Polaris RZR XP Turbo Service Manual
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Polaris RZR XP Turbo Service Manual

2017-2018
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Table of Contents

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2017-2018 RZR XP Turbo / XP4 Turbo
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 2017 (PN 9928491 R04)
© Copyright 2017 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 XP Turbo

  • Page 1 Publication Printed September 2017 (PN 9928491 R04) © Copyright 2017 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 SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 3 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. REVISION INDEX DATE CHANGES Initial Release;...
  • Page 5 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: EFI / FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE...

  • Page 7: Table Of Contents

    ................1.32 DECIMAL EQUIVALENTS 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 8: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018 VIN AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

  • Page 9: Reference Information

    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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 10: 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 11 PU-47471 PU-48951 Fuel Pressure Adapter Water Pump Drive & Fuel Pressure Gauge Smartlink Module Kit CV Boot Clamp Pliers Flywheel Removal (Stepless) Tool 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 12 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Valve Spring Tool Tool Tool Compressor Compressor Adapter PV-43526 PV-43531 PV-43568 PV-43570-1 Connector Test Kit Oil Presure gauge Fluke Multimeter Piston Ring Compressor Pliers 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 14: Master Torque Table

    Cylinder Head Bolts Step 3: Additional 180° Step 4: Additional 180° Step 5: M6 bolts: 7 ft-lb (10 Nm) 8 ft-lb (11 Nm) Door Fasteners 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 15 Oil Cooler Bolts 9 ft-lb (12 Nm) Oil Pan Bolts (M8) 26 ft-lb (35 Nm) Oil Pump Mounting Bolts 7 ft-lbs (10 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 16 Starter One-Way Clutch Screws 9 ft-lb (12 Nm) 35 in-lb (4 Nm) Cable Nuts Starter Solenoid Mounting Bolts 8 ft-lb (11 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 Water Pump Impeller 7 ft-lb (10 Nm) Cover Bolts (Apply Loctite® 204™ to bolt threads) Wheel Lug Nuts 120 ft-lbs (163 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.11 © Copyright Polaris Industries Inc.

  • Page 18: Vehicle Specifications

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.12 © Copyright Polaris Industries Inc.

  • Page 19: 2017 Rzr Xp Turbo Clutch Chart

    10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 10A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.13 © Copyright Polaris Industries Inc.
  • Page 20 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.14 © Copyright Polaris Industries Inc.

  • Page 21: 2017 Rzr Xp 4 Turbo

    10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 15A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.15 © Copyright Polaris Industries Inc.
  • Page 22 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 1830 lbs (830 kg) Hitch Tongue Capacity 165 lbs (75 kg) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 23: 2017 Rzr Xp Turbo Clutch Chart

    10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 10A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: 2018 Rzr Xp Turbo

    10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 10A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.19 © Copyright Polaris Industries Inc.

  • Page 26: 2018 Rzr Xp Turbo Fox Edition

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.20 © Copyright Polaris Industries Inc.

  • Page 27: 2018 Rzr Xp Turbo Clutch Chart

    10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 10A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 28: 2018 Rzr Xp Turbo Dynamix Edition

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.22 © Copyright Polaris Industries Inc.

  • Page 29: 2018 Rzr Xp Turbo 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.23 © Copyright Polaris Industries Inc.
  • Page 30 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.24 © Copyright Polaris Industries Inc.

  • Page 31: 2017 Rzr Xp4 Turbo 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.25 © Copyright Polaris Industries Inc.
  • Page 32 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.26 © Copyright Polaris Industries Inc.
  • Page 33 10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 15A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.27 © Copyright Polaris Industries Inc.
  • Page 34 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.28 © Copyright Polaris Industries Inc.

  • Page 35: 2018 Rzr Xp 4 Turbo

    10A Drive 10A EFI 10A Fuel 10A Instr 10A Key Fuses 10A Lights 15A Term 10A Unsw 10A Water 25A EPS 30A Fan 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.29 © Copyright Polaris Industries Inc.

  • Page 36: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.30 © Copyright Polaris Industries Inc.

  • Page 37: 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 7/16–14 3–4 2 3/4 7/16–20 25/64 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 38: 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″ 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 1.32 © Copyright Polaris Industries Inc.
  • Page 39 ................. . .2.44 TIRE INSPECTION 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 40 ................. . .2.53 SPARK PLUG SERVICE 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 41: Maintenance

    U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 2870652 16 oz (12) Fuel Stabilizer 2872280 2.5 gal (2) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 42: Pre-Ride Inspection

    • Verify coolant level is filled to the FULL COLD mark on Coolant Level coolant reservoir (if engine is cold) • Inspect hoses and radiator for leaks 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 43: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual...
  • Page 44 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual...
  • Page 45 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual...
  • Page 46 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual...
  • Page 47 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual...
  • Page 48 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.10...
  • Page 49 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.11...
  • Page 50 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.12...
  • Page 51 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.13...
  • Page 52 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.14...
  • Page 53 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.15...
  • Page 54 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.16...
  • Page 55 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.17...
  • Page 56 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.18...
  • Page 57 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.19...
  • Page 58 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.20...
  • Page 59 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.21...
  • Page 60 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.22...
  • Page 61 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.23...
  • Page 62 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 63: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant * More often under severe use, such as operation in water or under severe loads. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.25 © Copyright Polaris Industries Inc.
  • Page 64 ~64 oz Transmission Polaris AGL (1900 mL) * More often under severe use, such as operation in water or under severe loads. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 65: Grease Lubrication Points

    Polaris All Season Grease Bushings thoroughly washing or the vehicle submerging the vehicle Polaris Premium U-Joint Propshaft Yokes Grease fittings on the slip yoke Grease 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 66: Engine / Exhaust

    Make certain the dipstick is inserted all the way down to ensure an accurate reading. 6. Remove the dipstick and check the oil level. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 67: Engine Oil And Filter Change

    7. Lubricate the o-ring on the new oil filter with a film of clean engine oil. Check to make sure the o-ring is in good condition. Tighten to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 68: Engine Crankcase Breather Hose

    18. When finished, reinstall dipstick and lock the lever. 19. Reinstall the cargo box access panel, engine service panel and seats. 20. Dispose of used oil, filter and rags properly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 69: Valve Clearance Adjustment

    12. Reinstall the camshafts and camshaft carriers and specification, remove the camshaft carriers and tighten the bolts evenly to specification. proceed to Camshaft Installation / Timing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 70: Cam Chain Tensioner Inspection

    5. Retract the plunger all the way in and install into the cylinder. 6. Install the two mounting bolts. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 71: Spark Arrestor

    4. Inspect the screen for wear and damage. Replace if damaged. 5. Reinstall the spark arrestor. Torque fasteners to specification. TORQUE Spark Arrestor Fasteners: 8 ft-lb (11 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 72: Heat Shield Inspection

    Front Access Panel Heat Shield Rear Heat Shield Turbo Upper Heat Shield Rear Close-off Heat Shield Silencer Heat Shield Turbo Lower Heat Shield 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 73: Cooling System

    6. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 74: Cooling System Pressure Test

    Charge Air Cooler Hoses Water Pump Hoses Oil Cooler Coolant Hoses 3. Check tightness and condition of all hose spring clamps. Replace if necessary. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 75: Radiator Inspection / Cleaning

    6. Connect the coolant hoses at both water pumps and properly position the clamps.. 7. Ensure the transmission is in park and chock the rear tires. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 76: Cooling System Bleeding

    4. Remove the cargo box engine access panel. 5. Place a drain pan below the engine to catch any coolant out of the engine bleed hole. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.38 © Copyright Polaris Industries Inc.

  • Page 77: Charge Air Cooling System Bleeding

    The engine should take 3-5 minutes to warm up and the fan should cycle normally if all the air has been purged from the system. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 78: Fuel System And Air Intake

    CAUTION Compressed air or high pressure hose may damage the frog skin pre-filter on the intake. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 79: Air Filter Service

    2. Check the drain to ensure it is not plugged with debris so it can drain properly. If needed, remove the drain from the baffle box during inspection. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 80: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 81: Front Gearcase Lubrication

    4. Reinstall the fill plug and torque to specification. 8. Check for leaks. Dispose of used fluid properly. TORQUE Front Gearcase Fill / Drain Plug: 10 ft-lbs (14 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 82: Drive Shaft Boot Inspection

    120 ft-lbs (163 Nm) MEASUREMENT Hub Castle Nuts: Tire Lug Service Limit: 180 ft-lbs (244 Nm) Replace if 1/8″ (3 mm) or less. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.44 © Copyright Polaris Industries Inc.

  • Page 83: Maintenance

    18 PSI 19 PSI RZR XP Turbo (125 kPa) (130 kPa) 22 PSI 22 PSI RZR XP4 Turbo (152 kPa) (152 kPa) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.45 © Copyright Polaris Industries Inc.

  • Page 84: Transmission

    The drain plug is located on the bottom of the transmission gearcase. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.46 © Copyright Polaris Industries Inc.

  • Page 85: Steering

    • Refer to Chapter 7 Front Bearing Carrier Inspection / Removal, page 7.3 and Rear Bearing Carrier Inspection / Removal, page 7.6 for wheel bearing service procedures. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.47 © Copyright Polaris Industries Inc.

  • Page 86: Wheel Toe Alignment Inspection

    Damage may not be immediately Wheel Toe-Out: apparent if done incorrectly. 1/8" to 3/16″ (3.2 to 4.8 mm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.48 © Copyright Polaris Industries Inc.
  • Page 87 MUST have Steering Angle Sensor Centering procedure performed once everything is reinstalled. Refer to Steering Angle Sensor Centering (Dynamix), page 11.31. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.49 © Copyright Polaris Industries Inc.

