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RZR XP4 Turbo
Polaris RZR XP4 Turbo Manuals
Manuals and User Guides for Polaris RZR XP4 Turbo. We have
2
Polaris RZR XP4 Turbo manuals available for free PDF download: Service Manual
Polaris RZR XP4 Turbo Service Manual (564 pages)
2018-2019
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 26.07 MB
Table of Contents
Chapter 1 1 General Information
7
Table of Contents
7
Vehicle Identification
8
Model Number Designation (2015 +)
8
Vehicle Identification Number (Vin) Designation (2015+)
8
Vin and Engine Serial Number Locations
8
Reference Information
9
Replacement Keys
9
Publication Numbers
9
Special Tools
10
Master Torque Table
14
Vehicle Specifications
17
2018 Rzr Xp Turbo S
18
2018 Rzr Xp Turbo S Clutch Chart
18
2019 Rzr Xp Turbo S Clutch Chart
20
2019 Rzr Xp 4 Turbo S Clutch Chart
22
Misc. Specifications and Charts
23
Conversion Table
23
Sae Tap / Drill Sizes
24
Metric Tap / Drill Sizes
24
Decimal Equivalents
25
Maintenance Chapter 2 Maintenance 2
27
Lubricants / Service Products
29
Maintenance
29
Periodic Maintenance - General
29
Pre-Ride Inspection
30
Maintenance Intervals
31
Maintenance Quick Reference
51
Grease Lubrication Points
53
Engine / Exhaust
54
Engine Oil Level
54
Engine Oil and Filter Change
55
Engine Crankcase Breather Hose
56
Engine Cylinder Leakdown Test
56
Valve Clearance Adjustment
57
Cam Chain Tensioner Inspection
58
Spark Arrestor
59
Heat Shield Inspection
60
Coolant Level Inspection
62
Coolant Strength
62
Cooling System
62
Coolant Hose Inspection
63
Cooling System Pressure Test
63
Coolant Flush
64
Radiator Inspection / Cleaning
64
Cooling System Bleeding
65
Engine Cooling System Bleeding
65
Charge Air Cooling System Bleeding
66
Fuel System and Air Intake
67
Fuel Tank Vent Inspection
67
Throttle Pedal Inspection
67
Air Filter Service
68
Engine Intake Pre-Filter Service
68
Intake Duct Drain Inspection
69
Pvt / Final Drive / Wheel and Tire
70
Pvt Drain
70
Pvt Intake Pre-Filter Service
70
Front Gearcase Fluid Change
71
Front Gearcase Fluid Level Check
71
Front Gearcase Lubrication
71
Drive Shaft Boot Inspection
72
Tire Inspection
72
Wheel Installation
72
Wheel Removal
72
Maintenance
73
Tire Pressure
73
Tire Rotation
73
Transmission
74
Transmission Lubrication
74
Transmission Oil Change
74
Transmission Oil Level Check
74
Steering
75
Steering Inspection
75
Steering Wheel Free-Play
75
Tie Rod End / Wheel Hub Inspection
75
Wheel Toe Alignment Inspection
76
Wheel Toe Adjustment
77
Suspension
78
Suspension Inspection
78
Suspension Lubrication
78
Brake Fluid Inspection
79
Brake Hose and Fitting Inspection
79
Brake Pad Inspection
79
Brake System
79
Brake Disc Inspection
80
Battery Charging / off Season Storage
81
Battery Maintenance
81
Electrical and Ignition System
81
Engine / Chassis Electrical Ground
81
Spark Plug Service
82
Chapter 3 Engine / Cooling System
83
Engine Lubrication Specifications
86
General Information
86
Special Tools
86
Oil Pressure Test
87
Oil Flow Chart
88
Engine Service Specifications
89
Engine Specifications
89
Engine Torque Specifications
91
Intake / Exhaust System
93
Intake / Turbo System Overview
93
Engine Air Intake Assembly View
94
Air Box Removal
95
Air Box Installation
96
Exhaust Assembly View
97
