User Manuals: Polaris RZR PRO R 4 Off-Road Vehicle

Manuals and User Guides for Polaris RZR PRO R 4 Off-Road Vehicle. We have 1 Polaris RZR PRO R 4 Off-Road Vehicle manual available for free PDF download: Service Manual

Polaris RZR PRO R 4 Service Manual

Polaris RZR PRO R 4 Service Manual (508 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 19 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Vehicle Identification
  9
- Model Number Designation (2015 +)
  9
- Vehicle Identification Number (Vin) Designation (2015+)
  9
- Vin and Engine Serial Number Locations
  9
- Reference Information
  10
- Replacement Keys
  10
- Publication Numbers
  10
- Special Tools
  11
- Master Torque Table
  12
- Vehicle Specifications
  16
- 2022 Rzr Pro R Clutch Chart
  18
- Misc. Specifications and Charts
  22
- Conversion Table
  22
- Sae Tap / Drill Sizes
  23
- Metric Tap / Drill Sizes
  23
- Decimal Equivalents
  24
- General Diagnostics
  25
- General Diagnostics Information Overview
  25
- Guided Symptom Diagnostic
  25
- Guided Symptom References
  26
- Engine and Drivability Diagnostic Procedures
  27
- Engine Cranks but Does Not Start
  30
- No Crank no Start or Slow Crank
  32
- Over Heating
  33
- Warning Lights
  34
- Engine Troubleshooting
  35
- Cooling Troubleshooting
  37
- Engine Electrical Diagnostics
  38
- Diagnostic Trouble Codes Overview
  38
- Master Trouble Code List
  39
- Cylinder Misfire Detection
  51
- Fluid Leaks
  52
- Fluid Inspection
  52
- Fuel System Diagnostics
  53
- Fuel System Troubleshooting
  53
- Pvt System Diagnostics
  55
- Pvt System Troubleshooting
  55
- Pvt System Overheating / Diagnosis
  57
- Transmission Diagnostics
  58
- Hard Shifting
  58
- Transmission Isolation
  58
- Final Drive Diagnostics
  59
- Driveline Mode Diagnostics
  59
- Driveshaft (Half Shaft) Diagnostics
  60
- Brake System Diagnostics
  61
- Brake Noise Troubleshooting
  61
- Brake Vibration
  61
- Caliper Overheats (Brakes Drag)
  61
- Poor Brake Performance
  62
- Brakes Lock
  62
- Steering / Suspension Diagnostics
  63
- Eps Troubleshooting (Power Steering Non-Functional with Mil
  63
- Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
  64
- Eps Troubleshooting (Using Digital Wrench®)
  65
- Shock Analysis
  66
- Electrical Diagnostics
  67
- Electrical Service Notes
  67
- Digital Multi-Meter (DMM) Notes
  67
- Static and Dynamic Testing
  67
- Connector Probing Guidelines
  68
- Testing Continuity / Resistance
  69
- Testing for a Short to Ground
  69
- Testing for a Short to Voltage
  70
- Testing for Intermittent Conditions
  71
- Testing Current Flow (Amperage)
  71
- Current Draw - Key off
  72
- Testing Voltage Drop
  72
Maintenance Chapter 2 Maintenance 2

75
- Lubricants / Service Products
  77
- Maintenance
  77
- Periodic Maintenance - General
  77
- Pre-Ride Inspection
  78
- Polaris Maintenance Schedule
  79
- Maintenance Quick Reference
  82
- Grease Lubrication Points
  85
- Engine / Exhaust
  86
- Engine Oil Level
  86
- Engine Oil and Filter Change
  87
- Engine Breather Hose
  88
- Engine Cylinder Leakdown Test
  88
- Spark Arrestor
  88
- Coolant Strength
  90
- Cooling System
  90
- Heat Shield Inspection
  90
- Coolant Level Inspection
  91
- Cooling System Pressure Test
  91
- Coolant Hose Inspection
  92
- Radiator Inspection / Cleaning
  92
- Coolant Flush
  93
- Fuel System and Air Intake
  94
- Fuel Tank Vent Inspection
  94
- Throttle Pedal Inspection
  94
- Air Filter Service
  95
- Engine Intake Pre-Filter Service
  95
- Pvt / Final Drive / Wheel and Tire
  97
- Pvt Drain
  97
- Pvt Intake Pre-Filter Service
  97
- Front Gearcase Lubrication
  98
- Rear Gearcase Lubrication
  98
- Drive Shaft Boot Inspection
  99
- Wheel Removal
  99
- Tire Inspection
  100
- Tire Pressure
  100
- Wheel Installation
  100
- Transmission
  101
- Transmission Lubrication
  101
- Transmission Oil Change
  101
- Transmission Oil Level Check
  101
- Steering
  102
- Steering Inspection
  102
- Steering Wheel Free-Play
  102
- Tie Rod End / Wheel Hub Inspection
  102
- Wheel Toe Alignment Inspection
  103
- Wheel Toe Adjustment
  104
- Suspension
  105
- Suspension Inspection
  105
- Suspension Lubrication
  106
- Front / Rear Spring Preload Adjustment
  108
- Front / Rear Shock Compression Adjustment (Non-Dynamix)
  109
- Brake Fluid Inspection
  110
- Brake Hose and Fitting Inspection
  110
- Brake Pad Inspection
  110
- Brake System
  110
- Brake Disc Inspection
  111
- Battery Charging / off Season Storage
  112
- Battery Maintenance
  112
- Electrical and Ignition System
  112
- Engine / Chassis Electrical Ground
  112
- Spark Plug Service
  112
Chapter 3 Engine / Cooling System

