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9940259 R02 - 2022

RZR

PRO R / PRO R 4 Service Manual

11.1

BODY / FRAME

CHAPTER 11

BODY / FRAME

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

DECAL REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

BODY ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

CAB FRAME ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

CAB FRAME ASSEMBLY (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4

DOORS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5

REAR DOORS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6

DASH / CONTROLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7

HOOD / FRONT BODY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8

CHASSIS / MAIN FRAME

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9

CHASSIS / MAIN FRAME (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.11

SEAT ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13

REAR SEAT ASSEMBLY (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15

FLOOR / ROCKER PANELS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17

FLOOR / ROCKER PANELS (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18

REAR CARGO BOX / FENDERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19

BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20

SEATS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20

REAR CLOSE-OFF PANEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20

FRONT FASCIA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21

REAR FASCIA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22

HOOD / FRONT BODY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23

REAR FENDER / FENDER FLARE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24

CARGO BOX

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24

ROCKER PANELS, CONSOLE, AND FLOOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25

DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27

DOOR PANEL / LATCH REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27

DOOR ADJUSTMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27

Summary of Contents for RZR PRO R

Page 1: ...m any of the procedures outlined in this Service Manual contact an authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications mo...

Page 2: ...ns IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registere...

Page 3: ...r to provide Polaris with an overall satisfaction rating for this service manual provide comments on your experience or upload pictures video This feedback form is viewable on a mobile device by scann...

Page 4: ......

Page 5: ...ATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING SYSTEM CHAPTER 4 ENGINE ELECTRICAL CHAPTER 5 EFI FUEL SYSTEM CHAPTER 6 PVT SYSTEM CHAPTER 7 TRANSMISSION CHAPTER 8 FINAL DRIVE CHAPTER 9 STEERING S...

Page 6: ......

Page 7: ...ONVERSION TABLE 1 16 SAE TAP DRILL SIZES 1 17 METRIC TAP DRILL SIZES 1 17 DECIMAL EQUIVALENTS 1 18 GENERAL DIAGNOSTICS 1 19 GENERAL DIAGNOSTICS INFORMATION OVERVIEW 1 19 GUIDED SYMPTOM DIAGNOSTIC 1 19...

Page 8: ...SPENSION DIAGNOSTICS 1 57 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON 1 57 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF 1 58 EPS TROUBLESHOOTING USING DIGITAL WRENC...

Page 9: ...h calibration VEHICLE IDENTIFICATION NUMBER VIN DESIGNATION 2015 Example 4XARUE573FG000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE CHASSIS MODIFIER ENGINE SIZE ENGINE MO...

Page 10: ...from the original key Key Blank P N 4080125 Rubber Key Cover P N 5458344 PUBLICATION NUMBERS YEAR MODEL OWNER S MANUAL 2022 RZR PRO R 9931527 RZR PRO R 4 9931528 NOTICE When ordering service parts be...

Page 11: ...listed or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers m...

Page 12: ...ffler Studs 18 ft lbs 25 Nm Intake Hose Clamps 35 in lbs 3 Nm Intake Mounting Fasteners 9 ft lbs 12 Nm Isolator Mounting Bracket Fastener 18 ft lbs 25 Nm Oxygen Sensor 30 ft lbs 40 Nm PART DESCRIPTION...

Page 13: ...rm Mounting Fasteners 133 ft lbs 180 Nm Torque bolt side Hub Mounting Fasteners 81 ft lbs 110 Nm PART DESCRIPTION TORQUE SPECIFICATION Knuckle Mounting Fasteners 133 ft lbs 180 Nm Torque bolt side Low...

Page 14: ...eners 44 ft lbs 60 Nm Frame Cross Bar Fastener 4 Seat M8x1 25x20 18 ft lbs 25Nm Frame Cross Bar Fastener 4 Seat M8x1 25x16 15 ft lbs 20Nm PART DESCRIPTION TORQUE SPECIFICATION Front Bumper Fasteners 3...

Page 15: ...Underseat Flip Panel Fastener 6 ft lb 8 Nm Upper Control Arm Bracket Fasteners 52 ft lbs 70 Nm ELECTRICAL PART DESCRIPTION TORQUE SPECIFICATION Alternator Cover Fasteners 6 ft lbs 9 Nm Alternator Mou...

Page 16: ...rt 2085 lbs 946 kg Premium 2144 lbs 973 kg Ultimate 2187 lbs 992 kg Gross Vehicle Weight Sport 2940 lbs 1334 kg Premium 3010 lbs 1365 kg Ultimate 3040 lbs 1379 kg Cargo Box Capacity 300 lbs 136 kg Max...

Page 17: ...Flooded 400 CCA 31 A hr DC Outlet Standard 12 Volt Relays Start Fan EFI Pump Chassis EPS Accy Shocks SCM ELECTRICAL Fuses PDM2 10A Term Blk 10A Instr Accy 15A Start 7 5A Lights 10A SCM 15A Chassis 7 5...

Page 18: ...t Tire Make Model Size Maxxis Rampage Fury 32 x 10 R15 Rear Tire Make Model Size Maxxis Rampage Fury 32 x 10 R15 Tire Air Pressure Front 15 psi 103 kPa WHEELS BRAKES Rear 15 psi 103 kPa Brake System 4...

Page 19: ...2 kg Premium 2437 lbs 1105 kg Ultimate 2480 lbs 1125 kg Gross Vehicle Weight Sport 3471 lbs 1574 kg Premium 3545 lbs 1608 kg Ultimate 3555 lbs 1612 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight...

Page 20: ...v Flooded 400 CCA 31 A hr DC Outlet Standard 12 Volt Relays Start Fan EFI Pump Chassis EPS Accy Shocks SCM ELECTRICAL Fuses PDM2 10A Term Blk 10A Instr Accy 15A Start 7 5A Lights 10A SCM 15A Chassis 7...

Page 21: ...Front Tire Make Model Size Maxxis Rampage Fury 32 x 10 R15 Rear Tire Make Model Size Maxxis Rampage Fury 32 x 10 R15 Tire Air Pressure Front 18 psi 124 kPa Rear 18 psi 124 kPa Brake System 4 Wheel Hyd...

Page 22: ...nch x 2 54 cm mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0...

Page 23: ...1 1 2 12 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 1...

Page 24: ...6 10 mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 FRACTION DECIMAL MM TO INCHES 33 64 0 5156 17 32 0 5313 35...

Page 25: ...uplicated and compared to a like vehicle No If the concern has not been able to be duplicated gather more information about the concern After the concern has been duplicated please compare to a like v...

Page 26: ...ry been selected Refer to the Transmission or Final Drive Chapters for further diagnostic information No Is the concern related to a Noise Yes Refer to necessary service information for pin pointing n...

Page 27: ...Wrench Guided diagnosis Certain failures may not display a CEL MIL on the instrument cluster In this instance record CEL s from the instrument cluster and refer to the necessary section in the Servic...

Page 28: ...V Load test battery If battery fails the load test charge replace battery as needed Retest for concern before proceeding Check Ignition Switch and connections Concern may be caused by faulty Ignition...

Page 29: ...is not moving concern may be within transmission Refer to the necessary section in the applicable service manual u Test drive vehicle for concern If the concern is related to the PVTsystem Transmissio...

Page 30: ...ensure that the fuel being used meets the correct octane rating specific to the vehicle If filled with fuel vehicle starts and gauge still is not reading test the fuel sending unit 6 Check fuses or fu...

Page 31: ...n Check ECU for power and grounds to make sure that computer is turning on 12 If all previous checks pass concern may be caused by internal engine issue Refer to Cylinder Leakdown Test Previous testin...

Page 32: ...ck Positive terminals at starter and solenoid for available voltage using DMM Readings should be 12 6 V With battery disconnected check cables for high resistance Reading should be less than 1 Ohm If...

Page 33: ...pump may be faulty or not circulating enough coolant to keep temperature within specification Radiator core may not be functioning correctly or failed causing concern 7 Faulty Temp Sensor Circuit ECU...

Page 34: ...inspect hoses and radiator for coolant leaks Repair as necessary Pressurize cooling system and look for pressure losses This indicates a leak in the cooling system Inspect for external leaks if none...

Page 35: ...l Injector Fuel pump inoperative restricted Tank vent plugged or pinched Engine flooded Injector control circuit failure Low compression high cylinder leakage No spark Spark plug fouled ignition compo...

Page 36: ...linder Worn valve guides or seals Restricted breather Air filter dirty or contaminated LOW COMPRESSION Cylinder head gasket leak No valve clearance cam wear Valve not seating properly bent or carbon a...

Page 37: ...ocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump Fuel pump output weak Cooling fan inoperative or turning too slowly perform current draw test Faulty hot light...

Page 38: ...the engine If the CHECK ENGINE lamp or the EPAS lamp illuminates retrieve the active error codes from the display 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle but...

Page 39: ...l Operational Range P0502 2 Data Erratic or Intermittent or missing P0503 C1058 3 Voltage Too High P1507 4 Voltage Below Normal Or Shorted To Low Source P1506 8 Abnormal Frequency Or Pulse Width Or Pe...

Page 40: ...Voltage Too High P1108 4 Voltage Too Low P1107 107 Engine Air Filter 1 Differential Pressure Sensor 0 Data Valid But Above Normal Operational Range Most Severe Level P1280 2 Data Erratic Intermittent...

Page 41: ...16 Data Valid But Above Normal Operating Range Moderately Severe Level P1564 18 Data Valid But Below Normal Operating Range Moderately Severe Level P1565 171 Ambient Air Temperature 19 Received Netwo...

Page 42: ...chometer Driver Circuit 3 Voltage Above Normal Or Shorted To High Source P1739 4 Voltage Below Normal Or Shorted To Low Source P1738 5 Current Below Normal Or Open Circuit P1737 651 Injector 1 MAG 4 V...

Page 43: ...Or Grounded Circuit C1B34 7 Mechanical System Not Responding Or Out Of Adjustment C1734 8 Abnormal Frequency Or Pulse Width Or Period C1334 10 Abnormal Rate Of Change C1834 14 Special Instructions C1...

Page 44: ...age Below Normal P1616 5 Current Below Normal Or Open Circuit P1615 1347 Fuel Pump Driver Circuit 3 Voltage Above Normal P0232 4 Voltage Below Normal P0231 5 Current Below Normal Or Open Circuit P0230...

Page 45: ...ast Severe Level C2049 3057 Oxygen Sensor Bank 1 Sensor 2 2 Data Erratic Intermittent Or Incorrect P0136 3 Voltage Above Normal Or Shorted To High Source P0138 4 Voltage Below Normal Or Shorted To Low...

Page 46: ...dition Exists C2438 520152 ABS Solenoid Rear Left In 31 Condition Exists C1324 520153 ABS Solenoid Rear Left Out 31 Condition Exists C1325 520194 Throttle Release Signal 2 Data Erratic Intermittent Or...

Page 47: ...Open Circuit P1646 520220 Battery Charge Relay 3 Voltage Above Normal Or Shorted To High Source P163D 4 Voltage Below Normal Or Shorted To Low Source P163A 5 Current Below Normal Or Open Circuit P163C...

Page 48: ...Severe Level C2421 3 Voltage Above Normal Or Shorted To High Source C1039 C1241 4 Voltage Below Normal Or Shorted To Low Source C1038 520264 ABS Brake Controller ECU 12 Bad Intelligent Device Or Comp...

Page 49: ...ists P1531 520307 ECU ADC Fault Voltage 31 Condition Exists P1532 520308 Accelerator Sensor Sync Fault Sensor Diff Exceeds Limit 31 Condition Exists P1533 520309 ECU Fault ICO 31 Condition Exists P153...

Page 50: ...ed Circuit P1148 P1185 12 Bad Intelligent Device Or Component P1149 P1186 19 Received Network Data In Error P1150 P1187 520518 Motor Controller Contactor 5 Current Below Normal Or Open Circuit P1151 P...

Page 51: ...far the throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur T...

Page 52: ...not low at this time clean and continue to monitor It is possible that the fluid is residual from manufacturing or previous repairs 2 Thoroughly clean the area using an appropriate cleaner Brake clean...

Page 53: ...operly Fuel lines or fuel injectors restricted Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts air box cover Faulty oxygen sensor RICH MIXTURE SYMPTOMS CAUSES Hard...

Page 54: ...hen warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Erratic Idle Throttle cable incorrectly adjusted Air leaks dirty injector T MAP damaged check wi...

Page 55: ...ified operating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift...

Page 56: ...wner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Find leak and repair as necessary Operator error Instruct operator on guidelines for operation in wet terrain as outli...

Page 57: ...icle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may...

Page 58: ...ernal transmission components TRANSMISSION ISOLATION To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the transmission should be isolate...

Page 59: ...S As the Pinion Disconnect and Differential Lock Solenoids must remain powered for the 2WD and 4WD Lock Driveline Modes as in the Driveline Mode Operations in Normal Conditions table engine off batter...

Page 60: ...ated driver side of differential r Differential Lock Solenoid hidden located driver side of differential t Pinion Disconnect Solenoid Driver chassis harness connector Pin B of the Pinion Disconnect ch...

Page 61: ...Inspect Repair as necessary Clean piston s seal Educate operator Loose wheel hub or bearings Check wheel and hub for abnormal movement Check axle nut torque Inspect replace bearing if needed Brake dis...

Page 62: ...ged or lining ruptured Worn disc and or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged brake pad noise insulator Brake pads drag Brake caliper...

