Polaris RZR PRO XP 4 2021 User Manual

1.10
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
MASTER TORQUE TABLE
ITEM
TORQUE
A-Arm Fasteners
74 ft-lbs (100 Nm)
Air Box Mounting Bolts 8 ft-lb (11 Nm)
Air Intake Housing Screw (Engine
and PVT)
35 in-lb (4 Nm)
Ball Joint Fasteners
44 ft-lbs (60 Nm)
Battery
Mount
Bracket
53 in-lbs (6 Nm)
Terminal
Fasteners
60 in-lbs (7 Nm)
Bearing Carrier Mounting Bolts
(rear)
44 ft-lbs (60 Nm)
Body Panel Fasteners 7 ft-lbs (10 Nm)
Brake Bleed Screws
48 in-lb (5 Nm)
Brake Caliper
Mounting Bolts
front
33 ft-lbs (45 Nm)
rear
33 ft-lbs (45 Nm)
Brake Junction Block Mounting
Screws
35 in-lb (4 Nm)
Brake Line
Banjo Bolts 15 ft-lbs (20 Nm)
Flare Fittings 15 ft-lbs (20 Nm)
Brake Line Guide Fasteners
7 ft-lbs (10 Nm)
Brake Pedal Mount Bracket
Fasteners
18 ft-lbs (24 Nm)
Brake Scraper Fasteners 7 ft-lbs (10 Nm)
Brake Switch
15 ft-lbs (20 Nm)
Box Support Fastener 14 ft-lbs (19 Nm)
Cam Chain
Tensioner
Spring Bolt 15 ft-lb (20 Nm)
Mounting
Bolts
7 ft-lb (10 Nm)
Camshaft Carrier
Carrier Bolts
7 ft-lb (10 Nm)
Sprocket
Bolts
14 ft-lb (19 Nm)
Carbon Canister Fastener
9 ft-lbs (12 Nm)
Carbon Canister Filter Fastener
9 ft-lbs (12 Nm)
Cargo Box Fastener 7 ft-lbs (10 Nm)
Cargo Box Support Bracket
Fasteners
15 ft-lbs (20 Nm)
Charge Air Cooler Bolts
Torque in sequence to
7 ft-lb (10 Nm)
Chassis Ground Nut
5 ft-lb (7 Nm)
Connecting Rod Bolts
Step 1: 9 ft-lbs (12
Nm)
Step 2: 22 ft-lb (30
Nm)
Step 3: Tighten
add’n 90°
Coolant Hose Retainer Bolt
8 ft-lb (11 Nm)
Coolant Reservoir
8 ft-lb (11 Nm)
Coolant Temperature Sensor 17 ft-lb (23 Nm)
CPS Retaining Bolt 9 ft-lb (12 Nm)
Crankcase Bolts
M6
9 ft-lb (12 Nm)
M8
26 ft-lb (35 Nm)
ITEM
TORQUE
M10
Step 1: 9 ft-lb (12
Nm)
Step 2: 21 ft-lb (28
Nm)
Step 3: Tighten
add’n 90°
Crankcase Oil Gallery Plug 12 ft-lbs (16 Nm)
Cylinder Head Bolts
Torque in
sequence
Step 1: 13 ft-lbs (18
Nm)
Step 2: 26 ft-lb (35
Nm)
Step 3: Additional
180°
Step 4: Additional
180°
Step 5: M6 bolts: 7
ft-lb (10 Nm)
Dash Trim Fastener
7 ft-lbs (10 Nm)
Debris Scraper 20 ft-lbs (27 Nm)
Door Frame Fastener
7 ft-lbs (10 Nm)
Door Hinge Fastener 18 ft-lbs (24 Nm)
Door Latch/Actuator Fastener
9 ft-lbs (12 Nm)
Door Panel Fastener
35 in-lbs (4 Nm)
Door Striker Fastener
7 ft-lbs (10 Nm)
Door Trim Bracket Fastener
18 in-lbs (2 Nm)
Drive Clutch
Mounting
Bolt
140 ft-lbs (190 Nm)
Cover Plate
15 ft-lbs (21 Nm)
Shift Weight 20 in-lb (2 Nm)
Driven Clutch
Helix
Fasteners
32 ft-lbs (44 Nm)
Mounting
Bolt
43 ft-lbs (58 Nm)
Driveshaft Boot Guard Screws
14 ft-lb (19 Nm)
ECU Mounting Screws 24 in-lb (3 Nm)
Electric Coolant Pump Bracket
Fasteners
8 ft-lb (11 Nm)
Engine Breather Cover Screws 7 ft-lb (10 Nm)
Engine Mount
Bracket
Fasteners
42 ft-lb (57 Nm)
Isolator Bolt
55 ft-lb (75 Nm)
Engine Mount to Frame 22 ft-lb (30 Nm)
Engine Oil Plug 12 ft-lbs (16 Nm)
EPS-to-Bracket Fasteners
33 ft-lbs (45 Nm)
EPS Bracket Mounting Fasteners
(Lower)
26 ft-lbs (35 Nm)
EPS Bracket Mounting Fasteners
(Upper)
33 ft-lbs (45 Nm)
EPS to Lower Steering Shaft
Fastener
22 ft-lbs (30 Nm)
GENERAL INFORMATION

