Polaris RZR PRO XP 4 2021 Manuals

Manuals and User Guides for Polaris RZR PRO XP 4 2021. We have 1 Polaris RZR PRO XP 4 2021 manual available for free PDF download: Service Manual

Polaris RZR PRO XP 4 2021 Service Manual

Polaris RZR PRO XP 4 2021 Service Manual (598 pages)

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

Table of Contents

Chapter 1 1 General Information

7
Maintenance Chapter 2 Maintenance 2

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

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

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

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

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

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

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

405
- Special Tools
  407
- Steering System
  408
- Steering System Assembly View
  408
- Upper Steering Shaft Removal
  409
- Power Steering Unit Removal
  410
- Steering Wheel Removal
  410
- Lower Steering Shaft Removal
  411
- Steering Rack Removal / Installation
  412
- Lower Steering Shaft Installation
  415
- Power Steering Unit Installation
  415
- Steering Shaft Bushing Replacement
  418
- Eps Pre-Positioning / Steering Angle Centering
  419
- Front Suspension
  421
- Front Suspension Assembly View
  421
- Front A-Arm Removal / Installation
  422
- Front Stabilizer Bar Replacement
  423
- Ball Joint Removal
  424
- Ball Joint Installation
  425
- Rear Suspension
  426
- Rear Suspension Assembly View
  426
- Trailing Arm Removal / Installation
  427
- Trailing Arm Spherical Bearing Replacement
  429
- Radius Rod Removal / Installation
  430
- Stabilizer Bar Removal / Installation
  431
- Shock / Spring Replacement
  432
- Shock Assembly View
  432
- Shock Removal / Installation
  432
- Shocks / Springs
  432
- Fox 2.5" Shock Information
  434
- Fox 2.5" Shock Information (4-Seat)
  436
- Fox 3.0" Shock Information
  438
- Fox 3.0" Shock Information (4-Seat)
  440
- Fox 2.5" / 3.0" O.e. Podium Bypass
  442
- Shock Service
  442
- Offset Torque Formula
  443
- Fox Shock Disassembly
  444
- Fox Shock Assembly
  451
- Shock Service
  456
- Walker Evans™ 2.5" Front Shock / 3.0" Rear Shock
  456
- General Service Information
  457
- Front Shock Service Information
  458
- Rear Shock Service Information
  460
- Spring Adjustment (Walker Evans)
  462
- Shock Piston Orientation
  463
- Special Tools
  463
- Valve Shim Arrangement
  463
- Walker Evans™ Shock Disassembly
  464
- Walker Evans™ Shock Assembly
  467
- Dynamix Active Suspension
  472
- Dynamix Overview
  472
- Dynamix Shocks Disassembly / Assembly
  472
- Demonstration Mode
  473
- Suspension Control Module (Scm)
  473
- Cornering Control
  474
- Dynamix™ System Features
  474
- Vehicle Speed Sensitivity
  474
- Acceleration
  475
- Airborne Detection
  475
- Braking
  475
- Advanced Diagnostics
  476
- Processing Capability
  476
- Suspension Mode Switch (Dynamix Models)
  476
Chapter 10 Brake System

479
- Brake System Specifications
  480
- Special Tools
  480
- Brake System Overview
  481
- Brake System View
  481
- Brake System View (4-Seat)
  482
- Brake Line Routing / Retention
  483
- Brake Line Routing / Retention (4-Seat)
  486
- Brake System Service Notes
  489
- Hydraulic Brake System Operation
  489
- Master Cylinder
  490
- Master Cylinder Installation
  490
- Brake Pedal
  494
- Brake Caliper / Pad Removal
  495
- Front Brake Service
  495
- Front Caliper Assembly View
  497
- Front Caliper Assembly View (4-Seat)
  498
- Front Caliper Disassembly / Inspection
  499
- Front Caliper Disassembly / Inspection (4-Seat)
  500
- Brake Pad Inspection
  501
- Brake Disc Inspection
  502
- Front Caliper Assembly
  502
- Brake Caliper / Pad Installation
  503
- Front Brake Disc Replacement
  503
- Brake Burnishing Procedure
  504
- Brake Pedal Switch Inspection
  505
- Troubleshooting
  505
- Brake Caliper / Pad Removal
  506
- Rear Brake Service
  506
- Rear Caliper Disassembly / Inspection
  507
- Brake Pad Inspection
  508
- Rear Brake Disc Inspection
  509
- Rear Caliper Assembly
  509
- Rear Brake Disc Replacement
  510
- Rear Brake Caliper / Pad Installation
  511
- Brake Burnishing Procedure
  512
Chapter 11 Body / Frame

