTE If bearing ...

Page 268: ...e ring gear dowel pin and install the retainer on top ofthe torsion spring 7 20 8 Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly 9 Install the armature plate Be sure all ofthe armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTE Verify arm...

Page 269: ...upper A arm 2 Lubricate the splines ofthe front gearcase with Anti Seize 3 Install the propshaft onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 4 Install the 4 bolts that secure the front gearcase to the frame and torque to specification 13 Install the output cover assembly onto the gearcase housing Install the 7 cover plate screws and torque to specification C T C...

Page 270: ...y may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove the 4 wheel nuts and remove the rear wheel 4 Remove the cotter p...

Page 271: ...g arm FINAL DRIVE 10 Rotate bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down mo...

Page 272: ...ughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 6 Support the bottom ofthe bearing carrier housing A CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 7 Apply Loctite 603 retaining compound to the outer circumference ofthe new bearing race and carefully press th...

Page 273: ...ners that attach the rear bearing carrier to the trailing arm Install the 1 fastener that attaches the upper radius rod to the bearing carrier Torque bolts to specification NOTE Use new nuts upon installation of the rear bearing carrier T Bearing Carrier to Trailing Arm Bolts 50 ft Ibs 67 7 Nm T Radius Rod to Bearing Carrier Bolts 50 ft Ibs 67 7 Nm 3 Apply anti seize to drive shaft splines Wheel H...

Page 274: ... result if machine tips or falls Be sure machine is secure before beginning this procedure Always wear eye protection 2 Remove the wheel nuts from rear wheel Remove the rear wheel 3 Remove the cotter pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 4 Remove the 2 bolts attaching the upper and lower radius rods to the bearing carrier Di...

Page 275: ...ive shaft 12 Lower the trailing arm 13 With a short sharp jerk remove drive shaft from the transmission splines FINAL DRIVE Drive Shaft Installation 1 Install new spring ring on drive shaft Apply an anti seize compound to the splines NEW Spring Ring 0 Apply Anti Seize 2 Align splines of drive shaft with transmission splines and reinstall the drive shaft Use a rubber mallet to tap on the outboard e...

Page 276: ...astle nut Torque castle nut to specification Install new cotter pin Cone Washers Wheel Hub Out C T Rear Wheel Hub Castle Nut 80 ft Ibs 108 Nm 7 28 8 Install the radius rod bolts washers and new nuts Torque fasteners to specification C T Radius Rods to Bearing Carrier 50 ft Ibs 67 7 Nm 9 Install the rear brake caliper assembly and new bolts Torque to specification C T Rear Caliper Mounting Bolts 30...

Page 277: ...end of the boot from the CV joint and slide the boot down the shaft 3 Clean the grease from the face ofthe joint 4 Place the drive shaft in a soft jawed vise Using a soft faced hammer or brass drift strike the inner race ofthe joint to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding The drive shaft is not to be used as a lever arm to position other suspe...

Page 278: ...rior to reassembly 10 Slide the small boot clamp and boot small end first onto the drive shaft and positionthe boot in it s groove machined in the shaft 11 Install a new circlip on the end ofthe shaft 7 30 12 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s innerrace Pack the ball tracks and ...

Page 279: ...20 Install and tighten the small clamp on the boot using the appropriate clamp tool FINAL DRIVE Inner Plunging Joint I Boot Replacement 1 Using a side cutters cut away and discard the boot clamps 2 Remove the large end of the boot from the plunging joint and slide the boot down the shaft I 3 Clean the grease from the face of the joint and place the drive shaft in a soft jawed vise 4 Using a soft f...

Page 280: ...reasethejointwiththe specialjointgrease provided in the boot replacementkit Fill the cavity behindthe balls andthe splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot A CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability DO NOT use substitutes or mix with othe...

Page 281: ...II l 10 I W 1li1l2 J______ Small 1IIlO 4 II 41 Large Sprin 20 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end ofthe boot and the joint housing and lift up to equalize the air pressure in the boot 21 Position the boot lip in its groove Install and tighten the large clamp using the appropriate clamp too...

