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

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Table of Contents

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2020 RZR PRO XP / XP 4
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2019 (PN 9930583 R02)
© Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product
information at the time of publication. Due to constant improvements in the design and quality of production
components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be
accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within,
whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RZR PRO XP 2020

  • Page 1 Publication Printed September 2019 (PN 9930583 R02) © Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 3 REVISION INDEX DATE CHANGES – Preliminary 08/01/2019 Initial Release. 09/24/2019 4-Seat model information added. PVT System Special Tools list updated. 10/23/2019...
  • Page 4 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
  • Page 5 2020 RZR PRO XP / XP 4 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: ENGINE ELECTRICAL CHAPTER 5: EFI / FUEL SYSTEM CHAPTER 6: PVT SYSTEM CHAPTER 7: TRANSMISSION CHAPTER 8: FINAL DRIVE...

  • Page 7: Table Of Contents

    ........... . .1.40 POLARIS MOBILE DIGITAL WRENCH® (PMDW) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual ©...
  • Page 8 ................1.74 TESTING VOLTAGE DROP 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 9: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018; K=2019; L=2020 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 10: Reference Information

    NOTICE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www. polaris.com or purchased from www.purepolaris.com. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 11: 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 12 PU-47471 PU-48951 Fuel Pressure Adapter Water Pump Drive & Fuel Pressure Gauge Smartlink Module Kit CV Boot Clamp Pliers Flywheel Removal (Stepless) Tool 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 15: Master Torque Table

    33 ft-lbs (45 Nm) (Upper) 9 ft-lb (12 Nm) EPS to Lower Steering Shaft Crankcase Bolts 22 ft-lbs (30 Nm) 26 ft-lb (35 Nm) Fastener 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 16 26 ft-lb (35 Nm) Seat Frame Fastener (Front) M10 37 ft-lbs (50 Nm) Mounting x 1.5 x 16 Oil Pump 7 ft-lbs (10 Nm) Bolts 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 Steering Column Mounting Impeller (Apply Loctite® 33 ft-lbs (45 Nm) Impeller Fasteners 204™ to bolt Steering Rack Mounting Bolts 44 ft-lbs (60 Nm) threads) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 18 22 in-lb ( 3 Nm) Winch Cover Fastener Winch Mounting Plate Fasteners 18 ft-lbs (24 Nm) Wheel Lug Nuts 120 ft-lbs (163 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.12 © Copyright Polaris Industries Inc.

  • Page 19: Vehicle Specifications

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 20: 2020 Rzr Pro Xp Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: 2020 Rzr Pro Xp 4 Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 23: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.17 © Copyright Polaris Industries Inc.

  • Page 24: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: 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″ 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.19 © Copyright Polaris Industries Inc.

  • Page 26: General Diagnostics

    Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.20 © Copyright Polaris Industries Inc.

  • Page 27: Guided Symptom References

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

  • Page 28: Engine And Drivability Diagnostic Procedures

    • Connect to Digital Wrench®. Check codes and continue with Digital Wrench® Guided diagnosis. • If no codes are present, proceed to step 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.22 © Copyright Polaris Industries Inc.
  • Page 29 • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.25 for more information. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.23 © Copyright Polaris Industries Inc.
  • Page 30 These concerns may also be caused by a mechanical failure. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.24...

  • Page 31: Engine Cranks But Does Not Start

    • Unusual noise could suggest that there may be a mechanical engine concern. Proceed to step 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.25 © Copyright Polaris Industries Inc.
  • Page 32 – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.26 © Copyright Polaris Industries Inc.

  • Page 33: No Crank No Start Or Slow Crank

    (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake Switch operation. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.27 © Copyright Polaris Industries Inc.

  • Page 34: Over Heating

    • Check level and correct as necessary. Check maintenance history to determine if oil need to be changed. 7. Check Cooling Fan operation. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.28 © Copyright Polaris Industries Inc.

  • Page 35: Warning Lights

    • Refer to Over Heating page 1.28 for more info. 4. PERFORMANCE LIMITED Light. • Check for codes using Digital Wrench. Refer to Guided Diagnostic for further diagnosis. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.29 © Copyright Polaris Industries Inc.

  • Page 36: Engine Troubleshooting

    • Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.30 © Copyright Polaris Industries Inc.
  • Page 37 / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 38: Cooling Troubleshooting

    • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.32 © Copyright Polaris Industries Inc.

  • Page 39: Digital Wrench

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

  • Page 40: Digital Wrench® Software Installation And Updates

    PC, skip this section and proceed to “Installing a New available, do the following: Digital Wrench® Base Version”. 1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com). NOTICE If you are using Internet Explorer, do NOT select “Run”.

  • Page 41: Digital Wrench® Communication Errors

    VERSION To install a new Digital Wrench® Base Version, do the following: 1. Open a web browser and log on to your Polaris dealer website (www.polarisdealers.com). 2. From the Service and Warranty drop-down, select Digital Wrench, and then click Digital Wrench Base Version Installer.

  • Page 42: Digital Wrench® Serial Number Location

    2. On the Digital Wrench® main screen, select the ‘Configure the Diagnostic System Software’ menu icon. 3. Locate the serial number on the right side of the System Configuration screen. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.36 © Copyright Polaris Industries Inc.

  • Page 43: Digital Wrench® Feature Map

    Access the Digital Wrench® and adjustment functions System Help. service reports. Print the current screen as a Open the ASSERT ASK formatted printout. form. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.37 © Copyright Polaris Industries Inc.
  • Page 44 GENERAL INFORMATION 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.38 © Copyright Polaris Industries Inc.

  • Page 45: Engine Controller Reprogramming (Reflash)

    – Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®. progress. 10. Open a web browser and log on to your Polaris dealer • Understand the Process website (www.polarisdealers.com). Review the Digital Wrench® System Help before you 11.

  • Page 46: Polaris Mobile Digital Wrench® (Pmdw)

    PMDW app and the WVL. See the user’s guide for a complete list of compatible vehicles. You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download.

  • Page 47: General Information

    0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present). 5. Press MODE to exit to the settings menu. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.41 © Copyright Polaris Industries Inc.

  • Page 48: Master Trouble Code List

    Voltage Above Normal, Or Shorted To High Source P0108 Manifold Absolute Pressure Sensor Voltage Too Low P0107 Mechanical System Not Responding Or Out Of Adjustment P1106 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.42 © Copyright Polaris Industries Inc.
  • Page 49 Data Valid But Above Normal Operating Range - Moderately Severe P1571 Level Data Valid But Below Normal Operating Range - Moderately Severe P1573 Level 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.43 © Copyright Polaris Industries Inc.
  • Page 50 Camshaft Position Sensor Abnormal Frequency Or Pulse Width Or Period P0340 Voltage Above Normal, Or Shorted To High Source P1739 Tachometer Driver Circuit 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.44 © Copyright Polaris Industries Inc.
  • Page 51 Wheel Speed Sensor (Rear or Voltage Above Normal, Or Shorted To High Source C113D Rear Left) Voltage Below Normal, Or Shorted To Low Source C123D 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.45 © Copyright Polaris Industries Inc.
  • Page 52 Current Below Normal Or Open Circuit P0685 Voltage Above Normal P0694 1557 Fan Driver 2 Voltage Below Normal, Or Shorted To Low Source P0693 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.46 © Copyright Polaris Industries Inc.
  • Page 53 ECU Output Supply Voltage 3 3599 Voltage Above Normal, Or Shorted To High Source P17AA Voltage Below Normal, Or Shorted To Low Source P17AB 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.47 © Copyright Polaris Industries Inc.
  • Page 54 Voltage Above Normal, Or Shorted To High Source P1682 520206 Reverse Alarm Voltage Below Normal, Or Shorted To Low Source P1683 Current Below Normal Or Open Circuit P1681 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.48 © Copyright Polaris Industries Inc.
  • Page 55 Voltage Below Normal, Or Shorted To Low Source C1021 520260 ABS Motor Current Above Normal Or Grounded Circuit C101E Mechanical System Not Responding Or Out Of Adjustment C0020 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.49 © Copyright Polaris Industries Inc.
  • Page 56 Throttle Angle Not Plausible Condition Exists P1531 520306 ECU ADC Fault - No Load Condition Exists P1532 ECU ADC Fault - Voltage 520307 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.50 © Copyright Polaris Industries Inc.
  • Page 57 Data Valid But Below Normal Operating Range - Least Severe Level P151F Engine Oil Pressure Sensor/Switch 524076 Bad Intelligent Device Or Component C106C EPS Fault Lamp Driver Circuit 524085 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.51 © Copyright Polaris Industries Inc.
  • Page 58 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.52 © Copyright Polaris Industries Inc.

  • Page 59: Cylinder Misfire Detection

    Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.53 © Copyright Polaris Industries Inc.

  • Page 60: Fluid Leaks

    Refer to the Service Manual information related to the system in question. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.54 © Copyright Polaris Industries Inc.

  • Page 61: Fuel System Diagnostics

    • Intake air leak (throttle shaft, intake ducts, air box cover) • Spark plug erosion / fouling • Engine runs hot • Surging • High / Erratic idle 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.55 © Copyright Polaris Industries Inc.
  • Page 62 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.56 © Copyright Polaris Industries Inc.

  • Page 63: Pvt System Diagnostics

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.57 © Copyright Polaris Industries Inc.
  • Page 64 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.58 © Copyright Polaris Industries Inc.

  • Page 65: Pvt System Overheating / Diagnosis

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

  • Page 66: Transmission Diagnostics

    • If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.60 © Copyright Polaris Industries Inc.

  • Page 67: Final Drive Diagnostics

    Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.61 © Copyright Polaris Industries Inc.

  • Page 68: Brake System Diagnostics

    • Residue build up under caliper seals • Parking brake lever incorrectly adjusted (INT’L Model) • Operator riding brakes • Brake pedal binding or unable to return fully 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.62 © Copyright Polaris Industries Inc.

  • Page 69: Poor Brake Performance

    • Alignment of caliper to disc • Failed brake hose / line • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.63 © Copyright Polaris Industries Inc.

  • Page 70: Steering / Suspension Diagnostics

    Check wiring from Connector to Ignition Switch 12 VDC on Pin 3 of the 8 pin EPS Connector? Circuit ↓ Begin Digital Wrench EPS Troubleshooting Procedure 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.64 © Copyright Polaris Industries Inc.

  • Page 71: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    MIL lamp Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.65 © Copyright Polaris Industries Inc.

  • Page 72: Eps Troubleshooting (Using Digital Wrench®)

    If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.66 © Copyright Polaris Industries Inc.

  • Page 73: Shock Analysis

    (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.67 © Copyright Polaris Industries Inc.

  • Page 74: Electrical Diagnostics

    • All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.71 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) DYNAMIC TESTING for electrical testing.

  • Page 75: Connector Probing Guidelines

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

  • Page 76: Testing Continuity / Resistance

    1.71 page 1.72 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.70 © Copyright Polaris Industries Inc.