513
- Special Tools
  514
- Body Assembly Views
  515
- Cab Frame Assembly
  515
- Cab Frame Assembly (4-Seat)
  516
- Front Doors
  517
- Rear Doors
  518
- Dash / Controls
  519
- Hood / Front Body
  520
- Chassis / Main Frame
  521
- Chassis / Main Frame (4-Seat)
  522
- Seat Assembly
  523
- Floor / Rocker Panels
  524
- Floor / Rocker Panels (4-Seat)
  525
- Rear Cargo Box / Fenders
  526
- Rear Bumper
  527
- Body Component Removal
  528
- Rear Close-Off Panel
  528
- Seats
  528
- Front Fascia
  529
- Rear Fascia
  530
- Hood / Front Body
  531
- Cargo Box
  532
- Rear Fender / Fender Flare
  532
- Rocker Panels, Console, and Floor
  533
- Door Adjustment
  535
- Door Panel / Latch Replacement
  535
- Doors
  535
Chapter 12 Electrical

537
- Special Tools
  539
- Under-Dash Components
  539
- Electrical Service Notes
  540
- Electrical Component Locations (Rear)
  541
- Electrical Component Locations (Front)
  542
- Instrument Cluster
  543
- Rider Display Overview
  543
- Information Display Area
  545
- Ride Command Unit Replacement
  547
- Ignition / Key Switch
  550
- Switches / Controls
  550
- Seat Belt Switch
  551
- Brake Pressure Switch
  552
- Transmission / Gear Position Switch
  552
- Boost Control Solenoid / Valve
  553
- Suspension Mode Switch (Dynamix Models)
  553
- Steering Angle Sensor Centering (Dynamix)
  554
- Ignition Coil
  555
- Ignition Coil Replacement
  555
- Operation Overview
  555
- Charging System
  556
- Current Draw - Key off
  556
- Stator Testing
  557
- Regulator / Rectifier (Dynamix)
  558
- Battery
  560
- Battery Specifications
  560
- Battery Installation
  561
- Battery Removal
  561
- Battery Conductance Analyzer
  562
- Battery off Season Storage
  562
- Battery Testing
  562
- Load Test
  562
- Ocv - Open Circuit Voltage Test
  562
- Charging Procedure
  563
- Headlamp Replacement
  564
- Headlight Adjustment
  564
- Lighting System
  564
- Dash Light
  565
- Tail Light Replacement
  565
- Cooling Fan Description and Operation
  566
- Cooling Fan Testing
  566
- Cooling System
  566
- Cooling Fan Replacement
  567
- Electric Coolant Pump
  569
- Ect Sensor Test
  570
- Starter Solenoid Bench Test
  571
- Starter Solenoid Operation
  571
- Starter Solenoid Replacement
  571
- Starting System
  571
- Electronic Power Steering (Eps)
  572
- Eps Operation
  572
- Proper Eps System Diagnosing
  572
- Fuse / Relay Box
  573
- Fuses / Relays
  573
- Relay / Fuse Details
  576
- Voltage Regulator Fusible Link
  577
- Can System
  578
- Can System Overview
  578
- Can System Testing
  578
- Electrical Harness Routing
  579
- Electrical Harness Routing (4-Seat)
  579
- Wiring Harness
  579
- Electrical Harness Retention
  580
- Electrical Harness Retention (4-Seat)
  581
- Wiring Harness Replacement
  582
- Wiring Harness Replacement (4-Seat)
  583
- Break-Out Diagram Viewing
  584

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