Page 282: ...Nm Cotter Pin J Wheel Cap Wheel Nuts 30 ft Ibs 41 Nm 90 1 4 turn Rear Hub Exploded View Wheel Cap Wheel Nuts 30 ft Ibs 41 Nm 90 1 4 turn Studs Wheel Hub Castle Nut 80 ft Ibs _ 108 Cone Cotter Pin Washers Brake Disc Sealed Ball Bearing 7 34 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 283: ...N 8 3 SHIFT CABLE 8 4 INSPECTION ADJUSTMENT 8 4 TRANSMISSION SERVICE 8 5 TRANSMISSION REMOVAL 8 5 TRANSMISSION INSTALLATION 8 8 TRANSMISSION DISASSEMBLY 8 12 GEAR SHAFT BEARING INSPECTION 8 16 SNORKEL GEAR BACKLASH PROCEDURE 8 17 TRANSMISSION ASSEMBLY 8 19 TROUBLESHOOTING 8 23 TRANSMISSION EXPLODED VIEW 8 24 II 8 1 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 284: ...9 12 Nm Screw Transmission Mounting and Torque Values Special Tools PART NUMBER TOOL DESCRIPTION PA S0231 Snorkel Tool 2871698 Part of 2871702 Kit Rear Output Seal Driver 2871699 Part of 2871702 Kit Rear Driveshaft Seal Guide 2871282 Bearing Seal Driver SO mm PU SOS66 Transmission Nut Socket PU S06S8 Clutch Center Distance Tool Lubrication Recommended Transmission Lubricant AGL Plus PN 2878068 Qua...

Page 285: ...Torx driver Remove the console from the vehicle 5 Remove both bushings from the shift lever and service as needed 3 Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever Installation 1 Perform the removal steps in reverse order to install the gear shift lever lever cable console shift knob I Bushings Cover screw n Shift Knob Shift Lever...

Page 286: ...t is required loosen the lowerjam nut and pull the cable out ofthe mount to move the upper jam nut 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjust...

Page 287: ... 2872085 2872085 Correct Drive Clutch Puller For RZR XP900 PA 48595 Incorrect Drive Clutch Puller A CAUTION THE ENGINE TO TRANSMISSION COUPLER BRACKET REQUIRES A CRITICAL TORQUE PROCEDURE AS OUTLINED IN THIS CHAPTER e EP Critical Joint Failure to follow torque procedure outlined in Service Manual will result in damage to the engine case 1 10 ft Ibs 2 33 ft Ibs 3 75 ft Ibs threaded s cer jam nut bo...

Page 288: ...g the rest ofthe removal procedure 16 Place a spacer or support between the vehicle frame and engine to hold the engine up in position 17 Remove vent hose from transmission 18 Remove the gear position switch connector A speed sensor connector B harness from routing clip C shift bracket bolts D shift bracket D shift cable clevis pin and washer E from the transmission 19 To remove the through bolts ...

Page 289: ...3 Remove the 6 bolts attaching the rear transmission mount bracket to the frame Remove the 3 bolts that attach the 2 rear mounts to the transmission Remove the mount assemblies from the vehicle A CAUTION 20 Remove the through bolts from the left hand side of the vehicle after the nut has been removed Discard the through bolts and the nuts 21 Using special tooIPU 50566 loosen the innerjam nuts and ...

Page 290: ...t springs securing the muffler to the rear transmission mounting bracket 5 Install the Clutch Center Distance Tool PU 50658 onto the crankshaft and transmission input shaft to properly position the clutch center distance The pictures below show the tool PU 50658 properly installed 6 Align coupler and front transmission mounting holes 3 Install the rear transmission mount assemblies Torque all fast...

Page 291: ... torque to the nut A CAUTION The threaded spacers must not rotate while installing the through bolts Severe transmission damage may occur if the threaded spacers rotate while installing the through bolts Critical Joint Failure to follow torque procedure outlined in Service Manual will result in damage to the engine case A CAUTION 10 Lightly tighten both threaded spacers by hand Be sure innerjam nu...

Page 292: ...ing ring on rear drive shafts Apply an anti seize compound to the splines NEW Spring Ring 0 Apply Anti Seize 22 Swing the rear trailing arm out and up Align the splines of the drive shaft with the transmission splines Push inward on the trailing arm assembly until the rear drive shafts lock into the transmission splines 8 10 23 Install the rear shocks onto the trailing arms and install the lower m...

Page 293: ... cargo box as an assembly see Chapter 5 30 Connect the negative battery cable 31 Install the engine service panel console cover and seats 32 Iftransmission lubricant was drained fill the transmission with the specified amount of Polaris AGL Plus see Chapter 2 Transmission Lubrication Recommended Transmission Lubricant AGL Plus PN 2878068 Quart Capacity 44 oz 1300 ml 9923144 2011 RANGER RZR XP 900 ...

Page 294: ...emove the compression spring R 8 12 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J 9 Remove the shift shaft K detent pawl L and the shift sector gears M and N IMPORTANT Note the timing marks on the shift gears M and N for reassembly purposes 10 Remove the O rings P from each shaft and discard ...

Page 295: ...ks from the transmission housing as an assembly 14 Remove the rear output shaft assembly 8 by lifting underneath the gear or by tapping the shaft from the opposite side 16 Place the gear cluster assembly on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly I 17 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembly V Lift the pin...