  • Page 77: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.71 © Copyright Polaris Industries Inc.

  • Page 78: Testing For Intermittent Conditions

    Failure to do so can lead to Serious injury and/or damage to the machine. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.72 © Copyright Polaris Industries Inc.

  • Page 79: Current Draw - Key Off

    Damage will occur to electrical components. CAUTION Charging system damage will occur if incompatible components are installed. Always reference Polaris Electric Parts Catalog for proper part numbers. NOTICE Wait ten minutes with the key off for the ECU to power down.

  • Page 80: Testing Voltage Drop

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 1.74 © Copyright Polaris Industries Inc.
  • Page 81 ...............2.47 TRANSMISSION OIL CHANGE 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 82 ................. . .2.56 SPARK PLUG SERVICE 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 83: Maintenance

    U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 16 oz (12) 2870652 Fuel Stabilizer 2872280 2.5 gal (2) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 84: Pre-Ride Inspection

    Wheels / Lug Nuts • Verify proper lug nut torque • Inspect cable / line and switch Winch (if equipped) • Ensure operation 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 85: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual...
  • Page 86 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual...
  • Page 87 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual...
  • Page 88 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual...
  • Page 89 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual...
  • Page 90 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.10...
  • Page 91 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.11...
  • Page 92 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.12...
  • Page 93 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.13...
  • Page 94 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.14...
  • Page 95 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.15...
  • Page 96 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.16...
  • Page 97 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.17...
  • Page 98 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.18...
  • Page 99 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.19...
  • Page 100 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.20...
  • Page 101 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.21...
  • Page 102 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.22...
  • Page 103 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.23...
  • Page 104 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 105: Maintenance Quick Reference

    - Front-Left Side of Cargo Box coolant every two years Coolant * More often under severe use, such as operation in water or under severe loads. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.25 © Copyright Polaris Industries Inc.
  • Page 106 Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 107: Grease Lubrication Points

    Polaris Premium U-Joint thoroughly washing or Propshaft Yokes Grease fittings on the slip yoke Grease submerging the vehicle 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 108: Engine / Exhaust

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

  • Page 109: Engine Oil And Filter Change

    15 seconds before removing the oil dipstick. crankcase with a clean rag and ensure the original oil filter o-ring is not stuck to the crankcase. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 110: Engine Crankcase Breather Hose

    18. When finished, reinstall dipstick and lock the lever. 19. Reinstall the cargo box, engine service panel and seats. 20. Dispose of used oil, filter and rags properly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 111: Valve Clearance Adjustment

    3-digit tappet number. 9. Refer to Valve Lash - Tappet Selection page 3.101 and select the proper tappet. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 112: Cam Chain Tensioner Inspection

    Camshaft Installation / Timing page move freely, replace the tensioner assembly. 5. Retract the plunger all the way in and install into the cylinder. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 113: Spark Arrestor

    8 ft-lb (11 Nm) change. 1. Remove the spark arrestor retaining fasteners 2. Remove the arrestor from the end of the muffler. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 114: Heat Shield Inspection

    Engine Shield Silencer Shield Rear Close-Off Shield Front Head Pipe Shield Inner Head Pipe Shield Upper Turbo Shield Inlet Shield Lower Turbo Shield 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 115: Cooling System

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

  • Page 116: Cooling System Pressure Test

    Turbo Inlet Hose Turbo Outlet Hose Cylinder Head Vent Hose 3. Check tightness and condition of all hose spring clamps. Replace if necessary. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 117: Radiator Inspection / Cleaning

    9. Fill the reservoir to the FULL COLD line. 10. Proceed to bleed the cooling system. See Cooling System Bleeding. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 118: Cooling System Bleeding

    5. Place a drain pan below the engine to catch any coolant out of the engine bleed hole. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.38 © Copyright Polaris Industries Inc.
  • Page 119 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 120: Fuel System And Air Intake

    NOTICE Check throttle pedal periodically. Make sure vent line is not kinked or pinched. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 121: Engine Intake Pre-Filter Service

    Compressed air or high pressure hose may damage the frog skin pre-filter on the intake. 4. Pull cover outward far enough to remove air filter 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.41 © Copyright Polaris Industries Inc.
  • Page 122 Be sure the lower tabs on the air box cover are properly engaged into the air box. 8. Engage the cover latches. 9. Reinstall rear close off panel and seats. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 123: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 124: Front Gearcase Lubrication

    The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.44 © Copyright Polaris Industries Inc.

  • Page 125: Drive Shaft Boot Inspection

    5. Remove the wheel nuts and remove the wheel. CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.45 © Copyright Polaris Industries Inc.

  • Page 126: Tire Inspection

    TIRE PRESSURE SPECIFICATION (COLD) MODEL FRONT REAR 10 PSI 20 PSI RZR Pro XP (69 kPa) (138 kPa) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.46 © Copyright Polaris Industries Inc.

  • Page 127: Transmission

    4. Reinstall the fill plug and torque to specification. 8. Check for leaks. Dispose of used lubricant properly. TORQUE Transmission Fill / Drain Plug: 14 ft-lbs (19 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.47 © Copyright Polaris Industries Inc.

  • Page 128: Steering

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

  • Page 129: Wheel Toe Alignment Inspection

    3. Measure the distance between the marks and record the measurement. Call this measurement MEASUREMENT Wheel Toe: 1/4” (6.35 mm) toe-in – 1/4” (6.35 mm) toe-out 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.49 © Copyright Polaris Industries Inc.

  • Page 130: Wheel Toe Adjustment

    • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified. MEASUREMENT Wheel Toe: 1/4” (6.35 mm) toe-in – 1/4” (6.35 mm) toe-out 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.50 © Copyright Polaris Industries Inc.

  • Page 131: Suspension

    Inspect stabilizer bar and stabilizer bar bushings for damage/wear. Ensure the shocks are not leaking oil. especially around the shock caps and shaft seals. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.51 © Copyright Polaris Industries Inc.

  • Page 132: Suspension Lubrication

    Refer to Grease Lubrication Points page suspension lubrication. NOTE NOTICE Polaris does not recommend increasing the spring There are no grease fittings on the front control arm adjustment by more than one inch (25.4 mm) over the pivot points or the rear trailing arms.

  • Page 133: Shock Compression Adjustment (Walker Evans™)

    WALKER EVANS™ 2.5" REAR SHOCK: COMPRESSION ADJUSTMENT TABLE SETTING COMPRESSION DAMPING Full counter-clockwise position Softest Factory 8 clicks from softest position Full clockwise position Firmest 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.53 © Copyright Polaris Industries Inc.

  • Page 134: Brake System

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.54 © Copyright Polaris Industries Inc.

  • Page 135: 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) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.55 © Copyright Polaris Industries Inc.

  • Page 136: Electrical And Ignition System

    STORAGE plugs. Refer to Charging Procedure page 12.26 and Battery Off Season Storage page 12.25 in the electrical chapter. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.56 © Copyright Polaris Industries Inc.
  • Page 137 A wire brush or coated abrasive should not be used. 8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.57 © Copyright Polaris Industries Inc.
  • Page 138 MAINTENANCE NOTES 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 2.58 © Copyright Polaris Industries Inc.
  • Page 139 ............3.44 CRANKSHAFT PTO SEAL REPLACEMENT 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 140 ENGINE ASSEMBLY - TOP END ................3.92 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 141 ................3.102 VALVE COVER INSTALLATION 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 142: General Information

    PU-50625 Flywheel Holding Tool PU-51220 Valve Spring Compressor PV-1253 Valve Spring Compressor Adapter PV-43513-A Oil Pressure Gauge PV-43531 Piston Ring Compressor Pliers PV-43570-1 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 143: Oil Pressure Test

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

  • Page 144: Oil Flow Chart

    ENGINE / COOLING SYSTEM OIL FLOW CHART 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 145: 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° 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 146 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 147: 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) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 148 (10 Nm) STATOR COVER HEAD PIPE / TURBO Exhaust Head Pipe Stator Cover Bolts 9 ft-lb (12 Nm) 18 ft-lb (24 Nm) Fasteners 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 149: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 150: Engine Air Intake Assembly View

    Throttle Body Bolts Torque in sequence to 7 ft-lb (10 Oetiker Clamp 7 ft-lb (10 Nm) Engine Breather Hose Throttle Body Gasket Intake Manifold 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 151: Air Box Removal

    4. Remove two fasteners retaining the air box. 5. Lift air box upward to disengage lower mounting tabs and remove air box from vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 152: 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) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 153: Muffler Removal

    4. Pull muffler towards the rear of the vehicle to remove it from the mounting grommets. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 154: Exhaust Pipe Removal

    4. Remove upper and lower rear close off panels. 8. Remove two fasteners retaining the heat shield above the oxygen sensor location. 5. Remove the right rear shock assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.16 © Copyright Polaris Industries Inc.
  • Page 155 11. Remove four fasteners retaining exhaust pipe to the turbo. Remove exhaust pipe. NOTICE Front head pipe shields hidden for image clarity. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 156: Head Pipe / Turbo Removal

    IMPORTANT The oil line sealing washers MUST be replaced any time the oil line/fitting is removed. Use only the recommended washers shown in the Polaris Electronic Parts Catalog. 4. Remove two fasteners and remove the coolant inlet hose and outlet hose 8.

  • Page 157: Head Pipe / Turbo Installation

    4. Install the fasteners retaining the turbo to the mounting bracket. Torque fasteners to specification. TORQUE Turbocharger Mounting Fasteners: 18 ft-lb (24 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.19 © Copyright Polaris Industries Inc.
  • Page 158 The oil line sealing washers MUST be replace any time 18 ft-lb (24 Nm) the oil line/fitting is removed. Use only the recommended washers shown in the Polaris Electronic 14. Connect O2 sensor harness. Parts Catalog. 15. Install the right rear shock assembly. Torque fasteners to specification.

  • Page 159: Exhaust Pipe Installation

    Exhaust Pipe to Turbo Fasteners: 18 ft-lb (24 Nm) Exhaust Pipe to Muffler Fasteners: 18 ft-lb (24 Nm) Rear Shock Fasteners: 70 ft-lbs (95 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.21 © Copyright Polaris Industries Inc.

  • Page 160: Turbocharger Service

    Ensure the oil drain hose located between the turbocharger and oil pan is not kinked or obstructed in any way. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 161 10. Look for any signs of contact between the turbine wheel and the turbine housing profile. Check for any damage or deformation of the turbine exducer blades. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.23 © Copyright Polaris Industries Inc.
  • Page 162 If an excessive amount of oil is present in the compressor inlet, the source of oil is likely related to the crankcase ventilation system. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.24 © Copyright Polaris Industries Inc.

  • Page 163: Actuator / Wastegate Inspection

    5. With the use of an air regulator and pressure gauge, attach an air supply line to the actuator pod pressure reference port, located on the top of the canister. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.25 © Copyright Polaris Industries Inc.

