Polaris RZR PRO XP 2020 Page 479 Service Manual Download

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9850068 R01 - 2020-2021

RZR

PRO XP / XP 4 Service Manual

10.1

BRAKE SYSTEM

CHAPTER 10

BRAKE SYSTEM

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2

BRAKE SYSTEM SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2

BRAKE SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3

BRAKE SYSTEM VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3

BRAKE SYSTEM VIEW (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4

BRAKE LINE ROUTING / RETENTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5

BRAKE LINE ROUTING / RETENTION (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8

BRAKE SYSTEM SERVICE NOTES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

HYDRAULIC BRAKE SYSTEM OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

MASTER CYLINDER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

FRONT BRAKE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

BRAKE CALIPER / PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

FRONT CALIPER ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19

FRONT CALIPER ASSEMBLY VIEW (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20

FRONT CALIPER DISASSEMBLY / INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21

FRONT CALIPER DISASSEMBLY / INSPECTION (4-SEAT)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

BRAKE PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23

FRONT CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

BRAKE DISC INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

FRONT BRAKE DISC REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25

BRAKE CALIPER / PAD INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

BRAKE PEDAL SWITCH INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

REAR BRAKE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

BRAKE CALIPER / PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

REAR CALIPER DISASSEMBLY / INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

BRAKE PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30

REAR CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

REAR BRAKE DISC INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

REAR BRAKE DISC REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32

REAR BRAKE CALIPER / PAD INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34

Summary of Contents for RZR PRO XP 2020

Page 1: ...rized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual...

Page 2: ...provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING P...

Page 3: ...REVISION INDEX REV DATE CHANGES R01 11 10 2020 Initial Release...

Page 4: ...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 5: ...RMATION 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...

Page 6: ......

Page 7: ...1 19 2021 RZR PRO XP 4 1 20 2020 21 RZR PRO XP 4 CLUTCH CHART 1 21 MISC SPECIFICATIONS AND CHARTS 1 22 CONVERSION TABLE 1 22 SAE TAP DRILL SIZES 1 23 METRIC TAP DRILL SIZES 1 23 DECIMAL EQUIVALENTS 1...

Page 8: ...F SHAFT DIAGNOSTICS 1 66 BRAKE NOISE TROUBLESHOOTING 1 67 BRAKE VIBRATION 1 67 CALIPER OVERHEATS BRAKES DRAG 1 68 POOR BRAKE PERFORMANCE 1 68 BRAKES LOCK 1 68 EPS TROUBLESHOOTING POWER STEERING NON FU...

Page 9: ...IFICATION NUMBER VIN DESIGNATION 2015 Example 4XARUE573FG000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE CHASSIS MODIFIER ENGINE SIZE ENGINE MODIFIER CHECK DIGIT MODEL YE...

Page 10: ...1 4 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc GENERAL INFORMATION...

Page 11: ...the proper part number i e In this example the first two digits are 31 which would use key blank PN 4110141 SERIES PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110...

Page 12: ...tools 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 Deal...

Page 13: ...2871226 Clutch Bushing Replacement Tool Kit 2871282 Transmission Seal Driver 50 MM 2871358 B Drive Clutch Holding Fixture 2871745 Static Timing Light Harness 2872085 Drive Clutch Puller 2876389 Combi...

Page 14: ...U 50564 Water Pump Seal Installer PU 50569 Oil Pressure Gauge Adapter 1 4 NPT PU 50578 Clutch Spider Nut Socket PU 50624 Rolling Engine Stand PU 50625 Engine Stand Adapter Sleeve 2 PU 50784 Crankshaft...

Page 15: ...Tool PU 51861 Drive Clutch Holding Tool PU 51862 Transmission Snorkel Tool PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PV 43526 Connector Test Kit PV 43531 Oil Presure...

Page 16: ...2 22 ft lb 30 Nm Step 3 Tighten add n 90 Coolant Hose Retainer Bolt 8 ft lb 11 Nm Coolant Reservoir 8 ft lb 11 Nm Coolant Temperature Sensor 17 ft lb 23 Nm CPS Retaining Bolt 9 ft lb 12 Nm Crankcase B...

Page 17: ...to Front Frame Fastener 33 ft lbs 45 Nm Master Cylinder Mount Bolts 18 ft lbs 25 Nm Manifold Pressure Banjo Bolt 7 ft lb 10 Nm Oil Cooler Bolts 7 ft lb 10 Nm Oil Pan Bolts M8 M6 9 ft lb 12 Nm M8 26 f...

Page 18: ...eering Cast Mounting Fasteners Lower 42 ft lbs 57 Nm Steering Cast Mounting Fasteners Upper 22 ft lbs 30 Nm Steering Column Mounting Fasteners 33 ft lbs 45 Nm Steering Rack Mounting Bolts 44 ft lbs 60...

Page 19: ...al Copyright Polaris Industries Inc 1 13 ITEM TORQUE Cover Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads Winch Cover Fastener 22 in lb 3 Nm Winch Mounting Plate Fasteners 18 ft lbs 24 Nm Wheel...

Page 20: ...e 96 243 8 cm Ground Clearance 14 35 6 cm Dry Weight 1785 lbs 810 kg Gross Vehicle Weight 2623 lbs 1190 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 kg Includes rid...

Page 21: ...uses 7 5A Chassis 7 5A Fuel 7 5A Instr Accy 7 5A Instr Unsw 7 5A Key 7 5A Lights 7 5A SCM 7 5A Shocks 7 5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan DRIVETRAIN Transmission Type Polaris A...

Page 22: ...cm Ground Clearance 14 35 6 cm Dry Weight 2038 lbs 924 kg Gross Vehicle Weight 3055 lbs 1386 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 kg Includes riders cargo...

Page 23: ...hassis 7 5A Fuel 7 5A Instr Accy 7 5A Instr Unsw 7 5A Key 7 5A Lights 7 5A SCM 7 5A Shocks 7 5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan DRIVETRAIN Transmission Type Polaris Automatic PV...

Page 24: ...cm Ground Clearance 14 35 6 cm Dry Weight 1785 lbs 810 kg Gross Vehicle Weight 2623 lbs 1190 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 kg Includes riders cargo a...

Page 25: ...uses 7 5A Chassis 7 5A Fuel 7 5A Instr Accy 7 5A Instr Unsw 7 5A Key 7 5A Lights 7 5A SCM 7 5A Shocks 7 5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan DRIVETRAIN Transmission Type Polaris A...

Page 26: ...cm Ground Clearance 14 35 6 cm Dry Weight 2038 lbs 924 kg Gross Vehicle Weight 3055 lbs 1386 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 kg Includes riders cargo...

Page 27: ...hassis 7 5A Fuel 7 5A Instr Accy 7 5A Instr Unsw 7 5A Key 7 5A Lights 7 5A SCM 7 5A Shocks 7 5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan DRIVETRAIN Transmission Type Polaris Automatic PV...

Page 28: ...inch 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...

Page 29: ...7 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...

Page 30: ...06 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 31: ...duplicated 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...

Page 32: ...gory 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...

Page 33: ...l 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 Servi...

Page 34: ...6 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 Ignitio...

Page 35: ...t 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 Transmiss...

Page 36: ...l 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...

Page 37: ...g concern 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 Previou...

Page 38: ...eck 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 39: ...il in need of changing may cause increase in engine temperature Too high of oil level may cause engine temperatures may cause increase in engine temperature Check level and correct as necessary Check...

Page 40: ...ly 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 non...

Page 41: ...uel 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 com...

Page 42: ...cylinder 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...

Page 43: ...blocked 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 lig...

Page 44: ...ware refer to the Digital Wrench System Help To access the Digital Wrench System Help do one of the following Expand the Digital Wrench Help drop down on the left side of the main screen and click Sys...

Page 45: ...ty drop down select Digital Wrench and then click Digital Wrench Updates 3 Select the Digital Wrench X X Updates link 4 Select the update you want to install on your PC IMPORTANT You must have the lat...

Page 46: ...tions DIGITAL WRENCH DIAGNOSTIC CONNECTOR The diagnostic connector is located under the storage tray below the middle seat and is connected to a sealed plug To access the diagnostic connector lift up...

Page 47: ...NUMBER LOCATION To locate the Digital Wrench serial number do the following 1 Launch the Digital Wrench software 2 On the Digital Wrench main screen select the Configure the Diagnostic System Software...

Page 48: ...or chart format This is the most viewed screen Add and or update vehicle and customer information Also view ECU Identification View information from the main ECU sensors Access the Vehicle Home Page...

Page 49: ...9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 1 43 GENERAL INFORMATION 1...

Page 50: ...are Overview for information on how to access the System Help REPROGRAMMING REFLASH PROCEDURE 1 Verify the most current version of the Digital Wrench software is installed on your PC 2 Connect the Sma...

Page 51: ...IOS products Dual core processor 2 GB internal memory external micro SD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video microphon...

Page 52: ...ng 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 b...

Page 53: ...se Width Or Period P0501 9 Abnormal Update Rate P160A 10 Abnormal Rate Of Change C1068 C1705 12 Bad Intelligent Device Or Component P3503 19 Received Vehicle Speed Has Error P106B C1069 P306B 91 Accel...

Page 54: ...elow Normal Or Shorted To Low Source P2228 10 Abnormal Rate Of Change P2230 110 Engine Temperature Sensor 0 Engine Overheat Shutdown P1217 2 Data Erratic Intermittent Or Incorrect P0116 3 Voltage Too...

Page 55: ...d Computation P121D 523 Gear Sensor Signal 2 Data Erratic Intermittent Or Incorrect P0914 3 Voltage Above Normal Or Shorted To High Source P0917 4 Voltage Too Low P0916 9 Abnormal Update Rate P1914 11...

Page 56: ...oltage Above Normal Or Shorted To High Source P0647 4 Voltage Below Normal Or Shorted To Low Source P0646 5 Current Below Normal Or Open Circuit P0645 905 Wheel Speed Sensor Front Left 2 Data Erratic...

Page 57: ...2 Data Erratic Intermittent Or Incorrect P0236 3 Voltage Above Normal P0238 4 Voltage Below Normal P0237 31 Condition Exists P1234 1268 Ignition Coil Primary Driver 1 MAG 3 Voltage Above Normal P1353...

Page 58: ...30 3 Voltage Above Normal Or Shorted To High Source P0132 4 Voltage Below Normal Or Shorted To Low Source P0131 C1049 12 Bad Intelligent Device Or Component P113A 17 Data Valid But Below Normal Operat...

Page 59: ...4 Throttle Release Signal 2 Data Erratic Intermittent Or Incorrect P1553 3 Voltage Above Normal Or Shorted To High Source P1555 4 Voltage Below Normal Or Shorted To Low Source P1554 7 Mechanical Syste...

Page 60: ...ue Full Failure 31 Condition Exists C1053 520225 EPS Inverter Temperature 0 Data Valid But Above Normal Operational Range Most Severe Level C1055 12 Bad Intelligent Device Or Component C102F 16 Data V...

Page 61: ...Current Below Normal Or Open Circuit P125A 520275 Accelerator Position Brake Position Interaction 31 Condition Exists P150A U1007 520276 Throttle Position Sensor 1 or 2 Indeterminable 2 Data Erratic...

Page 62: ...Condition Exists C1681 520496 Intercooler Pump Driver Circuit 3 Voltage Above Normal Or Shorted To High Source P107D 4 Voltage Below Normal Or Shorted To Low Source P107C 5 Current Below Normal Or Op...

Page 63: ...Operating Range Least Severe Level P150F 524076 Engine Oil Pressure Sensor Switch 17 Data Valid But Below Normal Operating Range Least Severe Level P151F 524085 EPS Fault Lamp Driver Circuit 12 Bad I...

Page 64: ...w 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...

Page 65: ...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 66: ...or fuel injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts air box cover Faulty oxygen sensor RICH MIXTURE SYMPTOMS CAUSES H...

Page 67: ...when warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector TMAP damaged check wi...

Page 68: ...ecified 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 shi...

Page 69: ...Owner 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 outl...

Page 70: ...vehicle 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...

Page 71: ...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 72: ...plate or coil magnetized Rule out armature plate by putting it close to something metal to see if it tries to stick Drivetrain wedged Often caused by torsion spring coming out of place AWD Does not en...

Page 73: ...rfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake Adjust pad stop Set to proper level...

Page 74: ...sing the throttle and brakes at the same time Excessive use of the brakes POOR BRAKE PERFORMANCE POOR BRAKE PERFORMANCE Air in system Water in system brake fluid contaminated Caliper or disc misaligne...

Page 75: ...c 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 Wren...

Page 76: ...unctional 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 wit...

Page 77: ...w 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...

Page 78: ...lubricates 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...

Page 79: ...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 know...

Page 80: ...held 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 replacin...

Page 81: ...rn 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 Ther...

Page 82: ...circuit Testing Continuity Resistance page 1 75 4 Ensure you have checked for a short to ground Testing For A Short To Ground page 1 75 5 Ensure that neither end of the circuit is connected 6 Set you...

Page 83: ...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 a...

