Polaris Ranger RZR XP 900 2011 User manual

, PDLRRIS®
The Way Out.
2011 RANGER RZR XP 900
SERVICE MANUAL
PN 9923144

pA
1_
The Way
2011 RANGER RZR XP 900
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version ofthis Service Manual is available
in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer® technicians
in aproperly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in anormal riding position. .
Some procedures outlined in this manual require asound knowledge of mechanical theory, tool use, and shop
procedures
in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools
as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact
an authorized dealer for service.
We value your input and appreciate any assistance you can provide
in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click
on 'Ask Polaris', and then click on 'Publications Question'.
Consumers, please provide your feedback
in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy
55, Medina, MN 55340.
Publication Printed February 2011 (PN 9923144) Rev 1
©Copyright 2011 Polaris Sales Inc. AI/Information contained within this publication is based on the latest product information atthe time of publication. Due to constant
improvements
in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this pUblication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting
or reuse ofthe depictions and/or procedures contained within, whetherwhole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
.& WARNING
SAFETY ALERT WARNING indicates apotential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
'&CAUTION
SAFETY ALERT CAUTION indicates apotential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN TIllS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark
ofWm. F. Nye Co.
Fluke, Registered Trademark
of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark
of Neward Enterprises, Inc.
Torx, Registered Trademark
of Textron
Hilliard, Trademark
of the Hilliard Corporation
Warn, Trademark
of Warn Industries
FOX, Registered Trademark
of FOX RACING SHOX
RydeFX, Registered Trademark
of ArvinMeritor
Some Polaris factory publications can
be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.

GENERAL INFORMATION II
MAINTENANCE IfI
ENGINE ICOOLING II
ELECTRONIC FUEL INJECTION II
BODY ISTEERING ISUSPENSION II
CLUTCHING (PVT)
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
II
II
II
II
III

GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
MODEL INFORMATION 1.2
MODEL IDENTIFICATION 1.2
ENGINE DESIGNATION NUMBER 1.2
VIN IDENTIFICATION 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1.2
VEHICLE INFORMATION 1.3
PUBLICATION 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 IDRILL SIZES 1.8
METRIC TAP IDRILL SIZES 1.8
DECIMAL EQUIVALENTS 1.8
GLOSSARY OF TERMS 1.9
9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.
II
1.1

GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
R 11 JH 87AD
'-v-'~\~
Model Year / ~ Emissions &
Designation . /. Model Option
BaSIC ChassIs ...
Designation Engine DeSignatIOn
Engine Designation Number
ES0870LE011 4-Stroke DORC Twin Cylinder, Liquid Cooled, Electric Start
VIN Identification
Vehicle Identifier
10 11 12 13 14 15 16 17
BP0 0 0 00 0
I\Y)
Model I
Year Individual Serial No.
World
Mfg.
10 Vehicle Description
123456789
4XA JH 87A*
I E!e
Body Style Emissions Plant No.
Powerlrain Check Digit
Vehicle and Engine Serial Number Location
•This could be either
anumber or aletter
Whenever corresponding about aPolaris ORV, refer to the vehicle identification number (YIN) and the engine serial number.
The
VIN can be found stamped on aportion of the left rear frame rail, behind the lower shock mounting location (see Figure 1-1).
The engine serial number can be found on adecal applied to the crankcase, on the front side
of the engine (see Figure 1-2).
Engine Serial
Number
1.2 9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright
2011 Polaris Sales Inc.

GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers I
Model Model No. Owner's Manual Parts Manual
2011 RANGER RZR XP 900
R11JH87AA, AD
9922978 9922979
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris
factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.
Replacement Keys
Replacementkeys canbe made from the original key. To identify which series the key is, takethe first two digits on the original key
and refer to the chart 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
Specialtools may berequiredwhile servicingthisvehicle. Some ofthe toolslisted or depictedaremandatory, whileothertools maybe
substitutedwith asimilartool,
if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.
Dealers
may order special tools through Polaris' official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at
http://polaris.spx.com/.
1.3
9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2011 RANGER RZR XP 900
MODEL NUMBER: R11JH87AA, AD
ENGINE NUMBER: 1204098
Category Dimension 1Capacity
Length 108.4
in. 1275 cm
Width 64
in. 1162.5 cm
Height 73
in. 1185 cm
Wheel Base 81.4
in. 1207 cm
Ground Clearance
13in./33cm
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 ahitch.
1.4 9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