  • Page 88: Suspension

    Refer to Grease Lubrication Points, page 2.27 for suspension lubrication. NOTE There are no grease fittings on the front control arm pivot points or the rear trailing arms. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.50 © Copyright Polaris Industries Inc.

  • Page 89: Brake System

    5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.51 © Copyright Polaris Industries Inc.

  • Page 90: 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) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.52 © Copyright Polaris Industries Inc.

  • Page 91: Electrical And Ignition System

    WARNING A hot engine can cause serious burns. Allow engine to cool or wear protective gloves when removing the spark plugs. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.53 © Copyright Polaris Industries Inc.
  • Page 92 7. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION A wire brush or coated abrasive should not be used. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 2.54 © Copyright Polaris Industries Inc.
  • Page 93 ................3.45 ENGINE INSTALLATION 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 94 ............... . .3.85 CYLINDER HEAD INSTALLATION 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 95 ..............3.95 TURBOCHARGER TROUBLESHOOTING 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 96: General Information

    Clutch Center Distance Tool 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 97: Oil Pressure Test

    CAUTION The oil line may become damaged if the banjo is not held in place while removing the allen fitting. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 98: Oil Flow Chart

    ENGINE / COOLING SYSTEM OIL FLOW CHART 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 99: 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° 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 100 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 101: 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) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 102 (10 Nm) STATOR COVER HEAD PIPE / TURBO Exhaust Head Pipe Stator Cover Bolts 9 ft-lb (12 Nm) 18 ft-lb (24 Nm) Fasteners 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 103: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 104: Engine Air Intake Assembly View

    Throttle Body Bolts Oetiker Clamp Torque in sequence to 7 ft-lb (10 7 ft-lb (10 Nm) Engine Breather Hose Throttle Body Gasket Intake Manifold 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 105: Air Box Removal

    The cargo box only needs to be lifted up slightly to gain access to the air box fasteners. The cargo box or cab frame does not need to be removed. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 106: 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) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 107: Muffler Removal

    TORQUE Rear Fascia / Muffler Cover Screws: 8 ft-lb (11 Nm) EXHAUST PIPE REMOVAL 1. Lift and secure the vehicle. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.15 © Copyright Polaris Industries Inc.
  • Page 108 O2 sensor. 8. Remove the four fasteners retaining the exhaust pipe to the turbocharger. 9. Remove the exhaust pipe from the chassis. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 109: Head Pipe / Turbo Removal

    7. Remove the two fasteners retaining the heat shield the exhaust pipe. to the exhaust pipe / turbo joint. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.17 © Copyright Polaris Industries Inc.
  • Page 110 Polaris Electronic the bracket to pivot towards the front of the vehicle for Parts Catalog. turbo removal. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.18 © Copyright Polaris Industries Inc.

  • Page 111: Head Pipe / Turbo Installation

    Apply anti-seize on exhaust pipe to turbo joint and 1. Install a new head pipe gasket and install the head fasteners. pipe/turbo assembly on the cylinder head studs. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.19 © Copyright Polaris Industries Inc.

  • Page 112: Exhaust Pipe Installation

    15. Install the shock access panel. Torque fastener to 70 ft-lbs (95 Nm) specification. TORQUE Shock Access Panel: 35 in-lb (4 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.20 © Copyright Polaris Industries Inc.

  • Page 113: Turbocharger Service

    If filter is found to be clogged, replace the filter. CAUTION A clogged or restrictive air filter or intake tract can cause excessive turbocharger speeds and premature wear. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 114 9. Remove the four fasteners retaining the exhaust pipe to the turbocharger. 10. Remove the exhaust pipe from the chassis. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 115 16. 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.23 © Copyright Polaris Industries Inc.

  • Page 116: Actuator / Wastegate Inspection

    Do NOT pod. use compressed air. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.24 © Copyright Polaris Industries Inc.

  • Page 117: Actuator Pod Removal

    3. Remove both pieces to free the Heim joint from the assembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.25 © Copyright Polaris Industries Inc.

  • Page 118: Oil Drain Tube Service

    OIL DRAIN TUBE SERVICE 11 ft-lb (15 Nm) 1. Remove the two fasteners retaining the oil drain tube to the turbocharger. Discard the fasteners. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.26 © Copyright Polaris Industries Inc.

  • Page 119: Wastegate Flapper Inspection

    COOLING SYSTEM 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.27 © Copyright Polaris Industries Inc.

  • Page 120: Cooling System Flow

    ENGINE / COOLING SYSTEM COOLING SYSTEM FLOW 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.28 © Copyright Polaris Industries Inc.

  • Page 121: Cooling System Specifications

    COOLING SYSTEM PRESSURE TEST remove both hoses going to the charge air cooler and allow coolant to drain. 1. Remove the hood. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.29 © Copyright Polaris Industries Inc.
  • Page 122 10. Remove the four fasteners retaining the throttle body/ETC to the intake manifold. 6. Disconnect the transmission switch, speed sensor and CPS. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 123: Charge Air Cooler Installation

    Intake Manifold Clamps: 6 ft-lb (8 Nm) 4. Install the four fasteners retaining the throttle body to the intake manifold. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.31 © Copyright Polaris Industries Inc.

  • Page 124: Radiator Removal

    8. Install the two fasteners retaining the fuel injector wiring bracket to the intake manifold. Torque fasteners to specification. TORQUE Fuel Injector Wiring Bracket Fasteners: 7 ft-lb (10 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 125 5. Remove the zip ties on both sides retaining the from the chassis. headlight harnesses. 10. FOR ENGINE RADIATOR REMOVAL: Disconnect the fan harness. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 126: Radiator Installation

    Radiator Bracket Fasteners: 8 ft-lb (11 Nm) 8. Install the two fasteners retaining the voltage regulator bracket to the chassis. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 127 5. Remove the thermostat cover and hose to access the thermostat . Pull the thermostat up to remove it from the housing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 128: Water Pump Service

    13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 5. Remove impeller from water pump shaft. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.36 © Copyright Polaris Industries Inc.
  • Page 129 7 ft-lb (10 Nm)(Apply Loctite® 204™ to bolt threads) 18. Clean cover and housing gasket surfaces 19. Install a new water pump cover gasket 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.37 © Copyright Polaris Industries Inc.
  • Page 130 Water Pump Assembly View Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.38 © Copyright Polaris Industries Inc.

  • Page 131: Engine Service

    3. Remove the fasteners retaining the isolator mounts to the frame. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 132: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.40 © Copyright Polaris Industries Inc.
  • Page 133 5. Field test the vehicle before putting back into service. the flat side of the seal facing out as shown. Inspect for any leaks. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 134: Engine Removal

    / turbo joint. 10. Remove the three fasteners retaining the muffler to the exhaust pipe. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.42 © Copyright Polaris Industries Inc.
  • Page 135 Polaris Electronic Parts Catalog. 22. Slide the head pipe off the studs and remove the head pipe/turbo from the vehicle. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.43 © Copyright Polaris Industries Inc.
  • Page 136 30. Loosen and remove clamps retaining intake water pump hose manifold to engine. Remove lower manifold mounting bolt (to trans mount bracket). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.44 © Copyright Polaris Industries Inc.

  • Page 137: Engine Installation

    Torque fasteners to specification. TORQUE Engine Mounting Bracket Fasteners: 42 ft-lb (57 Nm) 37. Remove three bolts retaining inner cover to engine (over crank seal). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.45 © Copyright Polaris Industries Inc.
  • Page 138 Hose Clamps: 35 in-lb (4 Nm) Outer PVT Cover Fasteners: 35 in-lb (3 Nm) 9. Connect the starter wiring. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.46 © Copyright Polaris Industries Inc.
  • Page 139 19. Install the six fasteners retaining the head pipe to the cylinder head. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.47 © Copyright Polaris Industries Inc.
  • Page 140 34. Install cargo box brackets, exhaust shields on passenger side and wire/hose clamps on driver’s side. Torque fasteners to specification. TORQUE Cargo Box Bracket Fasteners: 8 ft-lb (11 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 141: Engine Disassembly / Inspection - Top End

    3. Remove the two bolts retaining the fixed cam chain The camshafts can be removed with the engine guide and remove the assembly from the engine. installed in the chassis. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 142: Camshaft Sprocket Inspection

    1. Visually inspect each cam lobe for wear or damage. NOTE Replace camshafts if damaged or if any part is worn past the service limit. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.50 © Copyright Polaris Industries Inc.
  • Page 143 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) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.51 © Copyright Polaris Industries Inc.