Page 84: ...o 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 85: ...0068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 1 79 For a video demonstration scan the QR code below or right click it and select open in new tab GENERAL INFORMATIO...

Page 86: ...1 80 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES GENERAL INFORMATION...

Page 87: ...HEAT SHIELD INSPECTION 2 34 COOLING SYSTEM 2 35 COOLANT STRENGTH 2 35 COOLANT LEVEL INSPECTION 2 35 COOLING SYSTEM PRESSURE TEST 2 36 COOLANT HOSE INSPECTION 2 36 RADIATOR INSPECTION CLEANING 2 37 COO...

Page 88: ...PENSION INSPECTION 2 50 SUSPENSION LUBRICATION 2 51 SHOCK ADJUSTMENT 2 51 SHOCK COMPRESSION ADJUSTMENT WALKER EVANS 2 53 BRAKE SYSTEM 2 54 BRAKE FLUID INSPECTION 2 54 BRAKE HOSE AND FITTING INSPECTION...

Page 89: ...tote 2879001 AGL 1 qt 12 2878068 1 gal 4 2878069 2 5 gal 2 2878070 Demand Drive 1 qt 12 2877922 2 5 gal 2 2877923 Gas Shock Oil 1 qt 6 2870995 2 5 gal 2 2872279 Antifreeze Coolant 50 50 Extended Life...

Page 90: ...chment Inspect heat shields Frame Body Fasteners Inspect ensure tightness check none are missing Front Rear Suspension Inspect bushings Check for damage to the control arms trailing arms Check for lea...

Page 91: ...nspect replace XU D Brake Pads Parking Brake Pads INT L Inspect pad wear Fuel System Turn key on to pressurize fuel pump check lines fittings for leaks and abrasion XU D Parking Brake Cable Adjustment...

Page 92: ...Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper...

Page 93: ...ng Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspec...

Page 94: ...Belt Inspect replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubrican...

Page 95: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 96: ...L Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for prop...

Page 97: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 98: ...ean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change...

Page 99: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 100: ...L Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for prop...

Page 101: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 102: ...e Belt Inspect replace as needed XU D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment...

Page 103: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 104: ...L Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for prop...

Page 105: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 106: ...replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubr...

Page 107: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 108: ...L Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for prop...

Page 109: ...ing Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspe...

Page 110: ...icant AGL Change lubricant D Fuel System Check for leaks at fill cap fuel line rail and fuel pump D Spark Plug Inspection Inspect replace as needed torque to specification XU Radiator Inspect clean ex...

Page 111: ...nger s side rear wheel well Polaris PS 4 or Polaris PS 4 Extreme Duty Add oil to proper level r on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereaf...

Page 112: ...ng pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant through fill hole w 8 5 oz 250 mL Do NOT fill to fill hole threads Initial level check at 25 hours...

Page 113: ...aces of water have been purged out at each of these areas ITEM METHOD RECOMMENDED LUBE FREQUENCY Rear Stabilizer Bar Bushings Grease two fittings through the skid plate access holes on each side of th...

Page 114: ...PARK 2 Allow engine to cool down before draining oil 3 Remove the access panels behind the seats to access the dipstick 4 Unlock the dipstick lever q Remove the dipstick and wipe it dry with a clean r...

Page 115: ...p the open end of the oil filter up to minimize oil spill Ensure all shop rags are removed after cleaning up any spilled oil Oil Filter Wrench PU 50105 2 5 64 mm 6 Clean the filter sealing surface on...

Page 116: ...reinstall dipstick and lock the lever 19 Reinstall the cargo box engine service panel and seats 20 Dispose of used oil filter and rags properly ENGINE CRANKCASE BREATHER HOSE The engine crankcase is...

Page 117: ...Intake Valve Clearance cold 006 002 0 15 0 05 mm Exhaust Valve Clearance cold 010 002 0 25 0 05 mm 4 Repeat steps 6 and 7 until all eight valves have been inspected 5 If any of the valve clearance mea...

Page 118: ...thin specification for each valve 14 If valve clearance is not within specification repeat this procedure 15 If all valve clearance measurements are now within specification remove the camshaft carrie...

Page 119: ...will affect engine performance Replace a cracked or damaged spark arrestor before running the vehicle NOTICE The spark arrestor should be cleaned each time the machine is submerged in water mud and af...

Page 120: ...fy all shields are properly installed and not damaged If a shield is damaged or missing it MUST be replaced q Front Box Shield y Rear Shield w Engine Shield u Silencer Shield e Rear Close Off Shield i...

Page 121: ...nt level should be filled to the FULL COLD level q indicated on the recovery bottle With the engine at operating temperature the coolant level should be between the upper and lower marks on the coolan...

Page 122: ...e servicing 3 To test the cooling system connect the pressure tester to the cooling neck w with the correct adapter 4 The system must maintain 10 psi for five minutes or longer If pressure loss is evi...

Page 123: ...hot 2 Place a drain pan below the engine water pump q and the charge air cooler water pump w NOTICE Shock guard is hidden for clarity 3 Remove the pressure cap from the coolant reservoir 4 Remove a c...

Page 124: ...perature The engine should take 3 5 minutes to warm up and the fan should cycle normally if all the air has been purged from the system NOTICE The cooling system is self bleeding 4 Install the coolant...

Page 125: ...r deterioration 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...

Page 126: ...Inspect 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 int...

Page 127: ...f 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...

Page 128: ...e throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission into Low 6 Test run the vehicle for slippage If the belt slips repe...

Page 129: ...the recommended fluid as needed Do not overfill IMPORTANT Do NOT fill to threads on fill plug If the fluid is up to the threads the front drive is overfilled 4 Reinstall the fill plug and torque to sp...

Page 130: ...de of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 Verify the transmission is still in PARK 2 Place the wheel in the correc...

Page 131: ...UREMENT Tire Lug Service Limit Replace if 1 8 3 mm or less WARNING Operating with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can c...

Page 132: ...icant level 3 If lubricant level is not even with bottom threads w add recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification TORQUE Transmission Fill Dr...

Page 133: ...free play and operation 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be about 0 8 1 0 20 25 mm of free play 4 If there is excessive free play...

Page 134: ...e height of both marks be equally positioned to get an accurate measurement 3 Measure the distance between the marks and record the measurement Call this measurement w 4 Rotate the tires 180 by moving...

Page 135: ...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 136: ...ntrol 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...

Page 137: ...t in serious injury or death Always adjust both the left and right spring equally The factory setting is appropriate for nearly all riding conditions If desired the spring setting may be adjusted to m...

Page 138: ...hes 27 4 cm NON DYNAMIX Front 2 90 inches 7 4 cm Rear 7 Coil Tender Spring 7 73 inches 19 6 cm Rear 5 Coil Tender Spring 8 30 inches 21 1 cm SHOCK LOCATION Preload Setting Max Setting Front Shock 0 5...

Page 139: ...to increase compression damping Turn the adjuster knob counter clockwise e to decrease compression damping NOTICE The recommended factory setting for the front and rear shocks are provided in the fol...

Page 140: ...le 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 lev...

Page 141: ...sing 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 Varian...

Page 142: ...vegetable 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 c...

Page 143: ...h electrical contact 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 ben...

Page 144: ...2 58 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES MAINTENANCE...

Page 145: ...ION 3 15 EXHAUST PIPE REMOVAL 3 16 HEAD PIPE TURBO REMOVAL 3 18 HEAD PIPE TURBO INSTALLATION 3 19 EXHAUST PIPE INSTALLATION 3 21 TURBOCHARGER INSPECTION 3 22 ACTUATOR WASTEGATE INSPECTION 3 25 ACTUATO...

Page 146: ...RANKSHAFT REMOVAL INSPECTION 3 69 CRANKCASE INSPECTION 3 71 CYLINDER PISTON REMOVAL 3 72 CYLINDER INSPECTION 3 73 PISTON DISASSEMBLY INSPECTION 3 74 PISTON RING REMOVAL 3 75 PISTON RING TO GROOVE CLEA...

Page 147: ...pyright Polaris Industries Inc 3 3 CYLINDER HEAD INSTALLATION 3 92 CAMSHAFT INSTALLATION TIMING 3 93 CAMSHAFT TIMING QUICK REFERENCE 3 97 VALVE CLEARANCE ADJUSTMENT 3 98 VALVE LASH TAPPET SELECTION 3...

Page 148: ...ngine Stand 2 Bore PU 50625 Engine Stand Sleeve Adapter PU 51220 Flywheel Holding Tool PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PV 43531 Oil Pressure Gauge PV 43570 1...

Page 149: ...rque the adapter to specification TORQUE PU 52492 12 ft lbs 16 Nm 4 Start the engine and allow it to reach operating temperature monitoring the gauge NOTE Test results are based on the use of the reco...

Page 150: ...3 6 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc OIL FLOW CHART ENGINE COOLING SYSTEM...

Page 151: ...ound Limit 001 0 025 mm Cylinder Taper Limit 001 0 025 mm Cylinder to Piston Clearance 0009 0019 0 025 0 050 mm Cylinder Head Cylinder Head Surface Warp Limit 0039 0 1 mm Cylinder Head Standard Height...

Page 152: ...Small End I D 8667 8673 22 015 22 03 mm 8677 22 04 mm 1 Marking Conn Rod Big End Bore I D 1 8892 1 8895 47 987 47 994 mm 2 Marking Conn Rod Big End Bore I D 1 8896 1 8898 47 995 48 001 mm 3 Marking C...

Page 153: ...CRANKCASE LOWER CRANKCASE UPPER M10 Bolts Step 1 9 ft lb 12 Nm Step 2 21 ft lb 28 Nm Step 3 Tighten add n 90 M8 Bolts 26 ft lb 35 Nm M8 Bolts 26 ft lb 35 Nm M6 Bolts 9 ft lb 12 Nm M6 Bolts 9 ft lb 12...

Page 154: ...D M8 26 ft lb 35 Nm Cylinder Head Bolts Torque in sequence Step 1 13 ft lbs 18 Nm Step 2 26 ft lb 35 Nm Step 3 Additional 180 Step 4 Additional 180 Step 5 M6 bolts 7 ft lb 10 Nm M6 9 ft lb 12 Nm STATO...

Page 155: ...uld read close to barometric pressure The manifold pressure sensor senses the air pressure that is going into the engine The boost control valve allows the ECU to control the amount of boost pressure...

Page 156: ...in lb 4 Nm i Manifold Pressure Reference Hose g Intake Drain e Intake Air Duct o Charge Air Duct h Air Box Inlet Hose r Blow Off Valve Vent Hose a Banjo Bolt 7 ft lb 10 Nm j Charge Air Cooler Cover t...

Page 157: ...air box upward to disengage 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 bo...

Page 158: ...VIEW q Heat Shield t Muffler o Exhaust Pipe w Heat Shield Fasteners 8 ft lb 11 Nm y Muffler Spring a Oxygen Sensor 13 ft lb 18 Nm e Turbo Head Pipe Assembly u Exhaust Pipe Nuts 18 ft lb 24 Nm s Exhaus...

Page 159: ...he vehicle to remove it from the mounting grommets MUFFLER INSTALLATION 1 Install the muffler studs into the mounting grommets on the chassis 2 Install a new muffler gasket and install the three faste...

Page 160: ...fasteners q and remove the cargo box 3 Remove seats 4 Remove upper and lower rear close off panels 5 Remove the right rear shock assembly 6 Disconnect and remove the oxygen sensor w 7 Remove three fa...

Page 161: ...ields in front and above the valve cover 10 Remove four fasteners y retaining the heat shield to the turbo 11 Remove four fasteners u retaining exhaust pipe to the turbo Remove exhaust pipe NOTICE Fro...

Page 162: ...aining the oil inlet hose and remove the oil drain hose e CAUTION Use caution when removing oil feed line to avoid bending damaging the hard line IMPORTANT The oil line sealing washers MUST be replace...

Page 163: ...ing the turbo assembly pour a few drops of new engine oil down the oil supply hole and rotate the turbo by hand Never used compressed air on the turbo assembly to rotate the vanes 1 Install a new head...

Page 164: ...Nm 8 Torque oil feed line banjo bolt to specification TORQUE Turbo Oil Line Banjo Bolt 33 ft lb 45 Nm 9 Install lower P clip fastener into the turbo mounting bracket Torque fastener to specification...

Page 165: ...fler flange and then install the exhaust pipe fasteners retaining the pipe to the turbocharger Torque fasteners to specification 3 Install the two fasteners retaining the heat shield to the exhaust pi...

Page 166: ...tlined in this chapter 2 Disengage five air box cover latches and remove the air filter 3 Inspect air filter and the inside of the air box for dirt or foreign debris If filter is found to be clogged r...

Page 167: ...ine housing r on the opposite side of the turbocharger 10 Look for any signs of contact between the turbine wheel and the turbine housing profile Check for any damage or deformation of the turbine exd...

Page 168: ...sor inlet the source of oil is likely related to the crankcase ventilation system 14 A compressor side oil leakage issue is likely if oil is present in the compressor discharge but not in the compress...

Page 169: ...have occurred 2 Feel for any free play on either end of the actuator rod Ensure that the actuator crank arm is holding the internal wastegate disc firmly closed 3 Using the turbine discharge flange as...

