Polaris RZR XP Service Manual
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Polaris RZR XP Service Manual

2018-2019
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Table of Contents

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2018-2019 RZR XP / XP 4 Turbo S
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 2018 (PN 9929419 R02)
© Copyright 2018 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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Summary of Contents for Polaris RZR XP

  • Page 1 Publication Printed September 2018 (PN 9929419 R02) © Copyright 2018 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.
  • Page 2 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 injury.
  • Page 3 Added Brake Monitor System Topics 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...
  • Page 5 2018-2019 RZR XP / XP 4 Turbo S Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: EFI / FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7:...

  • Page 7: Table Of Contents

    ................1.19 DECIMAL EQUIVALENTS 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 8: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018; K=2019 VIN AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

  • Page 9: Reference Information

    When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www. polaris.com or purchased from www.purepolaris.com. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 10: 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.
  • Page 11 PU-48951 Fuel Pressure Adapter Water Pump Drive & Fuel Pressure Gauge Smartlink Module Kit CV Boot Clamp Pliers Flywheel Removal (Stepless) Tool 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 12 Flywheel Holding Tool Shock Spanner Shock Spanner Shock Spanner Shock Body Holding Wrench 2.5–3.0 Inner Wrench 2.5 Outer Wrench 3.0 Outer Tool 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Tool Tool Tool Compressor Compressor Adapter PV-43526 PV-43531 PV-43568 PV-43570-1 Connector Test Kit Oil Presure gauge Fluke Multimeter Piston Ring Compressor Pliers 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 14: Master Torque Table

    Coolant Reservoir 26 ft-lb (35 Nm) Nuts Coolant Temperature Sensor 17 ft-lb (23 Nm) Exhaust Pipe to Muffler Nuts 18 ft-lb (24 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 15 Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm) Mounting Oil Pump 7 ft-lbs (10 Nm) Bolts 4 ft-lb (5 Nm) Seat Slider Plate Screws 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 16 8 ft-lb (11 Nm) 30 ft-lbs (41 Nm) + 90° Tie Rod End to Knuckle 40 ft-lbs (54 Nm) Tie Rod Jam Nuts 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.10 © Copyright Polaris Industries Inc.

  • Page 17: Vehicle Specifications

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.11 © Copyright Polaris Industries Inc.

  • Page 18: 2018 Rzr Xp Turbo S

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 20: 2019 Rzr Xp Turbo S Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: 2019 Rzr Xp 4 Turbo S Clutch Chart

    7.5A Key 7.5A Lights 7.5A SCM Fuses 7.5A Shocks 7.5A Water 10A EFI 10A Socket 10A Term Accy 25A EPS 30A Fan 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.16 © Copyright Polaris Industries Inc.

  • Page 23: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.17 © Copyright Polaris Industries Inc.

  • Page 24: Sae Tap / Drill Sizes

    2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: Decimal Equivalents

    0.4688″ 12 mm = 0.4724″ 31/32 0.9688″ 25 mm = 0.9843″ 31/64 0.4844″ 63/64 0.9844″ 0.500″ 13 mm = 0.5118″ 1.000″ 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.19 © Copyright Polaris Industries Inc.
  • Page 26 GENERAL INFORMATION NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 1.20 © Copyright Polaris Industries Inc.
  • Page 27 ................. . .2.46 TIRE INSPECTION 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 28 ................. . .2.56 SPARK PLUG SERVICE 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 29: Maintenance

    U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 2870652 16 oz (12) Fuel Stabilizer 2872280 2.5 gal (2) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 30: Pre-Ride Inspection

    • Verify coolant level is filled to the FULL COLD mark on Coolant Level coolant reservoir (if engine is cold) • Inspect hoses and radiator for leaks 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 31: Maintenance Intervals

    XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 32 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 33 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 34 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 35 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 36 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.10...
  • Page 37 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.11...
  • Page 38 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.12...
  • Page 39 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.13...
  • Page 40 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.14...
  • Page 41 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.15...
  • Page 42 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.16...
  • Page 43 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.17...
  • Page 44 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.18...
  • Page 45 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.19...
  • Page 46 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.20...
  • Page 47 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.21...
  • Page 48 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.22...
  • Page 49 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.23...
  • Page 50 When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.24 © Copyright Polaris Industries Inc.

  • Page 51: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant * More often under severe use, such as operation in water or under severe loads. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.25 © Copyright Polaris Industries Inc.
  • Page 52 Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 53: Grease Lubrication Points

    Polaris Premium U-Joint thoroughly washing or Propshaft Yokes Grease fittings on the slip yoke Grease submerging the vehicle 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 54: Engine / Exhaust

    5. Reinstall the dipstick to fully seat it. Do not lock the dipstick. IMPORTANT Make certain the dipstick is inserted all the way down to ensure an accurate reading. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 55: Engine Oil And Filter Change

    15 seconds before removing the oil dipstick. filter o-ring is not stuck to the crankcase. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 56: Engine Crankcase Breather Hose

    19. Reinstall the cargo box access panel, engine service panel and seats. 20. Dispose of used oil, filter and rags properly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 57: Valve Clearance Adjustment

    3-digit tappet number. 9. Refer to Valve Lash - Tappet Selection page 3.106 and select the proper tappet. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 58: Cam Chain Tensioner Inspection

    Camshaft Installation / Timing page move freely, replace the tensioner assembly. 5. Retract the plunger all the way in and install into the cylinder. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 59: Spark Arrestor

    Spark Arrestor Fasteners: 8 ft-lb (11 Nm) 1. Remove the spark arrestor retaining fasteners 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 60: Heat Shield Inspection

    HEAT SHIELD INSPECTION Verify all shields are properly installed and not damaged. If a shield is damaged or missing, it MUST be replaced. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.34 © Copyright Polaris Industries Inc.
  • Page 61 Turbo Lower Heat Shield Rear Close-off Heat Shield Inlet Silencer Heat Shield Headpipe Inner Heat Shield Front Head Pipe Heat Shield 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 62: Cooling System

    6. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 63: Cooling System Pressure Test

    Charge Air Cooler Hoses Water Pump Hoses Oil Cooler Coolant Hoses 3. Check tightness and condition of all hose spring clamps. Replace if necessary. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 64: Radiator Inspection / Cleaning

    6. Connect the coolant hoses at both water pumps and properly position the clamps.. 7. Ensure the transmission is in park and chock the rear tires. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.38 © Copyright Polaris Industries Inc.

  • Page 65: Cooling System Bleeding

    12. Proceed to bleed the cooling system. See . 3. Elevate the front of the vehicle at approx. 2 feet (60 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 66: Charge Air Cooling System Bleeding

    CAUTION Escaping coolant/steam can cause burns. Always allow the engine to cool before opening the bleed screw. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 67: Fuel System And Air Intake

    NOTE Check throttle pedal periodically. Make sure vent line is not kinked or pinched. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 68: Engine Intake Pre-Filter Service

    Compressed air or high pressure hose may damage the frog skin pre-filter on the intake. 3. Pull cover rearward far enough to remove air filter 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 69: Intake Duct Drain Inspection

    8. Reinstall the cargo box access panel. debris so it can drain properly. If needed, remove the drain from the baffle box during inspection. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 70: Pvt / Final Drive / Wheel And Tire

    Shift the transmission into Low. 6. Test run the vehicle for slippage. If the belt slips, repeat steps 1-5. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.44 © Copyright Polaris Industries Inc.

  • Page 71: Front Gearcase Lubrication

    4. Reinstall the fill plug and torque to specification. TORQUE Front Gearcase Fill / Drain Plug Torque: 10 ft-lbs (14 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.45 © Copyright Polaris Industries Inc.

  • Page 72: Drive Shaft Boot Inspection

    120 ft-lbs (163 Nm) MEASUREMENT Hub Castle Nuts: Tire Lug Service Limit: 180 ft-lbs (244 Nm) Replace if 1/8″ (3 mm) or less. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.46 © Copyright Polaris Industries Inc.

  • Page 73: Maintenance

    The rear tires are to be moved to the front as shown. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.47 © Copyright Polaris Industries Inc.

  • Page 74: Transmission

    4. Reinstall the fill plug and torque to specification. 8. Check for leaks. Dispose of used lubricant properly. TORQUE Transmission Fill / Drain Plug: 14 ft-lbs (19 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.48 © Copyright Polaris Industries Inc.

  • Page 75: Steering

    • Refer to Chapter 7 Front Bearing Carrier Inspection / Removal page and Rear Bearing Carrier Inspection / Removal page for wheel bearing service procedures. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.49 © Copyright Polaris Industries Inc.

  • Page 76: Wheel Toe Alignment Inspection

    3. Measure the distance between the marks and record the measurement. Call this measurement MEASUREMENT Wheel Toe: 1/4” (0.64 mm) toe-in – 1/4” (0.64 mm) toe-out 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.50 © Copyright Polaris Industries Inc.

  • Page 77: Wheel Toe Adjustment

    MEASUREMENT Wheel Toe: 1/4” (6.4 mm) toe-in – 1/4” (6.4 mm) toe-out 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.51 © Copyright Polaris Industries Inc.

  • Page 78: Suspension

    Refer to Grease Lubrication Points page suspension lubrication. NOTE There are no grease fittings on the front control arm pivot points or the rear trailing arms. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.52 © Copyright Polaris Industries Inc.

  • Page 79: Brake System

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.53 © Copyright Polaris Industries Inc.

  • Page 80: Brake Disc Inspection

    3. Mount a dial indicator. Slowly rotate the disc and read runout on the dial indicator Replace disc if runout exceeds specifications. MEASUREMENT Brake Disc Runout: .010″ (0.25 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.54 © Copyright Polaris Industries Inc.

  • Page 81: Electrical And Ignition System

    BATTERY CHARGING / OFF SEASON STORAGE Refer to Charging Procedure page 12.27 and Battery Off Season Storage page 12.26 in the electrical chapter. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.55 © Copyright Polaris Industries Inc.

  • Page 82: Spark Plug Service

    12. Reinstall the cargo box access panel. NOTE Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 2.56 © Copyright Polaris Industries Inc.
  • Page 83 ................3.43 WATER PUMP SERVICE 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 84 ..............3.90 LOWER CRANKCASE PREPARATION 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 85 ................3.107 VALVE COVER INSTALLATION 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 86: General Information

    Flywheel Holding Tool PU-51220 Valve Spring Compressor PV-1253 Valve Spring Compressor Adapter PV-43513-A Oil Pressure Gauge PV-43531 Piston Ring Compressor Pliers PV-43570-1 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 87: Oil Pressure Test

    Maximum @ All RPM: ≈ 80 PSI (relief valve) 5. Upon assembly, torque the crankcase gallery plug to specification. TORQUE Crankcase Oil Gallery Plug: 12 ft-lbs (16 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 88: Oil Flow Chart

    ENGINE / COOLING SYSTEM OIL FLOW CHART 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 89: Engine Service Specifications

    .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 90 (0.035 mm) Runout .002″ (0.05 mm) Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm) Shaft 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 91: Engine Torque Specifications

    9 ft-lb (12 Nm) VALVE COVER CAM CARRIER Camshaft Carrier Bolts Valve Cover Bolts 7 ft-lb (10 Nm) 7 ft-lbs (10 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 92 STATOR COVER HEAD PIPE / TURBO Exhaust Head Pipe Stator Cover Bolts 9 ft-lb (12 Nm) 18 ft-lb (24 Nm) Fasteners 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 93: Intake / Exhaust System

    .25 bar (3.6 PSI) sensed at the dump valve will cause it to open. The dump valve is normally open at idle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 94: Engine Air Intake Assembly View

    Oetiker Clamp Torque in sequence to 7 ft-lb (10 7 ft-lb (10 Nm) Engine Breather Hose Throttle Body Gasket Intake Manifold 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 95: Air Box Removal

    5. Lift the cargo box nearest to the front of the vehicle so you can access the lower air box mounting bolts and remove the two bolts. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 96: Air Box Installation

    Torque fasteners to specification. TORQUE Cargo Box Fasteners: 8 ft-lb (11 Nm) 5. Install engine access panel. 6. Install both seats. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 97: Exhaust Assembly View

    Turbo / Head Pipe Assembly 18 ft-lb (24 Nm) 18 ft-lb (24 Nm) Head Pipe Fasteners Exhaust Gasket 18 ft-lb (24 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 98: Muffler Removal

    4. Pull muffler towards the rear of the vehicle to remove it from the mounting grommets. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 99: Muffler Installation

    8 ft-lb (11 Nm) 3. Disconnect and remove the oxygen sensor 4. Remove the three fasteners retaining the muffler to the exhaust pipe. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.17 © Copyright Polaris Industries Inc.
  • Page 100 Front fasteners are plastic rivets and rear fasteners are bolt/washer/nut. 7. Remove the two fasteners retaining the heat shield to the exhaust pipe / turbo joint. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.18 © Copyright Polaris Industries Inc.