Muffler Removal
98
Exhaust Pipe Removal
99
Muffler Installation
99
Head Pipe / Turbo Removal
101
Head Pipe / Turbo Installation
103
Exhaust Pipe Installation
105
Turbocharger Inspection
106
Turbocharger Service
106
Actuator / Wastegate Inspection
110
Actuator Pod Removal
111
Oil Drain Tube Service
112
Boost Control Valve
113
P1234 Boost Reference Code Troubleshooting
113
Wastegate Flapper Inspection
113
Actuator / Wastegate
114
Boost Pressure Sensor Harness
114
Exhaust
114
Turbocharger
114
Cooling System
115
Cooling System Flow
115
Cooling System Pressure Test
116
Cooling System Specifications
116
Charge Air Cooler Removal
117
Charge Air Cooler Installation
119
Radiator Replacement
120
Thermostat Replacement
124
Water Pump Service
125
Engine Service
128
Front Engine Mount Isolator Replacement
128
Crankshaft Pto Seal Replacement
129
Engine Removal
131
Engine Installation
135
Cam Chain Tensioner Service
139
Installation
139
Removal
139
Camshaft Removal
140
Engine Disassembly / Inspection - Top End
140
Valve Cover Removal
140
Camshaft Sprocket Inspection
141
Camshaft / Camshaft Bore Inspection
142
Cylinder Head Inspection
144
Cylinder Head Removal
144
Cylinder Head Disassembly
145
Valve Inspection
146
Combustion Chamber Cleaning
147
Valve Seat Reconditioning
147
Engine Disassembly / Inspection - Bottom End
150
Stator Cover Removal / Inspection
150
Flywheel Removal
151
Water Pump Housing Removal
151
Starter One-Way Clutch Disassembly
152
Crankcase Disassembly
153
Balance Shaft Removal / Inspection
155
Crankshaft Removal / Inspection
156
Crankcase Inspection
158
Cylinder / Piston Removal
159
Cylinder Inspection
160
Piston Disassembly / Inspection
161
Piston Ring Installed Gap
162
Piston Ring Removal
162
Piston Ring to Groove Clearance
162
Connecting Rod Inspection
163
Piston to Cylinder Clearance
163
Bearing Selection Identification
165
Engine Assembly - Bottom End
165
Connecting Rod Bearing Selection
166
Crankshaft Main Bearing Selection
166
Piston Ring Installation
167
Upper Crankcase Preparation
167
Piston / Connecting Rod Assembly
168
Piston / Cylinder Installation
169
Crankshaft Installation
170
Balance Shaft Installation
172
Lower Crankcase Preparation
172
Crankcase Assembly
173
Starter One-Way Clutch Assembly
176
Flywheel Installation
177
Stator Cover Installation
178
Cylinder Head Assembly
179
Engine Assembly - Top End
179
Cylinder Head Installation
180
Valve Sealing Test
180
Camshaft Installation / Timing
181
Camshaft Timing Quick Reference
185
Valve Clearance Adjustment
186
Valve Lash - Tappet Selection
188
Valve Cover Installation
189
Chapter 4 Efi / Fuel System
191
General Information
193
Special Tools
193
Efi Overview
194
Efi System Components
194
Efi Operation Overview
195
Efi Service Notes
196
Initial Priming / Starting Procedure
197
Ecu Operation Overview
198
Ecu Replacement
198
Ecu Service
198
Electronic Control Unit (Ecu)
198
Etc Learn Procedure
199
Fuel Injector O-Rings
200
Fuel Injector Operation Overview
200
Fuel Injectors
200
Fuel Injector Test
201
Fuel Injector Troubleshooting
201
Fuel Injector Replacement
202
Fuel Lines
204
Fuel System Assembly View
204
Fuel System Assembly View (Evap)
205
Fuel Line Removal / Installation
206
Fuel Line Removal / Installation (Evap Models)
207