  • Page 164: Actuator Pod Removal

    1. Locate the actuator rod heim joint, located opposite to Actuator Rod Heim Joint Fasteners: the actuator pod. 7 ft-lb (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.26 © Copyright Polaris Industries Inc.

  • Page 165: Oil Drain Tube Service

    IMPORTANT The O-ring must be properly in place before installing the drain tube on the turbocharger to prevent an oil leak. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.27 © Copyright Polaris Industries Inc.

  • Page 166: Wastegate Flapper Inspection

    9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 167 EXHAUST Inspect the exhaust system for: • Clogged spark arrestor. • Damaged catalytic converter (use inspection mirror or borescope). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.29 © Copyright Polaris Industries Inc.

  • Page 168: Cooling System

    ENGINE / COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM FLOW 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 169: Cooling System Specifications

    Engine Protection Forced Idle 239° F (115° C) water pump weep hole for leakage. Engine Protection Shutdown 246° F (119° C) & Overheat Indicator Flashes 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.31 © Copyright Polaris Industries Inc.

  • Page 170: Charge Air Cooler Removal

    4. Remove the cargo box. 9. Remove the two fasteners retaining the fuel rail to the intake manifold. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 171 12. Loosen the clamps retaining the intake manifold to the engine. 13. Carefully remove the intake manifold out the passenger side of the vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 172: Charge Air Cooler Installation

    Intake Manifold Clamps: the transmission. Torque fasteners to specification. 6 ft-lb (8 Nm) TORQUE Intake Manifold Mounting Fasteners (lower): 20 ft-lb (27 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 173 16. Run the vehicle for several minutes and check the coolant level. Refill as required. 11. Install zip ties retaining the wiring harness around the intake manifold 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 174: Radiator Replacement

    6. Remove two large hoses and one vent line from the charge air radiator and remove charge air radiator from the vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 175: Thermostat Replacement

    7. Install thermostat cover. Torque fasteners to specification. TORQUE Thermostat Cover Fasteners: 7 ft-lb (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 176: Water Pump Service

    6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.38 © Copyright Polaris Industries Inc.
  • Page 177 12. Fully install the water pump shaft and two washers into the housing. 13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.39 © Copyright Polaris Industries Inc.
  • Page 178 WATER PUMP ASSEMBLY VIEW Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.40 © Copyright Polaris Industries Inc.

  • Page 179: Engine Service

    / stud. 9. Remove the starter from the engine. NOTICE Tilt the engine slightly forward to gain enough clearance to remove the starter. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 180: Starter Motor Installation

    STEP 4: Torque to 37 ft-lbs (50 Nm). STEP 5: Torque to 50 ft-lbs (68 Nm). STEP 6: If previously removed, torque to 37 ft-lbs (50 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 181: Front Engine Mount Isolator Replacement

    3. Remove the fasteners retaining the isolator mounts to the frame. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.43 © Copyright Polaris Industries Inc.

  • Page 182: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.44 © Copyright Polaris Industries Inc.
  • Page 183 5. Test drive the vehicle and recheck for leaks before putting back into service. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 184: Engine Removal

    IMPORTANT The oil line sealing washers MUST be replaced any time the oil line/fitting is removed. Use only the recommended washers shown in the Polaris Electronic 4. Remove cargo box, rear fascia and rear bumper. Parts Catalog. Disconnect rear light electrical harness from aluminum cross member.
  • Page 185 21. Disconnect TBAP, both TMAP sensors, CPS, coolant temp sensor, Trans switch, speed sensor, injectors, ETC. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.47 © Copyright Polaris Industries Inc.
  • Page 186 29. Remove secondary clutch, belt, and primary clutch. 30. Remove six fasteners and remove the inner PVT cover baffle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.48 © Copyright Polaris Industries Inc.
  • Page 187 34. Discard PVT inner cover o-ring around the crankshaft snout. 2#2$ 35. Remove fasteners retaining engine to the engine mount bracket. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 188: Engine Installation

    5. Loosely install the three allen screws and washers retaining inner cover to engine. TORQUE Inner PVT Cover Baffle Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.50 © Copyright Polaris Industries Inc.
  • Page 189 Rear Fender/Fender Flare Fasteners: 7 ft-lbs (10 Nm) 22. Install cargo box. Torque fasteners to specification. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.51 © Copyright Polaris Industries Inc.

  • Page 190: Cam Chain Tensioner Service

    1. Lubricate the rack on the tensioner with white lithium grease. 2. Remove the spring retainer bolt and push the adjuster all the way in. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.52 © Copyright Polaris Industries Inc.
  • Page 191 NOTICE The tensioner will automatically adjust to the proper tension once the spring and retainer are installed. No further adjustment is required. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 192: Engine Disassembly / Inspection - Top End

    3. If tearing down the top end of the engine, remove the spark plugs. Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 193: Camshaft Sprocket Inspection

    Replace timing chain and sprockets if worn or damaged. 6. Rotate the engine to allow access to the remaining bolt on each camshaft sprocket. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 194: Camshaft / Camshaft Bore Inspection

    Exhaust: 1.5772 - 1.5803" (40.06 - 40.14 mm) 1.5752" (40.01 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.56 © Copyright Polaris Industries Inc.
  • Page 195 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) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 196: Cylinder Head Removal

    6. Tap cylinder head lightly with a soft faced hammer until loose. CAUTION Tap only in reinforced areas or on thick parts of the cylinder head casting. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 197: Cylinder Head Disassembly

    8. Clean the combustion chamber and head gasket surface. 2. Compress the valve spring by hand using valve spring compressor adapter PV-43513-A 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 198: Valve Inspection

    4. Check the end of the valve stem for flaring, pitting, wear or damage. MEASUREMENT Valve Guide I.D.: .2165 - .2171" (5.500 - 5.515 mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 199: Combustion Chamber Cleaning

    1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.61 © Copyright Polaris Industries Inc.
  • Page 200 This is normal and should not cause valve leakage. Both valves shown are acceptable and would not require replacement. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.62 © Copyright Polaris Industries Inc.
  • Page 201 12. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 202: Engine Disassembly / Inspection - Bottom End

    / installation process or injury could result. 2. Carefully pry the stator cover off the engine using the two pry areas as shown below. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 203: Water Pump Housing Removal

    4. Using a commercially available strap wrench, hold the flywheel and remove the flywheel retaining bolt 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 204: Starter One-Way Clutch Disassembly

    9. Inspect the one-way gear bushing for wear or galling. If service is required, refer to Starter One-way Clutch Disassembly page 3.66. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.66 © Copyright Polaris Industries Inc.

  • Page 205: Crankcase Disassembly

    7. Remove the sump cover from the crankcase. 2. Remove the crankcase drain plug to drain any oil remaining in the engine. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.67 © Copyright Polaris Industries Inc.
  • Page 206 Access the sprocket bolt by removing the case plug. 13. Rotate the engine so the cylinder is facing up. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 207: Balance Shaft Removal / Inspection

    Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.69 © Copyright Polaris Industries Inc.

  • Page 208: Crankshaft Removal / Inspection

    4. Carefully lift the crankshaft out of the crankcase. 5. Remove the cam chain , PTO main seal and oil pump drive chain from the crankshaft. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.70 © Copyright Polaris Industries Inc.
  • Page 209 Main (40.996 - 41.004 mm) Bearing 1.6129" (40.970 mm) Service Limit Connecting 1.7715 - 1.7717" Standard Rod Bearing (44.995 - 45.002 mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 210: Crankcase Inspection

    4. Be sure oil passages are clean and free of any page 3.79 and Crankshaft Main Bearing Selection cleaning solvent. page 3.80 procedures. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 211: Cylinder / Piston Removal

    NOTICE Always replace plain bearings when the crankcase or connecting rods have been disassembled. Refer to Crankshaft Main Bearing Selection page 3.80. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 212: Cylinder Inspection

    3.6614 ± .0003" (93 mm ± 0.008 mm) Cylinder Taper: Service Limit: .001″ (0.025 mm) Cylinder Out of Round: Service Limit: .001″ (0.025 mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.74 © Copyright Polaris Industries Inc.

  • Page 213: Piston Disassembly / Inspection

    DO NOT apply heat to piston rings or a loss of radial .8659 - .8661" (21.995 - 22.000 mm) tension could result. Service Limit: .8651" (21.975 mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 214: Piston Ring Removal

    A difference between top and bottom end gap measurements is a general indication of cylinder taper (wear). The cylinder should be measured for taper and out of round. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.76 © Copyright Polaris Industries Inc.

  • Page 215: Piston To Cylinder Clearance

    Piston O.D. (Standard): 3.6597 ± .0003" (92.959 ± 0.008 mm) MEASUREMENT Piston to Cylinder Clearance: .0009 - .0019" (0.025 - 0.050 mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 216 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 217: Engine Assembly - Bottom End

    Green bearing for connecting rod journal and Yellow for connecting rod journal BEARING SELECTION CHART – ROD BEARINGS CRANKSHAFT Code White Blue White Yellow Blue White 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.79 © Copyright Polaris Industries Inc.

  • Page 218: Crankshaft Main Bearing Selection

    Blue bearing for Main #4 BEARING SELECTION CHART — MAIN BEARINGS Crankshaft Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 219: Piston Ring Installation

    6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.81 © Copyright Polaris Industries Inc.

  • Page 220: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 221: Piston / Cylinder Installation

    2. Verify that all ring end gaps are correctly located on each piston (see Piston Ring Installation page 3.81). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 222: Crankshaft Installation

    (PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft CRANKSHAFT INSTALLATION NOTICE Whether installing a new crankshaft or re-installing the original, refer to the bearing selection charts (see Crankshaft Main Bearing Selection page 3.80 and...

  • Page 223: Balance Shaft Installation

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

  • Page 224: Lower Crankcase Preparation

    LOWER CRANKCASE PREPARATION NOTICE Always replace plain bearings when the crankcase or 3. Apply Polaris PS-4 engine oil to the new bearings connecting rods have been disassembled. Refer to installed in the lower crankcase half. bearing selection procedures. 4. Clean crankcase mating surfaces to remove any oil.
  • Page 225 M8 Bolts: 26 ft-lb (35 Nm) M6 Bolts: 9 ft-lb (12 Nm) 13. Rotate the engine so the cylinder is facing up. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.87 © Copyright Polaris Industries Inc.
  • Page 226 18. Lift the oil pump drive chain and install the oil pump. oil. NOTICE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.88 © Copyright Polaris Industries Inc.
  • Page 227 27. Reinstall the oil cooler , if previously removed. Use new O-rings upon installation. Torque fasteners to specification. TORQUE Oil Cooler bolts: 7 ft-lb (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 228: Starter One-Way Clutch Assembly

    Replace crankshaft if surface damage is present. Clean taper of crankshaft to remove all oil or grease. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.90 © Copyright Polaris Industries Inc.

  • Page 229: Stator Cover Installation

    8. Install the starter torque limit gear as an assembly. 9. Proceed to Stator Cover Installation page 3.91. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.91 © Copyright Polaris Industries Inc.

