Polaris RZR PRO XP 4 2020 Manuals

Manuals and User Guides for Polaris RZR PRO XP 4 2020. We have 2 Polaris RZR PRO XP 4 2020 manuals available for free PDF download: Service Manual

Polaris RZR PRO XP 4 2020 Service Manual (598 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 27.15 MB

Chapter 1 1 General Information

7
Maintenance Chapter 2 Maintenance 2

87
- Lubricants / Service Products
  89
- Maintenance
  89
- Periodic Maintenance - General
  89
- Pre-Ride Inspection
  90
- Maintenance Intervals
  91
- Maintenance Quick Reference
  111
- Grease Lubrication Points
  113
- Engine / Exhaust
  114
- Engine Oil Level
  114
- Engine Oil and Filter Change
  115
- Engine Crankcase Breather Hose
  116
- Engine Cylinder Leakdown Test
  116
- Valve Clearance Adjustment
  117
- Cam Chain Tensioner Inspection
  118
- Spark Arrestor
  119
- Heat Shield Inspection
  120
- Coolant Level Inspection
  121
- Coolant Strength
  121
- Cooling System
  121
- Coolant Hose Inspection
  122
- Cooling System Pressure Test
  122
- Coolant Flush
  123
- Radiator Inspection / Cleaning
  123
- Cooling System Bleeding
  124
- Fuel System and Air Intake
  125
- Fuel Tank Vent Inspection
  125
- Throttle Pedal Inspection
  125
- Air Filter Service
  126
- Engine Intake Pre-Filter Service
  126
- Pvt / Final Drive / Wheel and Tire
  128
- Pvt Drain
  128
- Pvt Intake Pre-Filter Service
  128
- Front Gearcase Lubrication
  129
- Drive Shaft Boot Inspection
  130
- Wheel Installation
  130
- Tire Inspection
  131
- Tire Pressure
  131
- Transmission
  132
- Transmission Lubrication
  132
- Transmission Oil Change
  132
- Transmission Oil Level Check
  132
- Maintenance
  133
- Steering
  133
- Steering Inspection
  133
- Tie Rod End / Wheel Hub Inspection
  133
- Wheel Toe Alignment Inspection
  134
- Wheel Toe Adjustment
  135
- Suspension
  136
- Suspension Inspection
  136
- Shock Adjustment
  137
- Suspension Lubrication
  137
- Shock Compression Adjustment (Walker Evans™)
  139
- Brake Fluid Inspection
  140
- Brake Hose and Fitting Inspection
  140
- Brake Pad Inspection
  140
- Brake System
  140
- Brake Disc Inspection
  141
- Battery Charging / off Season Storage
  142
- Battery Maintenance
  142
- Electrical and Ignition System
  142
- Engine / Chassis Electrical Ground
  142
- Spark Plug Service
  142
Chapter 3 Engine / Cooling System

