Polaris RZR XP Service Manual page 136

ENGINE / COOLING SYSTEM
6. Install inner PVT cover.
TORQUE
PVT Inner Cover Fasteners:
STEP 1: Torque to 37 ft-lbs (50 Nm).
STEP 2: Install through bolts by adjusting the
transmission accordingly.
STEP 3: If previously removed, loosely install bolts
by hand.
STEP 4: Torque to 37 ft-lbs (50 Nm).
STEP 5: Torque to 50 ft-lbs (68 Nm).
STEP 6: If previously removed, torque to 37 ft-lbs
(50 Nm)
7. Install the primary clutch, belt and secondary clutch.
Install snap ring on transmission input shaft before
installing secondary clutch mounting bolt. Torque
fasteners to specification.
TORQUE
Primary Clutch Bolt:
96 ft-lb (130 Nm)
Secondary Clutch Bolt:
70 ft-lbs (95 Nm)
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)
3.54
9. Connect the starter wiring. Torque fasteners to
specification.
TORQUE
Starter Cable Nuts:
30 in-lb (3 Nm)
10. Install throttle body / intake manifold assembly.
Tighten clamps retaining intake manifold to engine.
Install lower manifold mounting bolt (to trans mount
bracket). Torque fasteners to specification.
TORQUE
Intake Manifold Clamps:
6 ft-lb (8 Nm)
Lower Intake Manifold Mounting Fasteners:
20 ft-lb (27 Nm)
11. Install zip ties retaining fuel lines and harnesses to
intake manifold.
12. Connect harness going to TBAP, both TMAP sensors,
CPS, coolant temp sensor, Trans switch, speed
sensor, injectors, ETC.
13. Connect the fuel supply and return hoses at the fuel
rail.
14. Connect stator harness.
15. Install the coolant hose to the thermostat housing and
the water pump hose.
16. Install the two hoses going to charge air cooler.
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.