  • Page 230: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.92 © Copyright Polaris Industries Inc.

  • Page 231: Valve Sealing Test

    5. Carefully set the cylinder head in place on alignment pins. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.93 © Copyright Polaris Industries Inc.

  • Page 232: Camshaft Installation / Timing

    Step 3: Additional 180° 3. Lubricate all camshaft lobes and bearing journal Step 4: Additional 180° surfaces with Polaris PS-4 engine oil prior to installation. Step 5: M6 bolts: 7 ft-lb (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.94...
  • Page 233 (PU-50563) into the end of camshafts as shown. Use NOTICE an open-end wrench to rotate camshafts slightly. Use new sprocket retaining bolts upon assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.95 © Copyright Polaris Industries Inc.
  • Page 234 15. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.96...
  • Page 235 NOTICE The tensioner will automatically adjust to the proper tension once the spring and retainer are installed. No further adjustment is required. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.97 © Copyright Polaris Industries Inc.

  • Page 236: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.98 © Copyright Polaris Industries Inc.

  • Page 237: Valve Clearance Adjustment

    3-digit tappet number. 9. Refer to Valve Lash - Tappet Selection page 3.101 and select the proper tappet. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.99 © Copyright Polaris Industries Inc.
  • Page 238 15. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to Camshaft Installation / Timing page 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.100 © Copyright Polaris Industries Inc.

  • Page 239: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.101 © Copyright Polaris Industries Inc.

  • Page 240: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts in sequence to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 3.102 © Copyright Polaris Industries Inc.
  • Page 241 ..............4.14 OXYGEN SENSOR REPLACEMENT 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 242: Electronic Control Unit (Ecu)

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

  • Page 243: Etc Learn Procedure

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Fasteners: 24 in-lbs (3 N·m) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 244: Pressure Sensors

    (TMAP) fails. The TMAP sensor and the Boost Pressure Sensor may be interchanged for testing purposes as the sensors are the same. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 245: Air Temperature Sensor Data

    203° F (95° C) 212° F (100° C) 221° F (105° C) 230° F (110° C) 239° F (115° C) 248° F (120° C) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 246: Knock Sensor

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

  • Page 247: Crankshaft Position Sensor (Cps)

    CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage. 5. If the resistance is incorrect, follow the CPS Replacement page 4.8 procedure. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 248: 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-lbs (12 N·m) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 249: Electronic Throttle Control (Etc) / Throttle Body

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

  • Page 250: Etc / Throttle Body Replacement

    TORQUE ETC Housing Retaining Bolts: 7 ft-lb (10 Nm) Intake Boot Clamp: 49 in-lb (6 Nm) Body Fasteners: 8 ft-lb (11 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 251: Pedal Position Sensor (Pps)

    (see Chapter 4 – PPS Replacement assembly. page 4.12). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 252: Pps Replacement

    7. Torque the three mounting bolts to specification and connect the PPS harness connection. TORQUE Throttle Pedal Mounting fasteners: 18 ft-lbs (24 N·m) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 253: Oxygen Sensor

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 254: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 255 ................5.28 FUEL SENDER TEST 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 256: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 257: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 258: Efi Operation Overview

    During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 259: Efi Service Notes

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 260: Initial Priming / Starting Procedure

    NOTICE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 261: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 262: Fuel Injector Troubleshooting

    Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 263: Fuel Injector Replacement

    The retaining clip(s) should click when properly engaged. 12. Lightly lubricate the injector O-rings and reinstall the fuel rail / injector assembly into the engine intake. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 264 18. Reinstall the cargo box. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 265: Fuel Lines

    Fuel Vent Line Fuel Tank Strap Fuel Fill Fuel Tank Fasteners 15 ft-lbs (20 Nm) Fuel Tank Fuel Pressure Sensor Fuel Pump Assembly 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 266: Fuel System Assembly View (Evap)

    Fuel Pump Fuel Tank Vent Rollover Valve Fuel Pressure Sensor Fuel Tank Strap Check Valve Fuel Tank Fasteners 15 ft-lbs (20 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.12 © Copyright Polaris Industries Inc.
  • Page 267 8. Turn the key on to prime the system. Check for leaking at both ends of the fuel lines. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 268: Fuel Line Removal / Installation

    7. Turn the key on to prime the system. Check for leaking at each end of the fuel line. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 269: Fuel Line Routing

    EFI / FUEL SYSTEM FUEL LINE ROUTING Double Clip Retaining Clip Zip Tie Fuel Rail 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 270: Fuel Line Routing (Evap)

    EFI / FUEL SYSTEM FUEL LINE ROUTING (EVAP) Double Clip Retaining Clip Zip Tie Fuel Rail 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 271: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.17 © Copyright Polaris Industries Inc.
  • Page 272 2. Route the fuel vent line up and attach to two retaining clips 3. Route fuel vent line back and attach vent line to the fitting in the left shock support tube. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 273: Fuel Vent Line Routing (Evap)

    Loss of engine performance High exhaust temperatures. 1. Route fuel vent line under the shift cable and secure vent line using two double clips 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 274: Vent Line Termination Fitting

    The ears on the clip (arrows) will not hold properly once it is removed. 5. Route vent line up from the canister filter and attach to two retaining clips 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 275: Fuel Tank / Pump

    PFA Nut Fuel Pickup Filter (not serviceable) 70 ft-lbs (95 Nm) Fuel Supply PFA Gasket Fuel Pump Fuel Tank Vent Fuel Sender Float 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.21 © Copyright Polaris Industries Inc.

  • Page 276: Fuel Tank Removal / Installation

    5. Remove the lower floor panels. See Console and Lower Floor Removal page 11.21. 6. Disconnect the fuel pump electrical harness. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.22 © Copyright Polaris Industries Inc.
  • Page 277 35 in-lbs (4 Nm) TORQUE Shift Knob Fastener: 13 ft-lb (18 Nm) TORQUE Battery Cable Fasteners: 60 in-lbs (7 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.23 © Copyright Polaris Industries Inc.

  • Page 278: Fuel Pump Operation Overview

    3. Cover the fuel supply line connection at the fuel tank with a shop towel and disconnect the supply line from the fuel pump outlet. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.24 © Copyright Polaris Industries Inc.
  • Page 279 NORMAL to see fuel pressure fluctuations as the throttle varies. Pressure may briefly drop below 58 PSI (400 kPa) when the throttle is released on a running vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.25 © Copyright Polaris Industries Inc.

  • Page 280: Fuel Pump Replacement

    A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.26 © Copyright Polaris Industries Inc.
  • Page 281 Service Tool (PU-50326) and a calibrated torque wrench. TORQUE Fuel Pump PFA Nut: 70 ft-lbs (95 Nm) 19. Verify alignment of fuel pump and tank orientation marks. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.27 © Copyright Polaris Industries Inc.

  • Page 282: Fuel Sender Test

    6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to Fuel Pump Replacement page procedure. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 5.28 © Copyright Polaris Industries Inc.
  • Page 283 ...............6.25 DRIVEN CLUTCH ALIGNMENT 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 284: General Information

    TOOL DESCRIPTION PU-50518-A Drive Clutch Compressor PU-52422 Drive Clutch Puller PU-50578 Spider Jam Nut Socket PU-52944 Drive Clutch Holding Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 2020 RZR PRO XP CLUTCH CHART SHIFT DRIVE DRIVEN MODEL ALTITUDE WEIGHT SPRING...

  • Page 285: Pvt System Overview

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

  • Page 286: Drive Belt

    The driven clutch spreader tool is included with the vehicle’s tool kit 6. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 287: Belt Installation

    36 in-lbs (4 Nm) 6. Install PVT intake hose, and torque hose clamp specification. TORQUE PVT Intake Hose Clamp: 25 in-lbs (3 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 288: Drive Clutch Service

    The driven clutch spreader tool is included with the vehicle’s tool kit 5. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 289: Drive Clutch Assembly View

    Washer Spider Sheave Assembly Bushing Clutch Spacer Washer Needle Bearing Stationary Sheave Shift Weight Shift Weight Fastener 20 in-lb (2 Nm) Clutch Button 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 290 PVT SYSTEM DESCRIPTION TORQUE Washer Spider Pin Bushing Roller 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 291: Clutch Disassembly

    3. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 292: Button To Tower Clearance Inspection

    Do not pull on the outer fingers of the spider or damage may occur. Position 3 jaw puller in the positions shown 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 293: Roller Replacement

    Refer to Roller, Pin, and Thrust Washer Inspection page 6.10 procedure. 4. Install the roller buttons and verify smooth operation of the roller. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 294: Clutch Inspection

    Replace if worn or damaged. MEASUREMENT Thrust Washer Thickness: Standard: 0.030 – 0.040” (0.76 - 0.96 mm) Service Limit: 0.020” (0.50 mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.12 © Copyright Polaris Industries Inc.

  • Page 295: Drive Clutch Spring Inspection

    Refer to Bushing Service page 6.14 procedure. MEASUREMENT Drive Clutch Spring Height: 7044938: 3.76 in (95.43 mm)7045110: 4.60” (116.74mm)7045326: 3.83” (97.26mm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.13 © Copyright Polaris Industries Inc.

  • Page 296: Bushing Service

    9. Remove nut from puller rod and set aside. 10. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.14 © Copyright Polaris Industries Inc.
  • Page 297 (PN 5020634) into center of clutch cover. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 298: Clutch Assembly

    Belleville washer must be installed with dome facing the outer post. 1. Install two washers , needle bearing , and clutch spacer onto the stationary sheave in the order shown. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.16 © Copyright Polaris Industries Inc.

  • Page 299: Drive Clutch Installation

    8. Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 300 36 in-lbs (4 Nm) 10. Install PVT intake hose, and torque hose clamp specification. TORQUE PVT Intake Hose Clamp: 25 in-lbs (3 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 301: Driven Clutch Service

    The driven clutch spreader tool is included with the vehicle’s tool kit 5. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.19 © Copyright Polaris Industries Inc.

  • Page 302: Driven Clutch Assembly View

    Moveable Sheave Bushing Helix Fasteners 32 ft-lbs (44 Nm) Driven Post E-Clip Stationary Sheave Roller Helix Washer Bushing Roller Pin Spring Spring Pin 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.20 © Copyright Polaris Industries Inc.

  • Page 303: Driven Clutch Disassembly

    The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 304: Helix And Movable Sheave Bushing Inspection

    2. From the bottom of the Helix, insert the new bushing and bushing adapter (PN 5020636) 3. Install the main adapter , spacer adapter, and securing nut on top of the Helix. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.22 © Copyright Polaris Industries Inc.

  • Page 305: Driven Clutch Assembly

    TORQUE Helix Fasteners: 32 ft-lbs (44 Nm) 6. Once back together, verify the alignment marks made during disassembly are properly aligned. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.23 © Copyright Polaris Industries Inc.

