Polaris RZR PRO XP 2020, Service Manual

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9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
STARTER MOTOR INSTALLATION
1. Inspect and replace starter motor O-ring if needed.
2. Lubricate starter motor O-ring with fresh engine oil.
3. Install the starter motor onto the engine case.
4. Hand tighten the upper starter mounting bolt / stud.
5. Install and torque the lower mounting bolt to
specification.
NOTICE
Tighten the lower starter bolt first, as the bottom hole
acts as a pilot hole to properly align the starter drive
(bendix) with the flywheel. This helps prevent binding
and starter damage.
6. Torque upper starter mounting screw to specification.
7. Install (-) negative battery cable to the upper starter
mounting bolt / stud. Torque nut to specification.
TORQUE
Starter Mounting Bolts:
7 ft-lb (10 Nm)
Starter Cable Nuts:
30 in-lb (3 Nm)
8. Install inner PVT cover.
TORQUE
PVT Inner Cover Fasteners:
STEP 1: Torque to 37 ft-lbs (50 Nm).
STEP 2: Install through bolts by adjusting the
transmission accordingly.
STEP 3: If previously removed, loosely install bolts
by hand.
STEP 4: Torque to 37 ft-lbs (50 Nm).
STEP 5: Torque to 50 ft-lbs (68 Nm).
STEP 6: If previously removed, torque to 37 ft-lbs
(50 Nm)
9. Install inner PVT cover baffle. Torque fasteners to
specification.
TORQUE
Inner PVT Cover Baffle Fasteners:
7 ft-lbs (10 Nm)
10. Install the drive clutch. Torque bolt to specification.
TORQUE
Drive Clutch Retaining Bolt:
96 ft-lb (130 Nm)
11. Install the driven clutch. Torque bolt to specification.
TORQUE
Driven Clutch Retaining Bolt:
70 ft-lb (95 Nm)
12. With the clutch spreader tool installed, loop the belt
over the drive clutch and over part of the driven
clutch.
13. Rotate driven clutch and walk the belt into the clutch.
14. Remove clutch spreader tool from driven clutch.
15. Rotate / spin the driven clutch and belt approximately
5-7 times to properly seat the belt in the driven clutch.
16. Install outer clutch cover and nine screws. Torque to
specification.
TORQUE
Outer Clutch Cover Screws:
35 in-lb (3 Nm)
ENGINE / COOLING SYSTEM