Polaris RZR PRO XP (2020) Service manual

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2020-2021 RZR PRO XP / XP 4

Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer®technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed September 2020 (PN 9850068 R01)

© Copyright 2020 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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SAFETY WARNINGS

The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

DANGER

DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING

SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious

SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate

NOTICE provides key information by clarifying instructions.

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

injury.

CAUTION

injury.

NOTICE

IMPORTANT

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

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REV DATE

R01 11/10/2020

REVISION INDEX

CHANGES

Initial Release.

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FEEDBACK FORM

A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile device by scanning the QR code or by clicking electronically.

HERE if viewing this document

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2020-2021 RZR PRO XP / XP 4

Service Manual

Chapter Summary

CHAPTER 1 : GENERAL INFORMATION

CHAPTER 2 : MAINTENANCE

CHAPTER 3 : ENGINE / COOLING SYSTEM

CHAPTER 4 : ENGINE ELECTRICAL

CHAPTER 5 : EFI / FUEL SYSTEM

CHAPTER 6 : PVT SYSTEM

CHAPTER 7 : TRANSMISSION

CHAPTER 8 : FINAL DRIVE

CHAPTER 9 : STEERING / SUSPENSION

CHAPTER 10 : BRAKE SYSTEM

CHAPTER 11 : BODY / FRAME

CHAPTER 12 : ELECTRICAL

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Page 7

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

MODEL NUMBER DESIGNATION (2015 +) ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VIN AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

2020 RZR PRO XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

2020-21 RZR PRO XP CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15

2020 RZR PRO XP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16

2020-21 RZR PRO XP 4 CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17

2021 RZR PRO XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

2020-21 RZR PRO XP CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19

2021 RZR PRO XP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

2020-21 RZR PRO XP 4 CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

CONVERSION TABLE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23

DECIMAL EQUIVALENTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24

GENERAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25

GENERAL DIAGNOSTICS INFORMATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25

GUIDED SYMPTOM DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25

GUIDED SYMPTOM REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27

ENGINE CRANKS BUT DOES NOT START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30

NO CRANK NO START OR SLOW CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32

OVER HEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33

WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34

ENGINE TROUBLESHOOTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35

COOLING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37

DIGITALWRENCH® SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38

GUIDED DIAGNOSTICS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38

DIGITALWRENCH® SOFTWARE INSTALLATION AND UPDATES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.39

DIGITALWRENCH® COMMUNICATION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40

DIGITALWRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40

DIGITALWRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

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GENERAL INFORMATION

DIGITALWRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42

ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44

POLARIS MOBILE DIGITAL WRENCH® (PMDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44

DIAGNOSTIC TROUBLE CODES OVERVIEW .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46

MASTER TROUBLE CODE LIST.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.47

CYLINDER MISFIRE DETECTION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58

FLUID LEAKS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59

FLUID INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59

FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60

PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62

PVT SYSTEM OVERHEATING / DIAGNOSIS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64

HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65

TRANSMISSION ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65

ALL WHEEL DRIVE (AWD) CONCERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66

DRIVESHAFT (HALF SHAFT) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66

BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67

BRAKE VIBRATION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67

CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68

POOR BRAKE PERFORMANCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68

BRAKES LOCK.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68

EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . . . . . . . 1.69

EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . . . . . . .1.70

EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71

SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72

ELECTRICAL SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73

DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73

STATIC AND DYNAMIC TESTING ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73

CONNECTOR PROBING GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74

TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75

TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75

TESTING FOR A SHORT TO VOLTAGE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76

TESTING FOR INTERMITTENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.77

TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.77

CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78

TESTING VOLTAGE DROP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.78

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

MODEL NUMBER DESIGNATION (2015 +)

Example: R15RUE57AC

GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**

R 1

R U E

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

Example: 4XARUE573FG000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

A C

WORLD MFG. ID

CHASSIS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R U E 5 7 3 F G 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J = 2018; K = 2019, L = 2020, M = 2021

CHASSIS

DRIVELINE

MODIFIER

ENGINE SIZE

CHECK DIGIT

MODEL YEAR *

ENGINE MODIFIER

MFG. LOCATION

INDIVIDUAL SERIAL NO.

VIN AND ENGINE SERIAL NUMBER LOCATIONS

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on the rear left vertical shock support tube

The engine serial number can be found on a decal applied to the front of the engine crankcase crankcase on the PTO side of the engine.

or stamped into the

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

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GENERAL INFORMATION

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GENERAL INFORMATION

REFERENCE INFORMATION

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.)

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

PUBLICATION NUMBERS

YEAR MODEL

2020 RZR PRO XP 9931012

OWNER’S

MANUAL

NOTICE

When ordering service parts be sure to use the correct

Polaris factory publications can be found at www.

polaris.com or purchased from www.purepolaris.com.

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

parts manual.

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GENERAL INFORMATION

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier.

Bosch Automotive Service Solutions:

1-800-345-2233 or http://polaris.service-solutions.com/

1.6

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 13

GENERAL INFORMATION

2200421

Gas Shock Recharging Kit

2870910-A

Roller Pin Tool

2871745

Static Timing Light Harness

2460761

Hall Sensor Probe Harness

2870975

Mity-Vac Pressure Test Tool

2872085

Drive Clutch Puller

2870386

Piston Pin Puller

2871226

Clutch Bushing Replacement Tool Kit

2876389

Combination Pliers

2870630

Timing Light

2871282

Transmission Seal Driver (50 MM)

2878925

Spanner Wrench / Clutch Spreader

PU-52522

Live Valve Tool

2871358-B

Drive Clutch Holding Fixture

8700226

CV Boot Clamp Pliers (ear)

PA-48838

Fuel Pressure Adapter

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

PA-49316

Water Pump Drive & Flywheel Removal Tool

PU-43506-A

Fuel Pressure Gauge Kit

PU-47471

Smartlink Module Kit

PU-48951

CV Boot Clamp Pliers (Stepless)

1.7

Page 14

GENERAL INFORMATION

PU-49466

Relay Bypass

PU-50562

Engine Stand Adapter

PU-50624

Rolling Engine Stand

PU-50105

Oil Filter Wrench

PU-50563

Cylinder Holding & Camshaft Timing Plate

PU-50625

Engine Stand Adapter Sleeve (2″)

PU-50296

Battery Tester

PU-50564

Water Pump Seal Installer

PU-50784

Crankshaft Puller/ Installer

PU-50338

Hydrometer

PU-50569

Oil Pressure Gauge Adapter (1/4 NPT)

PU-51410

Shock Rod Holding Tool (7/8″)

PU-50518-A

Clutch Compressor

PU-50578

Clutch Spider Nut Socket

PU-51039

Gas Shock Fill Tool

PU-51220

Flywheel Holding Tool

1.8

PU-51829

Shock Spanner Wrench 2.5–3.0 Inner

PU-51830

Shock Spanner Wrench 2.5 Outer

PU-51832

Shock Spanner Wrench 3.0 Outer

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

PU-51837

Shock Body Holding Tool

Page 15

GENERAL INFORMATION

PU-51838

Shock Body Holding Tool

PV-43526

Connector Test Kit

PU-51861

Drive Clutch Holding Tool

PV-43531

Oil Presure gauge

PU-51862

Transmission Snorkel Tool

PV-43568

Fluke Multimeter

PV-1253

Valve Spring Compressor

PV-43570-1

Piston Ring Compressor Pliers

PV-43513-A

Valve Spring Compressor Adapter

39800780

IFP Tool (FOX)

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

1.9

Page 16

GENERAL INFORMATION

MASTER TORQUE TABLE

ITEM

A-Arm Fasteners Air Box Mounting Bolts 8 ft-lb (11 Nm)

Air Intake Housing Screw (Engine and PVT)

Ball Joint Fasteners

Mount

Battery

Bearing Carrier Mounting Bolts (rear)

Body Panel Fasteners 7 ft-lbs (10 Nm)

Brake Bleed Screws

Brake Caliper Mounting Bolts

Brake Junction Block Mounting Screws

Brake Line

Brake Line Guide Fasteners Brake Pedal Mount Bracket

Fasteners Brake Scraper Fasteners 7 ft-lbs (10 Nm)

Brake Switch Box Support Fastener 14 ft-lbs (19 Nm)

Cam Chain Tensioner

Camshaft Carrier

Carbon Canister Fastener

Carbon Canister Filter Fastener Cargo Box Fastener 7 ft-lbs (10 Nm)

Cargo Box Support Bracket Fasteners

Charge Air Cooler Bolts

Chassis Ground Nut

Connecting Rod Bolts

Coolant Hose Retainer Bolt Coolant Reservoir Coolant Temperature Sensor 17 ft-lb (23 Nm) CPS Retaining Bolt 9 ft-lb (12 Nm)

Crankcase Bolts

Bracket

Terminal

Fasteners

front

rear

Banjo Bolts 15 ft-lbs (20 Nm)

Flare Fittings 15 ft-lbs (20 Nm)

Spring Bolt 15 ft-lb (20 Nm)

Mounting

Bolts

Carrier Bolts

Sprocket

Bolts

M6 M8

TORQUE

74 ft-lbs (100 Nm)

35 in-lb (4 Nm)

44 ft-lbs (60 Nm)

53 in-lbs (6 Nm)

60 in-lbs (7 Nm)

44 ft-lbs (60 Nm)

48 in-lb (5 Nm)

33 ft-lbs (45 Nm) 33 ft-lbs (45 Nm)

35 in-lb (4 Nm)

7 ft-lbs (10 Nm)

18 ft-lbs (24 Nm)

15 ft-lbs (20 Nm)

7 ft-lb (10 Nm)

14 ft-lb (19 Nm)

9 ft-lbs (12 Nm)

15 ft-lbs (20 Nm)

Torque in sequence to

7 ft-lb (10 Nm)

5 ft-lb (7 Nm)

Step 1: 9 ft-lbs (12

Nm)

Step 2: 22 ft-lb (30

Nm)

Step 3: Tighten

add’n 90° 8 ft-lb (11 Nm) 8 ft-lb (11 Nm)

9 ft-lb (12 Nm)

26 ft-lb (35 Nm)

ITEM

M10

Crankcase Oil Gallery Plug 12 ft-lbs (16 Nm)

Cylinder Head Bolts

Dash Trim Fastener Debris Scraper 20 ft-lbs (27 Nm)

Door Frame Fastener Door Hinge Fastener 18 ft-lbs (24 Nm)

Door Latch/Actuator Fastener

Door Panel Fastener

Door Striker Fastener

Door Trim Bracket Fastener

Mounting

Drive Clutch

Driven Clutch

Driveshaft Boot Guard Screws ECU Mounting Screws 24 in-lb (3 Nm) Electric Coolant Pump Bracket

Fasteners Engine Breather Cover Screws 7 ft-lb (10 Nm)

Engine Mount

Engine Mount to Frame 22 ft-lb (30 Nm) Engine Oil Plug 12 ft-lbs (16 Nm)

EPS-to-Bracket Fasteners EPS Bracket Mounting Fasteners

(Lower)

EPS Bracket Mounting Fasteners (Upper)

EPS to Lower Steering Shaft Fastener

Bolt

Cover Plate

Shift Weight 20 in-lb (2 Nm)

Helix

Fasteners

Mounting

Bolt

Bracket

Fasteners

Isolator Bolt

TORQUE

Step 1: 9 ft-lb (12

Nm)

Step 2: 21 ft-lb (28

Nm)

Step 3: Tighten

add’n 90°

Torque in

sequence

Step 1: 13 ft-lbs (18

Nm)

Step 2: 26 ft-lb (35

Nm)

Step 3: Additional

180°

Step 4: Additional

180°

Step 5: M6 bolts: 7

ft-lb (10 Nm)

7 ft-lbs (10 Nm)

9 ft-lbs (12 Nm)

35 in-lbs (4 Nm)

7 ft-lbs (10 Nm)

18 in-lbs (2 Nm)

140 ft-lbs (190 Nm)

15 ft-lbs (21 Nm)

32 ft-lbs (44 Nm)

43 ft-lbs (58 Nm)

14 ft-lb (19 Nm)

8 ft-lb (11 Nm)

42 ft-lb (57 Nm)

55 ft-lb (75 Nm)

33 ft-lbs (45 Nm)

26 ft-lbs (35 Nm)

33 ft-lbs (45 Nm)

22 ft-lbs (30 Nm)

1.10

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 17

GENERAL INFORMATION

ITEM

Exhaust Heat Shield Fasteners

Exhaust Manifold

Exhaust Pipe to Muffler Nuts 18 ft-lb (24 Nm) Exhaust Pipe to Turbo Bolts 18 ft-lb (24 Nm)

Fan Assembly Mounting Fastener 9 ft-lbs (12 Nm)

Front Fascia Fastener

Fender Flare Fastener

Floor / Rocker Panel Fastener

Flywheel Bolt

Frame Bolts (front to rear) 40 ft-lb (54 Nm)

Front Bumper Bracket Fastener 30 ft-lbs (40 Nm)

Front Crossbar Fastener

Front Fascia Fastener

Front Frame Fastener

Front Gearcase

Front Gearcase Mounting Fasteners

Fuel Pump PFA Nut 70 ft-lbs (95 Nm) Fuel Rail Mounting Screws 7 ft-lb (10 Nm)

Fuel Tank Block-off Panel

Fuel Tank Fasteners

Fuse Box Fasteners Gear Selector Knob

Heat Shield Fastener Hip Bolster Bolts 14 ft-lb (19 Nm)

Hood Fastener Hose Clamp 35 in-lb (4 Nm) Hub Castle Nut (front and rear) 180 ft-lbs (244 Nm)

Ignition Coil Fastener 7 ft-lbs (10 Nm)

Instrument Panel Fastener

Intake Cover Fasteners Intake Clamps 49 in-lb (6 Nm) Intake Manifold Mounting

Fasteners (lower) Intake Manifold to Cyl Head

Clamps

Knock / Det Sensor

Main-to-Front Frame Fastener Master Cylinder Mount Bolts 18 ft-lbs (25 Nm)

Manifold Pressure Banjo Bolt 7 ft-lb (10 Nm)

Oil Cooler Bolts

Oil Pan Bolts (M8)

Oil Pump

Bolts

Nuts

Cover Plate

Screws

Drain/Fill

Plugs

M6 M8

Mounting

Bolts

TORQUE

8 ft-lb (11 Nm) 17 ft-lb (23 Nm) 26 ft-lb (35 Nm)

7 ft-lbs (10 Nm)

133 ft-lbs (180 Nm),

loosen 180°, retorque

to 133 ft-lb (180 Nm)

40 ft-lbs (54 Nm)

8 ft-lbs (11 Nm)

148 ft-lbs (200 Nm)

11 ft-lbs (15 Nm)

10 ft-lbs (14 Nm)

52 ft-lbs (70 Nm) + 270°

8 ft-lbs (11 Nm)

15 ft-lbs (20 Nm)

5 ft-lb (7 Nm)

40 in-lb (5 Nm)

9 ft-lbs (12 Nm)

7 ft-lbs (10 Nm)

8 ft-lb (11 Nm)

36 in-lbs (4 Nm)

20 ft-lb (27 Nm)

6 ft-lb (8 Nm)

15 ft-lb (20 Nm)

33 ft-lbs (45 Nm)

7 ft-lb (10 Nm)

9 ft-lb (12 Nm) 26 ft-lb (35 Nm)

7 ft-lbs (10 Nm)

ITEM

Pickup

Oxygen Sensor 13 ft-lb (18 Nm) Power Steering Unit Shield Screws 15 ft-lb (20 Nm) Power Steering Bracket to Frame

Nuts Power Steering Unit to Mount Bracket Prop Shaft Roll Hoop Fasteners 13 ft-lbs (18 Nm)

Prop Shaft Support Bearing Fastener:

Prop Shaft Mounting Plate Fastener:

Prop Shaft to Transmission Coupler Fasteners

PVT Inner Cover Baffle Fasteners

PVT Cover Fasteners

PVT Intake Hose Clamp 25 in-lbs (3 Nm)

Radiator Bracket Radius Rod Fasteners (Inner) 52 ft-lbs (70 Nm) + 45°

Radius Rod Fasteners (Outer) 52 ft-lbs (70 Nm) + 90°

Rear Cargo Box / Fender Fastener 7 ft-lbs (10 Nm)

Rear Fascia/Bumper Fastener 7ft-lbs (10 Nm)

Rear Support Fastener 8 ft-lb (11 Nm)

Rear Fascia Fastener

Rear Fascia Bracket Fastener

ROPS Seat Belt Mount Fastener ROPS Fasteners (Front and Rear) 44 ft-lbs (60 Nm)

ROPS Fasteners (Middle) 89 ft-lbs (120 Nm)

Seat Base Support Bracket Fastener

Seat Bracket Fastener (Passenger)

Seat Frame Fastener (Rear) 30 ft-lbs (40 Nm)

Seat Frame Fastener (Front) M10 x 1.5 x 16

Screws

inner

outer

TORQUE

7 ft-lb (10 Nm)

18 ft-lb (24 Nm)

30 ft-lb (41 Nm)

30 ft-lbs (40 Nm)

15 ft-lbs (20 Nm)

11 ft-lbs (15 Nm)

7 ft-lbs (10 Nm)

(see image inEngine

Installation) page for

sequence

STEP 1: Torque to

37 ft-lb (50 Nm)

STEP 2: Torque to

10 ft-lb (14 Nm)

STEP 3: Loosely

install bolts by

hand

STEP 4: Torque to

37 ft-lb (50 Nm)

STEP 5: Torque to

50 ft-lb (68 Nm)

STEP 6: Torque to

37 ft-lb (50 Nm)

36 in-lbs (4 Nm)

8 ft-lb (11 Nm)

36 in-lbs (4 Nm)

40 ft-lbs (54 Nm)

15 ft-lbs (20 Nm)

9 ft-lbs (12 Nm)

37 ft-lbs (50 Nm)

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

1.11

Page 18

GENERAL INFORMATION

ITEM

Seat Frame Fastener (Front) M8 x

1.25 x 45 Seat Frame Fastener (Front) M8 x

1.25 x 50 Seat Hinge Bracket Fastener 7 ft-lbs (10 Nm)

Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm)

Seat Slide/Tilt Bracket Fastener

Seat Slide/Tilt Receiver Fastener

to shifter

Shift Cable

Shift Knob Fastener Shift Linkage Support Bracket

Fastener Shock Guard Screws

Shock

Shock Access Panel Fasteners Shock Mount (Front) 44 ft-lbs (60 Nm)

Shock Mount (Rear) 74 ft-lbs (100 Nm) Shock Reservoir Mounting Clamps

(rear)

Skid Plate Fasteners

Slider Rail Fastener Snorkel Shaft Coupler Jam Nut 140 ft-lb (190 Nm) Spark Arrestor 8 ft-lb (11 Nm) Spark Plug 9 ft-lbs (12 Nm) Speed Sensor Screw 12 ft-lb (16 Nm)

Stabilizer Bar Linkage (Front) 74 ft-lbs (100 Nm)

Stabilizer Bar Linkage (Rear) 44 ft-lbs (60 Nm)