145
- Engine Lubrication Specifications
  148
- Special Tools
  148
- Oil Pressure Test
  149
- Oil Flow Chart
  150
- Engine Service Specifications
  151
- Engine Specifications
  151
- Engine Torque Specifications
  153
- Intake / Exhaust System
  155
- Intake / Turbo System Overview
  155
- Engine Air Intake Assembly View
  156
- Air Box Installation
  157
- Air Box Removal
  157
- Exhaust Assembly View
  158
- Muffler Installation
  159
- Muffler Removal
  159
- Exhaust Pipe Removal
  160
- Head Pipe / Turbo Removal
  162
- Head Pipe / Turbo Installation
  163
- Exhaust Pipe Installation
  165
- Turbocharger Inspection
  166
- Actuator / Wastegate Inspection
  169
- Actuator Pod Removal
  170
- Oil Drain Tube Service
  171
- P1234 Boost Reference Code Troubleshooting
  172
- Wastegate Flapper Inspection
  172
- Cooling System
  174
- Cooling System Flow
  174
- Cooling System Pressure Test
  175
- Cooling System Specifications
  175
- Charge Air Cooler Removal
  176
- Charge Air Cooler Installation
  178
- Radiator Replacement
  180
- Thermostat Replacement
  181
- Engine Service
  185
- Starter Motor Removal
  185
- Starter Motor Installation
  186
- Front Engine Mount Isolator Replacement
  187
- Crankshaft Pto Seal Replacement
  188
- Engine Removal
  190
- Engine Installation
  193
- Cam Chain Tensioner Service
  196
- Camshaft Removal
  197
- Engine Disassembly / Inspection - Top End
  197
- Valve Cover Removal
  197
- Camshaft Sprocket Inspection
  198
- Camshaft / Camshaft Bore Inspection
  199
- Cylinder Head Inspection
  201
- Cylinder Head Removal
  201
- Cylinder Head Disassembly
  202
- Valve Inspection
  203
- Combustion Chamber Cleaning
  204
- Valve Seat Reconditioning
  204
- Engine Disassembly / Inspection - Bottom End
  207
- Stator Cover Removal / Inspection
  207
- Flywheel Removal
  208
- Water Pump Housing Removal
  208
- Starter One-Way Clutch Disassembly
  209
- Crankcase Disassembly
  210
- Balance Shaft Removal / Inspection
  212
- Crankshaft Removal / Inspection
  213
- Crankcase Inspection
  215
- Cylinder / Piston Removal
  216
- Cylinder Inspection
  217
- Piston Disassembly / Inspection
  218
- Piston Ring Installed Gap
  219
- Piston Ring Removal
  219
- Piston Ring to Groove Clearance
  219
- Connecting Rod Inspection
  220
- Piston to Cylinder Clearance
  220
- Bearing Selection Identification
  222
- Connecting Rod Bearing Selection
  222
- Engine Assembly - Bottom End
  222
- Crankshaft Main Bearing Selection
  223
- Upper Crankcase Preparation
  223
- Piston Ring Installation
  224
- Piston / Connecting Rod Assembly
  225
- Piston / Cylinder Installation
  226
- Crankshaft Installation
  227
- Balance Shaft Installation
  228
- Crankcase Assembly
  229
- Lower Crankcase Preparation
  229
- Flywheel Installation
  233
- Starter One-Way Clutch Assembly
  233
- Stator Cover Installation
  234
- Cylinder Head Assembly
  235
- Engine Assembly - Top End
  235
- Cylinder Head Installation
  236
- Valve Sealing Test
  236
- Camshaft Installation / Timing
  237
- Camshaft Timing Quick Reference
  241
- Valve Clearance Adjustment
  242
- Valve Lash - Tappet Selection
  244
- Valve Cover Installation
  245
Chapter 4 Engine Electrical

247
- Ecu Operation Overview
  248
- Ecu Replacement
  248
- Ecu Service
  248
- Electronic Control Unit (Ecu)
  248
- Etc Learn Procedure
  249
- Bap Sensor
  250
- Boost Pressure Sensor
  250
- Fuel Pressure Sensor (Evap Models)
  250
- Pressure Sensors
  250
- Tmap Sensor
  250
- Air Temperature Sensor Data
  251
- Knock Sensor
  252
- Knock Sensor Overview
  252
- Knock Sensor Replacement
  252
- Knock Sensor Testing
  252
- Crankshaft Position Sensor (Cps)
  253
- Operation Overview
  253
- Electronic Throttle Control (Etc) / Throttle Body
  255
- Etc Operation Overview
  255
- Etc Test
  255
- Etc / Throttle Body Replacement
  256
- Etc Learn Procedure
  256
- Operation Overview
  257
- Pedal Position Sensor (Pps)
  257
- Pps Test
  257
- Oxygen Sensor
  259
- Oxygen Sensor Information
  259
- Oxygen Sensor Replacement
  260
Chapter 5 Efi / Fuel System