  • Page 101: Head Pipe / Turbo Removal

    7. Remove the two fasteners retaining the heat shield to the exhaust pipe / turbo joint. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.19 © Copyright Polaris Industries Inc.
  • Page 102 Polaris Electronic turbo removal. Parts Catalog. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.20 © Copyright Polaris Industries Inc.

  • Page 103: Head Pipe / Turbo Installation

    4. Install the fasteners retaining the turbo to the mounting bracket. Torque fasteners to specification. TORQUE Turbocharger Mounting Fasteners: 18 ft-lb (24 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 104 11. Install two fasteners retaining the engine heat shield above O2 sensor. Torque heat shield fasteners to specification. TORQUE Heat Shield Fasteners: 8 ft-lb (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.22 © Copyright Polaris Industries Inc.

  • Page 105: Exhaust Pipe Installation

    Exhaust Pipe to Turbo Fasteners: 18 ft-lb (24 Nm) Exhaust Pipe to Muffler Fasteners: 18 ft-lb (24 Nm) Rear Shock Fasteners: 70 ft-lbs (95 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.23 © Copyright Polaris Industries Inc.

  • Page 106: Turbocharger Service

    If filter is found to be clogged, replace the filter. CAUTION A clogged or restrictive air filter or intake tract can cause excessive turbocharger speeds and premature wear. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 107 13. Inspect oil feed line for damage, or leaks. 9. Remove the four fasteners retaining the exhaust pipe to the turbocharger. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 108 Inspect for places where unfiltered air may be let into the intake tract. Make note of any possible sources of damaging material. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 109 If an excessive amount of oil is present in the compressor inlet, the source of oil is likely related to the crankcase ventilation system. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.27 © Copyright Polaris Industries Inc.

  • Page 110: Actuator / Wastegate Inspection

    5. With the use of an air regulator and pressure gauge, attach an air supply line to the actuator pod pressure reference port, located on the top of the canister. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.28 © Copyright Polaris Industries Inc.

  • Page 111: Actuator Pod Removal

    Actuator Rod Heim Joint Fasteners: 1. Locate the actuator rod heim joint, located opposite to 7 ft-lb (10 Nm) the actuator pod. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.29 © Copyright Polaris Industries Inc.

  • Page 112: Oil Drain Tube Service

    IMPORTANT The O-ring must be properly in place before installing the drain tube on the turbocharger to prevent an oil leak. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 113: Wastegate Flapper Inspection

    9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.31 © Copyright Polaris Industries Inc.

  • Page 114: Actuator / Wastegate

    EXHAUST Inspect the exhaust system for: • Clogged spark arrestor. • Damaged catalytic converter (use inspection mirror or borescope). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.32 © Copyright Polaris Industries Inc.

  • Page 115: Cooling System

    ENGINE / COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM FLOW 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 116: Cooling System Specifications

    239° F (115° C) water pump weep hole for leakage. Engine Protection Shutdown 246° F (119° C) & Overheat Indicator Flashes 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.34 © Copyright Polaris Industries Inc.

  • Page 117: Charge Air Cooler Removal

    8. Remove the two fasteners retaining the fuel rail to the intake manifold. 4. Remove the cargo box access panel. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.35 © Copyright Polaris Industries Inc.
  • Page 118 12. Carefully remove the intake manifold out the passenger side of the vehicle. 13. Remove the fasteners retaining the charge air cooler to the intake manifold. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 119: Charge Air Cooler Installation

    Torque fasteners to specification. Intake Manifold Clamps: 6 ft-lb (8 Nm) TORQUE Intake Manifold Mounting Fasteners (lower): 20 ft-lb (27 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 120: Radiator Replacement

    14. Elevate the front of the vehicle and fill the coolant bottle. 15. Run the vehicle for several minutes and check the coolant level. Refill as required. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.38 © Copyright Polaris Industries Inc.
  • Page 121 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.39 © Copyright Polaris Industries Inc.
  • Page 122 18. The fan and radiator can be removed as an remove it from the chassis. assembly. 16. Remove two hoses going to the radiator. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.40 © Copyright Polaris Industries Inc.
  • Page 123 14. Install winch cover and install two T25 fasteners. Torque to specification. TORQUE Winch Cover Fasteners: 22 in-lb ( 3 Nm) 15. Reconnect headlight connectors. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 124: Thermostat Replacement

    The front fastener is accessible through the cargo box access panel. The rear fastener is accessible through the passenger side with a wrench. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 125: Water Pump Service

    13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 5. Remove impeller from water pump shaft. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.43 © Copyright Polaris Industries Inc.
  • Page 126 7 ft-lb (10 Nm)(Apply Loctite® 204™ to bolt threads) 18. Clean cover and housing gasket surfaces 19. Install a new water pump cover gasket 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.44 © Copyright Polaris Industries Inc.
  • Page 127 Water Pump Assembly View Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 128: Engine Service

    6. Lower the lift or jack and align the isolator tang with the holes in the frame. Install isolator to frame fasteners. Torque fasteners to specification. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 129: Crankshaft Pto Seal Replacement

    3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.47 © Copyright Polaris Industries Inc.
  • Page 130 5. Field test the vehicle before putting back into service. Inspect for any leaks. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 131: Engine Removal

    9. Disconnect and remove the oxygen sensor shield above the valve cover. NOTE Front fasteners are plastic rivets and rear fasteners are bolt/washer/nut. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.49 © Copyright Polaris Industries Inc.
  • Page 132 20. Remove the lower turbo bracket fasteners remove the bracket from the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.50 © Copyright Polaris Industries Inc.
  • Page 133 27. Disconnect the fuel supply and return hoses at the fuel rail. 28. Disconnect TBAP, both TMAP sensors, CPS, coolant temp sensor, Trans switch, speed sensor, injectors, ETC. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.51 © Copyright Polaris Industries Inc.
  • Page 134 33. Remove PVT hoses and outer cover. 2#2$ 39. Remove fasteners retaining engine to the engine mount bracket. 34. Remove secondary clutch, belt, and primary clutch. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 135: Engine Installation

    4. Loosely install fasteners retaining inner cover to the transmission and engine/trans joint. 5. Loosely install the three allen screws and washers retaining inner cover to engine. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.53 © Copyright Polaris Industries Inc.
  • Page 136 35 in-lb (4 Nm) 16. Install the two hoses going to charge air cooler. Outer PVT Cover Fasteners: 35 in-lb (3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.54 © Copyright Polaris Industries Inc.
  • Page 137 Heat Shield Fasteners: 8 ft-lb (11 Nm) TORQUE Exhaust Pipe to Muffler Fasteners: 26 ft-lb (35 Nm) 30. Connect O2 sensor harness. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.55 © Copyright Polaris Industries Inc.
  • Page 138 11.6 for Turbo S4. WARNING The ROPS/roof should only be serviced by a certified Polaris dealer. 37. Install rear fenders and fender flairs. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 139: Cam Chain Tensioner Service

    No further adjustment is required. 2. Remove the spring retainer bolt and push the adjuster all the way in. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 140: Engine Disassembly / Inspection - Top End

    3. If tearing down the top end of the engine, remove the spark plugs. Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 141: Camshaft Sprocket Inspection

    Replace timing chain and sprockets if worn or damaged. 6. Rotate the engine to allow access to the remaining bolt on each camshaft sprocket. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 142: Camshaft / Camshaft Bore Inspection

    Exhaust: 1.5772 - 1.5803" (40.06 - 40.14 mm) 1.5752" (40.01 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.60 © Copyright Polaris Industries Inc.
  • Page 143 7 ft-lb (10 Nm) MEASUREMENT Camshaft Carrier Bore I.D.: .9055 - .9063" (23.000 - 23.021 mm) Service Limit: .9072" (23.044 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.61 © Copyright Polaris Industries Inc.

  • Page 144: Cylinder Head Removal

    6. Tap cylinder head lightly with a soft faced hammer until loose. CAUTION Tap only in reinforced areas or on thick parts of the cylinder head casting. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 145: Cylinder Head Disassembly

    8. Clean the combustion chamber and head gasket surface. 2. Compress the valve spring by hand using valve spring compressor adapter PV-43513-A 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 146: Valve Inspection

    4. Check the end of the valve stem for flaring, pitting, wear or damage. MEASUREMENT Valve Guide I.D.: .2165 - .2171" (5.500 - 5.515 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 147: Combustion Chamber Cleaning

    2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.65 © Copyright Polaris Industries Inc.
  • Page 148 This is normal and should not cause valve leakage. Both valves shown are acceptable and would not require replacement. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.66 © Copyright Polaris Industries Inc.
  • Page 149 12. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 150: Engine Disassembly / Inspection - Bottom End

    / installation process or injury could result. 2. Carefully pry the stator cover off the engine using the two pry areas as shown below. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 151: Water Pump Housing Removal

    4. Using a commercially available strap wrench, hold the flywheel and remove the flywheel retaining bolt 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.69 © Copyright Polaris Industries Inc.

  • Page 152: Starter One-Way Clutch Disassembly

    9. Inspect the one-way gear bushing for wear or galling. If service is required, refer to Starter One-way Clutch Disassembly page 3.70. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.70 © Copyright Polaris Industries Inc.

  • Page 153: Crankcase Disassembly

    7. Remove the sump cover from the crankcase. 2. Remove the crankcase drain plug to drain any oil remaining in the engine. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.71 © Copyright Polaris Industries Inc.
  • Page 154 Access the sprocket bolt by removing the case plug. 13. Rotate the engine so the cylinder is facing up. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 155: Balance Shaft Removal / Inspection

    Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 156: Crankshaft Removal / Inspection

    4. Carefully lift the crankshaft out of the crankcase. 5. Remove the cam chain , PTO main seal and oil pump drive chain from the crankshaft. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.74 © Copyright Polaris Industries Inc.
  • Page 157 Main (40.996 - 41.004 mm) Bearing 1.6129" (40.970 mm) Service Limit 1.7715 1.7717" Connecting Standard Rod Bearing (44.995 - 45.002 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 158: Crankcase Inspection

    4. Be sure oil passages are clean and free of any page 3.84 and Crankshaft Main Bearing Selection cleaning solvent. page 3.84 procedures. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.76 © Copyright Polaris Industries Inc.

  • Page 159: Cylinder / Piston Removal

    Always replace plain bearings when the crankcase or connecting rods have been disassembled. Refer to Crankshaft Main Bearing Selection page 3.84. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.77 © Copyright Polaris Industries Inc.

  • Page 160: Cylinder Inspection

    3.6614 ± .0003" (93 mm ± 0.008 mm) Cylinder Taper: Service Limit: .001″ (0.025 mm) Cylinder Out of Round: Service Limit: .001″ (0.025 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 161: Piston Disassembly / Inspection

    DO NOT apply heat to piston rings or a loss of radial .8659 - .8661" (21.995 - 22.000 mm) tension could result. Service Limit: .8651" (21.975 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.79 © Copyright Polaris Industries Inc.