Page 63: ...procedure s available in Digital Wrench Power Steering Non Functional MIL is ON Cycle the ignition switch Is MIL on No There is no issue MIL on due to 5 minute timeout Verify code using Digital Wrenc...

Page 64: ...ctional MIL is OFF Is Battery Voltage 11 and 16VDC No Determine cause of incorrect battery voltage and repair Yes Is EPS Fuse OK No Replace EPS Fuse Yes 12 VDC and GND across 2 Pin EPS Connector with...

Page 65: ...High EEPROM Failure These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit TABLE 2 EPS Inverter Temperature Test 1 Verify that th...

Page 66: ...bricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock b...

Page 67: ...DMM will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowl...

Page 68: ...eld upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing...

Page 69: ...to ground B so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There...

Page 70: ...ircuit Testing Continuity Resistance page 1 63 4 Ensure you have checked for a short to ground Testing For A Short To Ground page 1 63 5 Ensure that neither end of the circuit is connected 6 Set your...

Page 71: ...insulation damage Improper routing especially when it leads to chaffing or heat damage especially near exhaust You may need to use different techniques to duplicate these concerns These include but ar...

Page 72: ...sleep after switched power is removed 8 Maximum allowable is 10 milliamps If your meter is ranged to the 10 Amp scale this will appear as 0 010 Amps Current Draw Key Off Maximum of 01 DCA 10 mA 9 If...

Page 73: ...40259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 1 67 For a video demonstration scan the QR code below or right click it and select open in new tab GENERAL INFORMATION...

Page 74: ...1 68 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES GENERAL INFORMATION...

Page 75: ...GTH 2 16 COOLANT LEVEL INSPECTION 2 17 COOLING SYSTEM PRESSURE TEST 2 17 COOLANT HOSE INSPECTION 2 18 RADIATOR INSPECTION CLEANING 2 18 COOLANT FLUSH 2 19 FUEL SYSTEM AND AIR INTAKE 2 20 FUEL TANK VEN...

Page 76: ...USPENSION LUBRICATION 2 32 PRELOAD SETTINGS 2 32 FRONT REAR SPRING PRELOAD ADJUSTMENT 2 34 FRONT REAR SHOCK COMPRESSION ADJUSTMENT NON DYNAMIX 2 35 BRAKE SYSTEM 2 36 BRAKE FLUID INSPECTION 2 36 BRAKE...

Page 77: ...068 1 gal 4 2878069 2 5 gal 2 2878070 Angle Drive Fluid 1 qt 12 2889280 Gas Shock Oil 1 qt 6 2870995 2 5 gal 2 2872279 Antifreeze Coolant 50 50 Extended Life 1 qt 12 2880514 1 gal 6 2880513 55 gal dru...

Page 78: ...operation Exhaust Check fasteners Check spark arrester condition attachment Inspect heat shields Frame Body Fasteners Inspect ensure tightness check none are missing Front Rear Suspension Inspect bush...

Page 79: ...switch Ensure operation POLARIS MAINTENANCE SCHEDULE The intervals shown are based on vehicles operated under normal conditions Each interval is given in hours and miles kilometers Items should be se...

Page 80: ...n as needed The break in period consists of the first 25 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these c...

Page 81: ...place as needed Wiring Inspect for wear routing and retention Front Gearcase Fluid Change fluid Rear Gearcase Fluid Change fluid Transmission Fluid Initial fluid level inspection inspect for fluid lea...

Page 82: ...e Spark Plugs Replace Every 10 000 miles 16 000KM 500 hours Valve Clearance Inspect adjust as needed Have an authorized Polaris dealer or other qualified person perform these services MAINTENANCE QUIC...

Page 83: ...inder reservoir q Check level during pre ride inspection change fluid every two years Front Gearcase ORV Angle Drive Fluid 80W 140 Add lubricant through fill hole w 12 2 oz 360 mL Fill to Spill Initia...

Page 84: ...2 10 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc More often under severe use such as operation in water or under severe loads MAINTENANCE...

Page 85: ...ll traces of water have been purged out at each of these areas ITEM METHOD RECOMMENDED LUBE FREQUENCY Propshaft Yokes Grease fittings q on the slip yoke between transmission rear output shaft and rear...

Page 86: ...peration 4 Remove the dipstick and wipe dry with a clean cloth 5 Reinstall dipstick and ensure it seats completely NOTICE Make certain the dipstick is inserted all the way into the dipstick tube to pr...

Page 87: ...plug q and install Torque to specification TORQUE Oil Drain Plug 13 ft lbs 18 Nm 8 Using oil filter socket PU 52890 turn the oil filter w counter clockwise to remove and discard 9 Lubricate gasket ar...

Page 88: ...testers as crankshaft seals may dislodge and leak Cylinder Leakage Service Limit 15 If leakage exceeds service limit inspect the engine for the cause NOTICE A brand new or rebuilt engine will have hig...

Page 89: ...the screen on the arrestor If necessary blow debris from the screen with compressed air 5 Inspect the screen for wear and damage Replace if damaged 6 Reinstall the spark arrestor Torque fasteners to s...

Page 90: ...GTH Test the strength of the coolant using an antifreeze hydrometer A 50 50 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do...

Page 91: ...50 coolant mixture to the FULL COLD level on the tank Recommended Coolant Polaris 50 50 Extended Life Anti freeze 2880514 quart 2880513 gallon 5 Reinstall the pressure cap NOTICE Use of a non standard...

Page 92: ...gine Outlet Hose t Engine Inlet Hose y Coolant Bottle Hose u Engine Vent Hose 3 Check tightness and condition of all hose spring clamps Replace if necessary RADIATOR INSPECTION CLEANING 1 Check engine...

Page 93: ...engine of coolant Radiator a vacuum hose through each radiator hose port can help to drain the radiator side tanks 5 A wet vac may also be used to evacuate coolant from the system 6 Connect the coolan...

Page 94: ...terioration or damage Replace vent line if necessary NOTICE Most of the exposed fuel tank vent line can be seen through the left rear wheel well 3 Be sure the vent line is routed properly as shown and...

Page 95: ...nspect the pre filter on the outboard q and inboard w sides If necessary clean with soapy water and air dry CAUTION Compressed air or high pressure hose may damage the frog skin pre filter on the inta...

Page 96: ...the filter has been soaked with fuel or oil it must be replaced 6 Inspect the air filter and replace if necessary NOTICE DO NOTattempt to clean the air filter 7 Place air filter into the air box and r...

Page 97: ...el any moisture from the PVTand air dry the belt and clutches CAUTION Do not hold the throttle wide open for more than 10 seconds 7 Allow the engine RPM to settle to idle speed Apply the brakes Shift...

Page 98: ...CHANGE The drain plug is located on the bottom of the front gearcase Access the drain plug through the access hole in the frame underneath the front gearcase 1 Remove the fill plug 2 Place a drain pa...

Page 99: ...the drain plug and torque to specification 6 Add the recommended amount of fluid through the fill hole FLUID CAPACITY Recommended Front Gearcase Fluid 80W 140 Angle Drive Fluid 2889280 quart Capacity...

Page 100: ...g and tire wear TIRE INSPECTION Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires...

Page 101: ...vel 3 If lubricant level is not even with bottom threads add recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification TORQUE Transmission Fill Drain Plug 1...

Page 102: ...n ON to activate EPS system 3 Lightly turn the steering wheel left and right 4 There should be about 0 8 1 0 20 25 mm of free play 5 If there is excessive free play or the steering feels rough inspect...

Page 103: ...R2 FRONT TOE 1 Measure distances F1 and F2 between the chalk marks 2 Subtract measurement F1 from F2 to calculate the front wheel total toe A positive result indicates total toe IN A negative result i...

Page 104: ...ent Hold tie rod end to keep it from rotating Loosen jam nuts at both end of the tie rod Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified M...

Page 105: ...trol arm bushings bearings to make sure they are not broken missing or extremely loose w Check for damage impact to all control arms and or trailing arms and radius rods e Inspect stabilizer bar and s...

Page 106: ...occur if the MAX allowable preload is exceeded RZR PRO R FACTORY DEFAULT PRELOAD SETTINGS GVW SETTING MAX ALLOWABLE PRELOAD Meas ure ment Fox Walk er Evans Fox Walk er Evans Front Shock s q 3 06 in 7...

Page 107: ...2 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 2 33 WALKER EVANS SHOCKS IF EQUIPPED SHOCK LOCATION MEASUREMENT Front Shock Rear Shock MAINTENANCE...

Page 108: ...ed to move the cross over rings an equal amount The cross over rings need to be locked tight after any adjustment is made To lock the cross over rings take a punch and hammer to hit each side so the r...

Page 109: ...N ADJUSTMENT NON DYNAMIX The compression damping clicker knob is located at the top of the shock reservoir 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clock...

Page 110: ...on a level surface 2 Place the transmission in PARK 3 Inspect brake fluid level in the reservoir q The level should be between the MAX and MIN level lines 4 If fluid level is lower than the MIN level...

Page 111: ...ing a micrometer measure disc thickness at eight different points around the pad contact surface MEASUREMENT Brake Disc Thickness 295 008 7 5 2 mm Service Limit 268 6 8 mm Brake Disc Thickness Varianc...

Page 112: ...egetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when cha...

Page 113: ...t cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 8 Measure gap with a wire gauge Adjust gap if necessary by carefully bending the side elect...

Page 114: ...2 40 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES MAINTENANCE...

Page 115: ...W 3 17 COOLING SYSTEM SPECIFICATIONS 3 18 COOLING SYSTEM PRESSURE TEST 3 18 RADIATOR REPLACEMENT 3 19 THERMOSTAT REPLACEMENT 3 22 ENGINE SERVICE 3 24 STRETCH BELT REPLACMENT 3 24 HARMONIC DAMPER CLEAN...

Page 116: ...KSHAFT AND BEARING CLEANING AND INSPECTION 3 67 OIL PUMP DISASSEMBLY 3 68 ENGINE ASSEMBLY BOTTOM END 3 70 OIL PAN CLEANING AND INSPECTION 3 70 OIL PUMP ASSEMBLY 3 70 BEARING SELECTION IDENTIFICATION L...

Page 117: ...SPECIFICATIONS NOTICE Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear AMBIENT TEMPERATURE RANGE RECOMMENDED OIL 35 F to 100 F 37 C to 38 C PS 4...

Page 118: ...Head Valve 4 valves per cyl 2 Intake Valve 2 Exhaust Valve Camshaft Cam Lobe Height Intake 1 6385 1 6448 41 62 41 78 mm 1 6366 41 57 mm Cam Lobe Height Exhaust 1 6307 1 6370 41 42 41 58 mm 1 6287 41...

Page 119: ...ust 0011 0023 0 030 0 060 mm Valve Stem Overall Length Intake 3 7704 95 77 mm Valve Stem Overall Length Exhaust 3 8023 96 58 mm Valve Guide Valve Guide Inner Diameter 1956 2019 4 970 5 130 mm Valve Se...

Page 120: ...g Rod Connecting Rod Small End I D 0 8668 0 8673 22 017 22 030 mm 0 8677 in 22 04 mm Connecting Rod Axial Clearance 0 0039 0 0118 0 100 0 300 mm 1 Marking Conn Rod Big End Bore I D 1 8892 1 8895 47 98...

Page 121: ...before installation 1 Torque all fasteners to 14 ft lbs 20 N m in sequence specified 2 Torque all fasteners to 26 ft lbs 35 N m in sequence specified 3 Angle torque all fasteners in sequence an additi...

Page 122: ...AUST MANIFOLD INTAKE MANIFOLD Exhaust Manifold Fasteners Step 1 60 in lbs 7 Nm Step 2 22 ft lbs 30 Nm Intake Manifold Fasteners 16 ft lbs 22 N m ENGINE BREATHER OIL FILTER ADAPTER Engine Breather Fast...

Page 123: ...steners 1 Tighten fasteners in sequence shown using 3 turn 1080 intervals until fully seated 2 Torque to specification in sequence shown 13 ft lbs 17 N m Oil Transfer Plate Fasteners 53 in lbs 6 N m E...

Page 124: ...Manual Copyright Polaris Industries Inc OIL PAN M8 Fasteners Items 1 16 16 ft lbs 22 N m M10 Fasteners Items 17 19 35 ft lbs 48 N m FRONT COVER M6 Fasteners Items 1 16 80 in lbs 9 N m M8 Fasteners Ite...

Page 125: ...20 N m in sequence specified 2 Torque all fasteners to 26 ft lbs 35 N m in sequence specified 3 Angle torque all fasteners in sequence an additional 90 4 Angle torque all fasteners in sequence an addi...

Page 126: ...GINE INTAKE ASSEMBLY VIEW q Air Box Latch i Inlet Air Box Duct w Intake Clamp 35 in lbs 3 Nm o Lower Intake Bezel e Engine Intake Hose a Lower Intake Bezel Mounting Fastener r Engine Vent Hose s Upper...

Page 127: ...lower mounting tabs and remove air box from vehicle AIR BOX INSTALLATION 1 Install the air box and re engage lower mounting tabs 2 Install the intake hoses onto the air box Tighten hose clamps to spe...

Page 128: ...ler Heat Shield Fastener 71 in lbs 8 Nm o Headpipe e Spark Arrestor a Headpipe to Muffler Fastener 18 ft lbs 25 Nm r Spark Arrestor Fastener 8 ft lbs 11 Nm s Oxygen Sensor 30 ft lbs 40 Nm t Muffler d...