  • Page 144: Cylinder Head Removal

    Tap only in reinforced areas or on thick parts of the cylinder head casting. WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 145: Valve Inspection

    This is normal and should not cause valve leakage. Both valves shown are acceptable and would not require replacement. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 146: Combustion Chamber Cleaning

    Wear eye protection during combustion chamber cleaning. MEASUREMENT Valve Stem Diameter: Intake: .2155 - .2161" (5.475 - 5.490 mm) Exhaust: .2147 - .2153" (5.455 - 5.470 mm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 147: Valve Seat Reconditioning

    If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked the cylinder head must be replaced. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.55 © Copyright Polaris Industries Inc.
  • Page 148 Exhaust Seat Cutter Diameter: 1.260″ (32.00 mm) 6. Insert valve into guide and tap valve lightly into place a few times. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.56 © Copyright Polaris Industries Inc.
  • Page 149 9. If too low, use the 60° cutter to raise the seat. When 16. Thoroughly clean cylinder head and valves. contact area is centered on the valve face, measure seat width. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 150: Engine Disassembly / Inspection - Bottom End

    WATER PUMP HOUSING REMOVAL NOTE The water pump housing can be serviced with the engine installed in the chassis. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 151: Flywheel Removal

    The starter one-way clutch can be serviced with the mechanical seal), refer to Water Pump Service, page engine installed in the chassis. 3.36. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 152: Starter One-Way Clutch Disassembly

    CRANKCASE DISASSEMBLY 1. Remove the four fasteners retaining the oil cooler to the crankcase. 2. Remove the three one-way clutch retaining screws 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.60 © Copyright Polaris Industries Inc.
  • Page 153 5. Rotate engine to access the crankcase sump cover. 6. Remove the thirteen M6 and three M8 bolts retaining the sump cover to the crankcase. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.61 © Copyright Polaris Industries Inc.
  • Page 154 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 155: Balance Shaft Removal / Inspection

    CRANKSHAFT REMOVAL / INSPECTION Perform Balance Shaft Removal / Inspection, page 3.63 2. For ease of assembly, mark each connecting rod and end cap. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.63 © Copyright Polaris Industries Inc.
  • Page 156 Main Journal 2 PTO End NOTE If either the crankshaft gear or auxiliary sprocket is damaged, the crankshaft assembly must be replaced. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 157: Crankcase Inspection

    Connecting Rod Bearing Selection, page 3.72 and Crankshaft Main Bearing Selection, page 3.72 procedures. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 158: Cylinder / Piston Removal

    1. Perform “ENGINE DISASSEMBLY / INSPECTION - TOP END” and the “ENGINE DISASSEMBLY / INSPECTION - LOWER END” procedures. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.66 © Copyright Polaris Industries Inc.

  • Page 159: Cylinder Inspection

    2. Inspect cylinder for wear, scratches, or damage. CAUTION DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 160: Piston Ring Removal

    DO NOT expand the ring more than necessary to remove it from the piston or the ring may break or lose radial tension. 2. Repeat procedure for second compression ring 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 161: Piston Ring To Groove Clearance

    . Use the piston to push the ring squarely into cylinder. MEASUREMENT Piston O.D. (Standard): 3.6597 ± .0003" (92.959 ± 0.008 mm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.69 © Copyright Polaris Industries Inc.

  • Page 162: Connecting Rod Inspection

    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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.70 © Copyright Polaris Industries Inc.

  • Page 163: Engine Assembly - Bottom End

    BEARING SELECTION IDENTIFICATION Connecting Rod Bearing Crankcase Bearing Identification Crankshaft Bearing Identification Identification Number ( one number) Number (six numbers) Letters (six letters) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 164: Connecting Rod Bearing Selection

    Inspect the surfaces closely for nicks, burrs or damage. 2. Clean bolt hole threads to remove any oil or crankcase sealant. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 165: Piston Ring Installation

    Ends must butt squarely together and must not overlap. 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 166: Piston / Connecting Rod Assembly

    If the pistons are being reused, reassemble in the same cylinder bore and direction from which they were removed (MAG / PTO). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.74 © Copyright Polaris Industries Inc.

  • Page 167: Crankshaft Installation

    (main bearings), connecting rods and connecting rod caps. NOTE Base gasket and surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.75 © Copyright Polaris Industries Inc.
  • Page 168 14. Torque connecting rod bolts to specification. TORQUE Connecting Rod Bolts: Step 1: 9 ft-lbs (12 Nm) Step 2: 22 ft-lb (30 Nm) Step 3: Tighten add’n 90° 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.76 © Copyright Polaris Industries Inc.

  • Page 169: Balance Shaft Installation

    CRANKCASE ASSEMBLY 1. Check to be sure the PTO crankshaft seal is resting properly in the upper crankcase. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 170 10. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.78 © Copyright Polaris Industries Inc.
  • Page 171 M8 Bolts: 26 ft-lb (35 Nm) M6 Bolts: 9 ft-lb (12 Nm) 13. Rotate the engine so the cylinder is facing up. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.79 © Copyright Polaris Industries Inc.
  • Page 172 NOTE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 173: Starter One-Way Clutch Assembly

    Flywheel Starter Gear One-Way Clutch Asm Screws Torque Limit Gear Bolt 5. If starter gear was replaced, inspect the torque limit gear. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.81 © Copyright Polaris Industries Inc.

  • Page 174: Flywheel Installation

    DO NOT place fingers between cover and crankcase at any time during the removal / installation process or injury could result. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.82 © Copyright Polaris Industries Inc.
  • Page 175 ENGINE / COOLING SYSTEM 3. Install stator cover and thirteen screws. Torque TORQUE screws in sequence to specification. Stator Cover Screws: 9 ft-lb (12 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 176: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.84 © Copyright Polaris Industries Inc.

  • Page 177: Valve Sealing Test

    1. If necessary, rotate the engine so the cylinder is facing up. 5. Carefully set the cylinder head in place on alignment pins. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.85 © Copyright Polaris Industries Inc.

  • Page 178: Camshaft Installation / Timing

    Valve Clearance Adjustment, page 2.31 procedure prior to performing this procedure. 5. Carefully install the rear camshaft carriers onto the camshafts. Carriers should face each as shown. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.86 © Copyright Polaris Industries Inc.
  • Page 179 “E” marks aligned. Install the exhaust cam sprocket first to ensure proper cam timing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.87 © Copyright Polaris Industries Inc.
  • Page 180 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.88 © Copyright Polaris Industries Inc.
  • Page 181 26. Rotate crankshaft through two revolutions and verify camshaft timing is correct. TORQUE Cam Chain Tensioner: 7 ft-lb (10 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 182: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.90 © Copyright Polaris Industries Inc.

  • Page 183: Valve Clearance Adjustment

    12. Reinstall the camshafts and camshaft carriers and specification, remove the camshaft carriers and tighten the bolts evenly to specification. proceed to Camshaft Installation / Timing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.91 © Copyright Polaris Industries Inc.

  • Page 184: Valve Lash - Tappet Selection

    5. Install the four valve cover shoulder bolts isolators using a T40 driver. 6. Torque valve cover bolts in sequence to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.92 © Copyright Polaris Industries Inc.
  • Page 185 ENGINE / COOLING SYSTEM TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.93 © Copyright Polaris Industries Inc.

  • Page 186: Troubleshooting

    • Cylinder, piston, ring, or valve wear or damage (check compression) • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.94 © Copyright Polaris Industries Inc.

  • Page 187: Cooling Troubleshooting

    • Check oil feed / return line to turbo for leaks, damage • Faulty pump shaft oil seal (oil leak) or blockage. • Check for modified boost pressure sensor wiring. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.95 © Copyright Polaris Industries Inc.
  • Page 188 ENGINE / COOLING SYSTEM NOTES 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 3.96 © Copyright Polaris Industries Inc.
  • Page 189 ..............4.31 KNOCK SENSOR REPLACEMENT 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 190 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........

  • Page 191: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 192: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 193: Efi Operation Overview

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 194: Initial Priming / Starting Procedure

    NOTE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 195: Electronic Control Unit (Ecu)

    This process repeats it self in rapid succession, limiting operation to the preset maximum. RPM Limit: 8800 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 196: Etc Learn Procedure

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Screws: 24 in-lb (3 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 197: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 198: Fuel Injector Troubleshooting

    Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 199: Fuel Injector Replacement

    18. Reinstall the cargo box engine access panel. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.11 © Copyright Polaris Industries Inc.
  • Page 200 EFI / FUEL SYSTEM 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 201: Fuel Lines

    9. Turn the key on to prime the system. Check for leaking at both ends of the fuel lines. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 202: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 203 4. Feed the vent line through the shock mount bracket opening and attach the vent line to the fitting in the frame 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 204: Fuel Tank / Pump

    PFA Nut 70 ft-lbs (95 Nm) Fuel Return Fuel Supply Fuel Pump Fuel Pickup Filter (not serviceable) Fuel Sender Float PFA Gasket Fuel Tank Vent 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.16 © Copyright Polaris Industries Inc.

  • Page 205: Fuel Tank Removal

    A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.17 © Copyright Polaris Industries Inc.
  • Page 206 T40 Torx driver. 15. Cut the three zip ties retaining the wiring to the edges of the fuel tank. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.18 © Copyright Polaris Industries Inc.

  • Page 207: Fuel Tank Installation

    Torque fasteners to specification. 5. Install the Torx screws and plastic rivets retaining the block-off panel using a T40 Torx driver. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.19 © Copyright Polaris Industries Inc.
  • Page 208 60 in-lbs (7 Nm) cable to the shifter bracket and tighten the outer jam nut. Torque jam nut to specification. 15. Install the seats. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.20 © Copyright Polaris Industries Inc.

  • Page 209: Fuel Tank Removal (Xp4)

    A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.21 © Copyright Polaris Industries Inc.
  • Page 210 The strap does not need to be permanently deform the plastic. removed from the vehicle. Remove the seat base assembly from the vehicle. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.22 © Copyright Polaris Industries Inc.

  • Page 211: Fuel Tank Installation (Xp4)

    T40 Torx screws retaining the front of the seat base frame and two rear bolts Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.23 © Copyright Polaris Industries Inc.
  • Page 212 8 ft-lb (11 Nm) sole. Torque fasteners to specification. TORQUE Body Screws: 8 ft-lb (11 Nm) 12. Connect the fuel pump electrical harness. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 213: Fuel Pump Operation Overview

    As boost pressure increases, fuel pressure increases due to the manifold pressure controlled fuel regulator. It is NORMAL to see fuel pressure fluctuations as the throttle varies. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.25 © Copyright Polaris Industries Inc.