  • Page 162: Piston Ring Removal

    A difference between top and bottom end gap measurements is a general indication of cylinder taper (wear). The cylinder should be measured for taper and out of round. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 163: Piston To Cylinder Clearance

    Piston O.D. (Standard): 3.6597 ± .0003" (92.959 ± 0.008 mm) MEASUREMENT Piston to Cylinder Clearance: .0009 - .0019" (0.025 - 0.050 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.81 © Copyright Polaris Industries Inc.
  • Page 164 8. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided in the “Connecting Rod Bearing Selection” procedure in this chapter. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 165: Engine Assembly - Bottom End

    BEARING SELECTION IDENTIFICATION Connecting Rod Bearing Crankcase Bearing Identification Crankshaft Bearing Identification Identification Number ( one number) Number (six numbers) Letters (six letters) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 166: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings CRANKSHAFT Code Crankshaft White Code Blue White Blue Blue Green Case Yellow Blue White Blue Green Yellow Green Yellow Yellow 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.84 © Copyright Polaris Industries Inc.

  • Page 167: Upper Crankcase Preparation

    Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.85 © Copyright Polaris Industries Inc.

  • Page 168: Piston / Connecting Rod Assembly

    6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.86 © Copyright Polaris Industries Inc.

  • Page 169: Piston / Cylinder Installation

    1. Apply clean engine oil to each piston assembly and cylinder bore prior to installation. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.87 © Copyright Polaris Industries Inc.

  • Page 170: Crankshaft Installation

    Press bearing insert firmly into place. Repeat for the other connecting rod. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.88 © Copyright Polaris Industries Inc.
  • Page 171 8. Apply Polaris PS-4 engine oil to the new crankshaft oil seal and install the seal on the PTO end of the crankshaft. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 172: Balance Shaft Installation

    6. Flush all oil passages with solvent and then warm soapy water. Rinse with clear, warm water and dry with compressed air. 7. Ensure passages clean before assembling the crankcase. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.90 © Copyright Polaris Industries Inc.

  • Page 173: Crankcase Assembly

    Investigate the cause of any gaps. 6. Apply Polaris PS-4 engine oil to the new bearings installed in the upper crankcase half. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.91 © Copyright Polaris Industries Inc.
  • Page 174 M8 Bolts: 26 ft-lb (35 Nm) M6 Bolts: 9 ft-lb (12 Nm) 13. Rotate the engine so the cylinder is facing up. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.92 © Copyright Polaris Industries Inc.
  • Page 175 NOTE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.93 © Copyright Polaris Industries Inc.

  • Page 176: Starter One-Way Clutch Assembly

    , if previously removed. Use new O-rings upon installation. Torque fasteners to specification. TORQUE Oil Cooler bolts: 7 ft-lb (10 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.94 © Copyright Polaris Industries Inc.

  • Page 177: Flywheel Installation

    Replace crankshaft if surface damage is present. 9. Proceed to Stator Cover Installation page 3.96. Clean taper of crankshaft to remove all oil or grease. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.95 © Copyright Polaris Industries Inc.

  • Page 178: Stator Cover Installation

    3. Install stator cover and thirteen screws. Torque screws in sequence to specification. TORQUE Stator Cover Screws: 9 ft-lb (12 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.96 © Copyright Polaris Industries Inc.

  • Page 179: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.97 © Copyright Polaris Industries Inc.

  • Page 180: Valve Sealing Test

    4. Guide cam chain through a new head gasket and install the gasket on the cylinder, locating it on the alignment pins. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.98 © Copyright Polaris Industries Inc.

  • Page 181: Camshaft Installation / Timing

    Polaris PS-4 engine oil prior to Step 3: Additional 180° installation. Step 4: Additional 180° Step 5: M6 bolts: 7 ft-lb (10 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.99 © Copyright Polaris Industries Inc.
  • Page 182 (PU-50563) into the end of camshafts as shown. Use NOTE an open-end wrench to rotate camshafts slightly. Use new sprocket retaining bolts upon assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.100 © Copyright Polaris Industries Inc.
  • Page 183 Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.101 © Copyright Polaris Industries Inc.
  • Page 184 The tensioner will automatically adjust to the proper tension once the spring and retainer are installed. No further adjustment is required. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.102 © Copyright Polaris Industries Inc.

  • Page 185: Camshaft Timing Quick Reference

    Exhaust Cam CPS Mounting Hole Align Intake Marks with Top of Head Align Flywheel Mark (+) to edge of Mounting Hole 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.103 © Copyright Polaris Industries Inc.

  • Page 186: Valve Clearance Adjustment

    3-digit tappet number. 9. Refer to Valve Lash - Tappet Selection page 3.106 and select the proper tappet. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.104 © Copyright Polaris Industries Inc.
  • Page 187 15. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to Camshaft Installation / Timing page 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.105 © Copyright Polaris Industries Inc.

  • Page 188: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i. e. 459 should be rounded to 460 since there is a 460 tappet). Available Tappets 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.106 © Copyright Polaris Industries Inc.

  • Page 189: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts in sequence to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.107 © Copyright Polaris Industries Inc.
  • Page 190 ENGINE / COOLING SYSTEM NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 3.108 © Copyright Polaris Industries Inc.
  • Page 191 ..................4.38 TMAP SENSOR 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 192 ..............4.47 OXYGEN SENSOR REPLACEMENT 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 193: General Information

    Digital Wrench Vehicle Interface PU-47469 Cable Digital Wrench PC Interface PU-47470 Cable Fuel Pump Service Tool PU-50326 Fuel Pressure Gauge Adapter PA-48838 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 194: Efi Overview

    Located in the fuel tank under the passenger seat. Located on cylinder assembly between engine and transmission. Knock Sensor Oxygen Sensor Located on the exhaust pipe. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 195: Efi Operation Overview

    / fuel ratio is automatically calculated by the ECU. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 196: Efi Service Notes

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 197: Initial Priming / Starting Procedure

    NOTICE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 198: Electronic Control Unit (Ecu)

    This process repeats it self in rapid succession, limiting operation to the preset maximum. RPM Limit: 8800 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 199: Etc Learn Procedure

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Screws: 24 in-lb (3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 200: Fuel Injectors

    Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 201: Fuel Injector Troubleshooting

    Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 202: Fuel Injector Replacement

    Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.12 © Copyright Polaris Industries Inc.
  • Page 203 17. Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks. 18. Reinstall the cargo box engine access panel. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 204: Fuel Lines

    FUEL SYSTEM ASSEMBLY VIEW Fuel Feed Line Vent Rollover Valve Fuel Return Line Fuel Vent Line Fuel Fill Fuel Tank Strap 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.14 © Copyright Polaris Industries Inc.

  • Page 205: Fuel System Assembly View (Evap)

    8 ft-lbs (11 Nm) Carbon Canister Canister Fasteners 8 ft-lbs (11 Nm) Canister Filter Canister Filter Fasteners 8 ft-lbs (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 206: Fuel Line Removal / Installation

    9. Turn the key on to prime the system. Check for leaking at both ends of the fuel lines. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.16 © Copyright Polaris Industries Inc.

  • Page 207: Fuel Line Removal / Installation (Evap Models)

    7. Turn the key on to prime the system. Check for leaking at each end of the fuel line. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.17 © Copyright Polaris Industries Inc.

  • Page 208: Fuel Line Routing

    EFI / FUEL SYSTEM FUEL LINE ROUTING Routing Clip Panduit Strap Tree Clip Fuel Rail 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.18 © Copyright Polaris Industries Inc.

  • Page 209: Fuel Line Routing (Evap Models)

    EFI / FUEL SYSTEM FUEL LINE ROUTING (EVAP MODELS) Panduit Strap Routing Clip Fuel Rail 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.19 © Copyright Polaris Industries Inc.

  • Page 210: Fuel Vent Line Routing

    Engine miss or hesitation Symptoms of a restricted fuel tank vent include the following: Loss of engine performance High exhaust temperatures. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.20 © Copyright Polaris Industries Inc.
  • Page 211 4. Feed the vent line through the shock mount bracket opening and attach the vent line to the fitting in the frame 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.21 © Copyright Polaris Industries Inc.

  • Page 212: Fuel Vent Line Routing (Evap Models)

    Loss of engine performance High exhaust temperatures. 1. Retain the fuel vent line to the fuel supply line with a panduit strap 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.22 © Copyright Polaris Industries Inc.
  • Page 213 5. From the carbon canister, route the canister-to-filter line OVER the vent-to-canister line , and attach to the middle fittings in two triple clips 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.23 © Copyright Polaris Industries Inc.

  • Page 214: Vent Line Termination Fitting

    If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 215: Fuel Tank / Pump

    PFA Nut 70 ft-lbs (95 Nm) Fuel Return Fuel Supply Fuel Pump Fuel Pickup Filter (not serviceable) Fuel Sender Float PFA Gasket Fuel Tank Vent 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.25 © Copyright Polaris Industries Inc.

  • Page 216: Fuel Tank Removal

    A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.26 © Copyright Polaris Industries Inc.
  • Page 217 Install the fuel cap back on the fuel tank. 14. Remove the Torx screws and plastic rivets retaining the block-off panel using a T40 Torx driver. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.27 © Copyright Polaris Industries Inc.

  • Page 218: Fuel Tank Installation

    17. Lift the rear of the fuel tank up first. Carefully pull the fuel tank out of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.28 © Copyright Polaris Industries Inc.
  • Page 219 Torque jam nut to specification. TORQUE Shift Cable Jam Nut: 16 ft-lb (22 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.29 © Copyright Polaris Industries Inc.
  • Page 220 NOTICE There is no return line on EVAP models. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.30 © Copyright Polaris Industries Inc.

  • Page 221: Fuel Pump Operation Overview

    17. Install the battery into the vehicle. Torque fasteners to specification. TORQUE Battery Bracket Fastener: 24 in-lbs (3 Nm) Battery Terminal Fasteners: 60 in-lbs (7 Nm) 18. Install the seats. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 222: Fuel Pressure Test

    NORMAL to see fuel pressure fluctuations as the throttle varies. Pressure may briefly drop below 58 PSI (400 kPa) when the throttle is released on a running vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.32 © Copyright Polaris Industries Inc.

  • Page 223: Fuel Pump Replacement

    ECU operation by plugging in a known-good ECU of the same model. 11. If the pump still does not operate, replace the fuel pump. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.33 © Copyright Polaris Industries Inc.
  • Page 224 7. Ensure that static has been discharged by touching a ground source such as the engine or frame. 9. Disconnect the fuel pump electrical harness. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.34 © Copyright Polaris Industries Inc.
  • Page 225 The fuel pump will retain some interferences with the fuel level float arm and cause fuel. incorrect function. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.35 © Copyright Polaris Industries Inc.
  • Page 226 The connectors will be housed in the cap when properly installed. Do NOT pull the pump flying lead connector through the “+” cutout. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.36 © Copyright Polaris Industries Inc.

  • Page 227: Fuel Sender Test

    6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to Fuel Pump Replacement procedure. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.37 © Copyright Polaris Industries Inc.

  • Page 228: Pressure Sensors

    248° F (120° C) The TMAP sensor and the Boost Pressure Sensor may be interchanged for testing purposes as the sensors are the same. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.38 © Copyright Polaris Industries Inc.

  • Page 229: Knock Sensor

    Torque mounting bolt to specification. TORQUE Knock Sensor Mounting Bolt: 15 ft-lb (20 Nm) 4. Connect knock sensor harness. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.39 © Copyright Polaris Industries Inc.

  • Page 230: Crankshaft Position Sensor (Cps)

    CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage. 5. If the resistance is incorrect, follow the CPS Replacement page 4.41 procedure. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.40 © Copyright Polaris Industries Inc.

  • Page 231: Cps Replacement

    4. Install new sensor using a light coating of oil on the O-ring to aid installation. 5. Torque the CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 ft-lb (12 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.41 © Copyright Polaris Industries Inc.