261
- Special Tools
  262
- Efi Overview
  263
- Efi System Components
  263
- Efi Operation Overview
  264
- Efi Service Notes
  265
- Initial Priming / Starting Procedure
  266
- Fuel Injector O-Rings
  267
- Fuel Injector Operation Overview
  267
- Fuel Injectors
  267
- Fuel Injector Test
  268
- Fuel Injector Troubleshooting
  268
- Fuel Injector Replacement
  269
- Fuel Lines
  271
- Fuel System Assembly View
  271
- Fuel System Assembly View (Evap)
  272
- Fuel Line Removal / Installation
  274
- Fuel Line Removal / Installation (Evap)
  274
- Fuel Line Routing
  275
- Fuel Line Routing (Evap)
  276
- Fuel Vent Line Routing
  277
- Fuel Vent Line Routing (Evap)
  279
- Vent Line Termination Fitting
  280
- Fuel Pressure Regulation
  281
- Fuel Pressure Sensor
  281
- Operation Overview
  281
- Fuel Tank / Pump
  282
- Fuel Tank Assembly View
  282
- Fuel Tank Removal / Installation
  283
- Fuel Pressure Test
  285
- Fuel Pump Operation Overview
  285
- Fuel Pump Replacement
  287
- Fuel Sender Test
  289
Chapter 6 Pvt System

291
- 2020-21 Rzr Pro Xp Clutch Chart
  293
- Special Tools
  293
- Drive Clutch Operation
  294
- Driven Clutch Operation
  294
- General Operation
  294
- Pvt System Overview
  294
- Belt Inspection
  295
- Belt Removal
  295
- Drive Belt
  295
- Belt Break-In
  296
- Belt Installation
  296
- Drive Clutch Removal
  297
- Drive Clutch Service
  297
- Drive Clutch Assembly View
  299
- Bearing Inspection
  301
- Clutch Disassembly
  301
- Button to Tower Clearance Inspection
  302
- Roller, Pin, and Thrust Washer Inspection
  302
- Spider Removal
  302
- Roller Replacement
  303
- Shift Weight Inspection
  303
- Clutch Inspection
  304
- Drive Clutch Bushings Inspection
  305
- Drive Clutch Spring Inspection
  305
- Bushing Service
  306
- Clutch Assembly
  308
- Drive Clutch Installation
  309
- 2021 Drive Clutch Service
  311
- Drive Clutch Assembly View (2021)
  311
- Drive Clutch Removal (2021)
  312
- Clutch Disassembly (2021)
  313
- Bearing Inspection
  314
- Drive Clutch Spring Inspection (2021)
  314
- Button to Tower Clearance Inspection
  315
- Roller, Pin, and Thrust Washer Inspection
  315
- Spider Removal
  315
- Roller Replacement
  316
- Shift Weight Inspection
  316
- Clutch Inspection
  317
- Drive Clutch Bushings Inspection
  318
- Clutch Assembly
  320
- Driven Clutch Removal
  321
- Driven Clutch Service
  321
- Driven Clutch Assembly View
  323
- Driven Clutch Disassembly
  324
- Bushing Service
  325
- Helix and Movable Sheave Bushing Inspection
  325
- Driven Clutch Assembly
  326
- Driven Clutch Installation
  327
- Driven Clutch Alignment
  328
- 2021 Driven Clutch Service
  329
- Driven Clutch Assembly View (2021)
  330
- Driven Clutch Removal
  331
- Driven Clutch Disassembly
  332
- Bushing Service
  333
- Helix and Movable Sheave Bushing Inspection
  333
- Driven Clutch Assembly
  335
- Driven Clutch Alignment
  337
- Driven Clutch Installation
  337
Chapter 7 Transmission

339
- Special Tools
  340
- Shift Cable Inspection
  341
- Shift Lever / Cable
  341
- Shift Cable Adjustment
  342
- Transmission Removal
  343
- Transmission Service
  343
- Transmission Installation
  346
- Transmission Vent Line Routing
  348
- Transmission Disassembly
  349
- Gear, Shaft, Bearing Inspection
  353
- Transmission Assembly / Snorkel Gear Backlash
  354
Chapter 8 Final Drive

