2011 Polaris RZR XP 900 Workshop Service Repair Manual 11

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 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 2011 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2011 RANGER RZR XP 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2011 RANGER RZR XP 900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 2012 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 GENERAL: 2012 RANGER RZR XP 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2012 RANGER RZR XP 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2012 RANGER RZR XP 4 900 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2012 RANGER RZR XP 4 900 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.2 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number ES087OLE011.................................................................... 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start ES087OLE021 ................................................................... 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start VIN Identification Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the left rear frame behind the lower shock mounting location or behind the left rear fender, near the upper shock mounting location (see Figure 1-1). The engine serial number can be found on a decal applied to the engine crankcase or valve cover (see Figure 1-2). } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 1 2 J T 8 7 A D } 4 X A J T 8 7 A * C P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier Check Digit Model Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions VIN Figure 1-1 VIN Engine Serial Figure 1-2 Number Also stamped into crankcase here Engine Serial Number

1.3 GENERAL INFORMATION 1 VEHICLE INFORMATION Publication Numbers 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 Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, 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/ . Model Model No. Owner’s Manual Parts Manual 2011 RANGER RZR XP 900 R11JH87AA, AD 9922978 9922979 2012 RANGER RZR XP 900 R12JT87AB, AD, AS, AW 9923500 9923501 2012 RANGER RZR XP 900 EPS R12JT9EAW 9923500 9923501 2012 RANGER RZR XP 900 INT’L R12JT9EFX 9923500 9923503 2012 RANGER RZR XP 4 900 R12XT87AA 9923625 9923530 2012 RANGER RZR XP 4 900 EPS R12XT9EAS 9923625 9923530 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

1.4 GENERAL INFORMATION 2011 GENERAL SPECIFICATIONS MODEL: 2011 RANGER RZR XP 900 MODEL NUMBER: R11JH87AA, AD ENGINE NUMBER: 1204098 Category Dimension / Capacity Length 108.4 in. / 275 cm Width 64 in. / 162.5 cm Height 73 in. / 185 cm Wheel Base 81.4 in. / 207 cm Ground Clearance 13 in. / 33 cm Dry Weight 1190 lbs. / 540 kg Gross Vehicle Weight 1930 lbs. / 875 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes driver, passenger, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity

1.5 GENERAL INFORMATION 1 2011 RANGER RZR XP 900 MODEL NUMBER: R11JH87AA, AD ENGINE NUMBER: 1204098 CLUTCH CHART Engine Platform 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start Engine Number ES087OLE011 Engine Displacement 875cc Number of Cylinders 2 Bore & Stroke (mm) 93 x 64.4 mm Compression Ratio 10.5:1 Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 8750 RPM Lubrication Dry Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 3.5 qts. / 3.3 liters Coolant Capacity 4.9 qts. / 4.6 liters Overheat Warning Instrument Cluster Indicator Exhaust System Dual Headpipe / Single Silencer Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43.5 ± 2 psi (300 ± 14 kPa) Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output 750 Watts @ 3000 RPM Headlights 2 - Dual Beam LED: Low 27 Watts; High 40 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm) Battery Deka ETX30L / 30 AH 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump / EPS (OPT) Circuit Breaker 20 Amp: Fan Motor Fuses (Fuse/Relay Box) 10 Amp: Drive 10 Amp: Fuel Pump 20 Amp: Lights 20 Amp: EFI 20 Amp: Accessory Fuses (Power Fuse Holder) 30 Amp: EFI 30 Amp: Chassis 30 Amp: EPS (OPT) Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Fluid Type / Capacity Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission Fluid Type / Capacity Polaris AGL Plus 44 oz. (1300 ml) Clutching (PVT) Type Drive: Polaris, Basic, Non-Braking Bearing Driven: Team Roller Dampened Clutching (PVT) Center-to-Center Distance 10.5 in. (26.7 cm) PVT Drive Belt 3211142 Steering / Suspension Front Suspension / Shock Independent Dual A-arm FOX™ 2.0 Piggyback Front Travel 13.5 in. / 34.3 cm Rear Suspension / Shock Independent Trailing Arm FOX™ 2.0 Piggyback Rear Travel 14 in. / 35.6 cm Shock Preload Adjustment Front / Rear Threaded Spanner Wrench Adjustment Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Cast Aluminum ITP “900XCT” / 27 x 9 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Cast Aluminum ITP “900XCT” / 27 x 11 R12 Tire Air Pressure Front: 12 psi (82.7 kPa) Rear: 14 psi (96.5 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 25-60 (1322969) Blue / Yellow (7043766) Red (3234452) 26-59 (1322981) 1500-3700 (5000 - 12000) 26-56 (1322979) Blue / Yellow (7043766) Red (3234452) 26-55 (1322982)