Stabilizer Bar Mounting Brackets

Starter Cable Nuts Starter Mounting Bolts 7 ft-lb (10 Nm) Starter One-Way Clutch Screws 9 ft-lb (12 Nm)

Starter Solenoid

Stator Cover Screws Steering Tilt Shock Fastener 9 ft-lbs (12 Nm) Steering Cast Mounting Fasteners

(Lower) Steering Cast Mounting Fasteners

(Upper) Steering Column Mounting

Fasteners Steering Rack Mounting Bolts 44 ft-lbs (60 Nm)

Transmis-

sion Bracket

Jam Nut

Body Cap 100 ft-lb (135 Nm) Bearing Asm 35 ft-lb (47 Nm)

Bleed Screw

Eyelet 50 ft-lb (68 Nm)

Shaft Nut

front

rear

Cable Nuts

Mounting

Bolts

TORQUE

18 ft-lbs (25 Nm)

15 ft-lbs (20 Nm)

7 ft-lbs (10 Nm)

15 ft-lbs (20 Nm)

13 ft-lb (18 Nm)

37 ft-lb (50 Nm)

16 ft-lb (22 Nm)

35 in-lbs (4 Nm)

15 ft-lbs (20 Nm)

30 ft-lbs (40 Nm)

14 in-lb (2 Nm)

22 ft-lb (30 Nm)

36 in-lbs (4 Nm)

35 in-lb (4 Nm)

9 ft-lbs (12 Nm)

30 ft-lbs (40 Nm)

44 ft-lbs (60 Nm) 30 ft-lbs (40 Nm)

40 in-lb (5 Nm)

35 in-lb (4 Nm)

7 ft-lbs (10 Nm)

9 ft-lb (12 Nm)

42 ft-lbs (57 Nm)

22 ft-lbs (30 Nm)

33 ft-lbs (45 Nm)

ITEM

Steering Shaft to EPS Unit 22 ft-lbs (30 Nm)

Steering Shaft to Steering Rack 48 ft-lbs (65 Nm)

Steering Wheel Nut 66 ft-lbs (90 Nm)

Support Bearing Fastener 30 ft-lbs (40 Nm)

Suspension Control Module (SCM) Fasteners

Taillight Mounting Nuts 24 in-lb (3 Nm)

Terminal Block Nuts

Thermostat Cover Bolts Throttle Body / ETC Bolts 7 ft-lb (10 Nm)

Throttle Pedal Mounting Fasteners 8 ft-lb (11 Nm)

Tie Rod End to Knuckle

Tie Rod Jam Nuts

TMAP Fastener Trailing Arm to Frame Bolts 74 ft-lbs (100 Nm)

Trailing Arm to Bearing Carrier Fasteners

Transmission

Turbo Actuator Rod Heim Joint Fasteners

Turbo Boost Control Valve Bolts

Turbo Coolant Line Fasteners Turbo Mounting Bolts 18 ft-lb (24 Nm) Turbo Oil Banjo Bolt 33 ft-lb (45 Nm)

Turbo Oil Drain Tube Fasteners Turbo Oil Line Clamp (Lower) 35 in-lb (4 Nm)

Turbo Oil Line Clamp (Upper) 7 ft-lbs (10 Nm)

U-Joint Strap Fastener 11 ft-lbs (15 Nm)

Valve Cover Bolts Visor Mounting Screws 8 ft-lb (11 Nm) Voltage Regulator Bracket

Fasteners Voltage Regulator Fasteners 8 ft-lb (11 Nm)

Water Pump Impeller

Bell Crank

Nut

Case

Screws

Drain/FIll

Plugs

Isolator Bolt

(rear)

Rear Mount

to Frame

Park Flange

Screws

Sector Gear

Cover

Snorkel

Tube

Locking

Screw

Impeller

TORQUE

8 ft-lb (11 Nm)

30 in-lb (3 Nm)

7 ft-lb (10 Nm)

30 ft-lbs (40 Nm) + 90°

44 ft-lbs (60 Nm)

7 ft-lb (10 Nm)

44 ft-lbs (60 Nm)

18 ft-lb (24 Nm)

20 ft-lbs (27 Nm)

14 ft-lbs (19 Nm)

33 ft-lb (45 Nm)

22 ft-lb (30 Nm)

10 ft-lb (14 Nm)

12 ft-lb (16 Nm)

10 ft-lb (14 Nm)

7 ft-lb (10 Nm)

8 ft-lb (11 Nm)

7 ft-lbs (10 Nm)

11 ft-lb (15 Nm)

7 ft-lbs (10 Nm)

7 ft-lb (10 Nm)

(Apply Loctite®

204™ to bolt

threads)

1.12

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 19

GENERAL INFORMATION

ITEM

Cover Bolts

Winch Cover Fastener Winch Mounting Plate Fasteners 18 ft-lbs (24 Nm) Wheel Lug Nuts 120 ft-lbs (163 Nm)

TORQUE

7 ft-lb (10 Nm)

(Apply Loctite®

204™ to bolt

threads)

22 in-lb ( 3 Nm)

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

1.13

Page 20

GENERAL INFORMATION

VEHICLE SPECIFICATIONS

2020 RZR PRO XP

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.6 cm

Height

Wheel Base 96″ / 243.8 cm

Ground Clearance 14″ / 35.6 cm

Dry Weight 1785 lbs. / 810 kg

Gross Vehicle Weight 2623 lbs. / 1190 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity This vehicle is not equipped with

Hitch Tongue Capacity

126.1″ / 320.4 cm

71.7″ / 182.1 cm

740 lbs. / 336 kg (Includes riders, cargo and accessories)

a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch.

1.14

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 21

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Turbocharged., 4–Stroke,

DOHC

925cc

Bore & Stroke 93 x 68 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

9:1

1200 +/- 100 RPM

9100 RPM

Valve Clearance (Intake) .006 ± .002" (0.15 ± 0.05 mm)

Valve Clearance (Exhaust) .010 ± .002" (0.25 ± 0.05 mm)

Engine Hot Light

Lubrication

Instrument Cluster Indicator

Wet Sump

PS-4 Full Synthetic 5W-50 or

Oil Requirements

PS-4 Extreme Duty Full

Synthetic 10W-50

Oil Capacity 2.75 qt (2.6 L)

Coolant Type

Polaris 50/50 Extended Life

Anti-freeze

Coolant Capacity 10.8 qt (10.22 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure (key-on

75 ± 2 PSI (520 ± 14 kPa)

engine-off)

Fuel Capacity / Requirement

12 gal. (45.4 L)

91 Octane (minimum)

ELECTRICAL

Alternator Max Output 900 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam LED cluster

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap MR9F / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 575 CCA / 44 A/hr

DC Outlet Standard 12 Volt Relays Start, Fan, EFI, Pump, Chassis,

EPS, Accy, Shocks, SCM

7.5A Chassis

7.5A Fuel

7.5A Instr Accy

7.5A Instr Unsw

7.5A Key

7.5A Lights

Fuses

7.5A SCM

7.5A Shocks

7.5A Water 10A EFI

10A Socket

10A Term Accy

25A EPS

30A Fan

DRIVETRAIN

Transmission Type

Shift Type

Polaris Automatic PVT

In Line Shift - P/ R / N / L / H

Front Gearcase Lubricant Demand Drive Fluid Front Gearcase Capacity 9.5 oz (280 mL)

Transmission Lubricant

AGL Synthetic Gearcase

Lubricant

Transmission Capacity 61 oz (1800 mL)

STEERING / SUSPENSION

1/4” toe-in – 1/4” toe-out

Toe

Front Suspension

(0.64 mm toe-in – 0.64 mm toe-

out)

Independent Dual A-arm with

stabilizer bar

FOX 2.5 Podium with DYNAMIX

Front Travel

Rear Suspension

17″ (43.2 cm)

Independent Trailing Arm with

stabilizer bar

FOX 3.0 Podium with DYNAMIX

Rear Travel

Spring Adjustment

20″ (50.8 cm)

Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 6 Rear Rim / Size Aluminum 14 x 7 Front Tire Make / Model /

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Front

Rear

Maxxis Carnivore

30 x 10 R14

Maxxis Carnivore

30 x 10 R14

10 psi (69 kPa)

20 psi (138 kPa)

4 Wheel Hydraulic

Brake System

Front: Triple Bore Caliper

Rear – Double Bore Caliper

Brake Fluid DOT 4

2020-21 RZR PRO XP CLUTCH CHART

MODEL ALTITUDE

202021RZR Pro XP

0-1800 Meters

(0-6000 Feet)

1800-3700 Meters (6000-12000 Feet)

SHIFT

WEIGHT

W-34-112 (1323746)

W-34-104 (1323586)

DRIVE

SPRING

Black

(7045112)

DRIVEN SPRING

Black

(7045138)

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

1.15

Page 22

GENERAL INFORMATION

2020 RZR PRO XP 4

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.6 cm

Height

Wheel Base 125″ / 317.5 cm

Ground Clearance 14″ / 35.6 cm

Dry Weight 2038 lbs. / 924 kg

Gross Vehicle Weight 3055 lbs. / 1386 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity This vehicle is not equipped with

Hitch Tongue Capacity

155.0″ / 393.7 cm

73.6″ / 186.9 cm

900 lbs. / 408 kg (Includes riders, cargo and accessories)

a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch.

1.16

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 23

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Turbocharged., 4–Stroke,

DOHC

925cc

Bore & Stroke 93 x 68 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

9:1

1250 +/- 100 RPM

9100 RPM

Valve Clearance (Intake) .006 ± .002" (0.15 ± 0.05 mm)

Valve Clearance (Exhaust) .010 ± .002" (0.25 ± 0.05 mm)

Engine Hot Light

Lubrication

Instrument Cluster Indicator

Wet Sump

PS-4 Full Synthetic 5W-50 or

Oil Requirements

PS-4 Extreme Duty Full

Synthetic 10W-50

Oil Capacity 2.75 qt (2.6 L)

Coolant Type

Polaris 50/50 Extended Life

Anti-freeze

Coolant Capacity 11.6 qt (10.97 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure 75 ± 2 PSI (520 ± 14 kPa)

Fuel Capacity / Requirement

13 gal. (49.2 L)

91 Octane (minimum)

ELECTRICAL

Alternator Max Output 900 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam LED cluster

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap MR9F / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 400 CCA / 44 A/hr

DC Outlet Standard 12 Volt Relays Start, Fan, EFI, Pump, Chassis,

EPS, Accy, Shocks, SCM

7.5A Chassis

7.5A Fuel

7.5A Instr Accy

7.5A Instr Unsw

7.5A Key

7.5A Lights

Fuses

7.5A SCM

7.5A Shocks

7.5A Water 10A EFI

10A Socket

10A Term Accy

25A EPS

30A Fan

DRIVETRAIN

Transmission Type

Shift Type

Polaris Automatic PVT

In Line Shift - P/ R / N / L / H

Front Gearcase Lubricant Demand Drive Fluid Front Gearcase Capacity 9.5 oz (280 mL)

Transmission Lubricant

AGL Synthetic Gearcase

Lubricant

Transmission Capacity 61 oz (1800 mL)

STEERING / SUSPENSION

1/4” toe-in – 1/4” toe-out

Toe

Front Suspension

(0.64 mm toe-in – 0.64 mm toe-

out)

Independent Dual A-arm with

stabilizer bar

FOX 2.5 Podium with DYNAMIX

Front Travel

Rear Suspension

17″ (43.2 cm)

Independent Trailing Arm with

stabilizer bar

FOX 3.0 Podium with DYNAMIX

Rear Travel

Spring Adjustment

20″ (50.8 cm)

Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 6 Rear Rim / Size Aluminum 14 x 7 Front Tire Make / Model /

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Front

Rear

Maxxis Carnivore

30 x 10 R14

Maxxis Carnivore

30 x 10 R14

16 psi (110 kPa)

20 psi (138 kPa)

4 Wheel Hydraulic

Brake System

Front: Dual Bore Caliper

Rear – Double Bore Caliper

Brake Fluid DOT 4

2020-21 RZR PRO XP 4 CLUTCH CHART

MODEL ALTITUDE

2020-21 RZR Pro XP 4

0-1800 Meters

(0-6000 Feet)

1800-3700 Meters (6000-12000 Feet)

SHIFT

WEIGHT

W-34-112 (1323746)

W-34-104 (1323586)

DRIVE

SPRING

Black

(7045112)

DRIVEN SPRING

(7045138)

Black

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

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Page 24

GENERAL INFORMATION

2021 RZR PRO XP

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.6 cm

Height

Wheel Base 96″ / 243.8 cm

Ground Clearance 14″ / 35.6 cm

Dry Weight 1785 lbs. / 810 kg

Gross Vehicle Weight 2623 lbs. / 1190 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity This vehicle is not equipped with

Hitch Tongue Capacity

126.1″ / 320.4 cm

71.7″ / 182.1 cm

740 lbs. / 336 kg (Includes riders, cargo and accessories)

a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch.

1.18

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Page 25

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Turbocharged., 4–Stroke,

DOHC

925cc

Bore & Stroke 93 x 68 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

9:1

1200 +/- 100 RPM

9100 RPM

Valve Clearance (Intake) .006 ± .002" (0.15 ± 0.05 mm)

Valve Clearance (Exhaust) .010 ± .002" (0.25 ± 0.05 mm)

Engine Hot Light

Lubrication

Instrument Cluster Indicator

Wet Sump

PS-4 Full Synthetic 5W-50 or

Oil Requirements

PS-4 Extreme Duty Full

Synthetic 10W-50

Oil Capacity 2.75 qt (2.6 L)

Coolant Type

Polaris 50/50 Extended Life

Anti-freeze

Coolant Capacity 10.8 qt (10.22 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure (key-on

75 ± 2 PSI (520 ± 14 kPa)

engine-off)

Fuel Capacity / Requirement

12 gal. (45.4 L)

91 Octane (minimum)

ELECTRICAL

Alternator Max Output 900 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam LED cluster

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap MR9F / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 575 CCA / 44 A/hr

DC Outlet Standard 12 Volt Relays Start, Fan, EFI, Pump, Chassis,

EPS, Accy, Shocks, SCM

7.5A Chassis

7.5A Fuel

7.5A Instr Accy

7.5A Instr Unsw

7.5A Key

7.5A Lights

Fuses

7.5A SCM

7.5A Shocks

7.5A Water 10A EFI

10A Socket

10A Term Accy

25A EPS

30A Fan

DRIVETRAIN

Transmission Type

Shift Type

Polaris Automatic PVT

In Line Shift - P/ R / N / L / H

Front Gearcase Lubricant Demand Drive Fluid Front Gearcase Capacity 9.5 oz (280 mL)

Transmission Lubricant

AGL Synthetic Gearcase

Lubricant

Transmission Capacity 61 oz (1800 mL)

STEERING / SUSPENSION

1/4” toe-in – 1/4” toe-out

Toe

Front Suspension

(0.64 mm toe-in – 0.64 mm toe-

out)

Independent Dual A-arm with

stabilizer bar

FOX 2.5 Podium with DYNAMIX

Front Travel

Rear Suspension

17″ (43.2 cm)

Independent Trailing Arm with

stabilizer bar

FOX 3.0 Podium with DYNAMIX

Rear Travel

Spring Adjustment

20″ (50.8 cm)

Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 6 Rear Rim / Size Aluminum 14 x 7 Front Tire Make / Model /

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Front

Rear

Maxxis Carnivore

30 x 10 R14

Maxxis Carnivore

30 x 10 R14

10 psi (69 kPa)

20 psi (138 kPa)

4 Wheel Hydraulic

Brake System

Front: Triple Bore Caliper

Rear – Double Bore Caliper

Brake Fluid DOT 4

2020-21 RZR PRO XP CLUTCH CHART

MODEL ALTITUDE

202021RZR Pro XP

0-1800 Meters

(0-6000 Feet)

1800-3700 Meters (6000-12000 Feet)

SHIFT

WEIGHT

W-34-112 (1323746)

W-34-104 (1323586)

DRIVE

SPRING

Black

(7045112)

DRIVEN SPRING

Black

(7045138)

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

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Page 26

GENERAL INFORMATION

2021 RZR PRO XP 4

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.6 cm

Height

Wheel Base 125″ / 317.5 cm

Ground Clearance 14″ / 35.6 cm

Dry Weight 2038 lbs. / 924 kg

Gross Vehicle Weight 3055 lbs. / 1386 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity This vehicle is not equipped with

Hitch Tongue Capacity

155.0″ / 393.7 cm

73.6″ / 186.9 cm

900 lbs. / 408 kg (Includes riders, cargo and accessories)

a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch.

