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Polaris RZR XP User Manual
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9929419
R02
-
2018-2019
RZR
XP
/
XP
4
Turbo
S
Service
Manual
©
Copyright
Polaris
Industries
Inc.
1.5
2200421
Gas
Shock
Recharging
Kit
2460761
Hall
Sensor
Probe
Harness
2870386
Piston
Pin
Puller
2870630
T
iming
Light
PU-52522
Live
V
alve
T
ool
2870910-A
Roller
Pin
T
ool
2870975
Mity-V
ac
Pressure
T
est
T
ool
2871226
Clutch
Bushing
Replacement
T
ool
Kit
2871282
T
ransmission
Seal
Driver
(50
MM)
2871358-B
Drive
Clutch
Holding
Fixture
2871745
Static
T
iming
Light
Harness
2872085
Drive
Clutch
Puller
2876389
Combination
Pliers
2878925
Spanner
Wrench
/
Clutch
Spreader
8700226
CV
Boot
Clamp
Pliers
(ear)
P
A-48838
Fuel
Pressure
Adapter
P
A-49316
W
ater
Pump
Drive
&
Flywheel
Removal
T
ool
PU-43506-A
Fuel
Pressure
Gauge
Kit
PU-47471
Smartlink
Module
Kit
PU-48951
CV
Boot
Clamp
Pliers
(Stepless)
GENERAL
INFORMA
TION
1
10
12
Table of Contents
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
17
2018 Rzr Xp Turbo S
18
2018 Rzr Xp Turbo S Clutch Chart
18
2019 Rzr Xp Turbo S Clutch Chart
20
2019 Rzr Xp 4 Turbo S Clutch Chart
22
Misc. Specifications and Charts
23
Conversion Table
23
Sae Tap / Drill Sizes
24
Metric Tap / Drill Sizes
24
Decimal Equivalents
25
Maintenance Chapter 2 Maintenance 2
27
Lubricants / Service Products
29
Maintenance
29
Periodic Maintenance - General
29
Pre-Ride Inspection
30
Maintenance Intervals
31
Maintenance Quick Reference
51
Grease Lubrication Points
53
Engine / Exhaust
54
Engine Oil Level
54
Engine Oil and Filter Change
55
Engine Crankcase Breather Hose
56
Engine Cylinder Leakdown Test
56
Valve Clearance Adjustment
57
Cam Chain Tensioner Inspection
58
Spark Arrestor
59
Heat Shield Inspection
60
Coolant Level Inspection
62
Coolant Strength
62
Cooling System
62
Coolant Hose Inspection
63
Cooling System Pressure Test
63
Coolant Flush
64
Radiator Inspection / Cleaning
64
Cooling System Bleeding
65
Engine Cooling System Bleeding
65
Charge Air Cooling System Bleeding
66
Fuel System and Air Intake
67
Fuel Tank Vent Inspection
67
Throttle Pedal Inspection
67
Air Filter Service
68
Engine Intake Pre-Filter Service
68
Intake Duct Drain Inspection
69
Pvt / Final Drive / Wheel and Tire
70
Pvt Drain
70
Pvt Intake Pre-Filter Service
70
Front Gearcase Fluid Change
71
Front Gearcase Fluid Level Check
71
Front Gearcase Lubrication
71
Drive Shaft Boot Inspection
72
Tire Inspection
72
Wheel Installation
72
Wheel Removal
72
Maintenance
73
Tire Pressure
73
Tire Rotation
73
Transmission
74
Transmission Lubrication
74
Transmission Oil Change
74
Transmission Oil Level Check
74
Steering
75
Steering Inspection
75
Steering Wheel Free-Play
75
Tie Rod End / Wheel Hub Inspection
75
Wheel Toe Alignment Inspection
76
Wheel Toe Adjustment
77
Suspension
78
Suspension Inspection
78
Suspension Lubrication
78
Brake Fluid Inspection
79
Brake Hose and Fitting Inspection
79
Brake Pad Inspection
79
Brake System
79
Brake Disc Inspection
80
Battery Charging / off Season Storage
81
Battery Maintenance
81
Electrical and Ignition System
81
Engine / Chassis Electrical Ground
81
Spark Plug Service
82
Chapter 3 Engine / Cooling System
83
Engine Lubrication Specifications
86
General Information
86
Special Tools
86
Oil Pressure Test
87
Oil Flow Chart
88
Engine Service Specifications
89
Engine Specifications
89
Engine Torque Specifications
91
Intake / Exhaust System
93
Intake / Turbo System Overview
93
Engine Air Intake Assembly View
94
Air Box Removal
95
Air Box Installation
96
Exhaust Assembly View
97
Muffler Removal
98
Exhaust Pipe Removal
99
Muffler Installation
99
Head Pipe / Turbo Removal
101
Head Pipe / Turbo Installation
103
Exhaust Pipe Installation
105
Turbocharger Inspection
106
Turbocharger Service
106
Actuator / Wastegate Inspection