Page 129: ...Disengage muffler from isolator mounts and remove the muffler MUFFLER INSTALLATION 1 Engage muffler into isolator mounts 2 Install a new muffler gasket and install the two fasteners retaining the muff...

Page 130: ...eld and four fasteners onto the exhaust pipe Torque heat shield fasteners to specification TORQUE Headpipe Heat Shield Fasteners 71 in lbs 8 Nm 2 Install exhaust pipe and install nine headpipe fastene...

Page 131: ...3 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 3 17 COOLING SYSTEM COOLING SYSTEM FLOW ENGINE COOLING SYSTEM...

Page 132: ...ue Limit 244 F 118 C Engine Protection Cylinder Deactivation 250 F 121 C Engine Protection Shutdown Overheat Indicator Flashes 255 F 124 C COOLING SYSTEM PRESSURE TEST 1 Remove the coolant bottle cove...

Page 133: ...one push pin r and remove the front fender flare Repeat for opposite side of the vehicle 5 Remove one fastener t three push pins y and remove the front fender Repeat for opposite side of the vehicle...

Page 134: ...radiator shroud as an assembly 15 Remove push pins to separate radiator from fan and shroud assemblies INSTALLATION 1 Install new radiator onto cooling fan and shroud and install assembly mounting pus...

Page 135: ...7 ft lbs 10 Nm 9 Install front fender mounting bracket Torque fasteners to specification TORQUE Front Fender Mounting Bracket Fasteners 7 ft lbs 10 Nm 10 Install front fenders Torque fasteners to spec...

Page 136: ...STAT REPLACEMENT REMOVAL 1 Place a drain pan under the engine below the thermostat housing 2 Remove two fasteners q and remove the thermostat cover 3 Pull the thermostat up to remove it from the housi...

Page 137: ...3 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 3 23 ENGINE COOLING SYSTEM...

Page 138: ...r and balance pulley HARMONIC DAMPER CLEANING AND INSPECTION 1 Clean the harmonic damper 2 Clean the belt grooves of all dirt or debris with a wire brush CAUTION Wear safety glasses in order to avoid...

Page 139: ...rs q and remove the cargo box 6 Drain coolant Disconnect engine coolant inlet and outlet hoses 7 Disconnect fuel line from the fuel rail 8 Loosen hose clamp w and remove the PVT intake hose 9 Remove f...

Page 140: ...lder PU 52920 14 Remove inner clutch cover fasteners i and o and remove the inner clutch cover 15 Remove two O rings a from the transmission 16 Disengage hose clamps s and remove vent hoses from the t...

Page 141: ...t of the box support 22 Remove two rear fasteners k and remove cargo box support 23 Remove two exhaust pipe to muffler fasteners l and remove the muffler 24 Remove four fasteners 1 from the exhaust ma...

Page 142: ...remove shield 28 Disconnect gear position sensor electrical harness 29 Disconnect shift cables 2 30 Remove two fasteners 2 and remove shift cable bracket 31 Remove four fasteners 2 retaining the rear...

Page 143: ...assembly through the top of the vehicle CAUTION Verify that engine lift brackets are tight prior to removing engine from the chassis Use caution when lifting engine to avoid damaging the throttle bod...

Page 144: ...ng an engine hoist 2 Carefully place the engine mounting brackets from the engine on the mounts from the frame 3 Install the engine mount isolator nuts and torque to specification TORQUE Engine Mount...

Page 145: ...engine mount Torque fasteners to specification TORQUE Engine Mount Fasteners Step 1 26 in lbs 3 Nm Step 2 33 ft lbs 45 Nm 3 Attach engine hoist to lift brackets 2 Lower engine and transmission as an...

Page 146: ...ers to specification TORQUE Engine Transmission Mounting Fasteners 33 ft lbs 45 Nm 7 Connect main engine electrical harness 2 8 Install shift cable bracket and two fasteners 2 Torque fasteners to spec...

Page 147: ...Position Sensor Shield Fasteners q q 15 ft lbs 20 Nm w w 22 ft lbs 30 Nm e e 72 in lbs 8 Nm 11 Install exhaust pipe onto engine Install nine fasteners 2 Torque fasteners to specification in the seque...

Page 148: ...14 Install muffler into rubber grommets Install two exhaust pipe to muffler fasteners l Torque fasteners to specification TORQUE Head Pipe to Muffler Fasteners 18 ft lbs 25 Nm 15 Install rear cargo b...

Page 149: ...ts tighten two air box hose clamps g Torque hose clamps to specification TORQUE Intake Duct Hose Clamps 35 in lbs 3 Nm 19 Install rear fascia and rear bumper Install eight fasteners d into the rear fa...

Page 150: ...ave and drive clutch retaining bolt u Torque fastener to specification TORQUE Drive Clutch Retaining Bolt Step 1 140 ft lbs 190 Nm Step 2 Loosen two full turns 720 Step 3 118 ft lbs 160 Nm NOTICE When...

Page 151: ...s 3 Nm 30 Connect fuel line onto the fuel rail 31 Connect coolant inlet and outlet hoses to the engine 32 Fill coolant Refer to coolant fill bleed procedure outlined in this chapter 33 Install cargo b...

Page 152: ...2 Observe the engine mount while raising the engine Raising the engine removes the weight from the engine mount and creates slight tension on the rubber 3 Replace the engine mount if the engine mount...

Page 153: ...to remove IMPORTANT Place a shop rag over the end of the coolant line to catch any fluid that may be in the line For proper coolant line fitting removal Refer to Fuel Line Quick Connection page NOTIC...

Page 154: ...1 Park vehicle on a flat surface 2 Remove the cargo box 3 Remove alternator belt cover 4 Using special tool PU 52810 to hold the harmonic damper remove the harmonic damper fastener t and washer 5 Usi...

Page 155: ...olant bracket w 5 Remove fasteners u i and o and remove the front cover TIMING CHAIN SERVICE REMOVAL NOTICE The Engine must be removed from the chassis to perform this procedure See Engine Removal Pre...

Page 156: ...d Sprocket Installation page 3 90 TENSIONER SERVICE REMOVAL 1 Remove three tensioner cover fasteners w and tensioner cover IMPORTANT The timing chain tensioner must be removed to unload chain tension...

Page 157: ...ure works best when the tensioner piston is dry 3 Reinstall the piston assembly into the body of the tensioner 4 Install the tensioner assembly into the crankcase 5 Install chain tensioner assembly In...

Page 158: ...ylinder 1 TDC on compression stroke and mark the harmonic balancer and front cover with a paint pen for temporary TDC reference NOTICE Slots on the rear of the camshafts should line up horizontally 4...

Page 159: ...ust camshaft CAMSHAFT CLEANING AND INSPECTION Inspect the camshaft journals and lobes for wear or scoring Inspect the camshaft sprocket alignment notch for damage Inspect the camshaft cover for damage...

Page 160: ...fore proceeding with timing chain install 4 Replace the timing chain tensioner shoe if wear exceeds 0 045 in 1 12 mm depth on the chain guide surface 5 Inspect the timing chain w and actuators e i for...

Page 161: ...er method or technique to clean these gasket surfaces Do not use a tap to clean the cylinder head bolt holes IMPORTANT Be careful not to gouge or scratch the gasket surfaces Do not gouge or scrape the...

Page 162: ...nder head bolts IMPORTANT Do not use a wire brush on any gasket sealing surface 2 Clean the cylinder head Remove all varnish soot and carbon to the bare metal 3 Clean the valve guides 4 Clean the thre...

Page 163: ...wel pins d Corrosion in the seal area around the coolant passages e Chips or debris in the cylinder head bolt holes f Bolt holes in the cylinder block not drilled or tapped deep enough IMPORTANT Do no...

Page 164: ...runout w 5 Insert valves into their original locations in cylinder head 6 Inspect that each valve moves up and down smoothly without binding in guide 7 Measure valve stem deflection e for all valves...

Page 165: ...ve face WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly VALVE SEAT INSPECTION Inspect valve seat in cylinder head for pitting burnt spots roughness and une...

Page 166: ...face 5 To check the contact area of the seat on the valve face apply a thin coating of Prussian Blue paste to the valve seat If using an interference angle 46 apply black marker to the entire valve fa...

Page 167: ...h clean engine oil and apply oil or water based lapping compound to the face of the valve NOTICE Lapping is not required if an interference angle reconditioning method is used 10 Insert the valve into...

Page 168: ...an can be removed Remove the oil pan bolts IMPORTANT Use the pry points on the oil pan to release the seal between the crankcase and the oil pan LOWER CRANKCASE REMOVAL 1 Remove the bedplate perimeter...

Page 169: ...orientation as shown TORQUE Reed Valve Fasteners 80 in lbs 9 N m PISTON CONNECTING ROD AND BEARING REMOVAL 1 Rotate the crankshaft to a position where the connecting rod bolts are the most accessible...

Page 170: ...t the crown of the piston slightly with a heat gun if pin cannot be removed by hand Discard circlips CAUTION DO NOTapply heat to piston rings or a loss of radial tension could result 3 Measure piston...

Page 171: ...ite side Do not scratch ring lands 2 Repeat procedure for second compression ring w 3 The oil control ring e is a three piece design consisting of a top and bottom steel rail and a center expander sec...

Page 172: ...uarely into cylinder as shown below 2 Measure installed gap with a feeler gauge e at both the top and bottom of the cylinder NOTICE A difference between top and bottom end gap measurements is a genera...

Page 173: ...rod cap for damage galling of surface or pitting 4 Measure small end I D y in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service...

Page 174: ...47 987 47 994 mm 1 8895 1 8898 47 995 48 001 mm 1 8898 1 8900 48 002 48 008 mm 10 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart provided in...

Page 175: ...ION Do not damage the valve guide Remove any burrs that have formed at the key groove by chamfering the valve stem with an oil stone or a file 7 Using the a commercially available valve seal remover r...

Page 176: ...e from the flywheel fastener holes Use a nylon bristle brush to clean the holes in the crankshaft CRANKSHAFT AND BEARING REMOVAL 1 Remove the crankshaft from the block 2 Remove and discard the cranksh...

Page 177: ...n clean engine oil Burrs may be removed with a fine oil stone 10 Measure the crankshaft journals Use a micrometer or dial indicator to measure the taper and runout Note the result for the later select...

Page 178: ...es with engine oil 7 Inspect the threaded holes Clean the threaded holes with a rifle brush If necessary drill out the holes and install thread inserts NOTICE Do not attempt to machine the lower crank...

Page 179: ...dicator to 0 d Record the readings obtained from all of the bolt hole bosses The measurements should not vary more than 0 008 in 0 203 mm e Recheck the crankshaft flange runout if the readings vary mo...

Page 180: ...may not allow the belt to track properly Minor imperfections may be removed with a fine file Worn chunking or deteriorated rubber between the hub and pulley ENGINE FLYWHEEL CLEANING AND INSPECTION IM...

Page 181: ...falling edges Imperfections of the reluctor ring teeth may effect performance IMPORTANT Clean all patchlock from the crankshaft threads 5 The crankshaft position ring w may be replaced if damaged Use...

Page 182: ...so indicate fatigue 17 Inspect the crankshaft bearings for excessive scoring or discoloration w 18 Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material 19 Inspect the...

Page 183: ...Polaris Industries Inc 3 69 4 Remove the pickup tube oil tube and seals from the oil pump Clean all of the parts in cleaning solvent Remove varnish sludge and dirt 5 Inspect the oil pump components f...

Page 184: ...he oil pan for cracking near the pan rail and the transmission mounting points 5 Repair or replace the oil pan as necessary OIL PUMP ASSEMBLY IMPORTANT Lubricate seals with oil before installation or...

Page 185: ...pickup w and oil pump assembly fasteners e r Torque fasteners to specification in sequence shown TORQUE Oil Pump Pickup Fasteners 80 in lbs 9 N m TORQUE Oil Pump Fasteners 80 in lbs 9 N m 4 Install th...

Page 186: ...NUMBERS q Connecting Rod Bearing Identification Number one number w Crankcase Bearing Identification Number e Crankshaft Bearing Identification Letters nine letters the first five are the main bearin...

Page 187: ...ing for each connecting rod Red bearing for Rod 1 White bearing for Rod 2 Blue bearing for Rod 3 Yellow bearing for Rod 4 BEARING SELECTION CHART ROD Crankshaft Rod Code A B C 1 White Red Red 2 Blue W...

Page 188: ...the crankshaft position sensor O ring with engine oil 3 Install the crankshaft position sensor Torque fastener to specification TORQUE Crankshaft Position Sensor Fastener 80 in lbs 9 N m 4 Install the...

Page 189: ...our fasteners in sequence to specification TORQUE Engine Breather Fasteners 80 in lbs 9 N m 6 Install the piston jets IMPORTANT Lubricate the o rings with engine oil Ensure the piston jets are seated...

Page 190: ...ng rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is recommended they...

Page 191: ...urnals 4 Install the lower bearing halves without grooves into the lower crankcase Apply oil to bearing surfaces 5 If removed install the engine block alignment dowels 6 Install the lower block bearin...

Page 192: ...r a Torque all fasteners to 14 ft lbs 20 N m in sequence specified b Torque all fasteners to 26 ft lbs 35 N m in sequence specified c Angle torque all fasteners in sequence an additional 45 d Angle to...

Page 193: ...the new crankshaft seal into the housing The PU 52884 also establishes the depth of the seal in the crankshaft seal bore CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Install the seal into the front cover...

