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RZR PRO XP 4 2021
Polaris RZR PRO XP 4 2021 User Manual
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10
9850068
R01
-
2020-2021
RZR
PRO
XP
/
XP
4
Service
Manual
©
Copyright
Polaris
Industries
Inc.
10.5
BRAKE
LINE
ROUTING
/
RETENTION
Master
Cylinder
T
o
Front
Brake
Calipers
q
Master
Cylinder
w
Rivet
Clip
e
Routing
Clip
r
Front
Brake
Calipers
BRAKE
SYSTEM
482
484
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
11
Replacement Keys
11
Publication Numbers
11
Special Tools
12
Master Torque Table
16
Vehicle Specifications
20
2020-21 Rzr Pro Xp Clutch Chart
21
2020-21 Rzr Pro Xp 4 Clutch Chart
23
2020-21 Rzr Pro Xp Clutch Chart
25
2020-21 Rzr Pro Xp 4 Clutch Chart
27
Misc. Specifications and Charts
28
Conversion Table
28
Sae Tap / Drill Sizes
29
Metric Tap / Drill Sizes
29
Decimal Equivalents
30
General Diagnostics
31
General Diagnostics Information Overview
31
Guided Symptom Diagnostic
31
Guided Symptom References
32
Engine and Drivability Diagnostic Procedures
33
Engine Cranks but Does Not Start
36
No Crank no Start or Slow Crank
38
Over Heating
39
Warning Lights
40
Engine Troubleshooting
41
Cooling Troubleshooting
43
Digital Wrench® Software Overview
44
Special Tools
44
Guided Diagnostics
44
Digital Wrench® Software Installation and Updates
45
Digital Wrench® Communication Errors
46
Digital Wrench® - Diagnostic Connector
46
Digital Wrench® Serial Number Location
47
Digital Wrench® Feature Map
48
Engine Controller Reprogramming (Reflash)
50
Polaris Mobile Digital Wrench® (Pmdw)
50
Diagnostic Trouble Codes Overview
52
Cylinder Misfire Detection
64
Fluid Leaks
65
Fluid Inspection
65
Fuel System Troubleshooting
66
Pvt System Troubleshooting
68
Pvt System Overheating / Diagnosis
70
Hard Shifting
71
Transmission Isolation
71
All Wheel Drive (Awd) Concerns
72
Driveshaft (Half Shaft) Diagnostics
72
Brake Noise Troubleshooting
73
Brake Vibration
73
Caliper Overheats (Brakes Drag)
74
Poor Brake Performance
74
Brakes Lock
74
Eps Troubleshooting (Power Steering Non-Functional with Mil
75
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
76
Eps Troubleshooting (Using Digital Wrench®)
77
Shock Analysis
78
Electrical Service Notes
79
Digital Multi-Meter (DMM) Notes
79
Static and Dynamic Testing
79
Connector Probing Guidelines
80
Testing Continuity / Resistance
81
Testing for a Short to Ground
81
Testing for a Short to Voltage
82
Testing for Intermittent Conditions
83
Testing Current Flow (Amperage)
83
Current Draw - Key off
84
Testing Voltage Drop
84
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
5
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Polaris RZR PRO XP 4 2021 Specifications
General
Brand
Polaris
Model
RZR PRO XP 4 2021
Category
Offroad Vehicle
Language
English
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