Fuel Line Routing
208
Fuel Line Routing (Evap Models)
209
Fuel Vent Line Routing
210
Fuel Vent Line Routing (Evap Models)
212
Vent Line Termination Fitting
214
Fuel Tank / Pump
215
Fuel Tank Assembly View
215
Fuel Tank Removal
216
Fuel Tank Installation
218
Fuel Pump Operation Overview
221
Fuel Pressure Test
222
Fuel Pump Replacement
223
Fuel Sender Test
227
Air Temperature Sensor Data
228
Boost Pressure Sensor
228
Fuel Pressure Sensor (Evap Models)
228
Pressure Sensors
228
Tmap Sensor
228
Knock Sensor
229
Knock Sensor Overview
229
Knock Sensor Replacement
229
Knock Sensor Testing
229
Cps Test
230
Crankshaft Position Sensor (Cps)
230
Operation Overview
230
Cps Replacement
231
Electronic Throttle Control (Etc) / Throttle Body
232
Etc Operation Overview
232
Etc Test
232
Etc / Throttle Body Replacement
233
Etc Learn Procedure
233
Location
234
Operation Overview
234
Pedal Position Sensor (Pps)
234
Pps Test
234
Pps Replacement
235
Oxygen Sensor
236
Oxygen Sensor Information
236
Oxygen Sensor Replacement
237
Chapter 5 Pvt System
239
2018 Rzr Xp Turbo S Clutch Chart
240
General Information
240
Special Tools
240
Drive Clutch Operation
241
Driven Clutch Operation
241
General Operation
241
Pvt System Overview
241
Belt Inspection
242
Belt Removal
242
Drive Belt
242
Belt Break-In
243
Belt Installation
243
Drive Clutch Removal
244
Drive Clutch Service
244
Drive Clutch Assembly View
245
Drive Clutch Disassembly
246
Drive Clutch Disassembly / Inspection
246
Shift Weight Inspection
246
Slider Plate Inspection
246
Drive Clutch Assembly
249
Drive Clutch Installation
251
Driven Clutch Removal (2018 Models)
252
Driven Clutch Service
252
Driven Clutch Removal (2019 Models)
253
Driven Clutch Assembly View
254
Driven Clutch Disassembly / Inspection
255
Driven Clutch Assembly
256
Driven Clutch Installation
256
Driven Clutch Installation (2019 Models)
256
Chapter 6 Transmission
259
General Information
260
Special Tools
260
Shift Cable Inspection
261
Shift Lever / Cable
261
Shift Lever Installation
261
Shift Lever Removal
261
Shift Cable Adjustment
262
Transmission Removal
263
Transmission Service
263
Transmission Installation
266
Transmission Vent Line Routing
268
Transmission Disassembly
269
Gear Cluster Disassembly
271
Snorkel Tube Removal / Disassembly
271
Gear, Shaft, Bearing Inspection
273
Snorkel Gear Backlash
274
Transmission Assembly
274
Transmission Assembly / Snorkel Gear Backlash
274
Chapter 7 Final Drive
279
General Information
280
Special Tools
280
Bearing Carrier
281
Front Bearing Carrier Inspection / Removal
281
Front Bearing Replacement
282
Front Bearing Carrier Installation
283
Rear Bearing Carrier Inspection / Removal
284
Rear Bearing Replacement
286
Rear Bearing Carrier Installation
287
Drive Shaft
289
Front Drive Shaft Removal
289
Front Drive Shaft Installation
290
Rear Drive Shaft Removal
291
Rear Drive Shaft Installation
292
Drive Shaft / CV Joint Handling Tips
294
Outer CV Boot Replacement
295
Inner Plunging Joint / Boot Replacement
296
Prop Shaft
299
Prop Shaft Removal
299
Prop Shaft Removal (S4)
301
Prop Shaft Assembly View
303
Support Bearing Replacement
303
U-Joint Disassembly
303
U-Joint Assembly
304
Prop Shaft Installation
305
Front Gearcase / Centralized Hilliard
306
Front Gearcase Assembly View
