Polaris RZR XP 900
SERVICE MANUAL & OWNER´S MANUAL
POLARIS RZR XP 900 (2011-2013) - REPAIR, SERVICE, WORKSHOP MANUAL - English Service Manual and Wiring Diagram to Polaris RZR XP 900. CONTENTS: GENERAL INFORMATION - VEHICLE IDENTIFICATION - model number designation - engine designation number - vehicle identification number (vin) designation - vehicle and engine serial number location - VEHICLE INFORMATION - publication numbers - replacement keys - SPECIAL TOOLS - GENERAL SPECIFICATIONS - model: 2013 ranger rzr xp 900 - model: 2013 ranger rzr xp 900 eps / int’l - 2013 ranger rzr xp 900 / eps / int’l - model: 2013 ranger rzr xp 4 900 - model: 2013 ranger rzr xp 4 900 eps / int’l - 2013 ranger rzr xp 4 900 / eps / int’l - MISC. SPECIFICATIONS AND CHARTS - conversion table - standard bolt torque specification - metric bolt torque specification - sae tap / drill sizes - metric tap / drill sizes - decimal equivalents MAINTENANCE - PERIODIC MAINTENANCE CHART - periodic maintenance overview - break-in period - maintenance chart key - pre-ride - 50 hour maintenance interval - 50 - 500 hour maintenance interval - maintenance quick reference - maintenance quick reference, continued..... - grease lubrication points - LUBRICANTS / SERVICE PRODUCTS - polaris lubricants, maintenance and service products - GENERAL VEHICLE INSPECTION AND MAINTENANCE - pre-ride / daily inspection - frame, nuts, bolts, and fasteners - shift cable inspection / adjustment - FUEL SYSTEM AND AIR INTAKE - fuel system - fuel tank vent line and filter - fuel pump / fuel filters - fuel lines - throttle pedal inspection - throttle freeplay adjustment - engine intake pre-filter service - air filter service - intake baffle box drain inspection - air box / air filter exploded view - ENGINE - engine oil level - engine oil and filter change - engine crankcase breather hose inspection - engine cylinder leakdown test - valve clearance inspection - exhaust - spark arrestor - TRANSMISSION AND FRONT GEARCASE - specification chart - transmission lubrication - front gearcase lubrication - COOLING SYSTEM - cooling system overview - coolant strength - coolant level inspection - cooling system pressure test - cooling system hoses - radiator inspection / cleaning - coolant drain / fill - PVT / FINAL DRIVE / WHEEL AND TIRE - drive clutch / driven clutch / belt service - pvt intake pre-filter service - pvt drying - drive shaft boot inspection - wheel and hub torque table - wheel removal - wheel installation - tire inspection - tire pressure - ELECTRICAL AND IGNITION SYSTEM - battery maintenance - battery charging / off season storage - battery removal - battery installation - engine / chassis electrical ground - spark plug service - STEERING - steering inspection - steering wheel freeplay - tie rod end / wheel hub inspection - wheel toe alignment inspection - wheel toe adjustment - SUSPENSION (FOX™) - spring preload adjustment - shock compression adjustment - SUSPENSION (WALKER EVANS™) - spring preload adjustment - shock compression adjustment - BRAKE SYSTEM - brake fluid inspection - brake pad / disc inspection - brake hose and fitting inspection - parking brake cable adjustment (int’l) - parking brake pad inspection (int’l) ENGINE / COOLING - GENERAL INFORMATION - special tools - engine lubrication specifications - oil pressure test - engine oil flow chart - ENGINE SERVICE SPECIFICATIONS - engine specifications - ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES - main engine components - torque specification and sequence - balance shaft / connecting rods / crankcase / crankshaft / pistons - cylinder / oil cooler / oil filter / oil pump / oil sump / water pump - camshafts / cylinder head / flywheel / idler gears / stator cover - spark plugs / starter / thermostat