  • Page 214: Fuel Pump Replacement

    9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.26 © Copyright Polaris Industries Inc.
  • Page 215 6. Disconnect the fuel pump electrical harness. 9. Transfer old fuel pump to a suitable container capable of safely holding fuel. The fuel pump will retain some fuel. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.27 © Copyright Polaris Industries Inc.
  • Page 216 18. Torque PFA nut to specification using the Fuel Pump Service Tool (PU-50326) and a calibrated torque wrench. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.28 © Copyright Polaris Industries Inc.

  • Page 217: 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 procedure. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.29 © Copyright Polaris Industries Inc.

  • Page 218: Pressure Sensors

    203° F (95° C) 212° F (100° C) 221° F (105° C) 230° F (110° C) 239° F (115° C) 248° F (120° C) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.30 © Copyright Polaris Industries Inc.

  • Page 219: Knock Sensor

    4,870 kΩ 3. If the sensor measures OL between the pins or there is continuity to chassis ground, replace the knock sensor. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 220: 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 4.33 procedure. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.32 © Copyright Polaris Industries Inc.

  • Page 221: Cps Replacement

    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-lb (12 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.33 © Copyright Polaris Industries Inc.

  • Page 222: Electronic Throttle Control (Etc) / Throttle Body

    Pedal Position Sensor (PPS) and Electronic Control Unit (ECU). 3. Loosen the clamp retaining the intake boot to the ETC. Remove the boot from the ETC. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.34 © Copyright Polaris Industries Inc.

  • Page 223: Etc Learn Procedure

    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) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.35 © Copyright Polaris Industries Inc.

  • Page 224: Pedal Position Sensor (Pps)

    1. Remove the drivers seat and disconnect the negative (-) battery cable. 2. Disconnect the PPS harness connection located on the throttle pedal. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.36 © Copyright Polaris Industries Inc.
  • Page 225 8. Manually cycle the throttle pedal to verify the throttle pedal moves freely. 9. Connect the negative (-) battery cable and install the drivers seat. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.37 © Copyright Polaris Industries Inc.

  • Page 226: Oxygen Sensor

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.38 © Copyright Polaris Industries Inc.

  • Page 227: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.39 © Copyright Polaris Industries Inc.

  • Page 228: Efi Diagnostics

    • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.40 © Copyright Polaris Industries Inc.

  • Page 229: Digital Wrench Data Troubleshooting

    Differential unlocked Differential Lock ECU control of the Driver turf solenoid ECU is not grounding the diff relay. Differential is Inactive locked. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.41 © Copyright Polaris Industries Inc.
  • Page 230 How much load the Typical warm idle. Cold start up reading will be Percent Engine Load 20–30% engine is under higher 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.42 © Copyright Polaris Industries Inc.
  • Page 231 On or Off Inactive AWD or 2WD mode How fast the transmission output Vehicle Speed — varies is turning (calculated to wheel speed) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.43 © Copyright Polaris Industries Inc.

  • Page 232: Cylinder Misfire Detection

    • Wiring to the Crankshaft Position Sensor, ECU and Ignition Coil are not damaged. Chassis ground is clean and tight • Fuel pressure is within specification 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.44 © Copyright Polaris Industries Inc.

  • Page 233: Polaris Digital Wrench

    PV-43546 (Fluke 77: PV-43568) Commercially Available (refer to diagnostic software Laptop or Desktop Computer user manual or HELP section for minimum requirements) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.45 © Copyright Polaris Industries Inc.

  • Page 234: Digital Wrench Software Version And Update

    6. If the update file date listed is newer than your Chapter 4). current version and update (see Chapter 4 to download the file. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.46 © Copyright Polaris Industries Inc.

  • Page 235: Digital Wrench® Communication Errors

    Digital Wrench® related problem, visit the Digital Wrench® Knowledge Base for the most current troubleshooting information, FAQs, downloads and software updates at: http://polaris.diagsys.com/. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.47 © Copyright Polaris Industries Inc.

  • Page 236: Guided Diagnostics

    Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.48 © Copyright Polaris Industries Inc.

  • Page 237: Digital Wrench® Feature Map

    Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.49 © Copyright Polaris Industries Inc.

  • Page 238: Ecu Replacement

    Reprogramming (Reflash) Tips: keyboard. The process only takes a few minutes, and is best left alone until complete. Reprogramming (Reflash) Procedure: 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.50 © Copyright Polaris Industries Inc.
  • Page 239 EXACTLY as they appear on the screen. 9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop- down menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.51 © Copyright Polaris Industries Inc.
  • Page 240 12. An “Authorization Key” will appear in the upper left corner of the screen. Copy this key exactly as it appears. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.52 © Copyright Polaris Industries Inc.

  • Page 241: Polaris Mobile Digital Wrench (Pmdw)

    • Internet and Bluetooth wireless technology capable PMDW App Notes: • PMDW will not work on Microsoft Windows 8™ or Apple IOS™ products 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.53 © Copyright Polaris Industries Inc.
  • Page 242 EFI / FUEL SYSTEM NOTES 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 4.54 © Copyright Polaris Industries Inc.
  • Page 243 ................5.18 TROUBLESHOOTING 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 244: General Information

    0-1800 Meters W-31-68 (0-6000 Feet) (5140800) Black Black / white lettering 2018 RZR XP4 (7044762) (7044369) Turbo 1800-3700 Meters W-31-64 (6000–12000 Feet) (5141004) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 245: Pvt System Overview

    At lower RPM, the drive belt rotates low in the drive clutch sheaves. As engine RPM increases, centrifugal force causes the drive belt to be forced upward on drive clutch sheaves. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 246: Drive Belt

    3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 247: Belt Installation

    5-7 times to properly seat the belt in the driven clutch. 5. Install the outer clutch cover and eight screws. Torque screws to specification. TORQUE PVT Cover Screws: 35 in-lb (3 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 248: Drive Clutch Service

    NOTE The driven clutch spreader tool is included with the vehicle’s tool kit 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 249: Drive Clutch Assembly View

    300 ft-lb (407 Nm) Bushing Cover Bushing Clutch Spring Moveable Sheave Spring Spacer Slider Plates Spider Cover Cover Bolts Slider 9 ft-lb (12 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 250: Drive Clutch Disassembly / Inspection

    • Install weights and torque fasteners to specification. TORQUE Shift Weight Fasteners: 20 in-lb (2 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 251 4. Loosen and remove the clutch compression tool. Drive Clutch Holding Fixture: 2871358-B 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 252 3-jaw puller may also be used to help with spider removal. 12. Inspect the moveable sheave bearing for wear. If wear is present, replace the bearing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 253: Drive Clutch Assembly

    Install the clutch spider nut tool on the spider nut sleeve torque the nut to specification. Spider Nut Removal tool: PU-50578 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.11 © Copyright Polaris Industries Inc.
  • Page 254 Failure to assemble the clutch exactly how it was taken cover. Torque fasteners to specification. apart will cause the clutch to be out of balance and require clutch replacement. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 255: Drive Clutch Installation

    35 in-lb (3 Nm) 7. Install the driver’s rear shock guard. Torque fasteners to specification. TORQUE Shock Guard Fasteners: 14 in-lbs (2 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 256: Driven Clutch Service

    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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 257: Driven Clutch Assembly View

    35 in-lb (4 Nm) Thrust Bearing Spring Retainer Driven Clutch Bearing Helix Stationary Sheave Bushing Moveable Sheave Helix Cover Slider Cover Screws 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 258: Driven Clutch Disassembly / Inspection

    8. Inspect the sliders in the stationary sheave for wear and cracking. If replacement is required, remove the fasteners retaining the sliders to the sheave. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 259: Driven Clutch Assembly

    5-7 times to properly seat the belt in the driven clutch. 7. Install the outer clutch cover and eight screws. Torque screws to specification. TORQUE PVT Cover Screws: 35 in-lb (3 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 260: Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.18 © Copyright Polaris Industries Inc.
  • Page 261 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.19 © Copyright Polaris Industries Inc.
  • Page 262 PVT SYSTEM NOTES 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 5.20 © Copyright Polaris Industries Inc.
  • Page 263 ................6.18 SHIFTING DIFFICULTY 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 264: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 265: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 266 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 267: Transmission Service

    11. Disconnect the four fasteners retaining the prop shaft to the transmission output shaft. 12. Remove both rear half shafts. See Rear Drive Shaft Removal, page 7.13 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 268 22. Remove PVT hoses and outer cover. 17. Disconnect TBAP, both TMAP sensors, CPS, coolant temp sensor, Trans switch, speed sensor, injectors, ETC. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 269: Transmission Installation

    33 ft-lb (45 Nm) 28. Remove fasteners retaining inner cover to engine/ trans joint. Discard PVT inner cover o-ring around the crankshaft snout. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 270 Hose Clamps: 35 in-lb (4 Nm) Outer PVT Cover Fasteners: 35 in-lb (3 Nm) 9. Connect the starter wiring. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 271 35 in-lb (4 Nm) 15. Install zip ties retaining fuel lines and harnesses to intake manifold. TORQUE Rear Fascia Fasteners: 8 ft-lb (11 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 272: Transmission Vent Line Routing

    The line terminates to open air (does not terminate to a fitting or hole in the frame). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.10 © Copyright Polaris Industries Inc.
  • Page 273 Do not pry on the transmission case mating surfaces or the transmission cases will be damaged and leak oil after it is reassembled. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 274: Gear Cluster Disassembly

    22. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.12 © Copyright Polaris Industries Inc.
  • Page 275 CAUTION Support the end face of the gear teeth when pushing the shaft through or damage to the gear teeth may occur. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.13 © Copyright Polaris Industries Inc.

