Polaris RZR XP Manuals

Polaris RZR XP Manuals

Manuals and User Guides for Polaris RZR XP. We have 1 Polaris RZR XP manual available for free PDF download: Service Manual

Polaris RZR XP Service Manual

Polaris RZR XP Service Manual (564 pages)

2018-2019

Brand: Polaris | Category: Offroad Vehicle | Size: 26.07 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Vehicle Identification
  8
- Model Number Designation (2015 +)
  8
- Vehicle Identification Number (Vin) Designation (2015+)
  8
- Vin and Engine Serial Number Locations
  8
- Reference Information
  9
- Replacement Keys
  9
- Publication Numbers
  9
- Special Tools
  10
- Master Torque Table
  14
- Vehicle Specifications
  17
- 2018 Rzr Xp Turbo S
  18
- 2018 Rzr Xp Turbo S Clutch Chart
  18
- 2019 Rzr Xp Turbo S Clutch Chart
  20
- 2019 Rzr Xp 4 Turbo S Clutch Chart
  22
- Misc. Specifications and Charts
  23
- Conversion Table
  23
- Sae Tap / Drill Sizes
  24
- Metric Tap / Drill Sizes
  24
- Decimal Equivalents
  25
Maintenance Chapter 2 Maintenance 2

27
- Lubricants / Service Products
  29
- Maintenance
  29
- Periodic Maintenance - General
  29
- Pre-Ride Inspection
  30
- Maintenance Intervals
  31
- Maintenance Quick Reference
  51
- Grease Lubrication Points
  53
- Engine / Exhaust
  54
- Engine Oil Level
  54
- Engine Oil and Filter Change
  55
- Engine Crankcase Breather Hose
  56
- Engine Cylinder Leakdown Test
  56
- Valve Clearance Adjustment
  57
- Cam Chain Tensioner Inspection
  58
- Spark Arrestor
  59
- Heat Shield Inspection
  60
- Coolant Level Inspection
  62
- Coolant Strength
  62
- Cooling System
  62
- Coolant Hose Inspection
  63
- Cooling System Pressure Test
  63
- Coolant Flush
  64
- Radiator Inspection / Cleaning
  64
- Cooling System Bleeding
  65
- Engine Cooling System Bleeding
  65
- Charge Air Cooling System Bleeding
  66
- Fuel System and Air Intake
  67
- Fuel Tank Vent Inspection
  67
- Throttle Pedal Inspection
  67
- Air Filter Service
  68
- Engine Intake Pre-Filter Service
  68
- Intake Duct Drain Inspection
  69
- Pvt / Final Drive / Wheel and Tire
  70
- Pvt Drain
  70
- Pvt Intake Pre-Filter Service
  70
- Front Gearcase Fluid Change
  71
- Front Gearcase Fluid Level Check
  71
- Front Gearcase Lubrication
  71
- Drive Shaft Boot Inspection
  72
- Tire Inspection
  72
- Wheel Installation
  72
- Wheel Removal
  72
- Maintenance
  73
- Tire Pressure
  73
- Tire Rotation
  73
- Transmission
  74
- Transmission Lubrication
  74
- Transmission Oil Change
  74
- Transmission Oil Level Check
  74
- Steering
  75
- Steering Inspection
  75
- Steering Wheel Free-Play
  75
- Tie Rod End / Wheel Hub Inspection
  75
- Wheel Toe Alignment Inspection
  76
- Wheel Toe Adjustment
  77
- Suspension
  78
- Suspension Inspection
  78
- Suspension Lubrication
  78
- Brake Fluid Inspection
  79
- Brake Hose and Fitting Inspection
  79
- Brake Pad Inspection
  79
- Brake System
  79
- Brake Disc Inspection
  80
- Battery Charging / off Season Storage
  81
- Battery Maintenance
  81
- Electrical and Ignition System
  81
- Engine / Chassis Electrical Ground
  81
- Spark Plug Service
  82
Chapter 3 Engine / Cooling System

