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RZR XP Turbo
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Polaris RZR XP Turbo - Brake Line Routing; Retention; Front Brake Lines to Master Cylinder
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9
9928491
R04
-
2017-2018
RZR
XP
Turbo
/
XP4
T
urbo
Service
Manual
©
Copyright
Polaris
Industries
Inc.
9.5
BRAKE
LINE
ROUTING
/
RETENTION
FRONT
BRAKE
LINES
TO
MASTER
CYLINDER
q
Brake
Line
Retaining
Clip
w
Control
Arm
Brake
Line
Retainer
BRAKE
SYSTEM
382
384
Table of Contents
Main Page
Chapter 1 1 General Information
7
Table of Contents
7
Vehicle Identification
8
Model Number Designation (2015 +)
8
Vehicle Identification Number (Vin) Designation (2015+)
8
Vin and Engine Serial Number Locations
8
Reference Information
9
Replacement Keys
9
Publication Numbers
9
Special Tools
10
Master Torque Table
14
Vehicle Specifications
18
2017 Rzr Xp Turbo Clutch Chart
19
2017 Rzr Xp 4 Turbo
21
2017 Rzr Xp4 Turbo Clutch Chart
21
2017 Rzr Xp Turbo Clutch Chart
23
2018 Rzr Xp Turbo
25
2018 Rzr Xp Turbo Clutch Chart
25
2018 Rzr Xp Turbo Fox Edition
26
2018 Rzr Xp Turbo Clutch Chart
27
2018 Rzr Xp Turbo Dynamix Edition
28
2018 Rzr Xp Turbo Clutch Chart
29
2017 Rzr Xp4 Turbo Clutch Chart
31
2018 Rzr Xp 4 Turbo
35
2018 Rzr Xp 4 Turbo Clutch Chart
35
Misc. Specifications and Charts
36
Conversion Table
36
Sae Tap / Drill Sizes
37
Metric Tap / Drill Sizes
37
Decimal Equivalents
38
Maintenance Chapter 2 Maintenance 2
39
Lubricants / Service Products
41
Maintenance
41
Periodic Maintenance - General
41
Pre-Ride Inspection
42
Maintenance Intervals
43
Maintenance Quick Reference
63
Grease Lubrication Points
65
Engine / Exhaust
66
Engine Oil Level
66
Engine Oil and Filter Change
67
Engine Crankcase Breather Hose
68
Engine Cylinder Leakdown Test
68
Valve Clearance Adjustment
69
Cam Chain Tensioner Inspection
70
Spark Arrestor
71
Heat Shield Inspection
72
Coolant Level Inspection
73
Coolant Strength
73
Cooling System
73
Coolant Hose Inspection
74
Cooling System Pressure Test
74
Coolant Flush
75
Radiator Inspection / Cleaning
75
Cooling System Bleeding
76
Engine Cooling System Bleeding
76
Charge Air Cooling System Bleeding
77
Engine Intake Pre-Filter Service
78
Fuel System and Air Intake
78
Fuel Tank Vent Inspection
78
Throttle Pedal Inspection
78
Air Filter Service
79
Intake Duct Drain Inspection
79
Pvt / Final Drive / Wheel and Tire
80
Pvt Drain
80
Pvt Intake Pre-Filter Service
80
Front Gearcase Fluid Change
81
Front Gearcase Fluid Level Check
81
Front Gearcase Lubrication
81
Drive Shaft Boot Inspection
82
Tire Inspection
82
Wheel Installation
82
Wheel Removal
82
Maintenance
83
Tire Pressure
83
Transmission
84
Transmission Lubrication
84
Transmission Oil Change
84
Transmission Oil Level Check
84
Steering
85
Steering Inspection
85
Steering Wheel Free-Play
85
Tie Rod End / Wheel Hub Inspection
85
Wheel Toe Adjustment
86
Wheel Toe Alignment Inspection
86
Suspension
88
Suspension Inspection
88
Suspension Lubrication
88
Brake Fluid Inspection
89
Brake Hose and Fitting Inspection
89
Brake Pad Inspection
89
Brake System
89
Brake Disc Inspection
90
Battery Charging / off Season Storage
91
Battery Maintenance
91
Electrical and Ignition System
91
Engine / Chassis Electrical Ground
91
Spark Plug Service
91
Chapter 3 Engine / Cooling System
93
Engine Lubrication Specifications
96
General Information
96
Special Tools
96
Oil Pressure Test
97
Oil Flow Chart
98
Engine Service Specifications
99
Engine Specifications
99
Engine Torque Specifications
101
Intake / Exhaust System
103
Intake / Turbo System Overview
103
Engine Air Intake Assembly View
104
Air Box Installation
105
Air Box Removal
105
Exhaust Assembly View
106
Exhaust Pipe Removal
107
Muffler Installation
107