  • Page 276: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 277: Transmission Assembly / Snorkel Gear Backlash

    3 Bond sealant. Failure to properly clean the surfaces may lead to transmission case leaks. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.15 © Copyright Polaris Industries Inc.
  • Page 278 10. Install the transmission case cover and retaining bolts. Torque bolts to specification. TORQUE Transmission Case Bolts: 20 ft-lbs (27 Nm) 11. Thoroughly clean the shift shaft housing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 279 15. Apply a small amount of white lithium grease on the shift shafts and component contact surfaces prior to installing the sector cover. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.17 © Copyright Polaris Industries Inc.

  • Page 280: Troubleshooting

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 6.18 © Copyright Polaris Industries Inc.
  • Page 281 ............... .7.38 REAR HUB ASSEMBLY VIEW 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 282: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 283: Bearing Carrier

    12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 284: Front Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 285: Front Bearing Carrier Installation

    6. Install new brake caliper mounting bolts and torque to specification. TORQUE Front Caliper Mounting Bolts: 30 ft-lb (41 Nm) TORQUE Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 286: Rear Bearing Carrier Inspection / Removal

    5. Remove the lower radius rod outer mounting bolt nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 287 11. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 288: Rear Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 289: Rear Bearing Carrier Installation

    42 ft-lb (54 Nm) Radius Rod to Bearing Carrier Fasteners: 50 ft-lb (68 Nm) + 45° 3. Apply anti-seize to drive shaft splines. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 290 120 ft-lbs (163 Nm) 8. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 291: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 292: Front Drive Shaft Installation

    3. Install drive shaft into the front bearing carrier. 4. Install the upper and lower ball joint ends into the front bearing carrier. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.12 © Copyright Polaris Industries Inc.

  • Page 293: Rear Drive Shaft Removal

    11. Rotate wheel and check for smooth operation. 6. Remove the rear hub assembly from the bearing carrier. 7. Support the trailing arm from underneath. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.13 © Copyright Polaris Industries Inc.

  • Page 294: Rear Drive Shaft Installation

    3. Swing the rear trailing arm assembly outward and upward until the rear axle can be inserted into the bearing carrier. Support the trailing arm from underneath. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 295 Rear Hub Castle Nut: 180 ft-lbs (244 Nm) 8. Install the radius rod bolts, washers and new nuts. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 296: Drive Shaft / Cv Joint Handling Tips

    IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.16 © Copyright Polaris Industries Inc.
  • Page 297 10. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.17 © Copyright Polaris Industries Inc.

  • Page 298: Inner Plunging Joint / Boot Replacement

    9. Visually inspect the joint for damage. Replace if needed. 10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 299 17. 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 300: Prop Shaft

    Right front wheel can be removed to gain better access to the prop shaft roll pin. 2. Remove the fasteners retaining the front skid plate. 3. Remove the seats. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 301 The prop shafts have a master spline and will only go NOTE on one way. The front prop shaft cannot be removed with the isolator installed. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.21 © Copyright Polaris Industries Inc.

  • Page 302: Prop Shaft Removal (Xp4)

    Roll Pin Removal Tool: 2872608 NOTE Right front wheel can be removed to gain better access to the prop shaft roll pin. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 303 The prop shafts have a master spline and will only go NOTE on one way. The front prop shaft cannot be removed with the isolator installed. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 304: Prop Shaft Assembly View

    SUPPORT BEARING REPLACEMENT 1. Remove the rear prop shaft from the vehicle (see Chapter 7 – Rear Prop Shaft Removal, page 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.24 © Copyright Polaris Industries Inc.

  • Page 305: U-Joint Disassembly

    (bearing cap out) with a suitable press. 8. Install the rear prop shaft into the vehicle (see Chapter 7 – Rear Prop Shaft Installation, page 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 306: U-Joint Assembly

    PROP SHAFT INSTALLATION (XP4) 1. Install front prop shaft first and properly align the hole in the front yoke with the input shaft hole. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 307: Front Gearcase / Centralized Hilliard

    8. Install the front and rear center consoles. Torque fasteners to specification. TORQUE Center Console Torx Fasteners: 8 ft-lb (11 Nm) FRONT GEARCASE / CENTRALIZED HILLIARD 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 308: Centralized Hilliard Assembly View

    Cover Screws, M6 (T30 Torx) Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.28 © Copyright Polaris Industries Inc.

  • Page 309: All Wheel Drive Operation

    While in the engagement position, the front drive will be in an “over-running” 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.29 © Copyright Polaris Industries Inc.

  • Page 310: Awd Diagnosis

    The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.30 © Copyright Polaris Industries Inc.

  • Page 311: Front Gearcase Removal

    Lift and remove the gearcase from the front LH wheel well area and slide it out of the vehicle above the upper A-arm. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 312 AWD Diagnosis, page 7.30 for detailed inspection process. 6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.32 © Copyright Polaris Industries Inc.
  • Page 313 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.33 © Copyright Polaris Industries Inc.

  • Page 314: Front Gearcase Assembly

    Bearing Roller Surface Spacer Thrust Bearing 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 315 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.35 © Copyright Polaris Industries Inc.
  • Page 316 Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. TORQUE Cover Plate Screws: 9 ft-lbs (12 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.36 © Copyright Polaris Industries Inc.

  • Page 317: Front Gearcase Installation

    The vent line is secured by one retaining clip and is routed through a hole in the frame support behind the radiator. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.37 © Copyright Polaris Industries Inc.

  • Page 318: Wheel Hubs

    120 ft-lbs (163 Nm) Wheel Bearing Valve Stem Wheel Hub Hub Castle Nut Bearing Carrier Brake Disc 180 ft-lbs (244 Nm) REAR HUB ASSEMBLY VIEW 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 7.38 © Copyright Polaris Industries Inc.
  • Page 319 ..............8.30 FOX SHOCK DISASSEMBLY 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 320 ............. .8.59 SCM / INERTIAL MEASUREMENT UNIT 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 321: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 322: Steering System

    Steering Rack 40 ft-lb (54 Nm) 15 ft-lb (20 Nm) Tie Rod End Tilt Steering Shock EPS Mounting Bracket 14 ft-lbs (19 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 323: Upper Steering Shaft Removal

    3. Loosen the nut and back it half way off the steering shaft. 4. Place the assembly in a vise. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 324: Power Steering Unit Removal

    2. Disconnect the two electrical harnesses from the power steering unit . 5. Carefully remove the power steering unit and mount bracket from the vehicle as an assembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 325: Lower Steering Shaft Removal

    Refer to Steering Angle Sensor Centering (Dynamix), page 11.31. 3. Remove the power steering unit (see Power Steering Unit Removal, page 8.6). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 326: Power Steering Unit Installation

    Torque to specification. TORQUE Steering Shaft to EPS Unit Pinch Bolt: 25 ft-lb (34 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 327: Steering Shaft Bushing Replacement

    Torx fasteners. Install the lower portion of the steering shaft onto the power steering unit. Torque the lower pinch bolt to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 328 . Torque the steering wheel nut to specification. TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 10. Install steering wheel cap and field test steering operation. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 329: Front Suspension

    Ball Joint 42 ft-lbs (57 Nm) Upper A-Arm Lower A-Arm A-Arm Fasteners CV Guard Screws 42 ft-lb (57 Nm) 35 in-lb (4 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 330: Front A-Arm Removal / Replacement

    14. Install the nut retaining the front stabilizer bar link to the upper control arm.. Torque fasteners to specification. TORQUE Stabilizer Bar Link Fasteners: 40 ft-lb (54 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 331: Front Stabilizer Bar Removal

    21. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 22. Insert new A-arm bushings and pivot tube into new A-arm. A light press force may be needed. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 332: Front Stabilizer Bar Installation

    4. Install the nut retaining the front stabilizer bar link to the upper control arm on both sides. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 333: Ball Joint Removal

    CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 334: Rear Suspension

    Trailing Arm Mounting Bolts 50 ft-lb (68 Nm) + 45° 14 in-lbs (2 Nm) 70 ft-lb (95 Nm) Rear Shock Assembly Radius Rod 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 335: Trailing Arm Removal / Installation

    Swing radius rod down. Discard the nut. 8. Remove the bearing carrier from the rear drive shaft and trailing arm. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 336: Trailing Arm Spherical Bearing Replacement

    18. Torque all fasteners to specification. 4. Properly support the trailing arm and press the spherical bearing out of trailing arm casting. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 337: Radius Rod Removal / Installation

    Inner Radius Rod Mounting Bolts: 50 ft-lb (68 Nm) + 45° Outer Radius Rod Mounting Bolts: 50 ft-lbs (68 Nm) + 90° 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 338: Rear Stabilizer Bar Removal

    3. Torque all fasteners to specification (see below). 4. Lubricate stabilizer bar pivot bushings via grease fitting (fittings are accessible through skid plate). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 339: Shocks / Springs

    5. Tighten the spring adjustment ring to set the preload distance noted in Step 1. 6. Reinstall the shock onto the vehicle and torque new fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 340: Spring Adjustment

    DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting without verifying loaded ride height. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 341: Shock Compression Adjustment (Fox®)

    Full clockwise position Firmest The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counter-clockwise will decrease damping. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.23 © Copyright Polaris Industries Inc.
  • Page 342 300 lbs (136 kg) Driver +1 preload, front and 6 clicks out 6 clicks out rear * shaded cells are factory default settings 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 343: Fox 2.5" Front Shock Information

    0.875 x 0.100 (Back Up) 0.875 x 0.100 (Back Up) 0.800 x 0.015 0.900 x 0.015 1.570 x 0.128 (Top 1.570 x 0.128 (Top Out) Out) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 344: Fox 3.0" Rear Shock Information

    0.800 x 0.015 0.800 x 0.020 0.800 x 0.015 1.570 x 0.128 (Top Out) 0.875 x 0.100 (Back Up) 1.570 x 0.128 (TO) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.26 © Copyright Polaris Industries Inc.