1.20

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 27

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Turbocharged., 4–Stroke,

DOHC

925cc

Bore & Stroke 93 x 68 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

9:1

1250 +/- 100 RPM

9100 RPM

Valve Clearance (Intake) .006 ± .002" (0.15 ± 0.05 mm)

Valve Clearance (Exhaust) .010 ± .002" (0.25 ± 0.05 mm)

Engine Hot Light

Lubrication

Instrument Cluster Indicator

Wet Sump

PS-4 Full Synthetic 5W-50 or

Oil Requirements

PS-4 Extreme Duty Full

Synthetic 10W-50

Oil Capacity 2.75 qt (2.6 L)

Coolant Type

Polaris 50/50 Extended Life

Anti-freeze

Coolant Capacity 11.6 qt (10.97 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure 75 ± 2 PSI (520 ± 14 kPa)

Fuel Capacity / Requirement

13 gal. (49.2 L)

91 Octane (minimum)

ELECTRICAL

Alternator Max Output 900 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam LED cluster

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap MR9F / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 400 CCA / 44 A/hr

DC Outlet Standard 12 Volt Relays Start, Fan, EFI, Pump, Chassis,

EPS, Accy, Shocks, SCM

7.5A Chassis

7.5A Fuel

7.5A Instr Accy

7.5A Instr Unsw

7.5A Key

7.5A Lights

Fuses

7.5A SCM

7.5A Shocks

7.5A Water 10A EFI

10A Socket

10A Term Accy

25A EPS

30A Fan

DRIVETRAIN

Transmission Type

Shift Type

Polaris Automatic PVT

In Line Shift - P/ R / N / L / H

Front Gearcase Lubricant Demand Drive Fluid Front Gearcase Capacity 9.5 oz (280 mL)

Transmission Lubricant

AGL Synthetic Gearcase

Lubricant

Transmission Capacity 61 oz (1800 mL)

STEERING / SUSPENSION

1/4” toe-in – 1/4” toe-out

Toe

Front Suspension

(0.64 mm toe-in – 0.64 mm toe-

out)

Independent Dual A-arm with

stabilizer bar

FOX 2.5 Podium with DYNAMIX

Front Travel

Rear Suspension

17″ (43.2 cm)

Independent Trailing Arm with

stabilizer bar

FOX 3.0 Podium with DYNAMIX

Rear Travel

Spring Adjustment

20″ (50.8 cm)

Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 6 Rear Rim / Size Aluminum 14 x 7 Front Tire Make / Model /

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Front

Rear

Maxxis Carnivore

30 x 10 R14

Maxxis Carnivore

30 x 10 R14

16 psi (110 kPa)

20 psi (138 kPa)

4 Wheel Hydraulic

Brake System

Front: Dual Bore Caliper

Rear – Double Bore Caliper

Brake Fluid DOT 4

2020-21 RZR PRO XP 4 CLUTCH CHART

MODEL ALTITUDE

2020-21 RZR Pro XP 4

0-1800 Meters

(0-6000 Feet)

1800-3700 Meters (6000-12000 Feet)

SHIFT

WEIGHT

W-34-112 (1323746)

W-34-104 (1323586)

DRIVE

SPRING

Black

(7045112)

DRIVEN SPRING

(7045138)

Black

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

1.21

Page 28

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

CONVERSION TABLE

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs x 12 = in-lbs

in-lbs x 0.0833

ft-lbs

in-lbs x 0.0115 = kg-m

Nm x 0.7376

kg-m x 7.233

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi)

km x 0.6214 = mile

ounces (oz) x 28.35 = grams (g)

fluid ounces (fl oz)

cubic centimeters (cc)

grams (g) x 0.035

pounds (lb)

kilogram (kg)

cubic inches (cu in) x 16.387

cubic centimeters (cc)

US quarts

liters (L) x 1.057 = US quarts

US gallons

liters (L) x 0.264 = US gallons

PSI

kilopascals (kPa)

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x 1.356 = Nm

x 0.03937 = inch

x 1.6 = km

x 29.57

x .03381

x 0.454 = kg

x 2.2046 = lbs

x 0.061 = cubic inches

x 0.946

x 3.785

x 6.895

x 0.145

= ft-lbs

= mm

= cm

= cubic centimeters (cc)

= fluid ounces

= ounces

= cc

= liters (L)

= kilopascals (kPa)

PSI

= cylinder volume

1.22

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 29

GENERAL INFORMATION

SAE TAP / DRILL SIZES

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40 38 7/8–14 13/16

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

#8–32

#8–36

#10–24

#10–32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

7/16–20 25/64

F 2–12

U 3–4

THREAD

SIZE DRILL SIZE

1/2–20 29/64

5/8–11 17/32

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

1 1/8–7 63/64

1 1/8–12 1 3/64

1 1/4–7 1 7/64

1 1/4–12 1 11/64

1 1/2–6 1 11/32

1 3/4–12 1 43/64

2–4 1/2 1 25/32

2 1/4–4 1/2 2 1/32

1 59/64

2 3/4

METRIC TAP / DRILL SIZES

TAP SIZE DRILL SIZE DECIMAL

3 x .50

3 x .60

4 x .70 #30 0.1285 1/8

4 x .75

5 x .80 #19 0.166 11/64

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277

8 x 1.25 17/64 0.265 17/64

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

11 x 1.50

12 x 1.50

12 x 1.75 13/32 0.406 13/32

#39

3/32

1/8 0.125 1/8

#20

16/64

5/16

11/32

3/8

13/32

0.0995

0.0937

0.161

0.196

0.234

0.3125

0.3437

0.375

0.406

NEAREST

FRACTION

3/32

5/32

13/64

15/64

9/32

5/16

11/32

3/8

13/32

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

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Page 30

GENERAL INFORMATION

DECIMAL EQUIVALENTS

FRACTION DECIMAL MM TO INCHES

1/64 0.0156″

1/32

3/64

1/16 0.0625″

5/64

3/32

7/64 0.1094″ 3 mm = 0.1181″

1/8

9/64

5/32 0.1563″ 4 mm = 0.1575″

11/64 0.1719″

3/16

13/64

7/32 0.2188″

15/64

1/4

17/64 0.2656″ 7 mm = 0.2756″

9/32

19/64

5/16 0.3125″ 8 mm = 0.3150″

21/64

11/32

23/64 0.3594″

3/8 0.375″

25/64

13/32

27/64 0.4219″ 11 mm = 0.4331″

7/16

29/64

15/32 0.4688″ 12 mm = 0.4724″

31/64

1/2

0.0312″ 1 mm = 0.0394″

0.0469″

0.0781″ 2 mm = 0.0787″

0.0938″

0.1250″

0.1406″

0.1875″ 5 mm = 0.1969″

0.2031″

0.2344″ 6 mm = 0.2362″

0.25″

0.2813″

0.2969″

0.3281″

0.3438″ 9 mm = 0.3543″

0.3906″ 10 mm = 0.3937″

0.4063″

0.4375″

0.4531″

0.4844″

0.500″ 13 mm = 0.5118″

FRACTION DECIMAL MM TO INCHES

33/64 0.5156″

17/32

35/64

9/16 0.5625″

37/64 0.5781″ 15 mm = 0.5906″

19/32

39/64

5/8 0.625″ 16 mm = 0.6299″

41/64

21/32

43/64 0.6719″

11/16 0.6875″

45/64

23/32 0.7188″

47/64 0.7344″ 19 mm = 0.7480″

3/4

49/64

25/32 0.7813″ 20 mm = 0.7874″

51/64

13/16

53/64 0.8281″

27/32

55/64

7/8

57/64 0.8906″ 23 mm = 0.9055″

29/32

59/64

15/16 0.9375″ 24 mm = 0.9449″

61/64

31/32

63/64 0.9844″

1 1.000″

0.5313″

0.5469″ 14 mm = 0.5512″

0.5938″

0.6094″

0.6406″

0.6563″ 17 mm = 0.6693″

0.7031″ 18 mm = 0.7087″

0.750″

0.7656″

0.7969″

0.8125″ 21 mm = 0.8268″

0.8438″

0.8594″ 22 mm = 0.8661″

0.875″

0.9063″

0.9219″

0.9531″

0.9688″ 25 mm = 0.9843″

1.24

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 31

GENERAL INFORMATION

GENERAL DIAGNOSTICS

GENERAL DIAGNOSTICS INFORMATION OVERVIEW

NOTICE

General Diagnostics is a section within the Service Manual that contains information relating to various vehicle

diagnostics. These procedures are not vehicle specific and can be used for troubleshooting many different vehicles.

For vehicle specific troubleshooting and diagnostic information please refer to the specific system chapters for more

GUIDED SYMPTOM DIAGNOSTIC

Is this the first time that the

vehicle concern has been

diagnosed?

↓

Yes

Has the concern been

duplicated and compared to a

like vehicle?

→

information.

Refer to Guided Symptom

References

If the concern has not been

able to be duplicated gather

more information about the

concern. After the concern has been duplicated, please compare to a like vehicle. Is

the concern present on that

vehicle?

→

Yes

If the same concern is present

on the like vehicle, it is likely

that the concern is a normal

operational characteristic.

Yes

↓

Are there any bulletins related

to the concern?

No ↓

Connect Digital Wrench and check for any trouble codes.

Are there any codes present?

↓

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

↙

→

Yes

↙

→

Yes

↙

Proceed with instruction from

the bulletin. Has the problem

Has concern been repaired

after Guided Diagnostic?

been resolved?

Refer to Digital Wrench

Guided Diagnostic.

→

Yes

→

Yes

Concern has been repaired.

Return the vehicle to the

consumer at this time.

Concern has been repaired.

Return the vehicle to the

consumer at this time.

1.25

Page 32

GENERAL INFORMATION

Is the concern Starting

Related?

↓

Is the concern related to

Engine Performance or a

Running concern?

↓

→

Yes

→

Yes

Refer to, Engine Cranks but does Not Start page 1.30 or

No Crank No Start or Slow

Crank page 1.32.

Pay close attention to what is

noted in the Occurrence

Checklist for conditions when

concern is present. This will help in determining cause of

concern.

Refer to Engine and

Drivability Diagnostic

Procedures page 1.27.

Pay close attention to what is

noted in the Occurrence

Checklist for conditions when

concern is present. This will help in determining cause of

concern.

Have any concerns in the Transmission / Final Drive

Category been selected?

↓

Is the concern related to a

GUIDED SYMPTOM REFERENCES

• For concerns that have not been able to be duplicated or are repeat concerns :

– Refer to the Customer Questionnaire and gather more information from the Consumer. – Gather the information from previous repairs including Ask Polaris Cases. – Verify that the concern can be consistently duplicated. When the concern is duplicated, please note the conditions

under which the concern is happening. Refer to the Symptom Checklist for various conditions.

– If the concern has been verified and all of the information has already been collected, please start an Ask Polaris

case at this time. If this information has not yet been gathered, gather this information first.

Noise?

→

Yes

Refer to the Transmission or

Final Drive Chapters for

further diagnostic information.

Refer to necessary service information for pin-pointing

noise location and diagnosis.

1.26

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 33

GENERAL INFORMATION

ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES

NOTICE

The following chart is to prevent overlooking a simple problem. These basic systematic procedures should be

checked before further testing is performed.

What is the

customers concern

and can the concern

be duplicated at this

time?

Are there any

Team-Tips, Recalls,

or Other Bulletins for

this concern?

Are there any

warning lights or

messages on

vehicle? (Reference

necessary manual

for light

identification)

Yes

• Proceed to step

• If the concern can not be duplicated, check for any bulletins related to the concern. Gather more information from the consumer. Proceed to step the concern still can not be duplicated proceed to step

• Proceed to bulletin for repair procedure. If problem is still present, return to chart.

• Proceed to step

• For CHECK ENGINE LIGHT or PERFORMANCE LIMITED LIGHT

– Connect to Digital Wrench®. Check codes and continue with Digital

Wrench® Guided diagnosis.

– Certain failures may not display a CEL / MIL on the instrument cluster. In

this instance record CEL’s from the instrument cluster and refer to the necessary section in the Service Manual.

– Refer to Warning Lights page 1.34.

• For ENGINE HOT WARNING

– Check Coolant level. If not full, fill to correct level. – Check Oil level. If not full, fill to correct level. – Visually inspect for Oil or Coolant leaks. If any leaks are present repair

before continued diagnosis. – Refer to Warning Lights page 1.34. – Refer to Over Heating page 1.33.

• For EPS WARNING (if applicable) Refer to STEERING - EPS

TROUBLESHOOTING. – Check battery voltage and connections. – Check connections at EPS unit. If any connection or wiring damage is

found, repair before proceeding.

– Refer to EPS Troubleshooting (Using Digital Wrench®) page 1.71. Check

codes and continue with diagnosis.

– If no codes are present, refer to EPS Troubleshooting (Power Steering

Non-Functional with MIL OFF) page 1.70

– If codes are present, refer to EPS Troubleshooting (Power Steering Non-

Functional with MIL ON) page 1.69

. If

• Connect to Digital Wrench®. Check codes and continue with Digital

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

Wrench® Guided diagnosis.

• If no codes are present, proceed to step

1.27

Page 34

GENERAL INFORMATION

Yes

• Check Oil level. If not full, fill to correct level.

• Check Fuel Level. (Check tank using flash light - gauge may not be accurate

- add fuel if needed)

• Check Coolant level. If not full, fill to correct level.

Continue to step

Does the engine

crank?

Does the engine

stay running?

Yes

• Check Oil level. If oil is low concern may be caused by lack of oil or oil pressure. Suspect internal engine issue. Refer to Chapter 3 Engine / Cooling System.

• Check for battery power. Voltage should be ~ 12.6 V.

• Load test battery. If battery fails the load test, charge / replace battery as needed. Retest for concern before proceeding.

• Check Ignition Switch and connections. Concern may be caused by faulty Ignition Switch.

• Refer to No Crank No Start or Slow Crank page 1.32 for further diagnostic procedures

• Continue to step

• Check air filter for blockage.

• Check for spark. Refer toEngine Cranks but does Not Start page 1.30 for quick check.

• Check fuel supply using fuel pressure gauge. Is fuel pressure within specification?

• Check exhaust for blockage.

• After checking for air supply and fuel pressure, perform leakdown test.

• Refer to Engine Cranks but does Not Start page 1.30 for more information.

1.28

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 35

GENERAL INFORMATION

Will the vehicle

move under its own

power?

Test drive vehicle

for concern.

Yes

• Continue to step

• Remove PVT cover if necessary and check belt for damage or unusual wear. Refer to Belt Inspection for more information.

• If no damage is found, using the aid of an assistant slowly rev engine observing clutch engagement. If no engagement is seen refer to PVT System Troubleshooting.

• Using the aid of an assistant verify the propshaft is turning, while the clutch is engaged. If the driveshaft is turning refer to Differential Diagnosis / Disassembly in the applicable service manual.

• If the driveshaft is not moving, concern may be within transmission. Refer to the necessary section in the applicable service manual.

• If the concern is related to the PVT system, Transmission, or Final Drive, refer to the applicable section in the service manual.

• If the concern is electrical systems related, refer to Electrical Troubleshooting.

• If the concern is overheating or related to the cooling system, first refer to Over Heating page 1.33 , then Cooling Troubleshooting page 1.37.

• If the concern is driveability related (lack of power, misfire, etc.), refer to Fuel System Troubleshooting page 1.60, or Cylinder Misfire Detection page 1.58. These concerns may also be caused by a mechanical failure.

• If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team.

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual © Copyright Polaris Industries Inc.

1.29

Page 36

GENERAL INFORMATION

ENGINE CRANKS BUT DOES NOT START

1. Check battery voltage while cranking. If voltage is below 10.8V, vehicle may not start.

• Perform Voltage Drop Test on Starter Circuit. Refer

to Testing Voltage Drop page 1.78 for more information. Acceptable drop is 0.1V per connection, if too much drop is detected concern may be caused by faulty starter, or solenoid.

• Charge battery.

• If equipped with a serviceable battery, check

battery electrolyte level. Fill following procedure if low.

• If battery voltage is not ~12.6 V charge battery at

recommended rate. Attempt starting after charging.

• If battery still does not reach ~12.6 V, battery may

require replacement.

2. Visually inspect vehicle for any electrical connectors or wiring that may be loose or damaged. Check connectors for water intrusion or corrosion.

• If connections are found to be loose, repair

connector as necessary.

• If connector is found to have corrosion or water

within connectors, clean, dry, and reconnect.

• Repair any damage to wiring.

3. Check vehicle for trouble codes. Refer to Digital Wrench® Diagnostic.

• If codes are present proceed with testing per Digital

Wrench®.

4. Check air box and filter for debris or moisture.

• If debris is found clear debris and recheck for

concern.

• If water is found within air box, dry box and filter. It

is possible that engine may have ingested water. This could cause engine failure, refer to Engine Troubleshooting page 1.35

5. Check fuel level and condition in vehicle.

• Possible to have incorrect reading from fuel gauge.

Using a flashlight, check for fuel in tank. If no fuel is visible, fill with fuel before further diagnostic.

• Check fuel quality, pull fuel sample or drain tank

and refill with fresh fuel from a reliable source.

IMPORTANT

When filling with fuel, ensure that the fuel being used

meets the correct octane rating specific to the vehicle.

6. Check fuses or fuel system relays (where applicable).

• If any fuel related system fuses are blown, replace fuses and recheck. Wiring concern or faulty parts may cause fuse to blow.

• It is advisable to try swapping a relay with a known good relay to check operation. Swap relay with like relay and see if vehicle starts.

7. Check fuel lines and fittings for leaks or damage.

• If leak or damage is found repair, replace as necessary and recheck concern.

• If no concerns are found proceed with fuel pressure testing.

8. Perform a fuel pressure test during engine cranking.

• Verify that battery voltage is present at the fuel pump. A low voltage concern may cause the pump to be inoperable.

• Check using fuel pressure gauge to see that fuel pressure is within specification.

• If not within specification, if equipped check fuel filter / screen for restriction.

• If no concern is found with filter or pressure is still low after filter replacement, suspect weak or faulty fuel pump.

9. Inspect spark plug wiring, spark plug, and check for spark.

• Check to make sure that spark plug is tight.

• Inspect spark plug for fouling. Inspect plug gap

using feeler gauge or similar tool. Adjust to specification if needed.

• Disconnect plug wire and install an inline spark

tester between the spark plug wire and spark plug. Check for spark. If a spark tester is not available, remove the spark plug and reinstall wire to plug connection. Using caution crank engine while watching spark plug for spark.

CAUTION

DO NOT TOUCH SPARK PLUG DURING TEST.

TOUCHING SPARK PLUG COULD RESULT IN

ELECTRIC SHOCK.

• If plug does not spark in previous test, check

connections at ignition coil. Ensure that the ignition coil has power and is receiving signal from the ECU. Concern may be caused by faulty ignition coil or electrical concern.

• If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit.

1.30

10.Listen for unusual noises while cranking.

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• Broken or damaged flywheel, starter motor gear, or starter motor drive could sound like engine cranking but crankshaft may not be turning.

• Unusual noise could suggest that there may be a mechanical engine concern. Proceed to step

11.Check ECU and connections.

• ECU could be faulty causing concern.

• Check ECU for power and grounds to make sure that computer is turning on.

12.If all previous checks pass, concern may be caused

by internal engine issue.

• Refer to Cylinder Leakdown Test.

• Previous testing may be caused by or lead to replacement of one or more of the following:

– Cylinder head gasket leak – No valve clearance (cam wear) – Cylinder or piston worn – Piston rings worn, leaking, broken, or sticking – Bent valve or stuck valve – Valve spring broken or weak – Valve not seating properly (bent or carbon

accumulated on sealing surface)

– Rocker arm sticking

GENERAL INFORMATION

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GENERAL INFORMATION

NO CRANK NO START OR SLOW CRANK

1. Verify that battery is charged and has ~12.6 V using DMM or battery tester.

• Check battery electrolyte level. If low top off battery.

See Maintenance — Electrical and Ignition Systems.

• Charge battery at recommended rate. See. Attempt

starting after charging.

• If battery will not reach ~12.6 V could be caused by

battery draw. Refer to Diagnostic — Electrical Diagnostics.

• If battery will not reach ~12.6 V, load test battery.

Replace if necessary. Refer to Electrical — Battery Removal / Installation.

2. Verify connections at battery are installed correctly and are tight.

• If battery terminals are not installed correctly, install

terminals correctly

• Make sure terminals are clean of dirt and corrosion.

If not refer to Maintenance — Battery Maintenance.

3. Visually inspect vehicle for any electrical connectors or wiring that may be loose or damaged.

• If wiring issues are found, repair as necessary.

Refer to wiring diagrams if needed.

• Check battery ground. Follow Negative (-) Cable

from battery to chassis and make sure connection is clean and tight.

• Using Digital Wrench® verify that the Brake Switch is changing state from “Active” when the brake is depressed to “Inactive” when the brake is released.

• Most vehicles need to see brake being depressed before vehicle will start. If brake lights do not light when brake is depressed, concern may be caused by brake switch operation.

6. Possible faulty key switch.

• Attempt turning key switch on and off multiple times.

• Wiggle key switch while turning.

• If vehicle starts, concern may be caused by key switch or connection to switch. Refer to Electrical Chapter.

7. Check for communication with ECU using Digital Wrench®

• If there is no communications with ECU there may

be a concern with the CAN system or ECU causing the no start.

8. Concern may be caused by mechanical engine concern.

• Refer to Engine Troubleshooting.

4. Check connections at starter and starter solenoid. Refer to Electrical Chapter.

• Make sure connections are clean and tight. If not

repair before further diagnosis.

• Check Positive (+) terminals at starter and solenoid

for available voltage using DMM. Readings should be ~12.6 V

• With battery disconnected check cables for high

resistance. Reading should be less than 1 Ohm. If resistance is higher than specification replace wiring.

