Polaris RZR XP

IX.2
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
Installation (rear) ....................................................9.27
Removal (Front) .....................................................9.13
Removal (rear).......................................................9.22
Caliper, Front
Assembly View ......................................................9.15
Disassembly / Inspection .........................................9.16
Cam Chain Tensioner
Inspection.............................................................2.32
Camshaft
Inspection.............................................................3.60
Installation / Timing.................................................3.99
Removal...............................................................3.58
Sprocket Inspection ................................................3.59
Camshaft Timing
Quick Reference .................................................. 3.103
CAN ..................................................................... 12.42
Cargo Box
Removal............................................................. 11.22
Cargo Box) ............................................................ 11.16
Charge Air Cooler
Installation ............................................................3.37
Removal...............................................................3.35
Charging System
Stator Testing ...................................................... 12.21
Chassis
Assembly View .................................................... 11.11
Assembly View (4 Seat) ......................................... 11.12
Frame................................................................ 11.11
Chassis Harness
Break-Out Diagrams ............................................. 12.48
Clutch
Assembly (Drive).................................................... 5.11
Assembly (Driven) ..................................................5.18
Disassembly (Driven) ..............................................5.17
Installation (Drive) ..................................................5.13
Installation (Driven).................................................5.18
Removal (Drive) ...................................................... 5.6
Removal (Driven) ............................................ 5.14-5.15
Troubleshooting ................................................... 10.41
Clutch Chart
2018 XP Turbo S.............................................. 1.12, 5.2
2019 XP 4 Turbo S ........................................... 1.16, 5.2
2019 XP Turbo S.............................................. 1.14, 5.2
Clutch Cover
Drain ...................................................................2.44
Combustion Chamber Cleaning....................................3.65
Component Locations
Electrical (front)......................................................12.6
Electrical (rear) ......................................................12.5
Connecting Rod
Assembly .............................................................3.86
Bearing Selection ...................................................3.84
Inspection.............................................................3.81
Connector.............................................................. 10.31
Console
Removal............................................................. 11.23
Continuity .............................................................. 10.32
Control Arm
Replacement (front) ................................................8.23
Conversion Table ......................................................1.17
Coolant
Level Inspection .....................................................2.36
Coolant Flow Diagram ................................................3.33
Coolant Flush ...........................................................2.38
Coolant Hose
Inspection.............................................................2.37
Coolant Pump
Electric............................................................... 12.33
Coolant Temperature Sensor
Test ................................................................... 12.34
Cooling Fan
Bypass Test ........................................................ 12.31
Replacement....................................................... 12.31
Testing ............................................................... 12.30
Cooling System
Bleeding...............................................................2.39
Coolant Strength and Type .......................................2.36
Pressure Test ................................................ 2.37, 3.34
Specification .........................................................3.34
Troubleshooting ................................................... 10.15
Cornering Control ......................................................8.52
CPS .......................................................................4.40
Replacement.........................................................4.41
Testing .................................................................4.40
Crankcase
Assembly .............................................................3.91
Breather Hose Inspection.........................................2.30
Disassembly / Inspection .........................................3.71
Crankcase Inspection.................................................3.76
Crankshaft
Connecting Rod Bearing Selection .............................3.84
Installation ............................................................3.88
Journal Inspection ..................................................3.74
Main Bearing Selection............................................3.84
Removal / Inspection...............................................3.74
Crankshaft Position Sensor (CPS) ................................4.40
Crankshaft PTO Seal
Installation ............................................................3.47
Removal...............................................................3.47
Replacement.........................................................3.47
Crankshaft Sensor
Replacement.........................................................4.41
Testing .................................................................4.40
Current ................................................................. 10.34
Current Draw - Key Off ............................................. 12.20
CV Joint / Boot
Replacement (Outer) ..............................................7.17
Cylinder
Inspection.............................................................3.78
Installation ............................................................3.87
Misfire................................................................ 10.37
Cylinder Head
Assembly .............................................................3.97
Disassembly .........................................................3.63
Inspection.............................................................3.62
Installation ............................................................3.98
Removal...............................................................3.62
Cylinder Leakdown Test..............................................2.30
Cylinder Removal ......................................................3.77
D
Dash
Removal............................................................. 11.19
Dash Instruments / Controls ........................................ 11.9
Dash Light ............................................................. 12.29
Decal Replacement ................................................... 11.3
Decimal Equivalent Chart............................................1.19
Diagnostic ...............................................................10.5
Brake, Steering, and Suspension Diagnostic
Procedures........................................................ 10.44
Engine Cranks but does Not Start ..............................10.8
No Crank No Start or Slow Crank............................. 10.10
INDEX