306
Front Gearcase Vent Line Routing
307
All Wheel Drive Operation
308
Awd Diagnosis
309
Front Gearcase Removal
310
Front Gearcase Disassembly / Inspection
314
Front Gearcase Assembly
316
Front Gearcase Installation
319
Front Hub Assembly View
324
Wheel Hubs
324
Rear Hub Assembly View
325
Tire Balancing
326
Chapter 8 Steering / Suspension
327
General Information
329
Special Tools
329
Steering System
330
Steering System Assembly View
330
Upper Steering Shaft Removal
331
Hub Adapter Removal
332
Steering Wheel / Hub Adapter Removal
332
Steering Wheel Removal
332
Power Steering Unit Removal
333
Lower Steering Shaft Removal
334
Steering Rack Removal
335
Steering Rack Installation
338
Lower Steering Shaft Installation
342
Power Steering Unit Installation
342
Upper Steering Shaft Installation
344
Steering Shaft Bushing Replacement
345
Eps Pre-Position Procedure
346
Eps Pre-Positioning / Steering Angle Centering
346
Eps Steering Angle Centering
346
Front Suspension
348
Front Suspension Assembly View
348
Front A-Arm Removal / Installation
349
Front Stabilizer Bar Replacement
350
Removal
350
Ball Joint Removal
351
Ball Joint Service Preparation
351
Installation
351
Ball Joint Installation
352
Rear Suspension
353
Rear Suspension Assembly View
353
Trailing Arm Removal / Installation
354
Trailing Arm Spherical Bearing Replacement
356
Radius Rod Removal / Installation
357
Stabilizer Bar Installation
358
Stabilizer Bar Removal
358
Shock / Spring Replacement
359
Shock Assembly View
359
Shock Removal / Installation
359
Shocks / Springs
359
Fox 2.5" Shock Information
360
Fox 3.0" Shock Information
361
Fox 2.5" / 3.0" O.e. Podium Bypass
362
Fox Shock Service
362
Shock Service
362
Offset Torque Formula
363
Fox Shock Disassembly
364
Fox Shock Assembly
371
Dynamix Active Suspension
376
Dynamix Overview
376
Dynamix Shocks Disassembly / Assembly
376
Demonstration Mode
377
Scm Replacement
377
Suspension Control Module (Scm)
377
Cornering Control
378
Dynamix™ System Features
378
Vehicle Speed Sensitivity
378
Acceleration
379
Airborne Detection
379
Braking
379
Advanced Diagnostics
380
Processing Capability
380
Suspension Mode Switch (Dynamix Models)
381
Chapter 9 Brake System
383
Brake System Specifications
384
General Information
384
Special Tools
384
Brake System Overview
385
Brake System View
385
Brake Line Routing / Retention
386
Brake System Service Notes
389
Hydraulic Brake System Operation
389
Master Cylinder
390
Master Cylinder Installation
390
Master Cylinder Removal
390
Brake Bleeding / Fluid Change
392
Brake Pedal
394
Brake Pedal Installation
394
Brake Pedal Removal
394
Brake Caliper / Pad Removal
395
Front Brake Service
395
Front Caliper Assembly View
397
Front Caliper Disassembly / Inspection
398
Brake Pad Inspection
399
Brake Disc Inspection
400
Front Caliper Assembly
400
Brake Caliper / Pad Installation
401
Front Brake Disc Replacement
401
Brake Burnishing Procedure
402
Brake Pedal Switch Inspection
403
Brake Warning System (Intl Models)
403
Brake Warning System Inspection (Intl Models)
403
Troubleshooting
403
Brake Caliper / Pad Removal
404
Rear Brake Service
404
Rear Caliper Disassembly / Inspection
405
Brake Pad Inspection
406
Caliper Inspection
406
Rear Brake Disc Inspection
407
Rear Caliper Assembly