• Reconnect battery and perform voltage drop test

on wiring to starter and to starter solenoid. Concern may still be caused by high resistance in wires even if resistance is within specification when disconnected.

• If voltage drop test fails, continue testing to isolate

component that will require replacement (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection.

5. Check Brake Switch operation.

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GENERAL INFORMATION

OVER HEATING

1. Verify coolant is filled to correct level.

• If coolant is low, fill to correct level.

2. Test and check for correct coolant mixture.

• If coolant mix is incorrect, correct mixture as necessary.

• If incorrect coolant was used in vehicle, flush cooling system and bleed, fill to correct level, and recheck.

3. Check cooling system using combustion leak tester

for any combustion gasses entering the cooling system. This may suggest a head gasket, cylinder head failure, or other engine damage. Adding coolant before test may dilute the system and cause inaccurate test results.

4. Check Radiator and cooling fans for restrictions or

damage

• Check for debris, dirt, or mud between fan and radiator restricting air flow. If present, clean and recheck.

• Check for damage to radiator or cooling fans. If damage is found to components repair or replace as necessary.

• Inspect for any aftermarket modifications that may be restricting air flow. (Radiator Modifications, Grille

Modifications, Aftermarket Bumpers, Lightbars, etc.) Pay close attention to the Radiator Shroud

presence and placement.

5. Check for coolant leaks / air pockets.

• Visually check all hoses and radiator for leaks. If leaks are found repair as necessary.

• Check cooling system using coolant pressure tester. If leaks can not be seen on visual inspection, refer to Engine / Cooling system for more information.

• Check for air in cooling system. Bleed the cooling system if needed.

6. Check Oil level.

• Low oil level or oil in need of changing may cause increase in engine temperature.

• Too high of oil level may cause engine temperatures may cause increase in engine temperature.

• Check level and correct as necessary. Check maintenance history to determine if oil need to be changed.

• Make sure the cooling fan is engaging. Command cooling fans on and off using Digital Wrench to check operation.

• Monitor engine temperature using Digital Wrench® viewing the Engine Temperature PID. Once engine has reached running temperature cooling fan should engage.

8. Water Pump / Thermostat / Radiator may be suspect of concern.

• Thermostat could be opening too slowly or stuck

closed. Check temperature using Digital Wrench® viewing the Engine Temperature to check for correct operation.

• Water pump may be faulty or not circulating

enough coolant to keep temperature within specification.

• Radiator core may not be functioning correctly or

failed causing concern.

9. Faulty Temp Sensor / Circuit / ECU.

• Confirm engine is overheating. It could be possible

that the coolant sensor is sending an incorrect signal causing the ECU to think the vehicle is overheating when it is running at the proper temperature.

• Check connections at temp sensor and wiring. If

damage is found repair, as needed.

• Resistance test sensor, refer to ECT Sensor test. If

test fails, replace sensor.

• If concern is still present after sensor replacement

suspect the ECU is not receiving correct signal input. Inspect circuit wiring.

10.Engine Damage

• The overheating concern may be caused by an

engine concern.

• Refer to the necessary section in the Service

Manual for further engine testing.

11.Inspect ECU calibration level.

• If any ECU calibrations are available, update at this

time.

7. Check Cooling Fan operation.

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GENERAL INFORMATION

WARNING LIGHTS

1. CHECK ENGINE

• Engine fault has been detected. Refer to Digital Wrench for codes.

• Proceed with diagnosis after checking codes.

2. EPS WARNING (If applicable)

• Power steering fault has been detected.

• Check for codes using Digital Wrench. If no codes present refer to EPS System – Troubleshooting

• Check connections at battery, could be caused by voltage concern.

• Visually inspect connections at EPS Unit.

• For further diagnosis refer to Steering System –

Steering Assembly EPS

3. ENGINE HOT

• Over temperature condition detected.

• Check coolant level. If not full fill to correct level. Bleed the cooling system to ensure there are no air pockets present.

• Visually inspect hoses and radiator for coolant leaks. Repair as necessary.

• Pressurize cooling system and look for pressure losses. This indicates a leak in the cooling system. Inspect for external leaks, if none are found it is possible there is an internal leak.

• Check cooling system using combustion leak tester for any combustion gasses entering the cooling system. This could indicate possible Head / Headgasket failure.

• Check oil level. Verify that oil is filled to the correct level. Engine oil that is low, or overfull can cause overheating concerns. Check maintenance history to see if oil needs to be changed.

• Visually inspect for oil leaks.

• Refer to Over Heating page 1.33 for more info.

4. PERFORMANCE LIMITED

• Check for codes using Digital Wrench. Refer to Guided Diagnostic for further diagnosis.

5. BRAKE WARNING

• Detects brake system failure.

• Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information.

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ENGINE TROUBLESHOOTING

SPARK PLUG FOULING

GENERAL INFORMATION

• Spark plug cap loose or faulty

• Incorrect spark plug heat range or gap

• PVT system calibrated incorrectly/ components worn or mis-adjusted

• Fuel quality poor (old) or octane too high

• Improperly assembled air intake system

ENGINE TURNS OVER BUT FAILS TO START

• No fuel

• Dirt in fuel line or filter

• Fuel will not pass through fuel valve

• Clogged / Failed Fuel Injector

• Battery, Starter, and Ground Cable Connections

• Engine seized, rusted, or mechanical failure

• Injector Spray Pattern

• High Leakdown

• Valvetrain / Valve Clearances

• Restricted exhaust

• Vehicle not reaching operating temperature (Short tripping)

• Fuel pump inoperative/restricted

• Tank vent plugged or pinched

• Engine flooded

• Injector control circuit failure

ENGINE DOES NOT TURN OVER

• Starter motor does not turn

• Starting system circuit concern (blown fuse / failed relay / damaged wiring)

• Oil contaminated with fuel

• Weak ignition (loose coil ground, faulty coil, or stator)

• Restricted engine breather system

• Restricted air filter (main or precleaner) or breather system

• Low compression (high cylinder leakage)

• No spark (Spark plug fouled) ignition component failure

• Intake leak / vacuum leak

• Dead battery

ENGINE RUNS BUT WILL NOT IDLE

• Restricted fuel supply

• Intake leak / vacuum leak

• Spark plug fouled/weak spark

• Broken throttle cable

• Obstruction in air intake

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• Low compression

• TPS (installed incorrect / electrical concern / failed sensor)

ENGINE IDLES BUT WILL NOT ACCELERATE

• Air box removed (reinstall all intake components)

• Incorrect ignition timing

• Throttle Body

• Throttle Body (installed incorrect / electrical concern / failed)

• Crankcase breather restricted

• Cam worn excessively

• Restricted exhaust system

• Low fuel pressure

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GENERAL INFORMATION

ENGINE HAS LOW POWER

• Spark plug fouled

• Cylinder, piston, ring, or valve wear or damage (check compression)

• Poor fuel quality

• Lack of lubrication

• Improper air filter maintenance

EXCESSIVE SMOKE (BLUE / BLACK) AND CARBON BUILDUP

• Excessive piston-to-cylinder clearance

• Wet sumping

• Cylinder head gasket leak

• No valve clearance (cam wear)

• Valve not seating properly (bent or carbon accumulated on sealing surface)

• PVT not operating properly

• Cam worn excessively

PISTON FAILURE - SCORING

• Dirt entering engine through cracks in air filter or ducts

• Worn rings, piston, or cylinder

• Worn valve guides or seals

LOW COMPRESSION

• Cylinder or piston worn

• Bent valve or stuck valve

• Restricted exhaust muffler

• Low fuel pressure

• Engine oil dirty or contaminated

• Restricted breather

• Air filter dirty or contaminated

• Piston rings worn, leaking, broken, or sticking

• Valve spring broken or weak

• Ignition system faulty: – Spark plug cap cracked /

broken – Ignition coil faulty – Ignition or kill switch circuit

faulty – Poor connections in ignition

system – Ignition timing incorrect – Sheared flywheel key

1.36

BACKFIRING

• Intake system air leaks

• Fouled spark plug or incorrect plug or plug gap

• Low fuel pressure

• Poor fuel quality

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• Exhaust system air leaks

• Valve sticking

• Throttle Body (installed incorrect / electrical concern / failed)

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COOLING TROUBLESHOOTING

OVERHEATING

GENERAL INFORMATION

• Low coolant level

• Air in cooling system

• Wrong type/mix of coolant

• Faulty pressure cap or system leaks

• High oil level

• Spark plug incorrect heat range

• Radiator

• Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak)

• Thermostat stuck open

• Thermostat opening too soon

• Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage)

• Lean mixture (vents, fuel pump)

• Fuel pump output weak

• Cooling fan inoperative or turning too slowly (perform current draw test)

• Faulty hot light circuit

LEAK AT WATER PUMP WEEP HOLE

TEMPERATURE TOO LOW

• Contaminated coolant

• Electrical malfunction

• Water pump failure/ Loose impeller

• Thermistor failure

• Low oil level

• Thermostat stuck closed or not opening completely

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GENERAL INFORMATION

DIGITAL WRENCH

DIGITAL WRENCH® SOFTWARE OVERVIEW

The Polaris Digital Wrench® software allows a technician to perform the following tasks:

• Analyze real-time engine data

• Create customer service account records

• Generate / upload service reports

• Perform guided diagnostic procedures

• Perform output state control tests (most models)

• Reflash ECU calibration files

• View or clear trouble codes and freeze time data

See “Digital Wrench® Software Installation and Updates” for information on the latest software and updates.

For information on how to use the Digital Wrench® software, refer to the Digital Wrench® System Help. To access the Digital Wrench® System Help, do one of the following:

• Expand the Digital Wrench® Help drop-down on the left side of the main screen and click System Help.

• Select the ‘Display Diagnostic System Help’ menu icon (question mark) on the main screen.

SPECIAL TOOLS

SPECIAL TOOL

Digital Wrench® Diagnostic Kit PU-47063-C, which includes the following:

Wireless Vehicle Link (WVL) PU-51435

PART NUMBER

• Digital Wrench® Software: PU-48731-A

• Standard Interface Cable: PU-47151

• SmartLink Module Kit: PU-47471

• USB-Serial Adapter Cable: PU-50621

GUIDED DIAGNOSTICS

Guided diagnostics are available within Digital Wrench® for all supported Trouble Codes (that is, any fault that will turn on the ‘Check Engine’ indicator).

In addition, guided diagnostics are also available for many other electrical sub systems.

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DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES

Polaris recommends that you check your Digital Wrench® software version often and upgrade when available to make sure you are using the most current software. New programming files and diagnostic procedures are added to subsequent versions of the software as they become available.

To identify which Digital Wrench® software version is installed on your PC, do the following:

1. Launch the Digital Wrench® software.

2. On the Digital Wrench® main screen, locate the following information in the lower, right-hand corner:

• Base Version

• Update

(for example, Version: 4.1).

(release date), if available.

3. Select the Digital Wrench X.X Updates link.

4. Select the update you want to install on your PC.

You must have the latest Base Version installed on your

PC before you can install the update. Updates will not

install on older Base Versions of Digital Wrench®. If you

do not have the latest Base Version installed on your

PC, skip this section and proceed to “Installing a New

Digital Wrench® Base Version”.

If you are using Internet Explorer, do NOT select “Run”.

Instead, select “Save” and save the file to your PC

before you run the install.

GENERAL INFORMATION

IMPORTANT

NOTICE

If no updates for the Base Version are available, the information in the lower, right-hand corner displays only the Base Version (for example, Version: 4.1 Base). You

will not see an update (release date).

CHECKING FOR DIGITAL WRENCH® SOFTWARE UPDATES

To check if a Digital Wrench® software update is available, do the following:

1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com).

2. From the Service and Warranty drop-down, select Digital Wrench, and then click Digital Wrench Updates.

5. Follow the on-screen prompts to install the update.

6. Once the update is complete, launch the Digital Wrench® software and verify the information in the lower, right-hand corner matches the update you just installed.

INSTALLING A NEW DIGITAL WRENCH® BASE VERSION

To install a new Digital Wrench® Base Version, do the following:

1. Open a web browser and log on to your Polaris dealer website (www.polarisdealers.com).

2. From the Service and Warranty drop-down, select Digital Wrench, and then click Digital Wrench Base Version Installer.

NOTICE

If you are using Internet Explorer, do NOT select “Run”.

Instead, select “Save” and save the file to your PC

before you run the install.

3. Follow the on-screen prompts to install the new Base Version.

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GENERAL INFORMATION

4. Once the installation is complete, launch the Digital Wrench® software and verify the information in the lower, right-hand corner matches the new Base Version you just installed.

DIGITAL WRENCH® COMMUNICATION ERRORS

If you experience problems connecting to a vehicle, or any other Digital Wrench® software-related problem, visit the Digital Wrench® home page (www.polaris.diagsys. com) and locate the following information under Knowledge Base:

• Errors and Troubleshooting

• Frequently Asked Questions (FAQs)

• Procedures and Solutions

1. Assemble the MultiLink Module and attach the PC Interface Cable to your laptop.

2. Remove the protective cap from the Digital Wrench® connector.

3. Connect the Vehicle Interface Cable to the Digital Wrench® diagnostic connector.

4. Turn the ignition key to the ‘ON’ position, select the appropriate vehicle and wait for the status to display ‘Connected’ in the lower left corner of the screen.

5. Once connected, proceed with using Digital Wrench®.

DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR

The diagnostic connector is located under the storage tray below the middle seat and is connected to a sealed plug. To access the diagnostic connector lift up the passenger seat and remove the storage tray.

Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench® use:

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GENERAL INFORMATION

DIGITAL WRENCH® SERIAL NUMBER LOCATION

To locate the Digital Wrench® serial number, do the following:

1. Launch the Digital Wrench® software.

2. On the Digital Wrench® main screen, select the ‘Configure the Diagnostic System Software’ menu icon.

3. Locate the serial number on the right side of the System Configuration screen.

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GENERAL INFORMATION

DIGITAL WRENCH® FEATURE MAP

View and / or clear trouble codes in the Engine Controller Memory.

View sensor and ECU information in a grid, meter, or chart format. This is the most viewed screen.

View information from the main ECU sensors.

Set up data capture and record functions.

Perform specialized testing and adjustment functions service reports.

Add and / or update vehicle and customer information.

Add and / or update vehicle and customer information. Also view ECU Identification.

Access the Vehicle Home Page.

Access the System Configuration screen.

Access the Digital Wrench® System Help.

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Open the ASSERT ASK form.

Print the current screen as a formatted printout.

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GENERAL INFORMATION

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GENERAL INFORMATION

ENGINE CONTROLLER REPROGRAMMING (REFLASH)

OVERVIEW

The Digital Wrench® Engine Controller Reprogramming (or “Reflash”) feature allows reprogramming of the ECU fuel and ignition map. To successfully reprogram the ECU, an Authorization Key must be obtained by entering a Request Code in the field provided on the Reflash Authorization site. The Request Code is automatically generated by Digital Wrench® during the reprogramming process.

REPROGRAMMING (REFLASH) TIPS

• Check the Vehicle’s Battery Voltage

Make sure the vehicle’s battery voltage (no load) is at minimum 12.8 volts (12.5 volts with the key ON). If necessary, connect a battery charger to bring voltage level above minimum.

• Use a Dedicated PC for Diagnostics Only – Best results are obtained using a PC that is

dedicated to Digital Wrench® diagnostics only. Running Digital Wrench® software on a PC that includes other non-essential programs might affect the software performance.

– Make sure the PC is plugged in and charging

before you attempt to reprogram.

– Avoid using the PC while reprogramming is in

progress.

• Understand the Process

Review the Digital Wrench® System Help before you attempt to reprogram. See “Digital Wrench® Software Overview” for information on how to access the System Help.

REPROGRAMMING (REFLASH) PROCEDURE

1. Verify the most current version of the Digital Wrench®

software is installed on your PC.

2. Connect the SmartLink Module cables to your PC and

the vehicle.

3. Launch the Digital Wrench® software.

4. Select the ‘Change Vehicle’ menu icon.

5. Select the Year, Product Line, and Description.

6. Select the ‘Special Tests’ menu icon.

7. Select Engine Controller Reprogramming from the Special Tests menu.

8. Follow the on-screen prompts to perform the reflash.

9. Copy the Request Code in Digital Wrench®.

10.Open a web browser and log on to your Polaris dealer website (www.polarisdealers.com).

11. From the Service and Warranty drop-down, select Digital Wrench, and then click Reflash Authorization.

12.Paste the Request Code from Digital Wrench® into the field provided on the Reflash Authorization site and click Continue.

13.Continue to follow the on-screen prompts.

14.Copy and paste the Authorization Key into the field provided in Digital Wrench® and click Continue.

15.Once the reflash is complete, click Finish. Then verify the reflash worked by starting the vehicle.

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POLARIS MOBILE DIGITAL WRENCH® (PMDW)

Polaris Mobile Digital Wrench® (PMDW) is a diagnostic software application (app) designed specifically for Android™ devices. When paired with the Wireless Vehicle Link (WVL) (PU-51435), the PMDW app provides many of the same features and functions as the Digital Wrench® software.

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You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download.

MINIMUM SPECIFICATIONS FOR ANDROID DEVICES

• Minimum operating system: Android 3.1 “Honeycomb” or higher (Android 4.0 or higher preferred)

NOTICE

The PMDW app will not work on Microsoft Windows 8™

or Apple IOS™ products.

GENERAL INFORMATION

• Dual core processor / 2 GB internal memory / external micro SD (32 or 64 GB) slot / 500 MB RAM

• Rear facing camera with minimum 3.0 mega pixel resolution with auto / continuous focus

• Video, microphone, and voice-to-text capable

• Internet and Bluetooth wireless technology capable

• Device must be set to allow the installation of nonmarket applications

ADDITIONAL INFORMATION

• An electronic user’s guide is provided within the PMDW app. To access the user’s guide, launch the app, and then click “Help” under the Settings / Preferences menu.

• Only CAN-based vehicles are compatible with the PMDW app and the WVL. See the user’s guide for a complete list of compatible vehicles.

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GENERAL INFORMATION

ENGINE ELECTRICAL DIAGNOSTICS

DIAGNOSTIC TROUBLE CODES OVERVIEW

NOTICE

The diagnostic mode is accessible only when the check

If there is a diagnostic problem with the power steering

system, the power steering MIL will illuminate and blink

Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

If the CHECK ENGINE lamp or the EPAS lamp illuminates, retrieve the active error codes from the display.

1. Press and hold the MODE button to enter the settings menu.

2. Press either toggle button to cycle to the “DIAGCODE” option. Press MODE to select.

3. More than one diagnostic code may be present. Press the toggle UP button to see if more codes are present. Press MODE to select a code.

4. Record the three numbers displayed.

engine MIL has been activated.

in place of the check engine MIL.

• The first number (located top) can be 1 to 2 digits in

length. This number equates to the fault mode (FMI).

• The second number (located middle) can be 2 to 6

digits in length. This number equates to the suspected area of fault (SPN).

• The third number (located bottom) can range from

0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present).

5. Press MODE to exit to the settings menu.

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GENERAL INFORMATION

MASTER TROUBLE CODE LIST

IMPORTANT

Not all codes that are listed in this chart will be applicable to all vehicles. For vehicle specific codes, and pin-point

testing. Please refer to Digital Wrench for more information.