1.6 GENERAL INFORMATION 2012 GENERAL SPECIFICATIONS MODEL: 2012 RANGER RZR XP 900 MODEL NUMBER: R12JT87AB, AD, AS, AW ENGINE NUMBER: 1204460 / 1204561 MODEL: 2012 RANGER RZR XP 900 EPS / INT’L MODEL NUMBER: R12JT9EAW / R12JT9EFX ENGINE NUMBER: 1204460 / 1204561 Category Dimension / Capacity Length 108.4 in. / 275 cm Width 64 in. / 162.5 cm Height 73 in. / 185 cm Wheel Base 81.4 in. / 207 cm Ground Clearance 13 in. / 33 cm Dry Weight 1190 lbs. / 540 kg Gross Vehicle Weight 1930 lbs. / 875 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes driver, passenger, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity Category Dimension / Capacity Length 108.4 in. / 275 cm Width 64 in. / 162.5 cm Height 73 in. / 185 cm Wheel Base 81.4 in. / 207 cm Ground Clearance 13 in. / 33 cm Dry Weight 1190 lbs. / 540 kg Gross Vehicle Weight 1930 lbs. / 875 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes driver, passenger, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity

1.7 GENERAL INFORMATION 1 2012 RANGER RZR XP 900 / EPS / INT’L MODEL NUMBER: 87AB, AD, AS, AW / 9EAW / 9EFX ENGINE NUMBER: 1204460 / 1204561 CLUTCH CHART Engine Platform 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start Engine Number ES087OLE021 Engine Displacement 875cc Number of Cylinders 2 Bore & Stroke (mm) 93 x 64.4 mm Compression Ratio 10.5:1 Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 8750 RPM Lubrication Dry Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 3.5 qts. / 3.3 liters Coolant Capacity 4.9 qts. / 4.6 liters Overheat Warning Instrument Cluster Indicator Exhaust System Dual Headpipe / Single Silencer Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43.5 ± 2 psi (300 ± 14 kPa) Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output (Built Before 3/16/2012) 750 Watts @ 3000 RPM Alternator Max Output (Built On or After 3/16/2012) 650 Watts @ 7000 RPM Headlights 2 - Dual Beam LED: Low 27 Watts; High 40 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm) Battery Deka ETX30L / 30 AH 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump / EPS (OPT) Circuit Breaker 20 Amp: Fan Motor Fuses (Fuse/Relay Box) 10 Amp: Drive / Fuel Pump 20 Amp: Lights / EFI / Accy Fuses (Power Fuse Holder) 30 Amp: EFI 30 Amp: Chassis 30 Amp: EPS (OPT) Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Fluid Type / Capacity Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission Fluid Type / Capacity Polaris AGL Plus XP 900: 44 oz. (1300 ml) XP INT’L: 41 oz. (1200 ml) Clutching (PVT) Type Drive: Polaris, Basic, Non-Braking Bearing Driven: Team Roller Dampened Clutching (PVT) Center-to-Center Distance 10.5 in. (26.7 cm) PVT Drive Belt 3211148 Steering / Suspension Front Suspension / Shock Independent Dual A-arm FOX™ 2.0 Piggyback Front Travel 13.5 in. / 34.3 cm Rear Suspension / Shock Independent Trailing Arm FOX™ 2.0 Piggyback Rear Travel 14 in. / 35.6 cm Shock Preload Adjustment Front / Rear Threaded Spanner Wrench Adjustment Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 ITP “900XCT” / 27 x 9 R12 ITP “Baja Cross” / 26 x 9 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 ITP “900XCT” / 27 x 11 R12 ITP “Baja Cross” / 26 x 11 R12 Tire Air Pressure Front: 12 psi (82.7 kPa) Rear: 14 psi (96.5 kPa) Brakes - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake (INT’L Model Only) Hand Actuated (located in center console) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 26-59 (1322981) Blue / Yellow (7043766) Red (3234452) 1500-3700 (5000 - 12000) 26-55 (1322982) Blue / Yellow (7043766) Red (3234452)