407
Rear Brake Disc Replacement
408
Rear Brake Caliper / Pad Installation
409
Brake Burnishing Procedure
410
Advertisement
Polaris RZR XP4 Turbo Service Manual (510 pages)
2017-2018
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 30.86 MB
Table of Contents
Chapter 1 1 General Information
7
Table of Contents
7
Vehicle Identification
8
Model Number Designation (2015 +)
8
Vehicle Identification Number (Vin) Designation (2015+)
8
Vin and Engine Serial Number Locations
8
Reference Information
9
Replacement Keys
9
Publication Numbers
9
Special Tools
10
Master Torque Table
14
Vehicle Specifications
18
2017 Rzr Xp Turbo Clutch Chart
19
2017 Rzr Xp 4 Turbo
21
2017 Rzr Xp4 Turbo Clutch Chart
21
2017 Rzr Xp Turbo Clutch Chart
23
2018 Rzr Xp Turbo
25
2018 Rzr Xp Turbo Clutch Chart
25
2018 Rzr Xp Turbo Fox Edition
26
2018 Rzr Xp Turbo Clutch Chart
27
2018 Rzr Xp Turbo Dynamix Edition
28
2018 Rzr Xp Turbo Clutch Chart
29
2017 Rzr Xp4 Turbo Clutch Chart
31
2018 Rzr Xp 4 Turbo
35
2018 Rzr Xp 4 Turbo Clutch Chart
35
Misc. Specifications and Charts
36
Conversion Table
36
Sae Tap / Drill Sizes
37
Metric Tap / Drill Sizes
37
Decimal Equivalents
38
Maintenance Chapter 2 Maintenance 2
39
Lubricants / Service Products
41
Maintenance
41
Periodic Maintenance - General
41
Pre-Ride Inspection
42
Maintenance Intervals
43
Maintenance Quick Reference
63
Grease Lubrication Points
65
Engine / Exhaust
66
Engine Oil Level
66
Engine Oil and Filter Change
67
Engine Crankcase Breather Hose
68
Engine Cylinder Leakdown Test
68
Valve Clearance Adjustment
69
Cam Chain Tensioner Inspection
70
Spark Arrestor
71
Heat Shield Inspection
72
Coolant Level Inspection
73
Coolant Strength
73
Cooling System
73
Coolant Hose Inspection
74
Cooling System Pressure Test
74
Coolant Flush
75
Radiator Inspection / Cleaning
75
Cooling System Bleeding
76
Engine Cooling System Bleeding
76
Charge Air Cooling System Bleeding
77
Engine Intake Pre-Filter Service
78
Fuel System and Air Intake
78
Fuel Tank Vent Inspection
78
Throttle Pedal Inspection
78
Air Filter Service
79
Intake Duct Drain Inspection
79
Pvt / Final Drive / Wheel and Tire
80
Pvt Drain
80
Pvt Intake Pre-Filter Service
80
Front Gearcase Fluid Change
81
Front Gearcase Fluid Level Check
81
Front Gearcase Lubrication
81
Drive Shaft Boot Inspection
82
Tire Inspection
82
Wheel Installation
82
Wheel Removal
82
Maintenance
83
Tire Pressure
83
Transmission
84
Transmission Lubrication
84
Transmission Oil Change
84
Transmission Oil Level Check
84
Steering
85
Steering Inspection
85
Steering Wheel Free-Play
85
Tie Rod End / Wheel Hub Inspection
85
Wheel Toe Adjustment
86
Wheel Toe Alignment Inspection
86
Suspension
88
Suspension Inspection
88
Suspension Lubrication
88
Brake Fluid Inspection
89
Brake Hose and Fitting Inspection
89
Brake Pad Inspection
89
Brake System
89
Brake Disc Inspection
90
Battery Charging / off Season Storage
91
Battery Maintenance
91
Electrical and Ignition System
91
Engine / Chassis Electrical Ground
91
Spark Plug Service
91
Chapter 3 Engine / Cooling System
93
Engine Lubrication Specifications
96
General Information
96
Special Tools
96
Oil Pressure Test
97
Oil Flow Chart
98
Engine Service Specifications
99
Engine Specifications
99
Engine Torque Specifications
101
Intake / Exhaust System
