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RZR PRO R
Polaris RZR PRO R User Manual
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10.16
9940259
R02
-
2022
RZR
PRO
R
/
PRO
R
4
Service
Manual
©
Copyright
Polaris
Industries
Inc.
BRAKE
PEDAL
BRAKE
PEDAL
REMOV
AL
1.
Locate
the
brake
pedal
lever
e
and
remove
the
nut
w
and
master
cylinder
clevis
fastener
q
.
2.
Remove
the
nut
t
and
r
from
the
pedal
mount
and
remove
the
brake
pedal
lever
e
from
the
vehicle.
BRAKE
PEDAL
INST
ALLA
TION
1.
Reverse
the
“Removal”
steps
to
install
brake
pedal
lever
.
Compare
brake
pedal
free-play
to
specification.
Brake
Pedal
Free-play:
0.090″
(2.28
mm)
BRAKE
SYSTEM
417
419
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
4
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Polaris RZR PRO R Specifications
General
Brand
Polaris
Model
RZR PRO R
Category
Offroad Vehicle
Language
English
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