83
- Engine Lubrication Specifications
  86
- General Information
  86
- Special Tools
  86
- Oil Pressure Test
  87
- Oil Flow Chart
  88
- Engine Service Specifications
  89
- Engine Specifications
  89
- Engine Torque Specifications
  91
- Intake / Exhaust System
  93
- Intake / Turbo System Overview
  93
- Engine Air Intake Assembly View
  94
- Air Box Removal
  95
- Air Box Installation
  96
- Exhaust Assembly View
  97
- Muffler Removal
  98
- Exhaust Pipe Removal
  99
- Muffler Installation
  99
- Head Pipe / Turbo Removal
  101
- Head Pipe / Turbo Installation
  103
- Exhaust Pipe Installation
  105
- Turbocharger Inspection
  106
- Turbocharger Service
  106
- Actuator / Wastegate Inspection
  110
- Actuator Pod Removal
  111
- Oil Drain Tube Service
  112
- Boost Control Valve
  113
- P1234 Boost Reference Code Troubleshooting
  113
- Wastegate Flapper Inspection
  113
- Actuator / Wastegate
  114
- Boost Pressure Sensor Harness
  114
- Exhaust
  114
- Turbocharger
  114
- Cooling System
  115
- Cooling System Flow
  115
- Cooling System Pressure Test
  116
- Cooling System Specifications
  116
- Charge Air Cooler Removal
  117
- Charge Air Cooler Installation
  119
- Radiator Replacement
  120
- Thermostat Replacement
  124
- Water Pump Service
  125
- Engine Service
  128
- Front Engine Mount Isolator Replacement
  128
- Crankshaft Pto Seal Replacement
  129
- Engine Removal
  131
- Engine Installation
  135
- Cam Chain Tensioner Service
  139
- Installation
  139
- Removal
  139
- Camshaft Removal
  140
- Engine Disassembly / Inspection - Top End
  140
- Valve Cover Removal
  140
- Camshaft Sprocket Inspection
  141
- Camshaft / Camshaft Bore Inspection
  142
- Cylinder Head Inspection
  144
- Cylinder Head Removal
  144
- Cylinder Head Disassembly
  145
- Valve Inspection
  146
- Combustion Chamber Cleaning
  147
- Valve Seat Reconditioning
  147
- Engine Disassembly / Inspection - Bottom End
  150
- Stator Cover Removal / Inspection
  150
- Flywheel Removal
  151
- Water Pump Housing Removal
  151
- Starter One-Way Clutch Disassembly
  152
- Crankcase Disassembly
  153
- Balance Shaft Removal / Inspection
  155
- Crankshaft Removal / Inspection
  156
- Crankcase Inspection
  158
- Cylinder / Piston Removal
  159
- Cylinder Inspection
  160
- Piston Disassembly / Inspection
  161
- Piston Ring Installed Gap
  162
- Piston Ring Removal
  162
- Piston Ring to Groove Clearance
  162
- Connecting Rod Inspection
  163
- Piston to Cylinder Clearance
  163
- Bearing Selection Identification
  165
- Engine Assembly - Bottom End
  165
- Connecting Rod Bearing Selection
  166
- Crankshaft Main Bearing Selection
  166
- Piston Ring Installation
  167
- Upper Crankcase Preparation
  167
- Piston / Connecting Rod Assembly
  168
- Piston / Cylinder Installation
  169
- Crankshaft Installation
  170
- Balance Shaft Installation
  172
- Lower Crankcase Preparation
  172
- Crankcase Assembly
  173
- Starter One-Way Clutch Assembly
  176
- Flywheel Installation
  177
- Stator Cover Installation
  178
- Cylinder Head Assembly
  179
- Engine Assembly - Top End
  179
- Cylinder Head Installation
  180
- Valve Sealing Test
  180
- Camshaft Installation / Timing
  181
- Camshaft Timing Quick Reference
  185
- Valve Clearance Adjustment
  186
- Valve Lash - Tappet Selection
  188
- Valve Cover Installation
  189
Chapter 4 Efi / Fuel System