359
- Special Tools
  360
- Bearing Carrier
  361
- Front Bearing Carrier Inspection / Removal
  361
- Front Bearing Replacement
  362
- Front Bearing Carrier Installation
  363
- Rear Bearing Carrier Inspection / Removal
  364
- Rear Bearing Carrier Installation
  367
- Drive Shaft
  369
- Front Drive Shaft Removal
  369
- Front Drive Shaft Installation
  370
- Rear Drive Shaft Removal
  371
- Rear Drive Shaft Installation
  372
- Drive Shaft / CV Joint Handling Tips
  374
- CV Joint / Boot Replacement
  375
- Inner Plunging Joint / Boot Replacement
  376
- Prop Shaft
  379
- Prop Shaft Removal / Installation
  379
- Prop Shaft Removal / Installation (4-Seat)
  382
- Prop Shaft Assembly View
  385
- Prop Shaft Assembly View (4-Seat)
  386
- Support Bearing Replacement
  387
- U-Joint Disassembly
  387
- Front Gearcase / Centralized Hilliard
  389
- Front Gearcase Assembly View
  389
- All Wheel Drive Operation
  390
- Front Gearcase Vent Line Routing
  390
- Awd Diagnosis
  391
- Front Gearcase Removal / Installation
  393
- Front Gearcase Disassembly / Inspection
  395
- Front Gearcase Assembly
  398
- Front Hub Assembly View
  401
- Wheel Hubs
  401
- Rear Hub Assembly View
  402
- Tire Balancing
  403
Chapter 9 Steering / Suspension

405
- Special Tools
  407
- Steering System
  408
- Steering System Assembly View
  408
- Upper Steering Shaft Removal
  409
- Power Steering Unit Removal
  410
- Steering Wheel Removal
  410
- Lower Steering Shaft Removal
  411
- Steering Rack Removal / Installation
  412
- Lower Steering Shaft Installation
  415
- Power Steering Unit Installation
  415
- Steering Shaft Bushing Replacement
  418
- Eps Pre-Positioning / Steering Angle Centering
  419
- Front Suspension
  421
- Front Suspension Assembly View
  421
- Front A-Arm Removal / Installation
  422
- Front Stabilizer Bar Replacement
  423
- Ball Joint Removal
  424
- Ball Joint Installation
  425
- Rear Suspension
  426
- Rear Suspension Assembly View
  426
- Trailing Arm Removal / Installation
  427
- Trailing Arm Spherical Bearing Replacement
  429
- Radius Rod Removal / Installation
  430
- Stabilizer Bar Removal / Installation
  431
- Shock / Spring Replacement
  432
- Shock Assembly View
  432
- Shock Removal / Installation
  432
- Shocks / Springs
  432
- Fox 2.5" Shock Information
  434
- Fox 2.5" Shock Information (4-Seat)
  436
- Fox 3.0" Shock Information
  438
- Fox 3.0" Shock Information (4-Seat)
  440
- Fox 2.5" / 3.0" O.e. Podium Bypass
  442
- Shock Service
  442
- Offset Torque Formula
  443
- Fox Shock Disassembly
  444
- Fox Shock Assembly
  451
- Shock Service
  456
- Walker Evans™ 2.5" Front Shock / 3.0" Rear Shock
  456
- General Service Information
  457
- Front Shock Service Information
  458
- Rear Shock Service Information
  460
- Spring Adjustment (Walker Evans)
  462
- Shock Piston Orientation
  463
- Special Tools
  463
- Valve Shim Arrangement
  463
- Walker Evans™ Shock Disassembly
  464
- Walker Evans™ Shock Assembly
  467
- Dynamix Active Suspension
  472
- Dynamix Overview
  472
- Dynamix Shocks Disassembly / Assembly
  472
- Demonstration Mode
  473
- Suspension Control Module (Scm)
  473
- Cornering Control
  474
- Dynamix™ System Features
  474
- Vehicle Speed Sensitivity
  474
- Acceleration
  475
- Airborne Detection
  475
- Braking
  475
- Advanced Diagnostics
  476
- Processing Capability
  476
- Suspension Mode Switch (Dynamix Models)
  476

Polaris RZR PRO XP 4 2020 Service Manual (558 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 26.63 MB