115
- Engine Lubrication Specifications
  117
- General Information
  117
- Special Tools
  117
- Engine Service Specifications
  118
- Service Specifications - Engine
  118
- Torque Sequence - Engine
  121
- Engine Intake Assembly View
  126
- Intake / Exhaust System
  126
- Air Box Installation
  127
- Air Box Removal
  127
- Exhaust Assembly View
  128
- Muffler Installation
  129
- Muffler Removal
  129
- Exhaust Pipe Installation
  130
- Exhaust Pipe Removal
  130
- Cooling System
  131
- Cooling System Flow
  131
- Cooling System Pressure Test
  132
- Cooling System Specifications
  132
- Radiator Replacement
  133
- Thermostat Replacement
  136
- Engine Service
  138
- Harmonic Damper Cleaning and Inspection
  138
- Stretch Belt Replacment
  138
- Engine Removal
  139
- Engine Installation Preparation
  144
- Engine Installation
  145
- Engine Mount Inspection
  152
- Engine Disassembly / Inspection - Top End
  153
- Valve Cover Removal
  153
- Crankshaft Harmonic Damper Removal
  154
- Engine Front Cover Removal
  155
- Timing Chain Service
  155
- Tensioner Service
  156
- Camshaft Removal
  158
- Camshaft Cleaning and Inspection
  159
- Camshaft Timing Chain and Sprocket Cleaning and Inspection
  160
- Cylinder Head Removal
  161
- Cylinder Head Warp Inspection
  162
- Cylinder Head and Gasket Surface Cleaning and Inspection
  163
- Valve Inspection
  164
- Combustion Chamber Cleaning
  165
- Valve Seat Reconditioning
  165
- Engine Disassembly / Inspection - Bottom End
  168
- Lower Crankcase Removal
  168
- Oil Pan Removal
  168
- Piston, Connecting Rod, and Bearing Removal
  169
- Reed Valve Replacement
  169
- Piston Disassembly / Inspection
  170
- Piston Ring Removal
  171
- Piston Ring to Groove Clearance Inspection
  171
- Piston Ring Installed Gap
  172
- Piston-To-Cylinder Clearance
  172
- Connecting Rod Inspection
  173
- Cylinder Head Disassembly
  174
- Crankshaft and Bearing Removal
  176
- Flywheel Removal
  176
- Engine Block Disassembly
  177
- Engine Block Cleaning and Inspection
  178
- Engine Flywheel Cleaning and Inspection
  180
- Harmonic Damper Cleaning and Inspection
  180
- Crankshaft and Bearing Cleaning and Inspection
  181
- Oil Pump Disassembly
  182
- Engine Assembly - Bottom End
  184
- Oil Pan Cleaning and Inspection
  184
- Oil Pump Assembly
  184
- Bearing Selection Identification Letters and Numbers
  186
- Connecting Rod Bearing Selection
  187
- Engine Block Assembly
  188
- Piston / Connecting Rod Assembly
  190
- Lower Crankcase Installation
  191
- Crankshaft Front Oil Seal Installation
  193
- Crankshaft Rear Oil Seal Installation
  193
- Front Cover Installation
  194
- Oil Pan Installation
  195
- Crankshaft Harmonic Damper Installation
  197
- Flywheel Installation
  197
- Cylinder Head Assembly
  198
- Engine Assembly - Top End
  198
- Piston Ring Installation
  199
- Piston, Connecting Rod, and Bearing Installation
  201
- Cylinder Head Installation
  202
- Camshaft Installation
  203
- Camshaft Timing Chain and Sprocket Installation
  204
- Valve Clearance Adjustment
  206
- Valve Lash - Tappet Selection
  209
- Valve Cover Installation
  210
Chapter 4 Engine Electrical