  • Page 232: Electronic Throttle Control (Etc) / Throttle Body

    RPM ranges based off input provided by the Pedal Position Sensor (PPS) and Electronic Control Unit (ECU). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.42 © Copyright Polaris Industries Inc.

  • Page 233: Etc / Throttle Body Replacement

    ETC Housing Retaining Bolts: 7 ft-lb (10 Nm) Intake Boot Clamp: 49 in-lb (6 Nm) Body Fasteners: 8 ft-lb (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.43 © Copyright Polaris Industries Inc.

  • Page 234: Pedal Position Sensor (Pps)

    (see Chapter 4 – PPS Replacement assembly. page 4.45). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.44 © Copyright Polaris Industries Inc.

  • Page 235: Pps Replacement

    7. Torque the three mounting bolts to specification and connect the PPS harness connection. TORQUE Throttle Pedal Mounting fasteners: 18 ft-lb (24 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.45 © Copyright Polaris Industries Inc.

  • Page 236: Oxygen Sensor

    The sensor element in the oxygen sensor cannot be tested effectively with static tests. The heater circuit 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.46 © Copyright Polaris Industries Inc.

  • Page 237: Oxygen Sensor Replacement

    3. Install new oxygen sensor. Torque sensor to specification. TORQUE Oxygen Sensor: 13 ft-lb (18 Nm) 4. Connect the harness going to the oxygen sensor. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.47 © Copyright Polaris Industries Inc.
  • Page 238 EFI / FUEL SYSTEM NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 4.48 © Copyright Polaris Industries Inc.
  • Page 239 ...........5.18 DRIVEN CLUTCH INSTALLATION (2019 MODELS) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 240: General Information

    SPRING 0-1800 Meters W-31-74 2019 (0-6000 Feet) (5142487) Black Black RZR XP (7045147) (7045185) 4 Turbo 1800-3700 Meters W-31-64 (6000-12000 Feet) (5141004) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 241: Pvt System Overview

    At lower RPM, the drive belt rotates low in the drive clutch sheaves. As engine RPM increases, centrifugal force causes the drive belt to be forced upward on drive clutch sheaves. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 242: Drive Belt

    PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 243: Belt Installation

    5-7 times to properly seat the belt in the driven clutch. 5. Install the outer clutch cover and screws. Torque screws to specification. TORQUE PVT Cover Screws: 35 in-lb (3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 244: Drive Clutch Service

    5. Mark the drive belt direction of rotation so that it can puller. be installed in the same direction. Drive Clutch Puller: 2872085 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 245: Drive Clutch Assembly View

    300 ft-lb (407 Nm) Bushing Cover Bushing Clutch Spring Moveable Sheave Spring Spacer Slider Plates Spider Cover Cover Bolts Slider 9 ft-lb (12 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 246: Drive Clutch Disassembly / Inspection

    • Install weights and torque fasteners to specification. TORQUE Shift Weight Fasteners: 20 in-lb (2 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 247 4. Loosen and remove the clutch compression tool. Drive Clutch Holding Fixture: 2871358-B 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 248 3-jaw puller may also be used to help with spider removal. 12. Inspect the moveable sheave bearing for wear. If wear is present, replace the bearing. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 249: Drive Clutch Assembly

    2. Install the moveable sheave onto the shaft. 3. Install the spider onto the clutch shaft. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.11 © Copyright Polaris Industries Inc.
  • Page 250 6. Place the drive clutch in a clutch compression tool. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 251: Drive Clutch Installation

    35 in-lb (3 Nm) 9. Install the driver’s rear shock guard. Torque fasteners to specification. TORQUE Shock Guard Fasteners: 14 in-lbs (2 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 252: Driven Clutch Service

    The driven clutch is held together by the snap ring that was removed in the previous step. The driven clutch will become damaged if it is dropped. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 253: Driven Clutch Removal (2019 Models)

    NOTE The driven clutch spreader tool is included with the vehicle’s tool kit 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 254: Driven Clutch Assembly View

    Driven Clutch Bearing Spring Retainer Stationary Sheave Helix Bushing Slider Slider Screw Helix Cover 35 in-lb (4 Nm) Moveable Sheave Cover Screws 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 255: Driven Clutch Disassembly / Inspection

    If replacement is required, remove the fasteners retaining the sliders to the sheave. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 256: Driven Clutch Assembly

    DRIVEN CLUTCH INSTALLATION (2019 MODELS) 1. Install the driven clutch on the transmission input shaft. Install the thrust bearing, and cup washer. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.18 © Copyright Polaris Industries Inc.
  • Page 257 5-7 times to properly seat the belt in the driven clutch. 7. Install the outer clutch cover and screws. Torque screws to specification. TORQUE PVT Cover Screws: 35 in-lb (3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.19 © Copyright Polaris Industries Inc.
  • Page 258 PVT SYSTEM NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 5.20 © Copyright Polaris Industries Inc.
  • Page 259 ..............6.16 TRANSMISSION ASSEMBLY 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 260: General Information

    TRANSMISSION GENERAL INFORMATION SPECIAL TOOLS PART TOOL DESCRIPTION NUMBER PU-51862 Snorkel Tube Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 261: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 262: Shift Cable Adjustment

    5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTICE This procedure may require a few attempts to obtain the proper adjustment. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 263: Transmission Service

    8. Disconnect and remove the oxygen sensor to the transmission output shaft. 12. Remove both rear half shafts. See Rear Drive Shaft Removal page 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 264 22. Remove PVT hoses and outer cover. 17. Disconnect TBAP, both TMAP sensors, CPS, coolant temp sensor, Trans switch, speed sensor, injectors, ETC. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 265 27. Remove fasteners retaining inner cover to engine/ trans joint. Discard PVT inner cover o-ring around the crankshaft snout. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 266: Transmission Installation

    8. Install PVT hoses and outer PVT cover. Torque fasteners to specification. TORQUE Hose Clamps: 35 in-lb (4 Nm) Outer PVT Cover Fasteners: 35 in-lb (3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 267 Shock Access Panel: 35 in-lb (4 Nm) 21. Install cargo box. Torque fasteners to specification. TORQUE Cargo Box Fasteners: 8 ft-lb (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 268: Transmission Vent Line Routing

    26. Check and fill engine oil as required. See Engine Oil Level page 2.28. 27. Connect battery. Torque fasteners specification. TORQUE Battery Fasteners: 60 in-lbs (7 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 269: Transmission Disassembly

    Do not pry on the transmission case mating surfaces or the transmission cases will be damaged and leak oil after it is reassembled. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.11 © Copyright Polaris Industries Inc.
  • Page 270 22. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.12 © Copyright Polaris Industries Inc.

  • Page 271: Gear Cluster Disassembly

    The pinion shaft must be removed prior to removing the snorkel tube assembly. Failure to remove pinion shaft will result in damage to the snorkel tube or LH gearcase. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.13 © Copyright Polaris Industries Inc.
  • Page 272 Support the end face of the gear teeth when pushing the shaft through or damage to the gear teeth may occur. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 273: Gear, Shaft, Bearing Inspection

    Inspect all of the gears, shafts, and bearings shown for excessive wear or damage. IMPORTANT If gear replacement is required, also replace the corresponding gear and/or gear shaft. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 274: Transmission Assembly / Snorkel Gear Backlash

    Failure to properly clean the surfaces may lead snorkel shaft using your fingers, but it will feel rough to transmission case leaks. and may have some tight spots. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 275 Both shift forks need to be oriented the same way, so that the shift fork pins are both offset to the same side of the rail. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 276 ITEM DESCRIPTION Retaining Clip 13. Thoroughly clean the shift shaft housing. Washer Torsion Spring Drum 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.18 © Copyright Polaris Industries Inc.
  • Page 277 Install the nut and torque to specification. TORQUE Bell Crank Nut: 18 ft-lb (24 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 278 TRANSMISSION NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 279 ..................7.48 TIRE BALANCING 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 280: General Information

    GENERAL INFORMATION SPECIAL TOOLS PART NUMBER DESCRIPTION 2872608 Roll Pin Removal Tool CV Boot Clamp Pliers 8700226 Axle Boot Clamp Tool PU-48951 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 281: Bearing Carrier

    12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 282: Front Bearing Replacement

    2. Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 283: Front Bearing Carrier Installation

    Install washers with domed side out. TORQUE Tie Rod End Fastener: 15 ft-lbs (20 Nm) + 90° 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 284: Rear Bearing Carrier Inspection / Removal

    5. Remove the lower radius rod outer mounting bolt nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 285 11. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 286: Rear Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 287: Rear Bearing Carrier Installation

    50 ft-lbs (68 Nm) + 90° Outer Radius Rod Fastener: 50 ft-lbs (68 Nm) + 90° 3. Apply anti-seize to drive shaft splines. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 288 9. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 289: Drive Shaft

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 290: Front Drive Shaft Installation

    New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.12 © Copyright Polaris Industries Inc.

  • Page 291: Rear Drive Shaft Removal

    . Discard the nut. 10. Lift the trailing arm assembly upward so the rear drive shaft is parallel with the ground. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.13 © Copyright Polaris Industries Inc.

  • Page 292: Rear Drive Shaft Installation

    3. Swing the rear trailing arm assembly outward and upward until the rear axle can be inserted into the bearing carrier. Support the trailing arm from underneath. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 293 8. Install the radius rod bolts, washers and new nuts. Torque fasteners to specification. TORQUE Radius Rods to Bearing Carrier: 50 ft-lb (68 Nm) + 45° 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 294: Drive Shaft / Cv Joint Handling Tips

    Refer Wheel Lug Nuts: to text for grease capacity of CV joints and CV joint 120 ft-lbs (163 Nm) boots. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 295: Outer Cv Boot Replacement

    If the grease in the joint is obviously contaminated with CV Boot Clamp Pliers: 8700226 water and/or dirt, the joint should be replaced. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.17 © Copyright Polaris Industries Inc.

  • Page 296: Inner Plunging Joint / Boot Replacement

    3. Remove the large circlip near the boot end of the plunging joint. 4. Clean the grease from the face of the joint. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 297 IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.19 © Copyright Polaris Industries Inc.
  • Page 298 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.20 © Copyright Polaris Industries Inc.

  • Page 299: Prop Shaft

    2. Remove the fasteners retaining the front and rear skid plates. 3. Remove the seats. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.21 © Copyright Polaris Industries Inc.
  • Page 300 10. Remove the front prop shaft and support bearing isolator out the bottom of the vehicle, as an assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.22 © Copyright Polaris Industries Inc.

  • Page 301: Prop Shaft Removal (S4)

    2. Remove the fasteners retaining the front, middle, and rear skid plates. 3. Remove the seats. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.23 © Copyright Polaris Industries Inc.
  • Page 302 10. Remove the front prop shaft and support bearing isolator out the bottom of the vehicle, as an assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.24 © Copyright Polaris Industries Inc.

  • Page 303: Prop Shaft Assembly View

    If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting (if equipped) and mark inner and outer yoke for correct re-positioning during installation. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 304: U-Joint Assembly

    4. Force U-joint cross to one side and lift out of inner yoke. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 305: Prop Shaft Installation

    8 ft-lb (11 Nm) IMPORTANT The coupler fasteners have patch lock on the threads and must be replaced any time they are removed. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 306: Front Gearcase / Centralized Hilliard

    Drain Plug 10 ft-lbs (14 Nm) Bearing Fill/Check Plug 10 ft-lbs (14 Nm) Output Hub Cover Plate Screws 11 ft-lbs (15 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.28 © Copyright Polaris Industries Inc.

  • Page 307: Front Gearcase Vent Line Routing

    . The vent line continues upward where it is retained with a routing clip that is attached to the radiator fan shroud. The line then terminates into and open section of the frame. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.29...

  • Page 308: All Wheel Drive Operation

    “over-running” condition for the rollers upon disengagement. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.30 © Copyright Polaris Industries Inc.