Chapter 1 1 General Information

7
- Table of Contents
  7
- Model Number Designation (2015 +)
  9
- Vehicle Identification
  9
- Vehicle Identification Number (Vin) Designation (2015+)
  9
- Vin and Engine Serial Number Locations
  9
- Reference Information
  10
  - Replacement Keys
    10
  - Publication Numbers
    10
  - Special Tools
    11
  - Master Torque Table
    15
- Vehicle Specifications
  19
  - 2020 Rzr Pro Xp Clutch Chart
    20
  - 2020 Rzr Pro Xp 4 Clutch Chart
    22
- Misc. Specifications and Charts
  23
  - Conversion Table
    23
  - Sae Tap / Drill Sizes
    24
  - Metric Tap / Drill Sizes
    24
  - Decimal Equivalents
    25
- General Diagnostics
  26
- Engine Electrical Diagnostics
  47
- Fluid Inspection
  60
- Fluid Leaks
  60
- Fuel System Diagnostics
  61
  - Fuel System Troubleshooting
    61
- Pvt System Diagnostics
  63
  - Pvt System Troubleshooting
    63
  - Pvt System Overheating / Diagnosis
    65
- Transmission Diagnostics
  66
  - Hard Shifting
    66
  - Transmission Isolation
    66
- Final Drive Diagnostics
  67
  - All Wheel Drive (Awd) Concerns
    67
  - Driveshaft (Half Shaft) Diagnostics
    67
- Brake System Diagnostics
  68
  - Brake Noise Troubleshooting
    68
  - Brake Vibration
    68
  - Caliper Overheats (Brakes Drag)
    68
  - Poor Brake Performance
    69
  - Brakes Lock
    69
- Steering / Suspension Diagnostics
  70
- Electrical Diagnostics
  74
Maintenance Chapter 2 Maintenance 2

81
- Chapter 2
  83
- Lubricants / Service Products
  83
- Maintenance
  83
- Periodic Maintenance - General
  83
- Pre-Ride Inspection
  84
- Maintenance Intervals
  85
- Maintenance Quick Reference
  105
- Grease Lubrication Points
  107
- Engine / Exhaust
  108
  - Engine Oil Level
    108
  - Engine Oil and Filter Change
    109
  - Engine Crankcase Breather Hose
    110
  - Engine Cylinder Leakdown Test
    110
  - Valve Clearance Adjustment
    111
  - Cam Chain Tensioner Inspection
    112
  - Spark Arrestor
    113
  - Heat Shield Inspection
    114
- Cooling System
  115
  - Coolant Strength
    115
  - Coolant Level Inspection
    115
  - Cooling System Pressure Test
    116
  - Coolant Hose Inspection
    116
  - Radiator Inspection / Cleaning
    117
  - Coolant Flush
    117
  - Cooling System Bleeding
    118
- Fuel System and Air Intake
  120
  - Fuel Tank Vent Inspection
    120
  - Throttle Pedal Inspection
    120
  - Engine Intake Pre-Filter Service
    121
  - Air Filter Service
    121
- Pvt / Final Drive / Wheel and Tire
  123
  - Pvt Drain
    123
  - Pvt Intake Pre-Filter Service
    123
  - Front Gearcase Lubrication
    124
  - Drive Shaft Boot Inspection
    125
  - Wheel Removal
    125
  - Wheel Installation
    125
  - Tire Inspection
    126
  - Tire Pressure
    126
- Transmission
  127
  - Transmission Lubrication
    127
  - Transmission Oil Level Check
    127
  - Transmission Oil Change
    127
- Steering
  128
  - Steering Inspection
    128
  - Steering Wheel Free-Play
    128
  - Tie Rod End / Wheel Hub Inspection
    128
  - Wheel Toe Alignment Inspection
    129
  - Wheel Toe Adjustment
    130
- Suspension
  131
  - Suspension Inspection
    131
  - Suspension Lubrication
    132
  - Spring Adjustment
    132
  - Shock Compression Adjustment (Walker Evans™)
    133
- Brake System
  134
  - Brake Fluid Inspection
    134
  - Brake Hose and Fitting Inspection
    134
  - Brake Pad Inspection
    134
  - Brake Disc Inspection
    135
- Electrical and Ignition System
  136
  - Battery Maintenance
    136
  - Battery Charging / off Season Storage
    136
  - Engine / Chassis Electrical Ground
    136
  - Spark Plug Service
    136
Chapter 3 Engine / Cooling System

