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Polaris RZR PRO XP 4 2021 User Manual

Polaris RZR PRO XP 4 2021
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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'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2020 (PN 9850068 R01)
© Copyright 2020 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.
2020-2021 RZR PRO XP / XP 4
Service Manual

Table of Contents

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Polaris RZR PRO XP 4 2021 Specifications

General IconGeneral
BrandPolaris
ModelRZR PRO XP 4 2021
CategoryOffroad Vehicle
LanguageEnglish

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

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