103
Intake / Turbo System Overview
103
Engine Air Intake Assembly View
104
Air Box Installation
105
Air Box Removal
105
Exhaust Assembly View
106
Exhaust Pipe Removal
107
Muffler Installation
107
Muffler Removal
107
Head Pipe / Turbo Removal
109
Head Pipe / Turbo Installation
111
Exhaust Pipe Installation
112
Turbocharger Inspection
113
Turbocharger Service
113
Actuator / Wastegate Inspection
116
Actuator Pod Removal
117
Oil Drain Tube Service
118
Cooling System
119
Wastegate Flapper Inspection
119
Cooling System Flow
120
Charge Air Cooler Removal
121
Cooling System Pressure Test
121
Cooling System Specifications
121
Charge Air Cooler Installation
123
Radiator Removal
124
Radiator Installation
126
Thermostat Replacement
126
Water Pump Service
128
Engine Service
131
Front Engine Mount Isolator Replacement
131
Crankshaft Pto Seal Replacement
132
Engine Removal
134
Engine Installation
137
Camshaft Removal
141
Engine Disassembly / Inspection - Top End
141
Valve Cover Removal
141
Camshaft / Camshaft Bore Inspection
142
Camshaft Sprocket Inspection
142
Cylinder Head Disassembly
144
Cylinder Head Inspection
144
Cylinder Head Removal
144
Valve Inspection
145
Combustion Chamber Cleaning
146
Valve Seat Reconditioning
147
Engine Disassembly / Inspection - Bottom End
150
Stator Cover Removal / Inspection
150
Water Pump Housing Removal
150
Flywheel Removal
151
Crankcase Disassembly
152
Starter One-Way Clutch Disassembly
152
Balance Shaft Removal / Inspection
155
Crankshaft Removal / Inspection
155
Crankcase Inspection
157
Cylinder / Piston Removal
158
Cylinder Inspection
159
Piston Disassembly / Inspection
159
Piston Ring Removal
160
Piston Ring Installed Gap
161
Piston Ring to Groove Clearance
161
Piston to Cylinder Clearance
161
Connecting Rod Inspection
162
Bearing Selection Identification
163
Engine Assembly - Bottom End
163
Connecting Rod Bearing Selection
164
Crankshaft Main Bearing Selection
164
Upper Crankcase Preparation
164
Piston Ring Installation
165
Piston / Connecting Rod Assembly
166
Piston / Cylinder Installation
166
Crankshaft Installation
167
Balance Shaft Installation
169
Crankcase Assembly
169
Lower Crankcase Preparation
169
Starter One-Way Clutch Assembly
173
Flywheel Installation
174
Stator Cover Installation
174
Cylinder Head Assembly
176
Engine Assembly - Top End
176
Cylinder Head Installation
177
Valve Sealing Test
177
Camshaft Installation / Timing
178
Camshaft Timing Quick Reference
182
Valve Clearance Adjustment
183
Valve Cover Installation
184
Valve Lash - Tappet Selection
184
Engine Troubleshooting
186
Troubleshooting
186
Cooling Troubleshooting
187
Turbocharger Troubleshooting
187
Chapter 4 Efi / Fuel System
189
General Information
191
Special Tools
191
Efi Overview
192
Efi System Components/Locations
192
Efi Operation Overview
193
Efi Service Notes
193
Initial Priming / Starting Procedure
194
Ecu Operation Overview
195
Ecu Replacement
195
Ecu Service
195
Electronic Control Unit (Ecu)
195
Etc Learn Procedure
196
Fuel Injector O-Rings
197
Fuel Injector Operation Overview
197
Fuel Injectors
197
Fuel Injector Test
198
Fuel Injector Troubleshooting
198
Fuel Injector Replacement
199
Fuel Line Removal / Installation
201
Fuel Lines
201
Fuel Vent Line Routing
202
Vent Line Termination Fitting