  • Page 306: Driven Clutch Installation

    7. Install the outer clutch cover and fourteen fasteners . Torque fasteners to specification. TORQUE Outer Clutch Cover Fasteners: 36 in-lbs (4 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 307: Driven Clutch Alignment

    A mobile device can be used to capture a picture of the belt tracking to determine if adjustment is needed. 4. Remove the drive belt. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.25 © Copyright Polaris Industries Inc.
  • Page 308 Drive Clutch Retaining Bolt: 140 ft-lbs (190 Nm) 10. Reinstall the drive belt and outer cover assembly. Refer to Belt Installation page 6.5. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 6.26 © Copyright Polaris Industries Inc.
  • Page 309 .........7.16 TRANSMISSION ASSEMBLY / SNORKEL GEAR BACKLASH 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 310: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 311: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 312: Shift Cable Adjustment

    5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTICE This procedure may require a few attempts to obtain the proper adjustment. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 313: Transmission Service

    13. Disconnect TBAP, both TMAP sensors, CPS, coolant temp sensor, Trans switch, speed sensor, injectors, ETC. 9. Remove both rear half shafts. See Rear Drive Shaft Removal page 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 314 21. Remove the belt, secondary clutch, and primary clutch. 22. Remove six fasteners and remove the inner PVT cover baffle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 315 26. Remove fasteners retaining inner cover to engine/ trans joint. Discard PVT inner cover o-ring around the crankshaft snout. 27. Remove the rear transmission isolator fasteners 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 316: Transmission Installation

    5. Loosely install the three allen screws and washers retaining inner cover to engine. TORQUE Inner PVT Cover Baffle Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 317 Rear Fender/Fender Flare Fasteners: 7 ft-lbs (10 Nm) 22. Install cargo box. Torque fasteners to specification. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 318: Transmission Vent Line Routing

    60 in-lbs (7 Nm) 2. The vent line routes rearward and attaches to the intake manifold and throttle body with Panduit straps 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 319: Transmission Disassembly

    6. Remove detent spring, detent pawl and detent star. Note the master spline on the detent star and the shift shaft. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.11 © Copyright Polaris Industries Inc.
  • Page 320 15. Remove the reverse shaft assembly the transmission cases will be damaged and leak oil 16. Remove the idler shaft assembly after it is reassembled. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.12 © Copyright Polaris Industries Inc.
  • Page 321 22. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.13 © Copyright Polaris Industries Inc.
  • Page 322 CAUTION Support the end face of the gear teeth when pushing the shaft through or damage to the gear teeth may occur. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.14 © Copyright Polaris Industries Inc.

  • Page 323: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 324: Transmission Assembly / Snorkel Gear Backlash

    Failure to properly clean the surfaces may lead and may have some tight spots. to transmission case leaks. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.16 © Copyright Polaris Industries Inc.
  • Page 325 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 326 ITEM DESCRIPTION Retaining Clip 13. Thoroughly clean the shift shaft housing. Washer Torsion Spring Drum 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 327 Install the nut and torque to specification. TORQUE Bell Crank Nut: 18 ft-lb (24 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.19 © Copyright Polaris Industries Inc.
  • Page 328 TRANSMISSION NOTES 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 329 ..................8.45 TIRE BALANCING 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 330: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 331: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 332: Front Bearing Replacement

    2. Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 333: Front Bearing Carrier Installation

    Install washers with TORQUE domed side out. Tie Rod End Fastener: 30 ft-lbs (40 Nm) + 90° 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 334: Rear Bearing Carrier Inspection / Removal

    120 ft-lbs (163 N·m) 11. Rotate wheel and check for smooth operation. 5. Remove two fasteners and remove the rear brake line guide 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 335 12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 336: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 337: Rear Bearing Carrier Installation

    TORQUE Bearing Carrier to Trailing Arm Bolts: 44 ft-lbs (60 Nm) Outer Radius Rod Fastener: 52 ft-lbs (70 Nm) + 90° 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 338 13. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. TORQUE Brake Line Guide Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 339: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 340: Front Drive Shaft Installation

    CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 341: Rear Drive Shaft Removal

    Discard cotter pin, castle nut, and cone washer. IMPORTANT Cotter pin, castle nut, and cone washer are not reusable. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 342: Rear Drive Shaft Installation

    Loctite® material or corrosion is present. 4. Apply Loctite® Primer 7649 to the hub assembly splines. Allow 90 seconds for the primer to dry. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.14 © Copyright Polaris Industries Inc.
  • Page 343 52 ft-lbs (70 Nm) + 90° 9. Install wheel and four wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 344: Drive Shaft / Cv Joint Handling Tips

    Refer to text for grease capacity of CV joints and CV joint boots. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 345: Cv Joint / Boot Replacement

    9. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 346: Inner Plunging Joint / Boot Replacement

    3. Remove the large circlip near the boot end of the plunging joint. 4. Clean the grease from the face of the joint. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.18 © Copyright Polaris Industries Inc.
  • Page 347 IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.19 © Copyright Polaris Industries Inc.
  • Page 348 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 349: Prop Shaft

    6. Disconnect front prop shaft from the rear prop shaft. Remove front prop shaft out through the bottom of the vehicle. 3. Remove driver’s seat. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.21 © Copyright Polaris Industries Inc.
  • Page 350 10. Remove the two fasteners retaining roll hoop to the frame. Remove roll hoop. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.22 © Copyright Polaris Industries Inc.
  • Page 351 30 ft-lbs (40 Nm) + 90° TORQUE Ball Joint Fasteners: 44 ft-lbs (60 Nm) TORQUE Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 352: Prop Shaft Removal / Installation

    Roll Pin Removal Tool: 2872608 NOTICE Right front wheel can be removed to gain better access to the prop shaft roll pin. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.24 © Copyright Polaris Industries Inc.
  • Page 353 9. Remove rear prop shaft through the bottom of the NOTICE vehicle. The prop shafts have a master spline and will only go on one way. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.25 © Copyright Polaris Industries Inc.
  • Page 354 30 ft-lbs (40 Nm) + 90° TORQUE Ball Joint Fasteners: 44 ft-lbs (60 Nm) TORQUE Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.26 © Copyright Polaris Industries Inc.

  • Page 355: Prop Shaft Assembly View

    FINAL DRIVE PROP SHAFT ASSEMBLY VIEW Support Bearing Front Prop Shaft Cross and Bearing Rear Prop Shaft Slip Yoke 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 356: Prop Shaft Assembly View (4-Seat)

    11 ft-lbs (15 Nm) Front Prop Shaft Slip Yoke Transmission-to-Prop Shaft Yoke Support Bearing Cross and Bearing Support Bearing Fasteners 30 ft-lbs (40 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.28 © Copyright Polaris Industries Inc.

  • Page 357: Support Bearing Replacement

    6. Install front prop shaft into the vehicle (see Prop Shaft Removal / Installation page 8.21). U-JOINT DISASSEMBLY CAUTION Always wear eye protection. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.29 © Copyright Polaris Industries Inc.

  • Page 358: U-Joint Assembly

    4. Force U-joint cross to one side and lift out of inner stiff or binding, tap the yoke lightly to center the joint yoke. until it pivots freely in all directions. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.30 © Copyright Polaris Industries Inc.

  • Page 359: Front Gearcase / Centralized Hilliard

    Drain Plug 10 ft-lbs (14 Nm) Bearing Fill/Check Plug 10 ft-lbs (14 Nm) Output Hub Cover Plate Screws 11 ft-lbs (15 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.31 © Copyright Polaris Industries Inc.

  • Page 360: Front Gearcase Vent Line Routing

    This means, the front drive will engage once the rear wheels have lost traction, and will remain engaged until the torque requirement goes away (i.e. rear wheels regain traction). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.32 © Copyright Polaris Industries Inc.

  • Page 361: Awd Diagnosis

    Should have a minimum of 11 VDC. 3. If electrical tests are within specification, remove gearcase (see “Front Gearcase Removal” outlined in this chapter) and inspect components. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.33 © Copyright Polaris Industries Inc.
  • Page 362 If the pole gap increases the coil will not be strong enough to engage the AWD system. If this is found, replace the cover plate assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 363: Front Gearcase Removal / Installation

    5. Remove four fasteners and remove the front fascia. 8. Remove four control arm bolts and remove control arms from sub frame bracket. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.35 © Copyright Polaris Industries Inc.
  • Page 364 33 ft-lbs (45 Nm) TORQUE Front Bumper Mounting Fasteners: 30 ft-lbs (40 Nm) TORQUE Front Bumper Cover Mounting Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.36 © Copyright Polaris Industries Inc.

  • Page 365: Front Gearcase Disassembly / Inspection

    2. Remove the nine cover screws and remove the cover plate assembly. 3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 366 9. Inspect the pinion gear for chipped, broken or missing housing. teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 367 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.39 © Copyright Polaris Industries Inc.

  • Page 368: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 5. Install the plastic ring onto the clutch housing. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.40 © Copyright Polaris Industries Inc.
  • Page 369 NOTICE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.41 © Copyright Polaris Industries Inc.
  • Page 370 Install the nine cover plate screws and torque to specification. TORQUE Cover Plate Screws: 11 ft-lbs (15 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.42 © Copyright Polaris Industries Inc.

  • Page 371: Wheel Hubs

    Cotter Pin Hub Castle nut Cone Washer 180 ft-lbs (244 Nm) Wheel Hub Brake Disc Wheel Studs Bearing Carrier Wheel Bearing Snap Ring 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.43 © Copyright Polaris Industries Inc.

  • Page 372: Rear Hub Assembly View

    Cotter Pin Hub Castle Nut Cone Washer 180 ft-lbs (244 Nm) Wheel Hub Brake Disc Wheel Studs Bearing Carrier Wheel Bearing Snap Ring 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.44 © Copyright Polaris Industries Inc.