SPN COMPONENT

29 Accelerator Position 2

51 Throttle Position Sensor 1

91 Accelerator Position 1

100

102 Manifold Absolute Pressure Sensor

Parking Brake Switch

Vehicle Speed Sensor

Fuel Level Signal

Engine Oil Level Sensor/Switch

Engine Oil Pressure

FMI CONDITION CODE

0 Data Valid But Above Normal Operational Range P350A

2 Not Plausible P1225

3 Voltage Too High P1228

4 Voltage Too Low P1227

0 Data Valid But Above Normal Operational Range P1123

1 Data Valid But Below Normal Operational Range P1122

2 Signal Out of Range P0121

3 Voltage Too High P0123

4 Voltage Too Low P0122

10 Abnormal Rate Of Change P0120

13 Out Of Calibration P1120

19 Received Network Data In Error U25CD

0 Data Valid But Above Normal Operational Range P0500 / C1704 / C1057

1 Data Valid But Below Normal Operational Range P0502

2 Data Erratic or Intermittent (or missing) P0503 / C1058

3 Voltage Too High P1507

4 Voltage Below Normal, Or Shorted To Low Source P1506

8 Abnormal Frequency Or Pulse Width Or Period P0501

9 Abnormal Update Rate P160A

10 Abnormal Rate Of Change C1068 / C1705

12 Bad Intelligent Device Or Component P3503

19 Received Vehicle Speed Has Error P106B / C1069 / P306B

3 Voltage Too High P0228

4 Voltage Too Low P0227

2 Data Erratic, Intermittent Or Incorrect P0461

3 Voltage Above Normal, Or Shorted To High Source P0463

4 Voltage Too Low P0462

16 Data Valid But Above Normal Operating Range P1462

18 Data Valid But Below Normal Operating Range P1463

3 Voltage Above Normal, Or Shorted To High Source P1527

4 Voltage Too Low P1526

17 Data Valid But Below Normal Operating Range - Least Severe Level P250F

1 Data Valid But Below Normal Operational Range - Most Severe Level P1524

2 Data Erratic, Intermittent Or Incorrect P3021

5 Current Below Normal Or Open Circuit P1521

12 Bad Intelligent Device Or Component P3020

17 Data Valid But Below Normal Operating Range - Least Severe Level P0524

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

2 Data Erratic, Intermittent Or Incorrect P0106

3 Voltage Above Normal, Or Shorted To High Source P0108

4 Voltage Too Low P0107

7 Mechanical System Not Responding Or Out Of Adjustment P1106

P1523

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GENERAL INFORMATION

SPN COMPONENT

Intake Air Temperature Sensor (T-

105

106 Intake Air Pressure Sensor

107

108 Barometric Pressure Sensor

110

157 Fuel Rail Pressure Sensor

158

162

167

Engine Air Filter 1 Differential

Alternator Power Supply Potential

MAP)

Pressure Sensor

Engine Temperature Sensor

Battery Potential

Transmission Range

FMI CONDITION CODE

10 Abnormal Rate Of Change P0109

0 Data Valid But Above Normal Operational Range - Most Severe Level P1111

2 Data Erratic, Intermittent Or Incorrect P0111

3 Voltage Too High P0113

4 Voltage Too Low P0112

10 Abnormal Rate Of Change P0114

15 Data Valid But Above Normal Operating Range P0127

0 Data Valid But Above Normal Operational Range P110B

1 Data Valid But Below Normal Operational Range P110A

2 Data Erratic, Intermittent Or Incorrect P1109

3 Voltage Too High P1108

4 Voltage Too Low P1107

0 Data Valid But Above Normal Operational Range - Most Severe Level P1280

2 Data Erratic, Intermittent Or Incorrect P1284

3 Voltage Above Normal, Or Shorted To High Source P1282

4 Voltage Too Low P1283

7 Mechanical System Not Responding Or Out Of Adjustment P1286

10 Abnormal Rate Of Change P1285

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

2 Data Erratic, Intermittent Or Incorrect P2227

3 Voltage Above Normal, Or Shorted To High Source P2229

4 Voltage Below Normal, Or Shorted To Low Source P2228

10 Abnormal Rate Of Change P2230

0 Engine Overheat Shutdown P1217

2 Data Erratic, Intermittent Or Incorrect P0116

3 Voltage Too High P0118

4 Voltage Too Low P0117

10 Abnormal Rate Of Change P0119

15 Data Valid But Above Normal Operating Range P1116

16 Temperature Too High P0217

17 Data Valid But Below Normal Operating Range P0128

19 Received Network Data In Error U25C6

2 Data Erratic, Intermittent Or Incorrect P0194

3 Voltage Above Normal, Or Shorted To High Source P0193

4 Voltage Below Normal, Or Shorted To Low Source P0192

5 Current Below Normal Or Open Circuit P0197

15 Data Valid But Above Normal Operating Range - Least Severe Level P0199

17 Data Valid But Below Normal Operating Range - Least Severe Level P0195

3 Voltage Above Normal, Or Shorted To High Source P1567

4 Voltage Below Normal, Or Shorted To Low Source P1566

2 Invalid U108D

0 Data Valid But Above Normal Operational Range - Most Severe Level P1570

1 Data Valid But Below Normal Operational Range - Most Severe Level P1572

3 Voltage Above Normal, Or Shorted To High Source P1569

4 Voltage Below Normal, Or Shorted To Low Source P1568

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

P1281

P1571

P1573

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SPN COMPONENT

168

171

173

175

190

400

523

525

527 Cruise Control Panel Switches

563 ABS active

597 Brake Switch

627

628

630 Calibration 19 Checksum/CRC Error C1074

634 Idle Air Control

636 Crankshaft Position Sensor

637 Camshaft Position Sensor

645 Tachometer Driver Circuit

System Power

Ambient Air Temperature

Exhaust Temperature Sensor

Oil Temperature Sensor

Engine Speed

Gear Sensor Signal

Transmission Requested Gear

System Voltage

ECU Memory

FMI CONDITION CODE

1 Data Valid But Below Normal Operational Range - Most Severe Level P1563

2 Data Erratic, Intermittent Or Incorrect P0561

3 Voltage Too High C1063 / P0563 / C1820

4 Voltage Too Low P0562

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

19 Received Network Data In Error U25C7

0 Data Valid But Above Normal Operational Range - Most Severe Level P1517

3 Voltage Above Normal, Or Shorted To High Source P0546

4 Voltage Below Normal, Or Shorted To Low Source P0545

10 Abnormal Rate Of Change P1546

2 Data Erratic, Intermittent Or Incorrect P3096

12 Bad Intelligent Device Or Component P3097

0 Data Valid But Above Normal Operational Range - Most Severe Level P0219 / C1059

1 Data Valid But Below Normal Operational Range - Most Severe Level C1060

2 Data Erratic, Intermittent Or Incorrect C1061

7 Mechanical System Not Responding Or Out Of Adjustment P1219

19 Received Engine Speed Has Error P3219 / C1066

31 Error in Engine Speed Computation P121C

Error in Engine Speed Computation

2 Data Erratic, Intermittent Or Incorrect P0914

3 Voltage Above Normal, Or Shorted To High Source P0917

4 Voltage Too Low P0916

9 Abnormal Update Rate P1914

11 Root Cause Not Known P0915

19 Received Network Data In Error U255C

31 Condition Exists P153D

19 Received Network Data In Error U25C9

2 Data Erratic, Intermittent Or Incorrect C0040

9 Abnormal Update Rate C1240

10 Abnormal Rate Of Change C2453

19 Received Network Data In Error C1340

15 Data Valid But Above Normal Operating Range - Least Severe Level P2504

17 Data Valid But Below Normal Operating Range - Least Severe Level P2503

12 Bad Intelligent Device Or Component P1602 / C1073

13 Out Of Calibration P0601 / C1601

3 Voltage Above Normal, Or Shorted To High Source P0509

4 Voltage Below Normal, Or Shorted To Low Source P0508

5 Current Below Normal Or Open Circuit P0505

7 Mechanical System Not Responding Or Out Of Adjustment P0519

13 Out Of Calibration P1300

2 Plausibility Fault P0335

8 Abnormal Frequency Or Pulse Width Or Period P0336

7 Mechanical System Not Responding Or Out Of Adjustment P0016

8 Abnormal Frequency Or Pulse Width Or Period P0340

3 Voltage Above Normal, Or Shorted To High Source P1739

P1564

P1565

P121D

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GENERAL INFORMATION

SPN COMPONENT

651

652

677 Starter Solenoid Driver Circuit

731 Knock Sensor 1

746

876

905

906

907

Injector 1 (MAG)

Injector 2 (PTO)

Rear Differential Output (Turf)

AC Compressor Clutch Relay

Wheel Speed Sensor (Front Left)

Wheel Speed Sensor (Front Right)

Wheel Speed Sensor (Rear or

Rear Left)

FMI CONDITION CODE

4 Voltage Below Normal, Or Shorted To Low Source P1738

5 Current Below Normal Or Open Circuit P1737

4 Voltage Below Normal / Shorted To Low Source / Driver Circuit

Grounded.

5 Current Below Normal / Open Circuit / Driver Circuit Open / Grounded P0261

3 Voltage Above Normal, Or Shorted To High Source / Driver Circuit Short

to B+

4 Voltage Below Normal, Or Shorted To Low Source / Driver Circuit

Grounded

5 Current Below Normal Or Open Circuit / Driver Circuit Open / Grounded P0264

3 Voltage Above Normal, Or Shorted To High Source P0617

4 Voltage Below Normal, Or Shorted To Low Source P0616

5 Current Below Normal Or Open Circuit P0615

1 Data Valid But Below Normal Operational Range - Most Severe Level P0326

2 Data Erratic, Intermittent Or Incorrect P0325

3 Voltage Above Normal, Or Shorted To High Source P0328

4 Voltage Below Normal, Or Shorted To Low Source P0327

3 Driver Circuit Short to B+ P1692

4 Driver Circuit Grounded P1693

5 Driver Circuit Open / Grounded P1691

3 Voltage Above Normal, Or Shorted To High Source P0647

4 Voltage Below Normal, Or Shorted To Low Source P0646

5 Current Below Normal Or Open Circuit P0645

2 Data Erratic, Intermittent Or Incorrect C1131

3 Voltage Above Normal, Or Shorted To High Source C1231

4 Voltage Below Normal, Or Shorted To Low Source C1331

5 Current Below Normal Or Open Circuit C1631

6 Current Above Normal Or Grounded Circuit C1B31

7 Mechanical System Not Responding Or Out Of Adjustment C1731

8 Abnormal Frequency Or Pulse Width Or Period C1431

10 Abnormal Rate Of Change C1831

14 Special Instructions C1531

20 Data Drifted High C1931

21 Data Drifted Low C1A31

31 Condition Exists C0032

2 Data Erratic, Intermittent Or Incorrect C1034

3 Voltage Above Normal, Or Shorted To High Source C1134

4 Voltage Below Normal, Or Shorted To Low Source C1234

5 Current Below Normal Or Open Circuit C1634

6 Current Above Normal Or Grounded Circuit C1B34

7 Mechanical System Not Responding Or Out Of Adjustment C1734

8 Abnormal Frequency Or Pulse Width Or Period C1334

10 Abnormal Rate Of Change C1834

14 Special Instructions C1434

20 Data Drifted High C1934

21 Data Drifted Low C1A34

31 Condition Exists C1C34

2 Data Erratic, Intermittent Or Incorrect C103D

3 Voltage Above Normal, Or Shorted To High Source C113D

4 Voltage Below Normal, Or Shorted To Low Source C123D

P1262

P0265

P1265

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GENERAL INFORMATION

SPN COMPONENT

Wheel Speed Sensor (Rear Right)

908

1071

1127 Boost Pressure Sensor

1268

1269

1321 Starter Enable Circuit

1347

1352

1353

1485

1557 Fan Driver 2

Fan Relay Driver Circuit

Ignition Coil Primary Driver 1

(MAG)

Ignition Coil Primary Driver 2 (PTO)

Fuel Pump Driver Circuit

Knock Level Cylinder 1 (MAG)

Knock Level Cylinder 2 (PTO)

EFI Relay Control Circuit

FMI CONDITION CODE

5 Current Below Normal Or Open Circuit C163D

6 Current Above Normal Or Grounded Circuit C1B3D

7 Mechanical System Not Responding Or Out Of Adjustment C173D

8 Abnormal Frequency Or Pulse Width Or Period C133D

10 Abnormal Rate Of Change C183D

11 Root Cause Not Known C2429

14 Special Instructions C143D

20 Data Drifted High C193D

21 Data Drifted Low C1A3D

31 Condition Exists C1C3D

2 Data Erratic, Intermittent Or Incorrect C1047

5 Current Below Normal Or Open Circuit C1647

6 Current Above Normal Or Grounded Circuit C1B47

7 Mechanical System Not Responding Or Out Of Adjustment C1747

10 Abnormal Rate Of Change C1847

20 Data Drifted High C1947

21 Data Drifted Low C1A47

31 Condition Exists C1C47

3 Voltage Above Normal P1482

4 Voltage Below Normal P1483

5 Current Below Normal Or Open Circuit P1481

0 Data Valid But Above Normal Operational Range P0234

2 Data Erratic, Intermittent Or Incorrect P0236

3 Voltage Above Normal P0238

4 Voltage Below Normal P0237

31 Condition Exists P1234

3 Voltage Above Normal P1353

4 Voltage Below Normal P1361

5 Current Below Normal Or Open Circuit P1351

3 Voltage Above Normal P1354

4 Voltage Below Normal P1362

5 Current Below Normal Or Open Circuit P1352

3 Voltage Above Normal P1617

4 Voltage Below Normal P1616

5 Current Below Normal Or Open Circuit P1615

3 Voltage Above Normal P0232

4 Voltage Below Normal P0231

5 Current Below Normal Or Open Circuit P0230

8 Abnormal Frequency Or Pulse Width Or Period P0233

0 Data Valid But Above Normal Operational Range P1336

16 Data Valid But Above Normal Operating Range P2336

0 Data Valid But Above Normal Operational Range P1337

16 Data Valid But Above Normal Operating Range P2337

3 Voltage Above Normal P0687

4 Voltage Below Normal P0686

5 Current Below Normal Or Open Circuit P0685

3 Voltage Above Normal P0694

4 Voltage Below Normal, Or Shorted To Low Source P0693

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GENERAL INFORMATION

SPN COMPONENT

1809 Lateral Acceleration Sensor

Longitudinal Acceleration Sensor

1810

1888 PTO Solenoid Driver Circuit

2584 Brake Pressure Switches

2590

2596

2629

3056

3057

3597

3598

3599

Vehicle Speed

Speed Key Selected Maximum

Vehicle Speed Limit Message

Engine Turbocharger 1

Compressor Outlet Temperature

Oxygen Sensor Bank 1 Sensor 1

Oxygen Sensor Bank 1 Sensor 2

ECU Output Supply Voltage 1

ECU Output Supply Voltage 2

ECU Output Supply Voltage 3

FMI CONDITION CODE

5 Current Below Normal Or Open Circuit P0481

13 Out Of Calibration C1261

19 Received Network Data In Error U25CA

20 Data Drifted High C1161

7 Mechanical System Not Responding Or Out Of Adjustment C1362

13 Out Of Calibration C1262

19 Received Network Data In Error U25CB

20 Data Drifted High C1162

3 Voltage Above Normal, Or Shorted To High Source P1311

4 Voltage Below Normal, Or Shorted To Low Source P1312

5 Current Below Normal Or Open Circuit P1310

3 Voltage Above Normal, Or Shorted To High Source C2244

4 Voltage Below Normal, Or Shorted To Low Source C2044

13 Out Of Calibration C1263

17 Data Valid But Below Normal Operating Range - Least Severe Level C2144

20 Data Drifted High C1164

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

19 Received Network Data In Error U255A

31 Condition Exists U2259

3 Voltage Above Normal, Or Shorted To High Source P1235

4 Voltage Below Normal, Or Shorted To Low Source P1236

2 Data Erratic, Intermittent Or Incorrect P0130

3 Voltage Above Normal, Or Shorted To High Source P0132

4 Voltage Below Normal, Or Shorted To Low Source P0131 / C1049

12 Bad Intelligent Device Or Component P113A

17 Data Valid But Below Normal Operating Range - Least Severe Level C2049

2 Data Erratic, Intermittent Or Incorrect P0136

3 Voltage Above Normal, Or Shorted To High Source P0138

4 Voltage Below Normal, Or Shorted To Low Source P0137

0 Data Valid But Above Normal Operational Range - Most Severe Level P16A3

1 Data Valid But Below Normal Operational Range - Most Severe Level P16A6

3 Voltage Above Normal, Or Shorted To High Source P16A2

4 Voltage Below Normal, Or Shorted To Low Source P16A1

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

0 Data Valid But Above Normal Operational Range - Most Severe Level P16AA

1 Data Valid But Below Normal Operational Range - Most Severe Level P16AC

3 Voltage Above Normal, Or Shorted To High Source P16A9

4 Voltage Below Normal, Or Shorted To Low Source P16A8

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

0 Data Valid But Above Normal Operational Range - Most Severe Level P17AC

1 Data Valid But Below Normal Operational Range - Most Severe Level P17AE

3 Voltage Above Normal, Or Shorted To High Source P17AA

4 Voltage Below Normal, Or Shorted To Low Source P17AB

P1500

P16A5

P16A7

P16AB

P16AD

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GENERAL INFORMATION

SPN COMPONENT

8014

65559 CAN1 Bus Hardware

65613

516125 CAN 1

516178

520129 ABS Low Pressure Feed Circuit 1

520130 ABS Low Pressure Feed Circuit 2

520131

520132

520133 ABS Internal Pressure Sensor

520134

520137

520140 ABS Internal ECU Failure

520141

520152

520153

520194

520198 Throttle Position Sensor 2

520201

520202

520203

520204 Fuel Correction Front

520205 Fuel Correction Rear

520206 Reverse Alarm

Battery Charger

ETC Accelerator Position Sensor

Correlation

Idle Engine speed

ABS Valve Relay

ABS Pressure Sensor Supply Out

of Range

ABS Motor Supply Failure

ABS Manually Disabled

CAN1 Bus Wiring

ABS Solenoid (Rear Left In)

ABS Solenoid (Rear Left Out)

Throttle Release Signal

Overheat Indicator Lamp

Canister Purge Valve

Front Wheel Back Drive (Active

Descent System)