  • Page 345: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 346: Fox 3.0" O.e. Podium Bypass

    Reservoir End Cap Assembly O-ring Remote Reservoir Adjust Port Damping Adjust Assembly 3& O-ring Eyelet Spring Hardware Assembly O-ring Reducer O-ring Reservoir 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.28 © Copyright Polaris Industries Inc.

  • Page 347: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.29 © Copyright Polaris Industries Inc.

  • Page 348: Fox Shock Disassembly

    Rinse and dry shock. valve shim can be used. Ensure you have obtained the correct rebuild kit and oil prior to disassembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.30 © Copyright Polaris Industries Inc.
  • Page 349 7. Hold cinch ring with spanner and rotate bearing assembly counter-clockwise to release pressure on retaining ring. 12. Remove IFP. 13. Dump out used shock oil. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.31 © Copyright Polaris Industries Inc.
  • Page 350 16. Use the IFP tool to remove LSC. IFP Tool: commercially available also available from FOX 398-00-394 17. Use a strap wrench to remove the reservoir. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.32 © Copyright Polaris Industries Inc.
  • Page 351 27. Remove rebound valve stack from the assembly and cable tie together. Clean with contact cleaner. NOTE Damping pistons are directional. Rebound side shown. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.33 © Copyright Polaris Industries Inc.
  • Page 352 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.34 © Copyright Polaris Industries Inc.
  • Page 353 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.35 © Copyright Polaris Industries Inc.
  • Page 354 STEERING / SUSPENSION 2.5 Bypass Piston 3.0 Bypass Piston Compression Side Compression Side Rebound Side Rebound Side 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.36 © Copyright Polaris Industries Inc.

  • Page 355: Fox Shock Assembly

    30 ft-lb (42 Nm) 3. With body prepared with Loctite primer add a layer of Loctite 638 2 threads up, 2 threads wide 360°. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 356 23. Install bearing assembly with cinch ring. 27. Install rebound valve stack. 24. Install negative spring assembly. 28. Install shaft nut and torque to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 357 Torque bleed screw to specification. TORQUE Bleed Screw: 14 in-lb (2 Nm) 39. Run cinch ring down to the bottom thread on bearing assembly. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.39 © Copyright Polaris Industries Inc.
  • Page 358 Shock Specifications tables at the beginning of this section for proper IFP depth. 45. After setting IFP depth, install Bleed screw with o- ring. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.40 © Copyright Polaris Industries Inc.

  • Page 359: Walker Evans 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.41 © Copyright Polaris Industries Inc.

  • Page 360: General Service Information

    2. Using the shock spanner/spreader tool included in the vehicle’s tool kit, turn the adjustment collar increase or decrease ride height. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.42 © Copyright Polaris Industries Inc.
  • Page 361 RZR XP 1000 LE Matte Gold Metallic 1.30″ 8.17″ RZR XP 1000 High Lifter 1.46″ 6.32″ RZR XP 4 1000 High Lifter 2.19″ 8.05″ 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.43 © Copyright Polaris Industries Inc.

  • Page 362: Walker Evans™ Shock Rebuild Information

    The rebound and compression valve stacks will always be positioned as shown in the illustration, regardless of how the shock assembly is installed. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.44 © Copyright Polaris Industries Inc.
  • Page 363 6. Using a snap ring pliers, remove the retaining ring from the reservoir. 9. Slowly lift up and remove the shock rod assembly from the shock body. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.45 © Copyright Polaris Industries Inc.
  • Page 364 Front Shock Body Holding Tool: PU-50979 Front Shock Rod Holding Tool: 2872429 Rear Shock Body Holding Tool: PU-50938 Rear Shock Rod Holding Tool: PU-50931 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.46 © Copyright Polaris Industries Inc.

  • Page 365: Walker Evans™ Shock Assembly

    3. Install the appropriate Shock Seal Protector Sleeve over the shaft threads. Front Shock Seal Protector Sleeve: PU-50939 Rear Shock Seal Protector Sleeve: PU-50952 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.47 © Copyright Polaris Industries Inc.
  • Page 366 Tighten the valve stack fastener securely. FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.48 © Copyright Polaris Industries Inc.
  • Page 367 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.49 © Copyright Polaris Industries Inc.
  • Page 368 If it does not, disassemble and reassemble per this procedure. 32. Secure the shock body in a vise by its lower mount. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.50 © Copyright Polaris Industries Inc.
  • Page 369 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.51 © Copyright Polaris Industries Inc.

  • Page 370: Dynamix Active Suspension (If Equipped)

    While the Dynamix Shocks come apart similar to a FOX Podium Bypass shock, there are several differences. Refer to the training on Univerisity 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 371: Demonstration Mode

    Torque mounting fasteners to specification. IMPORTANT A sticker with an arrow on the SCM indicates which side MUST face the front of the vehicle. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.53 © Copyright Polaris Industries Inc.

  • Page 372: Dynamix™ System Features

    BRAKING The system continuously monitors the brake switch status and vehicle deceleration rate, reducing body motion in braking conditions. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.54 © Copyright Polaris Industries Inc.

  • Page 373: Acceleration

    SCM diagnostic indicator on the RideCommand™ display. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.55 © Copyright Polaris Industries Inc.

  • Page 374: Processing Capability

    SWITCH PINS 1 TO 7 PINS 6 TO 7 POSITION All Positions 4800 Ω 1200 Ω 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.56 © Copyright Polaris Industries Inc.

  • Page 375: Dynamix Troubleshooting

    4. Put vehicle into Sport or Comfort mode. 5. Disconnect the corresponding shock with the trouble code. Verify there is battery voltage between pin 1 and battery (-) ground. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.57 © Copyright Polaris Industries Inc.

  • Page 376: Scm Mode Switch

    5. If SPN 520572 FMI 2 is present, check brake switch input on data display. ECU pin 135. 6. If SPN 520574 FMI 2 or SPN 524000 FMI 2 is present, reflash ECU. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.58...

  • Page 377: Scm Steering Angle Adapted Offset Diagnostics

    3. If the code(s) is still active, reflash the SCM. 4. If the code(s) is still present after reflashing, replace the SCM. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.59 © Copyright Polaris Industries Inc.
  • Page 378 STEERING / SUSPENSION NOTES 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 8.60 © Copyright Polaris Industries Inc.
  • Page 379 ............9.28 REAR BRAKE CALIPER / PAD INSTALLATION 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 380 ................... .9.30 BRAKES LOCK 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 381: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 382: Brake System Overview

    Brake Junction Block Brake Line Fitting 15 ft-lbs (20 Nm) Sealing Washer Brake Disc Scraper Master Cylinder Mounting Bolts 23 ft-lbs (31 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 383: Brake Line Routing / Retention

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION FRONT BRAKE LINES TO MASTER CYLINDER Brake Line Retaining Clip Control Arm Brake Line Retainer 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 384: Rear Brake Line - Master Cylinder To Junction Block

    BRAKE SYSTEM REAR BRAKE LINE - MASTER CYLINDER TO JUNCTION BLOCK Brake Line Retaining Clip Zip Tie 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 385: Rear Brake Lines - Junction Block To Calipers

    REAR BRAKE LINES - JUNCTION BLOCK TO CALIPERS NOTE Brake lines route inside the stabilizer bar and shock mounts as shown. Brake Line Retaining Clip Trailing Arm Brake Line Retainer 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.

  • Page 386: 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 387: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual © Copyright Polaris Industries Inc.
  • Page 388 7. Perform the BRAKE BLEEDING / FLUID CHANGE, page 9.11 procedure. TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 389: Brake Bleeding / Fluid Change

    Mity Vac™: 2870975 NOTE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.11 © Copyright Polaris Industries Inc.
  • Page 390 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 391: 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) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 392: Secondary Hand Brake (Int

    The secondary service brake is NOT a parking brake. There is no locking mechanism to hold the braking force. A braking force is applied only when the lever is pulled upward. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.14...
  • Page 393 Secondary Brake Reservoir Right Rear Brake Line Junction Block Brake Line (from pedal master Secondary Brake Master Cylinder Left Rear Brake Line cylinder) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 394: Secondary Brake Fluid Reservoir

    This master cylinder controls only the rear brakes when the secondary brake lever is pulled. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 395: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.17 © Copyright Polaris Industries Inc.
  • Page 396 BRAKE SYSTEM 9. Remove the bolt retaining the brake line to the caliper. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 397: Front Caliper Assembly View

    Boots Scraper Bolts Caliper Assembly 48 in-lb (5 Nm) Bleeder Screw Mount Pins 48 in-lb (5 Nm) apply Silicone Grease on install 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 398: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 399: Brake Pad Inspection

    .180″ (4.6 mm) FRONT CALIPER ASSEMBLY 1. Install new sealing o-rings inside the caliper. 2. Carefully press the pistons into the caliper. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 400: Brake Disc Inspection

    120 ft-lbs (163 Nm) Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 7. Install new cotter pin into castle nut and install wheel cap. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 401: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.23 © Copyright Polaris Industries Inc.

  • Page 402: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 403: Rear Caliper Disassembly / Inspection

    NOTE Be sure to clean caliper body seal grooves. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 404: Caliper Inspection

    Service Limit: 1.498″ (38.05 mm) of bore smoothly with light resistance. 3. Inspect the brake disc and pads as outlined in this chapter. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 405: Rear Brake Disc Inspection

    Torque castle nut to specification and install a new Service Limit: 0.002″ (0.051 mm) cotter pin. TORQUE Rear Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 406: Rear Brake Caliper / Pad Installation

    1/2 turn. 5. Follow bleeding procedure outlined earlier in this chapter. 6. Install wheel and torque wheel nuts to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.28 © Copyright Polaris Industries Inc.
  • Page 407 Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.29 © Copyright Polaris Industries Inc.
  • Page 408 • Improper assembly of brake system components PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds service limit) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 9.30 © Copyright Polaris Industries Inc.
  • Page 409 ................10.21 DOOR ADJUSTMENT 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.1...