110
Actuator Pod Removal
111
Oil Drain Tube Service
112
Boost Control Valve
113
P1234 Boost Reference Code Troubleshooting
113
Wastegate Flapper Inspection
113
Actuator / Wastegate
114
Boost Pressure Sensor Harness
114
Exhaust
114
Turbocharger
114
Cooling System
115
Cooling System Flow
115
Cooling System Pressure Test
116
Cooling System Specifications
116
Charge Air Cooler Removal
117
Charge Air Cooler Installation
119
Radiator Replacement
120
Thermostat Replacement
124
Water Pump Service
125
Engine Service
128
Front Engine Mount Isolator Replacement
128
Crankshaft Pto Seal Replacement
129
Engine Removal
131
Engine Installation
135
Cam Chain Tensioner Service
139
Installation
139
Removal
139
Camshaft Removal
140
Engine Disassembly / Inspection - Top End
140
Valve Cover Removal
140
Camshaft Sprocket Inspection
141
Camshaft / Camshaft Bore Inspection
142
Cylinder Head Inspection
144
Cylinder Head Removal
144
Cylinder Head Disassembly
145
Valve Inspection
146
Combustion Chamber Cleaning
147
Valve Seat Reconditioning
147
Engine Disassembly / Inspection - Bottom End
150
Stator Cover Removal / Inspection
150
Flywheel Removal
151
Water Pump Housing Removal
151
Starter One-Way Clutch Disassembly
152
Crankcase Disassembly
153
Balance Shaft Removal / Inspection
155
Crankshaft Removal / Inspection
156
Crankcase Inspection
158
Cylinder / Piston Removal
159
Cylinder Inspection
160
Piston Disassembly / Inspection
161
Piston Ring Installed Gap
162
Piston Ring Removal
162
Piston Ring to Groove Clearance
162
Connecting Rod Inspection
163
Piston to Cylinder Clearance
163
Bearing Selection Identification
165
Engine Assembly - Bottom End
165
Connecting Rod Bearing Selection
166
Crankshaft Main Bearing Selection
166
Piston Ring Installation
167
Upper Crankcase Preparation
167
Piston / Connecting Rod Assembly
168
Piston / Cylinder Installation
169
Crankshaft Installation
170
Balance Shaft Installation
172
Lower Crankcase Preparation
172
Crankcase Assembly
173
Starter One-Way Clutch Assembly
176
Flywheel Installation
177
Stator Cover Installation
178
Cylinder Head Assembly
179
Engine Assembly - Top End
179
Cylinder Head Installation
180
Valve Sealing Test
180
Camshaft Installation / Timing
181
Camshaft Timing Quick Reference
185
Valve Clearance Adjustment
186
Valve Lash - Tappet Selection
188
Valve Cover Installation
189
Chapter 4 Efi / Fuel System
191
General Information
193
Special Tools
193
Efi Overview
194
Efi System Components
194
Efi Operation Overview
195
Efi Service Notes
196
Initial Priming / Starting Procedure
197
Ecu Operation Overview
198
Ecu Replacement
198
Ecu Service
198
Electronic Control Unit (Ecu)
198
Etc Learn Procedure
199
Fuel Injector O-Rings
200
Fuel Injector Operation Overview
200
Fuel Injectors
200
Fuel Injector Test
201
Fuel Injector Troubleshooting
201
Fuel Injector Replacement
202
Fuel Lines
204
Fuel System Assembly View
204
Fuel System Assembly View (Evap)
205
Fuel Line Removal / Installation
206
Fuel Line Removal / Installation (Evap Models)
207
Fuel Line Routing
208
Fuel Line Routing (Evap Models)
209
Fuel Vent Line Routing
210
Fuel Vent Line Routing (Evap Models)
212
Vent Line Termination Fitting
214
Fuel Tank / Pump
215
Fuel Tank Assembly View
215
Fuel Tank Removal
216
Fuel Tank Installation
218
Fuel Pump Operation Overview
221
Fuel Pressure Test
222
Fuel Pump Replacement
223
Fuel Sender Test
227
Air Temperature Sensor Data
228
Boost Pressure Sensor
228
Fuel Pressure Sensor (Evap Models)
228
Pressure Sensors
228
Tmap Sensor
228
Knock Sensor
229
Knock Sensor Overview
229
Knock Sensor Replacement
229
Knock Sensor Testing
229
Cps Test
230
Crankshaft Position Sensor (Cps)
230
Operation Overview
230
Cps Replacement
231
Electronic Throttle Control (Etc) / Throttle Body
232
Etc Operation Overview
232
Etc Test
232
