Polaris RZR PRO R Service Manual
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Polaris RZR PRO R Service Manual

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Table of Contents

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2022 RZR PRO R / PRO R 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'.
Publication Printed December 2021 (PN 9940259 R02)
© Copyright 2022 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 R

  • Page 1 Publication Printed December 2021 (PN 9940259 R02) © Copyright 2022 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. REVISION INDEX DATE...
  • Page 3 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 2022 RZR PRO R / PRO R 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...

  • Page 7: Table Of Contents

    ........... .1.51 PVT SYSTEM OVERHEATING / DIAGNOSIS 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 8 ................1.66 TESTING VOLTAGE DROP 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 9: Vehicle Identification

    M = 2021; N= 2022 VIN AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the rear left vertical shock support tube.

  • Page 10: Reference Information

    When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www. polaris.com or purchased from www.purepolaris.com. 9940259 R02 - 2022 RZR PRO R / PRO R 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 the Polaris official tool supplier.

  • Page 12: Master Torque Table

    18 ft-lbs (25 Nm) Fastener : 72 in-lbs (8 Nm) Oxygen Sensor 30 ft-lbs (40 Nm) Shift Cable Bracket 22 ft-lbs (30 Nm) Fasteners 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Torque bolt side Control Arm Mounting 133 ft-lbs (180 Nm) - Fasteners Torque bolt side Hub Mounting Fasteners 81 ft-lbs (110 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 15 ft-lbs (20 Nm)Starting Frame Cross Bar 15 ft-lbs (20Nm) Fastener Fastener (4 Seat) Seat Hinge Nut 7 ft-lbs (10 Nm) (M8x1.25x16)) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 Pedal Position Sensor 18 ft-lbs (24 Nm) (PPS) Fasteners Starter Mounting 26 ft-lbs (35 Nm) Fasteners Starter Positive Terminal 11 ft-lbs (15 Nm) Fastener 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 16: Vehicle Specifications

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 22.2″ (56.4 cm) Front Travel Independent Trailing Arm with stabilizer bar Rear Suspension Walker Evans 3.0” Velocity Needle Shock w/16-position adjustable clickers OR 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.11 © Copyright Polaris Industries Inc.

  • Page 18: 2022 Rzr Pro R Clutch Chart

    Rear Tire Make / Model / Maxxis Rampage Fury Size 32 x 10 R15 15 psi (103 kPa) Tire Air Pressure Front 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.13 © Copyright Polaris Industries Inc.
  • Page 20 22.2″ (56.4 cm) Front Travel Independent Trailing Arm with stabilizer bar Rear Suspension Walker Evans 3.0” Velocity Needle Shock w/16-position adjustable clickers OR 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 SPRING 0-1800 Meters W-38-117 2022 (0-6000 Feet) (1327358) Black Black (7045118) (7045119) 1800-3700 Meters W-38-110 PRO R 4 (6000-12000 Feet) (1323778) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 23: Sae Tap / Drill Sizes

    2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 3–4 7/16–14 2 3/4 7/16–20 25/64 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.17 © Copyright Polaris Industries Inc.

  • Page 24: Decimal Equivalents

    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″ 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: General Diagnostics

    Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.19 © Copyright Polaris Industries Inc.

  • Page 26: 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 27: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.21 © Copyright Polaris Industries Inc.
  • Page 28 • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.24 for more information. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.22...
  • Page 29 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 30: Engine Cranks But Does Not Start

    10. Listen for unusual noises while cranking. • If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.24 © Copyright Polaris Industries Inc.
  • Page 31 – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking (if applicable) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.25 © Copyright Polaris Industries Inc.

  • Page 32: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.26 © Copyright Polaris Industries Inc.

  • Page 33: Over Heating

    • Radiator core may not be functioning correctly or failed causing concern. 7. Faulty Temp Sensor / Circuit / ECU. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.27 © Copyright Polaris Industries Inc.

  • Page 34: Warning Lights

    • Detects brake system failure. • Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.28 © Copyright Polaris Industries Inc.

  • Page 35: Engine Troubleshooting

    • Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.29 © Copyright Polaris Industries Inc.
  • Page 36 / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.30 © Copyright Polaris Industries Inc.

  • Page 37: Cooling Troubleshooting

    • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 38: Engine Electrical Diagnostics

    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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.32 © Copyright Polaris Industries Inc.

  • Page 39: Master Trouble Code List

    Data Erratic, Intermittent Or Incorrect P3021 Engine Oil Pressure Current Below Normal Or Open Circuit P1521 Bad Intelligent Device Or Component P3020 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.33 © Copyright Polaris Industries Inc.
  • Page 40 Received Network Data In Error U25C6 Data Erratic, Intermittent Or Incorrect P0194 Fuel Rail Pressure Sensor Voltage Above Normal, Or Shorted To High Source P0193 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.34 © Copyright Polaris Industries Inc.
  • Page 41 Root Cause Not Known P0915 Received Network Data In Error U255C Transmission Requested Gear Condition Exists P153D Cruise Control Panel Switches 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.35 © Copyright Polaris Industries Inc.
  • Page 42 P0647 Voltage Below Normal, Or Shorted To Low Source P0646 AC Compressor Clutch Relay Current Below Normal Or Open Circuit P0645 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.36 © Copyright Polaris Industries Inc.
  • Page 43 Wheel Speed Sensor (Rear Right) Current Above Normal Or Grounded Circuit C1B47 Mechanical System Not Responding Or Out Of Adjustment C1747 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.37 © Copyright Polaris Industries Inc.
  • Page 44 Mechanical System Not Responding Or Out Of Adjustment C1362 Out Of Calibration C1262 Longitudinal Acceleration Sensor 1810 Received Network Data In Error U25CB 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.38 © Copyright Polaris Industries Inc.
  • Page 45 Voltage Below Normal, Or Shorted To Low Source P17AB Data Valid But Above Normal Operating Range - Moderately Severe P17AD Level 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.39 © Copyright Polaris Industries Inc.
  • Page 46 Current Below Normal Or Open Circuit P1685 Data Valid But Above Normal Operating Range - Least Severe Level P0172 520204 Fuel Correction Front 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.40 © Copyright Polaris Industries Inc.
  • Page 47 Condition Exists C1071 520231 EPS Power Save Condition Current Below Normal Or Open Circuit C1024 ABS Solenoid (Rear or Right Rear 520252 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.41 © Copyright Polaris Industries Inc.
  • Page 48 Throttle Body Control - Power 520277 Stage Voltage Below Normal, Or Shorted To Low Source P150E Abnormal Frequency Or Pulse Width Or Period P151B 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.42 © Copyright Polaris Industries Inc.
  • Page 49 Voltage Above Normal, Or Shorted To High Source P107D Intercooler Pump Driver Circuit 520496 Voltage Below Normal, Or Shorted To Low Source P107C 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.43 © Copyright Polaris Industries Inc.
  • Page 50 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.44 © Copyright Polaris Industries Inc.

  • Page 51: Cylinder Misfire Detection

    Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.45 © Copyright Polaris Industries Inc.

  • Page 52: Fluid Leaks

    Refer to the Service Manual information related to the system in question. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.46 © Copyright Polaris Industries Inc.

  • Page 53: Fuel System Diagnostics

    • Faulty oxygen sensor • Spark plug erosion / fouling • Engine runs hot • Surging • High / erratic idle 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.47 © Copyright Polaris Industries Inc.
  • Page 54 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.48 © Copyright Polaris Industries Inc.

  • Page 55: Pvt System Diagnostics

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.49 © Copyright Polaris Industries Inc.
  • Page 56 Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.50 © Copyright Polaris Industries Inc.

  • Page 57: Pvt System Overheating / Diagnosis

    Using High gear for heavy loads, hilly terrain, sand/dune environments, or in wet, muddy conditions will increase the chance of drive belt damage. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.51 © Copyright Polaris Industries Inc.

  • Page 58: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.52...

  • Page 59: Final Drive Diagnostics

    Pinion Disconnect. Powered Pinion Disconnect. Powered Both Solenoids OFF Both Solenoids OFF 4WD Lock 4WD Lock Both Solenoids OFF Differential Lock Powered 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.53 © Copyright Polaris Industries Inc.

  • Page 60: Driveshaft (Half Shaft) 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.54 © Copyright Polaris Industries Inc.

  • Page 61: Brake System Diagnostics

    – Operator using the throttle and brakes at the same time. • Incorrect brake fluid level (overfilled fluid reservoir) – Excessive use of the brakes. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.55 © Copyright Polaris Industries Inc.

  • Page 62: Poor Brake Performance

    • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder • Faulty distribution block (INTL models only ) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.56 © Copyright Polaris Industries Inc.

  • Page 63: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.57 © Copyright Polaris Industries Inc.

  • Page 64: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.58 © Copyright Polaris Industries Inc.

  • Page 65: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.59 © Copyright Polaris Industries Inc.

  • Page 66: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.60 © Copyright Polaris Industries Inc.

  • Page 67: Electrical Diagnostics

    The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.61 © Copyright Polaris Industries Inc.

  • Page 68: Connector Probing Guidelines

    If they contact each other, circuit or component damage could occur from a short. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.62 © Copyright Polaris Industries Inc.

  • Page 69: Testing Continuity / Resistance

    Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.64 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.63 © Copyright Polaris Industries Inc.

  • Page 70: 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”. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.64 © Copyright Polaris Industries Inc.

  • Page 71: Testing For Intermittent Conditions

    Failure to do so can lead to serious injury and/or damage to the machine. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.65 © Copyright Polaris Industries Inc.

  • Page 72: Current Draw - Key Off

    6. Momentarily key the ignition switch on, then off. IMPORTANT Ensure all electrical components are switched off, or damage to your jumper and/or meter will occur. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.66 © Copyright Polaris Industries Inc.
  • Page 73 GENERAL INFORMATION For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.67 © Copyright Polaris Industries Inc.
  • Page 74 GENERAL INFORMATION NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 1.68 © Copyright Polaris Industries Inc.
  • Page 75 ................2.28 STEERING INSPECTION 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 76 ................. . .2.38 SPARK PLUG SERVICE 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 77: Maintenance

    16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) 2872280 2871557 1215 (5 oz.) Crankcase Sealant, Three bond 1217H (5 oz.) 2884392 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 78: Pre-Ride Inspection

    • Check for proper air pressure in all tires Tires • Inspect for tire damage / objects in tire • Ensure adequate tread depth 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 79: Polaris Maintenance Schedule

    Initial Break-In Service. Continue to reference the following maintenance schedules at the given intervals as hours and miles (kilometers) increase on the vehicle. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 80 25 hours of operation. They do not need to be performed every 25 hours. * It is recommended to have an authorized Polaris dealer perform these services. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 81 Spark Arrestor Inspect; clean as needed. Suspension Inspect front and rear Components / suspension bushings, and ball Alignment* joints for loose or worn 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 82: Maintenance Quick Reference

    - Front-Right Side of Cargo Box Coolant months * More often under severe use, such as operation in water or under severe loads. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 83 16.1 oz (475 mL) - Fill to Spill Rear Gearcase comes first Add lubricant until it is visible at Transmission Polaris AGL the fill hole threads 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 84 MAINTENANCE * More often under severe use, such as operation in water or under severe loads. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.10 © Copyright Polaris Industries Inc.

