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Polaris Manuals
Utility Vehicle
Ranger RZR XP 900 2011
Service manual
Polaris Ranger RZR XP 900 2011 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Maintenance Chapter 2 Maintenance
Table of Contents
Break-In Period / Maintenance Chart Key
Chapter 2
Periodic Maintenance Chart
Pre-Ride - 50 Hour Maintenance Interval
50 - 500 Hour Maintenance Interval
Maintenance Quick Reference
Maintenance Quick Reference, Continued
Grease Lubrication Points
Lubricants / 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 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
Engine
Engine / Oil Tank Breather Hose Inspection
Engine Cylinder Leakdown Test
Valve Clearance Inspection
Exhaust - Spark Arrestor
Transmission and Front Gearcase
Transmission Lubrication
Front Gearcase Lubrication
Cooling System
Coolant Strength
Coolant Level Inspection
Cooling System Pressure Test / 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 / Installation
Tire Inspection
Tire Pressure
Electrical and Ignition System
Battery Maintenance
Battery Removal / Installation
Battery Charging / off Season Storage
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 (Foxtm)
Spring Preload Adjustment
Shock Compression Adjustment
Brake System
Brake Fluid Inspection
Brake Pad / Disc Inspection
Brake Hose and Fitting Inspection
Maintenance Log
Engine I Cooling Chapter 3 I Engine Cooling
Engine Detail - Torque Values I Sequences I Assembly Notes
Chapter 3
Cooling System Pressure Test / Pressure Cap Test
Cooling System Specifications
Engine Cooling System
Radiator Removal/Installation
Thermostat Replacement
Cooling System Exploded View
Cooling System Bleeding Procedure
Water Pump Service
Engine Service
Accessible Engine Components
Top-End Service (Engine in Chassis)
Engine Removal
Engine Installation
Engine Mounting and Torque Values
Engine Disassembly I Inspection - Top End
Valve Cover Removal
Camshaft Removal
Camshaft Sprocket Inspection
Cylinder Head Removal
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber Cleaning
Valve Seat Reconditioning
Engine Disassembly I Inspection - Lower End
Stator Cover Removal/Inspection
Water Pump Housing Removal
Flywheel Removal
Starter One-Way Clutch Assembly
Balance Shaft Removal/Inspection
Crankcase Inspection
Cylinder Inspection
Piston Ring Removal
Piston Ring to Groove Clearance Inspection
Piston Ring Installed Gap
Piston-To-Cylinder Clearance
Connecting Rod Inspection
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
Chapter 4
General Information
Special Tools
Efi Service Notes
Efi System Exploded View
Efi System Component Locations
Fuel Tank
Exploded View
Fuel Lines - Quick Connect Fittings
Fuel Tankremoval
Fuel Tank Installation
Electronic Fuel Injection
Initial Priming Istarting Procedure
Electronic Control Unit (Ecu)
Manifold Air Quality Sensor (Maqs)
Maqs Test Ireplacement
Crankshaft Position Sensor (Cps)
Cps Test
Cps Replacement
IDLE AIR CONTROL VALVE (Lac)
Lac TEST IREPLACEMENT
Engine Coolant Temperature Sensor (Ect)
Dual Throttle Body Assembly
Fuel Injectors
Fuel Injector Troubleshooting
Fuel Pump
Fuel Sender Test
Fuel Pump Test
Fuel Pump Replacement
Ignition Coil
Ignition Coil Iht Lead Replacement
Ignition Coil Tests
Efi Diagnostics
INSTRUMENT CLUSTER TROUBLE CODE Display
Efi Troubleshooting
Digital Wrenchtm Operation
Ecu Replacement
Guided Diagnostic Available
Digital Wrenchtm Serial Number Location
Engine Controller Reprogramming (Reflash)
Efi System Electrical Operation
Body Steering Suspensionii Chapter 5 Body I Steering I Suspension
Special Tools
Torque Specifications
Cab Frame
Body Exploded Views
Chapter 5 Side Safety Nets
Rear Cargo Box Fenders
Engine Service Panel
Hood and Front Body Work
Cargo Box Assembly Removal
Rocker Panels, Console and Floor
Steering Assembly
Steering Wheel Removal
Steering Shaft Removal
Steering Shaft Bearing Replacement
Front A-Arms
Removal/ Replacement