  • Page 410: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 411: Body Assembly Views

    Visor Screws 8 ft-lb (11 Nm) Front ROPS Bracket 40 ft-lb (54 Nm) Cab Frame Extenders Hip Bolster Lower Fasteners 14 ft-lb (19 Nm) Hip Bolster 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 412: Cab Frame Assembly Xp 4

    17 ft-lb (23 Nm) Hip Bolster Bottom Fasteners ROPS Mid Hoop 14 ft-lb (19 Nm) Visor Fasteners Hip Bolster 8 ft-lb (11 Nm) ROPS Main 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 413: Doors

    Latch Striker 8 ft-lb (11 Nm) Door Latch Screws Hinge Pin 8 ft-lb (11 Nm) Striker Screws Latch Release 8 ft-lb (11 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 414: Doors (Xp4)

    BODY / FRAME DOORS (XP4) Door Panel Latch Release Door Frame Latch Door panel (Rear) Latch Striker Hinge Pin Door Frame (Rear) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.6 © Copyright Polaris Industries Inc.

  • Page 415: Dash / Controls

    BODY / FRAME DASH / CONTROLS Headlight Switch Instrument Cluster Key Switch AWD Switch 12V Accessory Port 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 416: Hood / Front Body Work

    Body Screws Grill 8 ft-lb (11 Nm) Right Front Fender Flair Left Side Front Fender Flair Front Fascia Brackets Left Side Front Fender 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 417 Rear Skid Pan Fasteners 8 ft-lbs (11 Nm) Front Frame Cargo Box Support Bumper Bracket Muffler Mount Bracket Front Skid Pan Seat Frame 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.9 © Copyright Polaris Industries Inc.

  • Page 418: Chassis / Main Frame

    Rear Skid Pan Fasteners 8 ft-lbs (11 Nm) Front Frame Cargo Box Support Bumper Bracket Muffler Mount Bracket Front Skid Pan Seat Frame 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 419: Seat Assembly Front

    4 ft-lb (5 Nm) Screw Seat Back 4 ft-lb (5 Nm) Seat Base Seat Base Pad Seat Base Slider Assembly Seat Latch Lever 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.11 © Copyright Polaris Industries Inc.

  • Page 420: Floor / Rocker Panels (Xp)

    Push Rivots 8 ft-lb (11 Nm) LH Rocker Console Cover U-Type Nuts Seat Belt Boot Block Off Flap Shifter Boot Lower Floor 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 421: Floor / Rocker Panels (Xp4)

    Block Off Flap Console Rear Main Floor Lower Lower Rear Close-off Panel Upper Rear Close-off Panel Rocker RH B-Pillar Cover RH Floor Rear 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.13 © Copyright Polaris Industries Inc.

  • Page 422: Rear Cargo Box / Fenders

    Rear Fascia Support Brackets Shock Panel Bracket Fasteners Passenger Side Cargo Box Half 8 ft-lb (11 Nm) Driver Side Cargo Box Half Fender Flair 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 423: Rear Bumper

    Rear Fascia Fasteners Exhaust Cover/Bumper 8 ft-lb (11 Nm) Exhaust Cover Bracket (lower) Rear Fascia Fascia Support Brackets Exhaust Cover Bracket (upper) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 424: Body Component Removal

    • Remove the driver and passenger seats 2. Lift the panel upward and towards the front of the vehicle to remove the panel 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 425: Rear Bumper

    4. Remove the dash assembly from the vehicle. NOTE The lower dash is also held by clips. Pull the dash straight out to disengage the clips.. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 426: Front Fener Flair Removal

    3. Remove the one T-40 Torx screw on the top rear of the fender. 4. Remove the fender from the vehicle. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 427: Cargo Box Assembly Removal

    Remove the rear cab frame from the vehicle. 10. Remove the cargo box half from the vehicle. 7. Remove the engine access panel and the panel locking pin 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 428: Rocker Panels, Console And Floor Xp

    6. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 429: Doors

    Door Panel Fasteners: 22 in-lb (2 Nm) 5. Adjust the door so it properly opens and latches. Refer to Door Adjustment, page 10.21. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.21 © Copyright Polaris Industries Inc.
  • Page 430 . Torque to specification. TORQUE Door Hinge Fasteners: 8 ft-lb (11 Nm) 6. Install the door panel onto the door frame. Torque fasteners to specification. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 10.22 © Copyright Polaris Industries Inc.
  • Page 431 ................11.25 IGNITION / KEY SWITCH 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.1...
  • Page 432 COOLING SYSTEM ..................11.44 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.2...
  • Page 433 DIAGNOSTIC TROUBLE CODE LIST..............11.65 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.3...

  • Page 434: General Information

    / dash panel: • Speedometer • AWD Switch • Headlamp Switch • 12 Vdc Accessory Power Point • Ignition Switch • LED Ambiance Light 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 435: 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. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.5...

  • Page 436: Electrical Component Locations

    12V Receptacle Pedal Position Sensor Coolant Temp Sensor Instrument Cluster Diagnostic Plug Ignition Coil AWD Switch LED Dash Light Ignition Coil Ground 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 437: Electrical Diagnostics

    STATIC TESTING The two most common forms of static testing are: 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 438: Connector Probing Guidelines

    If they contact each other, circuit or component damage could occur from a short. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 439: Testing Continuity/Resistance

    There are many possible causes of a short to ground, here are some: • The harness rubbing against a component that is grounded, such as the frame, chassis component, or engine. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 440: Testing For A Short To Voltage

    Here is a list of possible failures that can be associated with an intermittent electrical failure: 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 441: Testing Parasitic Draw

    Most circuits will have one load. The load is the component in the circuit that uses the current flow to do work, such as move a solenoid or light a bulb. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 442: Instrument Cluster

    Fuel Gauge activated. All segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can Service Indicator provide scheduled maintenance. See Service Hours, page 11.22 for more information.

  • Page 443: Indicator Lamps

    This lamp illuminates when the headlamp switch is set to High Beam high beam. If applicable. Chassis Fault If applicable. Performance Limited 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 444: Display Area 1

    ELECTRICAL DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 Speed Engine Temperature Ambient Temperature (Optional) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 445: Display Area 2

    Toggle the Up/Down buttons to change the information displayed in Area 2 Engine Temperature Odometer Ambient Temperature Trip 1 (Optional) Trip 2 Voltage Speed Engine Hours Service Hours 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 446: Options Menu

    Select between 12H or 24H, and set time Backlight Color Select between Blue or Red Backlight Level Set backlight brightness level Service Hours View/Set Service hours Exit Menu Exit 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 447: Unit Selection Distance

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.17...

  • Page 448: Unit Selection Temperature

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.18...

  • Page 449: Clock

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.19...

  • Page 450: Back Light Color

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.20...

  • Page 451: Back Light Level

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.21...

  • Page 452: Service Hours

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.22...

  • Page 453: Diagnostic Code

    3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.23...

  • Page 454: Instrument Cluster Pinouts

    Carefully lift the panel to access the instrument cluster wiring. 3. Disconnect the wire harness connector from the back side of the instrument cluster. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.24 © Copyright Polaris Industries Inc.

  • Page 455: Switches / Controls

    1. Disconnect the key switch harness by depressing the connector lock and pulling on the connector. Do not pull on the wiring. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 456: Seat Belt Switch

    TERMINALS A AND B 1. Disconnect the harness running to the seat belt. HIGH 620 Ω 300 Ω 160 Ω 75 Ω PARK 24 Ω 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.26 © Copyright Polaris Industries Inc.

  • Page 457: Brake Pressure Switch

    Replace switch if necessary. More information relating to the turbocharger system and components may be found in the Engine and Fuel System chapters. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.27 © Copyright Polaris Industries Inc.

  • Page 458: Hazard Switch (Int'l / Tractor)

    2 and 6. • Turn on the Left Turn Signal. There should be continuity between switch pins 1 and 8. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.28 © Copyright Polaris Industries Inc.

  • Page 459: Flasher Module (Int'l/Tractor)

    The brake alarm will sound if the vehicle’s parking brake is applied and the throttle is pushed in a forward or reverse gear. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.29 © Copyright Polaris Industries Inc.

  • Page 460: Parking Brake Switch (Int'l/Tractor)

    SUSPENSION MODE SWITCH (DYNAMIX MODELS) For more information on the Dynamix suspension system, refer to the Steering / Suspension chapter - Dynamix Overview, page 8.52 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.30 © Copyright Polaris Industries Inc.

  • Page 461: Steering Angle Sensor Centering (Dynamix)

    8. If no EPS or SCM DTCs are present, drive straight and verify that the reported steering angle from the EPS is centered (+/– 5°). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.31 © Copyright Polaris Industries Inc.
  • Page 462 9. If the steering is properly centered, perform SCM Steering Angle Adaptation Value Reset procedure, found in Steering / Suspension System Utilities on the Special Tests menu in Digital Wrench. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.32 © Copyright Polaris Industries Inc.

  • Page 463: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Mounting Bolt: 8 ft-lb (11 Nm) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.33 © Copyright Polaris Industries Inc.

  • Page 464: Charging System

    Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each test should point may vary slightly. The battery should be fully measure: charged before performing this test. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.34 © Copyright Polaris Industries Inc.

