You’ve got your hands on a 2016 Polaris RZR 900 Trail, and you already know it’s a legend. It’s the rig that opened up tight, technical trails to thousands of riders, blending nimble handling with just the right amount of punch. But you also know that keeping a high-performance machine running strong isn’t about luck; it’s about knowledge and a little bit of wrench time.
We promise this comprehensive guide will give you the confidence to maintain, troubleshoot, and even upgrade your RZR. You’ll learn exactly what to look for, how to fix the small stuff before it becomes a big problem, and where to invest your money for the best performance gains.
We’re going to cover everything from the crucial pre-ride checklist and common issues to a full DIY maintenance plan and smart, trail-tested modifications. Let’s get your RZR ready to dominate the trail.
Why the 2016 Polaris RZR 900 Trail is a Modern Classic
Before we dive into the nuts and bolts, let’s appreciate what makes this machine special. The 2016 model hit a sweet spot in the side-by-side world, and understanding its design helps you maintain it better.
The key to its success is the 50-inch width. This allows it to legally access width-restricted trails that bigger, wider machines simply can’t touch. It’s the reason “Trail” is in its name, and it’s one of the primary benefits of 2016 polaris rzr 900 trail ownership.
Powering this agile chassis is the 75-horsepower ProStar 900 engine. This twin-cylinder, fuel-injected powerplant provides snappy throttle response and a torque curve that’s perfect for climbing hills and powering out of tight corners. It’s a reliable engine, but like any performance motor, it loves clean oil and a fresh air filter.
Your Pre-Ride Checklist: The 5-Minute Safety Walkaround
The single most important habit you can develop is a consistent pre-ride inspection. This simple routine can catch a minor issue before it turns into a major breakdown miles from the truck. Follow these 2016 polaris rzr 900 trail best practices every single time you ride.
T-C-L-O-C: The Rider’s Mantra
This is a simple acronym used by riders to remember the key inspection points. It stands for Tires, Controls, Lights, Oil, and Chassis.
- Tires & Wheels: Check the air pressure (refer to the sticker on your RZR or your tire’s sidewall). Look for any cuts, punctures, or bubbles in the rubber. Grab each wheel and check for any side-to-side play, which could indicate a bad wheel bearing.
- Controls & Brakes: Squeeze the brake pedal. It should feel firm, not spongy. Check your throttle lever for smooth operation. Turn the steering wheel from lock to lock, feeling for any binding or strange noises.
- Lights & Electrics: Turn the key on. Test your headlights (high and low beams), taillights, and brake lights to ensure they’re all working.
- Oil & Fluids: This is non-negotiable. With the RZR on level ground, pull the engine oil dipstick, wipe it, re-insert it fully, and pull it again for an accurate reading. Check your coolant level in the overflow bottle—it should be between the ‘MIN’ and ‘MAX’ lines.
- Chassis & Drivetrain: Do a quick visual inspection of the suspension A-arms, trailing arms, and radius rods for any cracks, bends, or loose bolts. Glance at your CV boots on all four axles; a torn boot will quickly lead to a failed CV joint if dirt gets in.
Common Problems with 2016 Polaris RZR 900 Trail and How to Fix Them
No machine is perfect. After years on the trail, the community has identified a few weak points on these RZRs. Knowing the common problems with 2016 polaris rzr 900 trail models allows you to be proactive with maintenance and repairs.
Carrier Bearing Failure
The stock driveshaft carrier bearing is a well-known weak link. It’s a rubber-mounted bearing that supports the main driveshaft running from the transmission to the front differential.
- The Symptom: A noticeable vibration, especially under acceleration, that you can often feel through the floorboards. You might also hear a rumbling or grinding noise from the center console area.
- The Fix: The best solution is to replace the OEM unit with a heavy-duty, greaseable aftermarket bearing from brands like Sandcraft RCR or SuperATV. This is a DIY-able job but requires removing the center console and driveshaft. This is one of the most valuable 2016 polaris rzr 900 trail tips you’ll get.
Clutch and Belt Issues
The CVT (Continuously Variable Transmission) clutch system is brilliant, but it’s also a wear item. Heat is the number one enemy of your drive belt.
- The Symptom: A smell of burning rubber, loss of power, or a jerky feeling when taking off. You might notice your RZR struggles to reach its top speed.
- The Fix: Regularly inspect your drive belt for glazing, cracks, or missing cogs. We recommend blowing the dust out of your clutch housing with compressed air after every few rides. If you frequently ride in low range at high RPMs (like in mud or sand), consider a clutch kit to optimize performance and belt life.
Voltage Regulator Location
On some models, the voltage regulator is mounted in a spot with poor airflow, leading to overheating and failure. A failed regulator can leave you stranded with a dead battery.
- The Symptom: The battery won’t stay charged, the headlights dim and brighten erratically, or the machine suddenly dies and won’t restart. The display might show a high or low voltage code.
- The Fix: Many owners choose to relocate the voltage regulator to an area with better airflow, like up under the front hood. Aftermarket regulators often offer better cooling fins and more robust construction.
The Essential 2016 Polaris RZR 900 Trail Care Guide: DIY Maintenance
Following a solid maintenance schedule is the core of this 2016 polaris rzr 900 trail care guide. Sticking to these intervals will dramatically extend the life of your machine and save you a fortune in shop labor costs.
