Polaris RZR XP Turbo - 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'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2017 (PN 9928491 R04)
© Copyright 2017 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.
2017-2018 RZR XP Turbo / XP4 Turbo
Service Manual

Polaris RZR XP Turbo Specifications

General

Brand	Polaris
Model	RZR XP Turbo
Category	Offroad Vehicle
Language	English

Summary

GENERAL INFORMATION

Chapter 1: GENERAL INFORMATION

Provides essential overview, specifications, and reference data for the vehicle.

MASTER TORQUE TABLE

MAINTENANCE

PERIODIC MAINTENANCE - GENERAL

PRE-RIDE INSPECTION

Lists essential items to inspect before operating the vehicle for safety.

MAINTENANCE INTERVALS

Outlines required maintenance based on vehicle hours or miles.

ENGINE; COOLING SYSTEM

ENGINE SPECIFICATIONS

ENGINE TORQUE SPECIFICATIONS

Lists torque values for various engine components like crankcase and valve cover.

COOLING SYSTEM

EFI; FUEL SYSTEM

EFI SYSTEM COMPONENTS;LOCATIONS

FUEL INJECTOR TROUBLESHOOTING

Addresses common injector problems like electrical issues, clogging, and leakage.

FUEL PRESSURE TEST

Details the procedure and specifications for testing fuel system pressure.

PVT SYSTEM

PVT SYSTEM OVERVIEW

DRIVE CLUTCH SERVICE

DRIVEN CLUTCH SERVICE

TRANSMISSION

TRANSMISSION REMOVAL

Step-by-step instructions for removing the transmission from the vehicle.

TRANSMISSION INSTALLATION

Steps for installing the transmission back into the vehicle chassis.

TRANSMISSION DISASSEMBLY

Detailed instructions for taking the transmission apart for inspection or repair.

FINAL DRIVE

BEARING CARRIER

DRIVE SHAFT

FRONT GEARCASE

STEERING; SUSPENSION

STEERING SYSTEM

Details the steering system assembly, components, and procedures.

FRONT SUSPENSION

Covers assembly view, A-arm, stabilizer bar, and ball joint service.

REAR SUSPENSION

Details assembly view, trailing arm, radius rod, and stabilizer bar service.

SHOCKS; SPRINGS

BRAKE SYSTEM

BRAKE SYSTEM OVERVIEW

FRONT BRAKE SERVICE

REAR BRAKE SERVICE

ELECTRICAL

ELECTRICAL SERVICE NOTES

STATIC AND DYNAMIC TESTING

DIAGNOSTIC TROUBLE CODE LIST

Lists EFI fault codes, components, conditions, and associated DTCs.

POLARIS DIGITAL WRENCH (PMDW)