213
- Ecu Operation Overview
  214
- Ecu Replacement
  214
- Ecu Service
  214
- Electronic Control Unit (Ecu)
  214
- Etc Learn Procedure
  215
- Air Temperature Sensor Data (Tbap)
  216
- Pressure Sensors
  216
- Tmap Sensor
  216
- Knock Sensor
  217
- Knock Sensor Overview
  217
- Knock Sensor Replacement
  217
- Knock Sensor Testing
  217
- Cps Operation Overview
  218
- Cps Test
  218
- Crankshaft Position Sensor (Cps)
  218
- Cps Replacement
  219
- Electronic Throttle Control (Etc) / Throttle Body
  220
- Etc Operation Overview
  220
- Etc Test
  220
- Etc / Throttle Body Replacement
  221
- Etc Learn Procedure
  221
- Operation Overview
  222
- Pedal Position Sensor (Pps)
  222
- Pps Test
  222
- Oxygen Sensor
  223
- Oxygen Sensor Information
  223
- Pps Replacement
  223
- Oxygen Sensor Replacement
  225
Chapter 5 Efi / Fuel System

227
- General Information
  228
- Special Tools
  228
- Efi Operation Overview
  229
- Efi Overview
  229
- Efi Service Notes
  230
- Initial Priming / Starting Procedure
  231
- Fuel Injector O-Rings
  232
- Fuel Injector Operation Overview
  232
- Fuel Injectors
  232
- Fuel Injector Test
  233
- Fuel Injector Troubleshooting
  233
- Fuel Injector Replacement
  234
- Fuel Lines
  236
- Fuel System Assembly View
  236
- Fuel System Assembly View (Evap)
  237
- Fuel Line Removal / Installation
  238
- Fuel Vent Line Routing
  239
- Fuel Vent Line Routing (Evap)
  241
- Vent Line Termination Fitting
  242
- Fuel Tank / Pump
  244
- Fuel Tank Assembly View
  244
- Fuel Tank Replacement
  245
- Fuel Tank Replacement (4-Seat)
  246
- Fuel Pump Operation Overview
  247
- Fuel Pressure Test
  248
- Fuel Pump Replacement
  249
- Fuel Sender Test
  250
Chapter 6 Pvt System

251
- General Information
  252
- Special Tools
  252
- Drive Clutch Operation
  253
- Driven Clutch Operation
  253
- General Operation
  253
- Pvt System Overview
  253
- Belt Inspection
  254
- Belt Removal
  254
- Drive Belt
  254
- Belt Installation
  255
- Belt Break-In
  256
- Drive Clutch Removal
  257
- Drive Clutch Service
  257
- Drive Clutch Assembly View
  258
- Bearing Inspection
  260
- Clutch Disassembly
  260
- Button to Tower Clearance Inspection
  261
- Roller, Pin, and Thrust Washer Inspection
  261
- Spider Removal
  261
- Roller Replacement
  262
- Shift Weight Inspection
  262
- Clutch Inspection
  263
- Drive Clutch Bushings Inspection
  264
- Drive Clutch Spring Inspection
  264
- Bushing Service
  265
- Clutch Assembly
  267
- Drive Clutch Installation
  268
- Driven Clutch Removal
  270
- Driven Clutch Service
  270
- Driven Clutch Assembly View
  271
- Driven Clutch Disassembly
  272
- Bushing Service
  273
- Driven Clutch Spring Inspection
  273
- Helix and Movable Sheave Bushing Inspection
  273
- Driven Clutch Assembly
  274
- Driven Clutch Installation
  275
- Driven Clutch Alignment
  276
Chapter 7 Transmission

279
- General Information
  280
- Special Tools
  280
- Shift Cable Inspection
  281
- Shift Lever / Cable
  281
- Shift Lever Installation
  281
- Shift Lever Removal
  281
- Shift Cable Adjustment
  282
- Transmission Removal
  283
- Transmission Service
  283
- Transmission Installation
  288
- Transmission Disassembly
  295
- Transmission Vent Line Routing
  295
- Transmission Assembly
  298
Chapter 8 Final Drive