Page 170: ...egate flapper at a supplied pod pressure of 7 PSI The nuts may be locked in place once again using the 17mm flats found on the actuator rod turnbuckle NOTICE The preload may change when the lock nuts...

Page 171: ...removed with a gasket removing solvent applied to a clean shop rag CAUTION It is critical that the surfaces are smooth and free of nicks and scratches Damage on the mating surfaces may lead to an oil...

Page 172: ...ate port and that no gap is visible that can let exhaust gas past the wastegate when fully closed P1234 BOOST REFERENCE CODE TROUBLESHOOTING 1 Visually inspect all vacuum lines and boost reference lin...

Page 173: ...the connector The reading will dive spike if a bad connections is found Or gently pull wires at connector to see if they easily break NOTICE Wire insulation may conceal broken sensor wiring Vibration...

Page 174: ...3 30 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc COOLING SYSTEM COOLING SYSTEM FLOW ENGINE COOLING SYSTEM...

Page 175: ...uction 232 F 111 C Engine Protection Forced Idle 239 F 115 C Engine Protection Shutdown Overheat Indicator Flashes 246 F 119 C COOLING SYSTEM PRESSURE TEST 1 Remove the coolant bottle cover 2 Remove p...

Page 176: ...ip ties e retaining the harness on the top of the intake manifold and the two zip ties rretaining the harness on the passenger side of the intake manifold 4 Remove the cargo box 5 Remove three hinge c...

Page 177: ...aining the throttle body ETC to the intake manifold 12 Loosen the clamps f retaining the intake manifold to the engine 13 Carefully remove the intake manifold out the passenger side of the vehicle 14...

Page 178: ...ifold Torque fasteners to specification TORQUE Throttle Body Fasteners 7 ft lb 10 Nm IMPORTANT Ensure the gasket between the throttle body and intake manifold is properly in place and not damaged An i...

Page 179: ...rs 7 ft lb 10 Nm 9 Connect the sensors switches and injectors 10 Connect three hinge clips t to the transmission vent line 11 Install zip ties retaining the wiring harness around the intake manifold w...

Page 180: ...an assembly 5 Remove six push pins w and remove the radiator shroud 6 Remove two large hoses and one vent line from the charge air radiator and remove charge air radiator from the vehicle 7 Remove two...

Page 181: ...ge Regulator Bracket Fasteners 7 ft lbs 10 Nm 9 Connect four voltage regulator harness connectors two per voltage regulator 10 Install front fascia TORQUE Front Fascia Fasteners 7 ft lbs 10 Nm 11 Fill...

Page 182: ...1 Remove water pump assembly as outlined in this chapter Engine Disassembly Inspection Bottom End Water Pump Housing Removal 2 Remove the three bolts retaining water pump cover q to water pump housing...

Page 183: ...l bores 11 Install a NEW oil seal into the water pump housing until fully seated 12 Fully install the water pump shaft and two washers into the housing 13 Place water pump drive tab vertically into so...

Page 184: ...TORQUE Water Pump Cover Bolts 7 ft lbs 10 N m Apply Loctite 204 to bolt threads 21 Install two new water pump O rings and lubricate them with fresh engine oil 22 Install water pump assembly into engi...

Page 185: ...h an engine lift 5 Remove the three allen screws w and washers e retaining inner cover to engine 6 Remove fasteners r and washers t retaining inner cover to transmission 7 Discard PVT inner cover o ri...

Page 186: ...e 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...

Page 187: ...ly available transmission lift or pump jack lift the front engine mount to take the weight off the isolators 3 Remove the fasteners q retaining the isolator mounts to the frame 4 Remove the isolator b...

Page 188: ...U 52493 does NOT work with 2017 and older models REMOVAL 1 Remove the Inner PVT Cover Refer to PVT Inner Cover Disassembly page 2 Using a commercially available seal puller tool remove crankcase seal...

Page 189: ...on of the seal is critical Install the seal with the flat side of the seal facing out as shown 2 Tighten the drive bolt e until the cylinder r bottoms out against the crankcase 3 Once the seal is prop...

Page 190: ...page 3 13 9 Remove two hoses q from the turbo going to the boost control valve 10 Remove air box unbolt heat shield above exhaust pipe to remove the aluminum cross member Remove aluminum plate below...

Page 191: ...ndle the turbo head pipe assembly by the actuator rod The rod will become damaged and the turbo will not function properly 19 Remove two hoses going to the charge air cooler and move the hoses towards...

Page 192: ...ting bolt k to trans mount bracket 27 Remove intake manifold and throttle body as assembly 28 Disconnect the starter wiring 29 Remove PVT hoses and outer cover 30 Remove secondary clutch belt and prim...

Page 193: ...e coolant hoses stator flywheel starter and engine sensors ENGINE INSTALLATION 1 If removed from engine install applicable coolant hoses stator flywheel starter and engine sensors 2 Install engine in...

Page 194: ...econdary clutch Install snap ring on transmission input shaft before installing secondary clutch mounting bolt Torque fasteners to specification TORQUE Primary Clutch Bolt 140 ft lbs 190 Nm Secondary...

Page 195: ...g Fasteners 8 ft lb 11 Nm Intake Clamps 49 in lb 6 Nm 20 Install head pipe turbo assembly See Head Pipe Turbo Installation page 3 19 21 Install rear fenders fender flares Torque fasteners to specifica...

Page 196: ...ner bolt w and push the adjuster all the way in 3 Using a new gasket install the cam chain tensioner y into the cylinder and torque mounting bolts t to specification TORQUE Cam Chain Tensioner 7 ft lb...

Page 197: ...l if oil leaks are evident 3 If tearing down the top end of the engine remove the spark plugs Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamb...

Page 198: ...t 7 Remove the remaining bolt from each camshaft sprocket 8 Lift the chain and sprockets off the camshafts to allow each sprocket to be removed 9 Using a paperclip or other tool hold cam chain up NOTI...

Page 199: ...if damaged or if any part is worn past the service limit 2 Measure the height of each cam lobe from the base circle to highest point on the lobe using a micrometer Compare to specification MEASUREMENT...

Page 200: ...r head if camshaft journal bores are damaged or if worn past the service limit TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm MEASUREMENT Camshaft Carrier Bore I D 9055 9063 23 000 23 021 mm Service Limi...

Page 201: ...nd head gasket y NOTICE Once the cylinder head is removed nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 Refer to...

Page 202: ...organized rack as you remove them 1 Remove the valve tappet and note the number on the bottom side of the tappet q 2 Compress the valve spring by hand using valve spring compressor adapter PV 43513 A...

Page 203: ...heck for bent valve stems mount valve in a drill or use V blocks and a dial indicator 4 Check the end of the valve stem w for flaring pitting wear or damage 5 Inspect split keeper groove for wear or f...

Page 204: ...structions provided by the valve reconditioning equipment manufacturer Do not grind seats more than necessary to provide proper seat surface width and contact point on valve face WARNING Wear eye prot...

Page 205: ...move only the amount of material necessary to repair the seat surface 5 To check contact area of the seat on the valve face apply a thin coating of Prussian Blue paste to the valve seat If using an in...

Page 206: ...ke 0393 0039 1 0 0 10 mm Service Limit 0551 1 4 mm Exhaust 0590 0039 1 5 0 10 mm Service Limit 0748 1 9 mm 11 If the seat is too narrow widen using the 45 cutter and re check contact point on the valv...

Page 207: ...ase at any time during the removal installation process or injury could result 2 Carefully pry the stator cover off the engine using the two pry areas as shown below 3 Inspect the condition of the sta...

Page 208: ...om the engine by using a twisting motion as you pull out on the housing 4 If water pump service is required impeller or mechanical seal refer to Water Pump Service page 3 38 FLYWHEEL REMOVAL NOTICE Th...

Page 209: ...ench with the one way clutch facing up Grasp clutch gear and rotate clockwise It should turn smoothly without binding 8 Rotate one way gear counterclockwise The gear should immediately lock in positio...

Page 210: ...asteners q retaining the oil cooler w to the crankcase 2 Remove the crankcase drain plug e to drain any oil remaining in the engine 3 Remove the oil filter 4 Install the Cylinder Holding Camshaft Timi...

Page 211: ...procket NOTICE If unable to extract the dowel pins from the oil pump the oil pump sprocket must be removed Access the sprocket bolt by removing the case plug 11 Lift the oil pump drive chain off the s...

Page 212: ...e eight M10 bolts 17 Tap on the lower crankcase in reinforced areas with a soft faced hammer to loosen Carefully lift up and remove the lower crankcase half BALANCE SHAFT REMOVAL INSPECTION 1 Perform...

Page 213: ...EASUREMENT Balance Shaft Diameter MAG PTO 1 4939 1 4946 37 946 37 962 mm Service Limit 1 4921 37 900 mm CRANKSHAFT REMOVAL INSPECTION 1 Perform Balance Shaft Removal Inspection page 3 68 2 For ease of...

Page 214: ...als Replace crankshaft if any journal is scratched or pitted 9 Measure each main journal and connecting rod journal in two locations 90 degrees apart Replace crankshaft if any journal is worn below th...

Page 215: ...1 1 7724 45 011 45 019 mm Service Limit 1 7710 44 984 mm 12 Whether installing a new crankshaft or re installing the original refer to the bearing selection chart provided in the Connecting Rod Bearin...

Page 216: ...ER PISTON REMOVAL IMPORTANT Pistons must be removed from the cylinders with the connecting rods attached DO NOTattempt to service the cylinder or pistons without disassembling the crankcase Although y...

Page 217: ...rface If warp exceeds the service limit replace the cylinder MEASUREMENT Cylinder Warp Limit 002 0 05 mm 2 Inspect cylinder for wear scratches or damage CAUTION DO NOT hone the cylinders or attempt to...

Page 218: ...n 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 pin bore I...

Page 219: ...and a center expander section Remove top rail first then bottom rail then the expander PISTON RING TO GROOVE CLEARANCE Measure piston ring to groove clearance q by placing the ring in the ring land a...

Page 220: ...t obtained in Step 4 of Cylinder Inspection procedure MEASUREMENT Piston O D Standard 3 6597 0003 92 959 0 008 mm MEASUREMENT Piston to Cylinder Clearance 0009 0019 0 025 0 050 mm CONNECTING ROD INSPE...

Page 221: ...of the connecting rod closest to the small bore end This number represents the bore diameter 7 The table below lists the big end bore diameter specifications CONNECTING ROD BIG END BORE DIAMETERS 1 2...

Page 222: ...number on each connecting rod and match that up with the rod journal letters on the crankshaft Reference Bearing Selection Identification page 3 78 For example the stamping on the crankshaft reads AB...

Page 223: ...e Green 2 Blue Green Yellow 3 Green Yellow Yellow UPPER CRANKCASE PREPARATION IMPORTANT Always replace plain bearings when the crankcase or connecting rods have been disassembled Refer to bearing sele...

Page 224: ...in oil ring groove Rotate expander in groove until butt ends are on PTO side of piston y NOTICE Ends must butt squarely together and must not overlap 2 Install lower rail with end gap positioned on th...

Page 225: ...onnecting 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 recommende...

Page 226: ...ts towards the exhaust side 1 Apply clean engine oil to each piston assembly q and cylinder bore prior to installation 2 Verify that all ring end gaps are correctly located on each piston see Piston R...

Page 227: ...faces of upper crankcase main bearings connecting rods and connecting rod caps 3 Align tab of new main bearing q with the slot in main bearing bore of crankcase Press bearing insert firmly into place...

Page 228: ...s made upon disassembly 13 Install new bolts i and tighten evenly until snug 14 Torque connecting rod bolts to specification TORQUE Connecting Rod Bolts Step 1 9 ft lbs 12 Nm Step 2 22 ft lb 30 Nm Ste...

Page 229: ...page 3 6 at the beginning of this chapter and trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dr...

Page 230: ...se with a rubber hammer to seat the case halves together 10 Inspect crankcase mating surfaces to be sure they are joined properly Investigate the cause of any gaps 11 Install the eight M10 y two M8 u...

Page 231: ...new seal on the oil pump 18 Lift the oil pump drive chain and install the oil pump 19 Install dowel pins s into oil pump mounting holes 20 Install the three bolts d that retain oil pump to the crankc...

Page 232: ...retain the oil sump cover k to the crankcase 25 Torque the oil sump cover bolts in sequence to specification Repeat the sequence to verify final torque TORQUE Oil Pan Bolts M8 Bolts 26 ft lb 35 Nm M6...

Page 233: ...utch Retaining Screws 9 ft lb 12 Nm 4 Reassemble starter one way clutch and gear using the following illustration w Torque Limit Gear Pin y Flywheel e Starter Gear u One Way Clutch Asm r Screws i Torq...

Page 234: ...ICE If the Cylinder Holding Camshaft Timing Plate PU 50563 is installed remove it before tightening the flywheel TORQUE Flywheel Retaining Bolt 133 ft lbs 180 Nm loosen 180 retorque to 133 ft lb 180 N...

Page 235: ...e and square with the guide NOTICE Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring e and retainer r in clean engine oil 6 Install the...