  • Page 309: Awd Diagnosis

    AWD system. If this is found, replace the cover plate assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.31 © Copyright Polaris Industries Inc.

  • Page 310: Front Gearcase Removal

    , and remove tie rod end joint with a proper pulling tool. Repeat the procedure for the opposite side of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.32 © Copyright Polaris Industries Inc.
  • Page 311 10. Remove two brake caliper fasteners and remove 7. Remove two mounting fasteners from right side the brake caliper. steering rack mount. Remove the mount. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 312 A-arm ball joint end while lifting upward on the upper A-arm. Completely remove the ball joint end from the bearing carrier. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 313 24. Remove lower steering shaft from the steering rack. 25. Remove steering rack from the right side of the vehicle. 26. Remove the front propshaft from the gearcase. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.35 © Copyright Polaris Industries Inc.

  • Page 314: Front Gearcase Disassembly / Inspection

    3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.36 © Copyright Polaris Industries Inc.
  • Page 315 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.37 © Copyright Polaris Industries Inc.

  • Page 316: Front Gearcase Assembly

    16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 5. Install the plastic ring onto the clutch housing. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.38 © Copyright Polaris Industries Inc.
  • Page 317 NOTICE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.39 © Copyright Polaris Industries Inc.
  • Page 318 Take care not to damage the new cover plate seal while installing the output hub. TORQUE Cover Plate Screws: 11 ft-lbs (15 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.40 © Copyright Polaris Industries Inc.

  • Page 319: Front Gearcase Installation

    30 ft-lbs (41 Nm) 5. Install the gearcase from the right side of the vehicle. TORQUE Ball Joint Pinch Bolt: 40 ft-lbs (54 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.41 © Copyright Polaris Industries Inc.
  • Page 320 NEW cotter pin .Torque to specification. TORQUE Wheel Scraper Mounting Fasteners: 7 ft-lbs (10 Nm) TORQUE Hub Castle Nut: 180 ft-lbs (244 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.42 © Copyright Polaris Industries Inc.
  • Page 321 22. Loosely install the front isolator bolts as well as the front drive mounting bracket fasteners securing the brackets to the chassis. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.43 © Copyright Polaris Industries Inc.
  • Page 322 Front Drive Mounting Bracket Fasteners (Front): Vehicles built before 01/07/2019:18 ft-lbs (24 Nm) Vehicles built on, or after 01/07/2019: 25 ft-lbs (34 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.44 © Copyright Polaris Industries Inc.
  • Page 323 Do NOT overfill. 42 ft-lbs (57 Nm) NOTE Recommended Front Gearcase Fluid: Demand Drive Fluid Capacity: 8.5 oz (250 mL) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.45 © Copyright Polaris Industries Inc.

  • Page 324: Wheel Hubs

    Hub Castle Nut Cotter Pin Cone Washer 180 ft-lbs (244 Nm) Wheel Hub Brake Disc Wheel Studs Snap Ring Wheel Bearing Bearing Carrier 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.46 © Copyright Polaris Industries Inc.

  • Page 325: Rear Hub Assembly View

    Hub Castle Nut Cotter Pin Cone Washer 180 ft-lbs (244 Nm) Wheel Hub Brake Disc Wheel Studs Snap Ring Wheel Bearing Bearing Carrier 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.47 © Copyright Polaris Industries Inc.

  • Page 326: Tire Balancing

    Symptoms of an imbalanced, or improperly balanced tire include: • Steering wheel vibration • Seat or floorboard vibration • Excessive or uneven tread wear 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 7.48 © Copyright Polaris Industries Inc.
  • Page 327 ..............8.35 FOX 3.0” SHOCK INFORMATION 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 328 ............8.55 SUSPENSION MODE SWITCH (DYNAMIX MODELS) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 329: General Information

    Spanner Wrench - 3.0″ Outer Internal PU-51832 Bypass Shock Body Holding Tool (2.5″) PU-51837 Shock Body Bolding Tool (3.0″) PU-51838 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 330: Steering System

    40 ft-lbs (54 Nm) Steering Column Fasteners EPS Bracket 40 ft-lb (54 Nm) EPS to Bracket Fasteners Steering Tilt Shock 30 ft-lb (41 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 331: Upper Steering Shaft Removal

    2. Remove the pinch bolt retaining the upper steering shaft to the power steering unit. 3. Lift the steering wheel up and remove the fasteners that retain the steering column. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 332: Steering Wheel / Hub Adapter Removal

    EPS unit, and cause a power steering fault. 2. Loosen the nut and back it half way off the steering shaft. 3. Place the assembly in a vise. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 333: Power Steering Unit Removal

    . IMPORTANT Power steering units have a steering position sensor. Avoid spinning steering shafts after removing power steering unit from the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 334: Lower Steering Shaft Removal

    Mark the lower steering shaft, gear box stub shaft and gear box to aid installation. 3. Remove the power steering unit (see Power Steering Unit Removal page 8.7). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 335: Steering Rack Removal

    Leave the mount in its position. 4. Remove four fasteners securing winch plate to gearcase bracket. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 336 16. With a short, sharp jerk, remove drive shaft from the front gearcase. 17. Repeat steps 9-17 on the opposite side of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.10 © Copyright Polaris Industries Inc.
  • Page 337 21. Loosen four mounting nuts on the EPS mounting bracket. Leave nuts loosely installed. 22. Remove lower steering shaft from the steering rack. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 338: Steering Rack Installation

    9. Install the tie rod end and fastener. Repeat step for remaining side. TORQUE Tie rod end: 30 ft-lbs (41 Nm) + 90° 10. Install hub assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.12 © Copyright Polaris Industries Inc.
  • Page 339 Front Brake Caliper Mounting Bolts: 70 ft-lbs (95 Nm) 30 ft-lb (41 Nm) 15. Repeat steps 5-14 for the opposite side of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.13 © Copyright Polaris Industries Inc.
  • Page 340 55 ft-lbs (75 Nm) + 180° rack mounting cast . Repeat step for opposite side of vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.14 © Copyright Polaris Industries Inc.
  • Page 341 Torque to specification. TORQUE TORQUE Steering Cast Mounting Fasteners (Lower): 42 ft-lbs (57 Nm) Winch Mounting plate Fasteners: 18 ft-lbs (24 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 342: Lower Steering Shaft Installation

    50 ft-lb (68 Nm) 3. Install the power steering unit and reassemble the vehicle (see Power Steering Unit Installation page 8.16). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.16 © Copyright Polaris Industries Inc.
  • Page 343 3. Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 344: Upper Steering Shaft Installation

    40 ft-lb (54 Nm) 3. Install the tilt shock and torque fastener to specification. TORQUE Tilt Shock Fastener: 7 ft-lb (10 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 345: Steering Shaft Bushing Replacement

    5. Reinstall the upper washers and spacers in the order in which they were removed. 6. Install the hub adapter and hand tighten the nut. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 346: Eps Pre-Positioning / Steering Angle Centering

    • The SCM is indicating out-of-alignment faults • New steering components have been installed • The SCM is indicating out-of-alignment faults 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.20 © Copyright Polaris Industries Inc.
  • Page 347 3. Select option 2 at the next menu. 4. Follow instructions in Digital Wrench to properly center the EPS steering angle sensor. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 348: Front Suspension

    70 ft-lbs (95 Nm) Upper A-Arm Lower A-Arm A-Arm Fasteners CV Guard Screws 70 ft-lbs (95 Nm) 14 ft-lbs (19 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 349: Front A-Arm Removal / Installation

    11. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 12. Insert new A-arm bushings and pivot tube into new A- arm. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 350: Front Stabilizer Bar Replacement

    Front Shock Mounting Bolts: 70 ft-lbs (95 Nm) 3. Remove the fasteners retaining the stabilizer bar link to the stabilizer bar. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 351: Installation

    2. Place a proper sized driver on the ball joint and place the A-arm in a press. 3. Carefully press the ball joint out of the A-arm and discard the ball joint. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 352: Ball Joint Installation

    6. If the installed end gap of the retaining ring exceeds 5 mm, remove retaining ring, inspect and clean groove as necessary. Install a NEW retaining ring and repeat measurement. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.26 © Copyright Polaris Industries Inc.

  • Page 353: Rear Suspension

    20 ft-lbs (27 Nm) 50 ft-lbs (68 Nm) + 45° Stabilizer Bar Mounting Bracket Fasteners Debris Scraper 20 ft-lbs (27 Nm) + 90° 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 354: Trailing Arm Removal / Installation

    4. Remove the lower radius rod mounting bolt , nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 355 Use new fastener nuts upon installation of the rear trailing arm and bearing carrier. 11. Remove the lower stabilizer bar linkage fastener Discard the nut. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.29 © Copyright Polaris Industries Inc.

  • Page 356: Trailing Arm Spherical Bearing Replacement

    7. Press in new bearing until fully seated into trailing arm casting. 8. Install new snap ring, O-rings (not required) and bushings. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.30 © Copyright Polaris Industries Inc.

  • Page 357: Radius Rod Removal / Installation

    6. Remove radius rods from vehicle. 7. Examine radius rod shafts, boots and spherical bearings. Replace entire radius rod if any excessive wear is evident. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.31 © Copyright Polaris Industries Inc.

  • Page 358: Stabilizer Bar Removal

    7. Carefully remove the stabilizer from the LH wheel well area of the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.32 © Copyright Polaris Industries Inc.

  • Page 359: Shocks / Springs

    5. Tighten the spring adjustment ring to set the preload distance noted in Step 1. 6. Reinstall the shock onto the vehicle and torque new fasteners to specification. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.33 © Copyright Polaris Industries Inc.

  • Page 360: Fox 2.5" Shock Information

    1.250 x 0.015 0.875 x 0.100 (Back Up) 1.100 x 0.015 0.950 x 0.015 0.0800 x 0.015 1.570 x 0.128 Top Out 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 361: Fox 3.0" Shock Information

    0.875 x 0.100 (Back Up) 1.350 x 0.015 1.250 x 0.015 1.100 x 0.015 0.950 x 0.015 0.800 x 0.015 1.570 x 0.128 Top Out 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.35 © Copyright Polaris Industries Inc.

  • Page 362: Shock Service

    Retaining Ring Bearing Assembly Retaining Ring Reservoir End Cap Assembly Bearing Cap Damping Adjust Assembly Body Cap Sparing Hardware Assembly Body 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.36 © Copyright Polaris Industries Inc.

  • Page 363: Offset Torque Formula

    L = 13.750″ Will equal 30 ft-lb of torque applied to the reservoir. E = 3.750″ or 2.500″ *depending on body cap 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.37 © Copyright Polaris Industries Inc.

  • Page 364: Fox Shock Disassembly

    Typically, a Ensure you have obtained the correct rebuild kit and oil valve shim can be used. prior to disassembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 365 The seal will be destroyed from the heat and must be replaced. 7. Hold cinch ring with spanner and rotate bearing assembly counter-clockwise to release pressure on retaining ring. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.39 © Copyright Polaris Industries Inc.
  • Page 366 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.40 © Copyright Polaris Industries Inc.
  • Page 367 26. Remove lock nut from the shaft assembly. stack. 30. Remove compression valve stack and cable tie together. Clean with contact cleaner. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.41 © Copyright Polaris Industries Inc.
  • Page 368 Loctite residue left in the eyelet and shaft threads. Clean thoroughly with contact cleaner and lint-free 36. Clean all surfaces of the bearing housing and cinch towel. ring. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.42 © Copyright Polaris Industries Inc.
  • Page 369 38. To remove the remote hose assembly, de-pressurize reservoir, push hose in and remove retaining ring with a small pick. 39. Remove hose o-rings. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.43 © Copyright Polaris Industries Inc.
  • Page 370 STEERING / SUSPENSION 2.5 Bypass Piston 3.0 Bypass Piston Compression Side Compression Side Rebound Side Rebound Side 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.44 © Copyright Polaris Industries Inc.