FMI CONDITION CODE

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

18 Data Valid But Below Normal Operating Range - Moderately Severe

Level

31 Condition Exists P0762

11 Root Cause Not Known P1130 / U2101

31 Condition Exists C1130

2 Data Erratic, Intermittent Or Incorrect P1135

9 Abnormal Update Rate U25E9

19 Received Network Data In Error U25C0

31 Condition Exists C1012

31 Condition Exists C1013

12 Bad Intelligent Device Or Component C2420

31 Condition Exists C2423

2 Data Erratic, Intermittent Or Incorrect C2439

12 Bad Intelligent Device Or Component C2424

31 Condition Exists C2425

31 Condition Exists C2433

12 Bad Intelligent Device Or Component C2437

31 Condition Exists C2438

31 Condition Exists C1324

31 Condition Exists C1325

2 Data Erratic, Intermittent Or Incorrect P1553

3 Voltage Above Normal, Or Shorted To High Source P1555

4 Voltage Below Normal, Or Shorted To Low Source P1554

7 Mechanical System Not Responding Or Out Of Adjustment P1552

0 Data Valid But Above Normal Operational Range - Most Severe Level P1223

1 Data Valid But Below Normal Operational Range - Most Severe Level P1222

3 Voltage Above Normal, Or Shorted To High Source P0223

4 Voltage Below Normal, Or Shorted To Low Source P0222

10 Abnormal Rate Of Change P0220

13 Out Of Calibration P1220

3 Voltage Above Normal, Or Shorted To High Source P1656

4 Voltage Below Normal, Or Shorted To Low Source P1657

5 Current Below Normal Or Open Circuit P1655

3 Voltage Above Normal, Or Shorted To High Source P0443

4 Voltage Below Normal, Or Shorted To Low Source P0445

5 Current Below Normal Or Open Circuit P0444

3 Voltage Above Normal, Or Shorted To High Source P1686

4 Voltage Below Normal, Or Shorted To Low Source P1687

5 Current Below Normal Or Open Circuit P1685

15 Data Valid But Above Normal Operating Range - Least Severe Level P0172

17 Data Valid But Below Normal Operating Range - Least Severe Level P0171

15 Data Valid But Above Normal Operating Range - Least Severe Level P0175

17 Data Valid But Below Normal Operating Range - Least Severe Level P0174

2 Data Erratic, Intermittent Or Incorrect P1684

3 Voltage Above Normal, Or Shorted To High Source P1682

P17AD

P17AF

P0761

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GENERAL INFORMATION

SPN COMPONENT

520207 All Wheel Drive Control Circuit

520208

520211

520219

520220

520221

520222

520223

520224

520225

520226

520227

520228 Position Encoder Error

520229 Software Error

520230 IC CAN Communication with EPS

520231 EPS Power Save Condition

520252

520253

520254

520255

520256

520257

520260 ABS Motor

Chassis Relay

Idle Speed

Accessory Relay

Battery Charge Relay

Steering Over Current Shut Down

Steering Excessive Current Error

Steering Torque Partial Failure

Steering Torque Full Failure

EPS Inverter Temperature

EPS Communications Receive

Data Error

EPS CAN Communications

Transmit Error

ABS Solenoid (Rear or Right Rear

ABS Solenoid (Front or Front Left

ABS Solenoid (Front Right In)

ABS Solenoid (Front Right Out)

In)

Out)

In)

Out)

FMI CONDITION CODE

4 Voltage Below Normal, Or Shorted To Low Source P1683

5 Current Below Normal Or Open Circuit P1681

3 Voltage Above Normal, Or Shorted To High Source P1835

4 Voltage Below Normal, Or Shorted To Low Source P1834

5 Current Below Normal Or Open Circuit P1836

3 Voltage Above Normal, Or Shorted To High Source P1614

4 Voltage Below Normal, Or Shorted To Low Source P1613

5 Current Below Normal Or Open Circuit P1611

3 Voltage Above Normal, Or Shorted To High Source P0507

4 Voltage Below Normal, Or Shorted To Low Source P0506

3 Voltage Above Normal, Or Shorted To High Source P1647

4 Voltage Below Normal, Or Shorted To Low Source P1645

5 Current Below Normal Or Open Circuit P1646

3 Voltage Above Normal, Or Shorted To High Source P163D

4 Voltage Below Normal, Or Shorted To Low Source P163A

5 Current Below Normal Or Open Circuit P163C

6 Current Above Normal Or Grounded Circuit C1050

12 Bad Intelligent Device Or Component C102E

6 Current Above Normal Or Grounded Circuit C1051

31 Condition Exists C1052

31 Condition Exists C1053

0 Data Valid But Above Normal Operational Range - Most Severe Level C1055

12 Bad Intelligent Device Or Component C102F

16 Data Valid But Above Normal Operating Range - Moderately Severe

Level

2 Data Erratic, Intermittent Or Incorrect U0100

31 Condition Exists C1067

2 Data Erratic, Intermittent Or Incorrect U1100

11 Root Cause Not Known C1065

12 Bad Intelligent Device Or Component C106A

31 Condition Exists C106B

12 Bad Intelligent Device Or Component C1070

31 Condition Exists C106F

31 Condition Exists U0131

31 Condition Exists C1071

5 Current Below Normal Or Open Circuit C1024

31 Condition Exists C1330

5 Current Below Normal Or Open Circuit C1025

31 Condition Exists C1332

5 Current Below Normal Or Open Circuit C1026

31 Condition Exists C1326

5 Current Below Normal Or Open Circuit C1027

31 Condition Exists C1327

5 Current Below Normal Or Open Circuit C1028

31 Condition Exists C1328

5 Current Below Normal Or Open Circuit C1029

31 Condition Exists C1329

3 Voltage Above Normal, Or Shorted To High Source C1020

C1054

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GENERAL INFORMATION

SPN COMPONENT

520262

520264 ABS/Brake Controller ECU

520265 ABS Module

520266

520272

520273

520275

520276

520277

520278

520279

520280

520281

520282

520283

520284

520285

520286

520287

520288

520289

ABS/Brake Controller Source

Voltage

ABS Brake Switch (Front/Rear)

Glow Plug Relay Driver Circuit

Fuel Pull Solenoid Relay Driver

Circuit (Low Side)

Accelerator Position/Brake Position

Throttle Body Control - Limp Home

Throttle Body Control - Mechanical

ECU Monitoring of Injection Cut Off

Interaction

Throttle Position Sensor (1 or 2

Indeterminable)

Throttle Body Control - Power

Throttle Body Control - Return

Throttle Body Control - Adaption

Throttle Body Control - Repeated

Throttle Body Control - Position

ECU Monitoring Error (Level 3)

Stage

Spring Check Failed

Aborted

Position Check Failed

Stop Adaptation Failure

Adaptation Failed

Throttle Body Control

Deviation Fault

Brake Switch (1 or 2

Indeterminable)

ECU Monitoring Error

(Level 1)

(Level 2)

FMI CONDITION CODE

4 Voltage Below Normal, Or Shorted To Low Source C1021

6 Current Above Normal Or Grounded Circuit C101E

7 Mechanical System Not Responding Or Out Of Adjustment C0020

8 Abnormal Frequency Or Pulse Width Or Period C101F

12 Bad Intelligent Device Or Component C101C

0 Data Valid But Above Normal Operational Range - Most Severe Level C2422

1 Data Valid But Below Normal Operational Range - Most Severe Level C2421

3 Voltage Above Normal, Or Shorted To High Source C1039 / C1241

4 Voltage Below Normal, Or Shorted To Low Source C1038

12 Bad Intelligent Device Or Component C1041

12 Bad Intelligent Device Or Component C1243

13 Out Of Calibration C1141

7 Mechanical System Not Responding Or Out Of Adjustment C1042

3 Voltage Above Normal, Or Shorted To High Source C1044

5 Current Below Normal Or Open Circuit C1043

3 Voltage Above Normal, Or Shorted To High Source P1384

4 Voltage Below Normal, Or Shorted To Low Source P1383

5 Current Below Normal Or Open Circuit P1385

3 Voltage Above Normal, Or Shorted To High Source P125D

4 Voltage Below Normal, Or Shorted To Low Source P125C

5 Current Below Normal Or Open Circuit P125A

31 Condition Exists P150A / U1007

2 Data Erratic, Intermittent Or Incorrect P150C

12 Bad Intelligent Device Or Component P150B

2 Data Erratic, Intermittent Or Incorrect P151A

3 Voltage Above Normal, Or Shorted To High Source P150D

4 Voltage Below Normal, Or Shorted To Low Source P150E

8 Abnormal Frequency Or Pulse Width Or Period P151B

31 Condition Exists P153F

31 Condition Exists P151C

31 Condition Exists P151D

31 Condition Exists P151E

31 Condition Exists P152A

31 Condition Exists P152B

2 Data Erratic, Intermittent Or Incorrect P152F

3 Voltage Above Normal, Or Shorted To High Source P152C

4 Voltage Below Normal, Or Shorted To Low Source P152D

31 Condition Exists P152E

2 Data Erratic, Intermittent Or Incorrect P153E

31 Condition Exists P1540

31 Condition Exists P1541

31 Condition Exists P1542

31 Condition Exists P1543

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GENERAL INFORMATION

SPN COMPONENT

520305

520306 ECU ADC Fault - No Load

520307

520308

520309 ECU Fault - ICO

520311

520331 Knock Sensor Positive Line

520332

520341

520342 Idle Fuel Correction Bank 1

520343 Idle Fuel Correction Bank 2

520344

520376

520381

520496

520498 Stator

520513 Motor Controller Encoder

520514

520515

520516

520517 Motor Controller

520518 Motor Controller Contactor

520519

520520 BMC CAN Communication

520522

524067 Drive Mode Select Switch

524070

Throttle Body Control - Requested

Throttle Angle Not Plausible

ECU ADC Fault - Voltage

Accelerator Sensor Sync Fault -

Sensor Diff Exceeds Limit

ECU Fault - Hardware Disruption

Knock Sensor Negative Line

Wastegate Solenoid Driver

Adaptive Fuel Correction Bank 1

Internal fault - Chassis Output

Disabled

Non Functional Application SW

Motor Controller Speed Sensor

Installed

Intercooler Pump Driver Circuit

Motor Controller Temperature

Sensor

Electric Motor Temperature

Motor Controller Temperature

Display Relay

Operator Presence Switch

FMI CONDITION CODE

31 Condition Exists P1530

31 Condition Exists P1531

31 Condition Exists P1532

31 Condition Exists P1533

31 Condition Exists P1534

31 Condition Exists P1537

3 Voltage Above Normal, Or Shorted To High Source P1327

4 Voltage Below Normal, Or Shorted To Low Source P1328

3 Voltage Above Normal, Or Shorted To High Source P132A

4 Voltage Below Normal, Or Shorted To Low Source P132B

3 Voltage Above Normal, Or Shorted To High Source P0243

4 Voltage Below Normal, Or Shorted To Low Source P0246

5 Current Below Normal Or Open Circuit P0245

15 Data Valid But Above Normal Operating Range - Least Severe Level P116C

15 Data Valid But Above Normal Operating Range - Least Severe Level P116E

17 Data Valid But Below Normal Operating Range - Least Severe Level P116F

15 Data Valid But Above Normal Operating Range - Least Severe Level P0170

17 Data Valid But Below Normal Operating Range - Least Severe Level P1170

31 Condition Exists P1618

31 Condition Exists C1681

3 Voltage Above Normal, Or Shorted To High Source P107D

4 Voltage Below Normal, Or Shorted To Low Source P107C

5 Current Below Normal Or Open Circuit P107E

4 Voltage Below Normal, Or Shorted To Low Source P1510

5 Current Below Normal Or Open Circuit P1511

2 Data Erratic, Intermittent Or Incorrect P1140 / P1368

31 Condition Exists P1141 / P1369

3 Voltage Above Normal, Or Shorted To High Source P1142 / P1165

4 Voltage Below Normal, Or Shorted To Low Source P1143 / P1166

31 Condition Exists P1144 / P1167

0 Data Valid But Above Normal Operational Range - Most Severe Level P1145 / P1168

4 Voltage Below Normal, Or Shorted To Low Source P1B0D / P1169

0 Data Valid But Above Normal Operational Range - Most Severe Level P1146 / P116A

3 Voltage Above Normal, Or Shorted To High Source P1147 / P1184

6 Current Above Normal Or Grounded Circuit P1148 / P1185

12 Bad Intelligent Device Or Component P1149 / P1186

19 Received Network Data In Error P1150 / P1187

5 Current Below Normal Or Open Circuit P1151 / P1177

6 Current Above Normal Or Grounded Circuit P1152 / P1178

31 Condition Exists P1153 / P116B

31 Condition Exists P0754

5 Current Below Normal Or Open Circuit P3038

2 Data Erratic, Intermittent Or Incorrect P153C

3 Voltage Above Normal, Or Shorted To High Source P153A

4 Voltage Below Normal, Or Shorted To Low Source P153B

3 Voltage Above Normal, Or Shorted To High Source P251C

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GENERAL INFORMATION

SPN COMPONENT

524075

524076

524085

524086

Hydraulic Oil Pressure Sensor/

Engine Oil Pressure Sensor/Switch

EPS Fault Lamp Driver Circuit

Switch

EPS SEPIC Voltage Error

FMI CONDITION CODE

17 Data Valid But Below Normal Operating Range - Least Severe Level P150F

17 Data Valid But Below Normal Operating Range - Least Severe Level P151F

12 Bad Intelligent Device Or Component C106C

3 Voltage Above Normal, Or Shorted To High Source C106D

4 Voltage Below Normal, Or Shorted To Low Source C106E

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GENERAL INFORMATION

CYLINDER MISFIRE DETECTION

NOTICE

This process only applies to some MY15 and later

models.

Refer to this procedure only if one of the codes shown

below is displayed in Digital Wrench.

The ECU monitors crankshaft speed via the crankshaft position sensor. A misfire will cause a fluctuation in crankshaft speed. A code will set and turn on the check engine light after an engine misfire threshold/rate is detected that is above a pre-determined limit. This threshold varies based on engine speed.

One or more of the following codes will be set if a misfire occurs:

• P0301 (SPN 65591/FMI 7) Misfire Detected, Cylinder

1 (MAG)

• P0302 (SPN 65592/FMI 7) Misfire Detected, Cylinder

2 (PTO)

• P0314 (SPN 65590/FMI 7) Misfire Detected, Cylinder

Not Identified

Once a cylinder misfire code is set, the following events will occur:

• Check Engine Light illuminates

• If the cylinder can be detected by the ECU (code

P0301 or P0302), the ECU will deactivate the fuel injector for that cylinder. This will remain in effect until the key is cycled off and back on.

• If the cylinder with the misfire cannot be detected

(code P0314), the ECU will limit available power by limiting how far the throttle plate opens.

If a misfire code has been set and there is no observed misfire, cycle the key and allow 4000 engine revolutions to see if the check engine light turns off. If it does not turn off, diagnose by verifying the following items:

• Low battery voltage (loose connection, low charge, bad battery)

• Faulty voltage regulator

• Ignition Coil and connections are good

• Spark plugs wires are secure

• The correct spark plugs are installed and the plugs are not fouled

• Crankshaft Position Sensor tests good

• Wiring to the Crankshaft Position Sensor, ECU and Ignition Coil are not damaged. Chassis ground is clean and tight

• Fuel pressure is within specification

• Fresh/good quality fuel is in the fuel tank

• Engine mechanical is good (leak down, timing)

• Confirm the belt is in good condition, specifically looking for signs of hour-glassing

• Confirm primary clutch operation (worn/incorrect weights, loose spider/jam nut)

• Confirm secondary clutch operation (sliders, rollers, helix)

One the key is cycled, the trouble code(s) will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur. The check engine light will remain illuminated until there are 4000 engine revolutions (i.e. 4000 RPM for one minute) without a significant misfire being detected. Once this condition is met, the check engine light will turn off and the code(s) will show as historic.

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GENERAL INFORMATION

FLUID LEAKS

Fluid leaks can apply to multiple different systems used in the vehicle. Leaks can be a common cause of concerns within these systems. Procedures that are used for checking leaks can apply to multiple systems.

When diagnosing fluid leaks, refer to the appropriate “Level Inspection” procedure, Fluid Inspection page 1.59, or the appropriate chapter in the Service Manual before proceeding with any repairs or parts replacement.

FLUID INSPECTION

OVERVIEW

Multiple vehicle systems will contain different fluids or lubricants within the system.

These fluids should be inspected for condition and level. Refer to Fluid Condition and the appropriate level check within the Service Manual for more information.

Most of these systems should be inspected for leaks using the same methods. Refer to Fluid Leak for more information.

FLUID LEAK

Perform the following inspection prior to replacement of any seals or gaskets.

1. Inspect the fluid level prior to any checks to verify that the system is currently leaking.

NOTICE

If the system is not low at this time, clean and continue to monitor. It is possible that the fluid is residual from

manufacturing or previous repairs.

2. Thoroughly clean the area using an appropriate cleaner (Brake cleaner, Throttle Body cleaner, Soap, etc.) prior to diagnosing the leak.

3. Operate the vehicle under the condition that the leak presented and re-inspect for leak.

4. Pinpoint location of leak. Check for any damage to parts and repair the leak as necessary.

NOTICE

If the leak can not be pin-pointed using this method, the leak may require dye to be added to the system, operated

and inspected for leaks using a UV light.

FLUID CONDITION

Refer to the appropriate “Level Check” procedure for the fluid being inspected. When the fluid is inspected it should be compared to NEW recommended replacement fluid.

INSPECTION ITEMS CAUSE

Inspect for the following:

• Unusual Color

• Unusual Odor

• Fluid Contamination

• The fluid has been contaminated with another fluid (cross-contamination, ex. Oil mixing with Coolant).

• Fluid overheated

• Natural fluid breakdown (replace fluid per recommended maintenance interval / fluid replacement procedure).

• If a fluid is contaminated with metal or debris, suspect that there is a mechanical failure causing the fluid contamination. Refer to the Service Manual information related to the system in question.

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GENERAL INFORMATION

FUEL SYSTEM DIAGNOSTICS

FUEL SYSTEM TROUBLESHOOTING

FUEL STARVATION / LEAN MIXTURE

SYMPTOMS CAUSES

• Hard start or no start

• Bog

• Backfire

• Popping through Intake / Exhaust

• Hesitation

• Detonation

• Low Power

• Spark plug erosion / fouling

• Engine runs hot

• Surging

• High / Erratic idle

RICH MIXTURE

SYMPTOMS CAUSES

• Hard start or no start

• Bog

• Backfire

• Popping through Intake / Exhaust

• Hesitation

• Detonation

• Low Power

• Spark plug erosion / fouling

• Engine runs hot

• Surging

• High / Erratic idle

• No fuel in tank

• Restricted tank vent, or routed improperly

• Fuel lines or fuel injectors restricted

• Fuel filter plugged

• Fuel pump inoperative

• Air leak in system

• Intake air leak (throttle shaft, intake ducts, air box cover)

• Faulty oxygen sensor

• No fuel in tank

• Restricted tank vent, or routed improperly

• Fuel lines or fuel injectors restricted

• Fuel filter plugged

• Fuel pump inoperative

• Air leak in system

• Intake air leak (throttle shaft, intake ducts, air box cover)

• Faulty oxygen sensor

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POOR IDLE

SYMPTOMS CAUSES

GENERAL INFORMATION

• Idle Too High (if > 1400 RPM when warm).

