Polaris RZR PRO XP 4 2021 User Manual

4
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
4.1
ENGINE ELECTRICAL
CHAPTER 4
ENGINE ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU) . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . 4.2
ECU OPERATION OVERVIEW . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 4.2
ECU SERVICE . . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . 4.2
ECU REPLACEMENT . . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. 4.2
ETC LEARN PROCEDURE . . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
PRESSURE SENSORS . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 4.4
BAP SENSOR . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . 4.4
BOOST PRESSURE SENSOR. . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. 4.4
FUEL PRESSURE SENSOR (EVAP MODELS). . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . 4.4
TMAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . . 4.4
AIR TEMPERATURE SENSOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . 4.5
KNOCK SENSOR . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . 4.6
KNOCK SENSOR OVERVIEW. .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . 4.6
KNOCK SENSOR TESTING . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . 4.6
KNOCK SENSOR REPLACEMENT . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . 4.6
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . 4.7
OPERATION OVERVIEW. . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . 4.7
ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. 4.9
ETC OPERATION OVERVIEW. .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . 4.9
ETC TEST. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . 4.9
ETC / THROTTLE BODY REPLACEMENT . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . . .4.10
ETC LEARN PROCEDURE . . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
PEDAL POSITION SENSOR (PPS) . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 4.11
OPERATION OVERVIEW. . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. 4.11
PPS TEST. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. 4.11
OXYGEN SENSOR. . .. . .. . .. . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .4.13
OXYGEN SENSOR INFORMATION. .. . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .4.13
OXYGEN SENSOR REPLACEMENT . . .. . .. . .. . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .4.14

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