Etc / Throttle Body Replacement
233
Etc Learn Procedure
233
Location
234
Operation Overview
234
Pedal Position Sensor (Pps)
234
Pps Test
234
Pps Replacement
235
Oxygen Sensor
236
Oxygen Sensor Information
236
Oxygen Sensor Replacement
237
Chapter 5 Pvt System
239
2018 Rzr Xp Turbo S Clutch Chart
240
General Information
240
Special Tools
240
Drive Clutch Operation
241
Driven Clutch Operation
241
General Operation
241
Pvt System Overview
241
Belt Inspection
242
Belt Removal
242
Drive Belt
242
Belt Break-In
243
Belt Installation
243
Drive Clutch Removal
244
Drive Clutch Service
244
Drive Clutch Assembly View
245
Drive Clutch Disassembly
246
Drive Clutch Disassembly / Inspection
246
Shift Weight Inspection
246
Slider Plate Inspection
246
Drive Clutch Assembly
249
Drive Clutch Installation
251
Driven Clutch Removal (2018 Models)
252
Driven Clutch Service
252
Driven Clutch Removal (2019 Models)
253
Driven Clutch Assembly View
254
Driven Clutch Disassembly / Inspection
255
Driven Clutch Assembly
256
Driven Clutch Installation
256
Driven Clutch Installation (2019 Models)
256
Chapter 6 Transmission
259
General Information
260
Special Tools
260
Shift Cable Inspection
261
Shift Lever / Cable
261
Shift Lever Installation
261
Shift Lever Removal
261
Shift Cable Adjustment
262
Transmission Removal
263
Transmission Service
263
Transmission Installation
266
Transmission Vent Line Routing
268
Transmission Disassembly
269
Gear Cluster Disassembly
271
Snorkel Tube Removal / Disassembly
271
Gear, Shaft, Bearing Inspection
273
Snorkel Gear Backlash
274
Transmission Assembly
274
Transmission Assembly / Snorkel Gear Backlash
274
Chapter 7 Final Drive
279
General Information
280
Special Tools
280
Bearing Carrier
281
Front Bearing Carrier Inspection / Removal
281
Front Bearing Replacement
282
Front Bearing Carrier Installation
283
Rear Bearing Carrier Inspection / Removal
284
Rear Bearing Replacement
286
Rear Bearing Carrier Installation
287
Drive Shaft
289
Front Drive Shaft Removal
289
Front Drive Shaft Installation
290
Rear Drive Shaft Removal
291
Rear Drive Shaft Installation
292
Drive Shaft / CV Joint Handling Tips
294
Outer CV Boot Replacement
295
Inner Plunging Joint / Boot Replacement
296
Prop Shaft
299
Prop Shaft Removal
299
Prop Shaft Removal (S4)
301
Prop Shaft Assembly View
303
Support Bearing Replacement
303
U-Joint Disassembly
303
U-Joint Assembly
304
Prop Shaft Installation
305
Front Gearcase / Centralized Hilliard
306
Front Gearcase Assembly View
306
Front Gearcase Vent Line Routing
307
All Wheel Drive Operation
308
Awd Diagnosis
309
Front Gearcase Removal
310
Front Gearcase Disassembly / Inspection
314
Front Gearcase Assembly
316
Front Gearcase Installation
319
Front Hub Assembly View
324
Wheel Hubs
324
Rear Hub Assembly View
325
Tire Balancing
326
Chapter 8 Steering / Suspension
327
General Information
329
Special Tools
329
Steering System
330
Steering System Assembly View
330
Upper Steering Shaft Removal
331
Hub Adapter Removal
332
Steering Wheel / Hub Adapter Removal
332
Steering Wheel Removal
332
Power Steering Unit Removal
333
Lower Steering Shaft Removal
334
Steering Rack Removal
335
Steering Rack Installation
338
Lower Steering Shaft Installation
342
Power Steering Unit Installation
342
Upper Steering Shaft Installation
344
Steering Shaft Bushing Replacement
345
Eps Pre-Position Procedure
346
Eps Pre-Positioning / Steering Angle Centering
346
Eps Steering Angle Centering
346
Front Suspension
348
Front Suspension Assembly View
348
Front A-Arm Removal / Installation
349
Front Stabilizer Bar Replacement
350
Removal
350
Ball Joint Removal
351
Ball Joint Service Preparation
351
Installation
351
Ball Joint Installation
352
Rear Suspension
353
Rear Suspension Assembly View
353
Trailing Arm Removal / Installation
354
Trailing Arm Spherical Bearing Replacement