• Idle Too Low (if < 1100 RPM when warm). • Plugged air filter

• Erratic Idle • Throttle cable incorrectly adjusted

• Throttle stop screw tampering

• Throttle cable sticking, improperly adjusted, routed incorrectly

• Faulty electrical connection

• Leaking injector (rich condition)

• Belt dragging

• Throttle stop screw tampering

• Air Leaks, dirty injector

• TMAP damaged (check with Digital Wrench®)

• Tight valves (low compression or high leakdown)

• Ignition timing incorrect

• Belt dragging

• Dirty air filter

• High percentage of cylinder leakdown (worn engine)

• Low compression (worn engine)

• Spark plug(s) fouled

• Spark plug wires loose or worn

• Faulty electrical connection

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Page 68

GENERAL INFORMATION

PVT SYSTEM DIAGNOSTICS

PVT SYSTEM TROUBLESHOOTING

SITUATION PROBABLE CAUSE REMEDY

Engine RPM below specified operating range, although engine is properly tuned.

Erratic engine operating RPM during acceleration or load variations.

Engine RPM above specified operating range.

Harsh drive clutch engagement.

Drive belt turns over

Belt burnt, thin spots

Wrong or broken drive clutch spring. Replace with recommended spring.

Drive clutch shift weight too heavy.

Driven clutch spring broken or installed in wrong helix location.

Drive clutch binding.

Belt worn unevenly - thin / burnt spots.

Driven clutch malfunction.

Sheave face grooved.

Incorrect drive clutch spring (too high of rate).

Drive clutch shift weights incorrect for application (too light).

Drive clutch binding.

Driven clutch binding.

Converter sheaves greasy; belt slipage. Clean sheaves with denatured alcohol or brake

Drive belt worn too narrow. Replace belt.

Excessive belt / sheave clearance with new belt.

Wrong belt for application. Replace with correct belt.

Abuse (continued throttle application when vehicle is stationary, excess load)

Dragging brake Inspect brake system.

Slow, easy clutch engagement Fast, effective use of throttle for efficient

Install correct shift weight kit to match engine application.

Replace spring; refer to proper installation location.

Disassemble drive clutch; inspect shift weights for wear and free operation.

Clean and polish stationary shaft hub; reassemble clutch without spring to determine problem area.

Replace belt.

Replace ramp buttons.

Inspect movable sheave for excessive bushing clearance.

Replace the clutch.

Install correct recommended spring.

Install correct recommended shift weights.

Disassemble and clean clutch, inspecting shift weights and rollers. Reassemble without the spring and move sheaves through entire range to further determine probable cause.

Disassemble, clean, and inspect driven clutch, noting worn sheave bushing and ramp buttons and helix spring location.

cleaner, install new belt.

Perform belt / sheave clearance adjustment with shim washers beneath spider.

Caution operator to operate machine within guidelines.

engagement.

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SITUATION PROBABLE CAUSE REMEDY

PVT cover overheating (melting)

Water ingestion

Belt slippage

PVT noise

Engagement erratic or stabby

Plugged air intake or outlet.

Belt slippage due to water, oil, grease, etc., rubbing on cover.

Clutches or weight being applied to cover while in operation.

High vs. low range.

Cover seals or ducts leaking

Operator error

Belt worn out

Water ingestion Inspect and seal PVT system.

Belt contaminated with oil or grease Inspect and clean.

Belt worn or separated, thin spots, loose belt Replace belt.

Broken or worn clutch components, cover hitting clutches

Thin spots on belt, worn belt

Drive clutch bushings stick Inspect and repair clutches.

Clear obstruction

Inspect system. Clean , repair or replace as necessary. Seal PVT system ducts.

Remove weight. Inform operator.

Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s Safety and Maintenance Manual.

Find leak and repair as necessary.

Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and Maintenance Manual.

Replace belt.

Inspect and repair as necessary.

Replace belt. Refer to belt burnt troubleshooting and instruct operator.

GENERAL INFORMATION

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GENERAL INFORMATION

PVT SYSTEM OVERHEATING / DIAGNOSIS

During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet duct for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when extended low vehicle speed operation is anticipated.

CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

POSSIBLE CAUSES SOLUTIONS / WHAT TO DO

Loading the vehicle into a tall trailer when in high range.

Starting out going up a steep incline from a stopped position.

Driving at low RPM or low ground speed (at approximately 3-7 MPH).

Insufficient engine warm-up when exposed to low ambient temperatures.

Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.

Stuck in mud or snow.

Climbing over large objects from a stopped position.

Belt slippage from water or snow ingestion into the PVTsystem.

Clutch malfunction.

Poor engine performance.

GENERAL RANGE OPERATION GUIDELINES:

Shift transmission to Low during loading of the vehicle to prevent belt burning.

When starting out on an incline, use Low gear. Shift transmission to Low during loading of the vehicle to prevent belt burning.

Drive at higher speed or use Low. The use of Low is highly recommended for cooler PVT operating temperatures and longer component life.

Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.

Shift the transmission to Low, carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Shift the transmission to Low, carefully use fast, aggressive, brief throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Remove the PVT drain plug. Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to full throttle. Repeat several times as required. During this procedure, the throttle should not be held at the full position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs.

Clutch component inspection should be performed by a Polaris MSD certified technician.

Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel pump may cause symptoms similar to clutching malfunction.

Low: Basic operational speeds less than 7 MPH, riding through rough terrain (swamps, mountains, ect.), or low ground speeds and when continuously operating at speeds less than 30 mph in sand/dune environments.

High: High ground speeds, or speeds above 7 MPH.

Operating in Low Gear

Low gear should be used when riding through rough terrain or when basic operational ground speeds are less than 7 MPH. Use High gear when basic operational ground speeds are more than 7 MPH.

General Sand / Dune Driving

The use of Low gear when continuously operating at speeds less than 30 mph will greatly increase belt life in sand/ dune environments.

NOTICE

Do not shift from Low to High without coming to a complete stop.

Using High gear for heavy loads, hilly terrain, sand/dune environments, or in wet, muddy conditions will increase the

chance of drive belt burning.

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GENERAL INFORMATION

TRANSMISSION DIAGNOSTICS

HARD SHIFTING

SYSTEM DIAGNOSIS

Difficulty shifting, or harsh shifting are generally caused by the Transmission or PVT Systems. The system causing the difficult shifting concern can generally be diagnosed using the following information.

SYMPTOM CAUSE

Vehicle is difficult to shift ONLY with the engine running Refer to PVT System Chapter for more information

Vehicle is difficult to shift all the time Refer to Transmission Isolation this will help determine

if the concern is internal or external to the transmission. After isolation proceed with diagnosis.

ADDITIONAL HARD SHIFTING CAUSES

SHIFTING CAUSES

• Shift cable adjustment/condition

• PVT alignment (clutch center distance)

• Transmission lubricant type/quality

• Transmission leaks / fluid level

• Loose fasteners on sector gear cover

• Worn rod ends, clevis pins, or pivot arm bushings

• Shift selector rail travel

• Worn, broken or damaged internal transmission components

TRANSMISSION ISOLATION

To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the transmission should be isolated using the following information.

After the transmission is isolated refer to Additional Shifting Causes or the proper chapter in the service manual for additional information.

1. Disconnect the shift cable from the bellcrank.

2. With the shift cable disconnected from the transmission shift the vehicle using the shift lever.

• If the shift lever continues to bind the concern is likely caused by the shift cable. Refer to the proper service information for replacement.

• If the shift lever moves freely proceed to step 3.

3. With the shift lever disconnected manually select each gear range at the transmission bellcrank.

• If the bellcrank requires more than approximately 15 ft-lbs (20 N·m) to rotate, the shifting concern is most likely caused by an internal transmission concern.

• If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue.

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GENERAL INFORMATION

FINAL DRIVE DIAGNOSTICS

ALL WHEEL DRIVE (AWD) CONCERNS

All Wheel Drive (AWD) concerns are generally caused by a mechanical concern within the front gearcase, or electrical concern. The following chart will help finding the root cause and assist with basic checks of the front gearcase and AWD system. Refer to the proper chapter in the service manual for additional vehicle specific information.

SYMPTOM CAUSE

AWD stays engaged even when switch is OFF

• Rollers flat-spotted. Remove all and roll across a table to check for flat spots

• Inside of ring gear is dimpled from harsh engagement. Check the ramps and low spots inside ring gear. Should be smooth.

• Output Hub races are flat spotted/dimpled. Run your finger along the outer surface that goes inside of the cage. Should be uniform with no high points.

• Armature plate or coil magnetized. Rule out armature plate by putting it close to something metal to see if it tries to stick.

• Drivetrain wedged. Often caused by torsion spring coming out of place.

AWD Does not engage

• Roller cage is broken. Can typically find debris in the oil if drained

• No power to AWD coil. Jump power and ground directly to the coil and verify AWD function. If AWD functions this confirms an electrical issue is causing the concern. Verify fuses are in good condition and inspect the wiring harness for damage or broken wires. Check all connections for damaged pins or bad connection.

• Weak magnetism. With power and ground to the coil, armature plate should not be able to be pried off with fingers.

• Armature plate bent/damaged. Check flatness and look for uneven wear marks

• Prop shaft not turning at transmission snorkel shaft. Internal transmission damage

DRIVESHAFT (HALF SHAFT) DIAGNOSTICS

Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures

CLICK HERE to view the “Half Shaft Analysis” poster.

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GENERAL INFORMATION

BRAKE SYSTEM DIAGNOSTICS

BRAKE NOISE TROUBLESHOOTING

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust.

POSSIBLE CAUSE REMEDY

Spray disc and pads with CRC Brakleen™ or an

Dirt, dust, or imbedded material on pads or disc

Pad(s) dragging on disc due to:

Improper adjustment Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston(s) not returning Operator error (riding the brake)

Loose wheel hub or bearings

Brake disc warped or excessively worn Replace disc

Brake disc misaligned or loose Inspect and repair as necessary

Noise is from other source (axle, hub, disc or wheel)

equivalent non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads.

Adjust pad stop Set to proper level Clean compensating port Inspect. Repair as necessary Clean piston(s) seal Educate operator

Check wheel and hub for abnormal movement. Check axle nut torque. Inspect/replace bearing if needed.

If noise does not change when brake is applied check other sources. Inspect and repair as necessary

BRAKE VIBRATION

PEDAL / LEVER VIBRATION (VIBRATION IS ONLY FELT IN PEDAL OR LEVER WHILE BRAKING)

• Brake Disc worn (runout or thickness variance exceeds service limit)

• Brake Disc damaged

VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING)

• Worn Suspension components

• Brake Pad wear (uneven / unusual wear)

• Alignment issues

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GENERAL INFORMATION

CALIPER OVERHEATS (BRAKES DRAG)

• Compensating port plugged

• Pad clearance set incorrectly

• Parking brake lever incorrectly adjusted (If Equipped)

• Brake pedal or brake lever binding or unable to return fully

• Incorrect brake fluid level (Overfilled Fluid Reservoir)

POOR BRAKE PERFORMANCE

• Air in system

• Water in system (brake fluid contaminated)

• Caliper or disc misaligned

• Caliper dirty or damaged

• Brake line damaged or lining ruptured

• Worn disc and/or friction pads

BRAKES LOCK

• Parking brake left on (If Equipped)

• Residue build up under caliper seals

• Incorrect operation of brakes – Operator using the throttle and brakes at the same

time.

– Excessive use of the brakes.

• Incorrectly adjusted stationary pad

• Worn or damaged master cylinder or components

• Damaged brake pad noise insulator

• Brake pads dragging

• Brake caliper dragging

• Alignment of caliper to disc

• Caliper pistons sticking

• Failed master cylinder

1.68

• Failed brake hose / line

• Improper assembly of brake system components

• Faulty distribution block (INTL models only )

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GENERAL INFORMATION

STEERING / SUSPENSION DIAGNOSTICS

EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON)

IMPORTANT

READ BEFORE YOU REPLACE THE EPS UNIT!

Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS unit. If not, update

to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®.

Power Steering Non Functional, MIL is ON

↓

Cycle the ignition switch. Is MIL on?

↓

Is Battery Voltage >11 and <16VDC?

↓

Yes

Is EPS Fuse OK?

Yes ↓

12 VDC and GND across 2 Pin EPS Connector

12 VDC on Pin 3 of the 8 pin EPS Connector?

with Key On?

Yes

↓

→

There is no issue. MIL on due to 5-minute timeout. Verify code using Digital Wrench.

Determine cause of incorrect battery voltage and

repair

Replace EPS Fuse.

Check EPS Power Relay and Circuit

Check wiring from Connector to Ignition Switch

Circuit

↓

Yes

Begin Digital Wrench EPS Troubleshooting

Procedure

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GENERAL INFORMATION

EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF)

IMPORTANT

READ BEFORE YOU REPLACE THE EPS UNIT!

Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS unit. If not, update

to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®.

Power

Steering

Non Functional, MIL is OFF

↓

Determine

Is Battery

Voltage >11

and

<16VDC?

Yes

↓

→

cause of

incorrect

battery

voltage and

repair

Begin

Digital

Wrench

EPS

Trouble-

shooting

Procedure

←

Yes

Is EPS Fuse

OK?

Yes ↓

12 VDC and GND across

2 Pin EPS

Connector

with Key

On?

Yes ↓

12 VDC on Pin 3 of the

8 pin EPS

Connector?

Yes ↓

EPS MIL

turns on

during

Instrument

Cluster Power Up Self Test?

→

Replace

EPS Fuse.

Check EPS

Power

Relay and

Circuit

Check

wiring from

Connector

to Ignition

Switch

Circuit

MIL Lamp

should

come on

briefly

during

Instrument

Cluster

Power Up.

→

Instrument

Cluster EPS

MIL lamp

OK?

→

Trouble-

shoot per

“Non

Functional

and MIL

ON”

1.70

↑

← ← ←

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Page 77

EPS TROUBLESHOOTING (USING DIGITAL WRENCH®)

Troubleshooting

Procedure Advises

Digital Wrench

↓

Connect Digital Wrench

to Diagnostic Connector

↓

Turn key to “On”Position

Is Digital Wrench able to

establish a connection to

→

Follow Digital Wrench

instructions

EPS?

→

Yes

↓ ↓

Trace/Repair CAN bus

wiring and ignition power

↓ Yes ↓

Replace Power Steering

Module if any of the Error

codes are present from

Table 1.

Perform further testing if Error Codes are present

from Table 2.

→

wires

GENERAL INFORMATION

Check wire harness for damaged/shorted CAN

→

←

bus wires. Repair or

replace harness if

necessary

Is DW able to establish a

connection to the ECM?

Replace EPS

TABLE 1

• Position Encoder Error

• EPS Software Error

• Steering Torque Sensor Full Failure

• Steering Excessive Current Error*

• Steering Over Current Shutdown*

• Phase Sensing Over Current

• Phase Sensing Excessive Current

• Torque Sensor Range

• Rotor Encoder Communication

• Rotor Encoder Variance

• SEPIC Voltage Low/High

• EEPROM Failure

*These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit.

TABLE 2

• EPS Inverter Temperature Test

1. Verify that the Power Steering module heat sink surface (top surface) is clean and free of mud and dirt. Make a note of how much debris was on heat sink before cleaning. Record all power steering error codes. EPS inverter temperature can be monitored through Digital Wrench.

2. Allow vehicle to set and cool for at least 2 hours.

3. Drive vehicle for 30 minutes of left and right turning and then connect to Digital Wrench and read Power Steering Error Codes. If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench.

• Battery Voltage Over / Under Test

1. Disconnect 2 pin power connector to EPS and verify battery voltage (12-14 VDC) is present on pins with key on. If voltage is low, investigate and correct cause. If voltage at pins is correct, cheak all connections for corrosion, damage, and tightness. Check pin 3 on 8 pin connector for 12V signal with key on.

• Calibration Error - Reflash EPS Unit

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Page 78

GENERAL INFORMATION

SHOCK ANALYSIS

Shock “misting”qor “weepage”wis common and should be present during normal vehicle operation. All Shock Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock. This thin film of oil lubricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod.

Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body (i.e. road conditions and operating temperature). It is important to properly identify the difference between normal operation (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock.

MISTING OR WEEPAGE LEAKAGE

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GENERAL INFORMATION

ELECTRICAL DIAGNOSTICS

ELECTRICAL SERVICE NOTES

Keep the following notes in mind when diagnosing an electrical problem.

• Refer to wiring diagram for stator and electrical component resistance specifications.

• When measuring resistance of a component that has a low resistance value (under 10 Ohms), remember to subtract meter lead resistance from the reading. Connect leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance.

• Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s Manual included with your meter.

• Voltage, amperage, and resistance values included in this manual are obtained with a Fluke™ 77 Digital Multimeter (PV-43568). This meter is acceptable for use when diagnosing electrical problems. Readings obtained with other meters may differ.

• Pay attention to the prefix on the meter reading (K, M, etc.) and the position of the decimal point.

• For resistance readings, isolate component to be tested. Disconnect wire harness or power supply.

DIGITAL MULTI-METER (DMM) NOTES

Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) for electrical testing.

Unless you are very familiar with Ohm’s Law, and have complete information about the circuit you are trying to diagnose, test lights are likely to provide results that would be misleading. This is especially true if any solid state component is involved, where you will almost certainly not have complete circuit information.

Polaris also specifically advises against the use of other circuit testing devices, including but not limited to:

• Short finders

• Simplified circuit testers

• Fuse piggy-back devices

Testers beside a DMM will only work in one scenario, and slight variables can provide you with misleading results. The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge.

STATIC AND DYNAMIC TESTING

There are many methods for testing a DC circuit. These methods fall into one of two categories, either static or dynamic.

STATIC TESTING

The two most common forms of static testing are:

• Resistance testing (the Ohms setting on your DMM)

• Measuring voltage with the circuit open, such as when the harness connector is off a sensor you are testing. This is commonly referred to as measuring “Available Voltage”.

These two tests will help you find the majority of electrical issues. If they do not, we must remember that static circuit testing does not take into account how current actually flows in that circuit. That is only accomplished with dynamic testing.

Before attempting dynamic testing (as it is intrusive on sealed connectors and damage could be done if not careful), verify the following:

• Static voltage testing advised for that circuit has been completed, and is in spec.

• All associated circuits have under 1 ohm of resistance from end to end. Testing Continuity / Resistance page

1.75

• All associated circuits have no shorts to ground. Testing For A Short To Ground page 1.75

• All associated circuits have no shorts to voltage. Testing For A Short To Voltage page 1.76

DYNAMIC TESTING

There are two types of dynamic testing we will advise to use when diagnosing electrical concerns:

• Current flow testing (Amperage) Testing Current Flow (Amperage) page 1.77. Measuring Amperage is not a common practice, as you will not typically have a spec to compare your reading to. Also, many components on this machine flow over 10 Amps, which will blow the majority of DMM fuses. The exception to this is a parasitic draw test refer to Current Draw - Key Off page 1.78.

• Measuring voltage drop. Performing this test correctly will give you understanding of how electrical pressure (voltage) varies in a circuit as current is flowing. Testing Voltage Drop page 1.78

1.73

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GENERAL INFORMATION

CONNECTOR PROBING GUIDELINES

FRONT PROBING

Front probing is accomplished by pulling the harness connector from the component, and then taking a measurement from the terminal face. This is the measurement taken in most situations.

The terminals in electrical connectors are small and fragile. Do not probe directly with your meter leads, as the meter leads are larger than almost all terminals. Probing with a meter lead will likely damage the terminal by spreading it beyond it’s design limits, causing no tension. If there is no tension, you will have either no connection or a poor connection.

