Polaris RZR PRO XP 2020 Service Manual
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Polaris RZR PRO XP 2020 Service Manual

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2020-2021 RZR PRO XP / XP 4
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2020 (PN 9850068 R01)
© Copyright 2020 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RZR PRO XP 2020

  • Page 1 Publication Printed September 2020 (PN 9850068 R01) © Copyright 2020 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 3 REVISION INDEX DATE CHANGES 11/10/2020 Initial Release.
  • Page 4 FEEDBACK FORM A feedback form has been created for the technician or consumer 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...
  • Page 5 2020-2021 RZR PRO XP / XP 4 Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING SYSTEM CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : EFI / FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION...

  • Page 7: Table Of Contents

    ..........1.41 DIGITAL WRENCH® SERIAL NUMBER LOCATION 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 8 ............1.44 POLARIS MOBILE DIGITAL WRENCH® (PMDW) .

  • Page 9: Vehicle Identification

    M = 2021 VIN AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the rear left vertical shock support tube...
  • Page 10 GENERAL INFORMATION 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 11: Reference Information

    NOTICE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www. polaris.com or purchased from www.purepolaris.com. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 12: Special Tools

    Special tools may be required while servicing this vehicle. Some of the 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. Dealers may order special tools through Polaris’ official tool supplier.
  • Page 13 PU-47471 PU-48951 Fuel Pressure Adapter Water Pump Drive & Fuel Pressure Gauge Smartlink Module Kit CV Boot Clamp Pliers Flywheel Removal (Stepless) Tool 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 PU-51837 Flywheel Holding Tool Shock Spanner Shock Spanner Shock Spanner Shock Body Holding Wrench 2.5–3.0 Inner Wrench 2.5 Outer Wrench 3.0 Outer Tool 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 Compressor Compressor Adapter PV-43526 PV-43531 PV-43568 PV-43570-1 39800780 Connector Test Kit Oil Presure gauge Fluke Multimeter Piston Ring IFP Tool (FOX) Compressor Pliers 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 16: Master Torque Table

    33 ft-lbs (45 Nm) (Upper) 9 ft-lb (12 Nm) EPS to Lower Steering Shaft Crankcase Bolts 22 ft-lbs (30 Nm) 26 ft-lb (35 Nm) Fastener 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 26 ft-lb (35 Nm) Seat Frame Fastener (Front) M10 37 ft-lbs (50 Nm) Mounting x 1.5 x 16 Oil Pump 7 ft-lbs (10 Nm) Bolts 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 18 33 ft-lbs (45 Nm) Fasteners Water Pump Impeller (Apply Loctite® Steering Rack Mounting Bolts 44 ft-lbs (60 Nm) Impeller 204™ to bolt threads) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 22 in-lb ( 3 Nm) Winch Cover Fastener Winch Mounting Plate Fasteners 18 ft-lbs (24 Nm) Wheel Lug Nuts 120 ft-lbs (163 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 20: Vehicle Specifications

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.14 © Copyright Polaris Industries Inc.

  • Page 21: 2020-21 Rzr Pro Xp Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.15 © Copyright Polaris Industries Inc.
  • Page 22 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 23: 2020-21 Rzr Pro Xp 4 Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.17 © Copyright Polaris Industries Inc.
  • Page 24 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: 2020-21 Rzr Pro Xp Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.19 © Copyright Polaris Industries Inc.
  • Page 26 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.20 © Copyright Polaris Industries Inc.

  • Page 27: 2020-21 Rzr Pro Xp 4 Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 28: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.22 © Copyright Polaris Industries Inc.

  • Page 29: Sae Tap / Drill Sizes

    5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 3–4 7/16–14 2 3/4 7/16–20 25/64 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 30: Decimal Equivalents

    15/32 0.4688″ 12 mm = 0.4724″ 31/32 0.9688″ 25 mm = 0.9843″ 31/64 0.4844″ 63/64 0.9844″ 0.500″ 13 mm = 0.5118″ 1.000″ 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.24 © Copyright Polaris Industries Inc.

  • Page 31: General Diagnostics

    Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.25 © Copyright Polaris Industries Inc.

  • Page 32: Guided Symptom References

    Refer to the Symptom Checklist for various conditions. – If the concern has been verified and all of the information has already been collected, please start an Ask Polaris case at this time. If this information has not yet been gathered, gather this information first.

  • Page 33: Engine And Drivability Diagnostic Procedures

    • Connect to Digital Wrench®. Check codes and continue with Digital Wrench® Guided diagnosis. • If no codes are present, proceed to step 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.27 © Copyright Polaris Industries Inc.
  • Page 34 • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.30 for more information. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.28 © Copyright Polaris Industries Inc.
  • Page 35 These concerns may also be caused by a mechanical failure. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.29...

  • Page 36: Engine Cranks But Does Not Start

    10. Listen for unusual noises while cranking. • If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.30 © Copyright Polaris Industries Inc.
  • Page 37 – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 38: No Crank No Start Or Slow Crank

    (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake Switch operation. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.32 © Copyright Polaris Industries Inc.

  • Page 39: Over Heating

    • Check level and correct as necessary. Check maintenance history to determine if oil need to be changed. 7. Check Cooling Fan operation. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.33 © Copyright Polaris Industries Inc.

  • Page 40: Warning Lights

    5. BRAKE WARNING • Detects brake system failure. • Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.34 © Copyright Polaris Industries Inc.

  • Page 41: Engine Troubleshooting

    • Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.35 © Copyright Polaris Industries Inc.
  • Page 42 / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.36 © Copyright Polaris Industries Inc.

  • Page 43: Cooling Troubleshooting

    • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.37 © Copyright Polaris Industries Inc.

  • Page 44: Digital Wrench® Software Overview

    GENERAL INFORMATION DIGITAL WRENCH DIGITAL WRENCH® SOFTWARE OVERVIEW The Polaris Digital Wrench® software allows a technician to perform the following tasks: • Analyze real-time engine data • Create customer service account records • Generate / upload service reports • Perform guided diagnostic procedures •...

  • Page 45: Digital Wrench® Software Installation And Updates

    To check if a Digital Wrench® software update is following: available, do the following: 1. Open a web browser and log on to your Polaris dealer 1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com).

  • Page 46: Digital Wrench® Communication Errors

    If you experience problems connecting to a vehicle, or ‘Connected’ in the lower left corner of the screen. any other Digital Wrench® software-related problem, visit the Digital Wrench® home page (www.polaris.diagsys. 5. Once connected, proceed with using Digital com) and locate the following information under Wrench®.

  • Page 47: Digital Wrench® Serial Number Location

    2. On the Digital Wrench® main screen, select the ‘Configure the Diagnostic System Software’ menu icon. 3. Locate the serial number on the right side of the System Configuration screen. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.41 © Copyright Polaris Industries Inc.

  • Page 48: Digital Wrench® Feature Map

    Access the Digital Wrench® and adjustment functions System Help. service reports. Print the current screen as a Open the ASSERT ASK formatted printout. form. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.42 © Copyright Polaris Industries Inc.
  • Page 49 GENERAL INFORMATION 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.43 © Copyright Polaris Industries Inc.

  • Page 50: Engine Controller Reprogramming (Reflash)

    – Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®. progress. 10. Open a web browser and log on to your Polaris dealer • Understand the Process website (www.polarisdealers.com). Review the Digital Wrench® System Help before you 11.
  • Page 51 GENERAL INFORMATION You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download. MINIMUM SPECIFICATIONS FOR ANDROID DEVICES • Minimum operating system: Android 3.1 “Honeycomb”...

  • Page 52: Diagnostic Trouble Codes Overview

    0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present). 5. Press MODE to exit to the settings menu. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.46 © Copyright Polaris Industries Inc.
  • Page 53 Voltage Above Normal, Or Shorted To High Source P0108 Manifold Absolute Pressure Sensor Voltage Too Low P0107 Mechanical System Not Responding Or Out Of Adjustment P1106 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.47 © Copyright Polaris Industries Inc.
  • Page 54 Data Valid But Above Normal Operating Range - Moderately Severe P1571 Level Data Valid But Below Normal Operating Range - Moderately Severe P1573 Level 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.48 © Copyright Polaris Industries Inc.
  • Page 55 Camshaft Position Sensor Abnormal Frequency Or Pulse Width Or Period P0340 Voltage Above Normal, Or Shorted To High Source P1739 Tachometer Driver Circuit 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.49 © Copyright Polaris Industries Inc.
  • Page 56 Wheel Speed Sensor (Rear or Voltage Above Normal, Or Shorted To High Source C113D Rear Left) Voltage Below Normal, Or Shorted To Low Source C123D 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.50 © Copyright Polaris Industries Inc.
  • Page 57 Current Below Normal Or Open Circuit P0685 Voltage Above Normal P0694 1557 Fan Driver 2 Voltage Below Normal, Or Shorted To Low Source P0693 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.51 © Copyright Polaris Industries Inc.
  • Page 58 ECU Output Supply Voltage 3 3599 Voltage Above Normal, Or Shorted To High Source P17AA Voltage Below Normal, Or Shorted To Low Source P17AB 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.52 © Copyright Polaris Industries Inc.
  • Page 59 Data Valid But Below Normal Operating Range - Least Severe Level P0174 Data Erratic, Intermittent Or Incorrect P1684 520206 Reverse Alarm Voltage Above Normal, Or Shorted To High Source P1682 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.53 © Copyright Polaris Industries Inc.
  • Page 60 C1029 ABS Solenoid (Front Right Out) 520257 Condition Exists C1329 Voltage Above Normal, Or Shorted To High Source C1020 520260 ABS Motor 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.54 © Copyright Polaris Industries Inc.
  • Page 61 P1542 ECU Monitoring of Injection Cut Off 520288 (Level 1) ECU Monitoring of Injection Cut Off Condition Exists P1543 520289 (Level 2) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.55 © Copyright Polaris Industries Inc.
  • Page 62 Voltage Below Normal, Or Shorted To Low Source P153B Operator Presence Switch Voltage Above Normal, Or Shorted To High Source P251C 524070 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.56 © Copyright Polaris Industries Inc.
  • Page 63 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.57 © Copyright Polaris Industries Inc.

  • Page 64: Cylinder Misfire Detection

    Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.58 © Copyright Polaris Industries Inc.

  • Page 65: Fluid Leaks

    Refer to the Service Manual information related to the system in question. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.59 © Copyright Polaris Industries Inc.

  • Page 66: Fuel System Troubleshooting

    • Spark plug erosion / fouling • Faulty oxygen sensor • Engine runs hot • Surging • High / Erratic idle 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.60 © Copyright Polaris Industries Inc.
  • Page 67 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.61 © Copyright Polaris Industries Inc.

  • Page 68: Pvt System Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.62 © Copyright Polaris Industries Inc.
  • Page 69 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.63 © Copyright Polaris Industries Inc.

  • Page 70: Pvt System Overheating / Diagnosis

    PVT system. than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel Poor engine performance.

  • Page 71: Hard Shifting

    • If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.65 © Copyright Polaris Industries Inc.

  • Page 72: All Wheel Drive (Awd) Concerns

    Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.66 © Copyright Polaris Industries Inc.

  • Page 73: Brake Noise Troubleshooting

    • Brake Disc damaged VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING) • Worn Suspension components • Alignment issues 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.67 © Copyright Polaris Industries Inc.

  • Page 74: Caliper Overheats (Brakes Drag)

    • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder • Faulty distribution block (INTL models only ) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.68 © Copyright Polaris Industries Inc.

  • Page 75: Eps Troubleshooting (Power Steering Non-Functional With Mil

    Check wiring from Connector to Ignition Switch 12 VDC on Pin 3 of the 8 pin EPS Connector? Circuit ↓ Begin Digital Wrench EPS Troubleshooting Procedure 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.69 © Copyright Polaris Industries Inc.

  • Page 76: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    MIL lamp Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.70 © Copyright Polaris Industries Inc.

  • Page 77: Eps Troubleshooting (Using Digital Wrench®)

    If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.71 © Copyright Polaris Industries Inc.

  • Page 78: Shock Analysis

    (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.72 © Copyright Polaris Industries Inc.

  • Page 79: Electrical Service Notes

    • All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.76 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) DYNAMIC TESTING for electrical testing.

  • Page 80: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate Back probing is typically not advisable on sealed adapters is required. Most terminals used on Polaris connectors, as it can easily cause damage to the wire, machines can be tested using terminal test kit PV–...

  • Page 81: Testing Continuity / Resistance

    Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.76 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.75 © Copyright Polaris Industries Inc.

  • Page 82: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.76 © Copyright Polaris Industries Inc.

  • Page 83: Testing For Intermittent Conditions

    Failure to do so can lead to serious injury and/or damage to the machine. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.77 © Copyright Polaris Industries Inc.