Page 296: ...her I i i 0 i bO i i I Fl i Gi Washer Silent Chain Engagement Dog Washer i Needle Bearing Bearing Retaining Ring Figure 8 1 21 Remove the retaining ring washer needle bearing and sprocket from the reverse shaft see Figure 8 1 20 Remove the retaining ring and engagement dog from the reverse shaft see Figure 8 1 19 Remove the bearing from the reverse shaft using a bearing puller Remove the retaining...

Page 297: ...emove the snap ring A and shim B retaining the bearing in the snorkel tube CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure to remove pinion shaft will result in damage to the snorkel shaft 26 Using the Snorkel Tool FA S0231 fully loosen the snorkel tube 2S Extract the seal from the snorkel shaft to access the snorkel tube for removal 8 15 9923144 2011 ...

Page 298: ...the snorkel shaft 13T Snorkel Gear Inspect all gear sets and shafts for excessive wear or damage IMPORTANT If gear replacement is required be sure to also replace the corresponding gear or gear shaft J I I I I l Inspect all bearings for signs of wear or damage If replacement is required use a standard bearing puller or an arbor press 8 16 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 201...

Page 299: ... are pressed onto the snorkel shaft flush to the shoulder install the washer and new retaining ring Seal Snorkel Gear Backlash Procedure 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly IMPORTANT Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehi...

Page 300: ... the notch is aligned with the hole 13 Slowly rotate the snorkel tube clockwisewhile counting the number ofnotches passing through the hole opening as you rotate the tube Rotate the snorkel tube to the 3rd notch from the zero backlash position obtained in step 11 14 Check the pinion shaft gear backlash again by feel Ifthe pinion shaft gear lash appears to be too tight rotate the snorkel shaft cloc...

Page 301: ...t and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after assembling the transmission C T Snorkel Locking Screw 8 10 ft Ibs 11 14 Nm 16 Torque the locking screw to specification 67T Low Gear I Input Shaft Retaining Ring Needle Reverse Shaft Bearing I 48T 5J Retaining II Sprocket 00 Rings I i v 53T Gear i Washer I i 0 0 I I I I l jZr b Washer Si...

Page 302: ...embled NOTE Both shift forks need to be orientated the same way so that the shift fork pins are both offset to the same side of the rail 8 20 NOTE Shift fork pins should be offset towards the input shaft as shown above 7 Inspect the shift drum for any damage or wear Inspect the splines ofthe shift drum 8 Install the shift drum E into the transmission housing Lift up on the shift shaft rail D and m...

Page 303: ...s as shown C T Transmission Case Bolts 15 20 ft Ibs 20 27 Nm The snorkel shaft seal F should be pressed in until it seats against the housing counter bore The input shaft seal G should be pressed in until it seats flush with the housing The rear output shaft seals H can be installed using a standard bushing installation tool Seals should be installed just past the case lead in chamfer 070 in or 1 ...

Page 304: ...hly 19 Apply Crankcase Sealant 3 Bond pN 2871557 onto the cover and transmission case mating surface 20 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification T Sector Cover Bolts 7 9 ft Ibs 9 12 Nm 8 22 21 Install the transmission drain plug and torque to specification T Filii Drain Plug 10 14ft lbs 14 19 Nm 22 Install ...

Page 305: ... NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is outside the transmission If transmission problem remains disassemble transmission a...

Page 306: ...Sealant 6Apply Loctite to the bolt threads 7 9 fl Ibs 10 12 Nm 10 14 fl Ibs 1 14 19 Nm l p 0 q rt kJ R v 1 Ple 10 y 6 C _ m 7 6 6 0 Q 1 _ 3 242 9 J 6 11 8 10 fl Ib A 1 S 8 1 _ 11 14 Nm 13 lI _ r r _ 41 l 62 l I 1 6 r O c i J y r 60 10 12 18f1lb r ef j 82 1 s C n 0 16 24 N 8 i 1 r W m y I I 0 f 15 20 ft J 20 s _ 9 27 Nm 37 37 1 15 20 fl Ibs 0 37 s 20 27 Nm _ 6 37 0 0 N t O 0 0 tOe rG Nrn o u UN 9 u...

Page 307: ...1 Gear Low 67T 20 2 Retaining Ring External 63 1 Engagement Dog 6 Face 21 2 Retaining Ring External 64 1 Gear 53T 22 3 Retaining Ring External 65 1 Shaft Pinion 11T 23 1 Retaining Ring External 66 1 Gear 46T 24 2 Washer Thrust 67 1 Gear Snorkel13T 25 1 Washer Thrust 68 1 Shaft Shift 26 1 Shim 69 1 Weldment Rear Mount Bracket 27 1 Shim 70 1 Bracket Rear Mount 28 2 Bearing Needle Cage 71 1 Cover Bea...