To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris machines can be tested using terminal test kit PV–

43526. It includes male and female adapters that can be plugged into banana connectors to adapt to your meter.

For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.

BACK PROBING

Back probing is typically not advisable on sealed connectors, as it can easily cause damage to the wire, terminal, connector body, or body to wire seal.

NOTICE

There are commercially available back probe kits. Fine,

narrow needles with no coating to block current flow

also work well for back probing.

If back probing must be done to see voltage drop while current is flowing in the circuit (dynamic testing), ensure it is done only on connectors that are large enough to accommodate the probe. Ensure back probing is done gently and carefully. Ensure no damage has been done after probing.

For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.

PV–43526 adapters are also used as known good terminal drag testers. Insert the male tester terminal into the female connector on the harness. There should be a noticeable amount of force to install and remove the tester, and you should be able to tip the harness connector with the tester hanging from the connector, and not have the tester fall out.

If very little or no resistance is felt, or if the tester falls out when the connector is held upside down, this is an indication that the female connector in the harness has insufficient tension and will cause connection issues. You can either replace that harness, or service it by replacing the terminal or attempting to adjust/tighten the tang in the female terminal.

1.74

BREAK OUT

This is a method of front probing to achieve the goal of back probing, which is to measure the circuit while it is functioning.

You can use test probe kit PV–43526, test leads, and electrical tape to create a bridge with exposed testing areas to have everything exposed but still working.

IMPORTANT

Use electrical tape to cover the exposed conductive

parts of the circuit, mainly the clamps of your test leads.

If they contact each other, circuit or component damage

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

could occur from a short.

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GENERAL INFORMATION

TESTING CONTINUITY / RESISTANCE

Testing using the Ohmmeter function of your DMM is one of the first things you will do when troubleshooting an electrical issue. It is especially convenient when the wiring diagram provides a resistance spec for the component in the circuit you are diagnosing. It can quickly give you a good idea if you simply need to replace a part, or if there might be another circuit issue.

Using the following points in conjunction with your DMM owner’s manual will ensure your resistance testing is always accurate:

• Only measure resistance on an isolated part of the circuit. This means if you are testing internal resistance of a component, it cannot be connected to the harness. If you are measuring a wire (typically from the ECU to a sensor) both the sensor and ECU would need to be unplugged. Most Ohmmeters provides a precise amount of current to determine resistance. Any other sources will make your reading inaccurate.

• Ensure you are making good contact by using the proper terminal adapters. Connector Probing Guidelines page 1.74

• If you are not using a self ranging meter, double check your range setting.

• If your continuity is under 1 ohm, leave the harness disconnected and move on to Testing For A Short To Ground page 1.75 and Testing For A Short To Voltage page 1.76.

For a video demonstration, scan the QR code below, or right click it and select “open in new tab.”

TESTING FOR A SHORT TO GROUND

Shorts to ground happen when the current flowing in a given circuit bypasses the load. The current flowing from B+ finds an easier way to return to ground (B-), so much more of it can flow than the circuit is designed for. This causes the circuit’s protection device (either a fuse or circuit breaker) to open, protecting the circuit from damage.

There are many possible causes of a short to ground, here are some:

• The harness rubbing against a component that is grounded, such as the frame, chassis component, or engine.

• A component’s internal circuitry contacting its case.

• Wire-to-wire chaffing causing contact with the conductor of a ground side circuit.

• Corrosion/moisture in a component providing a ground path.

• Moisture in a connector body providing a ground path.

NOTICE

This test is typically done right after checking continuity

from sensor to ECU when diagnosing an EFI DTC. It

can also be used to help diagnose concerns about

blowing fuses. Ensure you are able to duplicate the

concern before testing so that your results point you in

the right direction.Testing for Intermittent Conditions

page 1.77

TESTING PROCEDURE

1. Consult the wiring diagram. Determine which circuit

you will be testing.

2. Ensure that any static voltage checks advised in

relation to the DTC or concern you are diagnosing have been performed and are in spec.

3. Ensure you have checked continuity of the circuit.

Testing Continuity / Resistance page 1.75

4. Ensure that neither end of the circuit is connected.

5. Set your DMM to Ohms.

6. Connect one meter lead securely to the battery

negative post.

7. Connect the other lead to either end of the

disconnected circuit. Ensure you are using the correct adapter.Connector Probing Guidelines page 1.74

8. If there is continuity, the harness is damaged and

should be repaired or replaced.

9. If the DMM reads OL, there is no short to ground.

Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.76

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GENERAL INFORMATION

For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.

TESTING FOR A SHORT TO VOLTAGE

There are three possible short to voltage causes:

1. Internal electronic component short.

2. Harness chaffing leading to contact of the circuit being diagnosed to one with B+ or a different reference voltage.

3. Moisture in a connector or component.

TESTING PROCEDURE

1. Consult the wiring diagram. Determine which circuit you will be testing.

2. Ensure that any static voltage checks advised in relation to the DTC or concern you are diagnosing have been performed and are in spec.

3. Ensure you have checked continuity of the circuit. Testing Continuity / Resistance page 1.75

4. Ensure you have checked for a short to ground. Testing For A Short To Ground page 1.75

5. Ensure that neither end of the circuit is connected.

6. Set your DMM to DC volts.

7. Connect one meter lead securely to the battery negative post.

8. Connect the other lead to either end of the disconnected circuit. Ensure you are using the correct adapter.Connector Probing Guidelines page 1.74

9. If there is voltage present, the harness is damaged and should be repaired or replaced. You may need to remove the protective tape and tubing to inspect.

10.If the DMM reads 0 volts, the concern may be in a component related to the circuit. If so, checking internal continuity of non-electronic components may reveal the concern, but diagnosis at this point may require using known good parts.

For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.

1.76

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

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GENERAL INFORMATION

TESTING FOR INTERMITTENT CONDITIONS

Intermittent conditions are very difficult to diagnose, as when you are testing the circuit, you may not have the circuit failing to indicate where the issue is. Intermittent electrical failures are almost always related to a poor connection that only goes open in specific situations, such as going over a certain kind of bump, at a certain temperature, or when the machine is torque loaded in one way.

Here is a list of possible failures that can be associated with an intermittent electrical failure:

• Loose female terminal in an electrical connector.

NOTICE

If the terminals in question are the correct size/series,

always use PV–43526 to test the drag when inserting

and removing the test terminal adapters. Compare the

effort to the drag against the known good tester

terminal for reference.

• Poor terminal to wire crimp.

• Terminal crimp that occurred at least partially on insulation instead of the conductor wire strands.

• Terminal fretting corrosion

• Contamination/moisture corrosion

• A full or partial break of the conductor wires in the insulation, with or without visible insulation damage.

• Improper routing, especially when it leads to chaffing or heat damage, especially near exhaust.

TESTING CURRENT FLOW (AMPERAGE)

Performing a current flow test requires the meter leads be inserted into the correct cavities in the meter, and be placed in series in the circuit to be tested. Refer to your Digital Multi Meter’s owner’s manual for potential model specific instructions. Ensure you are using acceptable adapters to avoid damaging the connector terminals. See Connector Probing Guidelines page 1.74.

NOTICE

Amperage specs are generally not provided for circuits/

components. Please only perform this test when

advised in the manual.

IMPORTANT

Many circuits on this machine will exceed the 10 Amp

fuse in most Digital Multi Meters in normal operation.

You may need to use different techniques to duplicate these concerns. These include but are not limited to:

• Moving the harness by wiggling it or flexing certain areas.

• Pulling at or near the suspected connector.

• Pushing in different directions to flex the connector body and try to isolate poor connections.

• Changing the temperature. This can be accomplished with either heat guns or cold air guns.

WARNING

Always exercise caution when using these tools, and

use them for short periods of time when changing the

temperature of an area. Failure to do so can lead to

serious injury and/or damage to the machine.

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GENERAL INFORMATION

CURRENT DRAW - KEY OFF

Parasitic draw is when there is excessive current flow with the key off.

While the most common causes of draws are improperly installed accessories (tapping into un-switched B+ instead of switched) there can be electronic component failures that can cause this as well.

IMPORTANT

Do not connect or disconnect the battery cable, or

ammeter with the engine running. Damage will occur to

electrical components.

IMPORTANT

Charging system damage will occur if incompatible

components are installed. Always reference the Polaris

Electronic Parts Catalog for the proper part numbers.

NOTICE

Wait ten minutes with the key off for the ECU to power

down. This will avoid a faulty readout while testing

amperage draw.

TESTING PROCEDURE

1. Remove the negative cable from the battery.

2. Connect a jumper from the negative battery cable terminal to the negative battery post.

3. Ensure your meter leads and selector dial are set to measure amperage.

4. Connect your red lead to the battery negative cable terminal.

7. Wait 10 minutes before checking the value. Vehicles will vary, but electronic components will take time to fully go to sleep after switched power is removed.

8. Maximum allowable is 10 milliamps. If your meter is ranged to the 10 Amp scale, this will appear as 0.010 Amps.

Current Draw - Key Off:

Maximum of .01 DCA (10 mA)

9. If over 10 milliamps, go to the fuse block and start systematically removing one fuse at a time until the value drops, indicating the circuit that requires attention.

TESTING VOLTAGE DROP

NOTICE

If you disconnect the connector at the load, and

measure voltage with one lead on the power supply

wire, and one to ground, you will be measuring

available voltage. This is a static test and not dynamic

voltage drop testing. Refer to Static and Dynamic

Testing page 1.73.

The measurement of voltage is the DIFFERENCE in electrical pressure between the two points your DMM leads are touching.

Most circuits will have one load. The load is the component in the circuit that uses the current flow to do work, such as move a solenoid or light a bulb.

Voltage coming into the load should be near battery voltage with current flowing. There will be some loss from moving through electrical contacts in connectors and relays, but it will be minimal.

NOTICE

You will need to backprobe to perform this test. For

information about doing this safely, refer to Connector

Probing Guidelines page 1.74.

5. Connect your black lead to the battery negative post.

6. Momentarily key the ignition switch on, then off.

IMPORTANT

Ensure all electrical components are switched off, or

damage to your jumper and/or meter will occur.

1.78

Voltage should be near fully depleted by the load. This means that when measuring on the ground side of the circuit, immediately after the load, back to battery negative, you should have near zero pressure difference (voltage).

If you do have a difference in pressure, this means there is something adding resistance to the circuit such as corrosion.

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Page 85

For a video demonstration, scan the QR code below, or right click it and select “open in new tab”.

GENERAL INFORMATION

1.79

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GENERAL INFORMATION

NOTES

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MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE - GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

GREASE LUBRICATION POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

ENGINE / EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

ENGINE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

ENGINE CYLINDER LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

VALVE CLEARANCE ADJUSTMENT... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

SPARK ARRESTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

HEAT SHIELD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

COOLING SYSTEM .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

COOLANT STRENGTH.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

COOLANT LEVEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

COOLING SYSTEM PRESSURE TEST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

COOLANT HOSE INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36

RADIATOR INSPECTION / CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37

COOLANT FLUSH.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37

COOLING SYSTEM BLEEDING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39

FUEL TANK VENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39

THROTTLE PEDAL INSPECTION .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39

ENGINE INTAKE PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40

AIR FILTER SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

PVT / FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42

PVT DRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42

PVT INTAKE PRE-FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .2.42

FRONT GEARCASE LUBRICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.43

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44

WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44

TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46

TRANSMISSION LUBRICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46

TRANSMISSION OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46

TRANSMISSION OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47

2.1

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MAINTENANCE

STEERING INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47

TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.47

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48

WHEEL TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50

SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50

SUSPENSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51

SHOCK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51

SHOCK COMPRESSION ADJUSTMENT (WALKER EVANS™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.53

BRAKE SYSTEM ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.54

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.54

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.54

BRAKE DISC INSPECTION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56

BATTERY CHARGING / OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56

ENGINE / CHASSIS ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56

SPARK PLUG SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56

2.2

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Page 89

PERIODIC MAINTENANCE - GENERAL

LUBRICANTS / SERVICE PRODUCTS

PRODUCT SIZE (QUANTITY)

1 qt (12)

PS-4

PS-4 Extreme Duty

AGL

Demand Drive

Gas Shock Oil

Antifreeze / Coolant 50/50 Extended Life

Chain Lube

Fogging Oil

All Season Grease

U-Joint Grease

Carbon Clean

Fuel Stabilizer

1 gal (4)

16 gal keg 2876247

55 gal drum 2876246

1 qt (12) 2878920

2 qt (8)

1 gal (4) 2878919

16 gal keg 2879003

55 gal drum 2879002

330 gal tote 2879001

1 qt (12)

1 gal (4) 2878069

2.5 gal (2)

1 qt (12) 2877922

2.5 gal (2)

1 qt (6) 2870995

2.5 gal (2)

1 qt (12) 2880514

1 gal (6)

55 gal drum 2880512

16 oz aerosol (12)

12 oz aerosol (12)

1 qt (12)

Four 3 oz packs (6)

14 oz cartridge 2871423

3 oz tube (24) 2871515

14 oz cartridge 2871551

12 oz bottle (12)

16 oz (12) 2870652

2.5 gal (2)

MAINTENANCE

PART NUMBER

2876244

2876245

2878922

2878068

2878070

2877923

2872279

2880513

2872348

2870791

2871517

2871322

2871326

2872280

2.3

Page 90

MAINTENANCE

PRE-RIDE INSPECTION

ITEM INSPECTION / CHECK

Air Filter

Brake System

• Air filter / air box is clean

• Filter is properly installed

• Air box cover is secured and fastened

• Check brake fluid level is between MIN and MAX

• Check brake pedal is not soft when pushed

• Verify both brake lever and pedal stop and hold the vehicle

• Inspect for leaks

Cooling System

Engine Oil

Engine Stop Switch

Exhaust

Frame / Body Fasteners

Front / Rear Suspension

Fuel

Gauge Cluster

Headlights / Taillights

Shift Lever

• Verify coolant level is filled to the FULL COLD mark on coolant reservoir (if engine is cold)

• Inspect hoses and radiator for leaks

• Extract debris from radiator

• Verify oil level is in the SAFE range on the dipstick

• Inspect oil for color and contaminants

• Ensure operation

• Check fasteners

• Check spark arrester condition / attachment

• Inspect heat shields

• Inspect, ensure tightness, check none are missing

• Inspect bushings

• Check for damage to the control arms / trailing arms

• Check for leaking shocks

• Check shock mounting fasteners

• Inspect fuel lines for leaks and damage

• Start your ride on a full tank

• Ensure operation of indicator lamps

• Ensure all lights are operational

• Adjust headlight aim as required

• Ensure operation in all ranges (P, R, N, L, H)

Steering System

Throttle

Tires

Wheels / Lug Nuts

Winch (if equipped)

2.4

• Check for proper EPS operation (if equipped)

• Check for tightness/play in the steering wheel when turned lock to lock

• Ensure smooth operation

• Snaps closed with handlebars in any position

• Check for proper air pressure in all tires

• Inspect for tire damage / objects in tire

• Ensure adequate tread depth

• Ensure rim is not cracked / bent

• Verify proper lug nut torque

• Inspect cable / line and switch

• Ensure operation

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

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MAINTENANCE

MAINTENANCE INTERVALS

The maintenance interval charts outline required maintenance and inspection based on vehicle hours / miles. Each table states the number of hours / miles that service is required on the vehicle. Some items or components may need to be serviced more often due to severe use, such as operation in water or under severe loads. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.

25 HOUR / 250 MILE (400 KM) SERVICE

COMPONENT REMARKS

Engine Air Filter Inspect, replace

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

XU / D

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

XU / D

Engine Breather Inspect;clean

Battery

Engine Oil & Filter Change (Break-In)

Spark Arrestor

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Initial fluid level inspection; add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Perform a break-in oil and filter change at 25 hours or one month; perform every 50 hours or 6 months thereafter

Clean

Initial fluid level inspection; add lubricant if needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

2.5

Page 92

MAINTENANCE

50 HOUR / 500 MILE (800 KM) SERVICE

ITEM REMARKS

Engine Air Filter Inspect, replace

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

XU / D

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

XU / D

Engine Breather Inspect;clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

D Throttle Pedal

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

XU / D

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

2.6

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Page 93

75 HOUR / 750 MILE (1200 KM)SERVICE

COMPONENT REMARKS

Engine Air Filter Inspect, replace

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

XU / D

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

XU / D

Engine Breather Inspect;clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

Spark Arrestor

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Clean

Inspect / add lubricant if needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

MAINTENANCE

2.7

Page 94

MAINTENANCE

100 HOUR / 1000 MILE (1600 KM) SERVICE

ITEM REMARKS

Engine Air Filter Inspect, replace

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

XU / D

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

XU / D

Engine Breather Inspect;clean

Battery

XU General Lubrication

D Throttle Pedal

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU / D

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring

Clutches (Drive and Driven) Inspect; clean; replace worn parts

XU / D

Front Wheel Bearings Inspect; replace as needed

XU Shocks

Cam Chain Tensioner

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

Visually inspect shock seals; change oil and seals if leaking

Inspect/clean; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

2.8

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Page 95

125 HOUR / 1250 MILE (2000 KM) SERVICE

COMPONENT REMARKS

Engine Air Filter Inspect, replace

XU / D

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect;clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

Spark Arrestor

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Clean

Inspect / add lubricant if needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

MAINTENANCE

2.9

Page 96

MAINTENANCE

150 HOUR / 1500 MILE (2400 KM) SERVICE

ITEM REMARKS

Engine Air Filter Inspect, replace

XU / D

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect;clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

D Throttle Pedal

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

2.10

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 97

175 HOUR / 1750 MILE (2800 KM) SERVICE

COMPONENT REMARKS

Engine Air Filter Inspect, replace

XU / D

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect;clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

Spark Arrestor

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Clean

Inspect / add lubricant if needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

MAINTENANCE

2.11

Page 98

MAINTENANCE

200 HOUR / 2000 MILE (3200 KM) SERVICE

ITEM REMARKS

Engine Air Filter Inspect, replace

XU / D

XU / D Shocks

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect;clean

Battery

XU General Lubrication

D Throttle Pedal

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring Inspect routing and for wear; inspect connectors subjected to water/mud.

Front Wheel Bearings Inspect; replace as needed

D Brake Fluid

Spark Arrestor

Cam Chain Tensioner

D Valve Clearance

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Change shock oil and inspect seals

Change every two years (DOT 4)

Clean daily if driven in mud / water; replace a damaged arrestor before operating

Inspect/clean; replace as needed

Inspect; adjust as needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

2.12

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

Page 99

225 HOUR / 2250 MILE (3600 KM) SERVICE

COMPONENT REMARKS

Engine Air Filter Inspect, replace

XU / D

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect;clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

Spark Arrestor

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Clean

Inspect / add lubricant if needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

MAINTENANCE

2.13

Page 100

MAINTENANCE

250 HOUR / 2500 MILE (4000 KM) SERVICE

ITEM REMARKS

Engine Air Filter Inspect, replace

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

XU / D

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

XU / D

Engine Breather Inspect;clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

D Throttle Pedal

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

XU / D

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use.

D - Have an authorized Polaris dealer or qualified person perform these services.

2.14

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual