What kind of problems does a Polaris Ranger XP 900 normally have? In this blog, we’ve outlined all the most important things you should watch for when you’re in the market for a Polaris Ranger XP 900. In the rest of the article, we’ll discuss every single problem in detail. Furthermore, we’ll tell you how to identify it, fix it and how much it costs to fix. Read on!
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1. Shifting Problems
A customer reports,
“When trying to find reverse, my 2015 ranger 900xp grinds the gear roughly half of the time. Also, many times it’s not in gear when I go to take off and then grinds and pops in. The problem appears widespread. Has anyone found a solution that isn’t as pricey as a clutch replacement?”
Often, the XP 900 shifting issues stem from the selector mechanism. The machine will grind gears if the tranny selector can’t get the proper gear position on the transmission selector arm. The shift selector must be adjusted right out of the factory and preferably before the warranty term expires due to cable stretch. The older shifter mechanism is a pain to use, but once broken in and greased, it works quite well.
So, before making parts replacements, try adjusting and lubing the selector lever. Typically, the transmissions are trouble-free if the proper gear is selected. Get your selector adjusted immediately, if you wiggle the selector into gear and still hear grinding. Grinding gears will ruin your drivetrain. If you replace the selector lever, replace the selector cable, or you may experience no change after replacing the selector assembly.
Gear shifting troubles can also arise from an aftermarket drive belt, shredded or worn drive belt, misaligned clutches, or a defective or loose engine mount.
2. Clutch Problems
A customer says,
“My 2016 Ranger 900 has only 800 miles on it and the check engine light is not on. It idles at about 1200 rpm, which, I believe, is normal. It occasionally starts to move when I let off the brake, which seems to get worse after driving it for a while on start up. It’s normally fine, and it shifts and acts fine. The main problem here is that I almost can’t shift it when the engine is running.”
The worn-out components of the primary clutch, such as the one-way bearing, clutch bearings, or clutch kit arms or fingers, are often the source of clutch problems. They degrade with time and must be replaced. It is also possible that you will need to split the secondary clutch and inspect the rollers and cam. The one-way bearing could become trapped or tight, causing drag and making shifting difficult. The clutch kit’s rollers will wear out if you leave your machine idling for an extended time.
The plastic one-way bearing helix, which serves as an EBS lockout shim for primary clutches, might also fail due to debris and dust. A high idle, clutch, or belt issue may cause gear change problems that only occur when the engine is running. Gear change troubles can also present if the clutch spring is weak, the clutches are dirty, or the driving belt is excessively tight. A faulty clutch may also prompt belt failures.
OEM Polaris Ranger XP 900 clutch kit price is between $259.95 and $460.99. OEM Polaris Ranger XP 900 clutch drive belt costs $165.99. It is recommended to have it fixed by an experienced mechanic.
Also read: 5 x Most Common Polaris Clutch Problems!
3. Injector Problems
Low fuel pressure is the cause of most injector problems. For example, a customer reports,
“Only one injector on my 2015 Polaris Ranger 900 XP is injecting, and the other is not. I switched injectors from one side to the other, and the same side was injected, indicating that the injector isn’t damaged. I tried it on another XP 900 that I removed the ECM off. The main difference is that there is just one injector. I removed the ECM from the non-starting unit, and it successfully started the running ranger.
The results were the same when I switched the crank position sensors. I checked for continuity between the injector wires and the ECM plug and found it to be OK. I checked the three crank position sensor wires to the ECM plug for continuity and found they are all good. Furthermore, I charged the battery and cleaned up the ground wires. Has anyone else encountered this problem?”
If one injector does not fire most of the time, the likely cause is a clogged filter or a defective fuel regulator or fuel pump. You can use a fuel pressure tester attached to the fuel rail to test the fuel pressure. The factory setting is 39PSI +/- 2. Replace a faulty fuel regulator or fuel pump. OEM fuel pressure regulator for Polaris Ranger XP 900 goes for $34.99, while the replacement fuel pump assembly costs around $178.51
The symptoms of dirty, faulty, clogged, or leaking injectors include starting issues, poor idle, failed emissions, and rough engine performance. Also, increased fuel consumption, poor performance, engine not reaching full rpm, and surging and bucking under various throttle loads.
Fuel contamination is the most common cause of premature injector failure. You can clean the injector and replace damaged ones. Two OEM fuel injectors for Polaris Ranger XP 900 cost $46.99
Also read: 5 x Most Common Polaris Fuel Pump Problems!
4. Starting Problems
Starting issues may have many causes, for example, a customer reports,
“My 2016 Ranger 900XP has 800 miles and 92.3 hours on it. I am the original owner and keep it indoors in a climate-controlled environment. Never operate in flooded or deep water. When I turn the key to On, I hear the fuel pump cycle. There is no attempt to fire the engine, which cranks at a normal speed.
At 12.1 Vdc, the battery voltage is sufficient. It usually starts after 3-4 cranking efforts. When it does start, it runs quite rough and emits a rich fuel mixture from the exhaust. It will run erratically for several minutes before dying. It is occasionally necessary to apply throttle to keep it running.”
In such a case, you should check your fuel. Avoid using fuel over six months old because it degrades and contaminates the fuel system. It can also lead to corrosion. So, empty your tank and fill it with fresh fuel.
To diagnose other starting problems, begin by ensuring the Ranger is in neutral and the battery is good and fully charged. Also, turn the run switch on and check that the solenoid clicks when you turn the key. If it doesn’t click, examine the power to the solenoid from the key switch. Examine the switch if there is no power.
If the switch is ok, measure the solenoid connections while turning the key; both sides should read 12 volts. If not, clean the terminals, reconnect the wires, and retest. If the issue persists, replace the solenoid, it is defective.
If the solenoid works, meter the voltage at the starter motor. Examine the continuity between the non-powered solenoid lug and the wire lug on the starter. If there is continuity, attach a jumper cable to the battery positive terminal and the starter motor lug. Remove and rebuild the starter motor if it doesn’t turn.
Where the starter motor turns, see if the spark plug has a strong spark. If not, then there is an ignition problem. If the ignition is ok, check the fuel system by pulling the fuel line and starting the engine to ensure fuel is flowing. Investigate fuel and air filter blockage. If the engine doesn’t start until the motor is warm, it is likely due to water in the starter.
Also read: 6 x Polaris Starter (Solenoid) Problems!
5. Charging Problems
Many charging issues occur due to cheap aftermarket voltage regulators. For example, a customer says,
“My 2014 Ranger XP 900 has had four different voltage regulators. It is on number 5, which has not resolved my charging problem. The ranger battery isn’t charging at all. What could be the issue, and how can I resolve it?”
If you have a charging problem, start by ensuring your battery. Use a charger to charge your battery and perform a load test to determine its condition. Then, check all the connections, especially the grounds because faulty grounds can cause many problems, including charging system issues.
Meter the voltage at the voltage regulator’s alternator input. If it is 15v, or higher, the alternator is functioning well. If the battery is at 12v, the voltage isn’t getting through to the battery terminal because the VR is malfunctioning. Replace it. OEM Polaris Ranger Voltage Regulator costs approximately $119.99.
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