202
Fuel Tank / Pump
204
Fuel Tank Assembly View
204
Fuel Tank Removal
205
Fuel Tank Installation
207
Fuel Tank Removal (Xp4)
209
Fuel Tank Installation (Xp4)
211
Fuel Pressure Test
213
Fuel Pump Operation Overview
213
Fuel Pump Replacement
214
Fuel Sender Test
217
Air Temperature Sensor Data
218
Bap Sensor
218
Boost Pressure Sensor
218
Pressure Sensors
218
Tmap Sensor
218
Efi / Fuel System
219
Knock Sensor
219
Knock Sensor Overview
219
Knock Sensor Replacement
219
Knock Sensor Testing
219
Cps Test
220
Crankshaft Position Sensor (Cps)
220
Operation Overview
220
Cps Replacement
221
Electronic Throttle Control (Etc) / Throttle Body
222
Etc / Throttle Body Replacement
222
Etc Operation Overview
222
Etc Test
222
Etc Learn Procedure
223
Location
224
Operation Overview
224
Pedal Position Sensor (Pps)
224
Pps Replacement
224
Pps Test
224
Oxygen Sensor
226
Oxygen Sensor Information
226
Oxygen Sensor Replacement
227
Efi Diagnostics
228
Fuel System Troubleshooting
228
Digital Wrench Data Troubleshooting
229
Cylinder Misfire Detection
232
Digital Wrench® Diagnostic Software Overview
233
Polaris Digital Wrench
233
Special Tools (Digital Wrench)
233
Digital Wrench Software Version and Update
234
Digital Wrench® Updates
234
Digital Wrench Diagnostic Connector
235
Digital Wrench® Communication Errors
235
Digital Wrench® Serial Number Location
236
Guided Diagnostics
236
Digital Wrench® Feature Map
237
Ecu Replacement
238
Ecu Reprogramming (Reflash)
238
Etc Learn Procedure
238
Polaris Mobile Digital Wrench (Pmdw)
241
Chapter 5 Pvt System
243
2017 Rzr Xp Turbo Clutch Chart
244
2017 Rzr Xp4 Turbo Clutch Chart
244
General Information
244
Special Tools
244
Drive Clutch Operation
245
Driven Clutch Operation
245
General Operation
245
Pvt System Overview
245
Belt Inspection
246
Belt Removal
246
Drive Belt
246
Belt Break-In
247
Belt Installation
247
Drive Clutch Removal
248
Drive Clutch Service
248
Drive Clutch Assembly View
249
Drive Clutch Disassembly
250
Drive Clutch Disassembly / Inspection
250
Shift Weight Inspection
250
Slider Plate Inspection
250
Drive Clutch Assembly
253
Drive Clutch Installation
255
Driven Clutch Removal
256
Driven Clutch Service
256
Driven Clutch Assembly View
257
Driven Clutch Disassembly / Inspection
258
Driven Clutch Assembly
259
Driven Clutch Installation
259
Troubleshooting
260
Chapter 6 Transmission
263
General Information
264
Special Tools
264
Shift Cable Adjustment
265
Shift Cable Inspection
265
Shift Lever / Cable
265
Shift Lever Installation
265
Shift Lever Removal
265
Transmission Removal
267
Transmission Service
267
Transmission Installation
269
Transmission Disassembly
272
Transmission Vent Line Routing
272
Gear Cluster Disassembly
274
Snorkel Tube Removal / Disassembly
274
Gear, Shaft, Bearing Inspection
276
Snorkel Gear Backlash
277
Transmission Assembly
277
Transmission Assembly / Snorkel Gear Backlash
277
Shifting Difficulty
280
Troubleshooting
280
Chapter 7 Final Drive
281
General Information
282
Special Tools
282
Bearing Carrier
283
Front Bearing Carrier Inspection / Removal
283
Front Bearing Replacement
284
Front Bearing Carrier Installation
285
Rear Bearing Carrier Inspection / Removal
286
Rear Bearing Replacement
288
Rear Bearing Carrier Installation
289