Muffler Removal
107
Head Pipe / Turbo Removal
109
Head Pipe / Turbo Installation
111
Exhaust Pipe Installation
112
Turbocharger Inspection
113
Turbocharger Service
113
Actuator / Wastegate Inspection
116
Actuator Pod Removal
117
Oil Drain Tube Service
118
Cooling System
119
Wastegate Flapper Inspection
119
Cooling System Flow
120
Charge Air Cooler Removal
121
Cooling System Pressure Test
121
Cooling System Specifications
121
Charge Air Cooler Installation
123
Radiator Removal
124
Radiator Installation
126
Thermostat Replacement
126
Water Pump Service
128
Engine Service
131
Front Engine Mount Isolator Replacement
131
Crankshaft Pto Seal Replacement
132
Engine Removal
134
Engine Installation
137
Camshaft Removal
141
Engine Disassembly / Inspection - Top End
141
Valve Cover Removal
141
Camshaft / Camshaft Bore Inspection
142
Camshaft Sprocket Inspection
142
Cylinder Head Disassembly
144
Cylinder Head Inspection
144
Cylinder Head Removal
144
Valve Inspection
145
Combustion Chamber Cleaning
146
Valve Seat Reconditioning
147
Engine Disassembly / Inspection - Bottom End
150
Stator Cover Removal / Inspection
150
Water Pump Housing Removal
150
Flywheel Removal
151
Crankcase Disassembly
152
Starter One-Way Clutch Disassembly
152
Balance Shaft Removal / Inspection
155
Crankshaft Removal / Inspection
155
Crankcase Inspection
157
Cylinder / Piston Removal
158
Cylinder Inspection
159
Piston Disassembly / Inspection
159
Piston Ring Removal
160
Piston Ring Installed Gap
161
Piston Ring to Groove Clearance
161
Piston to Cylinder Clearance
161
Connecting Rod Inspection
162
Bearing Selection Identification
163
Engine Assembly - Bottom End
163
Connecting Rod Bearing Selection
164
Crankshaft Main Bearing Selection
164
Upper Crankcase Preparation
164
Piston Ring Installation
165
Piston / Connecting Rod Assembly
166
Piston / Cylinder Installation
166
Crankshaft Installation
167
Balance Shaft Installation
169
Crankcase Assembly
169
Lower Crankcase Preparation
169
Starter One-Way Clutch Assembly
173
Flywheel Installation
174
Stator Cover Installation
174
Cylinder Head Assembly
176
Engine Assembly - Top End
176
Cylinder Head Installation
177
Valve Sealing Test
177
Camshaft Installation / Timing
178
Camshaft Timing Quick Reference
182
Valve Clearance Adjustment
183
Valve Cover Installation
184
Valve Lash - Tappet Selection
184
Engine Troubleshooting
186
Troubleshooting
186
Cooling Troubleshooting
187
Turbocharger Troubleshooting
187
Chapter 4 Efi / Fuel System
189
General Information
191
Special Tools
191
Efi Overview
192
Efi System Components/Locations
192
Efi Operation Overview
193
Efi Service Notes
193
Initial Priming / Starting Procedure
194
Ecu Operation Overview
195
Ecu Replacement
195
Ecu Service
195
Electronic Control Unit (Ecu)
195
Etc Learn Procedure
196
Fuel Injector O-Rings
197
Fuel Injector Operation Overview
197
Fuel Injectors
197
Fuel Injector Test
198
Fuel Injector Troubleshooting
198
Fuel Injector Replacement
199
Fuel Line Removal / Installation
201
Fuel Lines
201
Fuel Vent Line Routing
202
Vent Line Termination Fitting
202
Fuel Tank / Pump
204
Fuel Tank Assembly View
204
Fuel Tank Removal
205
Fuel Tank Installation
207
Fuel Tank Removal (Xp4)
209
Fuel Tank Installation (Xp4)
211
Fuel Pressure Test
213
Fuel Pump Operation Overview
213
Fuel Pump Replacement
214
Fuel Sender Test
217
Air Temperature Sensor Data
218
Bap Sensor
218
Boost Pressure Sensor
218
Pressure Sensors
218
Tmap Sensor
218
Efi / Fuel System
219
Knock Sensor
219
Knock Sensor Overview
219
Knock Sensor Replacement
219
Knock Sensor Testing
219
Cps Test
220
Crankshaft Position Sensor (Cps)
220
Operation Overview
220
Cps Replacement
221
Electronic Throttle Control (Etc) / Throttle Body
222
Etc / Throttle Body Replacement
222