Page 236: ...st port e CYLINDER HEAD INSTALLATION 1 If necessary rotate the engine so the cylinder is facing up 2 If installed remove the Cylinder Holding Camshaft Timing Plate q from the cylinder NOTICE Once the...

Page 237: ...ION TIMING NOTICE If any valve train components were replaced refer to Valve Clearance Adjustment page 2 31 procedure prior to performing this procedure 1 Rotate the engine until the flywheel Top Dead...

Page 238: ...ned see Step 1 9 Pull cam chain upward making sure it is engaged with the drive sprocket on the crankshaft 10 While lifting the cam chain up engage the cam sprockets into the chain with the I and E ma...

Page 239: ...gh slots to lock cams in correct position 14 If timing marks are not aligned remove sprockets and correct alignment 15 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 from the end of the ca...

Page 240: ...ORQUE Cam Chain Tensioner 7 ft lb 10 Nm 24 Install the tensioner spring j washer k and retainer bolt l Torque retainer bolt to specification TORQUE Tensioner Spring Retainer 12 ft lb 16 Nm NOTICE The...

Page 241: ...right Polaris Industries Inc 3 97 CAMSHAFT TIMING QUICK REFERENCE q Intake Cam r Align Exhaust Marks with Top of Head w Exhaust Cam t CPS Mounting Hole e Align Intake Marks with Top of Head y Align Fl...

Page 242: ...Valve Clearance cold 006 002 0 15 0 05 mm Exhaust Valve Clearance cold 010 002 0 25 0 05 mm 4 Repeat steps 6 and 7 until all eight valves have been inspected 5 If any of the valve clearance measureme...

Page 243: ...een adjusted 12 Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 13 Measure and confirm that valve clearance is n...

Page 244: ...h Specification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the valve lash specification from the actual valve lash on the engine i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3...

Page 245: ...bs 12 Nm 2 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 3 Inspect the valve cover seal w and replace if necessary 4 Replace the isolators e around each T40 bolt 5...

Page 246: ...3 102 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES ENGINE COOLING SYSTEM...

Page 247: ...URE SENSOR EVAP MODELS 4 4 TMAP SENSOR 4 4 AIR TEMPERATURE SENSOR DATA 4 5 KNOCK SENSOR 4 6 KNOCK SENSOR OVERVIEW 4 6 KNOCK SENSOR TESTING 4 6 KNOCK SENSOR REPLACEMENT 4 6 CRANKSHAFT POSITION SENSOR C...

Page 248: ...quires a minimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is p...

Page 249: ...e ECU connector you should hear a click when the connector is fully closed TORQUE ECU Retaining Fasteners 24 in lbs 3 N m ETC LEARN PROCEDURE IMPORTANT This procedure MUST be performed on the vehicle...

Page 250: ...Sensor may be interchanged for testing purposes as the sensors are the same FUEL PRESSURE SENSOR EVAP MODELS On EVAP models the fuel pressure sensor r monitors fuel pressure in the fuel supply line a...

Page 251: ...2 F 30 C 26108 13 F 25 C 19999 4 F 20 C 15458 5 F 15 C 12000 14 F 10 C 9395 23 F 5 C 7413 32 F 0 C 5895 41 F 5 C 4711 50 F 10 C 3791 59 F 15 C 3068 68 F 20 C 2499 77 F 25 C 2056 86 F 30 C 1706 95 F 35...

Page 252: ...s no internal engine damage Verify the cooling system is working properly NOTICE Install the knock sensor fastener clean and without thread locker or oil KNOCK SENSOR TESTING 1 Disconnect the harness...

Page 253: ...tions 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...

Page 254: ...2 Using an 8mm socket remove the CPS retaining bolt q and remove the sensor w from the stator cover 3 Unclip the wire harness retainer e and remove the CPS harness from the retainer to allow replacem...

Page 255: ...attempt 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...

Page 256: ...intake boot clamps and body fasteners to specification TORQUE ETC Housing Retaining Bolts 7 ft lb 10 Nm Intake Boot Clamp 49 in lb 6 Nm Body Fasteners 8 ft lb 11 Nm ETC LEARN PROCEDURE IMPORTANT This...

Page 257: ...Sensor q is located in the drivers foot control area mounted on the top of the throttle pedal assembly PPS TEST The PPS can be tested utilizing Digital Wrench by verifying that throttle position reado...

Page 258: ...ers e retaining the throttle pedal assembly to the frame support 4 Remove the protective shield r 5 Remove the pedal assembly from the vehicle PPS Installation 6 Place the throttle pedal assembly and...

Page 259: ...sts The heater circuit element in the sensor however can be tested with an ohmmeter MEASUREMENT Oxygen Sensor Heater Element Resistance 15 8 18 6 Ohms NOTICE This test MUST be performed with the senso...

Page 260: ...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 261: ...INJECTOR TEST 5 8 FUEL INJECTOR REPLACEMENT 5 9 FUEL LINES 5 11 FUEL SYSTEM ASSEMBLY VIEW 5 11 FUEL SYSTEM ASSEMBLY VIEW EVAP 5 12 FUEL LINE REMOVAL INSTALLATION 5 13 FUEL LINE REMOVAL INSTALLATION E...

Page 262: ...cludes most recent version of software with serial number standard interface cable USB Serial Adapter cable and SmartLink Module Kit PU 47471 Digital Wrench SmartLink Module Kit includes PU 47470 PU 4...

Page 263: ...ed on the intake duct after the air filter box y Boost Pressure Sensor Located on the pressure duct before the throttle body u Temperature and Manifold Absolute Pressure TMAP Sensor Located on the int...

Page 264: ...inject into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This range can vary depending on fuel requirements The controlled injection of...

Page 265: ...if 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...

Page 266: ...fuel 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...

Page 267: ...el injected 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...

Page 268: ...hot restart problems and longer cranking times Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pressure the use of filters and the detergent ad...

Page 269: ...emove 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 damaged 9 Pull...

Page 270: ...el injector IMPORTANT Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector 15 Connect the fuel supply line to the fuel rail 16 Reconnect the negativ...

Page 271: ...Polaris Industries Inc 5 11 FUEL LINES FUEL SYSTEM ASSEMBLY VIEW q Fuel Supply Line y Vent Rollover Valve w Fuel Vent Line u Fuel Tank Strap e Fuel Fill i Fuel Tank Fasteners 15 ft lbs 20 Nm r Fuel T...

Page 272: ...Line o Purge Valve w Purge Line a Carbon Canister Filter e Fuel Vent Line s Carbon Canister Filter Fastener 9 ft lbs 12 Nm r Fuel Tank to Canister Line d Carbon Canister t Fuel Fill f Fuel Pump y Fuel...

Page 273: ...ll open tabs while moving the clip out to release the line 3 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 li...

Page 274: ...ch any dripping fuel 2 To remove fuel line q pull open tabs while moving the clip out to release the line 3 Release the fuel line from applicable retaining clips zip ties See image table above 4 Remov...

Page 275: ...5 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 5 15 FUEL LINE ROUTING q Double Clip e Retaining Clip w Zip Tie r Fuel Rail EFI FUEL SYSTEM...

Page 276: ...5 16 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc FUEL LINE ROUTING EVAP q Double Clip e Retaining Clip w Zip Tie r Fuel Rail EFI FUEL SYSTEM...

Page 277: ...ng Clip 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 278: ...1 Route fuel vent line under the shift cable and retain the vent line using two double clips w and a zip tie e 2 Route the fuel vent line up and attach to two retaining clips r 3 Route fuel vent line...

Page 279: ...Fuel Line Canister to Filter 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 n...

Page 280: ...wo retaining clips i 6 Route vent line back along the left shock support tube and attach to the fitting in the frame o VENT LINE TERMINATION FITTING This fitting should be inspected and tested using a...

Page 281: ...U commands the fuel pump control module which powers the fuel pump to the desired fuel pressure based on engine RPM and load FUEL PRESSURE REGULATION Fuel pressure is controlled both mechanically and...

Page 282: ...Service Manual Copyright Polaris Industries Inc FUEL TANK PUMP FUEL TANK ASSEMBLY VIEW q PFA Nut 70 ft lbs 95 Nm t Fuel Pickup Filter not serviceable w Fuel Supply y PFA Gasket e Fuel Pump u Fuel Tan...

Page 283: ...rear close off panels 3 Disconnect the negative q and positive w battery cables from the battery located under the driver s seat 4 Remove the battery bracket fasteners and remove the battery from the...

Page 284: ...rear of the fuel tank up first Carefully pull the fuel tank out of the vehicle FUEL TANK INSTALLATION 1 Reverse the removal procedure for fuel tank installation TORQUE Fuel Tank Fasteners 15 ft lbs 2...

Page 285: ...EL PRESSURE TEST NOTICE This test applies to non EVAP models only IMPORTANT As boost pressure increases fuel pressure increases due to the manifold pressure controlled fuel regulator It is NORMAL to s...

Page 286: ...uctuations as the throttle varies Pressure may briefly drop below 58 PSI 400 kPa when the throttle is released on a running vehicle 7 If the pump did not activate disconnect the harness connector from...

Page 287: ...ouching a ground source such as the engine or frame 6 While holding a shop towel over the fuel line connector disconnect the fuel supply line q from the pump CAUTION It is possible for pressurized fue...

Page 288: ...uel pump assembly r gasket t and PFA nut y from packaging Use care not to bend float arm u during un packaging Do not lift or carry fuel pump assembly by the float arm 12 Use cleaning wipes provided t...

Page 289: ...LL 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 position and compare to s...

Page 290: ...5 30 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES EFI FUEL SYSTEM...

Page 291: ...TOWER CLEARANCE INSPECTION 6 12 SPIDER REMOVAL 6 12 ROLLER PIN AND THRUST WASHER INSPECTION 6 12 ROLLER REPLACEMENT 6 13 SHIFT WEIGHT INSPECTION 6 13 CLUTCH INSPECTION 6 14 DRIVE CLUTCH SPRING INSPECT...

Page 292: ...IX AND MOVABLE SHEAVE BUSHING INSPECTION 6 35 BUSHING SERVICE 6 35 DRIVEN CLUTCH ASSEMBLY 6 36 DRIVEN CLUTCH INSTALLATION 6 37 DRIVEN CLUTCH ALIGNMENT 6 38 2021 DRIVEN CLUTCH SERVICE 6 39 DRIVEN CLUTC...

Page 293: ...Clutch Puller PU 50578 Spider Jam Nut Socket PU 52944 Drive Clutch Holding Tool Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com 2020 21 RZR PRO XP CLUTCH CHART...

Page 294: ...rd 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 i...

Page 295: ...nd turn the tool clockwise to open the sheaves on the driven clutch NOTE The driven clutch spreader tool is included with the vehicle s tool kit 6 Walk the belt out of the driven clutch and drive clut...

Page 296: ...lutch Cover Fasteners 36 in lbs 4 Nm 6 Install PVT intake hose and torque hose clamp w to specification TORQUE PVT Intake Hose Clamp 25 in lbs 3 Nm BELT BREAK IN A proper break in of the clutches and...

Page 297: ...the driven clutch NOTICE The driven clutch spreader tool is included with the vehicle s tool kit 5 Walk the belt out of the driven clutch and drive clutch Remove the belt from the vehicle 6 Install th...

Page 298: ...to remove the movable sheave by hand remove the six cover bolts drive spring outer post and washers Use a three jaw puller to remove the spider The Drive Clutch puller will not be needed if the Statio...

Page 299: ...Bolt 140 ft lbs 190 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 Sheave Assembly...

Page 300: ...6 10 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc REF DESCRIPTION TORQUE l Washer 1 Spider Pin 2 Bushing 2 Roller PVT SYSTEM...

Page 301: ...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 302: ...lutch 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 clutch assem...

Page 303: ...ooth 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 ma...

Page 304: ...bearing u and washers y Refer to Bushing Service page 6 16 3 Inspect the moveable clutch sheave i for damage or wear 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diamet...

Page 305: ...3 76 in 95 43 mm 7045110 4 60 116 74mm 7045326 3 83 97 26mm DRIVE CLUTCH BUSHINGS INSPECTION 1 Inspect the Teflon coating on the Moveable Sheave bushing Drive Clutch Cover Bushing and the One way Bear...

Page 306: ...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 307: ...removed 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 b...

Page 308: ...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 309: ...ATION 1 Clean drive clutch and crankshaft tapers with solvent Allow the tapers to completely dry before installing drive clutch 2 Install the drive clutch stationary sheave Ensure the sheave is fully...

Page 310: ...ult TORQUE Drive Clutch Retaining Bolt 140 ft lbs 190 Nm 6 With the clutch spreader tool installed loop the belt over the drive clutch and over part of the driven clutch Be sure to install belt in the...

Page 311: ...190 Nm d Washer w Drive Clutch Cover Bolts 15 ft lb 21 Nm f Needle Bearing e Drive Clutch Cover g Stationary Sheave r Outer Clutch Post h Shift Weight t Spring j Shift Weight Fastener 20 in lb 2 Nm y...

Page 312: ...en clutch NOTICE The driven clutch spreader tool is included with the vehicle s tool kit 5 Walk the belt out of the driven clutch and drive clutch Remove the belt from the vehicle 6 Install the Drive...

Page 313: ...uller will need to be used Remove the outer slip fit post in order to insert the Drive Clutch holding tool 10 If necessary remove the outer slip fit post and install the Drive Clutch Puller PN PU 5242...

Page 314: ...Belleville washer must be installed with dome facing the outer post DRIVE CLUTCH SPRING INSPECTION 2021 Measure the Drive Clutch Spring height Compare to specification and replace if necessary MEASUR...

Page 315: ...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 clutch asse...

Page 316: ...oth 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 mar...

Page 317: ...aring u and washers y Refer to Bushing Service page 6 16 3 Inspect the moveable clutch sheave i for damage or wear 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter...

Page 318: ...Piston Pin Puller PN2870386 q securely into bench vise and lightly grease puller threads 3 Remove nut from puller rod and set aside 4 Install adapter cup PN 5020632 w onto puller 5 With towers pointi...

Page 319: ...the barrel of the Piston Pin Puller as shown or damage to the cover may result 2 From inside of clutch cover insert adapter tool PN 5020629 e into cover bushing 3 With outside of cover toward the pull...

Page 320: ...Reassemble the drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly 1 Install two washers q needle bearing w and clutch s...

Page 321: ...5 Torque cover bolts in a cross pattern evenly to specification TORQUE Drive Clutch Cover Bolts 15 ft lb 21 Nm 6 Install drive clutch assembly and drive clutch bolt a Torque bolt to specification TORQ...

Page 322: ...e direction 4 Insert clutch spreader tool e into the driven clutch and turn the tool clockwise to open the sheaves on the driven clutch NOTICE The driven clutch spreader tool is included with the vehi...

Page 323: ...DRIVEN CLUTCH ASSEMBLY VIEW q Driven Clutch Bolt 43 ft lbs 58 Nm a Spring Cup w Washer s Bushing e Shim d Moveable Sheave r Bushing f Helix Fasteners 32 ft lbs 44 Nm t Driven Post g E Clip y Stationa...

Page 324: ...in 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 an...

Page 325: ...Helix bushing if more brass than Teflon is visible on the bushing Refer to Bushing Service page 6 35procedure BUSHING SERVICE HELIX BUSHING REMOVAL 1 Install the main adapter q on puller 2 From the in...

Page 326: ...y seated and roller rotates freely 2 Install clutch spring t and clutch spring cap y on the helix r Ensure the clutch spring is fully seated 3 Re install the retaining fasteners u and movable sheave i...

Page 327: ...aining Bolt 43 ft lbs 58 Nm 3 With the clutch spreader tool installed loop the belt over the drive clutch and over part of the driven clutch Be sure to install belt in the direction previously marked...

Page 328: ...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 tracking to determine if adjustment is needed 4 Remove the drive...

Page 329: ...ORTANT Ensure the drive 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 Bol...

Page 330: ...Driven 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 He...

Page 331: ...rotation so that it can be installed in the same direction 4 Insert clutch spreader tool e into the driven clutch and turn the tool clockwise to open the sheaves on the driven clutch NOTICE The drive...

Page 332: ...al Clutch Compressor Universal Clutch Compressor PU 50518 A 3 Spin the compressor down until it just starts to contact the helix cover Remove the three fasteners q that secure the cam Remove the unive...

Page 333: ...e Bushing Inspection Replace the movable sheave if more brass than Teflon is visible on the bushing 2 Inspect the Teflon coating e on the Helix bushing Inspect Helix for signs of wear grooving or notc...

Page 334: ...heave 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 tool and adapter from puller rod Remove bushing from...

Page 335: ...move bushing and bushing removal tool from puller Discard bushing COVER BUSHING INSTALLATION 1 Apply Loctite 620 evenly to bushing bore in cover 2 Install adapter cup PN 5020632 on puller insert cover...

Page 336: ...lance 4 Using clutch compressor PU 50518 compress the driven clutch assembly CAUTION The helix cover is loaded by the spring Not using a proper compressor may result in personal injury or damage to th...

Page 337: ...to properly seat the belt in the driven clutch 7 Install the outer clutch cover and fourteen fasteners r Torque fasteners to specification TORQUE Outer Clutch Cover Fasteners 36 in lbs 4 Nm 8 Install...

Page 338: ...e of debris 7 Reinstall the washers and Driven Clutch Bolt Torque to specification TORQUE Driven Clutch Bolt 26 ft lbs 35 Nm NOTICE When finished the driven clutch should not rotate on its own or shou...

Page 339: ...SPECIAL TOOLS 7 2 SHIFT LEVER CABLE 7 3 SHIFT CABLE INSPECTION 7 3 SHIFT CABLE ADJUSTMENT 7 4 TRANSMISSION SERVICE 7 5 TRANSMISSION REMOVAL 7 5 TRANSMISSION INSTALLATION 7 8 TRANSMISSION VENT LINE RO...

Page 340: ...4 Service Manual Copyright Polaris Industries Inc GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PU 51862 Snorkel Tube Tool Bosch Automotive Service Solutions 1 800 345 2233 or http po...

Page 341: ...he 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...

Page 342: ...e is the about the same amount of cable travel when shifting slightly past HIGH gear than when shifting to PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTICE...

Page 343: ...rs and rear fender flares See Rear Fender Fender Flare Removal page 11 20 6 Remove the muffler See Muffler Removal page 3 15 7 Remove the exhaust pipe See Exhaust Pipe Removal page 3 16 8 Disconnect t...

Page 344: ...l 16 Disconnect vent line h from the valve cover 17 Loosen and remove clamps j retaining intake manifold to engine Remove lower manifold mounting bolt k to trans mount bracket 18 Remove intake manifol...

Page 345: ...retaining inner cover to engine 25 Remove fasteners 2 and washers 2 retaining inner cover to transmission 26 Remove fasteners retaining inner cover to engine trans joint Discard PVT inner cover o ring...

Page 346: ...steners 33 ft lb 45 Nm 4 Loosely install fasteners retaining inner cover to the transmission and engine trans joint 5 Loosely install the three allen screws 2 and washers 2 retaining inner cover to en...

Page 347: ...ation TORQUE Intake Manifold Clamps 6 ft lb 8 Nm Lower Intake Manifold Mounting Fasteners 20 ft lb 27 Nm 12 Install zip ties retaining fuel lines and harnesses to intake manifold 13 Connect harness go...

Page 348: ...engine oil as required See Engine Oil Level page 2 28 26 Connect the battery Torque fasteners to specification TORQUE Battery Fasteners 60 in lbs 7 Nm TRANSMISSION VENT LINE ROUTING 1 The transmissio...

Page 349: ...SSION DISASSEMBLY NOTICE Refer to the exploded view at the end of this chapter as a reference 1 Place transmission in high gear 2 Drain and properly dispose of transmission fluid 3 Remove bell crank n...

Page 350: ...ansmission cases will be damaged and leak oil after it is reassembled 10 Lift up on the shift shaft rail s and move the rail assembly rearward to allow the shift fork pins to be removed from the shift...

Page 351: ...s and clean the cases in preparation for assembly GEAR CLUSTER DISASSEMBLY 1 Remove the bearing from the reverse shaft using a bearing puller Remove the retaining ring and slide the washers high gear...

Page 352: ...Extract the snorkel shaft seal g from the snorkel tube o by drilling a small pilot hole and threading a screw in to slowly pull the seal out e Snap Ring o Snorkel Tube r Thrust Washer a Bearing t Bea...

Page 353: ...opyright Polaris Industries Inc 7 15 GEAR SHAFT BEARING INSPECTION Inspect all of the gears shafts and bearings shown for excessive wear or damage IMPORTANT If gear replacement is required also replac...

Page 354: ...e counterclockwise using the snorkel tool until the snorkel gear and pinion gear have zero backlash NOTICE DO NOTovertighten the snorkel tube At the zero backlash position you should still be able to...

Page 355: ...forks need to be oriented the same way so that the shift fork pins are both offset to the same side of the rail 6 Install the shift shaft rail s and shift forks into the transmission housing as an as...

Page 356: ...m f Drum 10 Apply a continuous bead of Crankcase 3 Bond Sealant PN 2871557 to left hand transmission mating surface 11 Install the transmission case cover and retaining bolts Torque bolts to specifica...

Page 357: ...a new O ring 2 on each shift shaft Apply a small amount of white lithium grease on the O rings shift shafts and component contact surfaces prior to installing the sector cover 18 Clean the transmissi...

Page 358: ...7 20 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES TRANSMISSION...

Page 359: ...ALLATION 8 14 DRIVE SHAFT CV JOINT HANDLING TIPS 8 16 CV JOINT BOOT REPLACEMENT 8 17 INNER PLUNGING JOINT BOOT REPLACEMENT 8 18 PROP SHAFT 8 21 PROP SHAFT REMOVAL INSTALLATION 8 21 PROP SHAFT REMOVAL...

Page 360: ...1 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc GENERAL INFORMATION SPECIAL TOOLS PART NUMBER DESCRIPTION 2872608 Roll Pin Removal Tool 8700226 CV Boot Clamp Pliers PU 48951 Axle Boo...

Page 361: ...remove the caliper from the brake disc Discard brake caliper mounting bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 7 Remove the...

Page 362: ...idue has been removed from each surface 2 Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 3 Apply Loctite 603...

Page 363: ...ze to drive shaft axle splines 5 Install front wheel hub assembly w cone washer e and hand tighten the castle nut Install washers with domed side out 6 Install new brake caliper mounting bolts and tor...

Page 364: ...RING CARRIER INSPECTION REMOVAL 1 Elevate rear of vehicle and safely support machine under the frame area WARNING Serious injury may result if machine tips or falls Be sure machine is secure before be...

Page 365: ...m the hub 9 Remove the five remaining bolts i that attach the rear bearing carrier to the trailing arm Discard the nuts 10 Remove the bearing carrier from the rear drive shaft and trailing arm 11 Rota...

Page 366: ...he outer race on the new bearing Be sure that all oil and Loctite residue has been removed from each surface 5 Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on...

Page 367: ...thoroughly with contact cleaner and a wire brush Remove all any Loctite residue IMPORTANT Removal of all Loctite material is a labor intensive process and may take up to 10 minutes or more to complet...

Page 368: ...specification TORQUE Brake Line Guide Fasteners 7 ft lbs 10 Nm 10 Torque wheel hub nut to specification and install a new cotter pin i Tighten nut slightly if necessary to align cotter pin holes TORQ...

Page 369: ...ne washer e from the front wheel hub assembly Discard cotter pin castle nut and cone washer 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc R...

Page 370: ...all Joint Fasteners 44 ft lbs 60 Nm 6 Install front wheel hub assembly r new cone washer t and hand tighten the new castle nut Install washer with domed side out 7 Torque wheel hub nut y to specificat...

Page 371: ...f machine tips or falls Be sure machine is secure before beginning this procedure Always wear eye protection 2 Remove the four wheel nuts and rear wheel 3 Remove the cotter pin q and loosen the rear w...

Page 372: ...ound to the splines w IMPORTANT Apply anti seize to the transmission side splines only Do not apply anti seize to the hub side splines 2 Align splines of drive shaft with transmission splines and rein...

Page 373: ...OTICE Hub assembly hidden for image clarity 7 Install NEW cone washer r into the hub assembly e with domed side facing out and NEW castle nut Torque castle nut to specification Install NEW cotter pin...

Page 374: ...old of the interconnecting shaft to avoid disassembly or potential damage to the drive shaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface...

Page 375: ...is likely 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...

Page 376: ...l allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct loc...

Page 377: ...onents are precision fit and develop their own characteristic wear patterns Intermixing the internal components could result in looseness binding and or premature failure of the joint IMPORTANT If the...

Page 378: ...d shaft into the housing CAUTION DO NOT hammer on the joint to install it in the housing 15 Remove excess grease from the CV joint s external surfaces and place the excess grease in the boot 16 Pull t...

Page 379: ...rearward to remove it from the front gearcase input shaft Roll Pin Removal Tool 2872608 NOTICE Right front wheel can be removed to gain better access to the prop shaft roll pin 2 Remove the fasteners...

Page 380: ...s y retaining prop shaft bearing to the mounting plate 9 Remove the four fasteners y retaining the rear prop shaft to the transmission coupler Discard the fasteners Move the prop shaft off the coupler...

Page 381: ...teners 13 ft lbs 18 Nm TORQUE Prop Shaft to Transmission Coupler Fasteners 11 ft lbs 15 Nm TORQUE Prop Shaft Mounting Plate Fasteners 15 ft lbs 20 Nm TORQUE Body Fasteners 7 ft lbs 10 Nm TORQUE Contro...

Page 382: ...emoval Tool to remove the roll pin Discard roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft Roll Pin Removal Tool 2872608 NOTICE Right front wheel can be re...

Page 383: ...ough the bottom of the vehicle 6 Mark prop shafts for reassembly NOTICE The prop shafts have a master spline and will only go on one way 7 Remove two fasteners y retaining each prop shaft bearing to i...

Page 384: ...15 ft lbs 20 Nm TORQUE Body Fasteners 7 ft lbs 10 Nm TORQUE Control Arm Fasteners 74 ft lbs 100 Nm TORQUE Sub Frame Mounting Fasteners Rear 148 ft lbs 200 Nm TORQUE Sub Frame Mounting Fasteners Front...

Page 385: ...8 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 8 27 PROP SHAFT ASSEMBLY VIEW q Support Bearing r Front Prop Shaft w Cross and Bearing t Rear Prop Shaft e Slip Yoke FIN...

Page 386: ...c PROP SHAFT ASSEMBLY VIEW 4 SEAT q Rear Prop Shaft y U Joint Strap w Middle Prop Shaft u U Joint Strap fasteners 11 ft lbs 15 Nm e Front Prop Shaft i Slip Yoke r Transmission to Prop Shaft Yoke o Sup...

Page 387: ...Using a hydraulic press install the support bearing assembly onto the prop shaft IMPORTANT The notch on the bearing support should be oriented as shown 6 Install front prop shaft into the vehicle see...

Page 388: ...arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure...

Page 389: ...oller Cage w Cover Plate f Roller e O ring g Ring Gear r Backlash Spacer h Gear Spacer t AWD Coil j Gearcase Housing y Cage Plate k Isolation Bushing u Armature Plate l Snap Ring i Torsion Retainer 1...

Page 390: ...bled the front drive acts as an on demand AWD system This means the front drive will engage once the rear wheels have lost traction and will remain engaged until the torque requirement goes away i e r...

Page 391: ...Engage 1 Check the gearcase coil resistance To test the coil resistance measure between the ground wire q GY and power wire w BN WH Measurement should be within specification Front Gearcase Coil Resis...

Page 392: ...cover u The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped insert it raises the armatu...

Page 393: ...8 11 3 Remove left and right tie rod end nuts Remove tie rod end joints with a proper pulling tool 4 Remove four fasteners q and remove the front bumper cover 5 Remove four fasteners w and remove the...

Page 394: ...LATION 1 Reverse removal procedure for front gearcase installation TORQUE Front Gearcase Mounting Fasteners 52 ft lbs 70 Nm 270 TORQUE Control Arm Fasteners 74 ft lbs 100 Nm TORQUE Sub Frame Mounting...

Page 395: ...lbs 163 Nm FRONT GEARCASE DISASSEMBLY INSPECTION 1 Drain and properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the nine cover screws and remove the cove...

Page 396: ...he clutch housing ring gear roll cage and plastic spacer assembly i from the gearcase housing 7 Remove the RH output hub assembly o from the gearcase housing 8 Remove pinion seal a internal retaining...

Page 397: ...The rollers must slide up down in and out freely within the roll cage k sliding surfaces and H springs NOTICE Refer to the Electronic Parts Catalog for individual part availability Most parts are to b...

Page 398: ...snap ring 3 Install a new pinion shaft seal q into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Insta...

Page 399: ...cage plate is resting properly on the spring retainer and all tabs are fully engaged NOTICE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer 10 C...

Page 400: ...XP 4 Service Manual Copyright Polaris Industries Inc 13 Install the output cover assembly a onto the gearcase housing Install the nine cover plate screws s and torque to specification TORQUE Cover Pla...

Page 401: ...Industries Inc 8 43 WHEEL HUBS FRONT HUB ASSEMBLY VIEW q Wheel Cap w Wheel Lug Nuts 120 ft lbs 163 Nm e Valve Stem r Cotter Pin t Hub Castle nut 180 ft lbs 244 Nm y Cone Washer u Wheel Hub i Brake Dis...

Page 402: ...t Polaris Industries Inc REAR HUB ASSEMBLY VIEW q Wheel Cap w Wheel Lug Nuts 120 ft lbs 163 Nm e Valve Stem r Cotter Pin t Hub Castle Nut 180 ft lbs 244 Nm y Cone Washer u Wheel Hub i Brake Disc o Whe...

Page 403: ...ed 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 lifes...

Page 404: ...8 46 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES FINAL DRIVE...

Page 405: ...FRONT SUSPENSION ASSEMBLY VIEW 9 17 FRONT A ARM REMOVAL INSTALLATION 9 18 FRONT STABILIZER BAR REPLACEMENT 9 19 BALL JOINT REMOVAL 9 20 BALL JOINT INSTALLATION 9 21 REAR SUSPENSION 9 22 REAR SUSPENSIO...

Page 406: ...ENT 9 59 SHOCK PISTON ORIENTATION 9 59 WALKER EVANS SHOCK DISASSEMBLY 9 60 WALKER EVANS SHOCK ASSEMBLY 9 63 DYNAMIX ACTIVE SUSPENSION 9 68 DYNAMIX SHOCKS DISASSEMBLY ASSEMBLY 9 68 DYNAMIX OVERVIEW 9 6...

Page 407: ...ock Spring Preload Spanner Wrench 39800780 IFP tool FOX PU 50939 Seal Protector Sleeve PU 51039 Gas Shock Fill Tool PU 51829 Spanner Wrench 2 5 3 0 Inner Internal Bypass PU 51830 Spanner Wrench 2 5 Ou...

Page 408: ...r Steering Shaft Pinch Bolts 22 ft lbs 30 Nm 1 Steering Shaft to Steering Rack Pinch Bolts 48 ft lbs 65 Nm r Steering Bushing d EPS Unit 2 Steering Rack t Tilt Shock Fasteners 9 ft lbs 12 Nm f EPS Cov...

Page 409: ...the pinch bolt retaining the upper steering shaft to the power steering unit 3 Lift the steering wheel up and remove the fasteners t that retain the steering column 4 Disconnect electrical harness fr...

Page 410: ...Remove the upper steering shaft pivot tube and steering wheel from the vehicle as an assembly Refer to Upper Steering Shaft Removal page 9 5 CAUTION Striking the steering wheel or steering shaft while...

Page 411: ...hicle 6 If replacing the power steering unit remove the three bolts r that retain the power steering unit to the mount bracket IMPORTANT Electronic Power Steering EPS units are programmed to be vehicl...

Page 412: ...aft and remove it through the floor panel STEERING RACK REMOVAL INSTALLATION REMOVAL 1 Remove both front wheels 2 Remove Front Drive Shafts See Front Drive Shaft Removal page 8 11 3 Remove left and ri...

Page 413: ...move four control arm bolts t and remove control arms from sub frame bracket 9 Remove four rear bolts y from front sub frame to main frame 10 Remove front sub frame 11 Remove roll pin from front drive...

Page 414: ...60 Nm TORQUE Front Gearcase Mounting Fasteners 52 ft lbs 70 Nm 270 TORQUE Control Arm Fasteners 74 ft lbs 100 Nm TORQUE Sub Frame Mounting Fasteners Rear 148 ft lbs 200 Nm TORQUE Sub Frame Mounting F...

Page 415: ...Lower Steering Shaft Pinch Bolt 50 ft lb 68 Nm 3 Install the power steering unit and reassemble the vehicle see Power Steering Unit Installation page 9 11 4 Vehicles equipped with Dynamix suspension h...

Page 416: ...ghten the four nuts 4 Position the lower steering shaft on the power steering unit stub shaft and install new fasteners Torque to specification TORQUE Steering Shaft to EPS Unit Pinch Bolt 25 ft lb 34...

Page 417: ...ATION NOTICE If steering wheel was removed follow this procedure to ensure the upper steering shaft is properly positioned on the power steering stub shaft CAUTION Striking the steering wheel or steer...

Page 418: ...ensor Centering procedure performed once everything is reinstalled Refer to Steering Angle Sensor Centering Dynamix page 12 18 10 Turn the key switch on and test EPS operation STEERING SHAFT BUSHING R...

Page 419: ...The SCM is indicating out of alignment faults IMPORTANT Before continuing the steering rack and input shafts must be disconnected from the EPS module If necessary remove the EPS module If EPS module...

Page 420: ...XP 4 Service Manual Copyright Polaris Industries Inc 2 Select option 5 from Special Tests menu 3 Select option 2 at the next menu 4 Follow instructions in Digital Wrench to properly center the EPS ste...

Page 421: ...ION ASSEMBLY VIEW q Shock Fasteners 44 ft lbs 60 Nm u Front Stabilizer Bar w Shock Assembly i Stabilizer Bar Link e Knuckle Bearing Carrier o Ball Joint Fasteners 44 ft lbs 60 Nm r Ball Joint a Stabil...

Page 422: ...ely remove the ball joint end from the bearing carrier 6 To gain access to the front A arm fasteners remove four fasteners r and remove the front bumper cover 7 Loosen and remove the upper A arm front...

Page 423: ...ront Ball Joint Pinch Bolts 44 ft lbs 60 Nm 5 Install the nut retaining the front stabilizer bar link to the upper control arm Torque fasteners to specification TORQUE Stabilizer Bar Link Fasteners 74...

Page 424: ...Use this removal procedure only when replacing the ball joint 1 Properly lift and support the vehicle by the frame 2 Remove the appropriate front wheel 3 To service the upper ball joint Remove and di...

Page 425: ...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 and repeat measurement...

Page 426: ...s 40 Nm s Bearing Carrier Fasteners 44 ft lbs 60 Nm w Rear Shock Assembly u Rear Stabilizer Bar d Bearing Carrier e Shock Guard i Stabilizer Bar Link f Outer Radius Rod Fasteners 52 ft lbs 70 Nm 90 r...

Page 427: ...e the cotter pin q and loosen the rear wheel hub castle nut w Remove the nut cone washer e from the rear wheel hub assembly Discard cotter pin nut and cone washer 4 Remove the lower radius rod mountin...

Page 428: ...oughness is evident 12 Remove the four clipso that secure the brake line retainers to the trailing arm 13 Remove the lower stabilizer bar linkage fastener a Discard the nut 14 Support trailing arm wit...

Page 429: ...Wheel Nuts 120 ft lbs 163 Nm 3 After rear trailing arm installation test vehicle at low speeds before putting into service TRAILING ARM SPHERICAL BEARING REPLACEMENT 1 Remove trailing arm See Trailing...

Page 430: ...radius rods upper and lower 5 Remove the nut bolt and washer w e attaching the upper and lower radius rod to the bearing carrier Discard the nuts 6 Remove bolts r t attaching radius rods to the vehicl...

Page 431: ...well area of the vehicle 8 Inspect the stabilizer bar for straightness Inspect the pivot bushings and replace if needed INSTALLATION 1 Carefully install stabilizer bar through the LH wheel well area N...

Page 432: ...Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle 5 Reverse the procedure to reinstall the shock Torque fasteners to specification IMPORTANT Ensure Dynami...

Page 433: ...to scratch or damage the shock shaft 5 Remove mud guard ring e 6 Remove bottom spring perch r 7 Remove main spring t 8 Remove spring spacer y 9 Remove tender spring u 10 Installation is performed by...

Page 434: ...tment Setting r 3 40 8 63 cm Nitrogen Pressure 100 psi 690 kPa 5 Gas Shock Oil 2874124 qt SHOCK VALVING COMPRESSION REBOUND 1 800 x 0 010 DB 1 675 x 0 158 TO 1 800 x 0 010 DB 1 600 x 0 012 1 000 x 0 0...

Page 435: ...020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 9 31 COMPRESSION REBOUND 0 950 x 0 010 0 800 x 0 020 0 700 x 0 020 0 950 x 0 008 1 250 x 0 008 1 425 x 0 008 0 750 x 0 020 STEE...

Page 436: ...4 73 cm Spring Adjustment Setting r 3 40 8 63 cm Nitrogen Pressure 100 psi 690 kPa 5 Gas Shock Oil 2874124 qt SHOCK VALVING COMPRESSION REBOUND 1 800 x 0 010 DB 1 600 x 0 010 1 800 x 0 010 DB 1 425 x...

Page 437: ...al Copyright Polaris Industries Inc 9 33 COMPRESSION REBOUND 1 425 x 0 008 1 350 x 0 008 1 250 x 0 010 1 100 x 0 010 0 950 x 0 010 0 800 x 0 020 0 700 x 0 020 0 950 x 0 008 1 250 x 0 008 1 425 x 0 008...

Page 438: ...justment Setting r 3 60 9 14 cm Nitrogen Pressure 100 psi 690 kPa 5 Gas Shock Oil 2874124 qt SHOCK VALVING COMPRESSION REBOUND 1 800 x 0 010 DB 1 600 x 0 010 1 100 x 0 006 1 425 x 0 010 1 100 x 0 006...

Page 439: ...9 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 9 35 COMPRESSION REBOUND 0 800 x 0 020 1 570 x 0 128 TO STEERING SUSPENSION...

Page 440: ...djustment Setting r 3 60 9 14 cm Nitrogen Pressure 100 psi 690 kPa 5 Gas Shock Oil 2874124 qt SHOCK VALVING COMPRESSION REBOUND 1 800 x 0 006 SB 1 600 x 0 010 1 800 x 0 006 SB 1 425 x 0 010 1 250 x 0...

Page 441: ...4 Service Manual Copyright Polaris Industries Inc 9 37 COMPRESSION REBOUND 1 600 x 0 008 0 850 x 0 008 1 600 x 0 010 1 600 x 0 010 1 425 x 0 010 1 350 x 0 010 1 250 x 0 010 1 100 x 0 010 0 950 x 0 015...

Page 442: ...r 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...

Page 443: ...Run 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 o...

Page 444: ...ill completely disassemble the entire shock Many shock services may not require complete disassembly of some components Example if the eyelet is tight to the shaft it may not require removal or if the...

Page 445: ...need 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...

Page 446: ...essed 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 1...

Page 447: ...k 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 sta...

Page 448: ...eyelet 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 449: ...5 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 Re...

Page 450: ...6 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 2 5 Bypass Piston Compression Side Rebound Side 3 0 Bypass Piston Compression Side Rebound Side STEERING SUSPENS...

Page 451: ...sing clamp blocks to secure reservoir in vise torque body cap to specification using the offset formula See Offset Torque Formula page 9 39 TORQUE Body Cap step 1 30 ft lb 42 Nm 3 With body prepared w...

Page 452: ...ds 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 Insta...

Page 453: ...all 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 p...

Page 454: ...k 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...

Page 455: ...and 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...

Page 456: ...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 Crimp Nut 7 16 31 O Ring 6 Seal 19 Snap Ring 32 Detent Spr...

Page 457: ...ll perform the best if serviced at 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 r...

Page 458: ...RVICE INFORMATION FRONT SHOCK DESIGN DETAILS RZR PRO XP RZR PRO XP 4 Travel 8 47 21 51 cm 8 47 21 51 cm Extended Length 18 44 46 84 cm 19 43 49 35 cm IFP Depth 4 63 11 76 cm 4 63 11 76 cm Nitrogen Pre...

Page 459: ...010 0 625 x 0 065 1 450 x 0 012 0 750 x 0 065 1 500 x 0 012 1 200 x 0 008 1 550 x 0 010 1 200 x 0 008 1 550 x 0 010 Piston Bleed Orifice none RZR PRO XP 4 FRONT SHOCK VALVING COMPRESSION REBOUND CLIC...

Page 460: ...CE INFORMATION REAR SHOCK DESIGN DETAILS RZR PRO XP RZR PRO XP 4 Travel 13 55 34 42 cm 13 55 34 42 cm Extended Length 23 55 85 09 cm 23 55 85 09 cm IFP Depth 7 25 18 42 cm 7 25 18 42 cm Nitrogen Press...

Page 461: ...010 0 600 x 0 015 1 200 x 0 008 0 900 x 0 012 1 100 x 0 008 0 750 x 0 065 round side towards shim 0 800 x 0 012 0 800 x 0 012 1 500 x 0 125 No Piston Bleed Orifice RZR PRO XP 4 REAR SHOCK VALVING COMP...

Page 462: ...ting is appropriate for nearly all riding conditions If desired the spring setting may be adjusted to maintain vehicle clearance height when carrying loads 1 Raise and safely support front or rear of...

Page 463: ...recommended you wear safety glasses and ear protection during these procedures SPECIAL TOOLS PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit PS 45908 IFP Tool PU 50979 Shock Body Holding Too...

Page 464: ...bly It is strongly recommended 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 caref...

Page 465: ...5908 and 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 12 Clean and in...

Page 466: ...r 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 Shock Bod...

Page 467: ...Protector Sleeve PU 50939 Rear Shock Seal Protector Sleeve PU 50952 4 Install seal head assembly onto the shock shaft 5 Remove the Shock Seal Protector Sleeve 6 Place the compression valve stack on t...

Page 468: ...Holding 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...

Page 469: ...damping 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 s...

Page 470: ...k 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 an...

Page 471: ...hread 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 setti...

Page 472: ...and assembly of a Dymanix shock DYNAMIX OVERVIEW The suspension control screen provides additional information about the operation of the DYNAMIX Active Suspension system q Current Suspension Ride Mod...

Page 473: ...l speed and dynamic events to illicit the same visual response in the interface SUSPENSION CONTROL MODULE SCM The Suspension Control Module SCM contains the logic for suspension control including comm...

Page 474: ...y into the vehicle Torque mounting fasteners to specification IMPORTANT A sticker with an arrow on the SCM indicates which side MUST face the front of the vehicle TORQUE SCM Mounting Plate Fasteners 8...

Page 475: ...system continuously monitors vehicle speed accelerator pedal position and vehicle speed to increase damping of the rear shocks under certain acceleration conditions to reduce squat AIRBORNE DETECTION...

Page 476: ...tor on the RideCommand display Suspension activity notifications can be turned enabled disabled from the vehicle the setting menu PROCESSING CAPABILITY DYNAMIX Active Suspension controls current to th...

Page 477: ...2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 9 73 SWITCH POSITION CONTACT A CONTACT B PINS 1 TO 7 Comfort Closed Open 1270 Sport Open Open 1400 Firm Open Closed 1330 STEER...

Page 478: ...9 74 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc NOTES STEERING SUSPENSION...

Page 479: ...KE CALIPER PAD REMOVAL 10 17 FRONT CALIPER ASSEMBLY VIEW 10 19 FRONT CALIPER ASSEMBLY VIEW 4 SEAT 10 20 FRONT CALIPER DISASSEMBLY INSPECTION 10 21 FRONT CALIPER DISASSEMBLY INSPECTION 4 SEAT 10 22 BRA...

Page 480: ...tp polaris service solutions com BRAKE SYSTEM SPECIFICATIONS FRONT BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Front Pad Thickness 296 007 7 53 19 mm 180 4 6 mm Front Disc Thickness 295 008 7 5 2 mm 268...

Page 481: ...aliper w Bleeder Screw 48 in lb 5 Nm u Junction Block Fasteners 35 in lb 4 Nm d Brake Scraper e Brake Banjo Bolt 15 ft lbs 20 Nm i Junction Block f Brake Scraper Fasteners 7 ft lbs 10 Nm r Rear Brake...

Page 482: ...lbs 20 Nm r Rear Brake Caliper Fasteners 35 in lb 4 Nm t Junction Block Fasteners 35 in lb 4 Nm y Junction Block u Master Cylinder i Master Cylinder Shield Fasteners 18 ft lbs 25 Nm o Front Brake Cal...

Page 483: ...21 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 10 5 BRAKE LINE ROUTING RETENTION Master Cylinder To Front Brake Calipers q Master Cylinder w Rivet Clip e Routing Clip r Front Brake...

Page 484: ...10 6 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc Master Cylinder To Junction Block q Master Cylinder w Routing Clip e Junction Block BRAKE SYSTEM...

Page 485: ...50068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 10 7 Junction Block to Rear Brake Calipers q Junction Block w Rivet Clip e Routing Clip r Rear Brake Caliper BRAKE S...

Page 486: ...21 RZR PRO XP XP 4 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 Bra...

Page 487: ...10 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 10 9 Master Cylinder To Junction Block q Master Cylinder w Routing Clip e Junction Block BRAKE SYSTEM...

Page 488: ...0 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc Junction Block to Rear Brake Calipers q Junction Block w Rivet Clip e Routing Clip r Rear Brake Caliper BRAKE SY...

Page 489: ...ening 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 a...

Page 490: ...uid 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...

Page 491: ...as shown Torque banjo bolt and brake pressure switch to specification ITEM DESCRIPTION ANGLE q Rear Brake Line 150 w Front Right Brake Line 90 e Front Left Brake Line 90 TORQUE Banjo Bolt Brake Press...

Page 492: ...oir q with a Mity Vac pump or similar tool Mity Vac 2870975 3 Add brake fluid to the indicated MAX level of reservoir Polaris DOT 4 Brake Fluid 2872189 4 Bleed the brakes in the following order right...

Page 493: ...ems It may appear that there is fluid in the reservoir even if the rear half of the reservoir is empty 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to specification TO...

Page 494: ...pedal lever w and remove the clip q and master cylinder clevis pin r 2 Remove the E clip e from the pedal mount and remove the brake pedal lever w from the vehicle BRAKE PEDAL INSTALLATION 1 Reverse...

Page 495: ...wer caliper 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 ki...

Page 496: ...10 18 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 9 Remove the bolt r retaining the brake line to the caliper BRAKE SYSTEM...

Page 497: ...ALIPER ASSEMBLY VIEW q Brake Pads y Set Screw w Pistons lubricate with DOT 4 Brake Fluid u Piston O Rings lubricate with DOT 4 Brake Fluid e Boots i Brake Scraper r Caliper Assembly o Scraper Bolts 7...

Page 498: ...nc FRONT CALIPER ASSEMBLY VIEW 4 SEAT q Brake Pads y Set Screw w Pistons lubricate with DOT 4 Brake Fluid u Piston O Rings lubricate with DOT 4 Brake Fluid e Boots i Brake Scraper r Caliper Assembly o...

Page 499: ...ecome damaged if a standard 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 ca...

Page 500: ...clean the caliper before disassembly and prepare a clean work area for disassembly 3 Use a commercially available caliper piston pliers to extract the pistons e from the caliper IMPORTANT Do not remov...

Page 501: ...ct piston for nicks scratches pitting or wear 9 Measure piston diameter and replace if damaged or worn beyond service limit MEASUREMENT Front Caliper Piston O D Large 1 50 38 1 mm Small 1 19 30 226 mm...

Page 502: ...he dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease BRAKE DISC INSPECTION 1 Visually inspect di...

Page 503: ...g the brake line fitting to the caliper Torque banjo bolt to specification NOTICE The calipers have self orienting features brake lines do not need to be oriented if installed correctly TORQUE Brake L...

Page 504: ...er installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficien...

Page 505: ...ure or corrosion If moisture or corrosion is found clean first and re check 3 With connector disconnected check resistance across pins on the sensor When switch is closed brake pedal not depressed res...

Page 506: ...mounting 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 calipe...

Page 507: ...brake line to the caliper REAR CALIPER DISASSEMBLY INSPECTION 1 Remove brake pad adjustment set screw o 2 Push upper pad retainer pin inward and slip brake pads q past the edge and remove from the ca...

Page 508: ...Small 1 000 25 4 mm Service Limit 1 002 25 45 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit MEASUREMENT Rear Caliper Pist...

Page 509: ...cket and make sure the dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease REAR BRAKE DISC INSPECT...

Page 510: ...e and install new disc on wheel hub 5 Install new studs t 6 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Rear Wheel Hub Cast...

Page 511: ...atures brake lines do not need to be oriented if installed correctly TORQUE Banjo Bolts 15 ft lb 20 Nm 3 Install lower radius rod bolt washer and new nut Torque to specification TORQUE Radius Rod to B...

Page 512: ...er installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficien...

Page 513: ...ROLS 11 7 HOOD FRONT BODY 11 8 CHASSIS MAIN FRAME 11 9 CHASSIS MAIN FRAME 4 SEAT 11 10 SEAT ASSEMBLY 11 11 FLOOR ROCKER PANELS 11 12 FLOOR ROCKER PANELS 4 SEAT 11 13 REAR CARGO BOX FENDERS 11 14 REAR...

Page 514: ...ore 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...

Page 515: ...CAB FRAME ASSEMBLY q LH ROPS y Flanged Nyloc Nut M12 x 1 5 w RH ROPS u Fastener M10 x 1 5 x 45 10 9 44 ft lbs 60 Nm e Front Cross Member i Nyloc Nut M10 x 1 5 r Rear Cross Member o Fastener M10 x 1 5...

Page 516: ...EAT q LH ROPS u Flanged Nyloc Nut M12 x 1 5 w RH ROPS i Fastener M10 x 1 5 x 45 10 9 44 ft lbs 60 Nm e Front Cross Member o Nyloc Nut M10 x 1 5 r Middle Cross Member a Fastener M10 x 1 5 x 75 10 9 44...

Page 517: ...l i Door Latch Actuator Fastener 9 ft lbs 12 Nm w Front Door Panel o Door Latch e Door Frame a Door Latch Fastener 9 ft lbs 12 Nm r Door Frame Fastener 7 ft lbs 10 Nm s Door Hinge t Door Striker d Doo...

Page 518: ...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 Ac...

Page 519: ...1 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 11 7 DASH CONTROLS q 7 Display Turbo S Models Only r Headlight Switch w Key Switch t AWD Switch e Mode Switch Turbo S Models Only y 12...

Page 520: ...7 ft lbs 10 Nm s LH Front Fender e Dash Trim d Hood Liner r Dash Trim Fasteners 7 ft lbs 10 Nm f Upper Dash Panel t RH Front Fender Flare g Storage Cover y RH Inner Front Fender Flare h Nose Cone u R...

Page 521: ...s 33 ft lbs 45 Nm r Cargo Box Support Bracket g Flanged Nyloc Nut M10 x 1 5 t Cargo Box Support Bracket Fasteners 15 ft lbs 20 Nm h Front Frame Assembly y Main Frame Assembly j Front Frame Fasteners 1...

Page 522: ...ate Fasteners 9 ft lbs 12 Nm h Fastener M10 x 1 5 x 35 33 ft lbs 45 Nm t Cargo Box Support Bracket j Nut M10 x 1 5 Nyloc y Cargo Box Support Bracket Fasteners 15 ft lbs 20 Nm k Front Lower Frame Assem...