  • Page 371: Fox Shock Assembly

    30 ft-lb (42 Nm) 3. With body prepared with Loctite primer add a layer of Loctite 638 2 threads up, 2 threads wide 360°. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.45 © Copyright Polaris Industries Inc.
  • Page 372 19. Install 2nd T-seal back-up ring 20. Install wiper seal. 21. Lubricate all seals with Slick Honey. 22. Install external o-ring. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.46 © Copyright Polaris Industries Inc.
  • Page 373 28. Install shaft nut and torque to specification. 34. Install shaft assembly into inner body. TORQUE Shaft Nut: 22 ft-lb (30 Nm) 29. Install all Bypass check valves. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.47 © Copyright Polaris Industries Inc.
  • Page 374 45. After setting IFP depth, install Bleed screw with o- assembly. ring. 40. Install retaining ring, ensuring that it is fully seated in ring gland. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.48 © Copyright Polaris Industries Inc.
  • Page 375 49. Stroke shock absorber and inspect shock for leaks. 50. Install body cap. 51. Clean oil residue from shock. 52. Install o-ring and reducers in eyelet and body. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.49 © Copyright Polaris Industries Inc.

  • Page 376: Dynamix Active Suspension

    While the Dynamix Shocks come apart similar to a FOX Podium Bypass shock, there are several differences. Refer to the training on Univerisity of Polaris (https://lms.latitudelearning.com/home/main.aspx) and do a search for “Live Valve Shock” for complete disassembly and assembly of a Dymanix shock.

  • Page 377: Demonstration Mode

    8. Install the harness onto the SCM. Slide the tab inward to lock the harness to the SCM. Lightly pull on the connector to ensure it is retained. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.51 © Copyright Polaris Industries Inc.

  • Page 378: Dynamix™ System Features

    The system continuously monitors steering angle, lateral acceleration, and vehicle yaw rate to provide enhanced cornering control, reducing body motion for maximum performance. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.52 © Copyright Polaris Industries Inc.

  • Page 379: Braking

    9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.53 © Copyright Polaris Industries Inc.

  • Page 380: Advanced Diagnostics

    DYNAMIX™ Active Suspension controls current to the shock valve 1000 times per second, performs vehicle dynamics calculations 200 times per second, and can actuate a shock from soft to firm approximately 20 times per second. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.54...

  • Page 381: Suspension Mode Switch (Dynamix Models)

    CONTACT CONTACT PINS 1 TO POSITION Open Comfort Closed 1270 Ω Sport Open Open 1400 Ω Open Firm Closed 1330 Ω 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.55 © Copyright Polaris Industries Inc.
  • Page 382 STEERING / SUSPENSION NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 8.56 © Copyright Polaris Industries Inc.
  • Page 383 ..............9.28 BRAKE BURNISHING PROCEDURE 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 384: General Information

    (7.53 ± .19 mm) Thickness .295 ± .008″ Rear Disc .268″ (6.8 mm) (7.5 ± .2 mm) Thickness Rear Disc – .010″ (0.25 mm) Runout 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 385: Brake System Overview

    Master Cylinder Master cylinder shield Fasteners Front Brake Caliper Fasteners Front Brake Caliper Brake Scraper Fasteners Brake Scraper 7 ft-lbs (10 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 386: Brake Line Routing / Retention

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION Master Cylinder To Front Brake Calipers Master Cylinder Rivet Clip Front Brake Calipers 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 387 BRAKE SYSTEM Master Cylinder To Junction Block Master Cylinder Rivet Clip Junction Block Routing Clip Rubber Grommet 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 388 BRAKE SYSTEM Junction Block to Rear Brake Calipers Junction Block Routing Clip Rivet Clip Rear Brake Caliper 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 389: Brake System Service Notes

    HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.

  • Page 390: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.
  • Page 391 7. Perform the BRAKE BLEEDING / FLUID CHANGE page 9.10 procedure. TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual © Copyright Polaris Industries Inc.

  • Page 392: Brake Bleeding / Fluid Change

    Mity Vac™: 2870975 NOTICE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.10 © Copyright Polaris Industries Inc.
  • Page 393 With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 394: Brake Pedal

    2. Remove the E-clip from the pedal mount and remove the brake pedal lever from the vehicle. Brake Pedal Free-play: 0.090″ (2.28 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 395: Front Brake Service

    7. Remove the inner pad from the bracket and caliper. 8. TO REMOVE CALIPER: Place a catch pan under the brake caliper. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.13 © Copyright Polaris Industries Inc.
  • Page 396 BRAKE SYSTEM 9. Remove the bolt retaining the brake line to the caliper. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 397: Front Caliper Assembly View

    Scraper Bolts Caliper Assembly 48 in-lb (5 Nm) Bleeder Screw Mount Pins 48 in-lb (5 Nm) apply Silicone Grease on install 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 398: Front Caliper Disassembly / Inspection

    Do not remove the caliper pistons with a standard pliers. The piston sealing surface will become damaged if a standard pliers is used. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 399: Brake Pad Inspection

    10. Inspect the brake disc and pads as outlined in this chapter. MEASUREMENT Turbo S4 Brake Pad Thickness: .296 ± .007″(7.53 ± .19 mm) Service Limit: .180″ (4.6 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 400: Front Caliper Assembly

    3. Mount a dial indicator. Slowly rotate the disc and read runout on the dial indicator Replace disc if runout exceeds specifications. MEASUREMENT Brake Disc Runout: .010″ (0.25 mm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 401: Front Brake Disc Replacement

    1/2 turn (counterclockwise). 7. Install the front wheel and the wheel nuts. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 402: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 403: Troubleshooting

    5. When the brake pedal is depressed the Brake may be a concern with the ECU. Pressure Switches will become active before the Brake Pedal Switch. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 404: Rear Brake Service

    Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 405: Rear Caliper Disassembly / Inspection

    NOTE Be sure to clean caliper body seal grooves. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.23 © Copyright Polaris Industries Inc.

  • Page 406: Caliper Inspection

    Standard: 1.500″ (38.10 mm) Service Limit: 1.498″ (38.05 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 407: Rear Caliper Assembly

    Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 408: Rear Brake Disc Replacement

    7. Install rear caliper (see Brake Caliper / Pad Installation page ). Bleed the brake system. (See BRAKE BLEEDING / FLUID CHANGE page 9.10. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 409: Rear Brake Caliper / Pad Installation

    NOTE The vertical centerline used for measurement is based on the caliper pin locations. NOTE Banjo Bolts: 15 ft-lb (20 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 410: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 9.28 © Copyright Polaris Industries Inc.
  • Page 411 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........
  • Page 412 ..............10.54 SCM / INERTIAL MEASUREMENT UNIT 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.2...
  • Page 413 DIAGNOSTIC 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.3 © Copyright Polaris Industries Inc.
  • Page 414 DIAGNOSTIC 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 415: Engine And Drivability Diagnostic Procedures

    • Refer to Digital Wrench® Guided Diagnostics page 10.18. Check codes and continue with diagnosis. • If no codes are present, proceed to 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.5 © Copyright Polaris Industries Inc.
  • Page 416 • After checking for air supply and fuel pressure, perform leakdown test. • Refer toEngine Cranks but does Not Start page 10.8 for more information. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.6 © Copyright Polaris Industries Inc.
  • Page 417 10.38, or Cylinder Misfire Detection page 10.37. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 418: Engine Cranks But Does Not Start

    • Unusual noise could suggest that there may be a reading refer to Fuel Sender Test page 4.37. mechanical engine concern. Proceed to step 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 419 – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.9 © Copyright Polaris Industries Inc.

  • Page 420: No Crank No Start Or Slow Crank

    (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake light operation. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 421: Over Heating

    7. Check Cooling Fan operation. • Refer to the necessary section in the Service Manual for further engine testing. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.11 © Copyright Polaris Industries Inc.

  • Page 422: Warning Lights

    • Refer toOver Heating page 10.11 for more info. 4. PERFORMANCE LIMITED Light. • Check for codes using Digital Wrench. Refer to Guided Diagnostic for further diagnosis. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 423: Engine Troubleshooting

    • Spark plug fouled • Restricted exhaust muffler • Cylinder, piston, ring, or valve • Cam worn excessively wear or damage (check compression) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.13 © Copyright Polaris Industries Inc.
  • Page 424 – Ignition or kill switch circuit faulty – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 425: Cooling Troubleshooting

    Replace waste gate if it fails either test. • Check oil feed / return line to turbo for leaks, damage or blockage. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 426: Polaris Digital Wrench

    PV-43546 (Fluke 77: PV-43568) Commercially Available (refer to diagnostic software Laptop or Desktop Computer user manual or HELP section for minimum requirements) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 427: Digital Wrench Software Version And Update Id

    6. If the update file date listed is newer than your downloaded before using Digital Wrench® (see current version and update (see Chapter 4 to Chapter 4). download the file. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 428: Digital Wrench® Communication Errors

    Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 429: Digital Wrench® Serial Number Location

    Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 430: Digital Wrench® Feature Map

    Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 431: Ecu Replacement

    Replacement ECUs are programmed as “no-start” and require a reflash for them to work. Reprogramming (Reflash) Tips: 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.21 © Copyright Polaris Industries Inc.
  • Page 432 5. Select the “Special Tests” icon. NOTICE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.22 © Copyright Polaris Industries Inc.
  • Page 433 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 434: Polaris Mobile Digital Wrench (Pmdw)

    / continuous focus • Video, Microphone, and Voice-to-text capable • Internet and Bluetooth wireless technology capable PMDW App Notes: 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.24 © Copyright Polaris Industries Inc.

  • Page 435: Diagnostic Trouble Code List

    Voltage below normal C1064 Valid but above normal C1059 Engine Speed Data Erratic, Intermittent or Incorrect C1061 Receive network data-in error C1066 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.25 © Copyright Polaris Industries Inc.
  • Page 436 Sensor Outputs 1 & 2 P1135 Correlataion Invalid C1005 Suspension Mode Switch Short/Voltage too high C1006 516098 Input (Dynamix only) Short/Voltage too low C1007 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.26 © Copyright Polaris Industries Inc.
  • Page 437 Below MIN C108E 520572 Brake Switch Status Invalid U108C Accelerator Pedal Position 520574 Invalid U143D Data Engine Speed Data 524000 Invalid U102F 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.27 © Copyright Polaris Industries Inc.
  • Page 438 Throttle Body Control - 520278 Condition exists P151C Return Spring Check Failed Throttle Body Control - 520279 Condition exists P151D Adaption Aborted 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.28 © Copyright Polaris Industries Inc.
  • Page 439 Circuit Current below normal or open circuit P107E Voltage above normal C106D EPS SEPIC Voltage Error 524086 Voltage below normal C106E 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.29 © Copyright Polaris Industries Inc.

  • Page 440: Electrical Diagnostics

    Testing Voltage Drop page 10.35 results. The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.30 © Copyright Polaris Industries Inc.

  • Page 441: Connector Probing Guidelines

    If they contact each other, circuit or component damage could occur from a short. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.31 © Copyright Polaris Industries Inc.

  • Page 442: Testing Continuity/Resistance

    Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 10.33 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.32 © Copyright Polaris Industries Inc.

  • Page 443: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.33 © Copyright Polaris Industries Inc.

  • Page 444: Testing Current Flow (Amperage)

    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. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.34 © Copyright Polaris Industries Inc.

  • Page 445: Testing Voltage Drop

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.35 © Copyright Polaris Industries Inc.

  • Page 446: Efi Diagnostics

    • Belt dragging • Throttle stop screw tampering Erratic Idle • Air Leaks, dirty injector • TMAP damaged (check with Digital Wrench®) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.36 © Copyright Polaris Industries Inc.