GENERAL INFORMATION
Altitude Shift Drive Driven
Weight Spring Spring
25-60
0-1500 (1322969)
Blue/Yellow Red
(0-5000) 26-59 (7043766) (3234452)
Meters (1322981)
(Feet) 26-56
1500-3700 (1322979)
Blue/Yellow
Red
(5000 -12000) 26-55 (7043766) (3234452)
(1322982)
...... , ..... '.«............. . .. <S:
.. »S:·
•••.•.••••••• < •••••••..••. : ••••. :> ••••..•••..••••.•••.•••.• :... ••.•.•••.. . •.•••.••.•...
Transmission Type Polaris Automatic PVT
Drive Ratio -Front 3.82:1
Drive Ratio -Final 3.53:1
Shift Type
In Line Shift- H / LI N / R / P
Front Gearcase Polaris Demand Drive Plus
Fluid Type /Capacity 6.75 oz. (200 ml)
Transmission Polaris
AGL Plus
Fluid Type /Capacity 44 oz. (1300 ml)
Drive: Polaris, Basic,
Non-Braking Bearing
Clutching (PVT) Type Driven: Team Roller
Dampened
Clutching (PVT) 10.5
in. (26.7 cm)
Center-to-Center Distance
PVT Drive Belt 3211142
•• '< .. ; •. < ••• <<
••••• : •••• >, .••.•..
IS":
Front Suspension /Shock Independent Dual A-arm
FOXTM 2.0 Piggyback
Front Travel 13.5
in. /34.3 cm
Rear Suspension /Shock Independent Trailing Arm
FOXTM 2.0 Piggyback
Rear Travel 14 in.
/35.6 cm
Shock Preload Adjustment Threaded SpannerWrench
Front! Rear Adjustment
Toe Out 1/8 -3/16 in. (3.2 -4.8 mm)
..,: ..... • .••...... · ... · •.•• · .. · .... >.i ..... · .. < ... ··
;' ...• ·.·B,.ake~i .• <· ••.•••.•••••••••••••..• <>
<Si
Front Wheel Size 12 x
6/ Cast Aluminum
Front Tire Type /Size ITP "900XCT"
/27 x 9 R12
Rear Wheel Size 12 x
8/ Cast Aluminum
Rear Tire Type /Size ITP "900XCT'
/27 x12 R12
Tire Air Pressure Front: 12 psi (82.7 kPa)
Rear: 14 psi (96.5 kPa)
Brake -Front /Rear Foot Actuated - 4 Wheel
Hydraulic Disc
Brake Fluid
DOT4
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 x64.4 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 Synthetic
Oil Capacity 3.5 qts.
/3.3 liters
Coolant Capacity 4.9 qts.
/4.6 liters
Overheat Warning Instrument Cluster Indicator
Exhaust System Dual Headpipe /Single Silencer
........
....
•.••••••••••• : •...•.•••••••• ·.fHf;lI
. ·•· .. · .• ···I .. <I.>iN:'·:: •
.... : •.•.........•...
· .. i·.·.· ... ·.
Fuel System Type Bosch M17 EFI
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 43.5 ±2psi (300 ±14 kPa)
Fuel Filters See Chapter 4
Fuel Capacity /Requirement 7.25 gal. (27.4 liters)
87 Octane (minimum)
I.!«::»
•••.••.•.•• ::: .•••••.•• ':.:.: •.• < •.. <.: •.••• ' ••
Alternator Max Output 750 Watts @3000 RPM
Headlights 2 - Dual Beam LED:
Low 27 Watts; High
40 Watts
Tail/ Brake 2 - 6 Watts / 2 - 27 Watts
Starting System Electric Start
Ignition System Bosch M17 (ECU Controlled)
Spark Plug /Gap RG4YCX /0.03 in. (0.75 mm)
Battery Deka ETX30L /30 AH
365 CCA
/12 Volt
Instrument Type Multifunction InstrumentCluster
DC Outlet Standard 12 Volt
Relays Chassis /
EFI/ Fan
Fuel Pump /EPS (OPT)
Circuit Breaker 20 Amp: Fan Motor
10 Amp: Drive
10 Amp: Fuel Pump
Fuses (Fuse/Relay Box) 20 Amp: Lights
20 Amp: EFI
20 Amp: Accessory
30 Amp: EFI
Fuses (Power Fuse Holder) 30 Amp: Chassis
30 Amp: EPS (OPT)
CLUTCH CHART
•
1.5
9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Unit of Measure Multiplied by Converts to
ft.lbs. x12 =in.lbs.
in.lbs.
x.0833
=ft. Ibs.
ft.lbs.
x1.356 =Nm
in.lbs.
x.0115 =kg-m
Nm
x.7376 =ft.lbs.
kg-m x7.233 =ft.
Ibs.
kg-m x86.796 =in.lbs.
kg-m
x10
=Nm
in. x25.4 =mm
mm
x.03937 =in.
in. x2.54
=cm
mile (mi.) x1.6 =km
km
x.6214
=mile (mi.)
Ounces (oz) x28.35 =Grams
(g)
Fluid Ounces (fl. oz.) x29.57 =Cubic Centimeters (cc)
Cubic Centimeters (cc) x.03381 =Fluid Ounces (fl. oz.)
Grams
(g) x0.035 =Ounces (oz)
lb. x.454 =kg
kg x2.2046 =lb.
Cubic inches
(cu in) x16.387 =Cubic centimeters (cc)
Cubic centimeters (cc) x0.061 =Cubic inches (cu in)
Imperial pints (Imp pt) x0.568 =Liters
(I)
Liters (I) x1.76 =Imperial pints (Imp pt)
Imperial quarts (Imp
qt) x1.137 =Liters (I)
Liters (I)
xO.88 =Imperial quarts (Imp qt)
Imperial quarts (Imp
qt) x1.201 =US quarts (US qt)
US quarts (US
qt) x0.833 =Imperial quarts (Imp qt)
US quarts (US qt) x0.946 =Liters
(I)
Liters (I)
x1.057 =US quarts (US qt)
US gallons
(US gal) x3.785 =Liters
(I)
Liters (I) x0.264 =US gallons (US
gaO
Pounds -force per square inch (psi) x6.895 =Kilopascals (kPa)
Kilopascals (kPa) x0.145 =Pounds -force per square inch (psi)
Kilopascals (kPa) x
0.01 =Kilograms -force per square cm
Kilograms -force per square cm
x98.1 =Kilopascals (kPa)
rt (3.14) x R2 xH(height) =Cylinder Volume
1.6 9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