139
- Engine Lubrication Specifications
  142
- Special Tools
  142
- Oil Pressure Test
  143
- Oil Flow Chart
  144
- Engine Service Specifications
  145
  - Engine Specifications
    145
  - Engine Torque Specifications
    147
- Intake / Exhaust System
  149
  - Intake / Turbo System Overview
    149
  - Engine Air Intake Assembly View
    150
  - Air Box Removal
    151
  - Air Box Installation
    151
  - Exhaust Assembly View
    152
  - Muffler Removal
    153
  - Muffler Installation
    153
  - Exhaust Pipe Removal
    154
  - Head Pipe / Turbo Removal
    156
  - Head Pipe / Turbo Installation
    157
  - Exhaust Pipe Installation
    159
  - Turbocharger Service
    160
    
    Turbocharger Inspection
    160
    
    Actuator / Wastegate Inspection
    163
    
    Actuator Pod Removal
    164
    
    Oil Drain Tube Service
    165
    
    Wastegate Flapper Inspection
    166
  - P1234 Boost Reference Code Troubleshooting
    166
- Cooling System
  168
  - Cooling System Flow
    168
  - Cooling System Specifications
    169
  - Cooling System Pressure Test
    169
  - Charge Air Cooler Removal
    170
  - Charge Air Cooler Installation
    172
  - Radiator Replacement
    174
  - Thermostat Replacement
    175
  - Water Pump Service
    176
- Engine Service
  179
  - Starter Motor Removal
    179
  - Starter Motor Installation
    180
  - Front Engine Mount Isolator Replacement
    181
  - Crankshaft Pto Seal Replacement
    182
  - Engine Removal
    184
  - Engine Installation
    188
  - Cam Chain Tensioner Service
    190
- Engine Disassembly / Inspection - Top End
  192
  - Valve Cover Removal
    192
  - Camshaft Removal
    192
  - Camshaft Sprocket Inspection
    193
  - Camshaft / Camshaft Bore Inspection
    194
  - Cylinder Head Removal
    196
  - Cylinder Head Inspection
    196
  - Cylinder Head Disassembly
    197
  - Valve Inspection
    198
  - Combustion Chamber Cleaning
    199
  - Valve Seat Reconditioning
    199
- Engine Disassembly / Inspection - Bottom End
  202
  - Stator Cover Removal / Inspection
    202
  - Water Pump Housing Removal
    203
  - Flywheel Removal
    203
  - Starter One-Way Clutch Disassembly
    204
  - Crankcase Disassembly
    205
  - Balance Shaft Removal / Inspection
    207
  - Crankshaft Removal / Inspection
    208
  - Crankcase Inspection
    210
  - Cylinder / Piston Removal
    211
  - Cylinder Inspection
    212
  - Piston Disassembly / Inspection
    213
  - Piston Ring Removal
    214
  - Piston Ring to Groove Clearance
    214
  - Piston Ring Installed Gap
    214
  - Piston to Cylinder Clearance
    215
  - Connecting Rod Inspection
    215
- Engine Assembly - Bottom End
  217
  - Bearing Selection Identification
    217
  - Connecting Rod Bearing Selection
    217
  - Crankshaft Main Bearing Selection
    218
  - Upper Crankcase Preparation
    218
  - Piston Ring Installation
    219
  - Piston / Connecting Rod Assembly
    220
  - Piston / Cylinder Installation
    221
  - Crankshaft Installation
    222
  - Balance Shaft Installation
    223
  - Lower Crankcase Preparation
    224
  - Crankcase Assembly
    224
  - Starter One-Way Clutch Assembly
    228
  - Flywheel Installation
    228
  - Stator Cover Installation
    229
- Cylinder Head Assembly
  230
- Engine Assembly - Top End
  230
- Cylinder Head Installation
  231
- Valve Sealing Test
  231
- Camshaft Installation / Timing
  232
- Camshaft Timing Quick Reference
  236
- Valve Clearance Adjustment
  237
- Valve Lash - Tappet Selection
  239
- Valve Cover Installation
  240
Chapter 4 Engine Electrical