  • Page 85: Grease Lubrication Points

    Grease between transmission front output thoroughly washing or shaft and front propshaft. submerging the vehicle 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.11 © Copyright Polaris Industries Inc.

  • Page 86: Engine / Exhaust

    If the oil level is over the full mark, change the oil immediately. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.12 © Copyright Polaris Industries Inc.

  • Page 87: Engine Oil And Filter Change

    9. Lubricate gasket area on new oil filter with a film of fresh engine oil. Check to make sure the sealing areas are in good condition. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.13 © Copyright Polaris Industries Inc.

  • Page 88: Engine Breather Hose

    A brand new or rebuilt engine will have higher leakdown than an engine with 5 hours of runtime. Leakdown should decrease once the rings are broken in. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.14 © Copyright Polaris Industries Inc.
  • Page 89 8 ft-lbs (11 Nm) 7. Reinstall the rear bumper. Torque fasteners to specification. TORQUE Rear Bumper Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.15 © Copyright Polaris Industries Inc.

  • Page 90: Heat Shield Inspection

    • Straight water or antifreeze may cause the system to freeze, corrode, or overheat. Recommended Coolant: Polaris 50/50 Extended Life Anti-freeze 2880514 (quart) 2880513 (gallon) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.16 © Copyright Polaris Industries Inc.

  • Page 91: Coolant Level Inspection

    6. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.17 © Copyright Polaris Industries Inc.

  • Page 92: Coolant Hose Inspection

    Engine Inlet Hose Coolant Bottle Hose Engine Vent Hose 3. Check tightness and condition of all hose spring clamps. Replace if necessary. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.18 © Copyright Polaris Industries Inc.

  • Page 93: Coolant Flush

    5. A wet vac may also be used to evacuate coolant from the system. 6. Connect the coolant hoses and properly position the clamps. 7. Ensure the transmission is in park. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.19 © Copyright Polaris Industries Inc.

  • Page 94: Fuel System And Air Intake

    NOTICE Check throttle pedal periodically. Make sure vent line is not kinked or pinched. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.20 © Copyright Polaris Industries Inc.

  • Page 95: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.21 © Copyright Polaris Industries Inc.
  • Page 96 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.22 © Copyright Polaris Industries Inc.

  • Page 97: Pvt / Final Drive / Wheel And Tire

    Shift the transmission into Low. 8. Test run the vehicle for slippage. If the belt slips, repeat steps 1-5. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.23 © Copyright Polaris Industries Inc.

  • Page 98: Front Gearcase Lubrication

    • Check vent hose to be sure it is routed properly and unobstructed. 1. Remove the fill plug. 2. Place a drain pan under the front gearcase drain plug. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.24 © Copyright Polaris Industries Inc.

  • Page 99: Drive Shaft Boot Inspection

    4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.25 © Copyright Polaris Industries Inc.

  • Page 100: Wheel Installation

    15 psi (103 15 psi (103 RZR PRO R kPa) kPa) 18 psi (124 18 psi (124 RZR PRO R 4 kPa) kPa) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 101: 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 102: Steering

    • Refer to Front Bearing Carrier Inspection / Removal and Rear Bearing Carrier Inspection / Removal for wheel bearing service procedures. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 103: Wheel Toe Alignment Inspection

    IN. A negative result indicates total toe OUT. wheels. 2. Nominal difference between these two measurements should be less than 1/8” (3.1 mm). 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 104: Wheel Toe Adjustment

    MEASUREMENT Wheel Toe: 1/4” (6.35 mm) toe-in – 1/4” (6.35 mm) toe-out 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 105: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 106: Suspension Lubrication

    (11.4 (11.4 (11.4 *See the images in the Front / Rear Spring Preload Adjustment section to view corresponding preload measurement locations 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.32 © Copyright Polaris Industries Inc.
  • Page 107 MAINTENANCE WALKER EVANS® SHOCKS (IF EQUIPPED) SHOCK LOCATION MEASUREMENT* Front Shock Rear Shock 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 108: Front / Rear Spring Preload Adjustment

    Always adjust both the left and right spring preloads equally or have your POLARIS dealer or qualified person perform the adjustments. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 109: Front / Rear Shock Compression Adjustment (Non-Dynamix)

    1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression damping. LOCATION DEFAULT CLICKER POSITION Front 8/16 clicks Rear 8/16 clicks 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 110: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 111: 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 112: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.38 © Copyright Polaris Industries Inc.
  • Page 113 7. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION A wire brush or coated abrasive should not be used. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.39 © Copyright Polaris Industries Inc.
  • Page 114 MAINTENANCE NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 2.40 © Copyright Polaris Industries Inc.
  • Page 115 .................3.50 VALVE INSPECTION 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 116 ................3.96 VALVE COVER INSTALLATION 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 117: General Information

    Capacity: 5.5 qt (5.2 L) (Optional) * Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 118: Engine Service Specifications

    Valve Lash (Cold) - Exhaust 0.008 - 0.014” (0.2032 - 0.3556 mm) Valve 0.2155 - 0.2161" (5.475 - 5.490 mm) Valve Stem Diameter - Intake 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 119 45.75° ± 0.25° 51.0° ± 1.5° 15.0° ± 1.5° 30.0° ± 1.5° Valve Seat Angles - Exhaust 44.75° ± 0.25° 60.0° ± 1.5° 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 120 Less than 0.001” Crankshaft Runout Limit (PTO to MAG) (0.03 mm) Crankshaft Runout Limit (PTO MAG to Less than 0.001” Center) (0.04 mm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 121: Torque Sequence - Engine

    90° REED VALVE VALVE COVER 80 in-lbs (9 N·m) 89 in-lbs (10 N·m) Reed Valve Fasteners: Valve Cover Fasteners: 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 122 Step 2: 22 ft-lbs (30 Nm) Fasteners: ENGINE BREATHER OIL FILTER ADAPTER Engine Breather Oil Filter Adapter 80 in-lbs (9 N·m) 13 ft-lbs (18 N·m) Fasteners: Fasteners: 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 123 (17 N·m) ENGINE BREATHER FLYWHEEL Flywheel Fasteners Engine Breather 80 in-lbs (9 N·m) 24 ft-lbs (33 N·m) + 120° (single-use): Fasteners: 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 124 35 ft-lbs (48 N·m) Items 17–19 FRONT COVER M6 Fasteners: 80 in-lbs (9 N·m) Items 1–16 M8 Fasteners: 16 ft-lbs (22 N·m) Items 17–22 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.10 © Copyright Polaris Industries Inc.
  • Page 125 180° OIL PUMP WINDAGE PLATE Windage Plate Fasteners: 80 in-lbs (9 N·m) Oil Pump Fasteners: 80 in-lbs (9 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 126: Intake / Exhaust System

    Lower Intake Bezel Mounting Fastener Engine Vent Hose Upper Intake Bezel Air Box Intake Bezel Deflector Air Filter Push-Rivet Duct Coupler 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 127: Air Box Removal

    Rear Close Off Panel Cover Fasteners: 7 ft-lbs (10 Nm) 5. Install upper rear close off panel. 6. Install both seats. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 128: Exhaust Assembly View

    Headpipe Heat Shield Muffler Isolator Headpipe Heat Shield Fastener 71 in-lbs (8 Nm) Lower Isolator Mounting Fastener 18 ft-lbs (25 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 129: Muffler Removal

    2. Install a new muffler gasket and install the two fasteners retaining the muffler to the exhaust pipe. Torque fasteners to specification. TORQUE Exhaust Pipe Fasteners: 18 ft-lbs (25 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 130: Exhaust Pipe Removal

    4. Remove nine headpipe fasteners . Remove TORQUE headpipe from the vehicle. Headpipe to Muffler Fasteners: 18 ft-lbs (25 Nm) 5. Connect oxygen sensor wiring. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 131: Cooling System

    ENGINE / COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM FLOW 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 132: Cooling System Specifications

    Engine Protection Cylinder 250° F (121° C) Deactivation Engine Protection Shutdown 255° F (124° C) & Overheat Indicator Flashes 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.18 © Copyright Polaris Industries Inc.

  • Page 133: Radiator Replacement

    Repeat for opposite side of the vehicle. 8. Disconnect electrical connectors from the headlights and accent lights, if equipped.. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.19 © Copyright Polaris Industries Inc.
  • Page 134 2. Mount radiator assembly onto vehicle chassis and install radiator hoses. 3. Route and install wiring harness onto radiator assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.20 © Copyright Polaris Industries Inc.
  • Page 135 TORQUE Front Fender Flare Fasteners: TORQUE 7 ft-lbs (10 Nm) Front Fender Mounting Bracket Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.21 © Copyright Polaris Industries Inc.

  • Page 136: Thermostat Replacement

    2. Install thermostat cover. Torque fasteners to specification. TORQUE Thermostat Cover Fasteners: 9 ft-lbs (12 Nm) 3. Fill and bleed the cooling system. See Cooling System Bleeding. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 137 ENGINE / COOLING SYSTEM 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.23 © Copyright Polaris Industries Inc.

  • Page 138: Engine Service

    HARMONIC DAMPER CLEANING AND INSPECTION 1. Clean the harmonic damper. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.24 © Copyright Polaris Industries Inc.

  • Page 139: Engine Removal

    8. Loosen hose clamp and remove the PVT intake hose. 12. Remove drive clutch retaining bolt and remove the drive clutch moveable-sheave assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 140 15. Remove two O-rings from the transmission. 19. Loosen two air box hose clamps and disconnect air ducts from the air box. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 141 22. Remove two rear fasteners and remove cargo box support. 26. Remove nine fasteners from the exhaust manifold and remove the exhaust assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.27 © Copyright Polaris Industries Inc.
  • Page 142 Prop shaft hidden for image clarity. 32. Disconnect main engine electrical harness 30. Remove two fasteners and remove shift cable bracket. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 143 Verify that engine lift brackets are tight prior to removing engine from the chassis. Use caution when lifting engine to avoid damaging the throttle body. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.29 © Copyright Polaris Industries Inc.

