8.24
TRANSMISSION
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
Transmission Disassembly
NOTE: Refer to the exploded view at the end of this
chapter as a reference.
1. Place transmission in High gear before disassembly.
2. Drain and properly dispose of the transmission
lubricant (see Chapter 2).
3. Remove the bellcrank nut (A) and bellcrank (B).
4. Remove E-clip (C) that retains spring washer (D), flat
washer (D) and gear switch (E). Remove the switch.
5. Remove the sector cover bolts (F) and remove the
sector cover (G).
NOTE: Removal can be aided by using your thumbs
to press in on the shafts while pulling out the cover
with your fingers.
6. Remove the compression spring (H).
7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
outward for reassembly.
8. Remove the spacer (J).
9. Remove the shift shaft (K), detent pawl (L) and the
shift sector gears (M and N).
IMPORTANT: Note the timing marks on the shift gears
(M and N) for reassembly purposes.
10. Remove the O-rings (P) from each shaft and discard.
Use new O-rings upon assembly.
11. Remove the bolt and washer retaining the brake disc
to transmission pinion shaft. Remove disc from shaft.
12. Remove all transmission case bolts. Using suitable
pry bars, remove the cover using the designated pry
points (indicated by black arrows in illustration below).
Do not pry on case sealing surfaces.
Use only the designated pry points
on the transmission.
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