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2012 RZR XP 900 Build

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  • #46
    The past few rides I've noticed the front diff making a ratchet noise when I'm getting on it hard. Opened up the diff up today to see what's up.

    Found a tang missing and some bent ones on the armature plate.
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    • #47
      I bought a heavy-duty sprag to put in because I figured it was cracked but the old one was in great shape. Unfortunately I found that I had cracked the ring and pinion. So I got to buy a new one of those as well.
      The new Sprague
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      The crack in the ring gear
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      While I had the diff out I went ahead and replaced the three U joints and the carrier bearing on the drive shaft.

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      • #48
        I ordered a new ring and pinion and found out that the new ring and pinion does not exactly fit like my old one. So I'm hoping I can get the lip milled off of the new ring gear to match my old one. I'm already into this diff for $600. Super ATV website says it should fit but it won't. Evidently there were certain years on the XP 900 that it would not fit. You can see in the picture that there is a ring connecting the ring gear teeth on the new one and not on the old one, that part needs to be milled off.

        "Edit" I got the lip milled off and it worked great. Thanks for the help Chris.

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        Last edited by 93 Krawler; 10-13-2017, 12:22 PM.

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        • #49
          HD Extreme has some nice upgraded parts for the front RZR diffs. I bought their HD armature plate. This is way stronger than the stock one. They now have 2 options, strong and stronger. The one for the 800 or 900 XP has 5 or 10 tabs, and the 1000 XP has 6 or 12 tabs. I believe with that many tabs gripping the sprag carrier, you are less likely to crack the sprag. There is also more area for the magnet to grip.
          I tested it out at Harlan and the diff worked great.

          The stock one on top of the new one.

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          Last edited by 93 Krawler; 10-13-2017, 12:42 PM.

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          • #50
            I started having problems with my front diff at Winrock. I think my last trip to Harlan took a toll on it. All the new parts I put in last year are toast. Superatv now has a steel sprag that they claim is indestructible. That sounds like a challenge to me[emoji1]

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            • #51
              Originally posted by 93 Krawler View Post
              Superatv now has a steel sprag that they claim is indestructible. That sounds like a challenge to me

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              I believe 100% that you will be the person to prove them wrong and give them a bad name.
              No need for a Winch...You just have to make it !!

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              • #52
                Wow you Grenade’d that!


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                sigpic

                Keep them on all 4's

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                • #53
                  Good thing i quit when i did...[emoji54]Click image for larger version

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                  • #54
                    Kevin it's time to park that $$ pit and get your new rig together.
                    Your starting to spend more time and $$ in that thing than you are wheeling it.
                    You are proof that those things are not cut out for what you wanna do with it.
                    No need for a Winch...You just have to make it !!

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                    • #55
                      Originally posted by Runoveru2 View Post
                      Kevin it's time to park that $$ pit and get your new rig together.
                      Your starting to spend more time and $$ in that thing than you are wheeling it.
                      You are proof that those things are not cut out for what you wanna do with it.
                      Says the guy with a jacked up ring and pinion... Hey, put your factory parts back on your yota and tell me how it does... Most of our rigs weren't made for this abuse.

                      So how much have you spent this year on your rig?

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                      • #56
                        I got the front diff back together. Superatv has a lifetime warranty on their ring and pinion set and the sprag, so that cost me zero dollars. They also upgraded me to the 4140 steel sprag for free. I did have to buy a rebuild kit and a new armature plate. Between the 8 tab plate and the steel sprag, it should hold together better.

                        I believe the reason I broke the bearing carrier is I didn't know you were supposed to use Loctite 603 retaining compound on the bearing. That might have kept the c clip groove from breaking off. It will be on there from now on, so we will see if it happens again.
                        Last edited by 93 Krawler; 07-19-2018, 01:35 PM.

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                        • #57
                          [QUOTE=93 Krawler;89655] Most of our rigs weren't made for this abuse.

                          I'm ready to see progress and your new Rig on the trail that can handle abuse.
                          No need for a Winch...You just have to make it !!

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                          • #58
                            Originally posted by Runoveru2 View Post
                            I'm ready to see progress and your new Rig on the trail that can handle abuse.

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                            • #59
                              At the 2019 4th of July ride at Rush, I destroyed the front diff. Cracked the housing, so it was time for an upgrade. Got an all billet piece from Superatv. We'll see how it holds up.
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                              • #60
                                The ride quality was getting pretty bad, so I decided to bite the bullet and buy some dual rate springs from Shock Therapy. I did the front first, and they seemed ok. Got to the backs and found the shock would press straight down easily for about 2 inches. Read around the net and found it was time to rebuild them. Also found out that the Fox Podiums don't have Schrader valves. They have a self sealing needle setup that doesn't work very well. There was no nitrogen in the rear shocks at all, and very little up front. I ordered a rebuild kit and 4 Schrader valves. The rebuild was easy enough, but wish I would've found out before I had the front springs back on. I couldn't believe how nasty the shock oil was. Just tapped the aluminum caps for the new valves and aired them up to 200 psi. Will see how it rides when it warms up.

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                                Cap tapped

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                                Looks more like coffee than oil

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                                New springs and rebuilt

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