  • Page 144: Engine Installation Preparation

    TORQUE Transmission to Engine Fasteners: 40 ft-lbs (54 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 145: Engine Installation

    Rear Prop Shaft Coupling Fasteners: Engine Mount Fasteners: 11 ft-lbs (15 Nm) Step 1: 26 in-lbs (3 Nm)Step 2: 33 ft-lbs (45 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.31 © Copyright Polaris Industries Inc.
  • Page 146 9. Connect shift cables TORQUE Engine/Transmission Mounting Fasteners: 33 ft-lbs (45 Nm) 7. Connect main engine electrical harness Connect gear position sensor electrical harness. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 147 TORQUE Exhaust Headpipe Fasteners: Step 1: 60 in-lbs (7 Nm)Step 2: 22 ft-lbs (30 Nm) 12. Connect oxygen sensor electrical harness. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.33 © Copyright Polaris Industries Inc.
  • Page 148 TORQUE Cargo Box Support Fasteners: 22 ft-lbs (30 Nm) TORQUE Head Pipe to Muffler Fasteners: 18 ft-lbs (25 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 149 20. Connect rear tail light harness. 21. Install two transmission vent lines and engage hose clamps TORQUE Intake Duct Hose Clamps: 35 in-lbs (3 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.35 © Copyright Polaris Industries Inc.
  • Page 150 : 11 ft-lbs (15 Nm) : 35 in-lbs (4 Nm) 27. Install the drive belt. 24. Install drive clutch stationary sheave. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.36 © Copyright Polaris Industries Inc.
  • Page 151 31. Connect coolant inlet and outlet hoses to the engine. 32. Fill coolant. Refer to coolant fill/bleed procedure outlined in this chapter. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 152: Engine Mount Inspection

    • The rubber is split through the center of the engine mount. • The engine mount is leaking fluid. 4. For engine mount replacement, refer to ENGINE MOUNT REPLACEMENT procedure. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.38 © Copyright Polaris Industries Inc.

  • Page 153: Engine Disassembly / Inspection - Top End

    The vent line can be removed with the coil harness to avoid cutting the double zip tie. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 154: Crankshaft Harmonic Damper Removal

    NEVER place force on the 9. Remove valve cover fasteners . Remove valve cover and gasket outside of the harmonic damper as damage will occur. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.40 © Copyright Polaris Industries Inc.

  • Page 155: Engine Front Cover Removal

    5. Remove the chain tensioner. See Tensioner Service page 6. Remove two upper timing chain guide fasteners Remove the upper timing chain guide. 7. Remove the timing chain. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 156: Tensioner Service

    NOTICE The bottom fastener feature is slotted. 2. Remove chain tensioner fastener and chain tensioner. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.42 © Copyright Polaris Industries Inc.
  • Page 157 80 in-lbs (9 N·m) 6. Press in and release the tensioner piston to allow it to engage with the chain guide. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.43 © Copyright Polaris Industries Inc.

  • Page 158: Camshaft Removal

    5. Allow the chain to rest upon the front cover boss. IMPORTANT Note the orientation of the camshaft carriers for re- assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.44 © Copyright Polaris Industries Inc.

  • Page 159: Camshaft Cleaning And Inspection

    • Oil the camshaft. • Inspect the camshaft cover for cracks or other signs of damage. 9. Remove the intake and exhaust camshaft. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 160: Camshaft Timing Chain And Sprocket Cleaning And Inspection

    10. Verify oil nozzle oil flow with compressed air. 11. Inspect the timing chain tensioner for scoring or free movement. If damaged, replace the timing chain tensioner. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 161: Cylinder Head Removal

    CAUTION Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. 3. Remove the cylinder head. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.47 © Copyright Polaris Industries Inc.

  • Page 162: Cylinder Head Warp Inspection

    6. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools. 7. Replace all suspect bolts. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 163: Cylinder Head And Gasket Surface Cleaning And Inspection

    Do not use a wire brush on any part of the valve stem. Do not grind or condition the intake valve. 3. Inspect the cylinder head gasket surface. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 164: Valve Inspection

    5. Insert valves into their original locations in cylinder head. 6. Inspect that each valve moves up and down smoothly without binding in guide. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.50 © Copyright Polaris Industries Inc.

  • Page 165: Combustion Chamber Cleaning

    2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 4. Inspect the cut area of the seat: 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.51 © Copyright Polaris Industries Inc.
  • Page 166 The valve seat should contact the middle of the ITEM ANGLE 30º 45º or 46º 60º or 75º 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.52 © Copyright Polaris Industries Inc.
  • Page 167 12. Thoroughly clean cylinder head and valves. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 168: Engine Disassembly / Inspection - Bottom End

    Use the pry points on the oil pan to release the seal between the crankcase and the oil pan. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 169: Reed Valve Replacement

    Make sure they are in the proper orientation as shown.. TORQUE Reed Valve Fasteners: 80 in-lbs (9 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 170: Piston Disassembly / Inspection

    Service Limit: DO NOT apply heat to piston rings or a loss of radial 0.8651 in (21.975 mm) tension could result. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 171: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 172: Piston-To-Cylinder Clearance

    Service Limit: 0.0452 in (1.15 mm) NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 173: Connecting Rod Inspection

    3. Inspect the small end and big end of connecting rod (and matching rod cap) for damage, galling of surface or pitting. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 174: Cylinder Head Disassembly

    3.73 procedure in this chapter. 3. Remove the valve keys 4. Slowly release the PV-1253 compressor from the valve spring assembly. 5. Remove the retainers 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.60 © Copyright Polaris Industries Inc.
  • Page 175 7. Using the a commercially available valve seal remover , remove the valve seals . Do not reuse the valve seals. 8. Remove the intake and exhaust valves. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.61 © Copyright Polaris Industries Inc.

  • Page 176: Flywheel Removal

    8. Inspect the bearing journals and the thrust surfaces for the following conditions: • Cracks • Chips • Gouges • Roughness • Grooves • Overheating (discoloration) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 177: Engine Block Disassembly

    If they are not in line, the crankshaft is bent and must be replaced. 2. Remove the knock sensor and bolt. 3. Remove the crankshaft position (CKP) sensor and bolt. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 178: Engine Block Cleaning And Inspection

    11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side with a suitable tool. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.64 © Copyright Polaris Industries Inc.
  • Page 179 15. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification. 16. Remove the bed plate. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 180: Harmonic Damper Cleaning And Inspection

    • Worn, chunking or deteriorated rubber between the • A scored, grooved or damaged friction surface. hub and pulley 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.66 © Copyright Polaris Industries Inc.

  • Page 181: Crankshaft And Bearing Cleaning And Inspection

    11. Measure the crankshaft journals for taper. 12. Measure the crankshaft runout.. Using wooden V- blocks, support the crankshaft on the front and rear journals. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 182: Oil Pump Disassembly

    Generally, if the lower half is suitable for use, the upper half should also be suitable for use. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.68 © Copyright Polaris Industries Inc.
  • Page 183 Clean all of the parts in cleaning solvent. Remove varnish, sludge and dirt. 5. Inspect the oil pump components for wear. Replace components as necessary. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.69 © Copyright Polaris Industries Inc.

  • Page 184: Engine Assembly - Bottom End

    80 in-lbs (9 N·m) 2. Install the regulator valve into the oil pan. Torque to specification TORQUE Regulator Valve Assembly: 21 ft-lbs (28 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.70 © Copyright Polaris Industries Inc.
  • Page 185 TORQUE 80 in-lbs (9 N·m) Oil Pump Pickup Fasteners: 80 in-lbs (9 N·m) TORQUE Oil Pump Fasteners: 80 in-lbs (9 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 186: Bearing Selection Identification Letters And Numbers

    The last four are the rod bearing numbers, starting at the timing chain end. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 187: Connecting Rod Bearing Selection

    BEARING SELECTION CHART — ROD Green Blue Black Case Yellow Green Blue Crankshaft Yellow Green Code White Blue White Yellow Blue White 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 188: Engine Block Assembly

    3. Install the crankshaft position sensor. Torque fastener 16 ft-lbs (22 N·m) to specification. TORQUE Crankshaft Position Sensor Fastener: 80 in-lbs (9 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.74 © Copyright Polaris Industries Inc.
  • Page 189 7. Install the piston jet fasteners and torque to specification. TORQUE Piston Jet Fasteners: 89 in-lbs (10 N·m) TORQUE Engine Breather Fasteners: 80 in-lbs (9 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 190: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.76 © Copyright Polaris Industries Inc.

  • Page 191: Lower Crankcase Installation

    Ensure it is aligned the lower crankcase. Apply oil to bearing surfaces. properly on the alignment dowels. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 192 90° 10. Torque the lower crankcase perimeter bolts in sequence to specification. TORQUE Crankcase Fasteners, Outer: 16 ft-lbs (22 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 193: Crankshaft Rear Oil Seal Installation

    3. Using the PU-52884 rear seal installer, press the new crankshaft seal into the housing. The PU-52884 also establishes the depth of the seal in the crankshaft seal bore. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.79 © Copyright Polaris Industries Inc.

  • Page 194: Front Cover Installation

    6. Install the Alternator. See Alternator Installation page NOTICE The longer fasteners support the water pump. Make sure the pump is seated properly before installing the fasteners. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 195: Oil Pan Installation

    2. Clean with isopropyl alcohol prior to applying sealant. Apply sealant in approximately 3mm wide by 2mm high bead around the perimeter of the oil pan as shown. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.81 © Copyright Polaris Industries Inc.
  • Page 196 ENGINE / COOLING SYSTEM TORQUE M8 Fasteners (items 1-16): 16 ft-lbs (22 N·m) M10 Fasteners (items 17-19): 35 ft-lbs (48 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 197: Crankshaft Harmonic Damper Installation

    3. Install cargo box. Torque fasteners to specification. Flywheel Fasteners: TORQUE 24 ft-lbs (33 N·m) + 120° Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 198: Engine Assembly - Top End

    8. Using the PU-51126 compressor, compress the valve spring. 9. Install the valve keys 10. Slowly release the PU-51126 compressor from the valve/spring assembly 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.84 © Copyright Polaris Industries Inc.