191
- General Information
  193
- Special Tools
  193
- Efi Overview
  194
- Efi System Components
  194
- Efi Operation Overview
  195
- Efi Service Notes
  196
- Initial Priming / Starting Procedure
  197
- Ecu Operation Overview
  198
- Ecu Replacement
  198
- Ecu Service
  198
- Electronic Control Unit (Ecu)
  198
- Etc Learn Procedure
  199
- Fuel Injector O-Rings
  200
- Fuel Injector Operation Overview
  200
- Fuel Injectors
  200
- Fuel Injector Test
  201
- Fuel Injector Troubleshooting
  201
- Fuel Injector Replacement
  202
- Fuel Lines
  204
- Fuel System Assembly View
  204
- Fuel System Assembly View (Evap)
  205
- Fuel Line Removal / Installation
  206
- Fuel Line Removal / Installation (Evap Models)
  207
- Fuel Line Routing
  208
- Fuel Line Routing (Evap Models)
  209
- Fuel Vent Line Routing
  210
- Fuel Vent Line Routing (Evap Models)
  212
- Vent Line Termination Fitting
  214
- Fuel Tank / Pump
  215
- Fuel Tank Assembly View
  215
- Fuel Tank Removal
  216
- Fuel Tank Installation
  218
- Fuel Pump Operation Overview
  221
- Fuel Pressure Test
  222
- Fuel Pump Replacement
  223
- Fuel Sender Test
  227
- Air Temperature Sensor Data
  228
- Boost Pressure Sensor
  228
- Fuel Pressure Sensor (Evap Models)
  228
- Pressure Sensors
  228
- Tmap Sensor
  228
- Knock Sensor
  229
- Knock Sensor Overview
  229
- Knock Sensor Replacement
  229
- Knock Sensor Testing
  229
- Cps Test
  230
- Crankshaft Position Sensor (Cps)
  230
- Operation Overview
  230
- Cps Replacement
  231
- Electronic Throttle Control (Etc) / Throttle Body
  232
- Etc Operation Overview
  232
- Etc Test
  232
- Etc / Throttle Body Replacement
  233
- Etc Learn Procedure
  233
- Location
  234
- Operation Overview
  234
- Pedal Position Sensor (Pps)
  234
- Pps Test
  234
- Pps Replacement
  235
- Oxygen Sensor
  236
- Oxygen Sensor Information
  236
- Oxygen Sensor Replacement
  237
Chapter 5 Pvt System

239
- 2018 Rzr Xp Turbo S Clutch Chart
  240
- General Information
  240
- Special Tools
  240
- Drive Clutch Operation
  241
- Driven Clutch Operation
  241
- General Operation
  241
- Pvt System Overview
  241
- Belt Inspection
  242
- Belt Removal
  242
- Drive Belt
  242
- Belt Break-In
  243
- Belt Installation
  243
- Drive Clutch Removal
  244
- Drive Clutch Service
  244
- Drive Clutch Assembly View
  245
- Drive Clutch Disassembly
  246
- Drive Clutch Disassembly / Inspection
  246
- Shift Weight Inspection
  246
- Slider Plate Inspection
  246
- Drive Clutch Assembly
  249
- Drive Clutch Installation
  251
- Driven Clutch Removal (2018 Models)
  252
- Driven Clutch Service
  252
- Driven Clutch Removal (2019 Models)
  253
- Driven Clutch Assembly View
  254
- Driven Clutch Disassembly / Inspection
  255
- Driven Clutch Assembly
  256
- Driven Clutch Installation
  256
- Driven Clutch Installation (2019 Models)
  256
Chapter 6 Transmission

259
- General Information
  260
- Special Tools
  260
- Shift Cable Inspection
  261
- Shift Lever / Cable
  261
- Shift Lever Installation
  261
- Shift Lever Removal
  261
- Shift Cable Adjustment
  262
- Transmission Removal
  263
- Transmission Service
  263
- Transmission Installation
  266
- Transmission Vent Line Routing
  268
- Transmission Disassembly
  269
- Gear Cluster Disassembly
  271
- Snorkel Tube Removal / Disassembly
  271
- Gear, Shaft, Bearing Inspection
  273
- Snorkel Gear Backlash
  274
- Transmission Assembly
  274
- Transmission Assembly / Snorkel Gear Backlash
  274
Chapter 7 Final Drive