241
- Ecu Operation Overview
  242
- Ecu Replacement
  242
- Ecu Service
  242
- Electronic Control Unit (Ecu)
  242
- Etc Learn Procedure
  243
- Pressure Sensors
  244
  - Bap Sensor
    244
  - Boost Pressure Sensor
    244
  - Fuel Pressure Sensor (Evap Models)
    244
  - Tmap Sensor
    244
  - Air Temperature Sensor Data
    245
- Knock Sensor
  246
  - Knock Sensor Overview
    246
  - Knock Sensor Testing
    246
  - Knock Sensor Replacement
    246
- Crankshaft Position Sensor (Cps)
  247
  - Operation Overview
    247
  - Cps Test
    247
  - Cps Replacement
    248
- Electronic Throttle Control (Etc) / Throttle Body
  249
  - Etc Operation Overview
    249
  - Etc Test
    249
  - Etc / Throttle Body Replacement
    250
  - Etc Learn Procedure
    250
- Pedal Position Sensor (Pps)
  251
  - Operation Overview
    251
  - Location
    251
  - Pps Test
    251
  - Pps Replacement
    252
- Oxygen Sensor
  253
  - Oxygen Sensor Information
    253
  - Oxygen Sensor Replacement
    254
Chapter 5 Efi / Fuel System

255
- Efi Overview
  257
  - Efi System Components
    257
  - Efi Operation Overview
    258
  - Efi Service Notes
    259
  - Initial Priming / Starting Procedure
    260
- Fuel Injectors
  261
  - Fuel Injector Operation Overview
    261
  - Fuel Injector O-Rings
    261
  - Fuel Injector Troubleshooting
    262
  - Fuel Injector Test
    262
  - Fuel Injector Replacement
    263
- Fuel Lines
  265
  - Fuel System Assembly View
    265
  - Fuel System Assembly View (Evap)
    266
  - Fuel Line Removal / Installation
    268
  - Fuel Line Removal / Installation (Evap)
    268
  - Fuel Line Routing
    269
  - Fuel Line Routing (Evap)
    270
  - Fuel Vent Line Routing
    271
  - Fuel Vent Line Routing (Evap)
    273
  - Vent Line Termination Fitting
    274
- Fuel Tank / Pump
  275
  - Fuel Tank Assembly View
    275
  - Fuel Tank Removal / Installation
    276
  - Fuel Pump Operation Overview
    278
  - Fuel Pressure Test
    278
  - Fuel Pump Replacement
    280
  - Fuel Sender Test
    282
Chapter 6 Pvt System

283
- 2020 Rzr Pro Xp Clutch Chart
  284
- Special Tools
  284
- Pvt System Overview
  285
  - General Operation
    285
  - Drive Clutch Operation
    285
  - Driven Clutch Operation
    285
- Drive Belt
  286
  - Belt Removal
    286
  - Belt Inspection
    286
  - Belt Installation
    287
  - Belt Break-In
    287
- Drive Clutch Service
  288
  - Drive Clutch Removal
    288
  - Drive Clutch Assembly View
    289
  - Clutch Disassembly
    291
  - Bearing Inspection
    291
  - Button to Tower Clearance Inspection
    292
  - Spider Removal
    292
  - Roller, Pin, and Thrust Washer Inspection
    292
  - Roller Replacement
    293
  - Shift Weight Inspection
    293
  - Clutch Inspection
    294
  - Drive Clutch Spring Inspection
    295
  - Drive Clutch Bushings Inspection
    295
  - Bushing Service
    296
  - Clutch Assembly
    298
  - Drive Clutch Installation
    299
- Driven Clutch Service
  301
  - Driven Clutch Removal
    301
  - Driven Clutch Assembly View
    302
  - Driven Clutch Disassembly
    303
  - Helix and Movable Sheave Bushing Inspection
    304
  - Bushing Service
    304
  - Driven Clutch Assembly
    305
  - Driven Clutch Installation
    306
  - Driven Clutch Alignment
    307
Chapter 7 Transmission

309
- Shift Lever / Cable
  311
  - Shift Lever Removal
    311
  - Shift Lever Installation
    311
  - Shift Cable Inspection
    311
  - Shift Cable Adjustment
    312
- Transmission Service
  313
  - Transmission Removal
    313
  - Transmission Installation
    316
  - Transmission Vent Line Routing
    318
  - Transmission Disassembly
    319
  - Gear, Shaft, Bearing Inspection
    323
  - Transmission Assembly / Snorkel Gear Backlash
    324
Chapter 8 Final Drive