  • Page 447: Cylinder Misfire Detection

    • Low battery voltage (loose connection, low charge, bad battery) • Faulty voltage regulator • Ignition Coil and connections are good • Spark plugs wires are secure 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.37 © Copyright Polaris Industries Inc.

  • Page 448: Digital Wrench Data Troubleshooting

    Differential unlocked Differential Lock ECU control of the Driver turf solenoid ECU is not grounding the diff relay. Differential is Inactive locked. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.38 © Copyright Polaris Industries Inc.
  • Page 449 ”–” or Null indicates no reading from the sensor / Selected Gear transmission switch selected stuck between gear positions is in 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.39 © Copyright Polaris Industries Inc.
  • Page 450 On or Off Inactive AWD or 2WD mode How fast the transmission output Vehicle Speed — varies is turning (calculated to wheel speed) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.40 © Copyright Polaris Industries Inc.

  • Page 451: Pvt Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.41 © Copyright Polaris Industries Inc.
  • Page 452 Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.42 © Copyright Polaris Industries Inc.

  • Page 453: Transmission Troubleshooting

    (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.43 © Copyright Polaris Industries Inc.

  • Page 454: Brake, Steering, And Suspension Diagnostic Procedures

    Caliper Overheats (Brakes Drag) page 10.47 or Brakes Lock page 10.47 • Refer to Chapter 8 — Brake System for more information. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.44 © Copyright Polaris Industries Inc.
  • Page 455 • Repair or replace components based on inspection. Concern Inspection • Refer to Chapter 8 — Front Suspension, Rear Suspension, or Shocks / Springs for more information. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.45 © Copyright Polaris Industries Inc.

  • Page 456: Brake Noise Troubleshooting

    If noise does not change when brake is applied check Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.46 © Copyright Polaris Industries Inc.

  • Page 457: Poor Brake Performance

    • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.47 © Copyright Polaris Industries Inc.

  • Page 458: Eps Troubleshooting

    DIAGNOSTIC EPS TROUBLESHOOTING EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.48 © Copyright Polaris Industries Inc.

  • Page 459: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    DIAGNOSTIC EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.49 © Copyright Polaris Industries Inc.

  • Page 460: Eps Troubleshooting (Using Digital Wrench®)

    DIAGNOSTIC EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.50 © Copyright Polaris Industries Inc.

  • Page 461: Dynamix Troubleshooting

    8. Measure resistance between pin 68 and battery (-) negative. Resistance should be less than 5 Ω. 9. Measure resistance between pin 60 and battery (+) positive. Resistance should be less than 5 Ω. 10. Reflash SCM 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.51 © Copyright Polaris Industries Inc.

  • Page 462: Scm Shock Valve Diagnostics

    11. Measure voltage between shock plug signal and battery (+) power with SCM unplugged. The wires should not be shorted to battery voltage 12. Reflash the SCM. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.52 © Copyright Polaris Industries Inc.

  • Page 463: Scm Mode Switch

    5. If SPN 520572 FMI 2 is present, check brake switch input on data display. ECU pin 135. 6. If SPN 520574 FMI 2 or SPN 524000 FMI 2 is present, reflash ECU. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.53...

  • Page 464: Scm Steering Angle Adapted Offset Diagnostics

    3. If the code(s) is still active, reflash the SCM. 4. If the code(s) is still present after reflashing, replace the SCM. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 10.54 © Copyright Polaris Industries Inc.
  • Page 465 ............11.31 ROOF INSTALLATION (TURBO S ONLY) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.1...
  • Page 466 ............... . . 11.32 ROPS INSTALLATION (4 SEAT) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.2...

  • Page 467: General Information

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 468: Body Assembly Views

    WELD-ROPS, REAR, LH NUT-HXFL-M10X1.5 40 ft-lbs (54 Nm) WELD-ROPS, MNT, SEATBELT WARNING The ROPS/roof should only be serviced by a certified Polaris dealer. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 469: Roof Assembly

    Side Roof Foam LH Roof Cover Roof Mounting Fastener 8 ft-lbs (11 Nm) RH Roof Cover Washer Front Roof Foam Roof Mounting Bracket 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 470: Cab Frame Assembly (4 Seat)

    SCR-1/4-20 X 0.75 Push Rivet NUT-HXFL-M10X1.5 40 ft-lbs (54 Nm) WARNING The ROPS/roof should only be serviced by a certified Polaris dealer. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.6 © Copyright Polaris Industries Inc.
  • Page 471 BODY / FRAME 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 472: Full Doors (Turbo S Models)

    Striker Screws 8 ft-lb (11 Nm) Hinge Pin Lower Door Panel Latch Lower Door Frame Hinge Screws 8 ft-lb (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 473: Dash / Controls

    DASH / CONTROLS 7” Display (Turbo S Models Only) Headlight Switch Key Switch AWD Switch Mode Switch (Turbo S Models Only) 12V Accessory 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 474: Hood / Front Body

    Front Fascia Fastener8 ft-lbs (11 Nm) Front Fender Flair (Right) Winch Cover Fender Flair Fastener8 ft-lb (11 Nm) Winch Cover Fasteners22 in-lb ( 3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 475: Chassis / Main Frame

    Skid Plate Fastener 8 ft-lbs (11 Nm) Frame Center Joint Fastener Step 1: 60 ft-lbs (82 Step 2: 100 ft-lbs (149 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 476: Chassis / Main Frame (4 Seat)

    Front Seat Base Rear Skid Plate Dash Support Skid Plate Fastener 8 ft-lbs (11 Nm) Dash Support Fastener 14 ft-lbs (19 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 477: Main Frame Assembly

    Step 1: 35 ft-lbs (47 Nm)Step 2: 40 ft-lbs (54 Nm) 4. Torque center joints in sequence to step 2 specification. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 478: Seat Assembly Front

    4 ft-lb (5 Nm) Screw Seat Back 4 ft-lb (5 Nm) Seat Base Seat Base Pad Seat Base Slider Assembly Seat Latch Lever 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 479: Floor / Rocker Panels

    8 ft-lb (11 Nm) LH Rocker Console Cover U-Type Nuts Seat Belt Boot Master Cylinder Mounting Plate Shifter Boot Lower Floor 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 480: Rear Cargo Box / Fenders

    Rear Fascia Fastener 36 in-lbs (4 Nm) Intake Cover Rear Fascia Intake Cover Fastener 36 in-lbs (4 Nm) Rear Fascia Bracket 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 481: Rear Bumper

    Rear Fascia Fasteners Exhaust Cover/Bumper 8 ft-lb (11 Nm) Exhaust Cover Bracket (lower) Rear Fascia Fascia Support Brackets Exhaust Cover Bracket (upper) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 482: Body Component Removal

    6. For installation, reverse steps and torque to specification. TORQUE Front Fascia Fasteners: 8 ft-lb (11 Nm) TORQUE Winch Cover Fasteners: 22 in-lb ( 3 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 483: Rear Fascia

    1. Remove the hood as previously described. 2. Remove the four T-40 Torx screws retaining the upper dash cover between the front fenders 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 484: Front Fender Flair Removal

    FRONT FENDER FLAIR REMOVAL Remove the Five T-40 torx screws and one push pin. Remove fender flairs from the dash assembly. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 485: Rear Fender / Fender Flair

    1. Remove two Torx screws from the PVT and/or Air Intake cover/pre-filter. 2. Remove the PVT and/or Air Intake cover/pre-filter (engine air intake shown). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.21 © Copyright Polaris Industries Inc.

  • Page 486: Cargo Box

    7. Remove both cargo box halves from the vehicle. 5. Remove the 15 Torx screws and two plastic rivets in the bed of the cargo box. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 487: Rocker Panels, Console And Floor

    4. Remove Torx screws retaining upper floor to lower floor 5. Remove Torx screws retaining rear portion of the floor and remove lower floor from the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.23 © Copyright Polaris Industries Inc.

  • Page 488: Doors

    Door Panel Fasteners: 22 in-lb (2 Nm) 5. Adjust the door so it properly opens and latches. Refer to Door Adjustment page 11.24. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.24 © Copyright Polaris Industries Inc.
  • Page 489 5. Holding the door in position, tighten the top hinge bracket M8 fasteners and then bottom fasteners . Torque to specification. TORQUE Door Hinge Fasteners: 8 ft-lb (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 490: Rops And Roof

    6. Repeat steps 1-5 to install the LH rear ROPS assembly. 7. Install the front ROPS assembly onto the vehicle. 3. Install the RH rear ROPS assembly onto the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.26 © Copyright Polaris Industries Inc.
  • Page 491 C-Pillar mounts. ROPS assemblies. 10. Install the rear ROPS assembly onto the vehicle; align with C-Pillar mounts and rear ROPS mounting points. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.27 © Copyright Polaris Industries Inc.

  • Page 492: Rops Torque Procedure

    ROPS assembly. TORQUE TORQUE Front ROPS Fasteners: ROPS Fasteners: 40 ft-lbs (54 Nm) 40 ft-lbs (54 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.28 © Copyright Polaris Industries Inc.
  • Page 493 B-Pillar. to the left B-Pillar. TORQUE TORQUE Rear ROPS Fasteners: Rear ROPS Fasteners: 40 ft-lbs (54 Nm) 40 ft-lbs (54 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.29 © Copyright Polaris Industries Inc.
  • Page 494 ROPS assembly. TORQUE TORQUE Rear ROPS Mount Fasteners: ROPS Fasteners: 35 ft-lbs (47 Nm) 40 ft-lbs (54 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.30 © Copyright Polaris Industries Inc.

  • Page 495: Roof Installation (Turbo S Only)

    (PN 7519650). Torque to specification. TORQUE Seat Belt Cross Member Fasteners: 40 ft-lbs (54 Nm) TORQUE Roof Bracket Mounting Fasteners: 8 ft-lbs (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.31 © Copyright Polaris Industries Inc.
  • Page 496 4. Install the left front roof cover which has the RZR etching (PN 5267873-458) and the right front roof cover (PN 5267874-458). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.32 © Copyright Polaris Industries Inc.
  • Page 497 14 ft-lbs (19 Nm) 3. Install O-ring approximately 3/4″ (20 mm) from the end of the LH ROPS. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.33 © Copyright Polaris Industries Inc.
  • Page 498 M10 x 1.25 flanged Nyloc nuts (PN 7547333) cover panels on both sides. onto the bolster and middle mount point. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.34 © Copyright Polaris Industries Inc.
  • Page 499 M10 x 1.5 x 45 screws (PN 7519906) and M10 x 1.5 Nyloc nuts (PN 7547746) into each mount. TORQUE ROPS Cover Panel fasteners: 14 in-lb (2 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.35 © Copyright Polaris Industries Inc.
  • Page 500 19. Reinstall door striker and striker fasteners. Torque fasteners to specification. TORQUE Door Striker Fasteners: 8 ft-lbs (11 Nm) 20. Repeat for opposite side of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 11.36 © Copyright Polaris Industries Inc.
  • Page 501 ..............12.22 REGULATOR REPLACEMENT 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.1...
  • Page 502 ............... 12.48 BREAK-OUT DIAGRAM VIEWING 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.2...

  • Page 503: General Information

    Fluke™ 77 Digital Multimeter PV-43568 Digital Wrench® (see Chapter 4 – DIGITAL WRENCH® OPERATION page Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.3 © Copyright Polaris Industries Inc.

  • Page 504: Electrical Service Notes

    • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. • Most electrical issues are related to damaged wiring. Fully test wiring before replacing any components. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.4...
  • Page 505 Crank Position Sensor BAP Sensor Battery (-) Starter (+) Waste Gate Control Battery (+) Engine Ground Shock Actuator Detonation/Knock Sensor Starter Solenoid 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.5 © Copyright Polaris Industries Inc.

  • Page 506: Electrical Component Locations (Front)

    Voltage Regulator Key Switch Shock Actuator GPS Receiver 3& EPS Power Diagnostic Plug AAT Sensor 4& EPS Signal Left Headlight AWD Coil 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.6 © Copyright Polaris Industries Inc.
  • Page 507 ELECTRICAL 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.7 © Copyright Polaris Industries Inc.