Etc Operation Overview
222
Etc Test
222
Etc Learn Procedure
223
Location
224
Operation Overview
224
Pedal Position Sensor (Pps)
224
Pps Replacement
224
Pps Test
224
Oxygen Sensor
226
Oxygen Sensor Information
226
Oxygen Sensor Replacement
227
Efi Diagnostics
228
Fuel System Troubleshooting
228
Digital Wrench Data Troubleshooting
229
Cylinder Misfire Detection
232
Digital Wrench® Diagnostic Software Overview
233
Polaris Digital Wrench
233
Special Tools (Digital Wrench)
233
Digital Wrench Software Version and Update
234
Digital Wrench® Updates
234
Digital Wrench Diagnostic Connector
235
Digital Wrench® Communication Errors
235
Digital Wrench® Serial Number Location
236
Guided Diagnostics
236
Digital Wrench® Feature Map
237
Ecu Replacement
238
Ecu Reprogramming (Reflash)
238
Etc Learn Procedure
238
Polaris Mobile Digital Wrench (Pmdw)
241
Chapter 5 Pvt System
243
2017 Rzr Xp Turbo Clutch Chart
244
2017 Rzr Xp4 Turbo Clutch Chart
244
General Information
244
Special Tools
244
Drive Clutch Operation
245
Driven Clutch Operation
245
General Operation
245
Pvt System Overview
245
Belt Inspection
246
Belt Removal
246
Drive Belt
246
Belt Break-In
247
Belt Installation
247
Drive Clutch Removal
248
Drive Clutch Service
248
Drive Clutch Assembly View
249
Drive Clutch Disassembly
250
Drive Clutch Disassembly / Inspection
250
Shift Weight Inspection
250
Slider Plate Inspection
250
Drive Clutch Assembly
253
Drive Clutch Installation
255
Driven Clutch Removal
256
Driven Clutch Service
256
Driven Clutch Assembly View
257
Driven Clutch Disassembly / Inspection
258
Driven Clutch Assembly
259
Driven Clutch Installation
259
Troubleshooting
260
Chapter 6 Transmission
263
General Information
264
Special Tools
264
Shift Cable Adjustment
265
Shift Cable Inspection
265
Shift Lever / Cable
265
Shift Lever Installation
265
Shift Lever Removal
265
Transmission Removal
267
Transmission Service
267
Transmission Installation
269
Transmission Disassembly
272
Transmission Vent Line Routing
272
Gear Cluster Disassembly
274
Snorkel Tube Removal / Disassembly
274
Gear, Shaft, Bearing Inspection
276
Snorkel Gear Backlash
277
Transmission Assembly
277
Transmission Assembly / Snorkel Gear Backlash
277
Shifting Difficulty
280
Troubleshooting
280
Chapter 7 Final Drive
281
General Information
282
Special Tools
282
Bearing Carrier
283
Front Bearing Carrier Inspection / Removal
283
Front Bearing Replacement
284
Front Bearing Carrier Installation
285
Rear Bearing Carrier Inspection / Removal
286
Rear Bearing Replacement
288
Rear Bearing Carrier Installation
289
Drive Shaft
291
Front Drive Shaft Removal
291
Front Drive Shaft Installation
292
Rear Drive Shaft Removal
293
Rear Drive Shaft Installation
294
Drive Shaft / CV Joint Handling Tips
296
Outer CV Boot Replacement
296
Inner Plunging Joint / Boot Replacement
298
Prop Shaft
300
Prop Shaft Removal
300
Prop Shaft Removal (Xp4)
302
Prop Shaft Assembly View
304
Support Bearing Replacement
304
U-Joint Disassembly
305
Prop Shaft Installation
306
Prop Shaft Installation (Xp4)
306
U-Joint Assembly
306
Front Gearcase / Centralized Hilliard
307
Centralized Hilliard Assembly View
308
All Wheel Drive Operation
309
Awd Diagnosis
310
Front Gearcase Disassembly / Inspection
311
Front Gearcase Removal
311
Front Gearcase Assembly
314
Front Gearcase Installation
317
Front Gearcase Vent Line Routing
317
Front Hub Assembly View
318
Rear Hub Assembly View
318
Wheel Hubs
318
Chapter 8 Steering / Suspension
319
General Information
321
Special Tools
321
Steering System
322
Steering System Assembly View
322
Steering Wheel Removal
323
Upper Steering Shaft Removal
323
Power Steering Unit Removal
324
Lower Steering Shaft Installation
325
Lower Steering Shaft Removal
325
Power Steering Unit Installation
326