356
Radius Rod Removal / Installation
357
Stabilizer Bar Installation
358
Stabilizer Bar Removal
358
Shock / Spring Replacement
359
Shock Assembly View
359
Shock Removal / Installation
359
Shocks / Springs
359
Fox 2.5" Shock Information
360
Fox 3.0" Shock Information
361
Fox 2.5" / 3.0" O.e. Podium Bypass
362
Fox Shock Service
362
Shock Service
362
Offset Torque Formula
363
Fox Shock Disassembly
364
Fox Shock Assembly
371
Dynamix Active Suspension
376
Dynamix Overview
376
Dynamix Shocks Disassembly / Assembly
376
Demonstration Mode
377
Scm Replacement
377
Suspension Control Module (Scm)
377
Cornering Control
378
Dynamix™ System Features
378
Vehicle Speed Sensitivity
378
Acceleration
379
Airborne Detection
379
Braking
379
Advanced Diagnostics
380
Processing Capability
380
Suspension Mode Switch (Dynamix Models)
381
Chapter 9 Brake System
383
Brake System Specifications
384
General Information
384
Special Tools
384
Brake System Overview
385
Brake System View
385
Brake Line Routing / Retention
386
Brake System Service Notes
389
Hydraulic Brake System Operation
389
Master Cylinder
390
Master Cylinder Installation
390
Master Cylinder Removal
390
Brake Bleeding / Fluid Change
392
Brake Pedal
394
Brake Pedal Installation
394
Brake Pedal Removal
394
Brake Caliper / Pad Removal
395
Front Brake Service
395
Front Caliper Assembly View
397
Front Caliper Disassembly / Inspection
398
Brake Pad Inspection
399
Brake Disc Inspection
400
Front Caliper Assembly
400
Brake Caliper / Pad Installation
401
Front Brake Disc Replacement
401
Brake Burnishing Procedure
402
Brake Pedal Switch Inspection
403
Brake Warning System (Intl Models)
403
Brake Warning System Inspection (Intl Models)
403
Troubleshooting
403
Brake Caliper / Pad Removal
404
Rear Brake Service
404
Rear Caliper Disassembly / Inspection
405
Brake Pad Inspection
406
Caliper Inspection
406
Rear Brake Disc Inspection
407
Rear Caliper Assembly
407
Rear Brake Disc Replacement
408
Rear Brake Caliper / Pad Installation
409
Brake Burnishing Procedure
410
Chapter 10 Diagnostic
411
Engine and Drivability Diagnostic Procedures
415
Engine Cranks but Does Not Start
418
No Crank no Start or Slow Crank
420
Over Heating
421
Warning Lights
422
Engine Troubleshooting
423
Cooling Troubleshooting
425
Turbocharger Troubleshooting
425
Digital Wrench® Diagnostic Software Overview
426
Polaris Digital Wrench
426
Special Tools (Digital Wrench)
426
Digital Wrench Software Version and Update ID
427
Digital Wrench® Updates
427
Digital Wrench Diagnostic Connector
428
Digital Wrench® Communication Errors
428
Guided Diagnostics
428
Digital Wrench® Serial Number Location
429
Digital Wrench® Feature Map
430
Ecu Replacement
431
Ecu Reprogramming (Reflash)
431
Etc Learn Procedure
431
Polaris Mobile Digital Wrench (Pmdw)
434
Diagnostic Trouble Code List
435
Digital Multi-Meter (DMM) Notes
440
Dynamic Testing
440
Electrical Diagnostics
440
Electrical Service Notes
440
Static and Dynamic Testing
440
Static Testing
440
Back Probing
441
Break out
441
Connector Probing Guidelines
441
Front Probing
441
Testing Continuity/Resistance
442
Testing for a Short to Ground
442
Testing for a Short to Voltage
443
Testing for Intermittent Conditions
443
Testing Current Flow (Amperage)
444
Testing Parasitic Draw
444
Testing Voltage Drop
445
Efi Diagnostics
446
Fuel System Troubleshooting
446
Cylinder Misfire Detection
447
Digital Wrench Data Troubleshooting
448
Pvt Troubleshooting
451
Troubleshooting
451
Shifting Difficulty
453
Transmission Troubleshooting
453
Brake, Steering, and Suspension Diagnostic Procedures
454
Brake Noise Troubleshooting
456
Brakes Lock
457
Caliper Overheats (Brakes Drag)
457
Pedal Vibration
457
Poor Brake Performance
457
Eps Troubleshooting
458
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
458