  • Page 199: Piston Ring Installation

    Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.85 © Copyright Polaris Industries Inc.
  • Page 200 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. Second Ring Gap Position 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.86 © Copyright Polaris Industries Inc.

  • Page 201: Piston, Connecting Rod, And Bearing Installation

    IMPORTANT Do not brush the fracture face to clean it. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.87 © Copyright Polaris Industries Inc.

  • Page 202: Cylinder Head Installation

    Do not drop fasteners into cylinder head. Damage to the fastener threads may occur. 4. Install and torque the cylinder head bolts in sequence. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.88 © Copyright Polaris Industries Inc.

  • Page 203: Camshaft Installation

    1. Set the intake and exhaust camshafts. TORQUE Camshaft Carrier Fasteners: 13 ft-lbs (17 N·m) 4. Install the Valve Cover. See Valve Cover Installation page 3.96. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 204: Camshaft Timing Chain And Sprocket Installation

    2. If removed, install the intake and exhaust camshaft 22 ft-lbs (30 N·m) + 90° sprockets. Place the cam hex in a soft jaw vice. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.90 © Copyright Polaris Industries Inc.
  • Page 205 Route the timing chain around the crankshaft sprocket and align crankshaft indicator dot between the colored links in approximately the 4 o’clock position. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.91 © Copyright Polaris Industries Inc.

  • Page 206: Valve Clearance Adjustment

    15. Install the Alternator. See Alternator Installation page 5. Measure the valve clearance using a feeler gauge. Record the measurement if clearance is out of specification. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.92 © Copyright Polaris Industries Inc.
  • Page 207 TORQUE Camshaft Carrier Fasteners: 13 ft-lbs (17 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.93 © Copyright Polaris Industries Inc.
  • Page 208 17. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Timing”. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.94 © Copyright Polaris Industries Inc.

  • Page 209: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.95 © Copyright Polaris Industries Inc.

  • Page 210: Valve Cover Installation

    TORQUE Spark Plugs: 106 in-lbs (12 N·m) 5. Install the ignition coils TORQUE Valve Cover Fasteners: 89 in-lbs (10 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.96 © Copyright Polaris Industries Inc.
  • Page 211 7. Connect the spark plug wire connectors to the ignition coils. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.97 © Copyright Polaris Industries Inc.
  • Page 212 ENGINE / COOLING SYSTEM NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 3.98 © Copyright Polaris Industries Inc.
  • Page 213 ..............4.13 OXYGEN SENSOR REPLACEMENT 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 214: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU from another Polaris RZR of the same model may be used without system or engine component damage. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 215: Etc Learn Procedure

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Fasteners: 27 in-lbs (3 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 216: Pressure Sensors

    203° F (95° C) 212° F (100° C) 221° F (105° C) 230° F (110° C) 239° F (115° C) 248° F (120° C) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 217: Knock Sensor

    The sensor lead should point straight forward. Torque mounting bolt to specification. TORQUE Knock Sensor Fastener: 15 ft-lbs (20 Nm) 4. Connect knock sensor harness. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 218: 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 procedure. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 219: Cps Replacement

    3. Install new sensor using a light coating of oil on the O-ring to aid installation. 4. Install fastener and torque to specification. TORQUE CPS Fastener: 9 ft-lbs (12 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 220: Electronic Throttle Control (Etc) / Throttle Body

    RPM ranges based off input provided by the Pedal Position Sensor (PPS) and Electronic Control Unit (ECU). 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 221: Etc / Throttle Body Replacement

    TORQUE ETC Housing Fasteners: 7 ft-lbs (10 Nm) Intake Duct Clamp: 35 in-lbs (3 Nm) Body Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 222: Pedal Position Sensor (Pps)

    The Pedal Position Sensor is calibrated to the throttle pedal. If the PPS is faulty, the throttle pedal assembly must be replaced. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 223: Pps Replacement

    4 wire heated element. 2018 CONNECTOR WIRE PIN AND WIRE COLOR CONNECTION Purple Heater Power White Heater Ground Gray Sensor Output Black Sensor Ground 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 4.11 © Copyright Polaris Industries Inc.
  • Page 224 O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 225: Oxygen Sensor Replacement

    2. Remove the oxygen sensor from the exhaust pipe. Oxygen Sensor: 13 ft-lb (18 Nm) 4. Connect the harness going to the oxygen sensor. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 4.13 © Copyright Polaris Industries Inc.
  • Page 226 ENGINE ELECTRICAL NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 227 ................5.24 FUEL SENDER TEST 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 228: General Information

    GENERAL INFORMATION SPECIAL TOOLS PART NUMBER DESCRIPTION Fuel Pressure Gauge Kit PU-43506-A Fuel Pump Service Tool PU-50326 Fuel Pressure Gauge Adapter PA-48838 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 229: Efi Overview

    / fuel ratio is automatically calculated by the ECU. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 230: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 231: Initial Priming / Starting Procedure

    NOTICE Accurate testing of EFI components is recommended utilizing the Digital Wrench® II Diagnostic Software (dealer only). 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 232: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 233: Fuel Injector Troubleshooting

    Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 234: Fuel Injector Replacement

    6. Disconnect the wiring going to the fuel injectors. 14. Connect the wiring harness to the correct fuel injector. 15. Connect the fuel supply line to the fuel rail. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 235 19. Reinstall the cargo box. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 236: Fuel Lines

    Fuel Pump Assembly Fuel Vent Line Fuel Tank Strap Fuel Cap Fuel Tank Strap Fasteners 15 ft-lbs (20 Nm) Fuel Tank 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 237: Fuel System Assembly View (Evap)

    Carbon Canister Filter Fuel Cap Carbon Canister Filter Fasteners 9 ft-lbs (12 Nm) Fuel Tank Fuel Vent Line Fuel Tank Strap 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 238: Fuel Line Removal / Installation

    4. Remove the fuel line from the vehicle. 5. To install the line, verify the connections are clean and free of debris. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 239: Fuel Vent Line Routing

    Engine miss or hesitation Symptoms of a restricted fuel tank vent include the following: Loss of engine performance High exhaust temperatures. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.13 © Copyright Polaris Industries Inc.
  • Page 240 2. Secure vent line into the shock support tube with a termination fitting 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 241: Fuel Vent Line Routing (Evap)

    Engine miss or hesitation Symptoms of a restricted fuel tank vent include the following: Loss of engine performance High exhaust temperatures. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 242: Vent Line Termination Fitting

    Vac™ to ensure proper venting. Connect the Mity Vac to the fitting and give it 5 pumps. The gauge should return to 0 immediately or there is an obstruction. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.16 © Copyright Polaris Industries Inc.
  • Page 243 If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 244: Fuel Tank / Pump

    FUEL TANK ASSEMBLY VIEW PFA Nut Fuel Level Float 70 ft-lbs (95 Nm) PFA Gasket Fuel Pickup Supply Line Fuel Tank Vent Fuel Pump 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 245: Fuel Tank Replacement

    A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 246: Fuel Tank Replacement (4-Seat)

    3. Disconnect the battery cables from the battery, located under the driver’s seat. 4. Remove the lower floor panels. See Console and Lower Floor Removal page 11.25. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 247: Fuel Pump Operation Overview

    Seat Base Frame Fasteners: 15 ft-lbs (20 Nm) TORQUE Shift Knob Fastener: 35 in-lbs (4 Nm) TORQUE Battery Cable Fasteners: 60 in-lbs (7 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.21 © Copyright Polaris Industries Inc.

  • Page 248: Fuel Pressure Test

    8. If the pump still does not operate, replace the fuel the vehicle’s fuel tank. pump. Fuel Pressure Gauge Kit: PU-43506-A 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 249: Fuel Pump Replacement

    9. Transfer old fuel pump to a suitable container capable TORQUE of safely holding fuel. The fuel pump will retain some Fuel Pump PFA Nut: fuel. 70 ft-lbs (95 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.23 © Copyright Polaris Industries Inc.

  • Page 250: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 5.24 © Copyright Polaris Industries Inc.
  • Page 251 ...............6.26 DRIVEN CLUTCH ALIGNMENT 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 252: General Information

    SPRING SPRING 0-1800 Meters W-38-117 2022 (0-6000 Feet) (1327358) Black Black (7045118) (7045119) 1800-3700 Meters W-38-110 PRO R 4 (6000-12000 Feet) (1323778) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 253: Pvt System Overview

    At lower RPM, the drive belt rotates low in the drive clutch sheaves. As engine RPM increases, centrifugal force causes the drive belt to be forced upward on drive clutch sheaves. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 254: Drive Belt

    2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 255: Belt Installation

    7. Install upper and lower rear close-off panels. 8. Install seats. On 4-seat models, install the rear seats. TORQUE Outer PVT Cover Fasteners: 60 in-lbs (7 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 256: Belt Break-In

    Avoid prolonged low speed operation at high throttle. Avoid aggressive acceleration, high-speed operation and prolonged operation at a specific RPM during this period. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 257: Drive Clutch Service

    PU-52920 5. Remove five fasteners , disengage remaining 1/4 turn latches, and remove the outer PVT cover. 6. Remove the drive belt. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 258: Drive Clutch Assembly View

    Clutch Spacer Washer Needle Bearing Stationary Sheave Shift Weight Shift Weight Fastener 20 in-lb (2 Nm) Clutch Button Washer Spider Pin Bushing 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 259 PVT SYSTEM TORQUE DESCRIPTION Roller Wear Plate Nuts 27 in-lbs (3 Nm) Wear Plate 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 260: Clutch Disassembly

    3. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 261: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 262: Roller Replacement

    Roller, Pin, and Thrust Washer Inspection page 6.11 procedure. 4. Install the roller buttons and verify smooth operation of the roller. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.12 © Copyright Polaris Industries Inc.

  • Page 263: 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.13 © Copyright Polaris Industries Inc.

  • Page 264: Drive Clutch Spring Inspection

    Replace the bushing(s) if more brass than Teflon® is visible on the bushing(s). Refer to Bushing Service page 6.15 procedure. MEASUREMENT Drive Clutch Spring Height: 7045118: 2.44” (61.98 mm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 265: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.15 © Copyright Polaris Industries Inc.
  • Page 266 (PN 5020634) into center of clutch cover. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.16 © Copyright Polaris Industries Inc.

  • Page 267: Clutch Assembly

    1. Install two washers , needle bearing , and clutch spacer onto the stationary sheave in the order shown. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.17 © Copyright Polaris Industries Inc.