Upper Steering Shaft Installation
326
Steering Shaft Bushing Replacement
327
Front Suspension
329
Front Suspension Assembly View
329
Front A-Arm Removal / Replacement
330
Front Stabilizer Bar Removal
331
Ball Joint Service Preparation
332
Front Stabilizer Bar Installation
332
Ball Joint Installation
333
Ball Joint Removal
333
Rear Suspension
334
Rear Suspension Assembly View (Remote Reservoir)
334
Trailing Arm Removal / Installation
335
Trailing Arm Spherical Bearing Replacement
336
Radius Rod Removal / Installation
337
Rear Stabilizer Bar Removal
338
Stabilizer Bar Installation
338
Shock / Spring Replacement
339
Shock Assembly View
339
Shock Removal / Installation
339
Shocks / Springs
339
Spring Adjustment
340
Shock Compression Adjustment (Fox®)
341
Fox 2.5" Front Shock Information
343
Fox 3.0" Rear Shock Information
344
Fox 2.5" O.e. Podium Bypass
345
Fox Shock Service
345
Shock Service
345
Fox 3.0" O.e. Podium Bypass
346
Offset Torque Formula
347
Fox Shock Disassembly
348
Fox Shock Assembly
355
Walker Evans Shock Service
359
Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
359
General Service Information
360
Spring Adjustment (Walker Evans)
360
Shock Piston Orientation
362
Special Tools
362
Valve Shim Arrangement
362
Walker Evans™ Shock Disassembly
362
Walker Evans™ Shock Rebuild Information
362
Walker Evans™ Shock Assembly
365
Dynamix Active Suspension (if Equipped)
370
Dynamix Overview
370
Dynamix Shocks Disassembly / Assembly
370
Demonstration Mode
371
Scm Replacement
371
Suspension Control Module (Scm)
371
Braking
372
Cornering Control
372
Dynamix™ System Features
372
Vehicle Speed Sensitivity
372
Acceleration
373
Advanced Diagnostics
373
Airborne Detection
373
Processing Capability
374
Suspension Mode Switch (Dynamix Models)
374
Dynamix Troubleshooting
375
Scm Shock Valve Diagnostics
375
Scm System Voltage
375
Shock Valve Power Supply
375
Scm Can Diagnostics
376
Scm Mode Switch
376
Scm / Inertial Measurement Unit
377
Scm Steering Angle Adapted Offset Diagnostics
377
Chapter 9 Brake System
379
Brake System Specifications
381
General Information
381
Special Tools
381
Brake System Overview
382
Brake System View
382
Brake Line Routing / Retention
383
Front Brake Lines to Master Cylinder
383
Rear Brake Line - Master Cylinder to Junction Block
384
Rear Brake Lines - Junction Block to Calipers
385
Brake System Service Notes
386
Hydraulic Brake System Operation
386
Master Cylinder
387
Master Cylinder Installation
387
Master Cylinder Removal
387
Brake Bleeding / Fluid Change
389
Brake Pedal
391
Brake Pedal Installation
391
Brake Pedal Removal
391
Secondary Brake System Overview
392
Secondary Hand Brake (Int
392
Secondary Brake Fluid Reservoir
394
Secondary Brake Master Cylinder
394
Brake Caliper / Pad Removal
395
Front Brake Service
395
Front Caliper Assembly View
397
Front Caliper Disassembly / Inspection
398
Brake Pad Inspection
399
Front Caliper Assembly
399
Brake Caliper / Pad Installation
400
Brake Disc Inspection
400
Front Brake Disc Replacement
400
Brake Burnishing Procedure
401
Brake Caliper / Pad Removal
402
Rear Brake Service
402
Rear Caliper Disassembly / Inspection
403
Brake Pad Inspection
404
Caliper Inspection
404
Rear Caliper Assembly
404
Rear Brake Disc Inspection
405
Rear Brake Disc Replacement
405
Rear Brake Caliper / Pad Installation
406
Chapter 10 Body / Frame
409
General Information
410
Special Tools Decal Replacement
410
Body Assembly Views
411
Cab Frame Assembly
411
Cab Frame Assembly Xp 4
412
Doors
413
Doors (Xp4)
414
Dash / Controls
415
Hood / Front Body Work
416
Chassis / Main Frame
418
Seat Assembly Front
419
Floor / Rocker Panels (Xp)
420
Floor / Rocker Panels (Xp4)
421
Rear Cargo Box / Fenders
422
Rear Bumper
423
Body Component Removal
424
