Polaris RZR 900 Prop Shaft Replacement
Our 2015 Polaris RZR 900 side-by-side had a bit of a drive line issue, specifically with the prop shaft, so it was time to replace both the rear and front prop shafts.
Watch the video above or follow the steps below to learn how to replace the prop shafts on a Polaris RZR 900S.
Tools and Parts - Polaris RZR 900 Prop Shaft Replacement
- Jack stands
- T40 Torx wrench
- Impact wrench
- Ratchet and extensions
- Grease
Polaris RZR 900S Prop Shaft Removal
Step 1. Lift the Polaris UTV up on jack stands, then remove the front right tire.
Step 2. Remove each seat, which can be done by reaching behind the seat and pulling the lever to make it tilt forward, back and then out.
Step 3. Remove the center console, which runs from the bottom of the dash all the way back. The center console is held in by five Tuflok plastic rivets and two T40 Torx screws. Removing the console exposes most of the front half shaft and the pivot bearing.
Step 4. Remove the bottom covers from the machine, which are held in place by several 10mm bolts.
NOTE: When you're ready to remove the prop shaft, make sure the rear tires are all the way off the ground so you can rotate the prop shaft.
Step 5. Find the prop shaft roll pin (spring pin) all the way up front and use a roll pin removal tool to remove the roll pin.
PRO TIP: We used an extension with a 10mm that fit over a punch to get a good swing on it out near the end of the axle.
Step 6. Remove the center support, which is held in by two 15mm bolts.
Step 7. Pry the front prop shaft off of the front differential.
Step 8. Separate the front prop shaft from the rear prop shaft and then remove it.
Step 9. Remove the rear prop shaft.
Polaris RZR 900S Prop Shaft Replacement
When we pulled the old prop shaft assembly apart, there was a white mark that lines up with a painted black dot so you could see where the two prop shafts align on the splines.
On the new prop shaft assembly, there are two white alignment marks on there, but you don’t need them because there’s a notch that’s the alignment point for it to go onto the spline. With the little protrusion on the end of the splines and the slot that has been cut into the receiver cup, you can’t get the alignment wrong when putting the assembly together.
Step 10. Grease all the different connections before reinstalling the prop shaft assembly into the machine, including the zerk fittings.
NOTE: It’s important that you pre-grease the assembly to not only make it easier to take apart if it needs to be replaced again, but also because if it’s not greased, it's going to prematurely wear out the coupling. You also need to grease the zerk fittings at least once a year.
Also notice the little paint mark at the end of the front prop shaft that’s there to make sure you line it up properly with the front differential.
Step 11. Install the new rear prop shaft onto the machine.
NOTE: Take your time and be patient when lining things back up, but note that the alignment on the back doesn't matter, so however you can get it to go in will be fine.
Step 12. Install the new front prop shaft, using the alignment marks as your guide. Crawl under the machine and line up the marks facing up for the front differential, then reinstall the spring pin.
PRO TIP: Use a dead-blow hammer and the 10mm socket and extension suggested earlier to remove the shaft roll pin to tap the pin back into place if necessary.
Step 13. Add some blue threadlocker to the retaining bolts for the center support and torque them to 33 foot-pounds once they’re in place. Reinstall the center console and the seats and you’re done.
We mentioned greasing the zerk fittings on your Polaris side-by-side at least once a year. If you need guidance on how to do this, watch the video below to see how to grease zerk fittings on a Polaris ATV.