  • Page 268: Drive Clutch Installation

    1/4 turn latches to secure the cover. Torque fasteners to specification. TORQUE Outer PVT Cover Fasteners: 60 in-lbs (7 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.18 © Copyright Polaris Industries Inc.
  • Page 269 35 in-lbs (3 Nm) 6. Install upper and lower rear close-off panels. 7. Install seats. On 4-seat models, install the rear seats. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.19 © Copyright Polaris Industries Inc.

  • Page 270: Driven Clutch Service

    5. Remove five fasteners , disengage remaining 1/4 turn latches, and remove the outer PVT cover. 6. Remove the drive belt. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.20 © Copyright Polaris Industries Inc.

  • Page 271: Driven Clutch Assembly View

    Moveable Sheave Helix Fasteners Roller Pin 63 ft-lbs (85 Nm) Stationary Sheave Windage Plate Windage Plate Fastener Bearing 50 in-lbs (6 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 272: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.22 © Copyright Polaris Industries Inc.

  • Page 273: Helix And Movable Sheave Bushing Inspection

    5. Remove the nut from the puller rod and set aside. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.23 © Copyright Polaris Industries Inc.

  • Page 274: Driven Clutch Assembly

    The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 275: Driven Clutch Installation

    1/4 turn latches to secure the cover. Torque fasteners to specification. TORQUE Outer PVT Cover Fasteners: 60 in-lbs (7 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.25 © Copyright Polaris Industries Inc.

  • Page 276: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.26 © Copyright Polaris Industries Inc.
  • Page 277 (720°)Step 3: 118 ft-lbs (160 Nm) 10. Reinstall the drive belt and outer cover assembly. Refer to Belt Installation page 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.27 © Copyright Polaris Industries Inc.
  • Page 278 PVT SYSTEM NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 279 ............... . .7.20 TRANSMISSION ASSEMBLY 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 280: General Information

    TOOL DESCRIPTION NUMBER PU-51862 Snorkel Tube Tool PU-52919 Drive Clutch Puller PU-52920 Drive Clutch Holder Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 281: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 282: Shift Cable Adjustment

    9. Turn ignition on and check travel of the shifter throughout the gear range. Ensure each gear selects positively, and the selected gear is properly displayed on the gauge cluster. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 283: Transmission Service

    8. Loosen hose clamp and remove the PVT intake hose. 12. Remove drive clutch retaining bolt and remove the drive clutch moveable-sheave assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 284 15. Remove two O-rings from the transmission. 19. Loosen two air box hose clamps and disconnect air ducts from the air box. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 285 22. Remove two rear fasteners and remove cargo box support. 26. Remove nine fasteners from the exhaust manifold and remove the exhaust assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 286 29. Disconnect shift cables Prop shaft hidden for image clarity. 32. Disconnect main engine electrical harness 30. Remove two fasteners and remove shift cable bracket. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 287 Verify that engine lift brackets are tight prior to removing engine from the chassis. Use caution when lifting engine to avoid damaging the throttle body. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 288: Transmission Installation

    Rear Prop Shaft Coupling Fasteners: Engine Mount Fasteners: 11 ft-lbs (15 Nm) Step 1: 26 in-lbs (3 Nm)Step 2: 33 ft-lbs (45 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.10 © Copyright Polaris Industries Inc.
  • Page 289 9. Connect shift cables TORQUE Engine/Transmission Mounting Fasteners: 33 ft-lbs (45 Nm) 7. Connect main engine electrical harness Connect gear position sensor electrical harness. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.11 © Copyright Polaris Industries Inc.
  • Page 290 TORQUE Exhaust Headpipe Fasteners: Step 1: 60 in-lbs (7 Nm)Step 2: 22 ft-lbs (30 Nm) 12. Connect oxygen sensor electrical harness. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.12 © Copyright Polaris Industries Inc.
  • Page 291 TORQUE Cargo Box Support Fasteners: 22 ft-lbs (30 Nm) TORQUE Head Pipe to Muffler Fasteners: 18 ft-lbs (25 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.13 © Copyright Polaris Industries Inc.
  • Page 292 20. Connect rear tail light harness. 21. Install two transmission vent lines and engage hose clamps TORQUE Intake Duct Hose Clamps: 35 in-lbs (3 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 293 : 11 ft-lbs (15 Nm) : 35 in-lbs (4 Nm) 27. Install the drive belt. 24. Install drive clutch stationary sheave. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.15 © Copyright Polaris Industries Inc.
  • Page 294 31. Connect coolant inlet and outlet hoses to the engine. 32. Fill coolant. Refer to coolant fill/bleed procedure outlined in this chapter. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 295: Transmission Vent Line Routing

    Idler gear may come off with front transmission cover as shown. 3. Remove idler gear from transmission cover. 4. Remove one fastener and remove shift linkage plate. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 296 10. Remove the shift shaft and forks as an assembly. NOTICE External shift mechanism can be serviced in the vehicle without removal of the engine/transmission. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 297 If gear replacement is required, also replace the corresponding gear and/or gear shaft. 13. Remove front output shaft from gear housing. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 298: Transmission Assembly

    3. Install front output shaft into gear housing. 8. Install the two sector gears. 4. Install three idler gears as an assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 299 14. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to left-hand transmission 11. Install transmission position sensor mating surface. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.21 © Copyright Polaris Industries Inc.
  • Page 300 TRANSMISSION 15. Install transmission cover onto the transmission and install sixteen fasteners . Torque fasteners to specification. TORQUE Transmission Cover Fasteners:: 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 301 ..................8.37 TIRE BALANCING 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 302: General Information

    SPECIAL TOOLS PART NUMBER DESCRIPTION 2872608 Roll Pin Removal Tool CV Boot Clamp Pliers 8700226 Axle Boot Clamp Tool PU-48951 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 303: Bearing Carrier

    3. Remove wheel nuts and remove the front wheel. 4. Remove the front wheel hub axle nut and discard. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 304: Front Bearing Carrier Installation

    Upper Ball Joint Pinch Bolt: 52 ft-lbs (70 Nm) - Torque bolt side TORQUE Lower Ball Joint Nut: 44 ft-lbs (60 Nm) + 90° (Single Use) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 305: Rear Bearing Carrier Inspection / Removal

    TORQUE Wheel Nuts: 148 ft-lbs (200 Nm) 10. Rotate wheel and check for smooth operation. 6. Remove half shaft from knuckle assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 306: Rear Bearing Carrier Installation

    Inner Radius Rod Fasteners (Single Use): 52 ft-lbs (70 Nm) + 90°Outer Radius Rod Fasteners: 133 ft- lbs (180 Nm) - Torque bolt side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 307 89 ft-lbs (120 Nm) 5. Install wheel and five wheel nuts. Torque nuts to specification. TORQUE Wheel Nuts: 148 ft-lbs (200 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 308: Half Shaft

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 6. Remove the front wheel hub assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 309: Rear Half Shaft Removal

    6. Install front knuckle assembly and axle nut. Torque NEW axle nut to specification. TORQUE Wheel Axle Nut: 89 ft-lbs (120 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 310: Rear Half Shaft Installation

    (180 Nm) - Torque bolt side 4. Install NEW wheel axle nut. Torque nut to specification. TORQUE Wheel Axle Nut: 89 ft-lbs (120 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 311: Half Shaft / Cv Joint Handling Tips

    Refer to text for grease capacity of CV joints and CV joint boots. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 312: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.12 © Copyright Polaris Industries Inc.
  • Page 313 12. Install and tighten the small clamp on the boot using the appropriate clamp tool. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 314: Prop Shaft

    FINAL DRIVE PROP SHAFT PROP SHAFT ASSEMBLY VIEW Front Prop Shaft Slip Yoke Rear Prop Shaft Cross and Bearing 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 315: Prop Shaft Assembly View (4-Seat)

    REAR PROP SHAFT REPLACEMENT 2. Remove seven fasteners and remove engine mounting bracket. REMOVAL 1. Park vehicle on a flat, level surface. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.15 © Copyright Polaris Industries Inc.
  • Page 316 11 ft-lbs (15 Nm) INSTALLATION 1. Install prop shaft onto transmission output shaft. Grease front yoke/transmission output shaft upon installation. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 317: Intermediate Prop Shaft Replacement (4-Seat)

    2. Install prop shaft yoke into transmission output shaft. 4. Remove prop shaft slip yoke from the transmission and remove prop shaft out the bottom of the vehicle. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.17 © Copyright Polaris Industries Inc.
  • Page 318 Torque vertical bolts: 81 ft-lbs (110 Nm) 11. Install NEW front prop shaft roll pin. 12. Install two front gearcase electrical harnesses. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.18 © Copyright Polaris Industries Inc.
  • Page 319 16. Install brake disc and caliper assembly. Torque brake caliper fasteners to specification. TORQUE Front Caliper Mounting Bolts: 73 ft-lbs (100 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 320: Front Prop Shaft Replacement

    IMPORTANT The access panel must be removed from the driver’s side footwell to remove rear upper control arm fastener. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.20 © Copyright Polaris Industries Inc.
  • Page 321 12. Remove and discard roll pin from front prop shaft. 13. Disconnect two front gearcase electrical harnesses. 8. With a short, sharp jerk, remove half shaft from the front gearcase. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.21 © Copyright Polaris Industries Inc.
  • Page 322 NOTICE The slip yoke on 4-seat vehicles has a skip-tooth. Align skip tooth with the intermediate shaft to install. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.22 © Copyright Polaris Industries Inc.
  • Page 323 13. Install front knuckle assembly and axle nut. Torque axle nut to specification. TORQUE Wheel Axle Nut: 89 ft-lbs (120 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.23 © Copyright Polaris Industries Inc.
  • Page 324 16. Install ball joint pinch bolt, washer, nut. Torque fastener to specification. TORQUE Upper Ball Joint Pinch Bolt: 52 ft-lbs (70 Nm) - Torque bolt side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 325: U-Joint Disassembly

    2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a suitable press. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 326: U-Joint Assembly

    FRONT GEARCASE FRONT GEARCASE ASSEMBLY VIEW Cover Plate Dowel Pin Cover Plate Fasteners Shim Isolator Mount Bearing Vent Tube Differential Carrier 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 327 Pinion Disconnect Housing Bearing Disconnect Shaft Spider Gear Shift Collar Dowel Pin Shift Disconnect Fork Differential Pin Solenoid Output Gear Spring 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 328: Front Gearcase Vent Line Routing

    1. Place vehicle on a suitable lift or jack and remove front wheel. 2. Remove four front fascia fasteners and remove front fascia. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 329 9. With a short, sharp jerk, remove half shaft from the front gearcase. The access panel must be removed from the driver’s side footwell to remove rear upper control arm fastener. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.29 © Copyright Polaris Industries Inc.
  • Page 330 14. Disconnect vent line and remove gearcase through 4. Install two front gearcase isolator fasteners. Torque the opening in front of the frame. fasteners to specification. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.30 © Copyright Polaris Industries Inc.
  • Page 331 133 ft-lbs (180 Nm) - Torque bolt side Front Caliper Mounting Bolts: 73 ft-lbs (100 Nm) 10. Apply Anti-Seize to half shaft axle splines. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.31 © Copyright Polaris Industries Inc.
  • Page 332 15. Install ball joint pinch bolt, washer, nut. Torque fastener to specification. TORQUE Upper Ball Joint Pinch Bolt: 52 ft-lbs (70 Nm) - Torque bolt side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.32 © Copyright Polaris Industries Inc.

