How to Install a Polaris RZR 900XP Cylinder Head

Installing the cylinder head on a Polaris RZR 900XP is one of the easier stages of rebuilding its motor.

The installation needs to be done carefully to avoid damaging your Polaris RZR's engine. We'll walk you through the simple step-by-step process for how to install the cylinder head on your 900XP utility terrain vehicle. Before you get started, gather up all the parts and tools listed below that you'll need to get the job done.

Tools and Parts Needed - Polaris RZR Cylinder Head Install 

Tools

  • Ratchet and extensions
  • 8mm,14mm sockets
  • 5mm, 10mm Allens
  • Soft blow mallet
  • Torque wrench

Polaris RZR 900XP Cylinder Head Installation

Step 1. Set the engine to top dead center. To do this, bring the crankshaft around until the mark on the flywheel aligns with the point where the two halves of the crankcase meet.

Polaris RZR cylinder head install

Step 2. Install a new head gasket. Use brake/contact cleaner to make sure the face of the cylinder block is completely clean and all the debris from the old head gasket is removed. Handle the new cylinder head gasket by the edges to keep it as clean and flat as possible.

Polaris RZR cylinder head gasket

Step 3. Install the cylinder head by setting it onto the cylinder block and tapping it down gently with a soft blow mallet.

Polaris RZR 900 cylinder head installation

Step 4. Install the cylinder head bolts. All six cylinder bolts must be tightened in a specific sequence to keep an even pressure on and avoid causing any damage to the cylinder head as it's installed.

  • Finger-tighten the cylinder head bolts first.
  • Following the sequence below, torque each cylinder head bolt to 21 foot-pounds.
  • Following the same sequence again, further torque each cylinder head bolt to 26 foot-pounds.
  • Following the same sequence one last time, tighten each cylinder head bolt by an additional 180 degrees (half a turn).

Polaris RZR 900 cylinder head

Step 5. Install the two bolts on the cylinder head beside the cam timing chain housing. Torque each bolt to 89 inch-pounds and your Polaris RZR 900XP cylinder head installation is all done!

cylinder head installation Polaris RZR 900

Did you miss the video on how to remove the cylinder head from your Polaris RZR 900? No problem! Watch that video here: 

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