Polaris Ranger RZR XP 900 2011 Manuals

Polaris Ranger RZR XP 900 2011 Manuals

Manuals and User Guides for Polaris Ranger RZR XP 900 2011. We have 1 Polaris Ranger RZR XP 900 2011 manual available for free PDF download: Service Manual

Polaris Ranger RZR XP 900 2011 Service Manual

Polaris Ranger RZR XP 900 2011 Service Manual (376 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 29.27 MB

Table of Contents

Maintenance Chapter 2 Maintenance

17
- Table of Contents
  17
- Break-In Period / Maintenance Chart Key
  19
- Chapter 2
  19
- Periodic Maintenance Chart
  19
- Pre-Ride - 50 Hour Maintenance Interval
  20
- 50 - 500 Hour Maintenance Interval
  21
- Maintenance Quick Reference
  22
- Maintenance Quick Reference, Continued
  23
- Grease Lubrication Points
  24
- Lubricants / Service Products
  25
- General Vehicle Inspection and Maintenance
  26
- Fuel System and Air Intake
  27
  - Fuel Tank Vent Line and Filter
    27
  - Fuel Pump / Fuel Filters
    27
  - Fuel Lines
    28
  - Throttle Pedal Inspection
    28
  - Throttle Freeplay Adjustment
    29
  - Engine Intake Pre-Filter Service
    29
  - Air Filter Service
    30
  - Intake Baffle Box Drain Inspection
    30
- Engine
  32
- Transmission and Front Gearcase
  38
  - Transmission Lubrication
    38
  - Front Gearcase Lubrication
    39
- Cooling System
  40
  - Coolant Strength
    40
  - Coolant Level Inspection
    41
  - Cooling System Pressure Test / Hoses
    41
  - Radiator Inspection / Cleaning
    42
  - Coolant Drain / Fill
    42
- Pvt Final Drive Wheel and Tire
  43
  - Drive Clutch Driven Clutch Belt Service
    43
  - Pvt Intake Pre-Filter Service
    43
  - Pvt Drying
    43
  - Drive Shaft Boot Inspection
    44
  - Wheel and Hub Torque Table
    44
  - Wheel Removal / Installation
    44
  - Tire Inspection
    45
  - Tire Pressure
    45
- Electrical and Ignition System
  45
- Steering
  48
  - Steering Inspection
    48
  - Steering Wheel Freeplay
    48
  - Tie Rod End / Wheel Hub Inspection
    48
  - Wheel Toe Alignment Inspection
    49
  - Wheel Toe Adjustment
    49
- Suspension (Foxtm)
  50
  - Spring Preload Adjustment
    50
  - Shock Compression Adjustment
    51
- Brake System
  52
- Maintenance Log
  53
Engine I Cooling Chapter 3 I Engine Cooling

55
- Engine Detail - Torque Values I Sequences I Assembly Notes
  60
- Chapter 3
  65
- Cooling System Pressure Test / Pressure Cap Test
  65
- Cooling System Specifications
  65
- Engine Cooling System
  65
- Radiator Removal/Installation
  66
- Thermostat Replacement
  67
- Cooling System Exploded View
  68
- Cooling System Bleeding Procedure
  69
- Water Pump Service
  72
- Engine Service
  74
  - Accessible Engine Components
    74
  - Top-End Service (Engine in Chassis)
    74
  - Engine Removal
    74
  - Engine Installation
    78
  - Engine Mounting and Torque Values
    82
- Engine Disassembly I Inspection - Top End
  83
  - Valve Cover Removal
    83
  - Camshaft Removal
    83
  - Camshaft Sprocket Inspection
    85
  - Cylinder Head Removal
    86
  - Cylinder Head Disassembly
    87
  - Valve Inspection
    88
  - Combustion Chamber Cleaning
    89
  - Valve Seat Reconditioning
    90
- Engine Disassembly I Inspection - Lower End
  92
  - Stator Cover Removal/Inspection
    92
  - Water Pump Housing Removal
    93
  - Flywheel Removal
    93
  - Starter One-Way Clutch Assembly
    95
  - Balance Shaft Removal/Inspection
    98
  - Crankcase Inspection
    102
  - Cylinder Inspection
    103
  - Piston Ring Removal
    105
  - Piston Ring to Groove Clearance Inspection
    106
  - Piston Ring Installed Gap
    106
  - Piston-To-Cylinder Clearance
    107
  - Connecting Rod Inspection
    107
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