  • Page 333: Front Gearcase Disassembly / Inspection

    Inspect sealing o- ring on the cover and inspect the axle seal. Replace if damaged or worn. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.33 © Copyright Polaris Industries Inc.

  • Page 334: Front Gearcase Assembly

    Ring Gear Assembly Fasteners: 14 ft-lbs (19 Nm) + 40° TORQUE Cover Plate Fasteners: 23 ft-lbs (31 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 335: Wheel Hubs

    148 ft-lbs (200 Nm) Valve Stem Washers Axle Nut Hub Mounting Bolt 89 ft-lbs (120 Nm) 81 ft-lbs (110 Nm) Brake Rotor 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.35 © Copyright Polaris Industries Inc.

  • Page 336: Rear Hub Assembly View

    148 ft-lbs (200 Nm) Valve Stem Washers Axle Nut Hub Mounting Bolts 89 ft-lbs (120 Nm) 81 ft-lbs (110 Nm) Brake Rotor 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.36 © Copyright Polaris Industries Inc.

  • Page 337: Tire Balancing

    Balancing tires eliminates/minimizes steering vibrations, prevents excessive wear on suspension components, • Excessive or uneven tread wear and increases a tire’s lifespan and performance. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 338 FINAL DRIVE NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 339 ..... .9.51 FRONT / REAR SHOCK COMPRESSION ADJUSTMENT (NON-DYNAMIX) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 340 ............9.64 SUSPENSION MODE SWITCH (DYNAMIX MODELS) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 341: General Information

    -0.52° ± 0.46° Caster (Non-Adjustable) 4.49° ± 0.82° 0.00° ± 0.45° REAR WHEEL ALIGNMENT SPECIFICATIONS Camber (Non-Adjustable) -0.49° ± 0.75° 0.50° ± 0.45° 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 342: Steering System

    26 ft-lbs (35 Nm) + 90° 44 ft-lbs (60 Nm) UPPER STEERING SHAFT REPLACEMENT REMOVAL 1. Park vehicle on a flat, level surface. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 343: Lower Steering Shaft Replacement

    1. Park vehicle on a flat, level surface. 2. Remove steering wheel cover 5. Remove dash. See Dash Removal in the Body/Frame chapter. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 344 5. Remove dash. See Dash Removal in the Body/Frame chapter. 6. Remove two fasteners from the tilt bracket assembly, and remove tilt bracket and pivot tube as an assembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 345: Eps Unit / Steering Rack Replacement

    5. Driver’s side only: Remove two control arm mounting fasteners IMPORTANT The access panel must be removed from the driver’s side footwell to remove rear upper control arm fastener. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 346 9. With a short, sharp jerk, remove half shaft from the 15. Remove tie rod ball joints from steering knuckles. front gearcase. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 347 3. Install half shaft onto front gearcase input shaft. TORQUE Front Bumper Fasteners: 37 ft-lbs (50 Nm) 8. Install half shafts into front gearcase. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 348 11. Apply Anti-Seize to half shaft axle splines. TORQUE Control Arm Mounting Fasteners: 133 ft-lbs (180 Nm) - Torque bolt side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.10 © Copyright Polaris Industries Inc.
  • Page 349 52 ft-lbs (70 Nm) - Torque bolt side 16. Install front fascia and four front fascia mounting fasteners. TORQUE Front Fascia Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 350: Eps Pre-Positioning / Steering Angle Centering

    3. Select option 1 at the next menu. 4. Follow instructions in Digital Wrench to properly center the EPS steering angle sensor. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.12 © Copyright Polaris Industries Inc.
  • Page 351 STEERING / SUSPENSION 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 352: Front Suspension

    Sway Bar Link 44 ft-lbs (60 Nm) + 90° (Single Use) Control Arm Fasteners 133 ft-lbs (180 Nm) - Torque bolt side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 353: Upper Control Arm Replacement

    6. Remove control arm from the vehicle. INSTALLATION 1. Install control arm into its inner mounts, and ball joint into the bearing carrier. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 354: Lower Control Arm Replacement

    52 ft-lbs (70 Nm) - Torque bolt side REMOVAL 1. Park vehicle on a flat, level surface. 2. Safely raise front of the vehicle. 3. Remove wheel. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.16 © Copyright Polaris Industries Inc.
  • Page 355 7. Remove lower control arm. Shock Mounting Fastener: 133 ft-lbs (180 Nm) - Torque bolt side TORQUE Stabilizer Bar Link Fastener: 81 ft-lbs (110 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 356: Front Stabilizer Bar Replacement

    3. Remove stabilizer arm-to-bar fastener and remove stabilizer bar arm. Repeat on opposite side of vehicle 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 357: Stabilizer Bar Clocking

    STABILIZER BAR CLOCKING 1. Disconnect drop links from both ends of the stabilizer bar. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 358: Ball Joint Replacement

    Clean groove, if necessary. NOTICE A pick, stiff bristled brush, or other suitable tool may be used to clean the snap ring groove. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.20 © Copyright Polaris Industries Inc.
  • Page 359 7. Repeat the ball joint service procedure for any additional control arm ball joint replacements. 8. Refer to upper/lower control arm replacement for installation procedure and applicable torque specifications. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 360: Rear Suspension

    Stabilizer Bar Link Stabilizer Bar Arm Fastener Front Toe Link Fastener 81 ft-lbs (110 Nm) 133 ft-lbs (180 Nm) - Torque bolt side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 361: Trailing Arm Replacement

    9. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.23 © Copyright Polaris Industries Inc.
  • Page 362 Use new fastener nuts upon installation of the rear trailing arm and bearing carrier. 14. Remove two fasteners from toe link access panel. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 363: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 364: Radius Rod Replacement

    5. Remove bolts attaching radius rods to the vehicle frame. Discard the nuts. 6. Remove radius rods from vehicle. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 365: Rear Stabilizer Bar Replacement

    8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. INSTALLATION 1. Carefully install stabilizer bar through the LH wheel well area. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 366: Shocks / Springs

    4. Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.28 © Copyright Polaris Industries Inc.

  • Page 367: Shock / Spring Replacement

    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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 368: Fox 3.0" Dv Shock Information (Front)

    IFP Depth 2.20″ (5.58 cm) Spring Adjustment Setting Nitrogen Pressure 100 psi (690 kPa) +/- 5% 2874124 (qt.) Gas Shock Oil 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.30 © Copyright Polaris Industries Inc.

  • Page 369: Fox 3.0" Dv Shock Information (Rear)

    IFP Depth 6.63″ (16.84 cm) Spring Adjustment Setting Nitrogen Pressure 100 psi (690 kPa) +/- 5% 2874124 (qt.) Gas Shock Oil 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 370: Shock Service

    Retaining Ring Bearing Assembly Retaining Ring Reservoir End Cap Assembly Bearing Cap Damping Adjust Assembly Body Cap Sparing Hardware Assembly Body 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.32 © Copyright Polaris Industries Inc.

  • Page 371: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.33 © Copyright Polaris Industries Inc.

  • Page 372: Fox Shock Disassembly

    Clean the entire shock assembly with soapy water or mild solvent. Rinse and dry shock. Ensure you have obtained the correct rebuild kit and oil prior to disassembly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.34 © Copyright Polaris Industries Inc.
  • Page 373 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.35 © Copyright Polaris Industries Inc.
  • Page 374 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.36 © Copyright Polaris Industries Inc.
  • Page 375 26. Remove lock nut from the shaft assembly. 30. Remove compression valve stack and cable tie together. Clean with contact cleaner. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.37 © Copyright Polaris Industries Inc.
  • Page 376 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.38 © Copyright Polaris Industries Inc.
  • Page 377 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.39 © Copyright Polaris Industries Inc.
  • Page 378 STEERING / SUSPENSION 2.5 Bypass Piston 3.0 Bypass Piston Compression Side Compression Side Rebound Side Rebound Side 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.40 © Copyright Polaris Industries Inc.

  • Page 379: Fox Shock Assembly

    30 ft-lb (42 Nm) 3. With body prepared with Loctite primer add a layer of Loctite 638 2 threads up, 2 threads wide 360°. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.41 © Copyright Polaris Industries Inc.
  • Page 380 19. Install 2nd T-seal back-up ring 20. Install wiper seal. 21. Lubricate all seals with Slick Honey. 22. Install external o-ring. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.42 © Copyright Polaris Industries Inc.
  • Page 381 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.43 © Copyright Polaris Industries Inc.
  • Page 382 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.44 © Copyright Polaris Industries Inc.
  • Page 383 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.45 © Copyright Polaris Industries Inc.

  • Page 384: Shock Service

    Piston Wear Band (1.750" OD) 36. Shaft, Chrome Clicker Bolt Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.46 © Copyright Polaris Industries Inc.

  • Page 385: 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 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.47 © Copyright Polaris Industries Inc.
  • Page 386 0.750 x 0.065 1.10 x 0.010 (AN) 0.750 x 0.065 1.55 x 0.010 (AN) 0.750 x 0.065 (AN) Piston Bleed Orifice: none 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.48 © Copyright Polaris Industries Inc.

  • Page 387: Rear Shock Service Information

    IFP Depth 8.00″ (20.32 cm) All Models Nitrogen Pressure 150 psi (1034.21 kPa) +/- 5% 2874124 (qt.) Gas Shock Oil P/N 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.49 © Copyright Polaris Industries Inc.
  • Page 388 1.90 x 0.010 1.30 x 0.015 2.05 x 0.008 0.900 x 0.060 2.05 x 0.008 2.05 x 0.008 No Piston Bleed Orifice 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.50 © Copyright Polaris Industries Inc.