301
- General Information
  302
- Service Notes
  302
- Special Tools
  302
- Bearing Carrier
  303
- Front Bearing Carrier Inspection / Removal
  303
- Front Bearing Carrier Installation
  304
- Rear Bearing Carrier Inspection / Removal
  305
- Rear Bearing Carrier Installation
  306
- Front Half Shaft Installation
  308
- Front Half Shaft Removal
  308
- Half Shaft
  308
- Rear Half Shaft Removal
  309
- Rear Half Shaft Installation
  310
- Half Shaft / CV Joint Handling Tips
  311
- CV Joint / Boot Replacement
  312
- Prop Shaft
  314
- Prop Shaft Assembly View
  314
- Prop Shaft Assembly View (4-Seat)
  315
- Rear Prop Shaft Replacement
  315
- Intermediate Prop Shaft Replacement (4-Seat)
  317
- Front Prop Shaft Replacement
  320
- U-Joint Disassembly
  325
- Front Gearcase
  326
- Front Gearcase Assembly View
  326
- U-Joint Assembly
  326
- Front Gearcase Replacement
  328
- Front Gearcase Vent Line Routing
  328
- Front Gearcase Disassembly / Inspection
  333
- Front Gearcase Assembly
  334
- Front Hub Assembly View
  335
- Wheel Hubs
  335
- Rear Hub Assembly View
  336
- Tire Balancing
  337
Chapter 9 Steering / Suspension

339
- General Information
  341
- Special Tools
  341
- Steering Alignment Specifications
  341
- Steering System
  342
- Steering System Assembly View
  342
- Upper Steering Shaft Replacement
  342
- Lower Steering Shaft Replacement
  343
- Eps Unit / Steering Rack Replacement
  345
- Eps Pre-Positioning / Steering Angle Centering
  350
- Front Suspension
  352
- Front Suspension Assembly View
  352
- Upper Control Arm Replacement
  353
- Lower Control Arm Replacement
  354
- Front Stabilizer Bar Replacement
  356
- Stabilizer Bar Clocking
  357
- Ball Joint Replacement
  358
- Rear Suspension
  360
- Rear Suspension Assembly View
  360
- Trailing Arm Replacement
  361
- Trailing Arm Spherical Bearing Replacement
  363
- Radius Rod Replacement
  364
- Rear Stabilizer Bar Replacement
  365
- Shock Assembly View
  366
- Shock Replacement
  366
- Shocks / Springs
  366
- Shock / Spring Replacement
  367
- Fox 3.0" DV Shock Information (Front)
  368
- Fox 3.0" DV Shock Information (Rear)
  369
- Fox 2.5" / 3.0" O.e. Podium Bypass
  370
- Fox Shock Service
  370
- Shock Service
  370
- Offset Torque Formula
  371
- Fox Shock Disassembly
  372
- Fox Shock Assembly
  379
- Shock Service
  384
- Walker Evans Shock Service
  384
- Walker Evans™ 2.5" Front Shock / 3.0" Rear Shock
  384
- Front Shock Service Information
  385
- General Service Information
  385
- Rear Shock Service Information
  387
- Front / Rear Shock Compression Adjustment (Non-Dynamix)
  389
- Shock Piston Orientation
  390
- Special Tools
  390
- Valve Shim Arrangement
  390
- Walker Evans™ Shock Disassembly
  391
- Walker Evans™ Shock Assembly
  394
- Demonstration Mode
  399
- Dynamix Active Suspension
  399
- Dynamix Shocks Disassembly / Assembly
  399
- Dynamix™ DV System Features
  399
- Eps Response
  399
- Overview
  399
- Suspension Control Module (Scm)
  399
- Acceleration
  400
- Advanced Diagnostics
  400
- Airborne Detection
  400
- Braking
  400
- Button
  400
- Cornering Control
  400
- Vehicle Speed Sensitivity
  400
- Ride Mode Controls (if Equipped)
  401
- Suspension Mode Switch (Dynamix Models)
  402
Chapter 10 Brake System