137
- Chapter 4
  138
- General Information
  138
- Special Tools
  138
- Efi Service Notes
  140
- Efi System Exploded View
  141
- Efi System Component Locations
  142
- Fuel Tank
  144
  - Exploded View
    144
  - Fuel Lines - Quick Connect Fittings
    145
  - Fuel Tankremoval
    146
  - Fuel Tank Installation
    147
- Electronic Fuel Injection
  147
  - Initial Priming Istarting Procedure
    148
- Electronic Control Unit (Ecu)
  149
- Manifold Air Quality Sensor (Maqs)
  150
  - Maqs Test Ireplacement
    150
- Crankshaft Position Sensor (Cps)
  151
  - Cps Test
    151
  - Cps Replacement
    152
- IDLE AIR CONTROL VALVE (Lac)
  153
  - Lac TEST IREPLACEMENT
    153
- Engine Coolant Temperature Sensor (Ect)
  154
- Dual Throttle Body Assembly
  156
- Fuel Injectors
  158
  - Fuel Injector Troubleshooting
    158
  - Fuel Pump
    162
  - Fuel Sender Test
    162
  - Fuel Pump Test
    163
  - Fuel Pump Replacement
    164
- Ignition Coil
  167
  - Ignition Coil Iht Lead Replacement
    167
  - Ignition Coil Tests
    167
- Efi Diagnostics
  168
  - INSTRUMENT CLUSTER TROUBLE CODE Display
    168
  - Efi Troubleshooting
    171
- Digital Wrenchtm Operation
  172
  - Ecu Replacement
    172
  - Guided Diagnostic Available
    172
  - Digital Wrenchtm Serial Number Location
    173
  - Engine Controller Reprogramming (Reflash)
    176
- Efi System Electrical Operation
  180
Body Steering Suspensionii Chapter 5 Body I Steering I Suspension

181
- Special Tools
  182
- Torque Specifications
  182
- Cab Frame
  183
- Body Exploded Views
  184
- Chapter 5 Side Safety Nets
  184
- Rear Cargo Box Fenders
  190
- Engine Service Panel
  192
- Hood and Front Body Work
  193
- Cargo Box Assembly Removal
  194
- Rocker Panels, Console and Floor
  195
- Steering Assembly
  196
  - Steering Wheel Removal
    197
  - Steering Shaft Removal
    197
  - Steering Shaft Bearing Replacement
    198
- Front A-Arms
  199
  - Removal/ Replacement
    200
- Ball Joint Service
  200
  - Removal
    200
  - Installation
    201
- Rear Radius Rods
  202
  - Removal/Installation
    202
- Rear Trailing Arm
  203
- Rear Stabilizer Bar
  206
  - Removal/Installation
    206
- Decal Replacement
  207
- Foxtm Shock Exploded Views
  209
  - Foxtm 2.0 'Piggyback' Shock
    209
- Foxtm Shock Service
  210
  - General Service Information
    210
  - Foxtm Shock Rebuild Information
    211
  - Foxtm Shock Disassembly
    212
  - Foxtm Shock Rebuild
    214
  - Foxtm Shock Reassembly
    215
Clutching (Pvt) Chapter 6 Clutching (Pvt)

219
- Chapter 6
  220
- Drive Clutch Operation
  220
- General Operation
  220
- Pvt System Overview
  220
- Torque Specifications
  220
- Driven Clutch Operation
  221
- Pvt Break-In (Drive Belt / Clutches)
  221
- Pvt System Service
  223
  - Pvt Disassembly
    223
  - Pvt Assembly
    225
- Drive Belt
  226
  - Belt Inspection
    227
  - Belt Installation
    227
  - Pvt Break-In (Drive Belt / Clutches)
    227
- Drive Clutch Service
  228
  - Drive Clutch Exploded View
    228
  - Drive Clutch Spring Inspection
    230
  - Needle Bearing Inspection
    230
  - Shift Weight Inspection
    230
  - Button to Tower Clearance Inspection
    231
  - Spider Removal
    231
  - Roller, Pin, and Thrust Washer Inspection
    232
  - Clutch Inspection
    233
  - Moveable Sheave Bushing Inspection
    234
  - Bushing Service
    234
  - Drive Clutch Assembly
    236
- Driven Clutch Service
  239
  - Clutch Disassembly
    239
  - Bushing Service
    241
  - Clutch Assembly
    243
- Troubleshooting
  247
Final Drive Chapter 7 Final Drive