Page 194: ...he crankshaft and water pump before installing the front cover This helps accommodate the bearing in front cover 2 If required Install Timing Chain Tensioner See Timing Chain Tensioner Installation pa...

Page 195: ...Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris 2 Clean with isopropyl alcohol prior to applying sealant Apply sealant in approximately 3mm wide...

Page 196: ...3 82 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc TORQUE M8 Fasteners items 1 16 16 ft lbs 22 N m M10 Fasteners items 17 19 35 ft lbs 48 N m ENGINE COOLING SYSTEM...

Page 197: ...ent the crankshaft from rotating when tightening the fastener Torque to specification TORQUE Front Harmonic Pulley Fastener a Torque fastener to 74 ft lbs 100 N m b Loosen fastener 180 c Torque fasten...

Page 198: ...of Prussian blue on the entire valve face Seat the valve but do not rotate it The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat b Clean all tr...

Page 199: ...ne oil to all ring surfaces and ring lands upon installation Always check piston ring installed gap before rings are installed on piston Refer to PISTON RING INSTALLATION GAP procedure Clean accumulat...

Page 200: ...4 Install second ring with marking facing top of piston Rotate ring to position the end gap toward intake side of piston as shown below Second Ring Gap Position 5 Install top ring with mark facing to...

Page 201: ...handle Guide the connecting rod to the connecting rod journal while tapping the piston into place g Hold the piston ring compressor PU 52876 against the engine block until all the rings have entered t...

Page 202: ...block Do not use any sealing material 2 Before installation perform Valve Sealing Test See Valve Sealing Test page 3 Install the cylinder head IMPORTANT Cylinder head fasteners can be re used up to 4...

Page 203: ...lure to install the camshafts as directed in the instructions below may result in engine damage IMPORTANT Lubricate the bucket diameters with engine oil and the cam journals and lobes with assembly lu...

Page 204: ...number 1 piston should be at top dead center TDC crankshaft key at 12 o clock The engine is timed top dead center exhaust stroke 2 If removed install the intake and exhaust camshaft sprockets Place t...

Page 205: ...MPORTANT There are 4 colored links on the timing chain Use the following procedure to line up the links with the actuators Orient the chain so that the colors are visible Always use new actuator bolts...

Page 206: ...rks 13 Install the Front Cover See Front Cover Installation page 3 80 14 Install the Valve Cover See Valve Cover Installation page 3 96 15 Install the Alternator See Alternator Installation page VALVE...

Page 207: ...an organized rack as you remove them IMPORTANT If performing this procedure with the cylinder head installed on the engine make sure the crankshaft is rotated 90 degrees from TDC so the valves don t r...

Page 208: ...and confirm that valve clearance is now within specification for each valve 16 If valve clearance is not within specification repeat this procedure 17 If all valve clearance measurements are now with...

Page 209: ...Specification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3...

Page 210: ...ve cover IMPORTANT Apply liquid engine sealant at the T Joint 2 Install the cover on the cylinder head and hand start the fasteners u Using sequence shown torque fasteners to specification TORQUE Valv...

Page 211: ...ing Fasteners 80 in lbs 9 N m 7 Connect the spark plug wire connectors e to the ignition coils 8 Connect the breather hose by securing clip q to the valve cover fitting Connect the coolant vent line f...

Page 212: ...3 98 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES ENGINE COOLING SYSTEM...

Page 213: ...TBAP 4 4 KNOCK SENSOR 4 5 KNOCK SENSOR OVERVIEW 4 5 KNOCK SENSOR TESTING 4 5 KNOCK SENSOR REPLACEMENT 4 5 CRANKSHAFT POSITION SENSOR CPS 4 6 CPS OPERATION OVERVIEW 4 6 CPS TEST 4 6 CPS REPLACEMENT 4 7...

Page 214: ...is operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit is exceeded the...

Page 215: ...ECU connector you should hear a click when the connector is fully closed TORQUE ECU Retaining Fasteners 27 in lbs 3 Nm ETC LEARN PROCEDURE IMPORTANT This procedure MUST be performed on the vehicle wh...

Page 216: ...pproximate resistance reading of the temperature sensor at the given temperature TEMPERATURE RESISTANCE 40 F 40 C 45303 31 F 35 C 34273 22 F 30 C 26108 13 F 25 C 19999 4 F 20 C 15458 5 F 15 C 12000 14...

Page 217: ...fuel Verify there is no internal engine damage Verify the cooling system is working properly KNOCK SENSOR TESTING 1 Disconnect the harness going to the knock sensor 2 Set multimeter to ohms Check res...

Page 218: ...ns each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS TEST The CPS is a sea...

Page 219: ...CPS REPLACEMENT 1 Disconnect CPS electrical harness 2 Remove fastener q retaining sensor to the engine 3 Install new sensor using a light coating of oil on the O ring to aid installation 4 Install fa...

Page 220: ...ttempt to disassemble the ETC assembly Warranty is void if the end cover is opened or tampered with in any way All operating and control functions within the ETC are pre set No internal servicing or a...

Page 221: ...specification TORQUE ETC Housing Fasteners 7 ft lbs 10 Nm Intake Duct Clamp 35 in lbs 3 Nm Body Fasteners 7 ft lbs 10 Nm ETC LEARN PROCEDURE IMPORTANT This procedure MUST be performed on the vehicle w...

Page 222: ...used to control engine speed during vehicle operation PPS TEST The PPS can be tested utilizing Digital Wrench by verifying that throttle position readout varies as the pedal is pressed There should n...

Page 223: ...al 3 Remove the three fasteners q retaining the throttle pedal assembly to the frame 4 Remove pedal assembly 5 Reverse procedure for installation Torque fasteners to specification TORQUE PPS Mounting...

Page 224: ...18 6 Ohms NOTICE This test MUST be performed with the sensor at room temperature First verify if there are any stored codes for the oxygen sensor NOTICE The ECU must first run though the O2 sensor ti...

Page 225: ...OXYGEN SENSOR REPLACEMENT 1 Disconnect the harness going to the oxygen sensor 2 Remove the oxygen sensor from the exhaust pipe 3 Install new oxygen sensor Torque sensor to specification TORQUE Oxygen...

Page 226: ...4 14 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES ENGINE ELECTRICAL...

Page 227: ...INJECTOR O RINGS 5 6 FUEL INJECTOR TROUBLESHOOTING 5 7 FUEL INJECTOR TEST 5 7 FUEL INJECTOR REPLACEMENT 5 8 FUEL LINES 5 10 FUEL SYSTEM ASSEMBLY VIEW 5 10 FUEL SYSTEM ASSEMBLY VIEW EVAP 5 11 FUEL LINE...

Page 228: ...RO R 4 Service Manual Copyright Polaris Industries Inc GENERAL INFORMATION SPECIAL TOOLS PART NUMBER DESCRIPTION PU 43506 A Fuel Pressure Gauge Kit PU 50326 Fuel Pump Service Tool PA 48838 Fuel Pressu...

Page 229: ...g the length of time that the injectors are on This range can vary depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 strok...

Page 230: ...they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering th...

Page 231: ...uel cycle the key switch from OFF to ON two times waiting approximately 5 seconds at each ON cycle to allow the fuel pump to cycle and shut down Attempt to start the vehicle normally If the vehicle do...

Page 232: ...jected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length depending on the spee...

Page 233: ...but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the leakage can cause hot restart problems and...

Page 234: ...ne intake 8 Remove the fuel rail and fuel injectors from the engine intake NOTICE Both ends of the injector are sealed with o rings If the injectors are going to be reused ensure the o rings are not d...

Page 235: ...g around the connector in case of fuel leakage IMPORTANT Connection should NOTcome apart during push pull test 17 Reconnect the negative battery cable TORQUE Battery Terminal Fasteners 60 in lbs 7 Nm...

Page 236: ...ervice Manual Copyright Polaris Industries Inc FUEL LINES FUEL SYSTEM ASSEMBLY VIEW q Fuel Supply Line t Fuel Pump Assembly w Fuel Vent Line y Fuel Tank Strap e Fuel Cap u Fuel Tank Strap Fasteners 15...

Page 237: ...Fuel Tank Strap Fasteners 15 ft lbs 20 Nm w Fuel Purge Line a Fuel Pump e Purge Solenoid s Carbon Canister r Purge Solenoid Mounting Rivet d Carbon Canister Rivet t Fuel Tank to Canister Line f Carbo...

Page 238: ...Release the fuel line from the applicable retaining clips See image table above 4 Remove the fuel line from the vehicle 5 To install the line verify the connections are clean and free of debris 6 Plac...

Page 239: ...sure the vent line is routed properly and secured with cable tie s Check the fuel tank vent line for signs of wear deterioration or damage Replace vent line if necessary Symptoms of a restricted fuel...

Page 240: ...Service Manual Copyright Polaris Industries Inc 1 Route fuel vent line up the passenger side rear shock mounting tube and secure with two zip ties w 2 Secure vent line into the shock support tube with...

Page 241: ...Fitting NOTICE Be sure the vent line is routed properly and secured with cable tie s Check the fuel tank vent line for signs of wear deterioration or damage Replace vent line if necessary Symptoms of...

Page 242: ...ter filter y 4 Attach vent line to the canister filter with a hose clamp e and attach to the frame using a zip tie 5 Route vent line back along the left shock support tube and attach to the fitting in...

Page 243: ...R PRO R 4 Service Manual Copyright Polaris Industries Inc 5 17 NOTICE If the vent line fitting is removed from the frame it must be replaced The ears on the clip arrows will not hold properly once it...

Page 244: ...R PRO R 4 Service Manual Copyright Polaris Industries Inc FUEL TANK PUMP FUEL TANK ASSEMBLY VIEW q PFA Nut 70 ft lbs 95 Nm t Fuel Level Float w PFA Gasket y Fuel Pickup e Supply Line u Fuel Tank Vent...

Page 245: ...tery located under the driver s seat 4 Remove the lower floor panels See Console and Lower Floor Removal page 11 25 5 Disconnect the fuel pump electrical harness 6 While holding a shop towel over the...

Page 246: ...fety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications 1 Remove rear seats 2 Remove upper and lower rear close off panels 3 D...

Page 247: ...E Battery Cable Fasteners 60 in lbs 7 Nm FUEL PUMP OPERATION OVERVIEW When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off...

Page 248: ...rved the ignition switch ECU fuel pump and pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure Fuel Pressure key o...

Page 249: ...d be flushed and cleaned out prior to installation of new fuel pump assembly NOTICE It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel Do not use...

Page 250: ...EMPTY position 450 5 w FULL position 100 3 e Measure between the two pins 3 Allow the sender float to sit in the EMPTY position and compare to specification 4 Slowly move the sender float to the FULL...

Page 251: ...W 6 8 CLUTCH DISASSEMBLY 6 10 BEARING INSPECTION 6 10 BUTTON TO TOWER CLEARANCE INSPECTION 6 11 SPIDER REMOVAL 6 11 ROLLER PIN AND THRUST WASHER INSPECTION 6 11 ROLLER REPLACEMENT 6 12 SHIFT WEIGHT IN...

Page 252: ...Service Solutions 1 800 345 2233 or http polaris service solutions com 2022 RZR PRO R CLUTCH CHART MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 2022 RZR PRO R 0 1800 Meters 0 6000 Feet W 38...

Page 253: ...d and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in...

Page 254: ...emove the drive belt BELT INSPECTION 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move a...

Page 255: ...tool from the driven clutch 4 Rotate spin the driven clutch and belt approximately 5 7 times to properly seat the belt in the driven clutch 5 Install outer clutch cover Install five fastenerse and en...

Page 256: ...rtment Standard Break In Drive at slower speeds for the first 50 miles 80 km of operation Carry only light loads Avoid aggressive acceleration high speed operation and prolonged operation at a specifi...

Page 257: ...4 Loosen hose clamp w and remove the PVT intake hose 5 Remove five fasteners e disengage remaining 1 4 turn latches and remove the outer PVTcover 6 Remove the drive belt 7 Remove drive clutch retainin...

Page 258: ...l turns 720 Step 3 118 ft lbs 160 Nm w Drive Clutch Cover Bolts 15 ft lbs 21 Nm e Drive Clutch Cover r Outer Clutch Post t Spring y Belleville Washer Dome side facing outer post u Washer i Spider o Sh...

Page 259: ...6 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 6 9 REF DESCRIPTION TORQUE 2 Roller 2 Wear Plate Nuts 27 in lbs 3 Nm 2 Wear Plate PVT SYSTEM...

Page 260: ...ssembly 2 Remove cover bolts q evenly in a cross pattern and remove cover plate w 3 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or dam...

Page 261: ...entire clutch if worn damaged or cracked SPIDER REMOVAL 1 Remove the spider assembly If the spider cannot be removed by hand use a conventional 3 jaw puller as shown to remove the spider from the clut...

Page 262: ...th operation of the roller SHIFT WEIGHT INSPECTION Remove shift weight fasteners q and weights w Inspect the contact surface of the weight w The surface should be smooth and free of dents or gall mark...

Page 263: ...earing u and washers y Refer to Bushing Service page 6 15 3 Inspect the moveable clutch sheave i for damage or wear 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diamete...

Page 264: ...pring Height 7045118 2 44 61 98 mm DRIVE CLUTCH BUSHINGS INSPECTION 1 Inspect the Teflon coating on the Moveable Sheave bushing Drive Clutch Cover Bushing and the One way Bearing Bushing Inspect for s...

Page 265: ...f bushing until tiny smoke tailings appear 8 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 9 Remove nut from puller rod and set aside 10 Pull bushing removal to...