Drive Shaft
291
Front Drive Shaft Removal
291
Front Drive Shaft Installation
292
Rear Drive Shaft Removal
293
Rear Drive Shaft Installation
294
Drive Shaft / CV Joint Handling Tips
296
Outer CV Boot Replacement
296
Inner Plunging Joint / Boot Replacement
298
Prop Shaft
300
Prop Shaft Removal
300
Prop Shaft Removal (Xp4)
302
Prop Shaft Assembly View
304
Support Bearing Replacement
304
U-Joint Disassembly
305
Prop Shaft Installation
306
Prop Shaft Installation (Xp4)
306
U-Joint Assembly
306
Front Gearcase / Centralized Hilliard
307
Centralized Hilliard Assembly View
308
All Wheel Drive Operation
309
Awd Diagnosis
310
Front Gearcase Disassembly / Inspection
311
Front Gearcase Removal
311
Front Gearcase Assembly
314
Front Gearcase Installation
317
Front Gearcase Vent Line Routing
317
Front Hub Assembly View
318
Rear Hub Assembly View
318
Wheel Hubs
318
Chapter 8 Steering / Suspension
319
General Information
321
Special Tools
321
Steering System
322
Steering System Assembly View
322
Steering Wheel Removal
323
Upper Steering Shaft Removal
323
Power Steering Unit Removal
324
Lower Steering Shaft Installation
325
Lower Steering Shaft Removal
325
Power Steering Unit Installation
326
Upper Steering Shaft Installation
326
Steering Shaft Bushing Replacement
327
Front Suspension
329
Front Suspension Assembly View
329
Front A-Arm Removal / Replacement
330
Front Stabilizer Bar Removal
331
Ball Joint Service Preparation
332
Front Stabilizer Bar Installation
332
Ball Joint Installation
333
Ball Joint Removal
333
Rear Suspension
334
Rear Suspension Assembly View (Remote Reservoir)
334
Trailing Arm Removal / Installation
335
Trailing Arm Spherical Bearing Replacement
336
Radius Rod Removal / Installation
337
Rear Stabilizer Bar Removal
338
Stabilizer Bar Installation
338
Shock / Spring Replacement
339
Shock Assembly View
339
Shock Removal / Installation
339
Shocks / Springs
339
Spring Adjustment
340
Shock Compression Adjustment (Fox®)
341
Fox 2.5" Front Shock Information
343
Fox 3.0" Rear Shock Information
344
Fox 2.5" O.e. Podium Bypass
345
Fox Shock Service
345
Shock Service
345
Fox 3.0" O.e. Podium Bypass
346
Offset Torque Formula
347
Fox Shock Disassembly
348
Fox Shock Assembly
355
Walker Evans Shock Service
359
Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
359
General Service Information
360
Spring Adjustment (Walker Evans)
360
Shock Piston Orientation
362
Special Tools
362
Valve Shim Arrangement
362
Walker Evans™ Shock Disassembly
362
Walker Evans™ Shock Rebuild Information
362
Walker Evans™ Shock Assembly
365
Dynamix Active Suspension (if Equipped)
370
Dynamix Overview
370
Dynamix Shocks Disassembly / Assembly
370
Demonstration Mode
371
Scm Replacement
371
Suspension Control Module (Scm)
371
Braking
372
Cornering Control
372
Dynamix™ System Features
372
Vehicle Speed Sensitivity
372
Acceleration
373
Advanced Diagnostics
373
Airborne Detection
373
Processing Capability
374
Suspension Mode Switch (Dynamix Models)
374
Dynamix Troubleshooting
375
Scm Shock Valve Diagnostics
375
Scm System Voltage
375
Shock Valve Power Supply
375
Scm Can Diagnostics
376
Scm Mode Switch
376
Scm / Inertial Measurement Unit
377
Scm Steering Angle Adapted Offset Diagnostics
377
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