Page 309: ... 9 FRONT CALIPER SERVICE 9 10 CALIPER EXPLODED VIEW 9 10 CALIPER REMOVAL 9 10 CALIPER DISASSEMBLY 9 11 CALIPER INSPECTION ASSEMBLY 9 12 CALIPER INSTALLATION 9 13 FRONT BRAKE DISC 9 14 DISC RUNOUT INSPECTION REPLACEMENT 9 14 REAR BRAKE PADS 9 15 PAD REMOVAL 9 15 PAD INSPECTION 9 16 PAD ASSEMBLY INSTALLATION 9 17 BRAKE BURNISHING PROCEDURE 9 17 REAR CALIPER SERVICE 9 18 CALIPER EXPLODED VIEW 9 18 CA...

Page 310: ...ar Brake Disc Runout 010 254 mm TORQUE SPECIFICATIONS SPECIAL TOOLS Item Torque Torque ft lbs Nm Front Caliper Mounting Bolts 31 34 42 46 Rear Caliper Mounting Bolts 30 41 Brake Line Flare 12 15 16 20 Brake Line Banjo Bolts 15 20 Caliper Attachment Brake Line Banjo Bolt 15 20 Master Cylinder Attachment Brake Switch 15 20 Brake Disc to Hub Bolts 30 41 Master Cylinder to Frame 17 23 Brake Pedal Moun...

Page 311: ...by vibration If cleaning does not reduce the occurrence ofbrake noise Permatex Disc Brake Quiet can be applied to the back ofthe pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troubleshooting Possible Cause Remedy Spray disc and pads with CRC Brakeleen or an equivalent Dirt dust or imbedd...

Page 312: ...eated when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly As the temperature w...

Page 313: ... Style Fittings 15 ft Ibs 20 Nm f2l All Caliper Bleed Screws t J 47 in Ibs 5 3 Nm IJl All Flare Style Fittings 12 15 ft Ibs 16 20 Nm o Master Cylinder Side View LH Front Brake Line RH Front Brake Line I 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc 9 5 ...

Page 314: ... drain NOTE Dispose of fluid properly Do not re use 5 Remove the two mounting fasteners D that secure the master cylinder to the frame Installation 1 Reverse Steps 1 5 for master cylinder installation Refer to the torque specifications in the illustration 2 After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm BRAKE PEDAL LEVER Pedal Removal 1 Locate th...

Page 315: ...curely and remove bleeder hose Torque bleeder screw to 47 in Ibs 5 3 Nm 7 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir NOTE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder 2 If changing fluid remove old fluid from reservoir with a Mity Vac pump or similar...

Page 316: ...g or bending brake line 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 9 8 6 Push the mounting bracket inward and the slip outer brake pad out between the bracket a...

Page 317: ... entering the brake system 5 Install the adjustment set screw and tum clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts to specification ro T Wheel Nuts 30 ft Ibs 41 Nm 900 1 4 turn Brake Burnishing Procedure I It is required that a...

Page 318: ...cone Grease Caliper Removal 1 Elevate and safely support the front ofthe vehicle 2 Remove the 4 wheel nuts and the front wheel 4 Place a container below the caliper to catch brake fluid when removing the line Remove brake line from caliper A CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before removal Remove Brake Line o 9 10 ...

Page 319: ... the pistons from the caliper IMPORTANT Do not remove the caliper pistons with a standard pliers The piston sealing surfaces will become damaged if a standard pliers is used Caliper Disassembly 1 Remove both brake pads from the caliper see FRONT BRAKE PADS Pad Removal 2 Remove mount bracket assembly and dust boots Mount Bracket 5 Once the pistons are removed use a pick to carefully remove the squa...

Page 320: ...tting or wear Measure piston diameter and replace if damaged or worn beyond service limit 9 12 J v In 1mm Front Caliper Piston O D Std 1 370 34 80 mm Service Limit 1 368 34 75 mm 3 Inspect the brake disc and pads as outlined in this chapter Caliper Assembly 1 Install new a rings in the caliper body Be sure the grooves are clean and free of residue or brakes may drag upon assembly 2 Coat pistons wi...

Page 321: ...all the adjustment set screw and tum clockwise until stationary pad contacts disc then back off 1 2 tum counterclockwise C T 2 Install the caliper and torque the mounting bolts to specification 1 Install the brake line onto the caliper taking care not to allow any debris to enter the caliper Caliper Installation 4 Compress the mounting bracket andmake sure the dust seal boots are fully seated Inst...