Page 266: ...oved and cover comes free 6 Remove nut from puller rod and set aside 7 Remove bushing and bushing removal tool from puller Discard bushing COVER BUSHING INSTALLATION 1 Apply Loctite 620 evenly to bush...

Page 267: ...marks that were made earlier are aligned during each phase of assembly 1 Install two washers q needle bearing w and clutch spacer e onto the stationary sheave in the order shown 2 Install clutch spide...

Page 268: ...aining bolt u Torque fastener to specification TORQUE Drive Clutch Retaining Bolt Step 1 140 ft lbs 190 Nm Step 2 Loosen two full turns 720 Step 3 118 ft lbs 160 Nm NOTICE When drive clutch is fully i...

Page 269: ...is Industries Inc 6 19 5 Install clutch intake hose Tighten hose clamp w Torque hose clamp to specification TORQUE PVT Intake Hose Clamp 35 in lbs 3 Nm 6 Install upper and lower rear close off panels...

Page 270: ...el surface 2 Remove seats On 4 seat models remove the rear seats 3 Remove upper and lower rear close off panels 4 Loosen hose clamp w and remove the PVT intake hose 5 Remove five fasteners e disengage...

Page 271: ...ven Clutch Bolt 26 ft lbs 35 Nm s Snap Ring w Washer d Helix e Shim 0 8 f Spring r Bushing g Spring Cup t Driven Post h Snap Ring y Roller j Bearing u Spring Pin k Moveable Sheave i Roller Pin l Helix...

Page 272: ...the compressor down until it just starts to contact the helix cover Remove the three fasteners q that secure the cam helix assembly using a T50 Torx driver Remove the universal clutch compressor and...

Page 273: ...e Pad if needed Replace if needed Helix Bushing Inspection Replace the Helix bushing if more brass than Teflon is visible on the bushing Refer to Bushing Service page 6 23 procedure DRIVEN CLUTCH SPRI...

Page 274: ...ease pressure after bushing bottoms out or damage may result to bushing 5 Remove nut and spacer adapter from puller rod Re move Helix and bushing adapter from puller rod DRIVEN CLUTCH ASSEMBLY 1 Re in...

Page 275: ...Install the stationary and movable sheave on the vehicle See Driven Clutch Installation DRIVEN CLUTCH INSTALLATION 1 Install driven clutch bolt r spacer t and washer y Torque fastener to specification...

Page 276: ...le 2 Rotate the driven clutch clockwise several times before inspection 3 Inspect where the belt is riding on the drive clutch NOTICE A mobile device can be used to capture a picture of the belt track...

Page 277: ...rive clutch taper and engine taper are clean and free of debris 9 Reinstall the drive clutch and bolt Torque the drive clutch bolt to specification TORQUE Drive Clutch Retaining Bolt Step 1 140 ft lbs...

Page 278: ...6 28 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES PVT SYSTEM...

Page 279: ...SPECIAL TOOLS 7 2 SHIFT LEVER CABLE 7 3 SHIFT LEVER REMOVAL 7 3 SHIFT LEVER INSTALLATION 7 3 SHIFT CABLE INSPECTION 7 3 SHIFT CABLE ADJUSTMENT 7 4 TRANSMISSION SERVICE 7 5 TRANSMISSION REMOVAL 7 5 TR...

Page 280: ...ris Industries Inc GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PU 51862 Snorkel Tube Tool PU 52919 Drive Clutch Puller PU 52920 Drive Clutch Holder Bosch Automotive Service Solution...

Page 281: ...retaining ring t and slide the shift lever y off the mounting bracket and out from the frame 5 Remove both bushings u from the shift lever and service as needed SHIFT LEVER INSTALLATION Perform the r...

Page 282: ...and nuts are fully seated against the bracket 6 Thread top adjustment nut down until fully seated on the bracket then loosen the nut by one full rotation 7 While counter holding each top nut torque bo...

Page 283: ...move four fasteners q and remove the cargo box 6 Drain coolant Disconnect engine coolant inlet and outlet hoses 7 Disconnect fuel line from the fuel rail 8 Loosen hose clamp w and remove the PVT intak...

Page 284: ...h Holder PU 52920 14 Remove inner clutch cover fasteners i and o and remove the inner clutch cover 15 Remove two O rings a from the transmission 16 Disengage hose clamps s and remove vent hoses from t...

Page 285: ...front of the box support 22 Remove two rear fasteners k and remove cargo box support 23 Remove two exhaust pipe to muffler fasteners l and remove the muffler 24 Remove four fasteners 1 from the exhaus...

Page 286: ...and remove shield 28 Disconnect gear position sensor electrical harness 29 Disconnect shift cables 2 30 Remove two fasteners 2 and remove shift cable bracket 31 Remove four fasteners 2 retaining the...

Page 287: ...s an assembly through the top of the vehicle CAUTION Verify that engine lift brackets are tight prior to removing engine from the chassis Use caution when lifting engine to avoid damaging the throttle...

Page 288: ...nto the engine mount Torque fasteners to specification TORQUE Engine Mount Fasteners Step 1 26 in lbs 3 Nm Step 2 33 ft lbs 45 Nm 3 Attach engine hoist to lift brackets 2 Lower engine and transmission...

Page 289: ...asteners to specification TORQUE Engine Transmission Mounting Fasteners 33 ft lbs 45 Nm 7 Connect main engine electrical harness 2 8 Install shift cable bracket and two fasteners 2 Torque fasteners to...

Page 290: ...Gear Position Sensor Shield Fasteners q q 15 ft lbs 20 Nm w w 22 ft lbs 30 Nm e e 72 in lbs 8 Nm 11 Install exhaust pipe onto engine Install nine fasteners 2 Torque fasteners to specification in the s...

Page 291: ...8 Nm 14 Install muffler into rubber grommets Install two exhaust pipe to muffler fasteners l Torque fasteners to specification TORQUE Head Pipe to Muffler Fasteners 18 ft lbs 25 Nm 15 Install rear ca...

Page 292: ...ducts tighten two air box hose clamps g Torque hose clamps to specification TORQUE Intake Duct Hose Clamps 35 in lbs 3 Nm 19 Install rear fascia and rear bumper Install eight fasteners d into the rear...

Page 293: ...e sheave and drive clutch retaining bolt u Torque fastener to specification TORQUE Drive Clutch Retaining Bolt Step 1 140 ft lbs 190 Nm Step 2 Loosen two full turns 720 Step 3 118 ft lbs 160 Nm NOTICE...

Page 294: ...lbs 3 Nm 30 Connect fuel line onto the fuel rail 31 Connect coolant inlet and outlet hoses to the engine 32 Fill coolant Refer to coolant fill bleed procedure outlined in this chapter 33 Install carg...

Page 295: ...e clip w 3 Both lines join at a tee fitting e above the transmission 4 The vent line terminates into a fitting r on the rear sway bar mounting tube below the air box TRANSMISSION DISASSEMBLY 1 Drain t...

Page 296: ...r and the shift shaft NOTICE External shift mechanism can be serviced in the vehicle without removal of the engine transmission 8 Remove the two sector gears NOTICE Note the timing marks on the shift...

Page 297: ...shaft y 12 Remove three idler gears u as an assembly 13 Remove front output shaft i from gear housing 14 Remove output shaft gear o 15 Inspect all of the gears shafts and bearings for excessive wear...

Page 298: ...ransmission case leaks 2 Install output shaft gear o 3 Install front output shaft i into gear housing 4 Install three idler gears u as an assembly 5 Install transmission input shaft y 6 Install the sh...

Page 299: ...s r into rear transmission cover Torque fasteners to specification TORQUE Sector Gear Cover Fasteners 11 Install transmission position sensor e 12 Install shift linkage plate and one fastener w Torque...

Page 300: ...RO R PRO R 4 Service Manual Copyright Polaris Industries Inc 15 Install transmission cover onto the transmission and install sixteen fasteners q Torque fasteners to specification TORQUE Transmission C...

Page 301: ...SHAFT REMOVAL 8 9 REAR HALF SHAFT INSTALLATION 8 10 HALF SHAFT CV JOINT HANDLING TIPS 8 11 CV JOINT BOOT REPLACEMENT 8 12 PROP SHAFT 8 14 PROP SHAFT ASSEMBLY VIEW 8 14 PROP SHAFT ASSEMBLY VIEW 4 SEAT...

Page 302: ...orted during service procedures to reduce risk of injury component damage etc When shocks are disconnected the suspension must be supported and not allowed to hang from components to prevent damage to...

Page 303: ...checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts and remove the front wheel 4 Remove the front wheel hub axle nut q and discard 5 Remove the fas...

Page 304: ...race 13 Replace hub assembly if moisture dirt corrosion or roughness is evident The bearing should also be inspected for any scratches wear or damage Replace hub assembly if it is damaged FRONT BEARI...

Page 305: ...eel Nuts 148 ft lbs 200 Nm 10 Rotate wheel and check for smooth operation REAR BEARING CARRIER INSPECTION REMOVAL 1 Elevate rear of vehicle and safely support machine under the frame area WARNING Seri...

Page 306: ...gs should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 9 Replace hub assembly if moisture dirt corrosion or roughness is...

Page 307: ...al Copyright Polaris Industries Inc 8 7 4 Install NEW wheel axle nut Torque nut to specification TORQUE Wheel Axle Nut 89 ft lbs 120 Nm 5 Install wheel and five wheel nuts Torque nuts to specification...

Page 308: ...liper mounting bolts and remove the caliper from the brake disc CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the front wheel...

Page 309: ...o specification TORQUE Wheel Axle Nut 89 ft lbs 120 Nm 7 Install the steering tie rod end onto the front steering knuckle 8 Torque the tie rod end fastener to specification TORQUE Tie Rod End Fastener...

Page 310: ...TALLATION 1 Apply anti seize to inboard splines and install half shaft into rear gearcase 2 Install drive shaft through the backside of the bearing carrier 3 Install upper and lower radius rods Torque...

Page 311: ...nnecting shaft to avoid disassembly or potential damage to the half shaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and sp...

Page 312: ...kely to be damaged from striking the cage race to separate the CV joint from the shaft It is recommended to replace the entire half shaft assembly if there is damage to the outer joint 5 Remove the in...

Page 313: ...fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot i...

Page 314: ...14 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc PROP SHAFT PROP SHAFT ASSEMBLY VIEW q Front Prop Shaft e Slip Yoke w Rear Prop Shaft r Cross and Bearing FINAL DRI...

Page 315: ...4 SEAT q Front Prop Shaft t Support Bearing Fasteners 33 ft lbs 45 Nm w Intermediate Prop Shaft y Slip Yoke e Rear Prop Shaft u Cross and Bearing r Support Bearing REAR PROP SHAFT REPLACEMENT REMOVAL...

Page 316: ...U joint 5 Pull prop shaft rearward to disengage slip yoke from transmission output shaft INSTALLATION 1 Install prop shaft onto transmission output shaft Grease front yoke transmission output shaft u...

Page 317: ...haft See Front Prop Shaft Replacement outlined in this chapter 2 Remove front middle and rear skid plates 3 Remove four fasteners q retaining intermediate prop shaft and bearing to the frame 4 Remove...

Page 318: ...rmediate output shaft NOTICE The slip yoke on 4 seat vehicles has a skip tooth Align skip tooth with the intermediate shaft to install 7 Install front gearcase through the opening in front of the fram...

Page 319: ...m Torque bolt side TORQUE Sway Bar Link Fasteners 81 ft lbs 110 Nm 16 Install brake disc and caliper assembly Torque brake caliper fasteners to specification TORQUE Front Caliper Mounting Bolts 73 ft...

Page 320: ...RQUE Front Fascia Fasteners 7 ft lbs 10 Nm FRONT PROP SHAFT REPLACEMENT REMOVAL 1 Place vehicle on a suitable lift or jack and remove front wheel 2 Remove four front fascia fasteners q and remove fron...

Page 321: ...and sway bar link out of the way CAUTION Front suspension must be supported with a strap or jack before the shock is removed and must not be allowed to hang unsupported at full droop If hung unsuppor...

Page 322: ...t prop shaft slip yoke to the transmission output shaft On 4 seat vehicles connect slip yoke to intermediate output shaft NOTICE The slip yoke on 4 seat vehicles has a skip tooth Align skip tooth with...

Page 323: ...Torque fasteners to specification TORQUE Front Bumper Fasteners 37 ft lbs 50 Nm 10 Install half shafts into front gearcase 11 Install lower shock and sway bar link onto lower contol arms Torque fasten...

Page 324: ...arm mounting fasteners Torque fasteners to specification TORQUE Control Arm Mounting Fasteners 133 ft lbs 180 Nm Torque bolt side 16 Install ball joint pinch bolt washer nut Torque fastener to specifi...

Page 325: ...bearing is removed cross bearing must be replaced Note orientation of grease fitting if equipped and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as s...

Page 326: ...ain bearing cap just installed Repeat procedure for other side 4 Install outer yoke aligning marks made before disassembly 5 Repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing c...

Page 327: ...Seal a Spring 3 Pinion Gear s Engagement Dog 3 Bearing d Ring Gear 3 Bearing f Ring Gear Fasteners 3 Pinion Bearing Nut g Bearing 3 Lock Nut h Shim 3 Pinion Housing Fasteners j Output Gear 3 Triple Li...

Page 328: ...p the LH shock support tube It is then retained with two hinge clips q The vent line continues upward and terminates into and open section of the frame using a termination fitting w FRONT GEARCASE REP...