279
- General Information
  280
- Special Tools
  280
- Bearing Carrier
  281
- Front Bearing Carrier Inspection / Removal
  281
- Front Bearing Replacement
  282
- Front Bearing Carrier Installation
  283
- Rear Bearing Carrier Inspection / Removal
  284
- Rear Bearing Replacement
  286
- Rear Bearing Carrier Installation
  287
- Drive Shaft
  289
- Front Drive Shaft Removal
  289
- Front Drive Shaft Installation
  290
- Rear Drive Shaft Removal
  291
- Rear Drive Shaft Installation
  292
- Drive Shaft / CV Joint Handling Tips
  294
- Outer CV Boot Replacement
  295
- Inner Plunging Joint / Boot Replacement
  296
- Prop Shaft
  299
- Prop Shaft Removal
  299
- Prop Shaft Removal (S4)
  301
- Prop Shaft Assembly View
  303
- Support Bearing Replacement
  303
- U-Joint Disassembly
  303
- U-Joint Assembly
  304
- Prop Shaft Installation
  305
- Front Gearcase / Centralized Hilliard
  306
- Front Gearcase Assembly View
  306
- Front Gearcase Vent Line Routing
  307
- All Wheel Drive Operation
  308
- Awd Diagnosis
  309
- Front Gearcase Removal
  310
- Front Gearcase Disassembly / Inspection
  314
- Front Gearcase Assembly
  316
- Front Gearcase Installation
  319
- Front Hub Assembly View
  324
- Wheel Hubs
  324
- Rear Hub Assembly View
  325
- Tire Balancing
  326
Chapter 8 Steering / Suspension

327
- General Information
  329
- Special Tools
  329
- Steering System
  330
- Steering System Assembly View
  330
- Upper Steering Shaft Removal
  331
- Hub Adapter Removal
  332
- Steering Wheel / Hub Adapter Removal
  332
- Steering Wheel Removal
  332
- Power Steering Unit Removal
  333
- Lower Steering Shaft Removal
  334
- Steering Rack Removal
  335
- Steering Rack Installation
  338
- Lower Steering Shaft Installation
  342
- Power Steering Unit Installation
  342
- Upper Steering Shaft Installation
  344
- Steering Shaft Bushing Replacement
  345
- Eps Pre-Position Procedure
  346
- Eps Pre-Positioning / Steering Angle Centering
  346
- Eps Steering Angle Centering
  346
- Front Suspension
  348
- Front Suspension Assembly View
  348
- Front A-Arm Removal / Installation
  349
- Front Stabilizer Bar Replacement
  350
- Removal
  350
- Ball Joint Removal
  351
- Ball Joint Service Preparation
  351
- Installation
  351
- Ball Joint Installation
  352
- Rear Suspension
  353
- Rear Suspension Assembly View
  353
- Trailing Arm Removal / Installation
  354
- Trailing Arm Spherical Bearing Replacement
  356
- Radius Rod Removal / Installation
  357
- Stabilizer Bar Installation
  358
- Stabilizer Bar Removal
  358
- Shock / Spring Replacement
  359
- Shock Assembly View
  359
- Shock Removal / Installation
  359
- Shocks / Springs
  359
- Fox 2.5" Shock Information
  360
- Fox 3.0" Shock Information
  361
- Fox 2.5" / 3.0" O.e. Podium Bypass
  362
- Fox Shock Service
  362
- Shock Service
  362
- Offset Torque Formula
  363
- Fox Shock Disassembly
  364
- Fox Shock Assembly
  371
- Dynamix Active Suspension
  376
- Dynamix Overview
  376
- Dynamix Shocks Disassembly / Assembly
  376
- Demonstration Mode
  377
- Scm Replacement
  377
- Suspension Control Module (Scm)
  377
- Cornering Control
  378
- Dynamix™ System Features
  378
- Vehicle Speed Sensitivity
  378
- Acceleration
  379
- Airborne Detection
  379
- Braking
  379
- Advanced Diagnostics
  380
- Processing Capability
  380
- Suspension Mode Switch (Dynamix Models)
  381
Chapter 9 Brake System