Page 322: ...ght different points around the pad contact surface Replace disc ifwom beyond service limit Disc Replacement 1 Remove the front brake caliper see FRONT CALIPER SERVICE 2 Remove wheel hub cotter pin castle nut and washers 3 Remove the wheel hub assembly from the vehicle and remove the 4 bolts retaining the disc to the hub Cotter Pin IWashers i Nut 4 Clean the wheel hub mating surface and install ne...

Page 323: ... into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released Ifthe brake drags re check assembly and installation REAR BRAKE PADS Pad Removal 1 Elevate and support rear ofvehicle A CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the rear wheel 3 Loosen pad adjuster...

Page 324: ...re slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 9 16 8 Remove the inner brake pad Pad Inspection 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness ofthe pad material Replace pads...

Page 325: ...tering the brake system 6 Install the adjustment set screw andtum clockwise until the stationary pad contacts the disc then back off 1 2 tum 8 Install wheel and torque wheel nuts to specification I El T Wheel Nuts 30 ft Ibs 41 Nm 90 1 4 turn 7 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap El T Brake Burnishing Procedure Rear Caliper Mount Bolt 30 ...

Page 326: ...en supporting vehicle so that it does not tip or fall Severe injury may occur 2 Remove the 4 wheel nuts and rear wheel Clean caliper area before removal 3 Place a container below the caliper to catch the brake fluid when removing the line Remove brake line from caliper Remove Brake Line 9 18 4 Remove the lower radius rod outer mounting bolt nut and washer from the bearing carrier Swing radius rod ...

Page 327: ... Limit 1 507 38 28 mm Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace ifdamage is evident or ifwom beyond service limit NOTE Be sure to clean seal grooves in caliper body B Caliper Disassembly 1 Remove brake pad adjustment set screw K 2 Push upper pad retainer pin inward and slip brake pads past the edge and remove from ...

Page 328: ...kes may drag upon assembly 2 Coat piston with clean Polaris DOT 4 Brake Fluid pN 2872189 Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seals are fully seated Inst...

Page 329: ...cation E T Radius Rod to Bearing Carrier Bolt 50 ft Ibs 67 7 Nm 4 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 5 Follow bleeding procedure outlined earlier in this chapter NOTE If new pads are installed refer to REAR BRAKE PADS Brake Burnishing Procedure 15 ft Ibs 20 Nm 6 Install wheel and torque wheel nuts to specification E T Wheel Nuts 30 f...

Page 330: ...al runout on the dial indicator Replace the disc ifrunout exceeds specifications 6 7 Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal Install wheel hub assembly washers and castle nut Torque castlenutto 80 ft lbs 108 Nm and install anew cotterpin Install rear caliper see REAR CALIPER SERVICE Follow bleeding procedure outlined earli...

Page 331: ... insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment of caliper to disc Caliper pistons stickin...

Page 333: ...10 15 BULB REPLACEMENT 10 15 COOLING SYSTEM 10 16 COOLING SYSTEM BREAK OUT DIAGRAM 10 16 FAN CONTROL CIRCUIT OPERATION TESTING BYPASS TEST 10 17 COOLANT TEMPERATURE SENSOR 10 17 EFI DIAGNOSTICS 10 17 FUEL SENDER 10 17 FUSE BOX FUSES I RELAYS I CIRCUIT BREAKER 10 18 FUSE BOX DETAIL 10 19 RELAY OPERATION 10 20 CHARGING SYSTEM 10 21 CURRENT DRAW KEY OFF 10 21 CHARGING SYSTEM BREAK EVEN TEST 10 21 CHA...

Page 334: ... 10 28 STARTER SOLENOID OPERATION 10 28 STARTING SYSTEM TESTING FLOW CHART 10 29 ELECTRICAL SYSTEM BREAKOUTS 10 30 AWD 10 30 VEHICLE SPEED SENSOR 10 30 COOLING FAN 10 31 CHARGING SYSTEM 10 32 CHASSIS POWER 10 32 EFI 10 33 KEY ON BATTERY POWER 10 34 LIGHTS 10 35 STARTER INTERLOCK 10 36 10 2 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 335: ...ance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 1OA jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical proble...

Page 336: ...f a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 10 4 9...

Page 337: ... SteeringSystem MIL LED icon illuminates when a fault has occurred with the power steering system This indicator illuminates when the key is turned to the ON position and goes off when the engine is started EPS Option Only 15 Tum Signal Hazard Lamp Indicator LED icon illuminates whenever the LH RH or hazard lamps are activated INT L Models Only 16 Helmet Seat Belt Indicator LED icon illuminates fo...

Page 338: ...n not be reset Programmed Service Interval iJE jQjjQjjQjjQjjQjjQjjQjjQjF 1 1 The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service interval hours When the service interval reaches 0 the LCD wrench icon will flash for approximately 10 seconds each time the engine is started To change the hour setting or reset the fu...