housing / throttle body / valve cover - ENGINE COOLING SYSTEM - cooling system specifications - cooling system pressure test - pressure cap test - radiator removal / installation - thermostat replacement - cooling system exploded view - cooling system bleeding procedure - water pump removal - water pump installation - water pump service - ENGINE SERVICE - accessible engine components - top-end service (engine in chassis) - engine removal - engine installation - engine mounting and torque values - engine break-in period - engine lubrication specifications - ENGINE DISASSEMBLY / INSPECTION - TOP END - valve cover removal - camshaft removal - camshaft sprocket inspection - camshaft / camshaft bore inspection - cylinder head removal - cylinder head warp inspection - cylinder head disassembly - valve inspection - combustion chamber cleaning - valve seat reconditioning - ENGINE DISASSEMBLY / INSPECTION - LOWER END - stator cover removal / inspection - water pump housing removal - flywheel removal - starter one-way clutch inspection - starter one-way clutch disassembly - starter one-way clutch assembly - crankcase disassembly / inspection - balance shaft removal / inspection - crankshaft removal / inspection - crankcase inspection - cylinder / piston removal - cylinder inspection - piston disassembly / inspection - piston ring removal - piston ring to groove clearance inspection - piston ring installed gap - piston-to-cylinder clearance - connecting rod inspection - ENGINE ASSEMBLY - LOWER END - bearing selection identification letters and numbers - connecting rod bearing selection - crankshaft main bearing selection - upper crankcase preparation - piston ring installation - piston / connecting rod assembly - cylinder / piston installation - crankshaft installation - balance shaft installation - lower crankcase preparation - crankcase assembly - flywheel installation - stator cover installation - ENGINE ASSEMBLY - TOP END - cylinder head assembly - valve sealing test - cylinder head installation - camshaft installation / timing - camshaft timing - quick reference - valve clearance adjustment - intake valve lash - shim selection matrix - exhaust valve lash - shim selection matrix - valve cover installation - TROUBLESHOOTING - engine - cooling system ELECTRONIC FUEL INJECTION - GENERAL INFORMATION - special tools - efi service notes - efi system exploded view - efi system component locations - FUEL TANK - exploded view - fuel line removal / installation - fuel tank removal (rzr xp) - fuel tank installation (rzr xp) - fuel tank removal (rzr xp 4) - fuel tank installation (rzr xp 4) - ELECTRONIC FUEL INJECTION - principal components - efi operation overview - initial priming / starting procedure - ELECTRONIC CONTROL UNIT (ECU) - operation overview - ecu service - ecu replacement - MANIFOLD AIR QUALITY SENSOR (MAQS) - operation overview - maqs test / replacement - CRANKSHAFT POSITION SENSOR (CPS) - operation overview - cps test - cps replacement - IDLE AIR CONTROL VALVE (IAC) - operation overview - iac test - iac replacement - ENGINE COOLANT TEMPERATURE SENSOR (ECT) - operation overview - ect sensor test - ect sensor replacement - DUAL THROTTLE BODY ASSEMBLY - operation overview - throttle body service - throttle body removal - FUEL INJECTORS - operation overview - fuel injector troubleshooting - fuel injector test - fuel injector replacement - FUEL PUMP - operation overview - fuel sender test - fuel pump test - fuel pump replacement - IGNITION COIL - operation overview - ignition coil / ht lead replacement - ignition coil tests - EFI DIAGNOSTICS - instrument cluster trouble code display - efi troubleshooting - DIGITAL WRENCH® OPERATION - digital wrench® diagnostic software overview - special tools (also refer to page 