Engine Service Panel
424
Front Bumper
424
Seats
424
Dash Removal
425
Hood and Front Body Work
425
Hood Removal
425
Lower Dash Removal
425
Rear Bumper
425
Fender Flair Removal
426
Fender Removal
426
Front Body Removal
426
Front Fener Flair Removal
426
Rear Fender / Fender Flair Removal
426
Cargo Box Assembly Removal
427
Rocker Panels, Console and Floor Xp
428
Door Adjustment
429
Door Panel / Latch Replacement
429
Doors
429
Chapter 11 Electrical
431
General Information
434
Special Tools
434
Under-Dash Components
434
Electrical Service Notes
435
Electrical Component Locations
436
Digital Multi-Meter (DMM) Notes
437
Dynamic Testing
437
Electrical Diagnostics
437
Electrical Service Notes
437
Static and Dynamic Testing
437
Static Testing
437
Back Probing
438
Break out
438
Connector Probing Guidelines
438
Front Probing
438
Testing Continuity/Resistance
439
Testing for a Short to Ground
439
Testing Current Flow (Amperage)
440
Testing for a Short to Voltage
440
Testing for Intermittent Conditions
440
Testing Parasitic Draw
441
Testing Voltage Drop
441
Instrument Cluster
442
Overview
442
Indicator Lamps
443
Display Area 1
444
Display Area 2
445
Options Menu
446
Unit Selection Distance
447
Unit Selection Temperature
448
Clock
449
Back Light Color
450
Back Light Level
451
Service Hours
452
Diagnostic Code
453
Instrument Cluster Installation
454
Instrument Cluster Pinouts
454
Instrument Cluster Removal
454
Awd / 2Wd Switch (no Turf Mode)
455
Headlamp Switch
455
Ignition / Key Switch
455
Switches / Controls
455
Seat Belt Switch
456
Transmission / Gear Position Switch
456
Boost Control Solenoid / Valve
457
Brake Pressure Switch
457
Hazard Switch (Int'l / Tractor)
458
Horn
458
Turn Lights
458
Turn/Lights/Horn Switch (Int'l/Tractor)
458
Brake Alarm (Int'l/Tractor)
459
Flasher Module (Int'l/Tractor)
459
Parking Brake Switch (Int'l/Tractor)
460
Suspension Mode Switch (Dynamix Models)
460
Steering Angle Sensor Centering (Dynamix)
461
Ignition Coil
463
Ignition Coil / Ht Lead Replacement
463
Ignition Coil Tests
463
Operation Overview
463
Charging System
464
Charging System "Break Even" Test
464
Current Draw - Key off
464
Stator Testing
464
Test 1: Resistance Value of each Stator Leg
464
Regulator / Rectifier (Non-Dynamix)
465
Regulator Replacement
465
Test 3: Measure Ac Voltage Output of each Stator Leg at Charging Rpm
465
Regulator / Rectifier (Dynamix)
466
Regulator Replacement
466
Battery
468
Battery Removal
468
Battery Specifications
468
General Battery Information
468
Battery Installation
469
Battery off Season Storage
469
Battery Testing
469
Battery Conductance Analyzer
470
Charging Procedure
470
Load Test
470
Ocv - Open Circuit Voltage Test
470
Headlamp Replacement
472
Headlight Adjustment
472
Lighting System
472
Dash Light
473
Headlamp Installation
473
Taillight Replacement
473
Cooling Fan Description and Operation
474
Cooling Fan Testing
474
Cooling System
474
Fan Control Circuit Bypass Test
474
Cooling Fan Replacement
475
Bleeding
476
Electric Coolant Pump
476
Replacement
476
Ect Sensor Test
477
Starting System
477
Starter Solenoid Bench Test
478
Starter Solenoid Operation
478
Starter Solenoid Replacement
478
Electronic Power Steering (Eps)
479
Eps Operation
479
Proper Eps System Diagnosing
479
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
480
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
481
Eps Troubleshooting (Using Digital Wrench®)
482
Relay / Fuse Details
485
Voltage Regulator Fusible Link
488
Can System
489
Can System Overview
489
Can System Testing
489
Main Harness Routing
490
Wiring Harness
490
Main Harness Retention Locations
491
Wiring Harness Replacement
492
Break-Out Diagram Viewing
493
Diagnostic Trouble Code List
495
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