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.