Ball Joint Service
Removal
Installation
Rear Radius Rods
Removal/Installation
Rear Trailing Arm
Trailing Arm Removal/Installation
Trailing Arm Spherical Bearing Replacement
Rear Suspension Exploded View
Rear Stabilizer Bar
Removal/Installation
Decal Replacement
Foxtm Shock Exploded Views
Foxtm 2.0 'Piggyback' Shock
Foxtm Shock Service
General Service Information
Foxtm Shock Rebuild Information
Foxtm Shock Disassembly
Foxtm Shock Rebuild
Foxtm Shock Reassembly
Clutching (Pvt) Chapter 6 Clutching (Pvt)
Chapter 6
Drive Clutch Operation
General Operation
Pvt System Overview
Torque Specifications
Driven Clutch Operation
Pvt Break-In (Drive Belt / Clutches)
Pvt System Service
Pvt Disassembly
Pvt Assembly
Drive Belt
Belt Inspection
Belt Installation
Pvt Break-In (Drive Belt / Clutches)
Drive Clutch Service
Drive Clutch Exploded View
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
Troubleshooting
Final Drive Chapter 7 Final Drive
Front Bearing Carrier
Chapter 7 Bearing Carrier Installation
Front Drive Shaft
Drive Shaft Removal
Drive Shaft Installation
Propshaft Service
Support Bearing Replacement
Propshaft U-Joint Service
Front Gearcase I Centralized Hilliard
Centralized Hilliard Exploded View
All Wheel Drive Operation
Gearcaseassembly
Gearcase Installation
Rear Bearing Carrier
Rear Drive Shaft
Drive Shaft Removal
Drive Shaft Installation
Drive Shaft CV Joint I Boot Replacement
Drive Shaft Exploded View
Transmission Chapter 8 Transmission
Chapter 8 Lubrication
Specifications
Shift Lever
Shift Cable
Transmission Service
Transmission Removal
Transmission Installation
Transmission Disassembly
Snorkel Gear Backlash Procedure
Transmission Assembly
Troubleshooting
Brakes Chapter 9 Brakes
Brake Noise Troubleshooting
Chapter 9
Hydraulic Brake System Operation
Brake System Exploded View
Brake Pedal Lever
Brake Burnishing Procedure
Master Cylinder
Front Caliper Service
Caliper Exploded View
Caliper Removal
Caliper Disassembly
Front Brake Disc
Brake Burnishing Procedure
Rear Caliper Service
Caliper Exploded View
Caliper Removal
Rear Brake Disc
Troubleshooting
Electrical Chapter 10 Electrical
General Information
Instrument Cluster
Chapter 10
Information Display Area
Rider Information Display
Diagnostic Mode
Switches I Controls
BRAKE LIGHT Switch
Headlamp Switch
IGNITION KEY Switch
Transmission (Gear Position) Switch
Vehicle Speed Sensor
All Wheel Drive Coil
Headlight Adjustment
Headlamp Replacement
Headlamp Installation
Bulb Replacement
Cooling System
Cooling System Break-Out Diagram
Coolant Temperature Sensor
Fuel Sender
Fuse Box: Fuses I Relays I Circuit Breaker
Fuse Box Detail
Relay Operation
Current Draw - Key off
Charging System "Break Even" Test
General Battery Information
Battery off Season Storage
Battery Testing
Ocv - Open Circuit Voltage Test
Load Test
Starting System
Voltage Drop Test
Starter Motor Removal
Starter Motor Installation
Starter Solenoid Bench Test
Starter Solenoid Operation
Starting System Testing Flow Chart
Awd
Vehicle Speed Sensor
Cooling Fan
Chassis Power
Efi
Key-On Battery Power
Lights
Starter-Interlock
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The Way Out.
2011 RANGER RZR XP 900
SERVICE MANUAL
PN 9923144
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
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Chapters
Maintenance Chapter 2 Maintenance
17
Engine I Cooling Chapter 3 I Engine Cooling
55
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
137
Body Steering Suspensionii Chapter 5 Body I Steering I Suspension
181
Clutching (Pvt) Chapter 6 Clutching (Pvt)
219
Final Drive Chapter 7 Final Drive
249
Transmission Chapter 8 Transmission
283
Brakes Chapter 9 Brakes
309
Electrical Chapter 10 Electrical
333
Table of Contents
Troubleshooting
FUEL INJECTORS
158
EFI TROUBLESHOOTING
171
TROUBLESHOOTING
247
TROUBLESHOOTING
305
BRAKE NOISE TROUBLESHOOTING
311
TROUBLESHOOTING
331
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