  • Page 84: Current Draw - Key Off

    IMPORTANT Charging system damage will occur if incompatible components are installed. Always reference the Polaris TESTING VOLTAGE DROP Electronic Parts Catalog for the proper part numbers. NOTICE If you disconnect the connector at the load, and...
  • Page 85 GENERAL INFORMATION For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.79 © Copyright Polaris Industries Inc.
  • Page 86 GENERAL INFORMATION NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 1.80 © Copyright Polaris Industries Inc.
  • Page 87 STEERING....................2.47 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 88 ................. . .2.56 SPARK PLUG SERVICE 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 89: Maintenance

    U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 16 oz (12) 2870652 Fuel Stabilizer 2872280 2.5 gal (2) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 90: Pre-Ride Inspection

    Wheels / Lug Nuts • Verify proper lug nut torque • Inspect cable / line and switch Winch (if equipped) • Ensure operation 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 91: Maintenance Intervals

    Initial fluid level inspection; add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual...
  • Page 92 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual...
  • Page 93 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual...
  • Page 94 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual...
  • Page 95 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual...
  • Page 96 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.10...
  • Page 97 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.11...
  • Page 98 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.12...
  • Page 99 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.13...
  • Page 100 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.14...
  • Page 101 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.15...
  • Page 102 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.16...
  • Page 103 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.17...
  • Page 104 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.18...
  • Page 105 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.19...
  • Page 106 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.20...
  • Page 107 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.21...
  • Page 108 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.22...
  • Page 109 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.23...
  • Page 110 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.

  • Page 111: Maintenance Quick Reference

    - Front-Left Side of Cargo Box coolant every two years Coolant * More often under severe use, such as operation in water or under severe loads. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.25 © Copyright Polaris Industries Inc.
  • Page 112 Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 113: Grease Lubrication Points

    Polaris Premium U-Joint thoroughly washing or Propshaft Yokes Grease fittings on the slip yoke Grease submerging the vehicle 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 114: Engine / Exhaust

    Access the oil dipstick through the opening in front of the passenger rear tire. Access the oil fill cap by removing the cargo box. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic Engine Oil. FLUID CAPACITY...

  • Page 115: Engine Oil And Filter Change

    15 seconds before removing the oil dipstick. crankcase with a clean rag and ensure the original oil filter o-ring is not stuck to the crankcase. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 116: Engine Crankcase Breather Hose

    18. When finished, 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. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 117: Valve Clearance Adjustment

    3-digit tappet number. 9. Refer to Valve Lash - Tappet Selection page 3.100 and select the proper tappet. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 118: Cam Chain Tensioner Inspection

    Camshaft Installation / Timing page move freely, replace the tensioner assembly. 5. Retract the plunger all the way in and install into the cylinder. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 119: Spark Arrestor

    8 ft-lb (11 Nm) change. 1. Remove the spark arrestor retaining fasteners 2. Remove the arrestor from the end of the muffler. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 120: Heat Shield Inspection

    Engine Shield Silencer Shield Rear Close-Off Shield Front Head Pipe Shield Inner Head Pipe Shield Upper Turbo Shield Inlet Shield Lower Turbo Shield 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 121: Cooling System

    WARNING Recommended Coolant: Never remove the pressure cap when the engine is Polaris 50/50 Extended Life Anti-freeze warm or hot. Escaping steam can cause severe burns. 2880514 (quart) The engine must be cool before removing the pressure 2880513 (gallon) cap.

  • Page 122: Cooling System Pressure Test

    Turbo Inlet Hose Turbo Outlet Hose Cylinder Head Vent Hose 3. Check tightness and condition of all hose spring clamps. Replace if necessary. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 123: Radiator Inspection / Cleaning

    9. Fill the reservoir to the FULL COLD line. 10. Proceed to bleed the cooling system. See Cooling System Bleeding. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 124: Cooling System Bleeding

    NOTICE The cooling system is self-bleeding. 4. Install the coolant pressure cap. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.38 © Copyright Polaris Industries Inc.

  • Page 125: Fuel System And Air Intake

    NOTICE Check throttle pedal periodically. Make sure vent line is not kinked or pinched. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 126: Engine Intake Pre-Filter Service

    Compressed air or high pressure hose may damage the frog skin pre-filter on the intake. 4. Pull cover outward far enough to remove air filter 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.40 © Copyright Polaris Industries Inc.
  • Page 127 Be sure the lower tabs on the air box cover are properly engaged into the air box. 8. Engage the cover latches. 9. Reinstall rear close off panel and seats. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 128: Pvt / Final Drive / Wheel And Tire

    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, repeat steps 1-5. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 129: Front Gearcase Lubrication

    The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 130: Drive Shaft Boot Inspection

    5. Remove the wheel nuts and remove the wheel. CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.44 © Copyright Polaris Industries Inc.

  • Page 131: Tire Inspection

    TIRE PRESSURE SPECIFICATION (COLD) MODEL FRONT REAR 10 PSI 20 PSI RZR Pro XP (69 kPa) (138 kPa) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.45 © Copyright Polaris Industries Inc.

  • Page 132: Transmission

    4. Reinstall the fill plug and torque to specification. 8. Check for leaks. Dispose of used lubricant properly. TORQUE Transmission Fill / Drain Plug: 14 ft-lbs (19 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.46 © Copyright Polaris Industries Inc.

  • Page 133: Steering

    Check front end alignment whenever steering components are replaced. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized • Replace any worn steering components. Steering Polaris MSD certified technician.

  • Page 134: Wheel Toe Alignment Inspection

    3. Measure the distance between the marks and record the measurement. Call this measurement MEASUREMENT Wheel Toe: 1/4” (6.35 mm) toe-in – 1/4” (6.35 mm) toe-out 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.48 © Copyright Polaris Industries Inc.

  • Page 135: Wheel Toe Adjustment

    • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified. MEASUREMENT Wheel Toe: 1/4” (6.35 mm) toe-in – 1/4” (6.35 mm) toe-out 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.49 © Copyright Polaris Industries Inc.

  • Page 136: Suspension

    Inspect stabilizer bar and stabilizer bar bushings for damage/wear. Ensure the shocks are not leaking oil. especially around the shock caps and shaft seals. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.50 © Copyright Polaris Industries Inc.

  • Page 137: Suspension Lubrication

    Shock Spanner / Clutch Spreader Tool: 2878925 NOTICE Polaris does not recommend increasing the spring adjustment beyond the guidelines in the preload adjustment chart as it may negatively impact vehicle stability. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.51...
  • Page 138 If weight is added to the center of the unit, split the preload setting Both Shocks accordingly between the front and rear. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.52 © Copyright Polaris Industries Inc.

  • Page 139: Shock Compression Adjustment (Walker Evans™)

    WALKER EVANS™ 2.5" REAR SHOCK: COMPRESSION ADJUSTMENT TABLE SETTING COMPRESSION DAMPING Full counter-clockwise position Softest Factory 8 clicks from softest position Full clockwise position Firmest 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.53 © Copyright Polaris Industries Inc.

  • Page 140: Brake System

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.54 © Copyright Polaris Industries Inc.

  • Page 141: Brake Disc Inspection

    3. Mount a dial indicator. Slowly rotate the disc and read runout on the dial indicator Replace disc if runout exceeds specifications. MEASUREMENT Brake Disc Runout: .010″ (0.25 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.55 © Copyright Polaris Industries Inc.

  • Page 142: Electrical And Ignition System

    STORAGE plugs. Refer to Charging Procedure page 12.27 and Battery Off Season Storage page 12.26 in the electrical chapter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.56 © Copyright Polaris Industries Inc.
  • Page 143 A wire brush or coated abrasive should not be used. 8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.57 © Copyright Polaris Industries Inc.
  • Page 144 MAINTENANCE NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 2.58 © Copyright Polaris Industries Inc.
  • Page 145 ................3.49 ENGINE INSTALLATION 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 146 ..................3.92 VALVE SEALING TEST 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 147 ................3.101 VALVE COVER INSTALLATION 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 148: General Information

    PU-50625 Flywheel Holding Tool PU-51220 Valve Spring Compressor PV-1253 Valve Spring Compressor Adapter PV-43513-A Oil Pressure Gauge PV-43531 Piston Ring Compressor Pliers PV-43570-1 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 149: Oil Pressure Test

    NOTE Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) while at operating temperature and may vary considerably if any other oil is used or if the engine is not up to operating temperature.

  • Page 150: Oil Flow Chart

    ENGINE / COOLING SYSTEM OIL FLOW CHART 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 151: Engine Service Specifications

    .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 152 Less than .001″ (0.035 mm) Runout .002″ (0.05 mm) Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm) Shaft 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 153: Engine Torque Specifications

    M6 Bolts: 9 ft-lb (12 Nm) VALVE COVER CAM CARRIER Camshaft Carrier Bolts Valve Cover Bolts 7 ft-lb (10 Nm) 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 154 (10 Nm) STATOR COVER HEAD PIPE / TURBO Exhaust Head Pipe Stator Cover Bolts 9 ft-lb (12 Nm) 18 ft-lb (24 Nm) Fasteners 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 155: Intake / Exhaust System

    .25 bar (3.6 PSI) sensed at the dump valve will cause it to open. The dump valve is normally open at idle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 156: Engine Air Intake Assembly View

    Throttle Body Bolts Torque in sequence to 7 ft-lb (10 Oetiker Clamp 7 ft-lb (10 Nm) Engine Breather Hose Throttle Body Gasket Intake Manifold 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 157: Air Box Removal

    4. Remove two fasteners retaining the air box. 5. Lift air box upward to disengage lower mounting tabs and remove air box from vehicle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 158: Exhaust Assembly View

    Turbo / Head Pipe Assembly 18 ft-lb (24 Nm) 18 ft-lb (24 Nm) Head Pipe Fasteners Exhaust Gasket 18 ft-lb (24 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 159: Muffler Removal

    4. Pull muffler towards the rear of the vehicle to remove it from the mounting grommets. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 160: Exhaust Pipe Removal

    4. Remove upper and lower rear close off panels. 8. Remove two fasteners retaining the heat shield above the oxygen sensor location. 5. Remove the right rear shock assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.16 © Copyright Polaris Industries Inc.
  • Page 161 11. Remove four fasteners retaining exhaust pipe to the turbo. Remove exhaust pipe. NOTICE Front head pipe shields hidden for image clarity. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 162: Head Pipe / Turbo Removal

    IMPORTANT The oil line sealing washers MUST be replaced any time the oil line/fitting is removed. Use only the recommended washers shown in the Polaris Electronic Parts Catalog. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.18...

  • Page 163: Head Pipe / Turbo Installation

    4. Install the fasteners retaining the turbo to the mounting bracket. Torque fasteners to specification. TORQUE Turbocharger Mounting Fasteners: 18 ft-lb (24 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.19 © Copyright Polaris Industries Inc.
  • Page 164 IMPORTANT The oil line sealing washers MUST be replace any time the oil line/fitting is removed. Use only the recommended washers shown in the Polaris Electronic Parts Catalog. TORQUE Lower P-clip Fastener: 7. Install upper P-clip bracket onto the turbo bracket standoff bolt.

  • Page 165: Exhaust Pipe Installation

    Exhaust Pipe to Turbo Fasteners: 18 ft-lb (24 Nm) Exhaust Pipe to Muffler Fasteners: 18 ft-lb (24 Nm) Rear Shock Fasteners: 70 ft-lbs (95 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.21 © Copyright Polaris Industries Inc.

  • Page 166: Turbocharger Inspection

    Ensure the oil drain hose located between the turbocharger and oil pan is not kinked or obstructed in any way. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 167 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 exducer blades. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.23 © Copyright Polaris Industries Inc.
  • Page 168 If an excessive amount of oil is present in the compressor inlet, the source of oil is likely related to the crankcase ventilation system. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.24 © Copyright Polaris Industries Inc.

  • Page 169: Actuator / Wastegate Inspection

    5. With the use of an air regulator and pressure gauge, attach an air supply line to the actuator pod pressure reference port, located on the top of the canister. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.25 © Copyright Polaris Industries Inc.

  • Page 170: Actuator Pod Removal

    1. Locate the actuator rod heim joint, located opposite to Actuator Rod Heim Joint Fasteners: the actuator pod. 7 ft-lb (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.26 © Copyright Polaris Industries Inc.

  • Page 171: Oil Drain Tube Service

    IMPORTANT The O-ring must be properly in place before installing the drain tube on the turbocharger to prevent an oil leak. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.27 © Copyright Polaris Industries Inc.

  • Page 172: Wastegate Flapper Inspection

    9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 173 EXHAUST Inspect the exhaust system for: • Clogged spark arrestor. • Damaged catalytic converter (use inspection mirror or borescope). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.29 © Copyright Polaris Industries Inc.

  • Page 174: Cooling System

    ENGINE / COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM FLOW 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 175: Cooling System Specifications

    Engine Protection Forced Idle 239° F (115° C) water pump weep hole for leakage. Engine Protection Shutdown 246° F (119° C) & Overheat Indicator Flashes 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.31 © Copyright Polaris Industries Inc.

