Polaris RZR XP

IX
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
IX.3
Over Heating ....................................................... 10.11
Warning Lights..................................................... 10.12
Diagnostic Connector ............................................... 10.18
Diagnostic Trouble Codes ......................................... 10.25
Digital Wrench
Communication Errors........................................... 10.18
Data Display Information........................................ 10.38
Diagnostic Connector ............................................ 10.18
ECU Reprogramming ............................................ 10.21
Guided Diagnostics .............................................. 10.18
Overview ............................................................ 10.16
Serial Number ..................................................... 10.19
Updates ............................................................. 10.17
Disc
Inspection (rear).....................................................9.25
Inspection-Front............................................. 2.54, 9.18
Replacement (rear).................................................9.26
Replacement-Front.................................................9.19
DMM .................................................................... 10.30
Door Adjustment ..................................................... 11.24
Door Latch
Replacement....................................................... 11.24
Door Panel
Replacement....................................................... 11.24
Doors (Full) .............................................................. 11.8
Draw .................................................................... 10.34
Drive Belt
Break-In ................................................................ 5.5
Inspection.............................................................. 5.4
Installation ............................................................. 5.5
Removal................................................................ 5.4
Drive Clutch
Assembly ............................................................. 5.11
Assembly View ....................................................... 5.7
Disassembly / Inspection .......................................... 5.8
Installation ............................................................5.13
Operation .............................................................. 5.3
Removal................................................................ 5.6
Shift Weight Inspection ............................................. 5.8
Drive Shaft
Boot Inspection ......................................................2.46
CV Joint Handling...................................................7.16
Removal (Front) ..................................................... 7.11
Removal (Rear) .....................................................7.13
Drive Shaft, ...................................................... 7.12, 7.14
Driven Clutch
Assembly .............................................................5.18
Assembly View ......................................................5.16
Disassembly / Inspection .........................................5.17
Installation ............................................................5.18
Operation .............................................................. 5.3
Removal........................................................5.14-5.15
DTC List ................................................................ 10.25
Dynamic................................................................ 10.30
Dynamix..................................................................8.50
Demonstration Mode...............................................8.51
Mode Switch ................................................8.55, 12.17
Suspension Control Module......................................8.51
Dynamix Troubleshooting.......................................... 10.51
E
ECT
Test ................................................................... 12.34
ECU
ETC Learn Procedure .............................. 4.9, 4.43, 10.21
Operation Overview ................................................. 4.8
Replacement................................................. 4.8, 10.21
EFI
Component Locations .............................................. 4.4
Operation Overview ................................................. 4.5
Service Notes ......................................................... 4.6
Electrical ............................................. 10.30, 10.32-10.35
Component Locations (front).....................................12.6
Component Locations (rear) .....................................12.5
Current Draw....................................................... 12.20
Notes...................................................................12.4
Special Tools.........................................................12.3
Wiring Harness .................................................... 12.48
Electrical harness ........................................... 12.44-12.46
Electrical Harness ................................................... 12.43
Electronic Throttle Body
Learn Procedure .....................................4.9, 4.43, 10.21
Electronic Throttle Control ...........................................4.42
Engine
Balance Shaft Installation.........................................3.90
Balance Shaft Removal / Inspection ...........................3.73
Bearing Selection Identification .................................3.83
Camshaft Inspection ...............................................3.60
Camshaft Installation / Timing ...................................3.99
Camshaft Removal .................................................3.58
Camshaft Sprocket Inspection...................................3.59
Camshaft Timing - Quick Reference ......................... 3.103
Connecting Rod Inspection.......................................3.81
Crankcase Assembly ..............................................3.91
Crankcase Breather Hose Inspection..........................2.30
Crankcase Disassembly / Inspection ..........................3.71
Crankcase Inspection..............................................3.76
Crankshaft Installation .............................................3.88
Crankshaft Removal / Inspection ...............................3.74
Cylinder / Piston Removal ........................................3.77
Cylinder Head Assembly..........................................3.97
Cylinder Head Inspection .........................................3.62
Cylinder Head Installation ........................................3.98
Cylinder Head Removal ...........................................3.62
Cylinder Inspection .................................................3.78
Engine Service
Cam Chain Tensioner Service ................................3.57
Flywheel Removal ..................................................3.69
Installation ............................................................3.53
Limiting / Misfire ................................................... 10.37
Lubrication Specifications ......................................... 3.4
Mount Replacement................................................3.46
Oil and Filter Change ..............................................2.29
Oil Flow Chart......................................................... 3.6
Oil Level Check......................................................2.28
Oil Pressure Test..................................................... 3.5
Piston / Connecting Rod Assembly.............................3.86
Piston Disassembly / Inspection ................................3.79
Piston Ring Installation ............................................3.85
Piston Ring Installed Gap .........................................3.80
Piston Ring Removal / Inspection...............................3.80
Piston-to-Cylinder Clearance ....................................3.81
Piston/Cylinder Installation .......................................3.87
Removal...............................................................3.49
Special Tools.......................................................... 3.4
Specifications ......................................................... 3.7
Torque Sequences .................................................. 3.9
Troubleshooting ................................................... 10.13
Valve Clearance Adjustment ............................2.31, 3.104
Valve Cover Installation ......................................... 3.107
Valve Cover Removal..............................................3.58
Valve Inspection.....................................................3.64
INDEX