Polaris RZR PRO R User Manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Publication Printed December 2021 (PN 9940259 R02)
© Copyright 2022 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2022 RZR PRO R / PRO R 4
Service Manual

Polaris RZR PRO R Specifications

General

Brand	Polaris
Model	RZR PRO R
Category	Offroad Vehicle
Language	English

Summary

CHAPTER 1 GENERAL INFORMATION

MASTER TORQUE TABLE

Comprehensive list of torque specifications for various components across multiple systems.

GENERAL DIAGNOSTICS

Guides for troubleshooting vehicle concerns, including symptom-based diagnostics and procedures.

CHAPTER 2 MAINTENANCE

ENGINE / EXHAUST

Procedures for checking and changing engine oil, inspecting breather hose, and cylinder leakdown tests.

FUEL SYSTEM AND AIR INTAKE

Guidance on inspecting fuel tank vent, throttle pedal, pre-filters, and air filters.

PVT / FINAL DRIVE / WHEEL AND TIRE

Maintenance procedures for PVT system, front and rear gearcases, drive shafts, wheels, and tires.

TRANSMISSION

Procedures for transmission lubrication, oil level checks, and oil changes.

STEERING / SUSPENSION

Covers steering inspection, free-play checks, alignment, and suspension inspection.

BRAKE SYSTEM

Procedures for brake fluid inspection, hose/fitting inspection, pad inspection, and disc inspection.

ELECTRICAL AND IGNITION SYSTEM

Covers battery maintenance, charging, storage, testing, and spark plug service.

CHAPTER 3 ENGINE / COOLING SYSTEM

ENGINE SERVICE SPECIFICATIONS

Provides standard and service limit specifications for engine components like compression and clearances.

ENGINE SERVICE

Procedures for component removal/installation, including harmonic damper, engine, and cylinder head.

CHAPTER 4 ENGINE ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

Overview of ECU operation, service, replacement, and ETC learn procedure.

CRANKSHAFT POSITION SENSOR (CPS)

Operation overview, testing, and replacement procedures for the crankshaft position sensor.

ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE BODY

Covers ETC operation, testing, replacement, and learn procedure.

CHAPTER 5 EFI / FUEL SYSTEM

EFI OVERVIEW

Explains the EFI system's operation, ECU role, and fuel delivery process.

FUEL INJECTORS

Covers injector operation, O-rings, troubleshooting, testing, and replacement.

FUEL TANK / PUMP

Assembly views and procedures for fuel tank and pump replacement.

FUEL PRESSURE TEST

Procedure for testing fuel pressure and diagnosing potential issues.

FUEL PUMP REPLACEMENT

Step-by-step instructions for removing and installing the fuel pump assembly.

CHAPTER 6 PVT SYSTEM

PVT SYSTEM OVERVIEW

Explains the PVT system's major assemblies and operational principles.

DRIVE BELT

Covers belt removal, inspection, installation, and break-in procedures.

DRIVE CLUTCH SERVICE

Procedures for drive clutch removal, assembly view, disassembly, and installation.

DRIVEN CLUTCH SERVICE

Procedures for driven clutch removal, assembly view, disassembly, and inspection.

DRIVEN CLUTCH INSTALLATION

DRIVEN CLUTCH ALIGNMENT

CHAPTER 7 TRANSMISSION

TRANSMISSION SERVICE

CHAPTER 8 FINAL DRIVE

BEARING CARRIER

HALF SHAFT

PROP SHAFT

FRONT GEARCASE

WHEEL HUBS

CHAPTER 9 STEERING / SUSPENSION

STEERING SYSTEM

FRONT SUSPENSION

REAR SUSPENSION

SHOCKS / SPRINGS

DYNAMIX ACTIVE SUSPENSION

Information on Dynamix shock features, operation, and adjustment modes.

BALL JOINT REPLACEMENT

FRONT STABILIZER BAR REPLACEMENT

CHAPTER 10 BRAKE SYSTEM

BRAKE SYSTEM OVERVIEW

MASTER CYLINDER

FRONT BRAKE SERVICE

REAR BRAKE SERVICE

TROUBLESHOOTING

CHAPTER 11 BODY / FRAME

CHASSIS / MAIN FRAME

REAR CARGO BOX / FENDERS

CHAPTER 12 ELECTRICAL

INSTRUMENT CLUSTER

SWITCHES / CONTROLS

IGNITION COIL

CHARGING SYSTEM

BATTERY

COOLING SYSTEM

Details cooling fan operation, testing, and replacement procedures.

STARTING SYSTEM

ELECTRONIC POWER STEERING (EPS)

Overview of EPS operation and procedures for proper system diagnosing.

FUSES / RELAYS