  • Page 465: Test 3: Measure Ac Voltage Output Of Each Stator Leg At Charging Rpm

    (Y1 to Y2, Y1 to Y3, Y2 to Y3). 2. Disconnect the two wiring harnesses going to the regulator. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.35 © Copyright Polaris Industries Inc.

  • Page 466: Regulator / Rectifier (Dynamix)

    If the regulator / rectifier case temperature exceeds 230° F or 110° C, the unit will turn itself off to cool down. The 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.36 © Copyright Polaris Industries Inc.
  • Page 467 8. Connect the battery negative cable. Torque fastener to specification. NOTE Battery Terminal Fastener: 60 in-lbs (7 Nm) 9. Install the seat. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.37 © Copyright Polaris Industries Inc.

  • Page 468: Battery

    5. Charge the battery as recommended (see – Charging Procedure , page 11.40). BATTERY REMOVAL 1. Remove the driver’s seat to access the battery 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.38 © Copyright Polaris Industries Inc.

  • Page 469: Battery Installation

    The following are two tests which can easily be made on a sealed Maintenance Free battery to determine its condition: OCV Test and a Load Test. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.39 © Copyright Polaris Industries Inc.

  • Page 470: Ocv - Open Circuit Voltage Test

    If the voltage drops below 12.6 volts, charging was ineffective or the battery needs to be replaced. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.40 © Copyright Polaris Industries Inc.
  • Page 471 Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.41 © Copyright Polaris Industries Inc.

  • Page 472: Lighting System

    (see Chapter 10 – Front Bumper XP, page 3. Carefully lift and remove headlamp assembly from the bumper. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.42 © Copyright Polaris Industries Inc.

  • Page 473: Headlamp Installation

    12 volts and that a ground path is present. 1. Disconnect the wire harness 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.43 © Copyright Polaris Industries Inc.

  • Page 474: Cooling System

    1. Disconnect harness from coolant temperature sensor on the engine cylinder head (see Engine Coolant Temperature Sensor (ECT) Overview outlined in this chapter). 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.44 © Copyright Polaris Industries Inc.

  • Page 475: Cooling Fan Replacement

    7. Disconnect the front gearcase breather hose from the fan shroud. 3. Remove the zip ties on both sides retaining the headlight harnesses. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.45 © Copyright Polaris Industries Inc.

  • Page 476: Electric Coolant Pump

    15. Connect the front headlight harnesses on both sides and connect the two voltage regulator harness connections. 16. Install the hood panel. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.46 © Copyright Polaris Industries Inc.

  • Page 477: Ect Sensor Test

    323 Ω ± 6% 194 °F (90 °C) 243 Ω ± 6% 212 °F (100 °C) 186 Ω ± 6% STARTING SYSTEM 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.47 © Copyright Polaris Industries Inc.

  • Page 478: Starter Solenoid Replacement

    12V power to reach the TORQUE starter motor. Solenoid Cable Nuts: 35 in-lb (4 Nm) 7. Connect the harness to the solenoid. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.48 © Copyright Polaris Industries Inc.

  • Page 479: Electronic Power Steering (Eps)

    Engine Controller, but not the Power Steering Controller, while using Digital Wrench®. NOTE DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.49 © Copyright Polaris Industries Inc.

  • Page 480: Eps Troubleshooting (Power Steering Non-Functional With Mil On)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.50 © Copyright Polaris Industries Inc.

  • Page 481: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.51 © Copyright Polaris Industries Inc.

  • Page 482: Eps Troubleshooting (Using Digital Wrench®)

    ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.52 © Copyright Polaris Industries Inc.
  • Page 483 Power Out Power In Lights 10A Fuse Power Out Coil High Power In EFI Relay Power Out Coil Low Pump Relay Coil High 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.53 © Copyright Polaris Industries Inc.
  • Page 484 Power Out Power In Accy 10A Fuse Power Out Power In Key 10A Fuse Power Out Power In Insr 10A Fuse Power Out 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.54 © Copyright Polaris Industries Inc.

  • Page 485: 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 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.55 © Copyright Polaris Industries Inc.
  • Page 486 Power Out Coil Low Power In EPS 25A Fuse Power Out Power In Shocks 7.5A Fuse Power Out Lights Relay Coil High 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.56 © Copyright Polaris Industries Inc.
  • Page 487 Power Out Coil High Power In EFI Relay Power Out Coil Low – Spare 25A Fuse – – Spare 30A Fuse – 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.57 © Copyright Polaris Industries Inc.

  • Page 488: Voltage Regulator Fusible Link

    / charging system. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.58 © Copyright Polaris Industries Inc.

  • Page 489: Can System

    60 Ω. A reading of 120 Ω is bad. CAN SYSTEM TESTING A component not displaying information correctly could be the cause of damaged CAN wiring or a faulty component. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.59 © Copyright Polaris Industries Inc.

  • Page 490: Wiring Harness

    ELECTRICAL WIRING HARNESS MAIN HARNESS ROUTING 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.60 © Copyright Polaris Industries Inc.

  • Page 491: Main Harness Retention Locations

    ELECTRICAL MAIN HARNESS RETENTION LOCATIONS FRONT The white tape on a harness signifies a retention point. Zip Tie Retention Locations REAR 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.61 © Copyright Polaris Industries Inc.

  • Page 492: Wiring Harness Replacement

    Panels, Console and Floor XP, page 10.20. 11. Remove the seats and seat frame. 12. Remove the ECU cover and disconnect the harness from the ECU. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.62 © Copyright Polaris Industries Inc.

  • Page 493: Break-Out Diagram Viewing

    Refer to Main Harness Routing, page 11.60. 21. Install all previously removed parts and torque fasteners to specification. 3. Click on the Layers Icon. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.63 © Copyright Polaris Industries Inc.
  • Page 494 5. Click on the Wiring Diagram (black & white) box to get want to see. Deselect any other diagram that may be a shadow of the full diagram behind the break-out selected. diagram. 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.64 © Copyright Polaris Industries Inc.

  • Page 495: Diagnostic Trouble Code List

    Voltage below normal C1064 Valid but above normal C1059 Engine Speed Data Erratic, Intermittent or Incorrect C1061 Receive network data-in error C1066 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.65 © Copyright Polaris Industries Inc.
  • Page 496 Sensor Outputs 1 & 2 P1135 Correlataion Invalid C1005 Suspension Mode Switch Short/Voltage too high C1006 516098 Input Short/Voltage too low C1007 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.66 © Copyright Polaris Industries Inc.
  • Page 497 Below MIN C108E 520572 Brake Switch Status Invalid U108C Accelerator Pedal Position 520574 Invalid U143D Data Engine Speed Data 524000 Invalid U102F 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.67 © Copyright Polaris Industries Inc.
  • Page 498 Throttle Body Control - 520278 Condition exists P151C Return Spring Check Failed Throttle Body Control - 520279 Condition exists P151D Adaption Aborted 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.68 © Copyright Polaris Industries Inc.
  • Page 499 P107C Circuit Current below normal or open circuit P107E Voltage above normal C106D EPS SEPIC Voltage Error 524086 Voltage below normal C106E 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.69 © Copyright Polaris Industries Inc.
  • Page 500 ELECTRICAL NOTES 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual 11.70 © Copyright Polaris Industries Inc.
  • Page 501 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams 2017 RZR XP Turbo wiring diagram and break-outs. Click Here RZR XP 4 Turbo wiring diagram and break-outs. Click Here RZR XP Turbo Tractor (INT’L) wiring diagram. Click Here 2018 RZR XP Turbo wiring diagram.
  • Page 503 Caliper Body / Frame Assembly (front).............9.21 Special Tools ............10.2 Assembly (rear) .............9.26 Boost Control Valve ..........11.27 Disassembly / Inspection (rear) .........9.25 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 504 Diagnostic Connector ..........4.47 Coolant Flow Diagram ..........3.28 Coolant Flush ............2.37 Diagnostic Trouble Codes ......... 11.65 Coolant Hose Digital Wrench Inspection.............2.36 Communication Errors..........4.47 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 505 Installation ............. 8.8 Operation Overview ..........4.7 Operation ............11.49 Replacement........... 4.7, 4.50 Removal..............8.6 Troubleshooting ........... 11.50 Component Locations ..........4.4 ETC ...............4.34 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 506 Hydraulic Brake System Operation......... 9.8 O-rings..............4.9 Replacement............4.11 Test ..............4.10 Troubleshooting .............4.10 Ignition Coil ............11.33 Fuel Injectors Operation Overview ..........4.9 Replacement............11.33 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 507 Ring Installation .............3.73 Replacement............11.62 Ring Installed Gap ..........3.69 Retention............11.61 Ring to Groove Clearance ........3.69 Routing .............. 11.60 Piston Removal............3.66 Maintenance Piston Ring 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 508 Rear Bumper Walker Evans Rebuild Information ......8.44 Assembly View ............ 10.15 Shock Piston Orientation, Walker Evans......8.44 Removal............. 10.17 Shock, Walker Evans, Assembly........8.47 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 509 Special Tools ............6.2 Removal (lower)............8.7 Troubleshooting .............6.18 Removal (upper) ............. 8.5 Vent Line ..............6.10 Transmission Switch ..........11.26 Steering System Inspection.............2.47 Trouble Code 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.7 © Copyright Polaris Industries Inc.
  • Page 510 Wheel Installation ............2.44 Removal...............2.44 Wheel Alignment ............2.48 Wheel Bearing Replacement (front) ..........7.4 Replacement (rear)..........7.8 Wheel Hub Assembly View (front) ..........7.38 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual IX.8 © Copyright Polaris Industries Inc.

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