  • Page 389: Front / Rear Shock Compression Adjustment (Non-Dynamix)

    1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression damping. LOCATION DEFAULT CLICKER POSITION Front 8/16 clicks Rear 8/16 clicks 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.51 © Copyright Polaris Industries Inc.

  • Page 390: Special Tools

    FULLY COMPRESSED SHOCK ROD FULLY EXTENDED PISTON SHOCK ROD REBOUND VALVE STACK COMPRESSION VALVE STACK 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.52 © Copyright Polaris Industries Inc.

  • Page 391: Walker Evans™ Shock Disassembly

    Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.53 © Copyright Polaris Industries Inc.
  • Page 392 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.54 © Copyright Polaris Industries Inc.
  • Page 393 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.55 © Copyright Polaris Industries Inc.

  • Page 394: Walker Evans™ Shock Assembly

    If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.56 © Copyright Polaris Industries Inc.
  • Page 395 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 PS-45908 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.57 © Copyright Polaris Industries Inc.
  • Page 396 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.58 © Copyright Polaris Industries Inc.
  • Page 397 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.59 © Copyright Polaris Industries Inc.
  • Page 398 NOTICE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.60 © Copyright Polaris Industries Inc.

  • Page 399: 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 400: Button

    9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.62 © Copyright Polaris Industries Inc.

  • Page 401: Ride Mode Controls (If Equipped)

    Ride Modes using the UP or DOWN arrow buttons, then use the throttle, brakes, and steering wheel to assess the feel of each Ride Mode. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.63...

  • Page 402: Suspension Mode Switch (Dynamix Models)

    CONTACT CONTACT PINS 1 TO POSITION Open Comfort Closed 1270 Ω Sport Open Open 1400 Ω Open Firm Closed 1330 Ω 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 9.64 © Copyright Polaris Industries Inc.
  • Page 403 ............. . . 10.28 BRAKE BURNISHING PROCEDURE 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.1...

  • Page 404: General Information

    Thickness .295 ± .008″ Rear Disc .268″ (6.8 mm) (7.5 ± .2 mm) Thickness Rear Disc – .010″ (0.25 mm) Runout 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 405: Brake System Overview

    35 in-lbs (4 Nm) Rear Brake Caliper Fasteners Pop Rivet 51 ft-lbs (70 Nm) Master Cylinder Fasteners Clip - Fir Tree 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 406: Brake System View (4-Seat)

    35 in-lbs (4 Nm) Rear Brake Caliper Fasteners Pop Rivet 51 ft-lbs (70 Nm) Master Cylinder Fasteners Clip - Fir Tree 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 407: Brake Line Routing / Retention (2-Seat)

    BRAKE LINE ROUTING / RETENTION (2-SEAT) Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Routing Clip Front Brake Calipers Master Cylinder To Junction Block 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.5 © Copyright Polaris Industries Inc.
  • Page 408 BRAKE SYSTEM Master Cylinder Routing Clip Junction Block Junction Block to Rear Brake Calipers 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.6 © Copyright Polaris Industries Inc.
  • Page 409 BRAKE SYSTEM Junction Block Rivet Clip Routing Clip Rear Brake Caliper 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 410: Brake Line Routing / Retention (4-Seat)

    BRAKE LINE ROUTING / RETENTION (4-SEAT) Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Routing Clip Front Brake Calipers Master Cylinder To Junction Block 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 411 BRAKE SYSTEM Master Cylinder Routing Clip Junction Block Junction Block to Rear Brake Calipers 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.9 © Copyright Polaris Industries Inc.
  • Page 412 BRAKE SYSTEM Junction Block Rivet Clip Routing Clip Rear Brake Caliper 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 413: 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 414: Master Cylinder

    4. Loosen the brake line banjo bolts and allow fluid to drain. NOTICE Dispose of fluid properly. Do not re-use. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 415: Brake Bleeding / Fluid Change

    Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) CAUTION Always wear safety glasses when handling chemicals and fluids. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.13 © Copyright Polaris Industries Inc.
  • Page 416 Check for proper braking action and pedal pressure builds and holds. reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.14 © Copyright Polaris Industries Inc.
  • Page 417 BRAKE SYSTEM 13. Check brake system for fluid leaks. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 418: Brake Pedal

    1. Reverse the “Removal” steps to install brake pedal lever. Compare brake pedal free-play specification. Brake Pedal Free-play: 0.090″ (2.28 mm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 419: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.17 © Copyright Polaris Industries Inc.
  • Page 420 BRAKE SYSTEM 9. Remove the bolt retaining the brake line to the caliper. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 421: Front Caliper Assembly View

    Mount Pins Boots apply Silicone Grease on install Brake Pad Wear Clip Brake Scraper Bleeder Screw Caliper Assembly 48 in-lb (5 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 422: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 423: Brake Pad Inspection

    Brake Pad Thickness: .296 ± .007″(7.53 ± .19 mm) MEASUREMENT Service Limit: Brake Disc Runout: .180″ (4.6 mm) .010″ (0.25 mm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.21 © Copyright Polaris Industries Inc.

  • Page 424: Front Brake Disc Replacement

    Maintain at least 1/2" (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 425: Troubleshooting

    6. If the concern is still present, it is possible that there may be a concern with the ECU. BRAKE PEDAL BRAKE SWITCH Brake pedal depressed Active Brake pedal released Inactive 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 426: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.24 © Copyright Polaris Industries Inc.

  • Page 427: Rear Caliper Disassembly / Inspection

    10. To remove the brake caliper: place a catch pan under the brake caliper and remove the banjo bolt retaining the brake line to the caliper. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.25 © Copyright Polaris Industries Inc.

  • Page 428: Brake Pad Inspection

    Large: 1.368-1.370 (34.75-34.80 mm) Small (2-Seat Only): 1.1860-1.1875″ (30.12-30.16 3. Inspect the brake disc and pads as outlined in this chapter. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.26 © Copyright Polaris Industries Inc.

  • Page 429: Rear Brake Disc Inspection

    Brake Disc Thickness .295 ± .008″(7.5 ± .2 mm) .268″ (6.8 mm) Brake Disc Thickness Variance: Service Limit: 0.002″ (0.051 mm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.27 © Copyright Polaris Industries Inc.

  • Page 430: Brake Burnishing Procedure

    4. Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn. 5. Follow bleeding procedure outlined earlier in this chapter. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 10.28 © Copyright Polaris Industries Inc.
  • Page 431 ................11.27 DOOR ADJUSTMENT 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.1...

  • Page 432: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.2 © Copyright Polaris Industries Inc.

  • Page 433: Body Assembly Views

    : 89 ft-lbs (120 Nm) ROPS Assembly 3. A-Pillar Fasteners : 89 ft-lbs (120 Nm) 4. Confirm B-Pillar Fastener Torque: 148 ft-lbs (200 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 434: Cab Frame Assembly (4-Seat)

    : 89 ft-lbs (120 Nm) 4. B-Pillar Fasteners : 44 ft-lbs (60 Nm) 5. Confirm C-Pillar Fastener Torque: 148 ft-lbs (200 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 435: Doors

    9 ft-lbs (12 Nm) 18 in-lbs (2 Nm) Door Striker Door Hinge Pin Door Striker Fastener Door Hinge E-Clip 9 ft-lbs (12 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 436: 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 437: Dash / Controls

    BODY / FRAME DASH / CONTROLS Headlight Switch Key Switch AWD Switch Drive Mode Switch Instrument Cluster 7” Display 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 438: Hood / Front Body

    Dash Lid Firewall Fender (LH) Fender Flare (RH) Nose Cone Inner Fender Flare (RH) TORQUE Body Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 439: Chassis / Main Frame

    Box Support 44 in-lbs (5 Nm) Skid Plate Plug Fastener (Hex) Box Support Fastener 9 ft-lbs (12 Nm) 22 ft-lbs (30 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.9 © Copyright Polaris Industries Inc.
  • Page 440 (See Front Drive Removal / Installation for torque procedure) Upper Control Arm Bracket Front Drive Mount Casting Upper Control Arm Bracket Fastener 52 ft-lbs (70 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 441: Chassis / Main Frame (4-Seat)

    44 in-lbs (5 Nm) Skid Plate Plug Fastener (Hex) Box Support Fastener 9 ft-lbs (12 Nm) 22 ft-lbs (30 Nm) Front Bumper 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.11 © Copyright Polaris Industries Inc.
  • Page 442 (See Front Drive Removal / Installation for torque procedure) Frame Cross Bar Fastener (4 Seat) (M8x1.25x20) Front Drive Mount Casting 18 ft-lbs (25Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 443: Seat Assembly

    Seat Tilt Receiver Seat Hinge Bushing (upper) Latch Hook Seat Hinge Nut Latch Hook Fastener 7 ft-lbs (10 Nm) 9 ft-lbs (12 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.13 © Copyright Polaris Industries Inc.
  • Page 444 Seat Shell Tube Fastener 10 in-lbs (1 Nm) End Cap Seat Release Assembly Seat Shell Tube Seat Release Assembly Fastener 10 in-lbs (1 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 445: Rear Seat Assembly (4-Seat)

    15 ft-lbs (20 Nm) Underseat Flip Panel Door Hinge Pin Seat Strap E-Clip Seat Frame (Rear) Seat Bottom Assembly Seat Frame Hinge 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.15 © Copyright Polaris Industries Inc.
  • Page 446 22 in-lb ( 3 Nm) Handle Latch Rear Seat Striker Seat Latch Rod Rear Seat Striker Fastener 35 in-lbs (4 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 447: Floor / Rocker Panels

    Passenger Footrest Panel Battery Tray Front Main Floor Rocker (LH) Center Console (RH) Front Floor (LH) Center Console (LH) Driver Footrest Panel 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 448: 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 449: Rear Cargo Box / Fenders

    Rear Close-Off Panel (RH) Inner Fender (RH) Rear Fender Flare (RH) Rear Bottom Close-Off Panel Fill Neck Grommet EVAP Grommet Rear Outer Fender 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 450: 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). 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 451: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.21 © Copyright Polaris Industries Inc.

  • Page 452: Rear Fascia

    8. Disconnect all headlight and accent light electrical connections. 9. Remove two push pins and remove front fascia. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 453: Hood / Front Body

    1. Remove front fascia. See Front Fascia Removal page 11.21. 2. Remove LH and center dash trim 3. Remove RH dash trim 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.23 © Copyright Polaris Industries Inc.