  • Page 373: Tire Balancing

    Symptoms of an imbalanced, or improperly balanced tire include: • Steering wheel vibration • Seat or floorboard vibration • Excessive or uneven tread wear 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.45 © Copyright Polaris Industries Inc.
  • Page 374 FINAL DRIVE NOTES 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 8.46 © Copyright Polaris Industries Inc.
  • Page 375 ..............9.45 WALKER EVANS SHOCK SERVICE 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 376 ............9.63 SUSPENSION MODE SWITCH (DYNAMIX MODELS) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 377: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 378: Steering System

    30 ft-lbs (40 Nm) + 90° Steering Column Lower EPS Bracket Mounting Upper EPS Bracket Mounting Fasteners Fasteners 26 ft-lbs (35 Nm) 33 ft-lbs (45 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 379: Upper Steering Shaft Removal

    3. Lift the steering wheel up and remove the fasteners that retain the steering column. 4. Disconnect electrical harness from the C4 gauge. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 380: Steering Wheel Removal

    3. Remove the pinch bolt retaining the lower steering shaft to the power steering unit . 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 381: Lower Steering Shaft Removal

    Avoid spinning steering shafts after removing power steering unit from the vehicle. 3. Remove the power steering unit (see Power Steering Unit Removal page 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 382: Steering Rack Removal / Installation

    5. Lift up on the shaft and remove it through the floor panel. 5. Remove four fasteners and remove the front fascia. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 383 13. Remove gearcase fasteners and remove gearcase from vehicle. 14. Remove Steering shaft from Rack. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 384 180 ft-lbs (244 Nm) TORQUE Front Caliper Mounting Bolts: 33 ft-lbs (45 Nm) TORQUE Front Bumper Mounting Fasteners: 30 ft-lbs (40 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 385: Lower Steering Shaft Installation

    , reinstall it prior to vehicle installation. Torque the mounting bolts specification. TORQUE Power Steering Mounting Bolts: 30 ft-lb (41 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.11 © Copyright Polaris Industries Inc.
  • Page 386 3. Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.12 © Copyright Polaris Industries Inc.
  • Page 387 40 ft-lb (54 Nm) 3. Install the tilt shock and torque fastener to specification. TORQUE Tilt Shock Fastener: 7 ft-lb (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 388: Steering Shaft Bushing Replacement

    Install the lower portion of the steering shaft onto the power steering unit. Torque the lower pinch bolt to specification. TORQUE Steering Shaft Pinch Bolt: 25 ft-lb (34 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 389: Eps Pre-Positioning / Steering Angle Centering

    1. Connect vehicle to Digital Wrench, and select “Special Tests” menu. 1. Connect vehicle to Digital Wrench, and select “Special Tests” menu. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.15 © Copyright Polaris Industries Inc.
  • Page 390 3. Select option 2 at the next menu. 4. Follow instructions in Digital Wrench to properly center the EPS steering angle sensor. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 391: Front Suspension

    44 ft-lbs (60 Nm) Ball Joint Stabilizer Bar Link Fasteners 74 ft-lbs (100 Nm) Upper A-Arm Lower A-Arm A-Arm Fasteners 74 ft-lbs (100 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 392: Front A-Arm Removal / Installation

    10. If not replacing the A-arm, thoroughly clean the A-arm and pivot tube. INSTALLATION 1. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 393: Front Stabilizer Bar Replacement

    TORQUE Front Shock Mounting Bolts: 44 ft-lbs (60 Nm) 3. Remove the fasteners retaining the stabilizer bar link to the stabilizer bar. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 394: Ball Joint Service Preparation

    2. Place a proper sized driver on the ball joint and place the A-arm in a press. 3. Carefully press the ball joint out of the A-arm and discard the ball joint. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 395: Ball Joint Installation

    6. If the installed end gap of the retaining ring exceeds 5 mm, remove retaining ring, inspect and clean groove as necessary. Install a NEW retaining ring and repeat measurement. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 396: Rear Suspension

    74 ft-lbs (100 Nm) Stabilizer Bar Link Fasteners Trailing Arm Inner Radius Rod Fasteners 44 ft-lbs (60 Nm) 52 ft-lbs (70 Nm) + 45° 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 397: Trailing Arm Removal / Installation

    CAUTION Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.23 © Copyright Polaris Industries Inc.
  • Page 398 13. Remove the lower stabilizer bar linkage fastener trailing arm and bearing carrier. Discard the nut. 14. Support trailing arm with suitable jack stand or support. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 399: Trailing Arm Spherical Bearing Replacement

    7. Press in new bearing until fully seated into trailing arm casting. 8. Install new snap ring, O-rings (not required) and bushings. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 400: Radius Rod Removal / Installation

    Brake Line Guide Fasteners: 7 ft-lbs (10 Nm) WARNING Upon radius rod installation, test vehicle at low speeds before putting into service. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 401: Stabilizer Bar Removal / Installation

    Torque fasteners to specification (see below). 3. Torque all fasteners to specification (see below). 4. Lubricate stabilizer bar pivot bushings via grease fitting. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 402: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.28 © Copyright Polaris Industries Inc.

  • Page 403: Fox 2.5" Shock Information

    1.250 x 0.015 0.875 x 0.100 (Back Up) 1.100 x 0.015 0.950 x 0.015 0.0800 x 0.015 1.570 x 0.128 Top Out 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 404: Fox 3.0" Shock Information

    0.875 x 0.100 (Back Up) 1.350 x 0.015 1.250 x 0.015 1.100 x 0.015 0.950 x 0.015 0.800 x 0.015 1.570 x 0.128 Top Out 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.30 © Copyright Polaris Industries Inc.

  • Page 405: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 406: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.32 © Copyright Polaris Industries Inc.

  • Page 407: Fox Shock Disassembly

    STEERING / SUSPENSION FOX SHOCK DISASSEMBLY 1. Clamp the shock body securely in a vice. A training video is available on University of Polaris (https://lms.latitudelearning.com/home/main.aspx) for disassembly of Podium Internal Bypass shocks. Search for “Podium Internal Bypass Shock”. CAUTION Always wear safety glasses and read directions...
  • Page 408 The seal will be destroyed from the heat and must be replaced. 7. Hold cinch ring with spanner and rotate bearing assembly counter-clockwise to release pressure on retaining ring. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.34 © Copyright Polaris Industries Inc.
  • Page 409 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.35 © Copyright Polaris Industries Inc.
  • Page 410 26. Remove lock nut from the shaft assembly. 30. Remove compression valve stack and cable tie together. Clean with contact cleaner. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.36 © Copyright Polaris Industries Inc.
  • Page 411 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.37 © Copyright Polaris Industries Inc.
  • Page 412 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.38 © Copyright Polaris Industries Inc.
  • Page 413 STEERING / SUSPENSION 2.5 Bypass Piston 3.0 Bypass Piston Compression Side Compression Side Rebound Side Rebound Side 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.39 © Copyright Polaris Industries Inc.

  • Page 414: Fox Shock Assembly

    STEERING / SUSPENSION FOX SHOCK ASSEMBLY 4. Apply a thin layer of Slick Honey to body cap o-rings. A training video is available on University of Polaris (https://lms.latitudelearning.com/home/main.aspx) for assembly of Podium Internal Bypass shocks. Search for “Podium Internal Bypass Shock”.
  • Page 415 18. Install 1st T-seal back-up ring. 19. Install 2nd T-seal back-up ring 20. Install wiper seal. 21. Lubricate all seals with Slick Honey. 22. Install external o-ring. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.41 © Copyright Polaris Industries Inc.
  • Page 416 28. Install shaft nut and torque to specification. 34. Install shaft assembly into inner body. TORQUE Shaft Nut: 22 ft-lb (30 Nm) 29. Install all Bypass check valves. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.42 © Copyright Polaris Industries Inc.
  • Page 417 45. After setting IFP depth, install Bleed screw with o- assembly. ring. 40. Install retaining ring, ensuring that it is fully seated in ring gland. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.43 © Copyright Polaris Industries Inc.
  • Page 418 49. Stroke shock absorber and inspect shock for leaks. 50. Install body cap. 51. Clean oil residue from shock. 52. Install o-ring and reducers in eyelet and body. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.44 © Copyright Polaris Industries Inc.

  • Page 419: Shock Service

    Piston Wear Band (1.750" OD) 36. Clicker Bolt Shaft, Chrome Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.45 © Copyright Polaris Industries Inc.

  • Page 420: General Service Information

    26.00″ (66.04 cm) IFP Depth 6.25″ (15.88 cm) All models 150 psi (1034.21 kPa) +/- Nitrogen Pressure 2874124 (qt.) Gas Shock Oil 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.46 © Copyright Polaris Industries Inc.

  • Page 421: Rear Shock Service Information

    0.600 x 0.015 1.650 x 0.015 0.600 x 0.015 1.450 x 0.008 1.750 x 0.015 1.850 x 0.008 Piston Bleed Orifice: none 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.47 © Copyright Polaris Industries Inc.
  • Page 422 1.750 x 0.012 1.000 x 0.012 1.850 x 0.010 1.200 x 0.060 1.850 x 0.010 1.300 x 0.008 1.900 x 0.010 1.900 x 0.010 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.48 © Copyright Polaris Industries Inc.

  • Page 423: Spring Adjustment (Walker Evans)

    Shock Spanner / Clutch Spreader Tool: 2878925 NOTICE Polaris does not recommend increasing the spring adjustment by more than one inch (25.4 mm) over the factory setting as it may negatively impact vehicle stability. Always return the spring preload to the factory setting after the load is removed from the vehicle.

  • Page 424: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.50 © Copyright Polaris Industries Inc.

  • Page 425: Walker Evans™ Shock Disassembly

    Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.51 © Copyright Polaris Industries Inc.
  • Page 426 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.52 © Copyright Polaris Industries Inc.
  • Page 427 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.53 © Copyright Polaris Industries Inc.

  • Page 428: Walker Evans™ Shock Assembly

    NOTICE If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.54 © Copyright Polaris Industries Inc.
  • Page 429 15. Screw IFP Tool (PS-45908) onto the floating piston. FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.55 © Copyright Polaris Industries Inc.
  • Page 430 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.56 © Copyright Polaris Industries Inc.
  • Page 431 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.57 © Copyright Polaris Industries Inc.
  • Page 432 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTICE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.58 © Copyright Polaris Industries Inc.

  • Page 433: Dynamix Active Suspension

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

  • Page 434: Demonstration Mode

    SCM from it’s factory mounting location. SCM. SCM REPLACEMENT 1. Remove the hood. 5. Remove the 4 fasteners retaining the SCM to the mounting plate. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.60 © Copyright Polaris Industries Inc.

  • Page 435: Dynamix™ System Features

    The system continuously monitors steering angle, lateral acceleration, and vehicle yaw rate to provide enhanced cornering control, reducing body motion for maximum performance. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.61 © Copyright Polaris Industries Inc.

  • Page 436: Braking

    9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.62 © Copyright Polaris Industries Inc.

  • Page 437: Advanced Diagnostics

    SUSPENSION MODE SWITCH (DYNAMIX MODELS) For more information on the Dynamix suspension system, refer to the Steering / Suspension chapter - Dynamix Overview page 9.59 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.63 © Copyright Polaris Industries Inc.
  • Page 438 SWITCH CONTACT CONTACT PINS 1 TO POSITION Open Comfort Closed 1270 Ω Sport Open Open 1400 Ω Open Firm Closed 1330 Ω 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 9.64 © Copyright Polaris Industries Inc.
  • Page 439 ............. . . 10.34 BRAKE BURNISHING PROCEDURE 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.1 © Copyright Polaris Industries Inc.