Engine Oil & Filter Change
This is the lifeblood of your ProStar engine. Don’t cheap out and don’t stretch the intervals.
- When: Every 25-50 hours of use, or at least once a season, whichever comes first. Ride in dusty or wet conditions? Stick closer to 25 hours.
- What You Need: 2.5 quarts of Polaris PS-4 Full Synthetic Oil (or a compatible J-Spec JASO MA oil), an oil filter (OEM or quality aftermarket like K&N), a drain pan, and a basic socket set.
- How To: Warm up the engine for a few minutes to get the oil flowing. Park on a level surface, remove the drain plug, and let the old oil drain completely. Replace the oil filter, reinstall the drain plug (with a new crush washer!), and refill with fresh oil. Always double-check the level on the dipstick.
Air Filter Service
Your RZR breathes through its air filter. A clogged filter robs power and, if it fails, can allow dirt to destroy your engine. Learning how to 2016 polaris rzr 900 trail air filter service is critical.
- When: Inspect before every ride, clean every 10-15 hours, and replace when it’s damaged or can no longer be cleaned effectively.
- How To: The airbox is located in the bed. Unclip the cover and carefully remove the paper filter. Tap it gently on a clean surface to knock loose dirt out. Use low-pressure compressed air from the inside out to blow remaining dust away. Never use high pressure, as it can tear the filter media.
Drivetrain Fluid Checks
Your transmission and differentials need love, too. These fluids don’t need changing as often as engine oil, but they must be kept at the proper level.
- Transmission: Check the level via the dipstick located on the passenger side of the transmission case. It uses Polaris AGL fluid.
- Front Differential: Check the level by removing the fill plug on the side of the case. The fluid should be right at the bottom of the threads. This uses Polaris Demand Drive Fluid.
Smart Upgrades: Performance & Comfort Mods That Actually Work
Part of the fun of owning a RZR is making it your own. This isn’t a complete 2016 polaris rzr 900 trail guide to every mod, but these are the upgrades that provide the most bang for your buck on the trail.
Tires
The single best upgrade you can make. The stock tires are okay, but a quality 6-ply or 8-ply aftermarket tire will provide vastly better traction and puncture resistance. Look for an all-terrain tread that matches the conditions you ride in most often.
Skid Plates
The factory “skid plate” offers minimal protection. A full UHMW (Ultra-High-Molecular-Weight) plastic skid plate from a brand like Factory UTV or Ricochet will protect your frame, engine, and drivetrain from rocks and stumps that can end your day.
Harnesses and Seats
Safety first. Swapping the stock 3-point seatbelts for a 4-point or 5-point harness system will keep you securely planted in the vehicle over rough terrain. This isn’t just safer; it’s more comfortable and reduces fatigue.
Sustainable & Eco-Friendly Riding: Best Practices for the Trail
Being a responsible off-roader means protecting the trails we love. A sustainable 2016 polaris rzr 900 trail experience is about minimizing your impact and leaving the environment better than you found it.
Adopting an eco-friendly 2016 polaris rzr 900 trail mindset is easy. Always follow Tread Lightly! principles: stay on designated trails, cross streams only at designated crossings, and pack out everything you pack in.
During maintenance, collect all used fluids (oil, coolant, gear lube) in sealed containers and take them to an auto parts store or local recycling center for proper disposal. Never dump fluids on the ground. When washing your RZR, consider using a biodegradable, phosphate-free soap to minimize chemical runoff.
Frequently Asked Questions About the 2016 Polaris RZR 900 Trail
What kind of fuel should I use in my 2016 RZR 900?
The ProStar 900 engine is designed to run on a minimum of 87 octane unleaded gasoline. Using higher octane fuel will not provide any performance benefit and is not necessary.
What is the top speed of a 2016 RZR 900 Trail?
Under ideal conditions, a stock 2016 RZR 900 Trail can reach a top speed of around 60-65 mph. However, factors like tire size, clutch condition, and rider weight can affect this.
How often should I change the drive belt?
There is no set hour interval for belt changes. It’s based on inspection and riding style. A good rule of thumb is to carry a spare belt with you on the trail and replace your primary belt if you notice any signs of excessive wear, glazing, or cracking during your regular inspections.
Can I add a winch to my RZR 900 Trail?
Absolutely. A winch is one of the most practical accessories you can add. Most aftermarket bumpers are designed with a winch mount plate, and a 3,500 lb winch is a popular and effective choice for this size machine.
Your 2016 Polaris RZR 900 Trail is an incredible machine built for adventure. By investing a little time in routine checks, proactive maintenance, and smart upgrades, you ensure it will be ready to tackle any trail you point it at for years to come.
Remember to put safety first, respect the trails, and don’t be afraid to get your hands dirty. That’s what being part of the off-road community is all about. Now get out there and ride!
- Can-Am Outlander Years To Avoid – A Mechanic’S Guide To Buying Smart - November 30, 2025
- Polaris Sportsman 570 Vs Can Am Outlander 700 – The Ultimate Off-Road - November 30, 2025
- Can Am Outlander Fuel Pump Problems – Your Complete DIY Diagnostic & - November 30, 2025