Broken pin

 

Yeah, the idler gear bolt get loose and this could happened . My was loose too, honestly everybody with this system should check on it, before is to late. Will be interesting, if is possible to upgrade to new gear system which is used from 2012 models.
Milos

 

Take it from someone who had a similar issue with my starter gear. It's a lot cheaper to take care of these things before than it is after.

 

You would really think polaris would honor some kind of recall or something. It is obvious that there is an issue with this system. I mean for the price of these things new you would think there would be something. I could understand if it was an issue caused, due to abuse but this is related solely a design flaw.

 

So is this on all rzr 900's or did they fix the problem in some models.


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Sad to say all 2011 and 2012s best advice do a annual check to ensure that nut on the shaft or shaft itself is not loose. Especially if u hear engine kick like it's loaded up with fuel. It's easy to check and well with your time just pick up a spare gasket cause u won't get cover loose without messing up the old gasket.

 

So all you need is a stator cover gasket, and a flywheel puller.


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You can check it without the puller but you cannot pull shaft without it. So if it is loose u will have to buy puller. if u get a puller if it where me I would pull the shaft and loc tight the shaft treads and the nut threads. The threads that enter the case is reverse thread just FYI.

 

So here is what a nice case one looks like so well worth ur time. Plus if shaft breaks it can crack ur case which then it becomes a huge problem.

 

So when I pull cover I need to check the bolt behind the little gear, its looks like it has a c-clip that holds the gear to the bolt. Where is the nut you are referring to, is it on the back side of the gear. Tks for your help I'am going to order a gasket, and check mine this week.


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Yes you are all over it! That is exactly right. The shaft screws into your case and the nut is supposed to lock it
In place. So if either are loose get u a puller and fix it before u become a statistic and post a picture that turns ur stomach like me and many others.

 

FYI It is one piece part, not shaft and nut.
Milos

 

Thanks milo my new one is on order I just assumed it was that way. As u can see my is pretty much fubared so I just assumed that it was seized on there.

 

How have I never heard of this... I better get to checking mine

 

Where are you accessing this from the right side of the engine.

 

It's all behind the stator cover passenger side. Very easy to get to. Especially if u pull tire and shock.

 

So got puller today and this is what she looks like. Hole defiantly out of spec.

 

http://www.hpd-inc.com/900xp.htm this is link to place I bought mine. It worked great and is very well built.

 

I listed it earlier in thread but here it is again I hope this helps


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Defiantly not just random seems If u dig a little u find tons of post on this issue. Even the lucky ones who had checked theirs found that bolt for the idler was loose. I should have checked mine. I meet a guy who had this happen to his and two of his friends. I should have checked mine them. I figured mine was fine cause I had almost 4k miles on it. I was wrong now paying dearly due to my laziness.

 

When you go to put the flywheel back on, does it have a specific torque, or do you just tighten it up good.


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Around 90 ft.lbs torque .
Milos

 

found
This online

 

View attachment 91758 found
This online

here ya go.. page 2 post#26.. 74lbs

 

Well I'am glad I decided to check this out, because I wasn't having any problems what so ever, but when I took it all apart my bolt was lose. The gasket was less then $10 bucks, and my dealer loaned me a flywheel puller, so I may have saved my self some money down the road by checking this out early. My rzr only has 575 miles, so I think they all will get lose its just a matter of when it gets to lose, and causes a problem. Thanks for all the help, this forum is the best info available anywhere.


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Forums can be so hit or miss and I believe all of us do our best to give as factual information as possible. I am honestly glad i took the time and put my issues out for everyone to see. Just being able to help out one person made my day!! Glad u caught it in time giterdun24

 

Mine is having problems now too. Sometimes when I go to start it, it just spins and won't catch. I'm going to take it all apart soon and check it out. Even if the bolt isn't loose I'm going to take it out and put red loctite on it.

 

I'm still not clear on what I should be checking---- So looking at the diagram (Post 26) I need to check the tightness/torgue on the "Intermediate Gear Pin" nut?? I really want to check mine, my starter is sounding a "little funny" on my 2011 with 3200 miles..... Thanks in advance.. Ted

 

Yes, but actually how you can see on picture it is one piece, not pin and nut separately and have a left hand tread .
milos
[URL=http://s358.photobucket.com/user/milosusa/media/Packard%20Turbo/DSCN2590_zps45b4d935.jpg.html][/URL]

 

I would like to thank all of you that have shed light and posted photos on this issue. I am new to the RZR world just getting my 900 over the weekend. With all the bad weather I have been reading up on all the common issues with these and began second guessing my decision. Now with the help of you guys in the thread one of my biggest concerns has lifted. I will be checking mine as soon as it warms up. Is there any way to check and see if its tight or should I just pull it, lock-tite it and put it back together? I dont have a puller but buying it is cheaper than replacing the case. Thanks again!