Page 339: ... When the display flashes the distance setting tap the MODE button to advance to the desired setting 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1...

Page 340: ...o occur when the engine is at idle and a high electrical load is applied lights cooling fan or other accessories If battery voltage rises above 15 volts a warning screen will display OV and provide the present battery voltage Ifvoltage rises above 16 5 volts LCD backlighting and icons will tum off 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set ofthree numbers will appe...

Page 341: ...ON PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 International Models Only Turn Signal Input LH 6 Turn Signal Input RH 7 Instrument Cluster Removal 1 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily I NOTE Do not allo...

Page 342: ... For switch replacement refer to Chapter 9 Brakes Headlamp Switch 1 Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs OFF LOW HIGH If any ofthe tests fail replace headlamp switch assembly Move the switch to HIGH There should be continuity between switch pins 2 and 3 5 and 6 Move the s...

Page 343: ...AWD 2WD Ifany of the tests fail replace the switch assembly Tum the ignition key to ON There should be continuity between switch pins C and D Move the switch to AWD ON There should be continuity between switch pins 2 and 3 Tum the ignition key to START There should be continuity between switch pins A and B C and D Move the switch to 2WD NONE OFF There should be no continuity between any pins 1 2 3...

Page 344: ... Bm I To Pin A Special Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires from the Static Timing Light Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness pN 2460761 3 Pass a screwdriver back and forth in front ofthe sen...

Page 345: ...tional Test the AWD hub coil using an ohm meter See specifications below II VOLTS MINIMUM REQUIRED TO POWER HUB COl L 8_ Test Resistance Readings should be GY to BNIWH 24 Ohms GY to Ground No Connection iL Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connect properly Verify continuity ofwire connections with a known good volt ohm meter IMPORTANT Ve...

Page 346: ...the headlamp assembly Be sure to pull on the connector not on the wiring 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 With the machine in Park start the engine and tum the headlight switch to the LOW position 4 The most intense part of the LOW beam headlight beam should be aimed 2 in 5 em below the mark placed on the wall in ...

Page 347: ...the front bumper as shown in Chapter 5 ifpreviously removed 6 Connect headlamp electrical connector to the headlamp assembly 7 Perform the Headlight Adjustment procedure as shown in this chapter TAIL I BRAKE LIGHTS Bulb Replacement Before replacing the bulb s use a digital multi meter to test the harness to ensure the lamp is receiving 12volts andthat aground path is present Ifa taillight or brake...

Page 348: ...I I t OG WH I I I I I I I I I I L I I r 3 UJ 6 i Ii O A_NT_T_EMP_ S_EN_SO_R I CD I 0 CD 0 a 0 rcn I CD CD I CD I CD ill CD en I CD CD I m I CD N CD I C en I I CD I I I i f en T N RELAY FUSE BLOCK ECM Controlled Power et Ground et Jn I I I I I I I I I 18 T J 1 FAN I I 10 16 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 349: ...replace as necessary Ifthe fan runs with the sensor harness disconnected but will not tum on when the engine is hot check the coolant temperature sensor and connector terminals Fan Control Circuit Bypass Test NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air 3 Allow the sende...

Page 350: ...t INSTRUMENT CLUSTER JC eN HIGH 0 1 E 10 8EAM 5HI C iN Cl P N Fl j jcT 6N _ _ __ s i uGTfV ELi N UT 12 BLACKOuT r1GDE 1 3 _ _ _ _ IR MPER CRE SPARE PO OFOUND IG oIGI iNF 15 KEY 5W I Tell 5PUCE 8 UN5l iITCHED fUSED DNH J 20 A IP C1f CU 1T BF f KER RELAY IF USE BLCC S0 RD _ fDG RD rm FUSE RELAY PIN OUT GUIDE A9 B Unswitched EFI Relay Coil B3 B Unswitched to EPS Relay B7 B Unswitched Fused to Fan Rel...

Page 351: ... 8 M FUEL PUMP RELAY PWR OUT r V EW II i joF LA 4 I I I L_ S_J C2 ACC FUSE OUT C3 ACC FUSE IN 04 EFI FUSE OUT DS EFI FUSE IN C4 DR I VE FUSE OUT CS DR I VE FUSE IN OS FUEL PUMP FUSE OUT D7 FUEL PUMP FUSE IN CS LI GHTS FUSE OUT C7 LI GHTS FUSE IN r V EW i i i L _J C9 CHASSI S RELAY COI L 8 D9 CHASSI S RELAY POWER IN DB CHASSI S RELAY COI L B CB CHASSIS RELAY PWR OUT A EFI FUSE IN B EFI FUSE OUT C C...