GENERAL INFORMATION
Standard Torque Specifications I
The following torque specifications are to be used only as ageneral guideline. There are exceptions in the steering, suspension, and
engine areas. Always consultthe explodedviews
or eachmanual section for torque values of fasteners before using standardtorque.
o
Bolt Size
#10
#10
1/4
1/4
5/16 -
5/16 -
3/8
3/8
7/16 -
7/16 -
1/2
1/2
Metric
6x1.0
8 x 1.25
10x1.25
Threads/In Grade 2Grade 5Grade 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 by 1.382
*To convert Nm to
ft. Ibs. multiply Nm by.7376.
SPECIFIC TORQUE VALUES OF FASTENERS
Refer to exploded views in the appropriate section.
1.7
9923144 -2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

1/8. '" .1250
9/64 1406
5/32 1563 4mm =.1575"
11/64 1719
3/16 1875 5mm =.1969"
13/64 2031
7/32 2188
15/64 .2344 6mm =.2362"
1/4 25
17/64 .2656 7mm =.2756"
9/32 2813
19/64 2969
5/16 3125 8mm =.3150"
21/64
3281
11/32 . . . . . . . . .. .3438 ... 9mm =.3543"
23/64 3594
3/8 375
25/64 .3906 10 mm =.3937"
13/32 .4063
27/64 .4219
11 mm =.4331"
7/16 .4375
29/64
4531
15/32 .4688 12 mm =.4724"
31/64 .4844
1/2 513 mm =.5118
33/64 5156
17/32 5313
35/64 5469 14 mm =.5512"
9/16 5625
37/64
5781 15 mm =.5906"
19/32 5938
39/64 6094
5/8
.. ".625 16 mm =.6299"
41/64 6406
21/32 6563 17 mm =.6693"
43/64 6719
11/16 6875
45/64 7031 18 mm =.7087"
23/32 7188
47/64 7344 19 mm =.7480"
3/4 75
49/64 7656
25/32 7813 20 mm =.7874"
51/64 7969
13/16 8125
21 mm =.8268"
53/64
8281
27/32 8438
55/64 .8594 22 mm =.8661"
7/8 875
57/64 8906 23 mm =.9055"
29/32 9063
59/64 9219
15/16 .9375 24 mm =.9449"
61/64 9531
31/32 9688 25 mm =.9843
63/64 9844
11.0
GENERAL INFORMATION
SAE Tap IDrill Sizes
Thread Size/Drill Size Thread Size/Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56
51
9/16-18 33/64
#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 11/8-7 63/64
#8-36 29 11/8-12
13/64
#10-24 24 11/4-7
17/64
#10-32
21
#12-24 17 11/4-12 111/64
#12-28 4.6mm 11/2-6 111/32
1/4-20 711/2-12 127/64
1/4-28 313/4-5 19/16
5/16-18 F13/4-12 143/64
5/16-24 I
2-41/2
125/32
3/8-16 a2-12 159/64
3/8-24 Q
21/4-41/2
21/32
7/16-14 U
21/2-4 21/4
7/16-20 25/64 23/4-4
21/2
3-4 23/4
Metric Tap IDrill Sizes
Tap Size Drill Size Decimal Nearest
Equiva- Fraction
lent
3x .50 #39 0.0995 3/32
3x .60 3/32 0.0937 3/32
4x.70 #30 0.1285 1/8
4x .75 1/8 0.125 1/8
5x .80 #19 0.166 11/64
5x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x1.25 11/32 0.3437 11/32
10 x1.50 R0.339 11/32
11 x1.50 3/8 0.375 3/8
12x1.50
13/32 0.406 13/32
12 x1.75 13/32 0.406 13/32
1.8
Decimal Equivalents
1/64 .
1/32 .
3/64 .
1/16
..
5/64 .
3/32 .
7/64
.0156
.0312
...
.0469
.0625
.0781
...
.0938
.1094
...
1mm =.0394"
2mm =.0787"
3mm =.1181"
9923144 - 2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