1.8 GENERAL INFORMATION MODEL: 2012 RANGER RZR XP 4 900 MODEL NUMBER: R12XT87AA ENGINE NUMBER: 1204460 / 1204561 MODEL: 2012 RANGER RZR XP 4 900 EPS MODEL NUMBER: R12XT9EAS ENGINE NUMBER: 1204460 / 1204561 Category Dimension / Capacity Length 134.4 in. / 341.4 cm Width 64 in. / 162.5 cm Height 77 in. / 195.6 cm Wheel Base 107.4 in. / 272.8 cm Ground Clearance 12.5 in. / 31.8 cm Dry Weight 1390 lbs. / 630.5 kg Gross Vehicle Weight 2375 lbs. / 1077 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 900 lbs. / 408 kg (Includes driver, passengers, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity Category Dimension / Capacity Length 134.4 in. / 341.4 cm Width 64 in. / 162.5 cm Height 77 in. / 195.6 cm Wheel Base 107.4 in. / 272.8 cm Ground Clearance 12.5 in. / 31.8 cm Dry Weight 1406 lbs. / 638 kg Gross Vehicle Weight 2375 lbs. / 1077 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 900 lbs. / 408 kg (Includes driver, passengers, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity

1.9 GENERAL INFORMATION 1 2012 RANGER RZR XP 4 900 / EPS MODEL NUMBER: R12XT87AA / R12XT9EAS ENGINE NUMBER: 1204460 / 1204561 CLUTCH CHART Engine Platform 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start Engine Number ES087OLE021 Engine Displacement 875cc Number of Cylinders 2 Bore & Stroke (mm) 93 x 64.4 mm Compression Ratio 10.5:1 Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 8750 RPM Lubrication Dry Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 3.5 qts. / 3.3 liters Coolant Capacity 9.7 qts. / 9.2 liters Overheat Warning Instrument Cluster Indicator Exhaust System Dual Headpipe / Single Silencer Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43.5 ± 2 psi (300 ± 14 kPa) Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output (Built Before 3/16/2012) 750 Watts @ 3000 RPM Alternator Max Output (Built On or After 3/16/2012) 650 Watts @ 7000 RPM Headlights 2 - Dual Beam LED: Low 27 Watts; High 40 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm) Battery Deka ETX30L / 30 AH 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet 2- Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump / EPS (OPT) Circuit Breaker 20 Amp: Fan Motor Fuses (Fuse/Relay Box) 10 Amp: Drive / Fuel Pump 20 Amp: Lights / EFI / Accy Fuses (Power Fuse Holder) 30 Amp: EFI 30 Amp: Chassis 30 Amp: EPS (OPT) Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Fluid Type / Capacity Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission Fluid Type / Capacity Polaris AGL Plus 44 oz. (1300 ml) Clutching (PVT) Type Drive: Polaris, Basic, Non-Braking Bearing Driven: Team Roller Dampened Clutching (PVT) Center-to-Center Distance 10.5 in. (26.7 cm) PVT Drive Belt 3211148 Steering / Suspension Front Suspension / Shock Independent Dual A-arm Walker Evans™ 2.0" Piggyback Front Travel 13.5 in. / 34.3 cm Rear Suspension / Shock Independent Trailing Arm Walker Evans™ 2.5" Piggyback Rear Travel 14 in. / 35.6 cm Shock Preload Adjustment Front / Rear Threaded Spanner Wrench Adjustment Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 ITP “900XCT” / 27 x 9 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 ITP “900XCT” / 27 x 11 R12 Tire Air Pressure Front: 14 psi (96.5 kPa) Rear: 16 psi (110.3 kPa) Brakes - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 26-59 (1322981) Purple (7043805) Red (3234452) 1500-3700 (5000 - 12000) 26-55 (1322982) Purple (7043805) Red (3234452)

1.10 GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C

2011 Polaris RZR XP 900 Workshop Service Repair Manual 11

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