Page 352: ...Red I Dark Blue Provides 12 Vdc power for EFI system circuits FAN RELAY provides power to the following system FanMotor FAN RELAY COLOR FUNCTION Red 20 Amp circuit breaker protected 12 Vdc constant battery power Orange I White ECU ground input to enable relay Red I Dark Blue 12 Vdc switched power from EFI relay Orange I Black Provides 12 Vdc power for fan operation FUEL PUMP RELAY provides power t...

Page 353: ... time Do not run test with high amperage accessories 1 Using an inductive amperage metering device set to DC amps connect to the negative battery cable 2 With engine off key switch and lights in the on position the ammeter shouldreadnegative amps battery discharge 3 Shift transmission into park and start the engine With the engine running at idle observe meter readings 4 Increase engine RPM while ...

Page 354: ...cified RPM in the table Example The alternator current output reading should be approximately 21 VAC at 1300 RPM between each leg NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced RPM Reading AC Voltage VAC Reading 1300 21 VAC 25 3000 47VAC 25 5000 79VAC 25 Stator Alternator Replacement Refer to Engine Chapter S...

Page 355: ...below the Break Even RPM Con tinued problems would call for battery inspection Ohm stator wires if bad replace stator if good continue with alternator output test Meter Setting AC Volts Disconnect the Yellow wires from the regulator I rectifier Using a multimeter perform an Alternator No Output test See test procedure on Page 10 22 Does output meet specification Yes Inspect the wiring harness betw...

Page 356: ...with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries Keep out of reac...

Page 357: ...ry testing and charging See the following chart and Load Test NOTE Maintenance Free batteries should be kept at a high state of charge during storage If the battery is stored or used at a low state of charge hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery NOTE Use a volt ohm meter to test battery voltage Battery PN 4011224 OPEN CIRCUIT VOLTAGE...

Page 358: ...l not exceed 14 6 Vdc An automatic charger will signal when charging is complete NOTE Allow the battery to stand disconnected for at least 1 2 hours after being properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced A WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop cha...

Page 359: ...ds across the connection to be tested Refer to the voltage drop tests on the starter system in this chapter ELECTRICAL Starter Motor Removal 1 Remove the driver side seat and disconnect the battery 2 Raise and support rear ofvehic1e 3 Remove the RH rear wheel 4 Remove the positive wire from the starter motor terminal 5 From the RH side wheel well using an 8mm flex socket remove the negative batter...

Page 360: ...n To energize the Starter Solenoid the following must occur The brake must be applied to provide a ground path via the Orange wire The key switch must be turned to the start position to provide 12V power via the Green White wire Once the pull in coil is energized the solenoid provides a current path for 12V power to reach the starter motor NOTE See ELECTRICAL SYSTEM BREAOUTS Starter Interlock prov...

Page 361: ...he two terminals Ifresistance measurement is out ofspecification Voltage Drop replace the starter solenoid see Starter Solenoid Bench Test Testing Ir Reconnect the solenoid Connect the tester black lead No Clean the battery to solenoid cable ends to the battery positive and the red lead to the solenoid or replace the cable end ofthe battery to solenoid wire Apply the brake and turn the ignition ke...

Page 362: ...rom Chassis Relay to C7 C7 B Bus to C5 C3 C4 B Out toAWD SPLiCE H SB t DG I z l __OG i KEY SWITCH I SP RE BL ACKOUT MOOt CUtL LEVEL NPUT 1 i2 10 16 INSTRUMENT CLUSTER pitT FU JCi i ON CA HIGH PIN SPLlCt CAt HIGH 1 __ __ r SPL1C Vehicle Speed Sensor 10 30 9923144 2011 RANGER RZR XP 900 Service Manual Copyrighl2011 Polaris Sales Inc ...

Page 363: ...Fan Relay Out A7 B Fan Relay Coil A8 B EFI Relay out to Splice ECM B6 Fan Relay Coil Control B7 B Unswitched to Fan Relay I GROUND 6MM RING LJ BATTERY VOLTAGE I2V BK FRAME GROUND START SOL BATT PLUS p RD C J 20 AHr CIRCUIT BREAKER COOLANT TEMP SENSOR I I i I THERHISTOR I I PIN 4010644 NOMINAL RESrSTANCE I AT 20 D C 2 S kD 6 1 I k i f RD 1 f lJb 10 31 9923144 2011 RANGER RZR XP 900 Service Manual C...