383
- Brake System Specifications
  384
- General Information
  384
- Special Tools
  384
- Brake System Overview
  385
- Brake System View
  385
- Brake Line Routing / Retention
  386
- Brake System Service Notes
  389
- Hydraulic Brake System Operation
  389
- Master Cylinder
  390
- Master Cylinder Installation
  390
- Master Cylinder Removal
  390
- Brake Bleeding / Fluid Change
  392
- Brake Pedal
  394
- Brake Pedal Installation
  394
- Brake Pedal Removal
  394
- Brake Caliper / Pad Removal
  395
- Front Brake Service
  395
- Front Caliper Assembly View
  397
- Front Caliper Disassembly / Inspection
  398
- Brake Pad Inspection
  399
- Brake Disc Inspection
  400
- Front Caliper Assembly
  400
- Brake Caliper / Pad Installation
  401
- Front Brake Disc Replacement
  401
- Brake Burnishing Procedure
  402
- Brake Pedal Switch Inspection
  403
- Brake Warning System (Intl Models)
  403
- Brake Warning System Inspection (Intl Models)
  403
- Troubleshooting
  403
- Brake Caliper / Pad Removal
  404
- Rear Brake Service
  404
- Rear Caliper Disassembly / Inspection
  405
- Brake Pad Inspection
  406
- Caliper Inspection
  406
- Rear Brake Disc Inspection
  407
- Rear Caliper Assembly
  407
- Rear Brake Disc Replacement
  408
- Rear Brake Caliper / Pad Installation
  409
- Brake Burnishing Procedure
  410
Chapter 10 Diagnostic

411
- Engine and Drivability Diagnostic Procedures
  415
- Engine Cranks but Does Not Start
  418
- No Crank no Start or Slow Crank
  420
- Over Heating
  421
- Warning Lights
  422
- Engine Troubleshooting
  423
- Cooling Troubleshooting
  425
- Turbocharger Troubleshooting
  425
- Digital Wrench® Diagnostic Software Overview
  426
- Polaris Digital Wrench
  426
- Special Tools (Digital Wrench)
  426
- Digital Wrench Software Version and Update ID
  427
- Digital Wrench® Updates
  427
- Digital Wrench Diagnostic Connector
  428
- Digital Wrench® Communication Errors
  428
- Guided Diagnostics
  428
- Digital Wrench® Serial Number Location
  429
- Digital Wrench® Feature Map
  430
- Ecu Replacement
  431
- Ecu Reprogramming (Reflash)
  431
- Etc Learn Procedure
  431
- Polaris Mobile Digital Wrench (Pmdw)
  434
- Diagnostic Trouble Code List
  435
- Digital Multi-Meter (DMM) Notes
  440
- Dynamic Testing
  440
- Electrical Diagnostics
  440
- Electrical Service Notes
  440
- Static and Dynamic Testing
  440
- Static Testing
  440
- Back Probing
  441
- Break out
  441
- Connector Probing Guidelines
  441
- Front Probing
  441
- Testing Continuity/Resistance
  442
- Testing for a Short to Ground
  442
- Testing for a Short to Voltage
  443
- Testing for Intermittent Conditions
  443
- Testing Current Flow (Amperage)
  444
- Testing Parasitic Draw
  444
- Testing Voltage Drop
  445
- Efi Diagnostics
  446
- Fuel System Troubleshooting
  446
- Cylinder Misfire Detection
  447
- Digital Wrench Data Troubleshooting
  448
- Pvt Troubleshooting
  451
- Troubleshooting
  451
- Shifting Difficulty
  453
- Transmission Troubleshooting
  453
- Brake, Steering, and Suspension Diagnostic Procedures
  454
- Brake Noise Troubleshooting
  456
- Brakes Lock
  457
- Caliper Overheats (Brakes Drag)
  457
- Pedal Vibration
  457
- Poor Brake Performance
  457
- Eps Troubleshooting
  458
- Eps Troubleshooting (Power Steering Non-Functional with Mil On)
  458
- Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
  459
- Eps Troubleshooting (Using Digital Wrench®)
  460
- Dynamix Troubleshooting
  461
- Scm System Voltage
  461
- Shock Valve Power Supply
  461
- Scm Shock Valve Diagnostics
  462
- Scm Can Diagnostics
  463
- Scm Mode Switch
  463
- Scm / Inertial Measurement Unit
  464
- Scm Steering Angle Adapted Offset Diagnostics
  464
Chapter 11 Body / Frame