4.2) - diagnostic software version - ecu replacement - guided diagnostic available - digital wrench® communication errors - digital wrench® - diagnostic connector - digital wrench® serial number location - digital wrench® version and update id - digital wrench® updates - digital wrench® feature map - engine controller reprogramming (reflash) BODY / STEERING / SUSPENSION - TORQUE SPECIFICATIONS - SPECIAL TOOLS - multi-function pliers - CAB FRAME (RZR XP) - assembly / removal - CAB FRAME (RZR XP 4) - assembly / removal - BODY EXPLODED VIEWS - side safety nets (rzr xp) - side safety nets (rzr xp 4) - dash instruments / controls - hood / front body work - seat assembly - seat belts / mounting (rzr xp) - seat belts / mounting (rzr xp 4) - floor / rocker panels (rzr xp) - floor / rocker panels (rzr xp 4) - rear cargo box / fenders (rzr xp) - rear cargo box / fenders (rzr xp 4) - chassis / main frame (rzr xp) - chassis / main frame (rzr xp 4) - front bumper - rear bumper - BODY COMPONENT REMOVAL - seats - engine service panel - front bumper - rear bumper - hood and front body work - rear fender flair / box side removal - cargo box assembly removal - rocker panels, console and floor - DECAL REPLACEMENT - STEERING ASSEMBLY - exploded view (non-eps models) - steering wheel removal (non-eps models) - steering shaft removal (non-eps models) - steering shaft bearing replacement - ELECTRONIC POWER STEERING ASSEMBLY - exploded view (eps models) - upper steering shaft removal (eps models) - steering wheel removal (eps models) - power steering unit removal - lower steering shaft removal (eps models) - lower steering shaft installation (eps models) - power steering unit installation - upper steering shaft installation (eps models) - FRONT A-ARMS - removal / replacement - BALL JOINT SERVICE - service preparation - ball joint removal - ball joint installation - FRONT STABILIZER BAR (INT’L) - stabilizer bar linkage removal / installation - stabilizer bar removal / installation - exploded view - REAR RADIUS RODS - removal / installation - REAR TRAILING ARM - trailing arm removal / installation - trailing arm spherical bearing replacement - rear suspension exploded view - REAR STABILIZER BAR - stabilizer bar removal - stabilizer bar installation - SHOCKS / SPRINGS / FASTENERS - front shock exploded view - rear shock exploded view - shock removal / installation - shock replacement - FOX™ SHOCK EXPLODED VIEWS (RZR XP) - fox™ 2.0 ‘piggyback’ shock - FOX™ SHOCK SERVICE (RZR XP) - general service information - front shock service information - rear shock service information - fox™ shock rebuild information - special tools - fox™ shock disassembly - fox™ shock body and reservoir service - fox™ shock component rebuild - fox™ shock assembly - WALKER EVANS™ SHOCK EXPLODED VIEWS (RZR XP 4) - walker evans™ 2.0" front shock - walker evans™ 2.5" rear shock - WALKER EVANS™ SHOCK SERVICE (RZR XP 4) - general service information - front shock service information - rear shock service information - walker evans™ shock rebuild information - special tools - valve shim arrangement - piston orientation - walker evans™ shock disassembly - walker evans™ shock assembly CLUTCHING (PVT) - SPECIAL TOOLS AND SUPPLIES - TORQUE SPECIFICATIONS - pvt system fastener torques - HIGH ALTITUDE CLUTCH CHARTS - 2013 ranger rzr xp 900 / eps / int’l - 2013 ranger rzr xp 4 900 / eps / int’l - PVT SYSTEM OVERVIEW - general operation - drive clutch operation - driven clutch operation - pvt break-in (drive belt / clutches) - maintenance / inspection - overheating / diagnosis - PVT SYSTEM SERVICE - pvt covers and ducting components - pvt disassembly - pvt assembly - DRIVE BELT - belt removal - belt inspection - belt installation - pvt break-in (drive belt / clutches) - DRIVE CLUTCH SERVICE - drive clutch exploded view - drive clutch disassembly / inspection - drive clutch spring inspection - needle bearing inspection - shift weight inspection - button to tower clearance inspection - spider removal - roller, pin, and thrust washer inspection - clutch inspection - moveable sheave bushing inspection - bushing service - drive clutch assembly - DRIVEN CLUTCH SERVICE - clutch disassembly - bushing service - clutch assembly - exploded view - TROUBLESHOOTING FINAL DRIVE - SPECIAL TOOLS - TORQUE SPECIFICATIONS - wheel and hub torque table - FRONT BEARING CARRIER - bearing carrier inspection / removal - bearing replacement - bearing carrier installation - FRONT DRIVE SHAFT - drive shaft removal - drive shaft installation - PROPSHAFT SERVICE - front propshaft removal (rzr xp) - front propshaft removal (rzr xp 4) - front propshaft installation - rear propshaft removal (rzr xp) - rear propshaft removal (rzr xp 4) - rear propshaft installation - support bearing replacement - PROPSHAFT U-JOINT SERVICE - disassembly - assembly - FRONT GEARCASE / CENTRALIZED HILLIARD - centralized hilliard exploded view - all wheel drive operation - awd diagnosis - front gearcase removal - front gearcase disassembly / inspection - front gearcase assembly - front gearcase installation - REAR BEARING CARRIER - bearing carrier inspection / removal - bearing replacement - bearing carrier installation - REAR DRIVE SHAFT - drive shaft removal - drive shaft installation - DRIVE SHAFT CV JOINT / BOOT REPLACEMENT - drive shaft / cv joint handling tips - outer cv joint / boot replacement - inner plunging joint / boot replacement - drive shaft exploded view - WHEEL HUBS - front hub exploded view - rear hub exploded view TRANSMISSION - SPECIFICATIONS - torque specifications - special tools - lubrication - transmission mounting and torque values - SHIFT LEVER - removal - installation - SHIFT CABLE - inspection - adjustment - TRANSMISSION REMOVAL - TRANSMISSION INSTALLATION - TRANSMISSION SERVICE - transmission disassembly - gear / shaft / bearing inspection - snorkel gear backlash procedure - transmission assembly - TRANSMISSION SERVICE (INT'L) - differential operation - transmission disassembly - planetary differential disassembly - planetary differential bushing replacement - planetary differential assembly - gear / shaft / bearing inspection - snorkel gear backlash procedure - transmission assembly - TROUBLESHOOTING - troubleshooting checklist - TRANSMISSION EXPLODED VIEW - TRANSMISSION EXPLODED VIEW (INT'L) BRAKES - GENERAL SPECIFICATIONS - TORQUE SPECIFICATIONS - SPECIAL TOOLS - BRAKE SYSTEM SERVICE NOTES - BRAKE NOISE TROUBLESHOOTING - HYDRAULIC BRAKE SYSTEM OPERATION - BRAKE SYSTEM EXPLODED VIEW - rzr xp - rzr xp 4 - MASTER CYLINDER - removal - installation - BRAKE PEDAL LEVER - pedal removal - pedal installation - BRAKE BLEEDING / FLUID CHANGE - PARKING BRAKE (INT’L MODEL) - exploded view - parking brake inspection - parking brake cable adjustment - PARKING BRAKE CALIPER SERVICE (INT’L MODEL) - caliper exploded view - caliper removal - caliper disassembly / inspection - new brake pad installation - caliper installation - PARKING BRAKE DISC (INT’L MODEL) - disc inspection - disc replacement - FRONT BRAKE PADS - pad removal - pad inspection - pad assembly / installation - brake burnishing procedure - FRONT CALIPER SERVICE - caliper exploded view - caliper removal - caliper disassembly - caliper inspection - caliper assembly - caliper installation - FRONT BRAKE DISC - disc runout - disc inspection - disc replacement - REAR BRAKE PADS (RZR XP) - pad removal - pad inspection - pad assembly / installation - brake burnishing procedure - REAR BRAKE PADS (RZR XP 4) - pad removal - pad inspection - pad assembly / installation - brake burnishing procedure - REAR CALIPER SERVICE (RZR XP) - caliper exploded view - caliper removal - caliper disassembly - caliper inspection - caliper assembly - caliper installation - REAR CALIPER SERVICE (RZR XP 4) - rear caliper exploded view - caliper removal - caliper disassembly - caliper inspection - caliper assembly - caliper installation - REAR BRAKE DISC - disc inspection - disc replacement - TROUBLESHOOTING - brakes squeal / poor brake performance - pedal vibration - caliper overheats (brakes drag) - brakes lock ELECTRICAL - GENERAL INFORMATION - special tools - electrical service notes - under-dash components - INSTRUMENT CLUSTER - overview - rider information display - information display area - diagnostic mode - instrument cluster pinouts - instrument cluster removal - instrument cluster installation - SWITCHES / CONTROLS - brake light switch - headlamp switch - ignition key switch - ignition key switch (int’l) - awd / 2wd switch - awd / 2wd / turf switch (int’l) - turn signal switch (int’l) - hazard switch (int’l) - transmission (gear position) switch - parking brake switch (int’l model) - throttle release switch (trs) - REAR DIFF SOLENOID (INT’L) - differential solenoid overview - differential solenoid circuit operation - VEHICLE SPEED SENSOR - speed sensor location - speed sensor testing - ALL WHEEL DRIVE COIL - operation overview - diagnosing system failures - HEAD LIGHTS - headlight adjustment - headlamp replacement - headlamp installation - TAIL / BRAKE LIGHTS - bulb replacement - COOLING SYSTEM - cooling system break-out diagram - fan control circuit operation / testing - fan control circuit bypass test - coolant temperature sensor - EFI DIAGNOSTICS - efi component testing - FUEL SENDER - testing - FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER - overview / operation - fuse box detail - relay operation - CHARGING SYSTEM - current draw - key off - charging system “break even” test - charging system stator (alternator) tests - stator (alternator) replacement - regulator / rectifier - charging system testing flow chart - BATTERY SERVICE - battery specifications - general battery information - battery removal / installation - battery off season storage - battery testing - ocv - open circuit voltage test - load test - battery conductance analyzer - charging procedure - STARTING SYSTEM - troubleshooting - voltage drop test - starter motor removal - starter motor installation - starter solenoid bench test - starter solenoid operation - STARTING SYSTEM TESTING FLOW CHART - condition: starter fails to turn over the engine. - ELECTRONIC POWER STEERING (EPS) - eps operation - proper eps system diagnosing - eps system breakout - eps troubleshooting (power steering non-functional with mil on) - eps troubleshooting (power steering non-functional with mil off) - eps troubleshooting (using digital wrench®) - ELECTRICAL SYSTEM BREAKOUTS - awd - vehicle speed sensor - cooling fan - chassis power - starter-interlock - key-on battery power - lights - charging system WIRE DIAGRAMS 9924096_Wire_Diagram_RZR_XP_11x17 9924096_Wire_Diagram_RZR_XP_11x17_2 9924096_Wire_Diagram_RZR_XP_EPS_11x17 9924096_Wire_Diagram_RZR_XP_EPS_11x17_2 9924096_Wire_Diagram_RZR_XP_INTL_11x17 9924096_Wire_Diagram_RZR_XP_INTL_11x17_2 9924096_Wire_Diagram_RZR_XP4_11x17 9924096_Wire_Diagram_RZR_XP4_11x17_2 9924096_Wire_Diagram_RZR_XP4_EPS_11x17 9924096_Wire_Diagram_RZR_XP4_EPS_11x17_2 9924096_Wire_Diagram_RZR_XP4_INTL_11x17 9924096_Wire_Diagram_RZR_XP4_INTL_11x17_2 9924096_Wire_Diagram_RZR_XP_CargoBox_11x17 9924096_Wire_Diagram_RZR_XP_INTL_CargoBox_11x17
Polaris RZR XP 900 (2011-2013) - Service Manual - Wiring Diagram
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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