Page 329: ...f vehicle Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent...

Page 330: ...shaft 13 Disconnect two front gearcase electrical harnesses 14 Disconnect vent line and remove gearcase through the opening in front of the frame INSTALLATION 1 Install front gearcase through the ope...

Page 331: ...fasteners to specification TORQUE Lower Shock Fasteners 133 ft lbs 180 Nm Torque bolt side TORQUE Sway Bar Link Fasteners 81 ft lbs 110 Nm 9 Install brake disc and caliper assembly Torque brake calipe...

Page 332: ...to specification TORQUE Front Bumper Fasteners 37 ft lbs 50 Nm 15 Install ball joint pinch bolt washer nut Torque fastener to specification TORQUE Upper Ball Joint Pinch Bolt 52 ft lbs 70 Nm Torque bo...

Page 333: ...remove the shift arm t engagement dog r and shim e from the cover plate NOTICE If replacement of the shift arm engagement dog and shim is not required do not remove Inspect sealing o ring on the cover...

Page 334: ...gear assembly Torque fasteners to specification TORQUE Ring Gear Assembly Fasteners 14 ft lbs 19 Nm 40 5 If replaced Install shim engagement dog and shift arm onto cover plate Torque fasteners to spe...

Page 335: ...t Polaris Industries Inc 8 35 WHEEL HUBS FRONT HUB ASSEMBLY VIEW q Wheel Cap y Hub Assembly w Wheel Lug Nuts 148 ft lbs 200 Nm u Steering Knuckle e Valve Stem i Washers r Axle Nut 89 ft lbs 120 Nm o H...

Page 336: ...anual Copyright Polaris Industries Inc REAR HUB ASSEMBLY VIEW q Wheel Cap y Hub Assembly w Wheel Lug Nuts 148 ft lbs 200 Nm u Knuckle e Valve Stem i Washers r Axle Nut 89 ft lbs 120 Nm o Hub Mounting...

Page 337: ...to evenly distribute the weight of the tire and wheel assembly Balancing tires eliminates minimizes steering vibrations prevents excessive wear on suspension components and increases a tire s lifespa...

Page 338: ...8 38 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES FINAL DRIVE...

Page 339: ...9 19 BALL JOINT REPLACEMENT 9 20 REAR SUSPENSION 9 22 REAR SUSPENSION ASSEMBLY VIEW 9 22 TRAILING ARM REPLACEMENT 9 23 TRAILING ARM SPHERICAL BEARING REPLACEMENT 9 25 RADIUS ROD REPLACEMENT 9 26 REAR...

Page 340: ...CK ASSEMBLY 9 56 DYNAMIX ACTIVE SUSPENSION 9 61 DYNAMIX SHOCKS DISASSEMBLY ASSEMBLY 9 61 OVERVIEW 9 61 DEMONSTRATION MODE 9 61 SUSPENSION CONTROL MODULE SCM 9 61 DYNAMIX DV SYSTEM FEATURES 9 61 EPS RE...

Page 341: ...r Wrench 2 5 3 0 Inner Internal Bypass PART NUMBER TOOL DESCRIPTION PU 51830 FOX Spanner Wrench 2 5 Outer Internal Bypass PU 51832 FOX Spanner Wrench 3 0 Outer Internal Bypass PU 51838 FOX Shock Body...

Page 342: ...Plate Inner Fasteners 44 ft lbs 60 Nm e Steering Column Cover i Steering Shaft Bearing Fasteners 22 ft lbs 30 Nm f Tie Rod Jam Nut 89 ft lbs 120 Nm r Steering Column Cover Fasteners 27 in lbs 3 Nm o U...

Page 343: ...in the Body Frame chapter 6 Remove two fasteners r from the tilt bracket assembly and remove tilt bracket and pivot tube as an assembly INSTALLATION 1 Reverse removal procedure for installation TORQUE...

Page 344: ...emove the steering coil assembly Disconnect electrical harness 5 Remove dash See Dash Removal in the Body Frame chapter 6 Remove two fasteners r from the tilt bracket assembly and remove tilt bracket...

Page 345: ...Pinch Bolt 22 ft lbs 30 Nm EPS UNIT STEERING RACK REPLACEMENT REMOVAL 1 Remove upper and lower steering shaft Refer to lower steering shaft removal outlined in this chapter 2 Remove four front fascia...

Page 346: ...suspension must be supported with a strap or jack before the shock is removed and must not be allowed to hang unsupported at full droop If hung unsupported the weight of the suspension will be applied...

Page 347: ...rame Connect vent line 3 Install half shaft onto front gearcase input shaft 4 Install two front gearcase isolator fasteners Torque fasteners to specification TORQUE Front Gearcase Torque Sequence a In...

Page 348: ...ssembly Torque brake caliper fasteners to specification TORQUE Front Caliper Mounting Bolts 73 ft lbs 100 Nm 11 Apply Anti Seize to half shaft axle splines 12 Install front knuckle assembly and axle n...

Page 349: ...t fascia mounting fasteners TORQUE Front Fascia Fasteners 7 ft lbs 10 Nm 17 Install upper and lower steering shafts Refer to lower steering shaft replacement outlined in this chapter TORQUE Tilt Brack...

Page 350: ...ition key ON 1 Connect vehicle to Digital Wrench and select Special Tests menu 2 Select option 5 from Special Tests menu 3 Select option 1 at the next menu 4 Follow instructions in Digital Wrench to p...

Page 351: ...9 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 9 13 STEERING SUSPENSION...

Page 352: ...rs 133 ft lbs 180 Nm Torque bolt side o Sway Bar e Knuckle a Sway Bar Arm r Upper Ball Joint Pinch Bolt 52 ft lbs 70 Nm Torque bolt side s Sway Bar Fasteners 81 ft lbs 110 Nm t Lower Control Arm d Swa...

Page 353: ...ANT The access panel must be removed from the driver s side footwell to remove rear upper control arm fastener To remove the rear upper control arm fastener from the passenger side turn the steering w...

Page 354: ...nut Torque fastener to specification TORQUE Upper Ball Joint Pinch Bolt 52 ft lbs 70 Nm Torque bolt side 4 Align brake line mounts onto holes in the control arm Install four new rivets retaining brak...

Page 355: ...vehicle tie down point on the chassis 5 Remove lower shock fastener q and lower stabilizer bar link fastener w 6 Remove and discard ball joint nut e Remove two control arm mounting fasteners r 7 Remov...

Page 356: ...00 Nm FRONT STABILIZER BAR REPLACEMENT REMOVAL 1 Remove one fastener q retaining stabilizer bar link to the arm Repeat on opposite side of vehicle 2 Mark orientation of stabilizer bar arm onto the sta...

Page 357: ...fastener to specification Repeat on opposite side of vehicle TORQUE Stabilizer Arm to Bar Fasteners 81 ft lbs 110 Nm 4 Install one fastener retaining arm to stabilizer bar link Torque fastener to spec...

Page 358: ...he ball joint and place the control arm in a press 3 Carefully press the ball joint out of the control arm and discard the ball joint INSTALLATION 1 By hand install the NEW ball joint into the control...

Page 359: ...ing Ring Installed End Gap No greater than 5 mm 6 If the installed end gap of the retaining ring exceeds 5 mm remove retaining ring inspect and clean groove as necessary Install a NEW retaining ring a...

Page 360: ...u Stabilizer Bar d Trailing Arm Fastener 133 ft lbs 180 Nm Torque bolt side e Radius Rod i Stabilizer Bar Mounting Fastener 52 ft lbs 70 Nm f Toe Link r Radius Rod Fastener Inner Radius Rod Fasteners...

Page 361: ...q 4 Remove the radius rod mounting bolts w nuts and washers from the bearing carrier Swing radius rods down 5 Remove the two brake caliper mounting bolts u CAUTION Do not hang the caliper by the brake...

Page 362: ...the lower shock bolt u 14 Remove two fasteners i from toe link access panel 15 Remove the front trailing arm fastener o and toe link fastener a 16 Remove rear toe link fastener 17 Remove trailing arm...

Page 363: ...fer to Steering Alignment procedure outlined in this chapter to properly set rear wheel toe and thrust angle 4 After rear trailing arm installation test vehicle at low speeds before putting into servi...

Page 364: ...t and washer attaching the upper and lower radius rod to the bearing carrier Discard the nuts 5 Remove bolts w attaching radius rods to the vehicle frame Discard the nuts 6 Remove radius rods from veh...

Page 365: ...Carefully remove the stabilizer from the LH wheel well area of the vehicle 8 Inspect the stabilizer bar for straightness Inspect the pivot bushings and replace if needed INSTALLATION 1 Carefully inst...

Page 366: ...nder Spring y Spring Retainer Retainer gap should be 180 degrees from spring end SHOCK REPLACEMENT 1 Elevate the vehicle off the ground to relieve the suspension load 2 Support under A arm or trailing...

Page 367: ...k and note the spring preload distance see Spring Adjustment page 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spr...

Page 368: ...nc FOX 3 0 DV SHOCK INFORMATION FRONT SHOCK SPECIFICATIONS RZR XP TURBO S Shock Travel q 11 80 29 97 cm Extended Length w 35 47 90 09 cm IFP Depth e 7 30 18 54 cm Spring Adjustment Setting r 2 20 5 58...

Page 369: ...9 31 FOX 3 0 DV SHOCK INFORMATION REAR SHOCK SPECIFICATIONS RZR PRO R Shock Travel q 15 59 39 59 cm Extended Length w 42 24 107 28 cm IFP Depth e 9 70 24 64 cm Spring Adjustment Setting r 6 63 16 84...

Page 370: ...Screw 2 Reservoir t Reservoir Decal 2 Shaft y Band Decal 2 Spring Adjuster Ring u O ring 2 Spring Adjuster Ring Backup i O ring 2 Screw Assembly o O ring 2 Piston Assembly a O ring 2 Internal Bypass B...

Page 371: ...n down Body Cap on Reservoir Place reservoir in Body Clamps 803 00 XXXX in a Vise Use Body Cap Socket 398 00 XXX to torque the body cap with a torque wrench to 24 ft lb of torque Torque T 30 ft lb of...

Page 372: ...ere may be two or more seals in the rebuild kit that look similar In this manual we will completely disassemble the entire shock Many shock services may not require complete disassembly of some compon...

Page 373: ...ed to apply a sufficient amount of heat to the bearing assembly to break the Loctite bond between the cinch ring and the bearing assembly NOTICE The seal will be destroyed from the heat and must be re...

Page 374: ...ssed in reducers use a tapered pin punch and hammer Drive pin punch into reducer with a couple of medium taps with the hammer Tap the pin punch out and remove the reducer from the tapered pin punch 19...

Page 375: ...to remove any Loctite residue left on body cap threads Clean thoroughly with contact cleaner and lint free towel inside and out 26 Remove lock nut from the shaft assembly 27 Remove rebound valve stack...

Page 376: ...yelet with the correct body cap socket 33 Use a wire brush heat and a pick to remove any Loctite residue left in the eyelet and shaft threads Clean thoroughly with contact cleaner and lint free towel...

Page 377: ...64 hex wrench NOTICE Observe location size and thickness of bypass valves 38 To remove the remote hose assembly de pressurize reservoir push hose in and remove retaining ring with a small pick 39 Rem...

Page 378: ...40 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 2 5 Bypass Piston Compression Side Rebound Side 3 0 Bypass Piston Compression Side Rebound Side STEERING SUSPENSIO...

Page 379: ...ng clamp blocks to secure reservoir in vise torque body cap to specification using the offset formula See Offset Torque Formula page 9 33 TORQUE Body Cap step 1 30 ft lb 42 Nm 3 With body prepared wit...

Page 380: ...up 2 threads wide 360 14 Torque eyelet to specification with shaft secured in clamp blocks TORQUE Shock Eyelet 50 ft lb 68 Nm 15 Install 398 00 095 B Bullet tool on shaft to install bumper 16 Install...

Page 381: ...l Bypass check valves 30 Use Loctite 242 Blue on bypass screws Torque bypass screws to specification TORQUE Bypass Screw 14 in lb 2 Nm 31 Install assembled internal body Ensure that body is seated pro...

Page 382: ...Bearing Assembly 35 ft lb 47 Nm 42 On 2 5 Bypass shocks with Aluminum body apply 290 wicking Loctite to bearing assembly threads 3 0 Bypass shocks with steel outer bodies do not require 290 Loctite on...

Page 383: ...nd lubricate with Slick Honey 47 Install retaining ring ensure that it is fully seated in ring gland 48 Fill reservoir with specified nitrogen pressure 49 Stroke shock absorber and inspect shock for l...

Page 384: ...Spacer 1 235 x 1 985 2 Seal Head Asm 15 Reservoir End Cap 28 O Ring 3 Internal Bump Stop 16 Reservoir Body 29 Screw 8 32 4 Shaft Bushing 0 625 17 Washer 1 50 x 0 125 x 0 348 30 O Ring 5 O Ring 18 Cri...

Page 385: ...t regular intervals Every ride Wash and dry the vehicle and suspension Every 100 hours Visually inspect shock seals Every 1500 miles or Annually Change shock oil and replace seals FRONT SHOCK SERVICE...

Page 386: ...0 1 00 x 0 015 0 600 x 0 015 1 55 x 0 010 0 900 x 0 015 0 750 x 0 065 AN 0 750 x 0 065 AN 0 750 x 0 065 AN Piston Bleed Orifice none RZR PRO R 4 FRONT SHOCK VALVING COMPRESSION REBOUND CLICKER ASSEMBL...