  • Page 440: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 441: Brake System Overview

    15 ft-lbs (20 Nm) Rear Brake Line Guide Master Cylinder Fasteners Front Brake Caliper Fasteners 18 ft-lbs (25 Nm) 33 ft-lbs (45 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 442: Brake System View (4-Seat)

    Front Brake Caliper Front Brake Scraper Brake Scraper Fasteners 7 ft-lbs (10 Nm) Brake Line Guide Brake Line Guide Fasteners 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 443: Brake Line Routing / Retention

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Routing Clip Front Brake Calipers 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.5 © Copyright Polaris Industries Inc.
  • Page 444 BRAKE SYSTEM Master Cylinder To Junction Block Master Cylinder Routing Clip Junction Block 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.6 © Copyright Polaris Industries Inc.
  • Page 445 BRAKE SYSTEM Junction Block to Rear Brake Calipers Junction Block Rivet Clip Routing Clip Rear Brake Caliper 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 446: Brake Line Routing / Retention (4-Seat)

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION (4-SEAT) Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Routing Clip Front Brake Calipers 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 447 BRAKE SYSTEM Master Cylinder To Junction Block Master Cylinder Routing Clip Junction Block 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.9 © Copyright Polaris Industries Inc.
  • Page 448 BRAKE SYSTEM Junction Block to Rear Brake Calipers Junction Block Rivet Clip Routing Clip Rear Brake Caliper 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 449: 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 450: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.12 © Copyright Polaris Industries Inc.
  • Page 451 150° Front Right Brake Line 90° Front Left Brake Line 90° TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.13 © Copyright Polaris Industries Inc.

  • Page 452: Brake Bleeding / Fluid Change

    1. Clean master cylinder reservoir cover thoroughly and remove the cover Polaris DOT 4 Brake Fluid 2872189 4. Bleed the brakes in the following order: right rear, left rear, right front and finally the left front. Install a box end wrench on caliper bleeder screw.
  • Page 453 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 454: 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) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 455: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.17 © Copyright Polaris Industries Inc.
  • Page 456 BRAKE SYSTEM 9. Remove the bolt retaining the brake line to the caliper. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 457: Front Caliper Assembly View

    Boots Scraper Bolts Caliper Assembly 7 ft-lbs (10 Nm) Bleeder Screw Mount Pins 48 in-lb (5 Nm) apply Silicone Grease on install 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 458: Front Caliper Assembly View (4-Seat)

    DOT 4 Brake Fluid Boots Brake Scraper Caliper Assembly Scraper Bolts Bleeder Screw Mount Pins apply Silicone Grease on install 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 459: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.21 © Copyright Polaris Industries Inc.

  • Page 460: Front Caliper Disassembly / Inspection (4-Seat)

    6. Inspect caliper body for nicks, scratches, pitting or 2. Thoroughly clean the caliper before disassembly and wear. prepare a clean work area for disassembly. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 461: Brake Pad Inspection

    Front Caliper Piston O.D.: Large: 1.50″ (38.1 mm) Small: 1.19″ (30.226 mm) 10. Inspect the brake disc and pads as outlined in this chapter. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 462: Front Caliper Assembly

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

  • Page 463: Front Brake Disc Replacement

    1/2 turn (counterclockwise). 7. Install the front wheel and the wheel nuts. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.25 © Copyright Polaris Industries Inc.

  • Page 464: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.26 © Copyright Polaris Industries Inc.

  • Page 465: Troubleshooting

    If there is a concern found with the circuit repair and recheck operation. 6. If the concern is still present, it is possible that there may be a concern with the ECU. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.27 © Copyright Polaris Industries Inc.

  • Page 466: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.28 © Copyright Polaris Industries Inc.

  • Page 467: Rear Caliper Disassembly / Inspection

    NOTICE Be sure to clean caliper body seal grooves. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.29 © Copyright Polaris Industries Inc.

  • Page 468: Brake Pad Inspection

    Rear Caliper Piston Bore I.D.: Large: 1.1860-1.1875″ (30.12-30.16 mm) Small: 0.9985-1.000″ (25.36-25.40 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.30 © Copyright Polaris Industries Inc.

  • Page 469: Rear Caliper Assembly

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

  • Page 470: Rear Brake Disc Replacement

    7. Install rear caliper (see Brake Caliper / Pad Installation page ). Bleed the brake system. (See BRAKE BLEEDING / FLUID CHANGE page 10.14. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.32 © Copyright Polaris Industries Inc.

  • Page 471: Rear Brake Caliper / Pad Installation

    The calipers have self-orienting features, brake lines do not need to be oriented if installed correctly. TORQUE Banjo Bolts: 15 ft-lb (20 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.33 © Copyright Polaris Industries Inc.

  • Page 472: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 10.34 © Copyright Polaris Industries Inc.
  • Page 473 ................11.23 DOOR ADJUSTMENT 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.1 © Copyright Polaris Industries Inc.

  • Page 474: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.2 © Copyright Polaris Industries Inc.

  • Page 475: Cab Frame Assembly

    44 ft-lbs (60 Nm) Fastener - M12 x 1.5 x 80 (10.9) Flanged Nyloc Nut - M10 x 1.5 89 ft-lbs (120 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 476: Cab Frame Assembly (4-Seat)

    44 ft-lbs (60 Nm) Rear Cross Member Nyloc Nut - M10 x 1.5 Fastener - M12 x 1.5 x 80 (10.9) 89 ft-lbs (120 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 477: Front Doors

    Door Striker Door Hinge Fastener 18 ft-lbs (24 Nm) Door Striker Fastener Door Hinge Pin 7 ft-lbs (10 Nm) Door Latch Actuator 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 478: Rear Doors

    7 ft-lbs (10 Nm) Door Latch Actuator Door Latch Fastener 9 ft-lbs (12 Nm) Door Latch Actuator Fastener 9 ft-lbs (12 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 479: Dash / Controls

    DASH / CONTROLS 7” Display (Turbo S Models Only) Headlight Switch Key Switch AWD Switch Mode Switch (Turbo S Models Only) 12V Accessory 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 480: Hood / Front Body

    Front Fascia Fender Flare Fasteners Front Bumper 7 ft-lbs (10 Nm) LH Front Fender Flare Front Fascia Fasteners 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 481: Chassis / Main Frame

    Seat Base Support Bracket Front Bumper Seat Base Support Bracket Fasteners Front Bumper Bracket Fasteners 15 ft-lbs (20 Nm) 30 ft-lbs (40 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 482: Chassis / Main Frame (4-Seat)

    Front Seat Base Frame Front Bumper Fastener - M10 x 1.5 x 16 Front Bumper Fasteners 37 ft-lbs (50 Nm) 30 ft-lbs (40 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 483: Seat Assembly

    7 ft-lbs (10 Nm) Lower Hinge Bushing Fastener - M8 x 1.25 x 20 (10.9) 15 ft-lbs (20 Nm) Upper Hinge Bracket Bumper Grommet 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 484: Floor / Rocker Panels

    Storage Console Front Floor Panel Center Console Under-Seat Panel Battery Tray Rocker Panel Floor / Rocker Panel Fasteners 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 485: Floor / Rocker Panels (4-Seat)

    Rear Center Console Under-Seat Panel Front Center Console Front Rocker Panel Battery Tray Rear Rocker Panel Body Panel Fasteners 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 486: Rear Cargo Box / Fenders

    Top Rear Close-off Panel Rear Bumper Bottom Rear Close-off Panel Cargo Box Assembly Close-off Panel Cover Cargo Box / Fender Fasteners 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 487: Rear Bumper

    7ft-lbs (10 Nm) 7ft-lbs (10 Nm) Rear Fascia Mounting Bracket Rear Bumper Mounting Bracket Fastener Rear Bumper Mounting Bracket 7ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 488: Body Component Removal

    REAR CLOSE-OFF PANEL 1. Remove seats. 2. Unlock six 1/4 turn latches (four on top panel, two on bottom panel). 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 489: Front Fascia

    6. Remove three fasteners and one push pin from each fender, and remove front fenders. 3. Remove two fasteners and remove the front hood. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 490: Rear Fascia

    4. From the rear wheel well, remove one push pin either side of the rear fascia, and remove rear fascia. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 491: Hood / Front Body

    1. Remove front fascia. See Front Fascia Removal page 11.17. 2. Remove LH and center dash trim 3. Remove RH dash trim 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 492: Rear Fender / Fender Flare

    2. Pull the rear of the cargo box up and rearward to disengage front tabs and remove cargo box. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 493: Rocker Panels, Console, And Floor

    1. Remove seats and rocker panels. 2. Remove top half of shift knob 6. Remove one fastener from either side of the console under the dash. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.21 © Copyright Polaris Industries Inc.
  • Page 494 9. Remove one fastener from the shift linkage and remove shift cable from its mounting bracket. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 495: Doors

    9 ft-lbs (12 Nm) 5. Install new latch actuator. Torque fasteners to specification. TORQUE Door Latch Actuator Fasteners: 9 ft-lbs (12 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.23 © Copyright Polaris Industries Inc.
  • Page 496 5. Holding the door in position, tighten the top hinge bracket fasteners , and then the bottom fasteners . Torque to specification. TORQUE Hinge Bracket Fasteners: 18 ft-lbs (24 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 11.24 © Copyright Polaris Industries Inc.
  • Page 497 ............... . 12.27 HEADLIGHT ADJUSTMENT 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.1 © Copyright Polaris Industries Inc.
  • Page 498 ............... 12.47 BREAK-OUT DIAGRAM VIEWING 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.2 © Copyright Polaris Industries Inc.

  • Page 499: General Information

    Fluke™ 77 Digital Multimeter PV-43568 Digital Wrench® (see Chapter 4 – DIGITAL WRENCH® OPERATION page Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.3 © Copyright Polaris Industries Inc.

  • Page 500: 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. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.4 © Copyright Polaris Industries Inc.

  • Page 501: Electrical Component Locations (Rear)

    Crankshaft Position Sensor Waste Gate Control Seat Belt Switch Starter (+) Shock Actuator Engine Ground Fuel Pump Driver Module Barometric Air Pressure Sensor 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.5 © Copyright Polaris Industries Inc.

  • Page 502: Electrical Component Locations (Front)

    Front Accent Light 3& LED Dash Light AWD Coil GPS Antenna 4& Accent Light Antenna Harness Voltage Regulator 5& EPS Power Shock Actuator 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.6 © Copyright Polaris Industries Inc.

  • Page 503: Instrument Cluster

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.7 © Copyright Polaris Industries Inc.
  • Page 504 Parking Brake Indicator - Illuminates when parking brake is engaged (INT’L Models Only). Low Battery Indicator - Illuminates when battery voltage is low, charging system may be overloaded. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.8 © Copyright Polaris Industries Inc.

  • Page 505: Information Display Area

    Service Hours interval has been reached. AREA 3 MODES MODE DESCRIPTION The clock displays time in a 12-hour or 24-hour format. Clock 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.9 © Copyright Polaris Industries Inc.
  • Page 506 4. Press MODE to save and exit to the settings menu. 1. Press and hold the MODE button to enter the settings menu. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.10 © Copyright Polaris Industries Inc.
  • Page 507 1. Press either toggle button to cycle to the trip time option (TT). 2. Press and hold either toggle button until the meter resets to zero. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.11 © Copyright Polaris Industries Inc.
  • Page 508 Left Turn Signal Input Right Turn Signal Input High Beam Input Trailer Turn Sign Input Fuel Level Sensor Blackout Mode Input Accy Air Temp Input 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.12 © Copyright Polaris Industries Inc.