465
- Decal Replacement
  467
- General Information
  467
- Special Tools
  467
- Body Assembly Views
  468
- Cab Frame Assembly
  468
- Roof Assembly
  469
- Cab Frame Assembly (4 Seat)
  470
- Full Doors (Turbo S Models)
  472
- Dash / Controls
  473
- Hood / Front Body
  474
- Chassis / Main Frame
  475
- Chassis / Main Frame (4 Seat)
  476
- Main Frame Assembly
  477
- Seat Assembly Front
  478
- Floor / Rocker Panels
  479
- Rear Cargo Box / Fenders
  480
- Rear Bumper
  481
- Body Component Removal
  482
- Engine Service Panel
  482
- Front Fascia
  482
- Seats
  482
- Dash Removal
  483
- Hood / Front Body
  483
- Hood Removal
  483
- Rear Fascia
  483
- Front Body Removal
  484
- Front Fender Flair Removal
  484
- Fender Flair Removal
  485
- Fender Removal
  485
- Rear Fender / Fender Flair
  485
- Cargo Box
  486
- Console and Lower Floor Removal
  487
- Rocker Panel Removal
  487
- Rocker Panels, Console and Floor
  487
- Door Adjustment
  488
- Door Panel / Latch Replacement
  488
- Doors
  488
- Rops and Roof
  490
- Rops Installation
  490
- Rops Torque Procedure
  492
- Roof Installation (Turbo S Only)
  495
Chapter 12 Electrical

501
- General Information
  503
- Special Tools
  503
- Under-Dash Components
  503
- Electrical Service Notes
  504
- Electrical Component Locations (Front)
  506
- Instrument Cluster
  508
- Rider Display Overview
  508
- Display Area Modes
  510
- Information Display Area
  510
- Backlight Color
  511
- Clock
  511
- Display Units
  511
- Gauge Settings Menu
  511
- Programmed Service Interval
  512
- Trip Meter
  512
- Trip Time
  512
- Headlamp Switch
  514
- Ignition / Key Switch
  514
- Switches / Controls
  514
- Awd / 2Wd Switch (no Turf Mode)
  515
- Seat Belt Switch
  515
- Brake Pressure Switch
  516
- Transmission / Gear Position Switch
  516
- Boost Control Solenoid / Valve
  517
- Suspension Mode Switch (Dynamix Models)
  517
- Steering Angle Sensor Centering (Dynamix)
  518
- Ignition Coil
  519
- Ignition Coil / Ht Lead Replacement
  519
- Ignition Coil Tests
  519
- Operation Overview
  519
- Charging System
  520
- Charging System "Break Even" Test
  520
- Current Draw - Key off
  520
- Stator Testing
  521
- Test 1: Resistance Value of each Stator Leg
  521
- Regulator / Rectifier (Dynamix)
  522
- Regulator Replacement
  522
- Test 3: Measure Ac Voltage Output of each Stator Leg at Charging Rpm
  522
- Battery
  524
- Battery Specifications
  524
- General Battery Information
  524
- Battery Installation
  525
- Battery Removal
  525
- Battery Conductance Analyzer
  526
- Battery off Season Storage
  526
- Battery Testing
  526
- Load Test
  526
- Ocv - Open Circuit Voltage Test
  526
- Charging Procedure
  527
- Headlamp Replacement
  528
- Headlight Adjustment
  528
- Lighting System
  528
- Dash Light
  529
- Headlamp Installation
  529
- Taillight Replacement
  529
- Cooling Fan Description and Operation
  530
- Cooling Fan Testing
  530
- Cooling System
  530
- Cooling Fan Replacement
  531
- Fan Control Circuit Bypass Test
  531
- Bleeding
  533
- Electric Coolant Pump
  533
- Replacement
  533
- Ect Sensor Test
  534
- Starter Solenoid Bench Test
  535
- Starter Solenoid Operation
  535
- Starter Solenoid Replacement
  535
- Starting System
  535
- Electronic Power Steering (Eps)
  536
- Eps Operation
  536
- Proper Eps System Diagnosing
  536
- Relay / Fuse Details
  540
- Voltage Regulator Fusible Link
  541
- Can System
  542
- Can System Overview
  542
- Can System Testing
  542
- Electrical Harness Routing
  543
- Wiring Harness
  543
- Electrical Harness Retention
  544
- Electrical Harness Retention (4-Seat)
  546
- Wiring Harness Replacement
  547
- Break-Out Diagram Viewing
  548

Advertisement

Advertisement

Related Products

Polaris Categories

Offroad Vehicle Swimming Pool Vacuum Utility Vehicle Automobile Accessories Snowmobiles

More Polaris Manuals