Page 387: ...Polaris Industries Inc 9 49 REAR SHOCK SERVICE INFORMATION REAR SHOCK DESIGN DETAILS Travel 12 00 30 48 cm Extended Length 33 50 85 09 cm IFP Depth All Models 8 00 20 32 cm Nitrogen Pressure 150 psi 1...

Page 388: ...1 30 x 0 010 1 90 x 0 010 1 10 x 0 015 2 05 x 0 012 0 900 x 0 008 1 20 x 0 015 0 900 x 0 060 No Piston Bleed Orifice RZR PRO R 4 REAR SHOCK VALVING CHECK VALVE COMPRESSION REBOUND CLICKER ASSEMBLY 1...

Page 389: ...JUSTMENT NON DYNAMIX The compression damping clicker knob is located at the top of the shock reservoir 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise...

Page 390: ...ECIAL TOOLS PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit PS 45908 IFP Tool PU 50979 Shock Body Holding Tool Front PU 50938 Shock Body Holding Tool Rear 2872429 Shock Rod Holding Tool Front...

Page 391: ...ended you wear safety glasses and ear protection during these procedures 1 Clean and carefully remove shock from the vehicle 2 Back preload adjuster all the way down and carefully remove spring retain...

Page 392: ...d cycle the Internal Floating Piston IFP a few times to purge the shock oil from the reservoir 11 Remove the floating piston from the shock reservoir using the IFP Tool PS 45908 PS 45908 12 Clean and...

Page 393: ...iston wear band and replace if damaged or worn 18 Use the appropriate shock body holding tool to properly secure the shock assembly into a vice for service Front Shock Body Holding Tool PU 50979 Rear...

Page 394: ...0952 4 Install seal head assembly onto the shock shaft 5 Remove the Shock Seal Protector Sleeve 6 Place the compression valve stack on the rod in the reverse order of disassembly 7 Place valve piston...

Page 395: ...ng Tool PU 50979 Rear Shock Body Holding Tool PU 50938 12 Fill the shock body and remote reservoir 1 2 full of the recommended gas shock oil FLUID CAPACITY Recommended Shock Oil Racing Gas Shock Oil P...

Page 396: ...ping piston at least 1 4 below the surface of the oil during this process While holding the shock rod apply 2 3 sharp blows to the rod eyelet with a rubber mallet driving the piston down into the shoc...

Page 397: ...eck to make sure retaining ring is seated properly 31 Push the shock rod assembly completely into the shock body It should go all the way down smoothly without interference If it does not disassemble...

Page 398: ...ad the spring preload adjuster down against the spring and set the preload to the specified measurement see Chapter 2 Spring Adjustment 40 Set the compression adjuster knob to the recommended setting...

Page 399: ...ontrol algorithms CAUTION Moving or altering the orientation of the SCM may have an adverse effect on vehicle handling Never move the SCM from it s factory mounting location DYNAMIX DV SYSTEM FEATURES...

Page 400: ...itch status and vehicle deceleration rate reducing body motion and increasing available compression travel for braking into harsh terrains The compression on the front shocks increase as the rear shoc...

Page 401: ...d aggressive suspension events Good feeling of the front wheels with excellent bump rejection Rock Mode High compression and low rebound with angle based damping adjustments for maneuvering through ro...

Page 402: ...USPENSION MODE SWITCH DYNAMIX MODELS For more information on the Dynamix suspension system refer to the Steering Suspension chapter Dynamix Overview page SWITCH POSITION CONTACT A CONTACT B PINS 1 TO...

Page 403: ...10 13 BRAKE PEDAL 10 16 BRAKE PEDAL REMOVAL 10 16 BRAKE PEDAL INSTALLATION 10 16 FRONT BRAKE SERVICE 10 17 BRAKE CALIPER PAD REMOVAL 10 17 FRONT CALIPER ASSEMBLY VIEW 10 19 FRONT CALIPER DISASSEMBLY...

Page 404: ...polaris service solutions com BRAKE SYSTEM SPECIFICATIONS FRONT BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Front Pad Thickness 2 01 5 08 0 254 mm 003 0 76mm Front Disc Thickness 295 008 7 5 2 mm 268 6...

Page 405: ...Disk a Front Brake Caliper Fasteners 73 ft lbs 100 Nm e Button Clip s Master Cylinder Bolt r Bracket Hose Brake Knuckle d Nut Master Cylinder Fastener 21 23 ft lbs 28 31 Nm t Edge Clip f Nut Master C...

Page 406: ...Brake Caliper Fasteners 73 ft lbs 100 Nm e Button Clip s Master Cylinder Bolt r Bracket Hose Brake Knuckle d Nut Master Cylinder Fastener 21 23 ft lbs 28 31 Nm t Edge Clip f Nut Master Cylinder Bolt...

Page 407: ...vice Manual Copyright Polaris Industries Inc 10 5 BRAKE LINE ROUTING RETENTION 2 SEAT Master Cylinder To Front Brake Calipers q Master Cylinder w Rivet Clip e Routing Clip r Front Brake Calipers Maste...

Page 408: ...10 6 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc q Master Cylinder w Routing Clip e Junction Block Junction Block to Rear Brake Calipers BRAKE SYSTEM...

Page 409: ...10 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 10 7 q Junction Block w Rivet Clip e Routing Clip r Rear Brake Caliper BRAKE SYSTEM...

Page 410: ...Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING RETENTION 4 SEAT Master Cylinder To Front Brake Calipers q Master Cylinder w Rivet Clip e Routing Clip r Front Brake Calipers Master...

Page 411: ...10 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 10 9 q Master Cylinder w Routing Clip e Junction Block Junction Block to Rear Brake Calipers BRAKE SYSTEM...

Page 412: ...10 10 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc q Junction Block w Rivet Clip e Routing Clip r Rear Brake Caliper BRAKE SYSTEM...

Page 413: ...ning compensating port within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward an...

Page 414: ...will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTICE Make note of front and rear brake line locations to master cylinder 4 Loosen the brake line ban...

Page 415: ...w Front Right Brake Line 105 e Front Left Brake Line 105 TORQUE Banjo Bolt Brake Pressure Switch 15 ft lbs 20 Nm 4 Install the master cylinder retaining bolts r and nuts Torque bolts to specification...

Page 416: ...w and release pedal NOTICE Do not release foot pedal before bleeder screw is tight or air may be drawn into the brake system 7 Repeat procedure until clean fluid appears in bleeder hose and all air ha...

Page 417: ...10 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 10 15 13 Check brake system for fluid leaks BRAKE SYSTEM...

Page 418: ...l lever e and remove the nut w and master cylinder clevis fastener q 2 Remove the nut t and r from the pedal mount and remove the brake pedal lever e from the vehicle BRAKE PEDAL INSTALLATION 1 Revers...

Page 419: ...iper mounting bolts w and remove the caliper from the front hub NOTE When removing the caliper be careful to not damage the brake line Support the caliper with a wire hangar or rope to avoid kinking o...

Page 420: ...10 18 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 9 Remove the bolt e retaining the brake line to the caliper BRAKE SYSTEM...

Page 421: ...T CALIPER ASSEMBLY VIEW q Brake Pads y Pad Spacer w Pistons lubricate with DOT 4 Brake Fluid u Piston O Rings lubricate with DOT 4 Brake Fluid e Boots i Mount Pins apply Silicone Grease on install r B...

Page 422: ...tandard pliers is used 4 Once the pistons are removed use a pick to carefully remove the o rings r from the caliper O rings should be replaced during caliper service 5 Clean the caliper body pistons a...

Page 423: ...ut of bore smoothly with light resistance 2 Install new sealing o rings inside the caliper 3 Carefully press the pistons into the caliper 4 Install the mount bracket assembly and dust boots 5 Compress...

Page 424: ...n the knuckle Torque mounting fasteners to specification TORQUE Brake Caliper Mounting Bolts 73 ft lbs 100 Nm 5 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7...

Page 425: ...found clean first and re check 3 With connector disconnected check resistance across pins on the sensor When switch is inactive brake pedal not depressed resistance should be less than 0 5 ohms With s...

Page 426: ...ounting bolt q nut and washer from the bearing carrier Swing radius rod down Discard the nut 5 Remove the two caliper mounting bolts w and lift caliper off the brake disc NOTICE When removing caliper...

Page 427: ...banjo bolt retaining the brake line to the caliper REAR CALIPER DISASSEMBLY INSPECTION 1 Remove brake pad adjustment set screw f 2 Push upper pad retainer pin inward and slip brake pads q past the ed...

Page 428: ...EASUREMENT Rear Caliper Piston Bore I D Large 1 368 1 370 34 75 34 80 mm Small 2 Seat Only 1 1860 1 1875 30 12 30 16 mm 3 Inspect the brake disc and pads as outlined in this chapter BRAKE PAD INSPECTI...

Page 429: ...at eight different points around the pad contact surface Replace disc if worn beyond service limit Brake Disc Thickness 295 008 7 5 2 mm 268 6 8 mm Brake Disc Thickness Variance Service Limit 0 002 0...

Page 430: ...d turn until stationary pad contacts disc then back off 1 2 turn 5 Follow bleeding procedure outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification TORQUE Wheel Nuts 1...

Page 431: ...ROLS 11 7 HOOD FRONT BODY 11 8 CHASSIS MAIN FRAME 11 9 CHASSIS MAIN FRAME 4 SEAT 11 11 SEAT ASSEMBLY 11 13 REAR SEAT ASSEMBLY 4 SEAT 11 15 FLOOR ROCKER PANELS 11 17 FLOOR ROCKER PANELS 4 SEAT 11 18 RE...

Page 432: ...e they must be flame treated prior to installing a decal to ensure good adhesion The flame treating procedure can also be used to reduce or eliminate the whitish stress marks that are sometimes left a...

Page 433: ...3 BODY ASSEMBLY VIEWS CAB FRAME ASSEMBLY ROPS Assembly Follow the ROPS Torque sequence 1 B Pillar Fasteners q q w w 148 ft lbs 200 Nm 2 C Pillar Fasteners e e r r 89 ft lbs 120 Nm 3 A Pillar Fasteners...

Page 434: ...ft lbs 15 Nm w Front Roof e Rear Roof ROPS Assembly Follow the ROPS Torque sequence 1 C Pillar Fasteners q q w w 148 ft lbs 200 Nm 2 D Pillar Fasteners e e r r 89 ft lbs 120 Nm 3 A Pillar Fasteners t...

Page 435: ...ener 35 in lbs 4 Nm e Latch Actuator Assembly s Door Hinge r Latch Actuator Assembly Fastener 9 ft lbs 12 Nm d Door Hinge Fastener 18 ft lbs 24 Nm t Door Latch f Door Trim Bracket y Door Latch Fastene...

Page 436: ...q Rear Lower Door Panel u Door Hinge w Rear Upper Door Panel i Door Hinge Fastener 18 ft lbs 24 Nm e Rear Door Frame o Door Hinge Pin r Door Frame Fastener 7 ft lbs 10 Nm a Door Latch t Door Latch Act...

Page 437: ...259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc 11 7 DASH CONTROLS q Headlight Switch r Key Switch w AWD Switch t Drive Mode Switch e Instrument Cluster y 7 Display BODY...

Page 438: ...ies Inc HOOD FRONT BODY q Front Bumper Cover i A Pillar Cover w Front Bumper o Center Hood e Front Fascia a Hood Grill LH r Bumper Mount Bracket s Dash Lid t Firewall d Fender LH y Fender Flare RH f N...

Page 439: ...Front Bumper w Skid Plate Fastener 9 ft lbs 12 Nm i Front Bumper Fastener 37 ft lbs 50 Nm e Rear Skid Plate o Seat Base r Skid Plate Plug a Seat Base Fastener 15 ft lbs 20 Nm t Skid Plate Plug Fastene...

Page 440: ...lbs 60 Nm e Oil Filter Guard o Front Drive Mount Fastener M12 x 1 25 x 230 See Front Drive Removal Installation for torque procedure r Oil Filter Guard Fastener 44 in lbs 5 Nm a Front Drive Mount Fast...

Page 441: ...m w Middle Skid Plate a Seat Base e Rear Skid Plate s Seat Base Fastener 15 ft lbs 20 Nm r Skid Plate Fastener 9 ft lbs 12 Nm d Rear Seat Base t Skid Plate Plug f Rear Seat Base Fastener 22 ft lbs 30...

Page 442: ...52 ft lbs 70 Nm r Oil Filter Guard Fastener 44 in lbs 5 Nm d Propshaft Mount t Engine Mount f Propshaft Mount Fastener 15 ft lbs 20 Nm y Engine Mount Fastener 44 ft lbs 60 Nm g Front Drive Mount Faste...

Page 443: ...SEMBLY TORQUE REFERENCE q Seat Slider RH y Tilt Assembly Bracket w Seat Slider LH u Tilt Assembly Bracket Fastener 15 ft lbs 20 Nm e Seat Hinge Bushing lower i Seat Tilt Receiver r Seat Hinge Bushing...

Page 444: ...O R PRO R 4 Service Manual Copyright Polaris Industries Inc q Seat Assembly r Seat Shell Tube Fastener 10 in lbs 1 Nm w End Cap t Seat Release Assembly e Seat Shell Tube y Seat Release Assembly Fasten...

Page 445: ...Industries Inc 11 15 REAR SEAT ASSEMBLY 4 SEAT q Underseat Flip Panel Fastener 6 ft lb 8 Nm y Seat Frame Hinge Fastener 15 ft lbs 20 Nm w Underseat Flip Panel u Door Hinge Pin e Seat Strap i E Clip r...