  • Page 509: Switches / Controls

    NOTICE Pins 7 and 8 provide power and ground to light the switch lamp. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.13 © Copyright Polaris Industries Inc.

  • Page 510: Awd / 2Wd Switch (No Turf Mode)

    2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT DISENGAGED ENGAGED Between both ∞ (OL) < 1 Ω pins on switch 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.14 © Copyright Polaris Industries Inc.

  • Page 511: Transmission / Gear Position Switch

    0.5 Ω resistance when the brake is applied with slight pressure, first clean the switch contacts and re- 160 Ω test. Replace switch if necessary. 75 Ω PARK 24 Ω 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.15 © Copyright Polaris Industries Inc.

  • Page 512: Boost Control Solenoid / Valve

    Boost Control Valve: 22–24 Ω More information relating to the turbocharger system and components may be found in the Engine and Fuel System chapters. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.16 © Copyright Polaris Industries Inc.

  • Page 513: Steering Angle Sensor Centering (Dynamix)

    4. Come to a complete stop without turning the steering wheel. Turn key off. 5. Turn key to ON position. 6. Cycle key off and back on. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.17 © Copyright Polaris Industries Inc.

  • Page 514: Ignition Coil

    Ignition Coil Fastener: 7 ft-lbs (10 Nm) 5. Install Cargo Box and torque fasteners to specification. NOTICE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.18 © Copyright Polaris Industries Inc.

  • Page 515: Charging System

    Damage will occur to electrical components. CAUTION Charging system damage will occur if incompatible components are installed. Always reference Polaris Electric Parts Catalog for proper part numbers. NOTICE Wait ten minutes with the key off for the ECU to power down.

  • Page 516: Charging System "Break Even" Test

    If there are any significant variations in ohm readings between the three legs it is an indication that one of the stator legs may be weak or failed. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.20 © Copyright Polaris Industries Inc.

  • Page 517: Regulator / Rectifier (Dynamix)

    82 VAC ± 25% 5. Install new regulator(s) on the bracket. Torque fasteners to specification. TORQUE Regulator Fasteners: 8 ft-lb (11 Nm) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.21 © Copyright Polaris Industries Inc.
  • Page 518 8. Connect the battery negative cable. Torque fastener to specification. TORQUE Battery Terminal Fastener: 60 in-lbs (7 Nm) 9. Install the seat. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.22 © Copyright Polaris Industries Inc.

  • Page 519: Battery

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

  • Page 520: Battery Removal

    60 in-lbs (7 Nm) 6. Verify that cables are properly routed and reinstall the 5. Lift the battery out of the vehicle. driver’s seat. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.24 © Copyright Polaris Industries Inc.

  • Page 521: Battery Off Season Storage

    Battery charge can be maintained by using a Polaris For this reason, a battery capacity or load test should be battery tender or by charging once a month to make up conducted whenever poor battery performance is for self-discharge.

  • Page 522: Charging Procedure

    Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.26 © Copyright Polaris Industries Inc.

  • Page 523: Lighting System

    4. Install front fascia. Torque fasteners to specification. TORQUE Body fasteners: 7 ft-lbs (10 Nm) 5. Perform the Headlight Adjustment procedure outlined in this chapter. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.27 © Copyright Polaris Industries Inc.

  • Page 524: Tail Light Replacement

    24 in-lb (3 Nm) DASH LIGHT The LED light will remain ON for approximately 30 seconds after key has been switched to the OFF position. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.28 © Copyright Polaris Industries Inc.

  • Page 525: Cooling System

    1 Ω. • Power side should show battery voltage. If battery voltage is not seen, check voltage at the fan circuit breaker. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.29 © Copyright Polaris Industries Inc.

  • Page 526: Fan Control Circuit Bypass Test

    6. Remove two large hoses and one vent line from the charge air radiator and remove charge air radiator from the vehicle. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.30 © Copyright Polaris Industries Inc.
  • Page 527 Remove fan and cooling system. See Cooling System Bleeding page radiator as an assembly. 2.38. 12. Remove cooling fan from radiator. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.31 © Copyright Polaris Industries Inc.

  • Page 528: Electric Coolant Pump

    3. When the system is bled properly, remove the jumper and reinstall the Fuel Pump relay. REPLACEMENT 1. Place a drain pan underneath the coolant pump. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.32 © Copyright Polaris Industries Inc.

  • Page 529: Ect Sensor Test

    After a few seconds, the fan should turn on and the “Check Engine” indicator should display on the instrument cluster. This indicates all other components are working properly. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). TEMPERATURE °F (°C) RESISTANCE 68 °F (20 °C)

  • Page 530: Starting System

    8. Install the cables on the solenoid posts. Torque nuts to specification. TORQUE Solenoid Cable Nuts: 35 in-lb (4 Nm) 9. Connect the harness to the solenoid. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.34 © Copyright Polaris Industries Inc.

  • Page 531: Electronic Power Steering (Eps)

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

  • Page 532: Fuses / Relays

    Power Out Coil Low Power In Key 7.5A Fuse Power Out Power In Fan 30A Fuse Power Out Accy Relay Coil High 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.36 © Copyright Polaris Industries Inc.
  • Page 533 Power Out Coil Low Power In Water 7.5A Fuse Power Out Power In Fuel 7.5A Fuse (10A for EVAP only) Power Out 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.37 © Copyright Polaris Industries Inc.
  • Page 534 CIRCUIT FUNCTION Coil High Power In EFI Relay Power Out Coil Low Coil High Power In Brake Relay Power Out Coil Low 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.38 © Copyright Polaris Industries Inc.

  • Page 535: 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 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.39 © Copyright Polaris Industries Inc.

  • Page 536: Voltage Regulator Fusible Link

    There are two fusible links on this vehicle that protect the voltage regulator output circuits. These are located on the pigtails coming off the B+ post, under the front driver’s side fender. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.40 © Copyright Polaris Industries Inc.

  • Page 537: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.41 © Copyright Polaris Industries Inc.

  • Page 538: Wiring Harness

    ELECTRICAL WIRING HARNESS ELECTRICAL HARNESS ROUTING ELECTRICAL HARNESS ROUTING (4-SEAT) 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.42 © Copyright Polaris Industries Inc.

  • Page 539: Electrical Harness Retention

    ELECTRICAL ELECTRICAL HARNESS RETENTION Zip Tie Retention Point The white tape on the harness signifies a retention point 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.43 © Copyright Polaris Industries Inc.

  • Page 540: Electrical Harness Retention (4-Seat)

    ELECTRICAL ELECTRICAL HARNESS RETENTION (4-SEAT) Zip Tie Retention Point The white tape on the harness signifies a retention point 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.44 © Copyright Polaris Industries Inc.
  • Page 541 17. Remove the harness through the front of the vehicle. 18. Route new harness the same way as the old harness. Refer to Electrical Harness Retention page 12.43. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.45 © Copyright Polaris Industries Inc.

  • Page 542: Wiring Harness Replacement

    17. Remove the harness through the front of the vehicle. 18. Route new harness the same way as the old harness. Refer to Electrical Harness Retention page 12.44. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.46 © Copyright Polaris Industries Inc.

  • Page 543: Break-Out Diagram Viewing

    2. If the wiring diagram does not open the Adobe navigation bars, click on the Adobe Icon. 3. Click on the Layers Icon. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.47 © Copyright Polaris Industries Inc.
  • Page 544 5. Click on the Wiring Diagram (black & white) box to get a shadow of the full diagram behind the break-out diagram. 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual 12.48 © Copyright Polaris Industries Inc.
  • Page 545 .1 Symptom and Occurrence Checklist IMPORTANT This checklist is intended for Dealer use. It is a guide to help with concerns that are Intermittent and / or Hard to Duplicate. It is intended to collect as much information as possible before continuing with the diagnosis. •...
  • Page 546 2020 RZR PRO XP / XP 4 OCCURRENCE CHART ○ ALWAYS ○ MORE THAN 50% OF THE TIME WHEN IS PROBLEM APPARENT? ○ LESS THAN 50% OF THE TIME IF NO PLEASE EXPLAIN: ○ YES DOES IT HAVE TO BE RUNNING OR DRIVING? ○...
  • Page 547 Symptom and Occurrence Checklist ○ BEEN PRESENT SINCE NEW...
  • Page 549 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams Click here: RZR PRO XP (Base Model) Click here: RZR PRO XP Dynamix Edition Click here: RZR PRO XP Ride Command Click here: RZR PRO XP Box Click here: RZR PRO XP Box (Premium Model) Click here: RZR PRO XP Center Console Click here: RZR PRO XP Dash Lights Click here: RZR PRO XP Steering Column...
  • Page 551 Installation (front) ..........10.25 Brake Caliper Installation (rear) ..........10.33 Installation (rear) ..........10.33 Removal (Front) ........... 10.17 Removal (rear)............. 10.28 Removal (rear)............. 10.28 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 552 Cooling Fan Feature Map............1.37 Guided Diagnostics ..........1.33 Bypass Test ............12.30 Replacement............12.30 Polaris Mobile Digital Wrench® (PMDW) .....1.40 Testing ............... 12.29 Serial Number Location ...........1.36 Cooling System Software Installation and Updates ......1.34 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.2...
  • Page 553 Mount Replacement..........3.43 Test ..............12.33 Oil and Filter Change ..........2.29 Oil Flow Chart............3.6 Diagnostic Trouble Codes Overview ......1.41 Oil Level Check............2.28 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 554 Removal...............3.18 Front Bearing Carrier ..........8.5 Headlight Adjustment ............12.27 Front Body Removal............. 11.19 Replacement............12.27 Front Bumper Headlight Switch ............. 12.13 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 555 Main Harness Plunging Joint / Boot Replacement............12.45 Replacement (Inner) ..........8.18 Replacement (4-Seat) ........... 12.46 Power Steering Unit Maintenance Installation ............9.11 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 556 PVT System ............6.2 Removal............. 11.21 Shock ..............9.50 Rocker Panels Steering ..............9.3 Assembly View ............ 11.12 Suspension............9.3 Assembly View (4-Seat)......... 11.13 Transmission............7.2 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 557 Key ..............12.13 Turbocharger Seat Belt ............12.14 Inspection.............3.22 Oil Drain Tube Service..........3.27 Suspension Mode (Dynamix) ......9.63, 12.16 Transmission............12.15 Operation Overview ..........3.11 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.7 © Copyright Polaris Industries Inc.
  • Page 558 Alignment / Inspection ..........2.49 Installation ............2.45 Removal...............2.45 Toe Adjustment ............2.50 Wheel Bearing ............8.4 Replacement (rear)..........8.8 Wiring Harness Replacement............12.45 Replacement (4-Seat) ........... 12.46 9930583 R02 - 2020 RZR PRO XP / XP 4 Service Manual IX.8 © Copyright Polaris Industries Inc.

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