403
- Brake System Specifications
  404
- General Information
  404
- Special Tools
  404
- Brake System Overview
  405
- Brake System View (2-Seat)
  405
- Brake System View (4-Seat)
  406
- Brake Line Routing / Retention (2-Seat)
  407
- Brake Line Routing / Retention (4-Seat)
  410
- Brake System Service Notes
  413
- Hydraulic Brake System Operation
  413
- Master Cylinder
  414
- Master Cylinder Installation
  414
- Master Cylinder Removal
  414
- Brake Bleeding / Fluid Change
  415
- Brake Pedal
  418
- Brake Pedal Installation
  418
- Brake Pedal Removal
  418
- Brake Caliper / Pad Removal
  419
- Front Brake Service
  419
- Front Caliper Assembly View
  421
- Front Caliper Disassembly / Inspection
  422
- Brake Disc Inspection
  423
- Brake Pad Inspection
  423
- Front Caliper Assembly
  423
- Brake Burnishing Procedure
  424
- Brake Caliper / Pad Installation
  424
- Front Brake Disc Replacement
  424
- Brake Pedal Switch Inspection
  425
- Troubleshooting
  425
- Brake Caliper / Pad Removal
  426
- Rear Brake Service
  426
- Rear Caliper Disassembly / Inspection
  427
- Brake Pad Inspection
  428
- Rear Caliper Assembly
  428
- Rear Brake Caliper / Pad Installation
  429
- Rear Brake Disc Inspection
  429
- Rear Brake Disc Replacement
  429
- Brake Burnishing Procedure
  430
Chapter 11 Body / Frame

431
- General Information
  432
- Special Tools Decal Replacement
  432
- Body Assembly Views
  433
- Cab Frame Assembly
  433
- Cab Frame Assembly (4-Seat)
  434
- Doors
  435
- Rear Doors
  436
- Dash / Controls
  437
- Hood / Front Body
  438
- Chassis / Main Frame
  439
- Chassis / Main Frame (4-Seat)
  441
- Seat Assembly
  443
- Rear Seat Assembly (4-Seat)
  445
- Floor / Rocker Panels
  447
- Floor / Rocker Panels (4-Seat)
  448
- Rear Cargo Box / Fenders
  449
- Body Component Removal
  450
- Rear Close-Off Panel
  450
- Seats
  450
- Front Fascia
  451
- Rear Fascia
  452
- Hood / Front Body
  453
- Cargo Box
  454
- Rear Fender / Fender Flare
  454
- Rocker Panels, Console, and Floor
  455
- Door Adjustment
  457
- Door Panel / Latch Replacement
  457
- Doors
  457
Chapter 12 Electrical

459
- General Information
  461
- Special Tools
  461
- Electrical Service Notes
  462
- Engine/Chassis Harness Components
  462
- Electrical Component Locations (Rear)
  463
- Electrical Component Locations (Front)
  464
- Instrument Cluster
  465
- Rider Display Overview
  465
- Information Display Area
  466
- Instrument Cluster Pinouts
  470
- Headlight Switch
  471
- Ignition / Key Switch
  471
- Switches / Controls
  471
- Awd / 2Wd / Turf Switch
  472
- Seat Belt Switch
  472
- Brake Pressure Switch
  473
- Transmission / Gear Position Switch
  473
- Steering Angle Sensor Centering (Dynamix)
  474
- Suspension Mode Switch (Dynamix Models)
  474
- Ignition Coil
  475
- Ignition Coil Replacement
  475
- Operation Overview
  475
- Charging System
  476
- Charging System "Break Even" Test
  476
- Current Draw - Key off
  476
- Charging System Testing Flow Chart
  477
- Alternator Replacement
  478
- Battery
  481
- Battery Specifications
  481
- General Battery Information
  481
- Battery Installation
  482
- Battery Removal
  482
- Battery Conductance Analyzer
  483
- Battery off Season Storage
  483
- Battery Testing
  483
- Load Test
  483
- Ocv - Open Circuit Voltage Test
  483
- Charging Procedure
  484
- Headlamp Replacement
  485
- Headlight Adjustment
  485
- Lighting System
  485
- Dash Light
  486
- Tail Light Replacement
  486
- Cooling Fan Description and Operation
  487
- Cooling Fan Testing
  487
- Cooling System
  487
- Cooling Fan Replacement
  488
- Fan Control Circuit Bypass Test
  488
- Ect Sensor Test
  492
- Starter / Solenoid Replacement
  493
- Starter Solenoid Bench Test
  493
- Starter Solenoid Operation
  493
- Starting System
  493
- Electronic Power Steering (Eps)
  494
- Eps Operation
  494
- Proper Eps System Diagnosing
  495
- Fuse / Relay Centers
  496
- Fuses / Relays
  496
- Pdm Fuse Troubleshooting
  498
- Can System
  499
- Can System Overview
  499
- Can System Testing
  499
- Electrical Harness Retention
  500
- Wiring Harness
  500

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