Polaris RZR 900XP Engine Rebuild Part 3: Engine Removal

Welcome to the 3rd part of our Polaris RZR 900XP engine rebuild series, in which we highlight the important points of the process of removing the engine of the Polaris side-by-side.

Watch the video above and follow the steps below to remove the engine from a Polaris RZR 900 side by side. Use our Polaris RZR 900 exploded parts diagrams for additional reference.

Tools Needed – Polaris RZR Engine Removal

• Pliers
• Clutch puller tool
• Pry bar
• Engine hoist and chain

• Ratchet and extensions
• Socket set
• Allen set
• Screwdrivers

PRO TIP: Tag every wire and hose as you disconnect them, and bag every nut and bolt as you remove them. By doing so, you’ll find it much easier to reassemble your RZR’s motor when the time comes. Label each bag so you can easily retrieve the right parts when you need them again.

Removing the Clutches - Polaris RZR 900XP

Step 1. Remove the outer clutch cover, then remove the primary clutch and secondary clutch center bolts.

Step 2: Use a clutch puller tool to break both clutch assemblies free and remove them from the motor, then remove the inner clutch cover.

Watch the clip below to see the clutch removal segment of our Polaris RZR 900XP engine rebuild video.

Removing the Oil & Air Systems - Polaris RZR 900XP

Step 1. Disconnect the oil breather lines, and the oil send-and-return lines. Drain the oil canister, then unbolt it and remove it from the motor.

PRO TIP: Have a container ready to catch any oil remaining in the oil lines as you disconnect each of them.

Step 2. Disconnect the air intake ducting and boots, and remove the airbox from the engine. 

Step 3. Disconnect the wires connected to the engine, including the idle control valve and throttle position sensor wires.

Watch the clip below to see the oil and air system removal segment of our Polaris RZR 900XP engine rebuild video.

Removing the Fuel, Cooling & Exhaust Systems - Polaris RZR 900XP

Step 1. Disconnect the fuel injector lines.

PRO TIP: Although you should be tagging every line you disconnect, take extra care to tag both of the fuel injector lines so you can reattach them in the correct positions when the time comes. 

Step 2. Disconnect the send-and-return lines from the fuel rail, and pull the throttle body assembly from the adapter boots.

Step 3. Remove the thermostat hose and the hose at the base of the radiator.

PRO TIP: Have a container ready to catch any water remaining in the cooling system hoses as you disconnect each of them.

Step 4. Remove the exhaust header bolts, then disconnect the muffler from the headers and remove the header pipes. Unfasten and remove the muffler.

Step 5. Disconnect the cables from the starter motor, followed by the stator output cable.

Watch the clip below to see the fuel, cooling and exhaust systems removal segment of our Polaris RZR 900XP engine rebuild video.

Disconnecting the Engine/Transmission Fastenings - Polaris RZR 900XP

Step 1. Loosen the engine/transmission mounting bracket nuts while holding the threaded spacers the bolts run through at the other end to prevent them from turning (if the spacers turn, they will strip their threads). Remove the engine/transmission mounting bracket nuts and bolts.

Step 2. Remove the front engine mounting bolts that hold the engine to the chassis.

Step 3. Remove the engine/transmission mounting bracket jam nuts and spacers.

Watch the clip below to see the engine fastenings disconnection segment of our Polaris RZR 900XP engine rebuild video.

Removing the Engine - Polaris RZR 900XP

Step 1. Secure the engine with a chain, and carefully raise it up and out of the chassis with a hoist. 

NOTE: You may have to pry the engine at first to get it to release from the chassis mounts.

Step 2. Raise the engine slowly, and check that there are no wires or pipes still attached preventing the engine from lifting free.

Watch the clip below to see the engine removal segment of our Polaris RZR 900XP engine rebuild video.

The next stage in our Polaris RZR 900 engine rebuild project is to completely tear down the engine. Watch the video below to see how to tear down a Polaris RZR 900 engine.