Polaris RZR XP 900 (2011-2013) - Repair, Service Manual and Electrical Wiring Diagrams

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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