  • Page 454: Rear Fender / Fender Flare

    2. Pull the rear of the cargo box up and rearward to disengage front tabs and remove cargo box. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.24 © Copyright Polaris Industries Inc.

  • Page 455: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.25 © Copyright Polaris Industries Inc.
  • Page 456 9. Remove one fastener from the shift linkage and remove shift cable from its mounting bracket. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.26 © Copyright Polaris Industries Inc.

  • Page 457: 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.27 © Copyright Polaris Industries Inc.
  • Page 458 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) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 11.28 © Copyright Polaris Industries Inc.
  • Page 459 ............... 12.27 HEADLAMP REPLACEMENT 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.1...
  • Page 460 ..............12.42 ELECTRICAL HARNESS RETENTION 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.2...

  • Page 461: 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/ 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.3 © Copyright Polaris Industries Inc.

  • Page 462: Electrical Service Notes

    • Gear Position • Speed Sensor CHASSIS HARNESS • Ambient Air Temperature Sensor • Front Lighting • Radiator Fan • Audio 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.4 © Copyright Polaris Industries Inc.

  • Page 463: Electrical Component Locations (Rear)

    Transmission Harness Fuel Injector Fuse Box Alternator Harness 12V receptacle Alternator (+) Battery Negative (-) Coolant Temperature Sensor Battery Positive (+) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.5 © Copyright Polaris Industries Inc.

  • Page 464: Electrical Component Locations (Front)

    Key Switch EPS Signal Diagnostic Plug Speaker Drive Mode Switch Ambient Air Temperature Sensor Ride Command Display Headlight Fuse Block Accent Light 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.6 © Copyright Polaris Industries Inc.

  • Page 465: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.7...

  • Page 466: Information Display Area

    The LCD portion of the instrument cluster is the information display area. Information displayed in this area includes: odometer, trip meter, engine RPM, engine hours, service interval, clock, engine Diagnostic Trouble Codes (DTCs) and power steering DTCs. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.8 © Copyright Polaris Industries Inc.
  • Page 467 Service Hours interval has been reached. AREA 3 MODES MODE DESCRIPTION The clock displays time in a 12-hour or 24-hour format. Clock 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.9 © Copyright Polaris Industries Inc.
  • Page 468 4. Press MODE to save and exit to the settings menu. 1. Press and hold the MODE button to enter the settings menu. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.10 © Copyright Polaris Industries Inc.
  • Page 469 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.11 © Copyright Polaris Industries Inc.

  • Page 470: Instrument Cluster Pinouts

    Right Turn Signal Input High Beam Input Trailer Turn Sign Input Fuel Level Sensor Blackout Mode Input Accy Air Temp Input 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.12 © Copyright Polaris Industries Inc.

  • Page 471: Switches / Controls

    6 and 4 closed Neutral Low Beam 3 and 7 open, 6 and 4 closed Down 3 and 7 open, 6 and 4 open 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.13 © Copyright Polaris Industries Inc.

  • Page 472: Awd / 2Wd / Turf Switch

    5. Move the switch to TURF. There should be continuity between switch pins 1 and 2. NOTICE Pins 7 and 2 provide power and ground to light the switch lamp. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.14 © Copyright Polaris Industries Inc.

  • Page 473: Transmission / Gear Position Switch

    160 Ω test. Replace switch if necessary. 75 Ω PARK 24 Ω 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.15 © Copyright Polaris Industries Inc.

  • Page 474: Suspension Mode Switch (Dynamix Models)

    Steering Angle Adaptation Value Reset procedure, found in Steering / Suspension System Utilities on the Special Tests menu in Digital Wrench. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.16 © Copyright Polaris Industries Inc.

  • Page 475: Ignition Coil

    5. Install ignition coil harness retainers to the ignition coil fastener posts. 6. Install Cargo Box and torque fasteners to specification. TORQUE Cargo Box Fasteners: 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.17 © Copyright Polaris Industries Inc.

  • Page 476: Charging System

    5. Connect your black lead to the battery negative post. 3. Shift transmission into park and start the engine. With the engine running at idle, observe meter readings. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.18 © Copyright Polaris Industries Inc.

  • Page 477: Charging System Testing Flow Chart

    1. Inspect for poor connections at the alternator. – Go to STEP 12 Go to STEP 11 2. Was the problem located and corrected? 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.19 © Copyright Polaris Industries Inc.

  • Page 478: Alternator Replacement

    3. Remove four fasteners and remove alternator cover. 5. Disconnect the alternator electrical connector. 6. Cut the stretch belt and remove. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.20 © Copyright Polaris Industries Inc.
  • Page 479 Cover the terminal nut with the red protective cap. Alternator Mounting Fasteners: 15 ft-lbs (20 Nm) TORQUE Alternator Terminal Nut: 84 in-lbs (9 N·m) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.21 © Copyright Polaris Industries Inc.
  • Page 480 6. Install negative (-) cable to the battery and torque terminal bolt to specification. TORQUE Negative Battery Terminal: 60 in-lbs (9 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.22 © Copyright Polaris Industries Inc.

  • Page 481: Battery

    Refer to OCV table (see OCV - Open Circuit Voltage Test page 12.25). 5. Charge the battery as recommended (see – Charging Procedure page 12.26). 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.23 © Copyright Polaris Industries Inc.

  • Page 482: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.24 © Copyright Polaris Industries Inc.

  • Page 483: Battery Off Season Storage

    12.8 V and up 100% 75% Charged 12.6 V 50% Charged 12.3 V 25% Charged 12.0 V 0% Charged 11.8 V or less 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.25 © Copyright Polaris Industries Inc.

  • Page 484: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.26 © Copyright Polaris Industries Inc.

  • Page 485: 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. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.27 © Copyright Polaris Industries Inc.

  • Page 486: Tail Light Replacement

    DASH LIGHT The LED light will remain ON for approximately 30 seconds after key has been switched to the OFF position. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.28 © Copyright Polaris Industries Inc.

  • Page 487: Cooling System

    1 Ω. • Power side should show battery voltage. If battery voltage is not seen, check voltage at the fan fuse. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.29 © Copyright Polaris Industries Inc.

  • Page 488: Fan Control Circuit Bypass Test

    4. Remove thirteen fasteners , one push-pin , and remove the front fender flare. Repeat for opposite side of the vehicle. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.30 © Copyright Polaris Industries Inc.
  • Page 489 3. Route and install wiring harness onto radiator assembly. 8. Disconnect electrical connectors from the headlights and accent lights, if equipped.. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.31 © Copyright Polaris Industries Inc.
  • Page 490 6. Install front fascia and install two mounting push-pins. TORQUE 7. Install headlight and accent light electrical Front Fender Mounting Bracket Fasteners: connectors. 7 ft-lbs (10 Nm) 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.32 © Copyright Polaris Industries Inc.
  • Page 491 Hood Fasteners: 7 ft-lbs (10 Nm) 7 ft-lbs (10 Nm) 14. Fill and bleed the cooling system. Refer to Cooling System Specifications. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.33 © Copyright Polaris Industries Inc.

  • Page 492: Ect Sensor Test

    176 °F (80 °C) 323 Ω ± 6% 194 °F (90 °C) 243 Ω ± 6% 212 °F (100 °C) 186 Ω ± 6% 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.34 © Copyright Polaris Industries Inc.

  • Page 493: Starting System

    0 - 0.5 Ω between terminals (A) and (B). If resistance measurement is out of specification, replace the starter solenoid. Energize Here 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.35 © Copyright Polaris Industries Inc.

  • Page 494: Electronic Power Steering (Eps)

    PWM-T1 / TSM PWM-S Sub Torque Sensor Signal PWM-T2 / TSS CAN High CAN Signal High CAN Signal Low CAN Low 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.36 © Copyright Polaris Industries Inc.

  • Page 495: Proper Eps System Diagnosing

    EPS unit. If not, update to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.37 © Copyright Polaris Industries Inc.

  • Page 496: Fuses / Relays

    AUD AMP 30A Fuse Audio Amplifier Seat Belt Switch, SCM Wake-Up (optional), SCM Mode Switch (optional), AWD Coil, Gauge, Waste Gate 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.38 © Copyright Polaris Industries Inc.
  • Page 497 Front Differential CHARGE 15A Fuse Battery Charge Port Additional Fuses (if equipped) 10A Fuse Shock Control Module SHOCK 15A Fuse Shock Power 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.39 © Copyright Polaris Industries Inc.

  • Page 498: Pdm Fuse Troubleshooting

    If the problem persists, consult your dealer. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.40 © Copyright Polaris Industries Inc.

  • Page 499: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.41 © Copyright Polaris Industries Inc.

  • Page 500: Wiring Harness

    ELECTRICAL WIRING HARNESS ELECTRICAL HARNESS RETENTION Zip Tie Retention Point The white tape on the harness signifies a retention point 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual 12.42 © Copyright Polaris Industries Inc.
  • Page 501 WIRING DIAGRAMS APPENDIX A WIRING DIAGRAMS 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 502 ELECTRICAL NOTES 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 503 Front Caliper Assembly ......... 10.21 Coolant Front Caliper Assembly View ........10.19 Hose Inspection .............2.18 Front Caliper Disassembly / Inspection ..... 10.20 Level Inspection .............2.17 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 504 Troubleshooting - EPS Non-Functional MIL On .....1.57 Installation ............6.18 Troubleshooting - Using Digital Wrench® ....1.59 Operation .............. 6.3 Electronic Throttle Body 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 505 Cylinder Head Installation ........3.88 Replacement............5.8 Test ..............5.7 Cylinder Head Removal ...........3.47 Piston / Connecting Rod Installation ......3.87 Troubleshooting ............5.7 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 506 Disassembly / Inspection .........3.56 Instrument Cluster Piston Ring Removal..........3.57 Information Display Area..........12.8 Overview ..............12.7 Ring Groove Clearance ...........3.57 Ring Installation .............3.85 Pinouts .............. 12.12 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 507 Walker Evans 3.0 Shocks (Front) .......9.47 Rocker Panels Spring Assembly View ............ 11.17 Replacement............9.29 Assembly View (4-Seat)......... 11.18 Stabilizer Bar Routing ..............10.5 Replacement (Front) ..........9.18 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 508 Disassembly ............7.17 Installation ............7.10 Lubrication............2.27 Oil Change............2.27 Oil Level Check............2.27 Removal..............7.5 Special Tools ............7.2 Vent Line Routing ...........7.17 Transmission Diagnostics 9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual IX.6 © Copyright Polaris Industries Inc.

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