249
- Front Bearing Carrier
  250
- Chapter 7 Bearing Carrier Installation
  252
- Front Drive Shaft
  254
  - Drive Shaft Removal
    254
  - Drive Shaft Installation
    255
- Propshaft Service
  256
  - Support Bearing Replacement
    258
- Propshaft U-Joint Service
  259
- Front Gearcase I Centralized Hilliard
  261
  - Centralized Hilliard Exploded View
    261
  - All Wheel Drive Operation
    262
  - Gearcaseassembly
    267
  - Gearcase Installation
    269
- Rear Bearing Carrier
  270
- Rear Drive Shaft
  274
  - Drive Shaft Removal
    274
  - Drive Shaft Installation
    275
- Drive Shaft CV Joint I Boot Replacement
  277
  - Drive Shaft Exploded View
    281
Transmission Chapter 8 Transmission

283
- Chapter 8 Lubrication
  284
- Specifications
  284
- Shift Lever
  285
- Shift Cable
  286
- Transmission Service
  287
  - Transmission Removal
    287
  - Transmission Installation
    290
  - Transmission Disassembly
    294
  - Snorkel Gear Backlash Procedure
    299
  - Transmission Assembly
    301
- Troubleshooting
  305
Brakes Chapter 9 Brakes

309
- Brake Noise Troubleshooting
  311
- Chapter 9
  311
- Hydraulic Brake System Operation
  312
- Brake System Exploded View
  313
- Brake Pedal Lever
  314
  - Brake Burnishing Procedure
    317
- Master Cylinder
  314
- Front Caliper Service
  318
  - Caliper Exploded View
    318
  - Caliper Removal
    318
  - Caliper Disassembly
    319
- Front Brake Disc
  322
  - Brake Burnishing Procedure
    325
- Rear Caliper Service
  326
  - Caliper Exploded View
    326
  - Caliper Removal
    326
- Rear Brake Disc
  330
- Troubleshooting
  331
Electrical Chapter 10 Electrical

333
- General Information
  335
- Instrument Cluster
  336
- Chapter 10
  337
- Information Display Area
  337
- Rider Information Display
  337
- Diagnostic Mode
  340
- Switches I Controls
  342
  - BRAKE LIGHT Switch
    342
  - Headlamp Switch
    342
  - IGNITION KEY Switch
    343
  - Transmission (Gear Position) Switch
    344
- Vehicle Speed Sensor
  344
- All Wheel Drive Coil
  345
  - Headlight Adjustment
    346
  - Headlamp Replacement
    346
  - Headlamp Installation
    347
  - Bulb Replacement
    347
- Cooling System
  348
  - Cooling System Break-Out Diagram
    348
  - Coolant Temperature Sensor
    349
- Fuel Sender
  349
- Fuse Box: Fuses I Relays I Circuit Breaker
  350
  - Fuse Box Detail
    351
  - Relay Operation
    352
  - Current Draw - Key off
    353
  - Charging System "Break Even" Test
    353
  - General Battery Information
    356
  - Battery off Season Storage
    357
  - Battery Testing
    357
  - Ocv - Open Circuit Voltage Test
    357
  - Load Test
    357
- Starting System
  359
  - Voltage Drop Test
    359
  - Starter Motor Removal
    359
  - Starter Motor Installation
    359
  - Starter Solenoid Bench Test
    360
  - Starter Solenoid Operation
    360
- Starting System Testing Flow Chart
  361
  - Awd
    362
  - Vehicle Speed Sensor
    362
  - Cooling Fan
    363
  - Chassis Power
    364
  - Efi
    365
  - Key-On Battery Power
    366
  - Lights
    367
  - Starter-Interlock
    368

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