Page 364: ...CK FUSE I RELAY PIN OUT GUIDE A9 8 Unswitched EFI Relay Coli 83 8 Unswitched to EPS Relay 87 8 Unswitchad Fused to Fan Relay 89 8 UnswitchadTo EFI Relay 04 Unswitched Fusad to 8 Splice D9 8 Unswitched To Chassis Relay D5 8 Unswllched Supply to EFI Fuse 5HRT SOl UtlTT pur P FR EU 3E I L j r uu I FRAME GROUND 10 32 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 365: ...ut to Splice ECM A9 8 Unswitched EFI Relay Coil 84 Fuel Pump Relay Coil Control 85 8 Fuel Pump Relay 88 EFI Relay Coil Control 89 8 Unswitched to EFI Relay 04 8 Splice Unswitched 06 6 out to Fuel Pump Relay KEY S ITCH SPUCE fi 5 1 RELAY FUSE BLOCK Ol A R CONTROL CPS I 10 33 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 366: ...E lIGHT SPEED SENSOR riEI_ A FUSE BLOCK 30APower Fuse FUSE RELAY PIN OUT GUIDE A3 8 Switched to Chassis Relay Coil C2 8 To Splice ACC C3 8 From Buss C5 C7 C4 8 ToAWD Coil C6 8 To Splice Lights C8 8 Out from Chassis Relay to C7 C9 8 Chassis Relay Coil Control D5 8 30A Power Fuse D6 B Out to FIP Relay 10 34 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 367: ...OUND 8 rtt i tti ii t _1 GnOUNLj ll a ff 1 _ _ _ 10 fA IL fJRAKE L GHi f J J __ _ __ _ FUSE I RELAY PIN OUT GUIDE A9 8 Unswitched EFI Relay Coil 82 Ground EPS Relay Coil 89 8 Unswitched to EFI Relay C6 8 To Splice Lights 04 8 Splice Unswitched 08 Ground Chassis Relay Coil I 10 35 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 368: ... OCK FUSE I RELAY PIN OUT GUIDE A8 B Switched from EFI Relay B8 EFI Relay Coil Control B9 B Unswitched to EFI Relay 04 B Splice Unswitched 05 B to EFI Fuse J 89 88 i A8 10 36 9923144 2011 RANGER RZR XP 900 Service Manual Copyright 2011 Polaris Sales Inc ...

Page 369: ...14 Centralized Hilliard Exploded View 7 13 Charging Procedure 10 26 Charging System 10 21 Charging System Testing Flow Chart 10 23 Charging System Alternator Tests 10 21 Chassis 5 11 Circuit Breaker 10 18 Clutch Starter One Way 3 43 Combustion Chamber 3 37 Communication Problems Digital Wrench 4 36 Connecting Rod Assembly 3 61 Connecting Rod Inspection 3 55 Console and Floor Panel Removal 5 15 Con...

Page 370: ...n 1 2 Engine Service 3 22 Engine Specifications 3 6 Engine Accessible Components 3 22 IX 2 Engine Balance Shaft Bearing Selection 3 59 Engine Balance Shaft Removal Inspection 3 46 Engine Cam Shaft Removal 3 31 Engine Camshaft Installation Timing 3 74 Engine Camshaft Sprocket Inspection 3 33 Engine Camshaft Timing Quick Reference 3 77 Engine Connecting Rod Bearing Selection 3 58 Engine Cooling Syst...

Page 371: ...stem 2 11 Maintenance General Vehicle Inspection 2 10 Maintenance Service Products and Lubricants 2 9 Maintenance Steering 2 32 Maintenance Transmission and Gearcases 2 22 Manifold Air Quality Sensor MAQS 4 14 Master Cylinder Installation 9 6 Master Cylinder Removal 9 6 Model Identification 1 2 N Nets Side 504 o Oil Pressure Specifications 3A Oil Pressure Test 304 Oil Tank Breather Hose Inspection...

Page 372: ...ication Valve Stem Diameter 3 37 Specification Valve Stem Guide J D 3 37 IX 4 Specification Wheel Toe Out 2 33 Specifications Camshaft 3 33 Specifications Cooling System 3 13 Specifications Crankcase Fastener Torque 3 67 Specifications Engine 3 6 Specifications Engine Lubrication 3 3 3 30 Specifications Engine Oil Pressure 3 4 Specifications FOX 2 0 Shocks 5 30 Specifications General 1 4 Speed Sen...

Page 373: ...32 Troubleshooting Brake Noise 9 3 Troubleshooting Brake System 9 23 Troubleshooting Clutching 6 29 Troubleshooting Transmission 8 23 V Valve Clearance Inspection 2 18 Valve Cover Installation 3 82 Valve Cover Removal 3 31 Valve Sealing Test 3 72 Valve Seat Reconditioning 3 38 Valve Spring Free Length 3 36 Valve Spring Removal 3 35 Version Software 4 36 VIN Identification 1 2 VIN Location 1 2 Volt...

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Page 376: ...PN 9923144 Printed in USA ...

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