329
- Bearing Carrier
  331
- Drive Shaft
  339
  - Front Drive Shaft Removal
    339
  - Front Drive Shaft Installation
    340
  - Rear Drive Shaft Removal
    341
  - Rear Drive Shaft Installation
    342
  - Drive Shaft / CV Joint Handling Tips
    344
  - CV Joint / Boot Replacement
    345
  - Inner Plunging Joint / Boot Replacement
    346
- Prop Shaft
  349
  - Prop Shaft Removal / Installation
    352
  - Prop Shaft Removal / Installation (4-Seat)
    352
  - Prop Shaft Assembly View
    355
  - Prop Shaft Assembly View (4-Seat)
    356
  - Support Bearing Replacement
    357
  - U-Joint Disassembly
    357
  - U-Joint Assembly
    358
- Front Gearcase / Centralized Hilliard
  359
  - Front Gearcase Assembly View
    359
  - Front Gearcase Vent Line Routing
    360
  - All Wheel Drive Operation
    360
  - Awd Diagnosis
    361
  - Front Gearcase Removal / Installation
    363
  - Front Gearcase Disassembly / Inspection
    365
  - Front Gearcase Assembly
    368
- Wheel Hubs
  371
  - Front Hub Assembly View
    371
  - Rear Hub Assembly View
    372
  - Tire Balancing
    373
Chapter 9 Steering / Suspension

375
- Steering System
  378
  - Steering System Assembly View
    378
  - Upper Steering Shaft Removal
    379
  - Steering Wheel Removal
    380
  - Power Steering Unit Removal
    380
  - Lower Steering Shaft Removal
    381
  - Steering Rack Removal / Installation
    382
  - Lower Steering Shaft Installation
    385
  - Power Steering Unit Installation
    385
  - Steering Shaft Bushing Replacement
    388
  - Eps Pre-Positioning / Steering Angle Centering
    389
- Front Suspension
  391
  - Front Suspension Assembly View
    391
  - Front A-Arm Removal / Installation
    392
  - Front Stabilizer Bar Replacement
    393
  - Ball Joint Service Preparation
    394
  - Ball Joint Removal
    394
  - Ball Joint Installation
    395
- Rear Suspension
  396
- Shocks / Springs
  402
  - Shock Assembly View
    402
  - Shock Removal / Installation
    402
  - Shock / Spring Replacement
    402
  - Fox 2.5" Shock Information
    403
  - Fox 3.0" Shock Information
    404
- Shock Service
  405
  - Fox Shock Service
    405
    
    Fox 2.5" / 3.0" O.e. Podium Bypass
    405
    
    Offset Torque Formula
    406
    
    Fox Shock Disassembly
    407
    
    Fox Shock Assembly
    414
- Shock Service
  419
  - Walker Evans Shock Service
    419
- Steering / Suspension
  419
  - Walker Evans™ 2.5" Front Shock / 3.0" Rear Shock
    419
  - General Service Information
    420
  - Front Shock Service Information
    420
  - Rear Shock Service Information
    421
  - Spring Adjustment (Walker Evans)
    423
  - Walker Evans™ Shock Rebuild Information
    424
  - Special Tools
    424
  - Valve Shim Arrangement
    424
  - Shock Piston Orientation
    424
  - Walker Evans™ Shock Disassembly
    425
  - Walker Evans™ Shock Assembly
    428
- Dynamix Active Suspension
  433
- Dynamix Overview
  433
- Dynamix Shocks Disassembly / Assembly
  433
- Demonstration Mode
  434
- Suspension Control Module (Scm)
  434
- Dynamix™ System Features
  435
  - Vehicle Speed Sensitivity
    435
  - Cornering Control
    435
  - Braking
    436
  - Acceleration
    436
  - Airborne Detection
    436
  - Advanced Diagnostics
    437
  - Processing Capability
    437
- Suspension Mode Switch (Dynamix Models)
  437

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Polaris RZR PRO XP 4 2020 Manuals

Polaris RZR PRO XP 4 2020 Service Manual (598 pages)

Table of Contents

Chapter 1 1 General Information

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling System

Chapter 4 Engine Electrical

Chapter 5 Efi / Fuel System

Chapter 6 Pvt System

Chapter 7 Transmission

Chapter 8 Final Drive

Chapter 9 Steering / Suspension