Page 446: ...anual Copyright Polaris Industries Inc q Seat Latch t Door Latch Clip w Seat Latch Fastener 6 ft lb 9 Nm y Handle Latch Fastener 22 in lb 3 Nm e Handle Latch u Rear Seat Striker r Seat Latch Rod i Rea...

Page 447: ...OR ROCKER PANELS q Rocker RH i Rear Center Console w Underseat panel RH o Center Console Top e Front Floor RH a Underseat Panel LH r Passenger Footrest Panel s Battery Tray t Front Main Floor d Rocker...

Page 448: ...FLOOR ROCKER PANELS 4 SEAT q Front Main Floor u Rear Floor w Foot Rest Panel i Rear Under Seat Panel e Front Floor Panel o Rear Center Console r Under Seat Panel a Front Center Console t Front Rocker...

Page 449: ...lbs 10 Nm q Rear Bumper o PDM Guard w Rear Facia a Rear Close Off Plug LH e Rear Box Tub s Close Off Panel Plug LH r B Pillar Close off panel d Rear Top Close Off Panel t Coolant Access Panel f Rear C...

Page 450: ...er the front of the seat 2 Lift upward and forward on the seat while lifting up on the release lever and remove seat from the vehicle REAR CLOSE OFF PANEL 1 Remove seats 2 Unlock six 1 4 turn latches...

Page 451: ...er cover 2 Remove four fasteners w and remove the front bumper 3 Remove two fasteners e and remove the front hood 4 Remove twelve fasteners r and one push pin t from each fender flare and remove fende...

Page 452: ...e fasteners 8 Disconnect all headlight and accent light electrical connections 9 Remove two push pins a and remove front fascia REAR FASCIA 1 Remove cargo box 2 Disconnect rear tail light harness 3 Re...

Page 453: ...Remove two fasteners q and remove hood DASH REMOVAL 1 Remove front fascia See Front Fascia Removal page 11 21 2 Remove LH and center dash trim w 3 Remove RH dash trim e 4 Remove eight fasteners r and...

Page 454: ...move rear fender FENDER FLARE REMOVAL 1 Remove two fasteners e and three push pins r from the fender flare 2 Remove one fastener t near the fuel tank 3 Remove gas cap y and support grommet u passenger...

Page 455: ...nder Fender Flare Removal page 11 24 3 Remove five fasteners q and remove rocker panel CONSOLE AND LOWER FLOOR REMOVAL 1 Remove seats and rocker panels 2 Remove top half of shift knob w 3 Remove one f...

Page 456: ...8 Remove any remaining electrical connections and remove console i 9 Remove one fastener o from the shift linkage and remove shift cable a from its mounting bracket 10 Remove seat base frame fasteners...

Page 457: ...s 12 Nm 5 Install new latch actuator Torque fasteners to specification TORQUE Door Latch Actuator Fasteners 9 ft lbs 12 Nm 6 Install door panel Torque fasteners to specification TORQUE Door Panel Fast...

Page 458: ...assembly fasteners w for extra adjustment Once aligned torque striker fasteners TORQUE Door Striker Fasteners 7 ft lbs 10 Nm 5 Holding the door in position tighten the top hinge bracket fasteners e a...

Page 459: ...ANSMISSION GEAR POSITION SWITCH 12 15 BRAKE PRESSURE SWITCH 12 15 SUSPENSION MODE SWITCH DYNAMIX MODELS 12 16 STEERING ANGLE SENSOR CENTERING DYNAMIX 12 16 IGNITION COIL 12 17 OPERATION OVERVIEW 12 17...

Page 460: ...FAN REPLACEMENT 12 30 ECT SENSOR TEST 12 34 STARTING SYSTEM 12 35 STARTER SOLENOID REPLACEMENT 12 35 STARTER SOLENOID BENCH TEST 12 35 STARTER SOLENOID OPERATION 12 35 ELECTRONIC POWER STEERING EPS 1...

Page 461: ...e Harness 2870630 Timing Light 2871745 Static Timing Light Harness PU 49466 Relay Bypass PU 50296 Polaris MDX 610P Battery Tester PU 50338 Battery Hydrometer PV 43526 Connector Test Kit PV 43568 Fluke...

Page 462: ...with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electric...

Page 463: ...T LOCATIONS REAR q Tail Light Harness o Starter w Back Up Camera a ECU Harness e Rear Box Harness s Engine Harness r Oxygen Sensor d Transmission Harness t Fuel Injector f Fuse Box y Alternator Harnes...

Page 464: ...CAL COMPONENT LOCATIONS FRONT k Headlight Switch 2 12V Receptacle l AWD Switch 2 PULSE Bar 1 C4 Gauge 2 EPS Power 2 Key Switch 2 EPS Signal 2 Diagnostic Plug 2 Speaker 2 Drive Mode Switch 3 Ambient Ai...

Page 465: ...using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to con...

Page 466: ...ement system a AWD Indicator Illuminates 2WD 4WD and 4WD Lock modes when a forward reverse gear is selected s Neutral Gear Indicator Illuminates when gear selector is in the neutral N position d Gear...

Page 467: ...the total distance traveled by the vehicle The odometer can not be reset Trip Meters T1 T2 The trip meter records the miles traveled by the vehicle on each trip if reset before each trip Trip Time Tim...

Page 468: ...set to either blue or red 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the BL COLOR option Press MODE to select 3 Press either toggle button to...

Page 469: ...to cycle to the trip time option TT 2 Press and hold either toggle button until the meter resets to zero PROGRAMMED SERVICE INTERVAL The service interval counter is programmed to 25 hours at the fact...

Page 470: ...c INSTRUMENT CLUSTER PINOUTS FUNCTION PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 Left Turn Signal Input 6 Right Turn Signal Input 7 High Beam Input 8 Trailer Turn Sign...

Page 471: ...continuity between switch pins POSITION FUNCTION TERMINALS Up Hi Beam 3 and 7 closed 6 and 4 closed Neutral Low Beam 3 and 7 open 6 and 4 closed Down Off 3 and 7 open 6 and 4 open IGNITION KEY SWITCH...

Page 472: ...ce the switch assembly 3 Move the switch to AWD There should be continuity between switch pins 2 and 3 4 Move the switch to 2WD There should be no continuity between any pins 5 Move the switch to TURF...

Page 473: ...POSITION RESISTANCE VALUE WHEN MEASURED AT SWITCH TERMINALS A AND B HIGH 620 LOW 300 NEU 160 REV 75 PARK 24 BRAKE PRESSURE SWITCH The brake pressure switch q is located on the rear brake line outlet...

Page 474: ...nts have been installed SCM is indicating an alignment code SPN 516122 FMI 15 or 17 or SPN 524114 FMI 2 1 Connect to Digital Wrench 2 Perform EPS Steering Angle Centering procedure found in Steering S...

Page 475: ...The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fi...

Page 476: ...ait 10 minutes before checking the value Vehicles will vary but electronic components will take time to fully go to sleep after switched power is removed 8 Maximum allowable is 10 milliamps If your me...

Page 477: ...st current flow value 2 Maintain engine speed at 2 500 RPM 3 Measure the voltage between the alternator output terminal and the alternator metal housing 4 Is the voltage observed equal to the specifie...

Page 478: ...Was the ECU replaced Go to STEP 12 11 1 Replace the alternator assembly 2 Was the alternator assembly replaced Go to STEP 12 12 1 Run the vehicle to verify the repair 2 Was the problem corrected Charg...

Page 479: ...hown TORQUE Alternator Mounting Fasteners 15 ft lbs 20 Nm 2 Using a commercially available stretch belt installation tool install a NEW stretch belt over the alternator and balance pulleys 3 Connect t...

Page 480: ...Industries Inc 5 Install alternator covers and torque fasteners in the sequence shown TORQUE Alternator Cover Fasteners 6 ft lbs 9 Nm 6 Install negative cable to the battery and torque terminal bolt t...

Page 481: ...or clothing ANTIDOTE External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with wa...

Page 482: ...of the vehicle BATTERY INSTALLATION CAUTION Using a new battery that has not been fully charged can damage the battery result in a shorter life and hinder vehicle performance 1 Ensure the battery is...

Page 483: ...service life of the battery Use a volt ohm meter to test battery voltage OPEN CIRCUIT VOLTAGE STATE OF CHARGE VOLTAGE 100 12 8 V and up 75 Charged 12 6 V 50 Charged 12 3 V 25 Charged 12 0 V 0 Charged...

Page 484: ...ged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced WARNING An overheated battery could explode causing severe injury or death Always watch charging...

Page 485: ...n Repeat the procedure to adjust the other headlight WARNING Due to the nature of light utility vehicles and where they are operated headlight lenses become dirty Frequent washing is necessary to main...

Page 486: ...round path is present REMOVAL 1 Disconnect the wire harness q 2 While holding the taillight assembly remove the three nuts w retaining the taillight assembly and remove it from the rear fascia INSTALL...

Page 487: ...tal Wrench Output State Control From this menu you can turn the cooling fan off and on If the cooling fan does not come on when requested 1 Disconnect the harness going to the fan and check for power...

Page 488: ...s all other components are working properly 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition circuit breaker and mechanical relay for proper operation Repair...

Page 489: ...ove two push pins o and remove the front fascia 10 Disconnect coolant hoses from the radiator 11 Disconnect electrical connector from cooling fan assembly 12 Remove two fasteners a retaining the radia...

Page 490: ...Connect cooling fan electrical connector 6 Install front fascia and install two mounting push pins 7 Install headlight and accent light electrical connectors 8 install front bumper assembly Torque fa...

Page 491: ...10 Nm 11 Install fender flares Torque fasteners to specification TORQUE Front Fender Flare Fasteners 7 ft lbs 10 Nm 12 Install nose cone Torque fastener to specification TORQUE Nose Cone Fastener 7 ft...

Page 492: ...seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly Polaris dealers can test the sensor by u...

Page 493: ...D BENCH TEST Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds With the solenoid energized resistance should read about 0 0 5 between terminals A and B...

Page 494: ...u will need to cycle the key switch and restart the engine to regain power steering operation NOTICE To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the...

Page 495: ...GN Ignition Signal 6 GND PROPER EPS SYSTEM DIAGNOSING READ BEFORE YOU REPLACE THE EPS UNIT NOTICE Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS un...

Page 496: ...econdary Fuse Center for Lights Instrumentation Audio Amp Fuse and Accessory Relay PDM 2 30A MCASE Fuse Power to Secondary Fuse Center for Auxiliary Outlets Chassis SCM and Shock Fuse PDM 3 30A MCASE...

Page 497: ...y Coil Chassis Relay Coil Start Relay Coil EFI Relay Coil Injectors SCM Relay Coil optional Lights Relay Coil Ignition Coil Starter Solenoid Coil Brake Relay Coil COIL 7 5A Fuse Ignition coils FRONT D...

Page 498: ...osition 2 Access the Primary Fuse Center in the driver side rear wheel well 3 Gently nudge the suspected PDM fuse by hand and check to see if intermittent power occurs to vehicle functions This will s...

Page 499: ...n and a yellow wire CAN SYSTEM TESTING A component not displaying information correctly could be the cause of damaged CAN wiring or a faulty component The easiest location to test the CAN system is at...

Page 500: ...R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc WIRING HARNESS ELECTRICAL HARNESS RETENTION q Zip Tie Retention Point The white tape on the harness signifies a retention poi...

Page 501: ...A 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc A 1 WIRING DIAGRAMS APPENDIX A WIRING DIAGRAMS...

Page 502: ...A 2 9940259 R02 2022 RZR PRO R PRO R 4 Service Manual Copyright Polaris Industries Inc NOTES ELECTRICAL...

Page 503: ...10 22 Front Caliper Assembly 10 21 Front Caliper Assembly View 10 19 Front Caliper Disassembly Inspection 10 20 Front Disc Inspection 2 37 10 21 Front Disc Replacement 10 22 Hydraulic Brake System Op...

Page 504: ...lation 6 18 Operation 6 3 Removal 6 7 Roller Pin Thrust Washer Inspection 6 11 Roller Removal Roller Installation 6 12 Shift Weight Inspection 6 12 Spider Removal 6 11 Spring 6 14 Drive Shaft Boot Ins...

Page 505: ...ection 3 70 Oil Pan Installation 3 81 Oil Pan Removal 3 54 Oil Pump Assembly 3 70 Oil Pump Disassembly 3 68 Engine Installation Installation Preparation 3 30 Engine Mount Inspection 3 38 Engine Top En...

Page 506: ...1 23 Hood Front Body 11 8 Hydraulic Brake System Operation 10 11 I Ignition Coil 12 17 Replacement 12 17 Injector O rings 5 6 Installation Front 8 4 Instrument Cluster Information Display Area 12 8 Ov...

Page 507: ...ention 10 5 Retention 4 Seat 10 8 Ride Command Overview 9 61 Rocker Panel Removal 11 25 Rocker Panels Assembly View 11 17 Assembly View 4 Seat 11 18 Routing 10 5 Routing 4 Seat 10 8 S Seat Assembly Vi...

Page 508: ...gine 3 7 Trailing Arm Replacement 9 23 Spherical Bearing Replacement 9 25 Transmission Assembly 7 20 Disassembly 7 17 Installation 7 10 Lubrication 2 27 Oil Change 2 27 Oil Level Check 2 27 Removal 7...

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