Polaris RZR PRO XP 4 2021 Specifications

General

Brand	Polaris
Model	RZR PRO XP 4 2021
Category	Offroad Vehicle
Language	English

Summary

GENERAL INFORMATION

MASTER TORQUE TABLE

A comprehensive list of torque specifications for various fasteners and components.

GENERAL DIAGNOSTICS

Information on how to approach and perform general vehicle diagnostics.

MAINTENANCE

ENGINE / EXHAUST

Procedures for checking engine oil level and performing oil/filter changes.

COOLING SYSTEM

Information on coolant level inspection, pressure testing, and bleeding procedures.

ENGINE / COOLING SYSTEM

OIL PRESSURE TEST

Procedure for testing engine oil pressure using specialized gauges.

ENGINE SERVICE SPECIFICATIONS

Standard and service limit specifications for camshaft, cylinder head, and valves.

ENGINE TORQUE SPECIFICATIONS

Torque values for critical engine components like crankcase and cylinder head.

ENGINE ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

Overview of ECU operation, service, and replacement procedures.

ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE BODY

ETC operation, testing, and replacement procedures.

EFI / FUEL SYSTEM

FUEL PUMP REPLACEMENT

Step-by-step instructions for replacing the fuel pump assembly.

PVT SYSTEM

DRIVE BELT

Procedures for drive belt removal, inspection, installation, and break-in.

DRIVE CLUTCH SERVICE

Procedures for drive clutch removal and disassembly.

CLUTCH DISASSEMBLY

Step-by-step instructions for disassembling the drive clutch.

TRANSMISSION

SHIFT CABLE ADJUSTMENT

Procedure for adjusting the shift cable for proper gear engagement.

TRANSMISSION SERVICE

Procedures for transmission removal and installation.

TRANSMISSION INSTALLATION

Step-by-step instructions for installing the transmission into the chassis.

TRANSMISSION DISASSEMBLY

Step-by-step instructions for disassembling the transmission.

GEAR, SHAFT, BEARING INSPECTION

Inspection of gears, shafts, and bearings for wear or damage.

TRANSMISSION ASSEMBLY / SNORKEL GEAR BACKLASH

Procedures for assembling the transmission and setting gear backlash.

FINAL DRIVE

BEARING CARRIER

Procedures for front and rear bearing carrier inspection, removal, and installation.

DRIVE SHAFT

Procedures for front and rear drive shaft removal and installation.

CV JOINT / BOOT REPLACEMENT

Procedures for replacing CV joints and boots on drive axles.

ALL WHEEL DRIVE OPERATION

Explanation of how the AWD system engages and disengages.

AWD DIAGNOSIS

Troubleshooting guide for when the AWD system will not engage.

FRONT GEARCASE REMOVAL / INSTALLATION

Procedures for removing and installing the front gearcase.

STEERING / SUSPENSION

POWER STEERING UNIT REMOVAL

Procedure for removing the power steering unit.

STEERING RACK REMOVAL / INSTALLATION

Procedures for removing and installing the steering rack.

FRONT A-ARM REMOVAL / INSTALLATION

Procedures for removing and installing the front A-arm.

BALL JOINT INSTALLATION

Procedure for installing new ball joints into the A-arm.

TRAILING ARM REMOVAL / INSTALLATION

Procedures for removing and installing the trailing arm.

WALKER EVANS™ SHOCK REBUILD INFORMATION

Information and precautions for rebuilding Walker Evans™ shocks.

DYNAMIX ACTIVE SUSPENSION

Overview of the Dynamix Active Suspension system.

BRAKE SYSTEM

BRAKE SYSTEM SERVICE NOTES

Important notes and precautions for brake system service.

HYDRAULIC BRAKE SYSTEM OPERATION

Explanation of how the hydraulic brake system functions.

MASTER CYLINDER

Procedures for master cylinder removal and installation.

FRONT BRAKE SERVICE

Procedures for front brake caliper and pad service.

REAR BRAKE SERVICE

Procedures for rear brake caliper and pad service.

TROUBLESHOOTING

Troubleshooting guide for brake system issues.

ELECTRICAL

ELECTRICAL SERVICE NOTES

INSTRUMENT CLUSTER

CHARGING SYSTEM

STATOR TESTING

BATTERY TESTING

CHARGING PROCEDURE

ECT SENSOR TEST

STARTING SYSTEM

ELECTRONIC POWER STEERING (EPS)

FUSES / RELAYS