GENERAL INFORMATION
Glossary of Terms I
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 =3/8" or 1cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation ofthe movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to
close and grip the drive belt.
Crankshaft Run-Out: Run-outor"bend" of crankshaftmeasuredwith adial indicatorwhile crankshaftis supportedbetween centers
on Vblocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: Acylinder measuring instrument which uses adial indicator. Good for showing taper and out-of-round in the
cylinder bore.
Electrical Open: Open circuit.
An electrical circuit which isn't complete.
ElectricalShort: Short circuit.
An electrical circuitwhich is completedbeforethe currentreachesthe intended load. (i.e. abare wire
touching the chassis).
End Seals: Rubber seals at each end ofthe crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. Aforce of one pound at the end of alever one foot in length, applied in arotational direction.
g: Gram. Unit of weight 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: Aforce of one kilogram at the end of alever one meter in length, applied in arotational direction.
I
or ltr: Liter.
Ibs/in2:Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position ofthe driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As aconductor (coil) is moved through amagnetic field, avoltage will be generated in the windings.
Mechanical energy
is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit oflength in the metric system. 1mm =approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance:
In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling
of the sides of apiston. Usually there is atransfer of aluminum from the piston onto the cylinder wall.
Possible causes:
1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit
of measure for electrical pressure of electromotive force. Measured by avoltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts =amperes xvolts.
WOT: Wide open throttle. 1.9
9923144 - 2011 RANGER RZR XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

GENERAL INFORMATION
NOTES
1.10 9923144 -2011 RANGER RZR
XP 900 Service Manual
©Copyright 2011 Polaris Sales Inc.

MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART 2.3
BREAK-IN PERIOD /MAINTENANCE CHART KEY 2.3
PRE-RIDE -50 HOUR MAINTENANCE INTERVAL 2.4
50 -500 HOUR MAINTENANCE INTERVAL 2.5
MAINTENANCE QUICK REFERENCE 2.6
MAINTENANCE QUICK REFERENCE, CONTINUED 2.7
GREASE LUBRICATION POINTS 2.8
LUBRICANTS /SERVICE PRODUCTS 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE 2.10
PRE-RIDE /DAILY INSPECTION 2.10
FRAME, NUTS, BOLTS, AND FASTENERS 2.10
SHIFT CABLE INSPECTION /ADJUSTMENT. 2.10
FUEL SYSTEM AND AIR INTAKE 2.11
FUEL TANK VENT LINE AND FILTER. 2.11
FUEL PUMP /FUEL FILTERS 2.11
FUEL LINES 2.12
THROTTLE PEDAL INSPECTION 2.12
THROTTLE FREEPLAY ADJUSTMENT 2.13
ENGINE INTAKE PRE-FILTER SERVICE 2.13
AIR FILTER SERVICE 2.14
INTAKE BAFFLE BOX DRAIN INSPECTION 2.14
AIR BOX /AIR FILTER EXPLODED
VIEW 2.15
ENGINE 2.16
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 -SPARKARRESTOR. 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
RADIATOR INSPECTION /CLEANING 2.26
COOLANT DRAIN /FILL 2.26
PVT /FINAL DRIVE /WHEEL AND TIRE 2.27
DRIVE CLUTCH /DRIVEN CLUTCH /BELT SERVICE 2.27
PVT INTAKE PRE-FILTER SERVICE 2.27
PVT DRYING 2.27
DRIVE SHAFT BOOT INSPECTION 2.28
WHEEL AND HUB TORQUE TABLE 2.28
WHEEL REMOVAL /INSTALLATION 2.28
TIRE INSPECTION 2.29
TIRE PRESSURE 2.29
ELECTRICAL AND IGNITION SYSTEM 2.29
BATTERY MAINTENANCE 2.29
BATTERY REMOVAL /INSTALLATION 2.30
BATTERY CHARGING /OFF SEASON STORAGE 2.30
ENGINE /CHASSIS ELECTRICAL GROUND 2.30
SPARK PLUG SERVICE 2.31
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MAINTENANCE
STEERING 2.32
STEERING INSPECTION 2.32
STEERING WHEEL FREEPLAY 2.32
TIE ROD END /WHEEL HUB INSPECTION 2.32
WHEEL TOE ALIGNMENT INSPECTION 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
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MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. 2
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Pure Polaris parts available from yourPolaris dealer.
NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment
procedures, have aqualified dealer perform these operations.
Maintenanceintervals inthe following chart are baseduponaverage riding conditions and an averagevehiclespeedofapproximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
•Frequent immersion in mud, water or sand
•Racing orrace-style high
RPM use
•Prolonged low speed, heavy load operation
•Extended idle
•Short trip cold weather operation
Pay special attention to the oil level. Arise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately
if the oil level begins 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 of the first 25 hours of operation. Careful treatment of anew 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 not operate at sustained idle.
•Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
•Change both the engine oil and filter after 25 hours or one month.
•See "Owner's Manual" for additional break-in information.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
•=CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
~ =SEVERE USE ITEM: See information provided above.
E=Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
A WARNING
Improperly performing the procedures marked. could result in componentfailure and lead to serious injury ordeath.
Have an authorized Polaris dealer perform these services.
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MAINTENANCE
Pre-Ride -50 Hour Maintenance Interval
Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles
(KM)
Steering -Pre-Ride -
Front Suspension -Pre-Ride -
Rear Suspension -Pre-Ride -
Tires -Pre-Ride -
Brake Fluid Level -Pre-Ride -Inspect or adjust as needed.
Brake Pedal Travel -Pre-Ride -See Pre-Ride Checklist
on Page 2.10.
Brake System -Pre-Ride -
Wheels IFasteners -Pre-Ride -
Frame Fasteners -Pre-Ride -
EEngine Oil Level -Pre-Ride -
EEngine Intake Pre-Filter -Daily -Inspect and clean often
PVT Intake Pre-Filter -Daily -Inspect and clean often
Coolant Level -Daily -Check level daily
Head Lights I
Tail Lights -Daily -Check operation
~
Brake Pad Wear 10 HMonthly 100 (160) Inspect periodically
•
~
Engine Oil &Filter Change Perform abreak-in oil and filter change at
25 H 1 M -25 hours or one month; perform every 50
E(Break-In) hours or 6months thereafter
~
Air Filter 25 HMonthly 250 (400) Inspect; replace as needed
E
Battery 25 HMonthly 250 (400) Check terminals; clean; test
~
Front Gearcase Lubricant 25 HMonthly 250 (400) Inspect level; add lubricant
if needed
(Demand Drive Plus)
~
Transmission Lubricant 25 HMonthly 250 (400) Inspect level; add lubricant
if needed
(AGL Gearcase Lubricant)
~ Engine Breather Filter 25 HMonthly 250 (400) Inspect; replace if necessary
E(if equipped)
~ General Lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
•Throttle Cable IThrottle
50 H
6M 300 (500) Inspect; adjust; replace if necessary
EPedal
EThrottle Body Intake Boots
50 H 6M 300 (500) Inspect ducts for proper sealing Iair leaks
Shift Linkage 50 H
6M 500 (800) Inspect; adjust as needed
~ Front Suspension 50 H 6M
500 (800) LUbricate
~
Rear Suspension 50 H 6M 500 (800) Lubricate
~ Perform these procedures more often for vehicles subjected to severe use.
EEmission Control System Service (California)
•Have
an authorized Polaris dealer perform these services.
2.4 9923144 -2011 RANGER RZR XP 900 Service Manual
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