  • Page 508: Instrument Cluster

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.8...
  • Page 509 Parking Brake Indicator - Illuminates when parking brake is engaged (INT’L Models Only). Low Battery Indicator - Illuminates when battery voltage is low, charging system may be overloaded. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.9...

  • Page 510: Information Display Area

    Service Hours interval has been reached. AREA 3 MODES MODE DESCRIPTION The clock displays time in a 12-hour or 24-hour format. Clock 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.10 © Copyright Polaris Industries Inc.

  • Page 511: Gauge Settings Menu

    4. Press MODE to save and exit to the settings menu. 1. Press and hold the MODE button to enter the settings menu. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.11 © Copyright Polaris Industries Inc.

  • Page 512: Trip Meter

    1. Press either toggle button to cycle to the trip time option (TT). 2. Press and hold either toggle button until the meter resets to zero. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.12 © Copyright Polaris Industries Inc.
  • Page 513 Right Turn Signal Input High Beam Input Trailer Turn Sign Input Fuel Level Sensor Blackout Mode Input Accy Air Temp Input 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.13 © Copyright Polaris Industries Inc.

  • Page 514: Switches / Controls

    NOTICE Pins 7 and 8 provide power and ground to light the switch lamp. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.14 © Copyright Polaris Industries Inc.

  • Page 515: Awd / 2Wd Switch (No Turf Mode)

    2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT DISENGAGED ENGAGED Between both ∞ (OL) < 1 Ω pins on switch 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.15 © Copyright Polaris Industries Inc.

  • Page 516: Transmission / Gear Position Switch

    160 Ω slight pressure, first clean the switch contacts and re- 75 Ω test. Replace switch if necessary. PARK 24 Ω 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.16 © Copyright Polaris Industries Inc.

  • Page 517: Boost Control Solenoid / Valve

    22–24 Ω More information relating to the turbocharger system and components may be found in the Engine and Fuel System chapters. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.17 © Copyright Polaris Industries Inc.

  • Page 518: Steering Angle Sensor Centering (Dynamix)

    4. Come to a complete stop without turning the steering wheel. Turn key off. 5. Turn key to ON position. 6. Cycle key off and back on. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.18 © Copyright Polaris Industries Inc.

  • Page 519: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Mounting Bolt: 8 ft-lb (11 Nm) 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.19 © Copyright Polaris Industries Inc.

  • Page 520: Charging System

    3. Shift transmission into park and start the engine. With the engine running at idle, observe meter readings. 5. Connect your black lead to the battery negative post. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.20 © Copyright Polaris Industries Inc.

  • Page 521: Stator Testing

    Each test should measure: CONNECT OHMS TEST METER READING LEADS TO: Open Line Battery Charge Y1, Y2, or Y3 (Infinity) Coil to Ground 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.21 © Copyright Polaris Industries Inc.

  • Page 522: Test 3: Measure Ac Voltage Output Of Each Stator Leg At Charging Rpm

    50 VAC ± 25% 5000 82 VAC ± 25% 3. Disconnect the two wiring harnesses going to the regulator(s) being removed. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.22 © Copyright Polaris Industries Inc.
  • Page 523 8. Connect the battery negative cable. Torque fastener to specification. NOTE Battery Terminal Fastener: 60 in-lbs (7 Nm) 9. Install the seat. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.23 © Copyright Polaris Industries Inc.

  • Page 524: Battery

    Refer to OCV table (see OCV - Open Circuit Voltage Test page 12.26). 5. Charge the battery as recommended (see – Charging Procedure page 12.27). 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.24 © Copyright Polaris Industries Inc.

  • Page 525: Battery Removal

    60 in-lbs (7 Nm) 6. Verify that cables are properly routed and reinstall the driver’s seat. 5. Lift the battery out of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.25 © Copyright Polaris Industries Inc.

  • Page 526: Battery Off Season Storage

    75% Charged 12.6 V 50% Charged 12.3 V 25% Charged 12.0 V 0% Charged 11.8 V or less Polaris MDX-610P PU-50296 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.26 © Copyright Polaris Industries Inc.

  • Page 527: Charging Procedure

    Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.27 © Copyright Polaris Industries Inc.

  • Page 528: Lighting System

    (see Chapter 10 – Front Bumper XP page 3. Carefully lift and remove headlamp assembly from the bumper. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.28 © Copyright Polaris Industries Inc.

  • Page 529: Headlamp Installation

    6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlight Adjustment” procedure as shown in this chapter. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.29 © Copyright Polaris Industries Inc.

  • Page 530: Cooling System

    1 Ω. • Power side should show battery voltage. If battery voltage is not seen, check voltage at the fan circuit breaker. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.30 © Copyright Polaris Industries Inc.

  • Page 531: Fan Control Circuit Bypass Test

    3. Remove the zip ties on both sides retaining the headlight harnesses. 4. Remove two fasteners retaining the voltage regulator bracket, and remove the bracket. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.31 © Copyright Polaris Industries Inc.
  • Page 532 Remove the fan assembly out the top of the vehicle. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.32 © Copyright Polaris Industries Inc.

  • Page 533: Electric Coolant Pump

    3. When the system is bled properly, remove the jumper and reinstall the Fuel Pump relay. REPLACEMENT 1. Place a drain pan underneath the coolant pump. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.33 © Copyright Polaris Industries Inc.

  • Page 534: Ect Sensor Test

    176 °F (80 °C) 323 Ω ± 6% 194 °F (90 °C) 243 Ω ± 6% 212 °F (100 °C) 186 Ω ± 6% 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.34 © Copyright Polaris Industries Inc.

  • Page 535: Starting System

    12V power to reach the to specification. starter motor. TORQUE Solenoid Cable Nuts: 35 in-lb (4 Nm) 7. Connect the harness to the solenoid. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.35 © Copyright Polaris Industries Inc.

  • Page 536: Electronic Power Steering (Eps)

    NOTICE See Steering System Assembly page 8.4 in the Steering / Suspension chapter for power steering unit removal and installation procedures. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.36 © Copyright Polaris Industries Inc.
  • Page 537 Power Out Coil Low Power In Key 7.5A Fuse Power Out Power In Fan 30A Fuse Power Out Accy Relay Coil High 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.37 © Copyright Polaris Industries Inc.
  • Page 538 Power Out Coil Low Power In Water 7.5A Fuse Power Out Power In Fuel 7.5A Fuse (10A for EVAP only) Power Out 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.38 © Copyright Polaris Industries Inc.
  • Page 539 FUNCTION Coil High Power In EFI Relay Power Out Coil Low Coil High Power In Brake Relay Power Out Coil Low 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.39 © Copyright Polaris Industries Inc.

  • Page 540: Relay / Fuse Details

    Accy 10A Fuse 12V Receptacle(s) Key 10A Fuse Key Switch LED Light(s) Instr Fuse Out Splice Diagnostic Plug Insr 10A Fuse Speedometer 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.40 © Copyright Polaris Industries Inc.

  • Page 541: Voltage Regulator Fusible Link

    These are located on the pigtails coming off the B + post, under the front driver’s side fender. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.41 © Copyright Polaris Industries Inc.

  • Page 542: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.42 © Copyright Polaris Industries Inc.

  • Page 543: Wiring Harness

    ELECTRICAL WIRING HARNESS ELECTRICAL HARNESS ROUTING NOTICE If replacing the harness, Noting routing during removal will aid in proper installation. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.43 © Copyright Polaris Industries Inc.

  • Page 544: Electrical Harness Retention

    ELECTRICAL ELECTRICAL HARNESS RETENTION Zip Tie Retention Point The white tape on the harness signifies a retention point 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.44 © Copyright Polaris Industries Inc.
  • Page 545 ELECTRICAL ELECTRICAL HARNESS RETENTION (4-SEAT) Zip Tie Retention Point The white tape on the harness signifies a retention point 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.45 © Copyright Polaris Industries Inc.

  • Page 546: Electrical Harness Retention (4-Seat)

    ELECTRICAL ELECTRICAL HARNESS RETENTION (4-SEAT) Zip Tie Retention Point The white tape on the harness signifies a retention point 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.46 © Copyright Polaris Industries Inc.

  • Page 547: Wiring Harness Replacement

    Panels, Console, and Floor page 11.23. 12. Remove the seats and seat frames. 13. Remove the ECU cover and disconnect the harness from the ECU. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.47 © Copyright Polaris Industries Inc.

  • Page 548: Break-Out Diagram Viewing

    Break-Out diagrams for this model may be found in the online service manual in with the main wiring diagrams. To access the interactive break-out diagrams: 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.48 © Copyright Polaris Industries Inc.
  • Page 549 Deselect any other diagram that may be a shadow of the full diagram behind the break-out selected. diagram. 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.49 © Copyright Polaris Industries Inc.
  • Page 550 ELECTRICAL NOTES 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual 12.50 © Copyright Polaris Industries Inc.
  • Page 551 .1 Symptom and Occurrence Checklist IMPORTANT This checklist is intended for Dealer use. It is a guide to help with concerns that are Intermittent and / or Hard to Duplicate. It is intended to collect as much information as possible before continuing with the diagnosis. •...
  • Page 552 2018-2019 RZR XP / XP 4 Turbo S OCCURRENCE CHART ○ ALWAYS ○ MORE THAN 50% OF THE TIME WHEN IS PROBLEM APPARENT? ○ LESS THAN 50% OF THE TIME IF NO PLEASE EXPLAIN: ○ YES DOES IT HAVE TO BE RUNNING OR DRIVING? ○...
  • Page 553 Symptom and Occurrence Checklist ○ BEEN PRESENT SINCE NEW...
  • Page 555 A.1 Wiring Diagrams 2018: Click here: RZR XP Turbo S wiring diagram 2019: Click here: RZR XP Turbo S Wiring Diagram Click here: RZR XP Turbo S EVAP Wiring Diagram Click here: RZR XP 4 Turbo S EVAP Wiring Diagram...
  • Page 557 Boost Pressure Sensor..........4.38 Assembly (front).............9.18 Brake Assembly (rear) .............9.25 Brake Warning System Disassembly / Inspection (rear) .........9.23 Half Plausibility ...........9.21 Installation (front) ...........9.19 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 558 Coolant Hose Procedures............10.44 Inspection.............2.37 Engine Cranks but does Not Start ......10.8 Coolant Pump No Crank No Start or Slow Crank......10.10 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 559 Test ..............12.34 Valve Cover Installation ......... 3.107 Valve Cover Removal ..........3.58 ETC Learn Procedure ......4.9, 4.43, 10.21 Valve Inspection.............3.64 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 560 Fuel Injector O-rings..............4.10 Replacement............4.12 Ignition Coil ............12.19 Replacement............12.19 Test ..............4.11 Test ..............12.19 Troubleshooting ............. 4.11 Fuel Injectors Injector 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 561 Misfire Detection ............. 10.37 Pressure Test Mode Switch (Dynamix) ........8.55, 12.17 Cooling System..........2.37, 3.34 Model Number Designation .......... 1.2 Primary Clutch 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 562 Roof Assembly ............11.5 PVT System ............5.2 ROPS Steering ..............8.3 Installation ............11.26 Suspension............8.3 Installation (4 Seat)..........11.32 Transmission............6.2 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 563 Operation Overview ..........3.11 Symptom Checklist ............51 Troubleshooting ........... 10.15 Taillight U-joint Replacement............12.29 Disassembly ............7.25 Tap / Drill Sizes {Metric} ..........1.18 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.7 © Copyright Polaris Industries Inc.
  • Page 564 Alignment / Inspection ..........2.50 Installation ............2.46 Removal...............2.46 Toe Adjustment ............2.51 Wheel Bearing ............7.4 Replacement (rear)..........7.8 Wiring Harness Replacement............12.47 9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual IX.8 © Copyright Polaris Industries Inc.

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