  • Page 176: Charge Air Cooler Removal

    4. Remove the cargo box. 9. Remove the two fasteners retaining the fuel rail to the intake manifold. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 177 12. Loosen the clamps retaining the intake manifold to the engine. 13. Carefully remove the intake manifold out the passenger side of the vehicle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 178: Charge Air Cooler Installation

    Intake Manifold Clamps: the transmission. Torque fasteners to specification. 6 ft-lb (8 Nm) TORQUE Intake Manifold Mounting Fasteners (lower): 20 ft-lb (27 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 179 16. Run the vehicle for several minutes and check the coolant level. Refill as required. 11. Install zip ties retaining the wiring harness around the intake manifold 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 180: Radiator Replacement

    6. Remove two large hoses and one vent line from the charge air radiator and remove charge air radiator from the vehicle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 181: Thermostat Replacement

    6. Install new thermostat into the housing. CAUTION Installing the thermostat upside down will damage the thermostat and lead to engine overheating. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.37 © Copyright Polaris Industries Inc.
  • Page 182 6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.38 © Copyright Polaris Industries Inc.
  • Page 183 12. Fully install the water pump shaft and two washers into the housing. 13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.39 © Copyright Polaris Industries Inc.
  • Page 184 WATER PUMP ASSEMBLY VIEW Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.40 © Copyright Polaris Industries Inc.

  • Page 185: Engine Service

    / stud. 9. Remove the starter from the engine. NOTICE Tilt the engine slightly forward to gain enough clearance to remove the starter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 186: Starter Motor Installation

    STEP 4: Torque to 37 ft-lbs (50 Nm). STEP 5: Torque to 50 ft-lbs (68 Nm). STEP 6: If previously removed, torque to 37 ft-lbs (50 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 187: Front Engine Mount Isolator Replacement

    3. Remove the fasteners retaining the isolator mounts to the frame. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.43 © Copyright Polaris Industries Inc.

  • Page 188: Crankshaft Pto Seal Replacement

    3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.44 © Copyright Polaris Industries Inc.
  • Page 189 5. Test drive the vehicle and recheck for leaks before putting back into service. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 190: Engine Removal

    IMPORTANT The oil line sealing washers MUST be replaced any time the oil line/fitting is removed. Use only the recommended washers shown in the Polaris Electronic Parts Catalog. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.46...
  • Page 191 23. Remove zip ties retaining electrical harnesses and actuator rod. The rod will become damaged and the transmission vent line to intake manifold turbo will not function properly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.47 © Copyright Polaris Industries Inc.
  • Page 192 33. Remove the three allen screws and washers retaining inner cover to engine. 27. Remove intake manifold and throttle body as assembly. 28. Disconnect the starter wiring. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 193: Engine Installation

    37. Lift engine out of the chassis, be careful not to snag any hoses or wiring. 38. If replacing engine: remove applicable coolant hoses, stator/flywheel, starter and engine sensors. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.49 © Copyright Polaris Industries Inc.
  • Page 194 6 ft-lb (8 Nm) Lower Intake Manifold Mounting Fasteners: 20 ft-lb (27 Nm) TORQUE Inner PVT Cover Baffle Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.50 © Copyright Polaris Industries Inc.
  • Page 195 Rear Fender/Fender Flare Fasteners: 7 ft-lbs (10 Nm) 22. Install cargo box. Torque fasteners to specification. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.51 © Copyright Polaris Industries Inc.

  • Page 196: Cam Chain Tensioner Service

    No further adjustment is required. 2. Remove the spring retainer bolt and push the adjuster all the way in. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 197: Engine Disassembly / Inspection - Top End

    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 chamber. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 198: Camshaft Sprocket Inspection

    Replace timing chain and sprockets if worn or damaged. 6. Rotate the engine to allow access to the remaining bolt on each camshaft sprocket. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 199: Camshaft / Camshaft Bore Inspection

    Exhaust: 1.5772 - 1.5803" (40.06 - 40.14 mm) 1.5752" (40.01 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.55 © Copyright Polaris Industries Inc.
  • Page 200 O.D.s from camshaft carrier bore I.D.s. Compare to specification. MEASUREMENT Calculated Camshaft Oil Clearance: .0009 - .0026" (0.022 - 0.067 mm)Service Limit: .0039" (0.1 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 201: Cylinder Head Removal

    6. Tap cylinder head lightly with a soft faced hammer until loose. CAUTION Tap only in reinforced areas or on thick parts of the cylinder head casting. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 202: Cylinder Head Disassembly

    8. Clean the combustion chamber and head gasket surface. 2. Compress the valve spring by hand using valve spring compressor adapter PV-43513-A 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 203: Valve Inspection

    4. Check the end of the valve stem for flaring, pitting, wear or damage. MEASUREMENT Valve Guide I.D.: .2165 - .2171" (5.500 - 5.515 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 204: Combustion Chamber Cleaning

    1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.60 © Copyright Polaris Industries Inc.
  • Page 205 This is normal and should not cause valve leakage. Both valves shown are acceptable and would not require replacement. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.61 © Copyright Polaris Industries Inc.
  • Page 206 12. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 207: Engine Disassembly / Inspection - Bottom End

    / installation process or injury could result. 2. Carefully pry the stator cover off the engine using the two pry areas as shown below. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 208: Water Pump Housing Removal

    4. Using a commercially available strap wrench, hold the flywheel and remove the flywheel retaining bolt 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 209: Starter One-Way Clutch Disassembly

    9. Inspect the one-way gear bushing for wear or galling. If service is required, refer to Starter One-way Clutch Disassembly page 3.65. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 210: Crankcase Disassembly

    7. Remove the sump cover from the crankcase. 2. Remove the crankcase drain plug to drain any oil remaining in the engine. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.66 © Copyright Polaris Industries Inc.
  • Page 211 Access the sprocket bolt by removing the case plug. 13. Rotate the engine so the cylinder is facing up. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 212: Balance Shaft Removal / Inspection

    Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 213: Crankshaft Removal / Inspection

    4. Carefully lift the crankshaft out of the crankcase. 5. Remove the cam chain , PTO main seal and oil pump drive chain from the crankshaft. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.69 © Copyright Polaris Industries Inc.
  • Page 214 Main (40.996 - 41.004 mm) Bearing 1.6129" (40.970 mm) Service Limit Connecting 1.7715 - 1.7717" Standard Rod Bearing (44.995 - 45.002 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.70 © Copyright Polaris Industries Inc.

  • Page 215: Crankcase Inspection

    4. Be sure oil passages are clean and free of any page 3.78 and Crankshaft Main Bearing Selection cleaning solvent. page 3.79 procedures. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 216: Cylinder / Piston Removal

    NOTICE Always replace plain bearings when the crankcase or connecting rods have been disassembled. Refer to Crankshaft Main Bearing Selection page 3.79. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 217: Cylinder Inspection

    3.6614 ± .0003" (93 mm ± 0.008 mm) Cylinder Taper: Service Limit: .001″ (0.025 mm) Cylinder Out of Round: Service Limit: .001″ (0.025 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 218: Piston Disassembly / Inspection

    DO NOT apply heat to piston rings or a loss of radial .8659 - .8661" (21.995 - 22.000 mm) tension could result. Service Limit: .8651" (21.975 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.74 © Copyright Polaris Industries Inc.

  • Page 219: Piston Ring Removal

    A difference between top and bottom end gap measurements is a general indication of cylinder taper (wear). The cylinder should be measured for taper and out of round. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 220: Piston To Cylinder Clearance

    Piston O.D. (Standard): 3.6597 ± .0003" (92.959 ± 0.008 mm) MEASUREMENT Piston to Cylinder Clearance: .0009 - .0019" (0.025 - 0.050 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.76 © Copyright Polaris Industries Inc.
  • Page 221 8. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided in the “Connecting Rod Bearing Selection” procedure in this chapter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.77 © Copyright Polaris Industries Inc.

  • Page 222: Engine Assembly - Bottom End

    Green bearing for connecting rod journal and Yellow for connecting rod journal BEARING SELECTION CHART – ROD BEARINGS CRANKSHAFT Code White Blue White Yellow Blue White 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 223: Crankshaft Main Bearing Selection

    Blue bearing for Main #4 BEARING SELECTION CHART — MAIN BEARINGS Crankshaft Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.79 © Copyright Polaris Industries Inc.

  • Page 224: Piston Ring Installation

    6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 225: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.81 © Copyright Polaris Industries Inc.

  • Page 226: Piston / Cylinder Installation

    8. Carefully place the cylinder and pistons into the upper crankcase. 1. Apply clean engine oil to each piston assembly and cylinder bore prior to installation. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 227: Crankshaft Installation

    (PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft CRANKSHAFT INSTALLATION NOTICE Whether installing a new crankshaft or re-installing the original, refer to the bearing selection charts (see Crankshaft Main Bearing Selection page 3.79 and...

  • Page 228: Balance Shaft Installation

    3. Rotate the crankshaft until the alignment dot on the crankshaft MAG end gear is visible. 4. Apply Polaris PS-4 engine oil to both balance shaft journals. 14. Torque connecting rod bolts to specification. TORQUE...

  • Page 229: Lower Crankcase Preparation

    LOWER CRANKCASE PREPARATION NOTICE Always replace plain bearings when the crankcase or 3. Apply Polaris PS-4 engine oil to the new bearings connecting rods have been disassembled. Refer to installed in the lower crankcase half. bearing selection procedures. 4. Clean crankcase mating surfaces to remove any oil.
  • Page 230 M8 Bolts: 26 ft-lb (35 Nm) M6 Bolts: 9 ft-lb (12 Nm) 13. Rotate the engine so the cylinder is facing up. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.86 © Copyright Polaris Industries Inc.
  • Page 231 18. Lift the oil pump drive chain and install the oil pump. oil. NOTICE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.87 © Copyright Polaris Industries Inc.
  • Page 232 , if previously removed. Use 27. Reinstall the oil cooler new O-rings upon installation. Torque fasteners to specification. TORQUE Oil Cooler bolts: 7 ft-lb (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.88 © Copyright Polaris Industries Inc.

  • Page 233: Starter One-Way Clutch Assembly

    Replace crankshaft if surface damage is present. Clean taper of crankshaft to remove all oil or grease. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 234: Stator Cover Installation

    8. Install the starter torque limit gear as an assembly. 9. Proceed to Stator Cover Installation page 3.90. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.90 © Copyright Polaris Industries Inc.

  • Page 235: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.91 © Copyright Polaris Industries Inc.

  • Page 236: Valve Sealing Test

    5. Carefully set the cylinder head in place on alignment pins. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.92 © Copyright Polaris Industries Inc.

  • Page 237: Camshaft Installation / Timing

    Step 3: Additional 180° 3. Lubricate all camshaft lobes and bearing journal Step 4: Additional 180° surfaces with Polaris PS-4 engine oil prior to installation. Step 5: M6 bolts: 7 ft-lb (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.93...
  • Page 238 (PU-50563) into the end of camshafts as shown. Use NOTICE an open-end wrench to rotate camshafts slightly. Use new sprocket retaining bolts upon assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.94 © Copyright Polaris Industries Inc.
  • Page 239 15. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.95...
  • Page 240 NOTICE The tensioner will automatically adjust to the proper tension once the spring and retainer are installed. No further adjustment is required. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.96 © Copyright Polaris Industries Inc.

  • Page 241: Camshaft Timing Quick Reference

    Align Exhaust Marks with Top of Head Exhaust Cam CPS Mounting Hole Align Intake Marks with Top of Head Align Flywheel Mark (+) to edge of Mounting Hole 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.97 © Copyright Polaris Industries Inc.

  • Page 242: Valve Clearance Adjustment

    3-digit tappet number. 9. Refer to Valve Lash - Tappet Selection page 3.100 and select the proper tappet. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.98 © Copyright Polaris Industries Inc.
  • Page 243 15. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to Camshaft Installation / Timing page 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.99 © Copyright Polaris Industries Inc.

  • Page 244: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.100 © Copyright Polaris Industries Inc.

  • Page 245: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts in sequence to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.101 © Copyright Polaris Industries Inc.
  • Page 246 ENGINE / COOLING SYSTEM NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 3.102 © Copyright Polaris Industries Inc.
  • Page 247 ..............4.14 OXYGEN SENSOR REPLACEMENT 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 248: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU appropriate fuel and ignition requirements for the from another Polaris RZR of the same model may be immediate operating conditions. The ECU then sends used without system or engine component damage.

  • Page 249: Etc Learn Procedure

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Fasteners: 24 in-lbs (3 N·m) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 250: Pressure Sensors

    (TMAP) fails. The TMAP sensor and the Boost Pressure Sensor may be interchanged for testing purposes as the sensors are the same. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 251: Air Temperature Sensor Data

    203° F (95° C) 212° F (100° C) 221° F (105° C) 230° F (110° C) 239° F (115° C) 248° F (120° C) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 252: Knock Sensor

    • Drain the fuel and fill with fresh fuel. Always use premium fuel (91+ octane) 2. Remove the knock sensor mounting bolt • Check for non-approved Polaris modifications to the remove the sensor from the cylinder. engine or exhaust system NOTICE •...

  • Page 253: Crankshaft Position Sensor (Cps)

    CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage. 5. If the resistance is incorrect, follow the CPS Replacement page 4.8 procedure. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 254 4. Install new sensor using a light coating of oil on the O-ring to aid installation. 5. Torque the CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 ft-lbs (12 N·m) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 255: Electronic Throttle Control (Etc) / Throttle Body

    All operating and control functions within the ETC are pre-set. No internal servicing or adjustments may be performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization.

  • Page 256: Etc / Throttle Body Replacement

    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) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 257: Pedal Position Sensor (Pps)

    (see Chapter 4 – PPS Replacement assembly. page 4.12). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 4.11 © Copyright Polaris Industries Inc.
  • Page 258 7. Torque the three mounting bolts to specification and connect the PPS harness connection. TORQUE Throttle Pedal Mounting fasteners: 18 ft-lbs (24 N·m) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 259: Oxygen Sensor

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 260: Oxygen Sensor Replacement

    3. Install new oxygen sensor. Torque sensor to specification. TORQUE Oxygen Sensor: 13 ft-lb (18 Nm) 4. Connect the harness going to the oxygen sensor. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 261 ................5.29 FUEL SENDER TEST 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 262: General Information

    Module Digital Wrench Vehicle Interface PU-47469 Cable Digital Wrench PC Interface PU-47470 Cable Fuel Pump Service Tool PU-50326 Fuel Pressure Gauge Adapter PA-48838 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 263: Efi Overview

    Located in the fuel tank under the passenger seat. Located on cylinder assembly between engine and transmission. Knock Sensor Oxygen Sensor Located on the exhaust pipe. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 264: Efi Operation Overview

    During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 265: Efi Service Notes

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 266: Initial Priming / Starting Procedure

    NOTICE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 267: Fuel Injectors

    IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 268: Fuel Injector Troubleshooting

    Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 269: Fuel Injector Replacement

    The retaining clip(s) should click when properly engaged. 12. Lightly lubricate the injector O-rings and reinstall the fuel rail / injector assembly into the engine intake. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 270 18. Reinstall the cargo box. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 271: Fuel Lines

    Fuel Vent Line Fuel Tank Strap Fuel Fill Fuel Tank Fasteners 15 ft-lbs (20 Nm) Fuel Tank Fuel Pressure Sensor Fuel Pump Assembly 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 272: Fuel System Assembly View (Evap)

    Fuel Pump Fuel Tank Vent Rollover Valve Fuel Pressure Sensor Fuel Tank Strap Check Valve Fuel Tank Fasteners 15 ft-lbs (20 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.12 © Copyright Polaris Industries Inc.
  • Page 273 8. Turn the key on to prime the system. Check for leaking at both ends of the fuel lines. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 274: Fuel Line Removal / Installation

    7. Turn the key on to prime the system. Check for leaking at each end of the fuel line. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 275: Fuel Line Routing

    EFI / FUEL SYSTEM FUEL LINE ROUTING Double Clip Retaining Clip Zip Tie Fuel Rail 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 276: Fuel Line Routing (Evap)

    EFI / FUEL SYSTEM FUEL LINE ROUTING (EVAP) Double Clip Retaining Clip Zip Tie Fuel Rail 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 277: Fuel Vent Line Routing

    Collapsing fuel tank Engine miss or hesitation Symptoms of a restricted fuel tank vent include the following: Loss of engine performance High exhaust temperatures. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.17 © Copyright Polaris Industries Inc.
  • Page 278 2. Route the fuel vent line up and attach to two retaining clips 3. Route fuel vent line back and attach vent line to the fitting in the left shock support tube. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 279: Fuel Vent Line Routing (Evap)

    Loss of engine performance High exhaust temperatures. 1. Route fuel vent line under the shift cable and secure vent line using two double clips 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 280: Vent Line Termination Fitting

    The ears on the clip (arrows) will not hold properly once it is removed. 5. Route vent line up from the canister filter and attach to two retaining clips 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 281: Fuel Pressure Sensor

    75 psi regulator mounted in the fuel pump. At idle and low RPM/load operation the fuel pressure is electronically reduced and can be as low as 43.5 psi. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.21 © Copyright Polaris Industries Inc.

  • Page 282: Fuel Tank / Pump

    PFA Nut Fuel Pickup Filter (not serviceable) 70 ft-lbs (95 Nm) Fuel Supply PFA Gasket Fuel Pump Fuel Tank Vent Fuel Sender Float 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 283: Fuel Tank Removal / Installation

    5. Remove the lower floor panels. See Console and Lower Floor Removal page 11.21. 6. Disconnect the fuel pump electrical harness. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.23 © Copyright Polaris Industries Inc.
  • Page 284 35 in-lbs (4 Nm) TORQUE Shift Knob Fastener: 13 ft-lb (18 Nm) TORQUE Battery Cable Fasteners: 60 in-lbs (7 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.24 © Copyright Polaris Industries Inc.

  • Page 285: Fuel Pump Operation Overview

    3. Cover the fuel supply line connection at the fuel tank with a shop towel and disconnect the supply line from the fuel pump outlet. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.25 © Copyright Polaris Industries Inc.
  • Page 286 NORMAL to see fuel pressure fluctuations as the throttle varies. Pressure may briefly drop below 58 PSI (400 kPa) when the throttle is released on a running vehicle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.26 © Copyright Polaris Industries Inc.

  • Page 287: Fuel Pump Replacement

    A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.27 © Copyright Polaris Industries Inc.
  • Page 288 Service Tool (PU-50326) and a calibrated torque wrench. TORQUE Fuel Pump PFA Nut: 70 ft-lbs (95 Nm) 19. Verify alignment of fuel pump and tank orientation marks. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.28 © Copyright Polaris Industries Inc.

  • Page 289: Fuel Sender Test

    6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to Fuel Pump Replacement page procedure. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.29 © Copyright Polaris Industries Inc.
  • Page 290 EFI / FUEL SYSTEM NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 5.30 © Copyright Polaris Industries Inc.
  • Page 291 ............6.28 DRIVE CLUTCH BUSHINGS INSPECTION 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 292 ................6.47 DRIVEN CLUTCH ALIGNMENT 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 293: General Information

    TOOL DESCRIPTION PU-50518-A Drive Clutch Compressor PU-52422 Drive 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 SHIFT DRIVE DRIVEN MODEL ALTITUDE WEIGHT SPRING...

  • Page 294: Pvt System Overview

    During the development of optimum engine RPM. At full throttle a perfectly matched the Polaris vehicle, the PVT system is matched first to the PVT system should hold engine RPM at the peak of the engine power curve; then to average riding conditions power curve.

  • Page 295: Drive Belt

    The driven clutch spreader tool is included with the vehicle’s tool kit 6. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 296: Belt Installation

    36 in-lbs (4 Nm) 6. Install PVT intake hose, and torque hose clamp specification. TORQUE PVT Intake Hose Clamp: 25 in-lbs (3 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 297: Drive Clutch Service

    2. Loosen fourteen fasteners that retain the outer clutch cover. Remove the clutch cover. 7. Polaris also recommends using a 1” diameter by 18” long hardwood dowel for holding the clutch. For removal, the dowel must pass through the drive clutch and rest against the chassis underneath the front engine cross member as shown.
  • Page 298 10. If necessary, remove the outer slip-fit post and install the Drive Clutch Puller (PN PU-52422) to remove the stationary sheave. Drive Clutch Puller: PU-52422 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 299: Drive Clutch Assembly View

    Washer Spider Sheave Assembly Bushing Clutch Spacer Washer Needle Bearing Stationary Sheave Shift Weight Shift Weight Fastener 20 in-lb (2 Nm) Clutch Button 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 300 PVT SYSTEM DESCRIPTION TORQUE Washer Spider Pin Bushing Roller 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 301: Clutch Disassembly

    3. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 302: Button To Tower Clearance Inspection

    Do not pull on the outer fingers of the spider or damage may occur. Position 3 jaw puller in the positions shown 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.12 © Copyright Polaris Industries Inc.

  • Page 303: Roller Replacement

    Refer to Roller, Pin, and Thrust Washer Inspection page 6.12 procedure. 4. Install the roller buttons and verify smooth operation of the roller. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.13 © Copyright Polaris Industries Inc.

  • Page 304: Clutch Inspection

    Replace if worn or damaged. MEASUREMENT Thrust Washer Thickness: Standard: 0.030 – 0.040” (0.76 - 0.96 mm) Service Limit: 0.020” (0.50 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 305: Drive Clutch Spring Inspection

    Refer to Bushing Service page 6.16 procedure. MEASUREMENT Drive Clutch Spring Height: 7044938: 3.76 in (95.43 mm)7045110: 4.60” (116.74mm)7045326: 3.83” (97.26mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 306: Bushing Service

    9. Remove nut from puller rod and set aside. 10. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 307 (PN 5020634) into center of clutch cover. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.17 © Copyright Polaris Industries Inc.

  • Page 308: Clutch Assembly

    Belleville washer must be installed with dome facing the outer post. 1. Install two washers , needle bearing , and clutch spacer onto the stationary sheave in the order shown. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 309: Drive Clutch Installation

    4. Install the Drive Clutch Holding Tool onto the drive clutch. Torque drive clutch retaining bolt to specification. Drive Clutch Holding Tool: PU-52944 TORQUE Drive Clutch Bolt: 140 ft-lbs (190 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 310 PVT SYSTEM 5. Polaris also recommends using a 1” diameter by 18” 9. Rotate / spin the driven clutch and belt approximately long wooden dowel for holding the clutch. For 5-7 times to properly seat the belt in the driven clutch.

  • Page 311: 2021 Drive Clutch Service

    20 in-lb (2 Nm) Belleville Washer (Dome side facing outer post) Clutch Button Washer Washer Spider Spider Pin Sheave Assembly Bushing Bushing Roller Clutch Spacer 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 312: Drive Clutch Removal (2021)

    2. Loosen fourteen fasteners that retain the outer clutch cover. Remove the clutch cover. 7. Polaris also recommends using a 1” diameter by 18” long hardwood dowel for holding the clutch. For removal, the dowel must pass through the drive clutch and rest against the chassis underneath the front engine cross member as shown.

  • Page 313: Clutch Disassembly (2021)

    Drive Clutch Spring Inspection (2021) page 6.24 procedure. CAUTION The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly! 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.23 © Copyright Polaris Industries Inc.

  • Page 314: Drive Clutch Spring Inspection (2021)

    7045112: 4.80 in (122 mm) BEARING INSPECTION • Verify there is no binding or rough spots. If problems are noted continue with disassembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 315: Button To Tower Clearance Inspection

    Do not pull on the outer fingers of the spider or damage may occur. Position 3 jaw puller in the positions shown 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.25 © Copyright Polaris Industries Inc.

  • Page 316: Roller Replacement

    Refer to Roller, Pin, and Thrust Washer Inspection page 6.25 procedure. 4. Install the roller buttons and verify smooth operation of the roller. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.26 © Copyright Polaris Industries Inc.

  • Page 317: Clutch Inspection

    Replace if worn or damaged. MEASUREMENT Thrust Washer Thickness: Standard: 0.030 – 0.040” (0.76 - 0.96 mm) Service Limit: 0.020” (0.50 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.27 © Copyright Polaris Industries Inc.

  • Page 318: Drive Clutch Bushings Inspection

    9. Remove nut from puller rod and set aside. 10. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 319 (PN 5020634) into center of clutch cover. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.29 © Copyright Polaris Industries Inc.

  • Page 320: Clutch Assembly

    Belleville washer must be installed with dome facing the outer post. 1. Install two washers , needle bearing , and clutch spacer onto the stationary sheave in the order shown. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.30 © Copyright Polaris Industries Inc.

  • Page 321: Driven Clutch Service

    140 ft-lbs (190 Nm) DRIVEN CLUTCH SERVICE DRIVEN CLUTCH REMOVAL 1. Loosen the clamp retaining PVT inlet duct to the outer clutch cover. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.31 © Copyright Polaris Industries Inc.
  • Page 322 NOTICE The driven clutch spreader tool is included with the vehicle’s tool kit 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.32 © Copyright Polaris Industries Inc.

  • Page 323: Driven Clutch Assembly View

    Moveable Sheave Bushing Helix Fasteners 32 ft-lbs (44 Nm) Driven Post E-Clip Stationary Sheave Roller Helix Washer Bushing Roller Pin Spring Spring Pin 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.33 © Copyright Polaris Industries Inc.

  • Page 324: Driven Clutch Disassembly

    The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.34 © Copyright Polaris Industries Inc.

  • Page 325: Helix And Movable Sheave Bushing Inspection

    2. From the bottom of the Helix, insert the new bushing and bushing adapter (PN 5020636) 3. Install the main adapter , spacer adapter, and securing nut on top of the Helix. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.35 © Copyright Polaris Industries Inc.

  • Page 326: Driven Clutch Assembly

    TORQUE Helix Fasteners: 32 ft-lbs (44 Nm) 6. Once back together, verify the alignment marks made during disassembly are properly aligned. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.36 © Copyright Polaris Industries Inc.

  • Page 327: Driven Clutch Installation

    7. Install the outer clutch cover and fourteen fasteners . Torque fasteners to specification. TORQUE Outer Clutch Cover Fasteners: 36 in-lbs (4 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.37 © Copyright Polaris Industries Inc.

  • Page 328: Driven Clutch Alignment

    A mobile device can be used to capture a picture of the belt tracking to determine if adjustment is needed. 4. Remove the drive belt. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.38 © Copyright Polaris Industries Inc.

  • Page 329: 2021 Driven Clutch Service

    Drive Clutch Retaining Bolt: 140 ft-lbs (190 Nm) 10. Reinstall the drive belt and outer cover assembly. Refer to Belt Installation page 6.6. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.39 © Copyright Polaris Industries Inc.

  • Page 330: Driven Clutch Assembly View (2021)

    Moveable Sheave Helix Fasteners 44 ft-lbs (60 Nm) Roller Pin Stationary Sheave Windage Plate Bearing Windage Plate Fastener 50 in-lbs (6 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.40 © Copyright Polaris Industries Inc.

  • Page 331: Driven Clutch Removal

    NOTICE The driven clutch spreader tool is included with the vehicle’s tool kit 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.41 © Copyright Polaris Industries Inc.

  • Page 332: Driven Clutch Disassembly

    The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.42 © Copyright Polaris Industries Inc.

  • Page 333: Helix And Movable Sheave Bushing Inspection

    Teflon® is visible on the bushing. BUSHING SERVICE MOVEABLE SHEAVE - BUSHING REMOVAL 1. Remove clutch as outlined previously in this chapter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.43 © Copyright Polaris Industries Inc.
  • Page 334 Turn puller barrel to increase tension on sheave if needed. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.44 © Copyright Polaris Industries Inc.

  • Page 335: Driven Clutch Assembly

    (PN 5020634) into center of clutch cover. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.45 © Copyright Polaris Industries Inc.
  • Page 336 6. Once back together, verify the alignment marks made during disassembly are properly aligned. 7. Install the stationary and movable sheave on the vehicle. See Driven Clutch Installation. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.46 © Copyright Polaris Industries Inc.

  • Page 337: Driven Clutch Installation

    A mobile device can be used to capture a picture of the belt tracking to determine if adjustment is needed. Outer Clutch Cover Fasteners: 36 in-lbs (4 Nm) 4. Remove the drive belt. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.47 © Copyright Polaris Industries Inc.
  • Page 338 When finished, the driven clutch should not rotate on its own, or should stop with minimal drag when using a new bearing. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 6.48 © Copyright Polaris Industries Inc.
  • Page 339 .........7.16 TRANSMISSION ASSEMBLY / SNORKEL GEAR BACKLASH 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 340: General Information

    TRANSMISSION GENERAL INFORMATION SPECIAL TOOLS PART TOOL DESCRIPTION NUMBER PU-51862 Snorkel Tube Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 341: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 342: Shift Cable Adjustment

    5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTICE This procedure may require a few attempts to obtain the proper adjustment. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 343: Transmission Service

    13. Disconnect TBAP, both TMAP sensors, CPS, coolant temp sensor, Trans switch, speed sensor, injectors, ETC. 9. Remove both rear half shafts. See Rear Drive Shaft Removal page 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 344 21. Remove the belt, secondary clutch, and primary clutch. 22. Remove six fasteners and remove the inner PVT cover baffle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 345 26. Remove fasteners retaining inner cover to engine/ trans joint. Discard PVT inner cover o-ring around the crankshaft snout. 27. Remove the rear transmission isolator fasteners 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 346: Transmission Installation

    5. Loosely install the three allen screws and washers retaining inner cover to engine. TORQUE Inner PVT Cover Baffle Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 347 Rear Fender/Fender Flare Fasteners: 7 ft-lbs (10 Nm) 22. Install cargo box. Torque fasteners to specification. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 348: Transmission Vent Line Routing

    60 in-lbs (7 Nm) 2. The vent line routes rearward and attaches to the intake manifold and throttle body with Panduit straps 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 349: Transmission Disassembly

    6. Remove detent spring, detent pawl and detent star. Note the master spline on the detent star and the shift shaft. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.11 © Copyright Polaris Industries Inc.
  • Page 350 Do not pry on the transmission case mating surfaces or the transmission cases will be damaged and leak oil 16. Remove the idler shaft assembly after it is reassembled. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.12 © Copyright Polaris Industries Inc.
  • Page 351 22. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.13 © Copyright Polaris Industries Inc.
  • Page 352 CAUTION Support the end face of the gear teeth when pushing the shaft through or damage to the gear teeth may occur. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.14 © Copyright Polaris Industries Inc.

  • Page 353: 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 replace the corresponding gear and/or gear shaft. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 354: Transmission Assembly / Snorkel Gear Backlash

    Failure to properly clean the surfaces may lead and may have some tight spots. to transmission case leaks. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.16 © Copyright Polaris Industries Inc.
  • Page 355 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 356 ITEM DESCRIPTION Retaining Clip 13. Thoroughly clean the shift shaft housing. Washer Torsion Spring Drum 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 357 Install the nut and torque to specification. TORQUE Bell Crank Nut: 18 ft-lb (24 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.19 © Copyright Polaris Industries Inc.
  • Page 358 TRANSMISSION NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 359 ..................8.45 TIRE BALANCING 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 360: General Information

    FINAL DRIVE GENERAL INFORMATION SPECIAL TOOLS PART NUMBER DESCRIPTION 2872608 Roll Pin Removal Tool CV Boot Clamp Pliers 8700226 Axle Boot Clamp Tool PU-48951 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 361: Bearing Carrier

    Replace bearing if it is damaged. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 362: Front Bearing Replacement

    6. Allow Loctite to cure for at least 3 hours before CAUTION vehicle operation. Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 363: Front Bearing Carrier Installation

    Install washers with domed side out. TORQUE Tie Rod End Fastener: 30 ft-lbs (40 Nm) + 90° 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 364: Rear Bearing Carrier Inspection / Removal

    120 ft-lbs (163 N·m) 11. Rotate wheel and check for smooth operation. 5. Remove two fasteners and remove the rear brake line guide 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 365 12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 366 5. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 367: Rear Bearing Carrier Installation

    TORQUE Bearing Carrier to Trailing Arm Bolts: 44 ft-lbs (60 Nm) Outer Radius Rod Fastener: 52 ft-lbs (70 Nm) + 90° 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 368 13. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. TORQUE Brake Line Guide Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 369: Drive Shaft

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 370: Front Drive Shaft Installation

    CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 371: Rear Drive Shaft Removal

    Discard cotter pin, castle nut, and cone washer. IMPORTANT Cotter pin, castle nut, and cone washer are not reusable. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 372: Rear Drive Shaft Installation

    Loctite® material or corrosion is present. 4. Apply Loctite® Primer 7649 to the hub assembly splines. Allow 90 seconds for the primer to dry. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.14 © Copyright Polaris Industries Inc.
  • Page 373 52 ft-lbs (70 Nm) + 90° 9. Install wheel and four wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 374: Drive Shaft / Cv Joint Handling Tips

    Refer to text for grease capacity of CV joints and CV joint boots. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 375: Cv Joint / Boot Replacement

    9. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 376: Inner Plunging Joint / Boot Replacement

    12. Install and tighten the small clamp on the boot using the appropriate clamp tool. 3. Clean the grease from the face of the joint. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.18 © Copyright Polaris Industries Inc.
  • Page 377 “click” indicating the internal circlip has fully engaged with the cage assembly. inner joint. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.19 © Copyright Polaris Industries Inc.
  • Page 378 16. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 379: Prop Shaft

    6. Disconnect front prop shaft from the rear prop shaft. Remove front prop shaft out through the bottom of the vehicle. 3. Remove driver’s seat. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.21 © Copyright Polaris Industries Inc.
  • Page 380 10. Remove the two fasteners retaining roll hoop to the frame. Remove roll hoop. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.22 © Copyright Polaris Industries Inc.
  • Page 381 30 ft-lbs (40 Nm) + 90° TORQUE Ball Joint Fasteners: 44 ft-lbs (60 Nm) TORQUE Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 382: Prop Shaft Removal / Installation (4-Seat)

    Roll Pin Removal Tool: 2872608 NOTICE Right front wheel can be removed to gain better access to the prop shaft roll pin. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.24 © Copyright Polaris Industries Inc.
  • Page 383 9. Remove rear prop shaft through the bottom of the NOTICE vehicle. The prop shafts have a master spline and will only go on one way. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.25 © Copyright Polaris Industries Inc.
  • Page 384 30 ft-lbs (40 Nm) + 90° TORQUE Ball Joint Fasteners: 44 ft-lbs (60 Nm) TORQUE Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.26 © Copyright Polaris Industries Inc.

  • Page 385: Prop Shaft Assembly View

    FINAL DRIVE PROP SHAFT ASSEMBLY VIEW Support Bearing Front Prop Shaft Cross and Bearing Rear Prop Shaft Slip Yoke 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 386: Prop Shaft Assembly View (4-Seat)

    11 ft-lbs (15 Nm) Front Prop Shaft Slip Yoke Transmission-to-Prop Shaft Yoke Support Bearing Cross and Bearing Support Bearing Fasteners 30 ft-lbs (40 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.28 © Copyright Polaris Industries Inc.

  • Page 387: Support Bearing Replacement

    6. Install front prop shaft into the vehicle (see Prop Shaft Removal / Installation page 8.21). U-JOINT DISASSEMBLY CAUTION Always wear eye protection. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.29 © Copyright Polaris Industries Inc.
  • Page 388 4. Force U-joint cross to one side and lift out of inner stiff or binding, tap the yoke lightly to center the joint yoke. until it pivots freely in all directions. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.30 © Copyright Polaris Industries Inc.

  • Page 389: Front Gearcase / Centralized Hilliard

    Drain Plug 10 ft-lbs (14 Nm) Bearing Fill/Check Plug 10 ft-lbs (14 Nm) Output Hub Cover Plate Screws 11 ft-lbs (15 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.31 © Copyright Polaris Industries Inc.

  • Page 390: Front Gearcase Vent Line Routing

    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. rear wheels regain traction). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.32 © Copyright Polaris Industries Inc.

  • Page 391: Awd Diagnosis

    Should have a minimum of 11 VDC. 3. If electrical tests are within specification, remove gearcase (see “Front Gearcase Removal” outlined in this chapter) and inspect components. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.33 © Copyright Polaris Industries Inc.
  • Page 392 If the pole gap increases the coil will not be strong enough to engage the AWD system. If this is found, replace the cover plate assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 393: Front Gearcase Removal / Installation

    5. Remove four fasteners and remove the front fascia. 8. Remove four control arm bolts and remove control arms from sub frame bracket. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.35 © Copyright Polaris Industries Inc.
  • Page 394 33 ft-lbs (45 Nm) TORQUE Front Bumper Mounting Fasteners: 30 ft-lbs (40 Nm) TORQUE Front Bumper Cover Mounting Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.36 © Copyright Polaris Industries Inc.

  • Page 395: Front Gearcase Disassembly / Inspection

    2. Remove the nine cover screws and remove the cover plate assembly. 3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 396 9. Inspect the pinion gear for chipped, broken or missing housing. teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 397 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.39 © Copyright Polaris Industries Inc.

  • Page 398: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 5. Install the plastic ring onto the clutch housing. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.40 © Copyright Polaris Industries Inc.
  • Page 399 NOTICE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.41 © Copyright Polaris Industries Inc.
  • Page 400 Install the nine cover plate screws and torque to specification. TORQUE Cover Plate Screws: 11 ft-lbs (15 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.42 © Copyright Polaris Industries Inc.

  • Page 401: Wheel Hubs

    Cotter Pin Hub Castle nut Cone Washer 180 ft-lbs (244 Nm) Wheel Hub Brake Disc Wheel Studs Bearing Carrier Wheel Bearing Snap Ring 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.43 © Copyright Polaris Industries Inc.

  • Page 402: Rear Hub Assembly View

    Cotter Pin Hub Castle Nut Cone Washer 180 ft-lbs (244 Nm) Wheel Hub Brake Disc Wheel Studs Bearing Carrier Wheel Bearing Snap Ring 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.44 © Copyright Polaris Industries Inc.

  • Page 403: Tire Balancing

    Symptoms of an imbalanced, or improperly balanced tire include: • Steering wheel vibration • Seat or floorboard vibration • Excessive or uneven tread wear 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.45 © Copyright Polaris Industries Inc.
  • Page 404 FINAL DRIVE NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 8.46 © Copyright Polaris Industries Inc.
  • Page 405 ........9.52 WALKER EVANS™ 2.5" FRONT SHOCK / 3.0" REAR SHOCK 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 406 ............9.72 SUSPENSION MODE SWITCH (DYNAMIX MODELS) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 407: General Information

    Spanner Wrench - 3.0″ Outer Internal PU-51832 Bypass Shock Body Holding Tool (2.5″) PU-51837 Shock Body Bolding Tool (3.0″) PU-51838 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 408: Steering System

    30 ft-lbs (40 Nm) + 90° Steering Column Lower EPS Bracket Mounting Upper EPS Bracket Mounting Fasteners Fasteners 26 ft-lbs (35 Nm) 33 ft-lbs (45 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 409: Upper Steering Shaft Removal

    3. Lift the steering wheel up and remove the fasteners that retain the steering column. 4. Disconnect electrical harness from the C4 gauge. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 410: Steering Wheel Removal

    3. Remove the pinch bolt retaining the lower steering shaft to the power steering unit . 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 411: Lower Steering Shaft Removal

    Avoid spinning steering shafts after removing power steering unit from the vehicle. 3. Remove the power steering unit (see Power Steering Unit Removal page 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 412: Steering Rack Removal / Installation

    5. Lift up on the shaft and remove it through the floor panel. 5. Remove four fasteners and remove the front fascia. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 413 13. Remove gearcase fasteners and remove gearcase from vehicle. 14. Remove Steering shaft from Rack. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 414 180 ft-lbs (244 Nm) TORQUE Front Caliper Mounting Bolts: 33 ft-lbs (45 Nm) TORQUE Front Bumper Mounting Fasteners: 30 ft-lbs (40 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 415: Lower Steering Shaft Installation

    , reinstall it prior to vehicle installation. Torque the mounting bolts specification. TORQUE Power Steering Mounting Bolts: 30 ft-lb (41 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.11 © Copyright Polaris Industries Inc.
  • Page 416 3. Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.12 © Copyright Polaris Industries Inc.
  • Page 417 40 ft-lb (54 Nm) 3. Install the tilt shock and torque fastener to specification. TORQUE Tilt Shock Fastener: 7 ft-lb (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 418: Steering Shaft Bushing Replacement

    Install the lower portion of the steering shaft onto the power steering unit. Torque the lower pinch bolt to specification. TORQUE Steering Shaft Pinch Bolt: 25 ft-lb (34 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 419: Eps Pre-Positioning / Steering Angle Centering

    1. Connect vehicle to Digital Wrench, and select “Special Tests” menu. 1. Connect vehicle to Digital Wrench, and select “Special Tests” menu. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.15 © Copyright Polaris Industries Inc.
  • Page 420 3. Select option 2 at the next menu. 4. Follow instructions in Digital Wrench to properly center the EPS steering angle sensor. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 421: Front Suspension

    44 ft-lbs (60 Nm) Ball Joint Stabilizer Bar Link Fasteners 74 ft-lbs (100 Nm) Upper A-Arm Lower A-Arm A-Arm Fasteners 74 ft-lbs (100 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 422: Front A-Arm Removal / Installation

    10. If not replacing the A-arm, thoroughly clean the A-arm and pivot tube. INSTALLATION 1. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 423: Front Stabilizer Bar Replacement

    TORQUE Front Shock Mounting Bolts: 44 ft-lbs (60 Nm) 3. Remove the fasteners retaining the stabilizer bar link to the stabilizer bar. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 424: Ball Joint Removal

    2. Place a proper sized driver on the ball joint and place the A-arm in a press. 3. Carefully press the ball joint out of the A-arm and discard the ball joint. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 425: Ball Joint Installation

    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. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 426: Rear Suspension

    74 ft-lbs (100 Nm) Stabilizer Bar Link Fasteners Trailing Arm Inner Radius Rod Fasteners 44 ft-lbs (60 Nm) 52 ft-lbs (70 Nm) + 45° 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 427: Trailing Arm Removal / Installation

    CAUTION Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.23 © Copyright Polaris Industries Inc.
  • Page 428 13. Remove the lower stabilizer bar linkage fastener trailing arm and bearing carrier. Discard the nut. 14. Support trailing arm with suitable jack stand or support. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 429: Trailing Arm Spherical Bearing Replacement

    7. Press in new bearing until fully seated into trailing arm casting. 8. Install new snap ring, O-rings (not required) and bushings. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 430: Radius Rod Removal / Installation

    Brake Line Guide Fasteners: 7 ft-lbs (10 Nm) WARNING Upon radius rod installation, test vehicle at low speeds before putting into service. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 431: Stabilizer Bar Removal / Installation

    Torque fasteners to specification (see below). 3. Torque all fasteners to specification (see below). 4. Lubricate stabilizer bar pivot bushings via grease fitting. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 432: Shocks / Springs

    3. Use spanner wrench (2878925-329) loosen the jam nut (if applicable) and adjustment ring until the spring is loose. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.28 © Copyright Polaris Industries Inc.
  • Page 433 The spring retainer gap should be 180° from the end of the spring upon installation. 6. Remove bottom spring perch 11. Adjust the shocks. Reference Shock Adjustment page 2.51. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 434: Fox 2.5" Shock Information

    1.600 x 0.008 0.800 x 0.020 1.425 x 0.008 0.875 x 0.050 BU 1.350 x 0.008 1.250 x 0.010 1.100 x 0.010 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.30 © Copyright Polaris Industries Inc.
  • Page 435 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 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 436: Fox 2.5" Shock Information (4-Seat)

    1.800 x 0.008 0.800 x 0.020 1.800 x 0.008 0.875 x 0.050 BU 1.600 x 0.008 0.800 x 0.015 1.600 x 0.008 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.32 © Copyright Polaris Industries Inc.
  • Page 437 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 1.675 x 0.158 TO 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.33 © Copyright Polaris Industries Inc.

  • Page 438: Fox 3.0" Shock Information

    1.600 x 0.010 1.230 x 0.082 TO 1.425 x 0.010 1.350 x 0.010 1.250 x 0.010 1.100 x 0.010 0.950 x 0.010 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.34 © Copyright Polaris Industries Inc.
  • Page 439 STEERING / SUSPENSION COMPRESSION REBOUND 0.800 x 0.020 1.570 x 0.128 TO 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.35 © Copyright Polaris Industries Inc.

  • Page 440: Fox 3.0" Shock Information (4-Seat)

    1.800 x 0.008 1.230 x 0.082 TO 1.800 x 0.008 1.800 x 0.008 1.800 x 0.008 1.600 x 0.008 1.600 x 0.008 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.36 © Copyright Polaris Industries Inc.
  • Page 441 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 1.570 x 0.128 TO 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.37 © Copyright Polaris Industries Inc.

  • Page 442: Shock Service

    Valving Assembly Retaining Ring Bearing Assembly Retaining Ring Reservoir End Cap Assembly Bearing Cap Damping Adjust Assembly Body Cap Sparing Hardware Assembly Body 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.38 © Copyright Polaris Industries Inc.

  • Page 443: Offset Torque Formula

    L = 13.750″ Will equal 30 ft-lb of torque applied to the reservoir. E = 3.750″ or 2.500″ *depending on body cap 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.39 © Copyright Polaris Industries Inc.

  • Page 444: Fox Shock Disassembly

    STEERING / SUSPENSION FOX SHOCK DISASSEMBLY 1. Clamp the shock body securely in a vice. A training video is available on University of Polaris (https://lms.latitudelearning.com/home/main.aspx) for disassembly of Podium Internal Bypass shocks. Search for “Podium Internal Bypass Shock”. CAUTION Always wear safety glasses and read directions...
  • Page 445 The seal will be destroyed from the heat and must be replaced. 7. Hold cinch ring with spanner and rotate bearing assembly counter-clockwise to release pressure on retaining ring. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.41 © Copyright Polaris Industries Inc.
  • Page 446 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.42 © Copyright Polaris Industries Inc.
  • Page 447 26. Remove lock nut from the shaft assembly. 30. Remove compression valve stack and cable tie together. Clean with contact cleaner. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.43 © Copyright Polaris Industries Inc.
  • Page 448 Loctite residue left in the eyelet and shaft threads. Clean thoroughly with contact cleaner and lint-free 36. Clean all surfaces of the bearing housing and cinch towel. ring. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.44 © Copyright Polaris Industries Inc.
  • Page 449 38. To remove the remote hose assembly, de-pressurize reservoir, push hose in and remove retaining ring with a small pick. 39. Remove hose o-rings. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.45 © Copyright Polaris Industries Inc.
  • Page 450 STEERING / SUSPENSION 2.5 Bypass Piston 3.0 Bypass Piston Compression Side Compression Side Rebound Side Rebound Side 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.46 © Copyright Polaris Industries Inc.

  • Page 451: Fox Shock Assembly

    STEERING / SUSPENSION FOX SHOCK ASSEMBLY 4. Apply a thin layer of Slick Honey to body cap o-rings. A training video is available on University of Polaris (https://lms.latitudelearning.com/home/main.aspx) for assembly of Podium Internal Bypass shocks. Search for “Podium Internal Bypass Shock”.
  • Page 452 18. Install 1st T-seal back-up ring. 19. Install 2nd T-seal back-up ring 20. Install wiper seal. 21. Lubricate all seals with Slick Honey. 22. Install external o-ring. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.48 © Copyright Polaris Industries Inc.
  • Page 453 28. Install shaft nut and torque to specification. 34. Install shaft assembly into inner body. TORQUE Shaft Nut: 22 ft-lb (30 Nm) 29. Install all Bypass check valves. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.49 © Copyright Polaris Industries Inc.
  • Page 454 45. After setting IFP depth, install Bleed screw with o- assembly. ring. 40. Install retaining ring, ensuring that it is fully seated in ring gland. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.50 © Copyright Polaris Industries Inc.
  • Page 455 49. Stroke shock absorber and inspect shock for leaks. 50. Install body cap. 51. Clean oil residue from shock. 52. Install o-ring and reducers in eyelet and body. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.51 © Copyright Polaris Industries Inc.

  • Page 456: Shock Service

    Piston Wear Band (1.750" OD) 36. Shaft, Chrome Clicker Bolt Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.52 © Copyright Polaris Industries Inc.

  • Page 457: General Service Information

    If leakage from a remote shock reservoir hose fitting is evident, check for a loose fitting and seal threads with Three Bond 1215 (PN 2871557) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.53 © Copyright Polaris Industries Inc.

  • Page 458: Front Shock Service Information

    4.63″ (11.76 cm) Nitrogen Pressure 150 psi (1034.21 kPa) +/- 5% 150 psi (1034.21 kPa) +/- 5% 2874124 (qt.) 2874124 (qt.) Gas Shock Oil 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.54 © Copyright Polaris Industries Inc.
  • Page 459 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 1.550 x 0.012 Piston Bleed Orifice: none 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.55 © Copyright Polaris Industries Inc.

  • Page 460: Rear Shock Service Information

    Nitrogen Pressure 150 psi (1034.21 kPa) +/- 5% 150 psi (1034.21 kPa) +/- 5% 2874124 (qt.) 2874124 (qt.) Gas Shock Oil P/N 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.56 © Copyright Polaris Industries Inc.
  • Page 461 0.900 x 0.012 0.600 x 0.015 0.750 x 0.065 (round side 0.800 x 0.012 towards shim) 1.500 x 0.125 No Piston Bleed Orifice 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.57 © Copyright Polaris Industries Inc.

  • Page 462: Spring Adjustment (Walker Evans)

    Shock Spanner / Clutch Spreader Tool: 2878925 NOTICE NOTICE Polaris does not recommend increasing the spring adjustment beyond the guidelines in the preload adjustment chart as it may negatively impact vehicle stability. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.58...

  • Page 463: Special Tools

    The rebound and compression valve stacks will always be positioned as shown in the illustration, regardless of how the shock assembly is installed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.59 © Copyright Polaris Industries Inc.

  • Page 464: Walker Evans™ Shock Disassembly

    Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.60 © Copyright Polaris Industries Inc.
  • Page 465 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.61 © Copyright Polaris Industries Inc.
  • Page 466 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.62 © Copyright Polaris Industries Inc.

  • Page 467: Walker Evans™ Shock Assembly

    NOTICE If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.63 © Copyright Polaris Industries Inc.
  • Page 468 15. Screw IFP Tool (PS-45908) onto the floating piston. FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.64 © Copyright Polaris Industries Inc.
  • Page 469 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.65 © Copyright Polaris Industries Inc.
  • Page 470 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.66 © Copyright Polaris Industries Inc.
  • Page 471 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTICE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.67 © Copyright Polaris Industries Inc.

  • Page 472: Dynamix Active Suspension

    While the Dynamix Shocks come apart similar to a FOX Podium Bypass shock, there are several differences. Refer to the training on University of Polaris (https://lms.latitudelearning.com/home/main.aspx) and do a search for “Live Valve Shock” for complete disassembly and assembly of a Dymanix shock.

  • Page 473: Demonstration Mode

    SCM from it’s factory mounting location. SCM. SCM REPLACEMENT 1. Remove the hood. 5. Remove the 4 fasteners retaining the SCM to the mounting plate. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.69 © Copyright Polaris Industries Inc.

  • Page 474: Dynamix™ System Features

    The system continuously monitors steering angle, lateral acceleration, and vehicle yaw rate to provide enhanced cornering control, reducing body motion for maximum performance. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.70 © Copyright Polaris Industries Inc.

  • Page 475: Braking

    9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.71 © Copyright Polaris Industries Inc.

  • Page 476: Advanced Diagnostics

    SUSPENSION MODE SWITCH (DYNAMIX MODELS) For more information on the Dynamix suspension system, refer to the Steering / Suspension chapter - Dynamix Overview page 9.68 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.72 © Copyright Polaris Industries Inc.
  • Page 477 SWITCH CONTACT CONTACT PINS 1 TO POSITION Open Comfort Closed 1270 Ω Sport Open Open 1400 Ω Open Firm Closed 1330 Ω 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.73 © Copyright Polaris Industries Inc.
  • Page 478 STEERING / SUSPENSION NOTES 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 9.74 © Copyright Polaris Industries Inc.
  • Page 479 ............. . . 10.34 BRAKE BURNISHING PROCEDURE 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.1 © Copyright Polaris Industries Inc.

  • Page 480: General Information

    (7.53 ± .19 mm) Thickness .295 ± .008″ Rear Disc .268″ (6.8 mm) (7.5 ± .2 mm) Thickness Rear Disc – .010″ (0.25 mm) Runout 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 481: Brake System Overview

    15 ft-lbs (20 Nm) Rear Brake Line Guide Master Cylinder Fasteners Front Brake Caliper Fasteners 18 ft-lbs (25 Nm) 33 ft-lbs (45 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 482: Brake System View (4-Seat)

    Front Brake Caliper Front Brake Scraper Brake Scraper Fasteners 7 ft-lbs (10 Nm) Brake Line Guide Brake Line Guide Fasteners 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 483: Brake Line Routing / Retention

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Routing Clip Front Brake Calipers 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.5 © Copyright Polaris Industries Inc.
  • Page 484 BRAKE SYSTEM Master Cylinder To Junction Block Master Cylinder Routing Clip Junction Block 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.6 © Copyright Polaris Industries Inc.
  • Page 485 BRAKE SYSTEM Junction Block to Rear Brake Calipers Junction Block Rivet Clip Routing Clip Rear Brake Caliper 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 486: Brake Line Routing / Retention (4-Seat)

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION (4-SEAT) Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Routing Clip Front Brake Calipers 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 487 BRAKE SYSTEM Master Cylinder To Junction Block Master Cylinder Routing Clip Junction Block 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.9 © Copyright Polaris Industries Inc.
  • Page 488 BRAKE SYSTEM Junction Block to Rear Brake Calipers Junction Block Rivet Clip Routing Clip Rear Brake Caliper 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 489: Brake System Service Notes

    HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.

  • Page 490: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.12 © Copyright Polaris Industries Inc.
  • Page 491 150° Front Right Brake Line 90° Front Left Brake Line 90° TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.13 © Copyright Polaris Industries Inc.
  • Page 492 1. Clean master cylinder reservoir cover thoroughly and remove the cover Polaris DOT 4 Brake Fluid 2872189 4. Bleed the brakes in the following order: right rear, left rear, right front and finally the left front. Install a box end wrench on caliper bleeder screw.
  • Page 493 Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 494: Brake Pedal

    2. Remove the E-clip from the pedal mount and remove the brake pedal lever from the vehicle. Brake Pedal Free-play: 0.090″ (2.28 mm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 495: Front Brake Service

    7. Remove the inner pad from the bracket and caliper. 8. TO REMOVE CALIPER: Place a catch pan under the brake caliper. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.17 © Copyright Polaris Industries Inc.
  • Page 496 BRAKE SYSTEM 9. Remove the bolt retaining the brake line to the caliper. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 497: Front Caliper Assembly View

    Boots Scraper Bolts Caliper Assembly 7 ft-lbs (10 Nm) Bleeder Screw Mount Pins 48 in-lb (5 Nm) apply Silicone Grease on install 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 498: Front Caliper Assembly View (4-Seat)

    DOT 4 Brake Fluid Boots Brake Scraper Caliper Assembly Scraper Bolts Bleeder Screw Mount Pins apply Silicone Grease on install 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 499: Front Caliper Disassembly / Inspection

    Do not remove the caliper pistons with a standard pliers. The piston sealing surface will become damaged if a standard pliers is used. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.21 © Copyright Polaris Industries Inc.

  • Page 500: Front Caliper Disassembly / Inspection (4-Seat)

    6. Inspect caliper body for nicks, scratches, pitting or 2. Thoroughly clean the caliper before disassembly and wear. prepare a clean work area for disassembly. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 501: Brake Pad Inspection

    Front Caliper Piston O.D.: Large: 1.50″ (38.1 mm) Small: 1.19″ (30.226 mm) 10. Inspect the brake disc and pads as outlined in this chapter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 502: Front Caliper Assembly

    BRAKE SYSTEM FRONT CALIPER ASSEMBLY BRAKE DISC INSPECTION 1. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 1. Visually inspect disc for scoring, scratches and 2872189). Install piston with a twisting motion while gouges. Replace disc if deep scratches are evident.

  • Page 503: Front Brake Disc Replacement

    1/2 turn (counterclockwise). 7. Install the front wheel and the wheel nuts. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.25 © Copyright Polaris Industries Inc.

  • Page 504: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.26 © Copyright Polaris Industries Inc.

  • Page 505: Troubleshooting

    If there is a concern found with the circuit repair and recheck operation. 6. If the concern is still present, it is possible that there may be a concern with the ECU. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.27 © Copyright Polaris Industries Inc.

  • Page 506: Rear Brake Service

    Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.28 © Copyright Polaris Industries Inc.

  • Page 507: Rear Caliper Disassembly / Inspection

    NOTICE Be sure to clean caliper body seal grooves. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.29 © Copyright Polaris Industries Inc.

  • Page 508: Brake Pad Inspection

    Rear Caliper Piston Bore I.D.: Large: 1.1860-1.1875″ (30.12-30.16 mm) Small: 0.9985-1.000″ (25.36-25.40 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.30 © Copyright Polaris Industries Inc.

  • Page 509: Rear Caliper Assembly

    2. Use a 0-1″ micrometer and measure disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion while pushing inward.

  • Page 510: Rear Brake Disc Replacement

    7. Install rear caliper (see Brake Caliper / Pad Installation page ). Bleed the brake system. (See BRAKE BLEEDING / FLUID CHANGE page 10.14. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.32 © Copyright Polaris Industries Inc.

  • Page 511: Rear Brake Caliper / Pad Installation

    The calipers have self-orienting features, brake lines do not need to be oriented if installed correctly. TORQUE Banjo Bolts: 15 ft-lb (20 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.33 © Copyright Polaris Industries Inc.

  • Page 512: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 10.34 © Copyright Polaris Industries Inc.
  • Page 513 ................11.23 DOOR ADJUSTMENT 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.1 © Copyright Polaris Industries Inc.

  • Page 514: General Information

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.2 © Copyright Polaris Industries Inc.

  • Page 515: Body Assembly Views

    44 ft-lbs (60 Nm) Fastener - M12 x 1.5 x 80 (10.9) Flanged Nyloc Nut - M10 x 1.5 89 ft-lbs (120 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 516: Cab Frame Assembly (4-Seat)

    44 ft-lbs (60 Nm) Rear Cross Member Nyloc Nut - M10 x 1.5 Fastener - M12 x 1.5 x 80 (10.9) 89 ft-lbs (120 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 517: Front Doors

    Door Striker Door Hinge Fastener 18 ft-lbs (24 Nm) Door Striker Fastener Door Hinge Pin 7 ft-lbs (10 Nm) Door Latch Actuator 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 518: Rear Doors

    7 ft-lbs (10 Nm) Door Latch Actuator Door Latch Fastener 9 ft-lbs (12 Nm) Door Latch Actuator Fastener 9 ft-lbs (12 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 519: Dash / Controls

    DASH / CONTROLS 7” Display (Turbo S Models Only) Headlight Switch Key Switch AWD Switch Mode Switch (Turbo S Models Only) 12V Accessory 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 520: Hood / Front Body

    Front Fascia Fender Flare Fasteners Front Bumper 7 ft-lbs (10 Nm) LH Front Fender Flare Front Fascia Fasteners 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 521: Chassis / Main Frame

    Seat Base Support Bracket Front Bumper Seat Base Support Bracket Fasteners Front Bumper Bracket Fasteners 15 ft-lbs (20 Nm) 30 ft-lbs (40 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 522: Chassis / Main Frame (4-Seat)

    Front Seat Base Frame Front Bumper Fastener - M10 x 1.5 x 16 Front Bumper Fasteners 37 ft-lbs (50 Nm) 30 ft-lbs (40 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 523: Seat Assembly

    7 ft-lbs (10 Nm) Lower Hinge Bushing Fastener - M8 x 1.25 x 20 (10.9) 15 ft-lbs (20 Nm) Upper Hinge Bracket Bumper Grommet 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 524: Floor / Rocker Panels

    Storage Console Front Floor Panel Center Console Under-Seat Panel Battery Tray Rocker Panel Floor / Rocker Panel Fasteners 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 525: Floor / Rocker Panels (4-Seat)

    Rear Center Console Under-Seat Panel Front Center Console Front Rocker Panel Battery Tray Rear Rocker Panel Body Panel Fasteners 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 526: Rear Cargo Box / Fenders

    Top Rear Close-off Panel Rear Bumper Bottom Rear Close-off Panel Cargo Box Assembly Close-off Panel Cover Cargo Box / Fender Fasteners 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 527: Rear Bumper

    7ft-lbs (10 Nm) 7ft-lbs (10 Nm) Rear Fascia Mounting Bracket Rear Bumper Mounting Bracket Fastener Rear Bumper Mounting Bracket 7ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 528: Body Component Removal

    REAR CLOSE-OFF PANEL 1. Remove seats. 2. Unlock six 1/4 turn latches (four on top panel, two on bottom panel). 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 529: Front Fascia

    6. Remove three fasteners and one push pin from each fender, and remove front fenders. 3. Remove two fasteners and remove the front hood. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 530: Rear Fascia

    4. From the rear wheel well, remove one push pin either side of the rear fascia, and remove rear fascia. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 531: Hood / Front Body

    1. Remove front fascia. See Front Fascia Removal page 11.17. 2. Remove LH and center dash trim 3. Remove RH dash trim 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 532: Rear Fender / Fender Flare

    2. Pull the rear of the cargo box up and rearward to disengage front tabs and remove cargo box. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 533: Rocker Panels, Console, And Floor

    1. Remove seats and rocker panels. 2. Remove top half of shift knob 6. Remove one fastener from either side of the console under the dash. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.21 © Copyright Polaris Industries Inc.
  • Page 534 9. Remove one fastener from the shift linkage and remove shift cable from its mounting bracket. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 535: Doors

    9 ft-lbs (12 Nm) 5. Install new latch actuator. Torque fasteners to specification. TORQUE Door Latch Actuator Fasteners: 9 ft-lbs (12 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.23 © Copyright Polaris Industries Inc.
  • Page 536 5. Holding the door in position, tighten the top hinge bracket fasteners , and then the bottom fasteners . Torque to specification. TORQUE Hinge Bracket Fasteners: 18 ft-lbs (24 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 11.24 © Copyright Polaris Industries Inc.
  • Page 537 ..................12.29 DASH LIGHT 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.1 © Copyright Polaris Industries Inc.
  • Page 538 ............... 12.48 BREAK-OUT DIAGRAM VIEWING 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.2 © Copyright Polaris Industries Inc.

  • Page 539: General Information

    Fluke™ 77 Digital Multimeter PV-43568 Digital Wrench® (see Chapter 4 – DIGITAL WRENCH® OPERATION page Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.3 © Copyright Polaris Industries Inc.

  • Page 540: Electrical Service Notes

    • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. • Most electrical issues are related to damaged wiring. Fully test wiring before replacing any components. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.4 © Copyright Polaris Industries Inc.

  • Page 541: Electrical Component Locations (Rear)

    Crankshaft Position Sensor Waste Gate Control Seat Belt Switch Starter (+) Shock Actuator Engine Ground Fuel Pump Driver Module Barometric Air Pressure Sensor 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.5 © Copyright Polaris Industries Inc.

  • Page 542: Electrical Component Locations (Front)

    Front Accent Light 3& LED Dash Light AWD Coil GPS Antenna 4& Accent Light Antenna Harness Voltage Regulator 5& EPS Power Shock Actuator 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.6 © Copyright Polaris Industries Inc.

  • Page 543: Instrument Cluster

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.7 © Copyright Polaris Industries Inc.
  • Page 544 Parking Brake Indicator - Illuminates when parking brake is engaged (INT’L Models Only). Low Battery Indicator - Illuminates when battery voltage is low, charging system may be overloaded. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.8 © Copyright Polaris Industries Inc.

  • Page 545: Information Display Area

    Service Hours interval has been reached. AREA 3 MODES MODE DESCRIPTION The clock displays time in a 12-hour or 24-hour format. Clock 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.9 © Copyright Polaris Industries Inc.
  • Page 546 4. Press MODE to save and exit to the settings menu. 1. Press and hold the MODE button to enter the settings menu. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.10 © Copyright Polaris Industries Inc.

  • Page 547: Ride Command Unit Replacement

    1. Press either toggle button to cycle to the trip time option (TT). 2. Press and hold either toggle button until the meter resets to zero. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.11 © Copyright Polaris Industries Inc.
  • Page 548 1. Reverse removal procedure for installation. Torque fasteners to specification. TORQUE Body Panel Fasteners: 7 ft-lbs (10 Nm) 4. Remove eight fasteners and remove dash. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.12 © Copyright Polaris Industries Inc.
  • Page 549 Left Turn Signal Input Right Turn Signal Input High Beam Input Trailer Turn Sign Input Fuel Level Sensor Blackout Mode Input Accy Air Temp Input 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.13 © Copyright Polaris Industries Inc.

  • Page 550: Switches / Controls

    NOTICE Pins 7 and 8 provide power and ground to light the switch lamp. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.14 © Copyright Polaris Industries Inc.

  • Page 551: Seat Belt Switch

    2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT DISENGAGED ENGAGED Between both ∞ (OL) < 1 Ω pins on switch 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.15 © Copyright Polaris Industries Inc.

  • Page 552: Transmission / Gear Position Switch

    0.5 Ω resistance when the brake is applied with slight pressure, first clean the switch contacts and re- 160 Ω test. Replace switch if necessary. 75 Ω PARK 24 Ω 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.16 © Copyright Polaris Industries Inc.

  • Page 553: Boost Control Solenoid / Valve

    Boost Control Valve: 22–24 Ω More information relating to the turbocharger system and components may be found in the Engine and Fuel System chapters. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.17 © Copyright Polaris Industries Inc.

  • Page 554: Steering Angle Sensor Centering (Dynamix)

    4. Come to a complete stop without turning the steering wheel. Turn key off. 5. Turn key to ON position. 6. Cycle key off and back on. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.18 © Copyright Polaris Industries Inc.

  • Page 555: Ignition Coil

    Ignition Coil Fastener: 7 ft-lbs (10 Nm) 5. Install Cargo Box and torque fasteners to specification. NOTICE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.19 © Copyright Polaris Industries Inc.

  • Page 556: Charging System

    Maximum of .01 DCA (10 mA) Charging system damage will occur if incompatible components are installed. Always reference the Polaris 9. If over 10 milliamps, go to the fuse block and start Electronic Parts Catalog for the proper part numbers.

  • Page 557: Stator Testing

    If there are any significant variations in ohm readings between the three legs it is an indication that one of the stator legs may be weak or failed. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.21 © Copyright Polaris Industries Inc.

  • Page 558: Regulator / Rectifier (Dynamix)

    82 VAC ± 25% 5. Install new regulator(s) on the bracket. Torque fasteners to specification. TORQUE Regulator Fasteners: 8 ft-lb (11 Nm) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.22 © Copyright Polaris Industries Inc.
  • Page 559 8. Connect the battery negative cable. Torque fastener to specification. TORQUE Battery Terminal Fastener: 60 in-lbs (7 Nm) 9. Install the seat. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.23 © Copyright Polaris Industries Inc.

  • Page 560: Battery

    ELECTRICAL BATTERY BATTERY SPECIFICATIONS WARNING Polaris / Johnson Controls 575 Battery electrolyte is poisonous. It contains acid! Type Sealed - Maintenance Free Serious burns can result from contact with the skin, eyes, or clothing. Voltage 12 Vdc Nominal Capacity ANTIDOTE:...

  • Page 561: Battery Removal

    60 in-lbs (7 Nm) 6. Verify that cables are properly routed and reinstall the 5. Lift the battery out of the vehicle. driver’s seat. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.25 © Copyright Polaris Industries Inc.

  • Page 562: Battery Off Season Storage

    A battery may indicate a full charge condition in the OCV NOTICE test, but still may not have the storage capacity Battery charge can be maintained by using a Polaris necessary to properly function in the electrical system. battery tender or by charging once a month to make up For this reason, a battery capacity or load test should be for self-discharge.

  • Page 563: Charging Procedure

    Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.27 © Copyright Polaris Industries Inc.

  • Page 564: Lighting System

    4. Install front fascia. Torque fasteners to specification. TORQUE Body fasteners: 7 ft-lbs (10 Nm) 5. Perform the Headlight Adjustment procedure outlined in this chapter. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.28 © Copyright Polaris Industries Inc.

  • Page 565: Tail Light Replacement

    24 in-lb (3 Nm) DASH LIGHT The LED light will remain ON for approximately 30 seconds after key has been switched to the OFF position. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.29 © Copyright Polaris Industries Inc.

  • Page 566: Cooling System

    1 Ω. • Power side should show battery voltage. If battery voltage is not seen, check voltage at the fan circuit breaker. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.30 © Copyright Polaris Industries Inc.

  • Page 567: Cooling Fan Replacement

    6. Remove two large hoses and one vent line from the charge air radiator and remove charge air radiator from the vehicle. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.31 © Copyright Polaris Industries Inc.
  • Page 568 Remove fan and cooling system. See Cooling System Bleeding page radiator as an assembly. 2.38. 12. Remove cooling fan from radiator. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.32 © Copyright Polaris Industries Inc.

  • Page 569: Electric Coolant Pump

    3. When the system is bled properly, remove the jumper and reinstall the Fuel Pump relay. REPLACEMENT 1. Place a drain pan underneath the coolant pump. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.33 © Copyright Polaris Industries Inc.

  • Page 570: Ect Sensor Test

    After a few 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 using Digital Wrench® Diagnostic Software (dealer only). TEMPERATURE °F (°C) RESISTANCE 68 °F (20 °C)

  • Page 571: Starting System

    8. Install the 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. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.35 © Copyright Polaris Industries Inc.

  • Page 572: Electronic Power Steering (Eps)

    The READ BEFORE YOU REPLACE THE EPS UNIT! system is Polaris Digital Wrench® compatible for simplified diagnostics and system troubleshooting NOTICE through the vehicle’s diagnostic port.

  • Page 573: Fuses / Relays

    Power Out Coil Low Power In Key 7.5A Fuse Power Out Power In Fan 30A Fuse Power Out Accy Relay Coil High 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.37 © Copyright Polaris Industries Inc.
  • Page 574 Power Out Coil Low Power In Water 7.5A Fuse Power Out Power In Fuel 7.5A Fuse (10A for EVAP only) Power Out 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.38 © Copyright Polaris Industries Inc.
  • Page 575 CIRCUIT FUNCTION Coil High Power In EFI Relay Power Out Coil Low Coil High Power In Brake Relay Power Out Coil Low 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.39 © Copyright Polaris Industries Inc.

  • Page 576: Relay / Fuse Details

    Accy 10A Fuse 12V Receptacle(s) Key 10A Fuse Key Switch LED Light(s) Instr Fuse Out Splice Diagnostic Plug Insr 10A Fuse Speedometer 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.40 © Copyright Polaris Industries Inc.

  • Page 577: 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 off the B+ post, under the front driver’s side fender. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.41 © Copyright Polaris Industries Inc.

  • Page 578: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.42 © Copyright Polaris Industries Inc.

  • Page 579: Wiring Harness

    ELECTRICAL WIRING HARNESS ELECTRICAL HARNESS ROUTING ELECTRICAL HARNESS ROUTING (4-SEAT) 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.43 © Copyright Polaris Industries Inc.

  • Page 580: Electrical Harness Retention

    ELECTRICAL ELECTRICAL HARNESS RETENTION Zip Tie Retention Point The white tape on the harness signifies a retention point 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.44 © Copyright Polaris Industries Inc.

  • Page 581: Electrical Harness Retention (4-Seat)

    ELECTRICAL ELECTRICAL HARNESS RETENTION (4-SEAT) Zip Tie Retention Point The white tape on the harness signifies a retention point 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.45 © Copyright Polaris Industries Inc.

  • Page 582: Wiring Harness Replacement

    17. Remove the harness through the front of the vehicle. 18. Route new harness the same way as the old harness. Refer to Electrical Harness Retention page 12.44. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.46 © Copyright Polaris Industries Inc.

  • Page 583: Wiring Harness Replacement (4-Seat)

    17. Remove the harness through the front of the vehicle. 18. Route new harness the same way as the old harness. Refer to Electrical Harness Retention page 12.45. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.47 © Copyright Polaris Industries Inc.

  • Page 584: Break-Out Diagram Viewing

    2. If the wiring diagram does not open the Adobe navigation bars, click on the Adobe Icon. 3. Click on the Layers Icon. 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual 12.48 © Copyright Polaris Industries Inc.
  • Page 585 .1 Symptom and Occurrence Checklist IMPORTANT This checklist is intended for Dealer use. It is a guide to help with concerns that are Intermittent and / or Hard to Duplicate. It is intended to collect as much information as possible before continuing with the diagnosis. •...
  • Page 586 2020-2021 RZR PRO XP / XP 4 OCCURRENCE CHART ○ ALWAYS ○ MORE THAN 50% OF THE TIME WHEN IS PROBLEM APPARENT? ○ LESS THAN 50% OF THE TIME IF NO PLEASE EXPLAIN: ○ YES DOES IT HAVE TO BE RUNNING OR DRIVING? ○...
  • Page 587 Symptom and Occurrence Checklist ○ BEEN PRESENT SINCE NEW...
  • Page 589 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams Click here: RZR PRO XP (Base 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 PRO XP Dash Lights Click here: RZR PRO XP Steering Column...
  • Page 591 Installation (rear) ..........10.33 Brake Caliper Removal (Front) ........... 10.17 Installation (rear) ..........10.33 Removal (rear)............. 10.28 Removal (rear)............. 10.28 Caliper, Front 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 592 Cooling Fan Feature Map............1.42 Guided Diagnostics ..........1.38 Bypass Test ............12.31 Replacement............12.31 Polaris Mobile Digital Wrench® (PMDW) .....1.44 Testing ............... 12.30 Serial Number Location ...........1.41 Cooling System Software Installation and Updates ......1.39 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.2...
  • Page 593 Limiting / Misfire .............1.58 Lubrication Specifications ......... 3.4 Mount Replacement..........3.43 Test ..............12.34 Oil and Filter Change ..........2.29 Oil Flow Chart............3.6 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 594 Assembly View ............9.38 Disassembly ............9.40 Front A-arm Replacement............9.18 Head Pipe Installation ............3.19 Front Bearing Carrier ..........8.5 Front Body Removal...............3.18 Removal............. 11.19 Headlight 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 595 Ring to Groove Clearance ........3.75 Removal...............3.63 Piston Removal............3.72 Main Bearing Piston Ring Selection Chart ............3.79 Removal...............3.75 Main Harness Plunging Joint / Boot 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 596 Relay Box .............. 12.37 Spark Plug Replacement............3.36 Service ..............2.56 Replacement (Front) ........... 8.4 Special Tools retention..............12.44 Body / Frame............11.2 Retention..............10.5 Brakes ..............10.2 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 597 Shock Adjustment ..........2.51 EPS Non-Functional MIL Off ........1.70 EPS Non-Functional MIL On ........1.69 Shock Analysis ............1.72 Special Tools ............9.3 EPS Using Digital Wrench®........1.71 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.7 © Copyright Polaris Industries Inc.
  • Page 598 Alignment / Inspection ..........2.48 Installation ............2.44 Removal...............2.44 Toe Adjustment ............2.49 Wheel Bearing ............8.4 Replacement (rear)..........8.8 Wiring Harness Replacement............12.46 Replacement (4-Seat) ........... 12.47 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual IX.8 © Copyright Polaris Industries Inc.

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