Polaris RZR XP Turbo User Manual

3.92
9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc.
TORQUE
Camshaft Carrier Bolts:
7 ft-lb (10 Nm)
13.Measure and confirm that valve clearance is now
within specification for each valve.
14.If valve clearance is not within specification, repeat
this procedure.
15.If all valve clearance measurements are now within
specification, remove the camshaft carriers and
proceed to Camshaft Installation / Timing, page
VALVE LASH - TAPPET SELECTION
A 440 tappet means the thickness of the tappet is 4.40 mm. Part Number: 5138477-XXX (X’s represent 3 digit tappet
size)
An Engine Valve Lash Adjustment calculator has been created and is located under Service and Warranty – News,
Forms and Links. Click or go to
https://www.polarisdealers.com/files/ServWarr/English/Engine%20Valve%20Adjustment%20Calculator.pdf
The proper valve tappet may also be obtained by completing these steps:
IMPORTANT
The Valve Lash Specification and Measured Valve lash must be calculated in millimeters (mm)
1. Subtract the actual valve lash on the engine from the valve lash specification (i.e. 0.29 mm – 0.20 mm) = 0.09 mm.
2. Divide the 3 digit tappet number by 100 (i.e. 450 / 100) = 4.5 mm.
3. Add the results of step 1 and step 2 (i.e. 0.09 mm + 4.5 mm) = 4.59 mm.
4. Multiply that answer by 100 to obtain the correct new tappet (i.e. 4.59 mm x 100 = 459).
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i. e. 459 should be
rounded to 460 since there is a 460 tappet).
Available Tappets
440 450 460 470 480 490 500 510 520 530 540
442 452 462 472 482 492 502 512 522 532 542
445 455 465 475 485 495 505 515 525 535 545
448 458 468 478 488 498 508 518 528 538
VALVE COVER INSTALLATION
1. Install spark plugs
q
and torque to specification.
TORQUE
Spark Plugs:
9 ft-lbs (12 Nm)
2. Prepare valve cover sealing surfaces by cleaning
thoroughly to remove all residue.
3. Inspect the valve cover seal
w
and replace if
necessary.
4. Replace the isolators
e
around each T40 bolt.
5. Install the four valve cover shoulder bolts
r
and
isolators using a T40 driver.
6. Torque valve cover bolts in sequence to specification.
ENGINE / COOLING SYSTEM

Polaris RZR XP Turbo Specifications

General

Brand	Polaris
Model	RZR XP Turbo
Category	Offroad Vehicle
Language	English