Page 523: ...11 11 SEAT ASSEMBLY q Seat Assembly y Nyloc Nut 6 mm x 1 7 ft lbs 10 Nm w Seat Slider Frame u Slide Tilt Bracket e Slide Tilt Receiver i Nyloc Nut 6 mm x 1 7 ft lbs 10 Nm r Lower Hinge Bushing o Faste...

Page 524: ...right Polaris Industries Inc FLOOR ROCKER PANELS q Front Main Floor y Center Console w Foot Rest Panel u Storage Console e Front Floor Panel i Center Console r Under Seat Panel o Battery Tray t Rocker...

Page 525: ...13 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 Rock...

Page 526: ...ERS q Outer Rear Fender u Rear Inner Fender w Rear Fender Flare i Rear Fascia Mounting Bracket e Rear Close off Panel o Rear Fascia Assembly r Top Rear Close off Panel a Rear Bumper t Bottom Rear Clos...

Page 527: ...s Inc 11 15 REAR BUMPER q Rear Fascia t Rear Fascia to box Mounting Bracket w Rear Fascia Fastener 7ft lbs 10 Nm y Mounting Bracket Fastener 7ft lbs 10 Nm e Rear Fascia Mounting Bracket u Rear Bumper...

Page 528: ...nder 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 latche...

Page 529: ...per 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 fend...

Page 530: ...ct all headlight and accent light electrical connections 9 Remove two push pins a and remove front fascia REAR FASCIA 1 Remove six fasteners q and remove rear bumper 2 Disconnect all electrical connec...

Page 531: ...1 Remove two fasteners q and remove hood DASH REMOVAL 1 Remove front fascia See Front Fascia Removal page 11 17 2 Remove LH and center dash trim w 3 Remove RH dash trim e 4 Remove eight fasteners r a...

Page 532: ...emove 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 passenge...

Page 533: ...ender Fender Flare Removal page 11 20 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...

Page 534: ...e 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 fastene...

Page 535: ...bs 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 Fas...

Page 536: ...r 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...

Page 537: ...ON GEAR POSITION SWITCH 12 16 BRAKE PRESSURE SWITCH 12 16 BOOST CONTROL SOLENOID VALVE 12 17 SUSPENSION MODE SWITCH DYNAMIX MODELS 12 17 STEERING ANGLE SENSOR CENTERING DYNAMIX 12 18 IGNITION COIL 12...

Page 538: ...ID OPERATION 12 35 ELECTRONIC POWER STEERING EPS 12 36 EPS OPERATION 12 36 PROPER EPS SYSTEM DIAGNOSING 12 36 FUSES RELAYS 12 37 FUSE RELAY BOX 12 37 RELAY FUSE DETAILS 12 40 VOLTAGE REGULATOR FUSIBLE...

Page 539: ...DX 610P Battery Tester PU 50338 Battery Hydrometer PV 43526 Connector Test Kit PV 43568 Fluke 77 Digital Multimeter Digital Wrench see Chapter 4 DIGITAL WRENCH OPERATION page Bosch Automotive Service...

Page 540: ...resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10...

Page 541: ...Throttle Body f PTO Injector 2 Stator 2 r Boost Pressure Sensor g TMAP Sensor 2 Fuel Pump and Sender t Oxygen Sensor h MAG Coil 2 Charge Air Cooler Pump y Vehicle Speed Sensor j PTO Coil 2 Battery u...

Page 542: ...witch 4 Chassis Ground 5 Cooling Fan 3 C4 Gauge 4 Audio Amplifier 5 Left Headlight 3 Key Switch 4 Right Tweeter 5 Right Headlight 3 Diagnostic Plug 4 Rear Audio 5 Ambient Air Temperature Sensor 3 Ride...

Page 543: ...e 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 co...

Page 544: ...aches 0 o Check Engine MIL Illuminates when the ECU has detected a Diagnostic Trouble Code in the engine management system a AWD Indicator Illuminates when the AWD TURF switch is in the AWD position s...

Page 545: ...lant Vehicle Speed Speed of vehicle Tachometer Engine speed RPM AREA 2 MODES MODE DESCRIPTION Odometer The odometer records and displays the total distance traveled by the vehicle The odometer can not...

Page 546: ...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 547: ...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 factory As hours of engine operation incre...

Page 548: ...move RH dash trim e 4 Remove eight fasteners r and remove dash 5 Remove center dash panel t 6 Remove connections from the back of the Ride Command unit and remove unit from the vehicle INSTALLATION 1...

Page 549: ...2 13 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 S...

Page 550: ...e switch to OFF There should be continuity between switch pins 1 and 2 4 and 5 7 and 8 NOTICE Pins 7 and 8 provide power and ground to light the switch lamp IGNITION KEY SWITCH 1 Disconnect the key sw...

Page 551: ...hould be continuity between switch pins 2 and 3 as well as 3 and 7 Move the switch to 2WD NONE OFF There should ONLY be continuity between pins 3 and 7 SEAT BELT SWITCH Location Found on the driver s...

Page 552: ...AR 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 outle...

Page 553: ...a proportion of exhaust gas bypasses the turbine The boost control valve vents to atmosphere when building boost If the vent hose w to atmosphere is plugged an underboost code will set If a trouble c...

Page 554: ...Perform EPS Steering Angle Centering procedure found in Steering Suspension System Utilities on the Special Tests menu in Digital Wrench 3 Drive vehicle straight at 10 mph 16 km h for at least 10 seco...

Page 555: ...ponding to specific crankshaft position This signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines whe...

Page 556: ...Wait 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 m...

Page 557: ...s can be performed using a multi meter to determine the condition of the stator alternator TEST 1 RESISTANCE VALUE OF EACH STATOR LEG Measure the resistance value of each of the three stator legs Y1 t...

Page 558: ...specified RPM in the table NOTICE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced RPM READING AC VOLTAGE VAC READIN...

Page 559: ...Polaris Industries Inc 12 23 6 Connect the two regulator harnesses on each regulator 7 Install the front fascia grill 8 Connect the battery negative cable Torque fastener to specification TORQUE Batte...

Page 560: ...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 561: ...out 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...

Page 562: ...will form on the plates reducing the efficiency and 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 1...

Page 563: ...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 times care...

Page 564: ...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 565: ...a ground 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 INST...

Page 566: ...ion by using Digital 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...

Page 567: ...an motor wiring ground motor condition circuit breaker and mechanical relay for proper operation Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn o...

Page 568: ...to specification TORQUE Fan Assembly Mounting Fasteners 9 ft lbs 12 Nm 4 Connect the two coolant hoses and one vent line going to the radiator 5 Install the charge air radiator into the chassis 6 Inst...

Page 569: ...to bypass the Fuel Pump relay Relay Bypass Jumper PU 49466 2 When the key is turned on the coolant pump will continuously cycle even when the engine is not running 3 When the system is bled properly...

Page 570: ...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...

Page 571: ...cables on the solenoid posts Torque nuts to specification TORQUE Solenoid Cable Nuts 35 in lb 4 Nm 9 Connect the harness to the solenoid STARTER SOLENOID BENCH TEST Test the start solenoid by powering...

Page 572: ...E To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction Indicator Light will illuminate t...

Page 573: ...N FUNCTION Start Relay 1 Coil High 2 Power In 7 Power Out 8 Coil Low Term Accy 10A Fuse 3 Power In 9 Power Out Instr Accy 7 5A Fuse 4 Power In 10 Power Out Spare 30A Fuse 5 Power In 11 Power Out Fan 3...

Page 574: ...34 Power Out Shocks Relay 29 Coil High 30 Power In 35 Power Out 36 Coil Low Lights 7 5A Fuse 37 Power In 43 Power Out Instr Unsw 7 5A Fuse 38 Power In 44 Power Out Chassis Relay 39 Coil High 40 Power...

Page 575: ...RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 12 39 CIRCUIT PIN FUNCTION EFI Relay 63 Coil High 64 Power In 69 Power Out 70 Coil Low Brake Relay 65 Coil High 66 Power In 71 Power Ou...

Page 576: ...ECU Seatbelt Switch O2 Sensor Brake Pressure Switch Ignition Coil EFI B Splice 2 Chassis Relay coil high Pump Relay coil high Pump Relay Pump Splice Fuel 10A Fuse Water 10A Fuse Unsw 10A Fuse B Unswi...

Page 577: ...ght Polaris Industries Inc 12 41 VOLTAGE REGULATOR FUSIBLE LINK There are two fusible links on this vehicle that protect the voltage regulator output circuits These are located on the pigtails coming...

Page 578: ...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 579: ...12 9850068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 12 43 WIRING HARNESS ELECTRICAL HARNESS ROUTING ELECTRICAL HARNESS ROUTING 4 SEAT ELECTRICAL...

Page 580: ...50068 R01 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc ELECTRICAL HARNESS RETENTION q Zip Tie Retention Point The white tape on the harness signifies a retention point ELE...

Page 581: ...1 2020 2021 RZR PRO XP XP 4 Service Manual Copyright Polaris Industries Inc 12 45 ELECTRICAL HARNESS RETENTION 4 SEAT q Zip Tie Retention Point The white tape on the harness signifies a retention poin...

Page 582: ...e pedal and brake pedal assembly 11 Remove the center console and floor Refer to Rocker Panels Console and Floor page 11 21 12 Remove the seats and seat frames 13 Remove the ECU cover and disconnect t...

Page 583: ...rottle pedal and brake pedal assembly 11 Remove the center console and floor Refer to Rocker Panels Console and Floor page 11 13 12 Remove the seats and seat frames 13 Remove the ECU cover and disconn...

Page 584: ...n with the main wiring diagrams To access the interactive break out diagrams 1 Open the wiring diagram PDF and open the left side menu 2 If the wiring diagram does not open the Adobe navigation bars c...

Page 585: ...PPLY SYMPTOM CHART STARTING CONCERNS IF NEEDED REFER TO OWNERS MANUAL SERVICE MANUAL FOR NORMAL STARTING CONCERNS WILL NOT CRANK STARTS BUT TAKES A LONG TIME CRANKS BUT WILL NOT RUN TAKES MULTIPLE KEY...

Page 586: ...ELOW 0 F WARM 60 80 F COLD 0 32 F HOT 80 F COOL 32 60 F ALL TEMPERATURES TYPE OF FUEL USED FUEL CONDITION 87 OCTANE HAVE ANY ADDITIVES BEEN ADDED OCTANE BOOSTER CLEANERS ETC IF SO PLEASE LIST BELOW 89...

Page 587: ...Symptom and Occurrence Checklist BEEN PRESENT SINCE NEW 51...

Page 588: ......

Page 589: ...e Model Click here RZR PRO XP Dynamix Edition Click here RZR PRO XP Ride Command Click here RZR PRO XP Box Click here RZR PRO XP Box Premium Model Click here RZR PRO XP Center Console Click here RZR P...

Page 590: ......

Page 591: ...tallation rear 10 33 Removal Front 10 17 Brake Pads Removal rear 10 28 Brake Pedal Installation 10 16 Removal 10 16 Brake Pressure Switch 12 16 Brake System Brake Hose and Fitting Inspection 2 54 Brak...

Page 592: ...Coolant Temperature Sensor Test 12 34 Cooling Fan Bypass Test 12 31 Replacement 12 31 Testing 12 30 Cooling System Bleeding 2 38 Coolant Strength and Type 2 35 Pressure Test 2 36 3 31 Specifications...

Page 593: ...5 5 Electrical Component Locations front 12 6 Component Locations rear 12 5 Connector Probing Guidelines 1 74 Continuity Resistance 1 75 Current Draw Key Off 1 78 12 20 Digital Multi Meter DMM 1 73 No...

Page 594: ...Fluid Leak 1 59 Flywheel Installation 3 89 Removal 3 64 Flywheel Starter Drive Exploded View 3 89 FOX Shock Assembly 9 47 Assembly View 9 38 Disassembly 9 40 Front A arm Replacement 9 18 Front Bearin...

Page 595: ...ion Chart 3 79 Main Harness Replacement 12 46 Replacement 4 Seat 12 47 Maintenance Battery 2 56 Quick Reference 2 25 Steering System 2 47 Maintenance Intervals 2 5 Manifold Pressure Sensor 4 4 Master...

Page 596: ...y View 9 22 Relay Power Circuits 12 40 Relay Box 12 37 Replacement 3 36 Replacement Front 8 4 retention 12 44 Retention 10 5 Retention 4 Seat 10 8 Ride Command Unit Replacement 12 11 Rocker Panel Remo...

Page 597: ...bly View 9 17 Inspection 2 50 Shock Adjustment 2 51 Shock Analysis 1 72 Special Tools 9 3 Spring Adjustment WALKER EVANS 9 58 Suspension Control Module 9 69 Suspension Mode Switch Dynamix 9 72 12 17 S...

Page 598: ...1 Removal 3 53 Valve Seat Reconditioning 3 60 Valve Spring Free Length 3 58 Removal 3 58 Vehicle Identification Model Number Designation 1 3 Vehicle Identification Number 1 3 Vehicle Speed Sensitivity...

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