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
459
Eps Troubleshooting (Using Digital Wrench®)
460
Dynamix Troubleshooting
461
Scm System Voltage
461
Shock Valve Power Supply
461
Scm Shock Valve Diagnostics
462
Scm Can Diagnostics
463
Scm Mode Switch
463
Scm / Inertial Measurement Unit
464
Scm Steering Angle Adapted Offset Diagnostics
464
Chapter 11 Body / Frame
465
Decal Replacement
467
General Information
467
Special Tools
467
Body Assembly Views
468
Cab Frame Assembly
468
Roof Assembly
469
Cab Frame Assembly (4 Seat)
470
Full Doors (Turbo S Models)
472
Dash / Controls
473
Hood / Front Body
474
Chassis / Main Frame
475
Chassis / Main Frame (4 Seat)
476
Main Frame Assembly
477
Seat Assembly Front
478
Floor / Rocker Panels
479
Rear Cargo Box / Fenders
480
Rear Bumper
481
Body Component Removal
482
Engine Service Panel
482
Front Fascia
482
Seats
482
Dash Removal
483
Hood / Front Body
483
Hood Removal
483
Rear Fascia
483
Front Body Removal
484
Front Fender Flair Removal
484
Fender Flair Removal
485
Fender Removal
485
Rear Fender / Fender Flair
485
Cargo Box
486
Console and Lower Floor Removal
487
Rocker Panel Removal
487
Rocker Panels, Console and Floor
487
Door Adjustment
488
Door Panel / Latch Replacement
488
Doors
488
Rops and Roof
490
Rops Installation
490
Rops Torque Procedure
492
Roof Installation (Turbo S Only)
495
Chapter 12 Electrical
501
General Information
503
Special Tools
503
Under-Dash Components
503
Electrical Service Notes
504
Electrical Component Locations (Front)
506
Instrument Cluster
508
Rider Display Overview
508
Display Area Modes
510
Information Display Area
510
Backlight Color
511
Clock
511
Display Units
511
Gauge Settings Menu
511
Programmed Service Interval
512
Trip Meter
512
Trip Time
512
Headlamp Switch
514
Ignition / Key Switch
514
Switches / Controls
514
Awd / 2Wd Switch (no Turf Mode)
515
Seat Belt Switch
515
Brake Pressure Switch
516
Transmission / Gear Position Switch
516
Boost Control Solenoid / Valve
517
Suspension Mode Switch (Dynamix Models)
517
Steering Angle Sensor Centering (Dynamix)
518
Ignition Coil
519
Ignition Coil / Ht Lead Replacement
519
Ignition Coil Tests
519
Operation Overview
519
Charging System
520
Charging System "Break Even" Test
520
Current Draw - Key off
520
Stator Testing
521
Test 1: Resistance Value of each Stator Leg
521
Regulator / Rectifier (Dynamix)
522
Regulator Replacement
522
Test 3: Measure Ac Voltage Output of each Stator Leg at Charging Rpm
522
Battery
524
Battery Specifications
524
General Battery Information
524
Battery Installation
525
Battery Removal
525
Battery Conductance Analyzer
526
Battery off Season Storage
526
Battery Testing
526
Load Test
526
Ocv - Open Circuit Voltage Test
526
Charging Procedure
527
Headlamp Replacement
528
Headlight Adjustment
528
Lighting System
528
Dash Light
529
Headlamp Installation
529
Taillight Replacement
529
Cooling Fan Description and Operation
530
Cooling Fan Testing
530
Cooling System
530
Cooling Fan Replacement
531
Fan Control Circuit Bypass Test
531
Bleeding
533
Electric Coolant Pump
533
Replacement
533
Ect Sensor Test
534
Starter Solenoid Bench Test
535
Starter Solenoid Operation
535
Starter Solenoid Replacement
535
Starting System
535
Electronic Power Steering (Eps)
536
Eps Operation
536
Proper Eps System Diagnosing
536
Relay / Fuse Details
540
Voltage Regulator Fusible Link
541
Can System
542
Can System Overview
542
Can System Testing
542
Electrical Harness Routing
543
Wiring Harness
543
Electrical Harness Retention
544
Electrical Harness Retention (4-Seat)
546
Wiring Harness Replacement
547
Break-Out Diagram Viewing
548
4
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Polaris RZR XP Specifications
General
Brand
Polaris
Model
RZR XP
Category
Offroad Vehicle
Language
English
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