Polaris RZR XP Turbo & XP4 Turbo (2019-2020) - Service Manual, Repair Manual - Wiring Diagrams

POLARIS RZR XP TURBO & XP4 TURBO (2019-2020) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for UTV Polaris RZR XP Turbo & XP4 Turbo (2019-2020).

 
CONTENTS:


SERVICE MANUAL

2019–2020 RZR XP Turbo / XP4 Turbo
- Foreword
- Trademarks
- Revision Index
- Feedback Form

1: GENERAL INFORMATION
- Vehicle Identification
- Model Number Designation (2015 +)
- Vehicle Identification Number (VIN) Designation (2015+)
- VIN and Engine Serial Number Locations
- Reference Information
- Replacement Keys
- Publication Numbers
- Special Tools
- Master Torque Table
- Vehicle Specifications
- 2019 RZR XP Turbo
- 2019 RZR XP Turbo Clutch Chart
- 2019 RZR XP 4 Turbo
- 2019 RZR XP 4 Turbo Clutch Chart
- 2019 RZR XP Turbo Fox Edition
- 2019 RZR XP Turbo Clutch Chart
- 2019 RZR XP 4 Turbo Fox Edition
- 2019 RZR XP 4 Turbo Clutch Chart
- 2019 RZR XP Turbo Dynamix Edition
- 2019 RZR XP Turbo Clutch Chart
- 2019 RZR XP 4 Turbo Dynamix Edition
- 2019 RZR XP 4 Turbo Clutch Chart
- 2020 RZR XP Turbo
- 2020 RZR XP Turbo Clutch Chart
- 2020 RZR XP 4 Turbo
- 2020 RZR XP 4 Turbo Clutch Chart
- 2020 RZR XP Turbo Fox Edition
- 2020 RZR XP Turbo Clutch Chart
- 2020 RZR XP 4 Turbo Fox Edition
- 2020 RZR XP 4 Turbo Clutch Chart
- 2020 RZR XP Turbo Dynamix Edition
- 2020 RZR XP Turbo Clutch Chart
- 2020 RZR XP 4 Turbo Dynamix Edition
- 2020 RZR XP 4 Turbo Clutch Chart
- Misc. Specifications and Charts
- Conversion Table
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

2: MAINTENANCE
- PERIODIC MAINTENANCE - GENERAL
- Lubricants / Service Products
- Pre-Ride Inspection
- Maintenance Intervals
- Maintenance Quick Reference
- Grease Lubrication Points
- ENGINE / EXHAUST
- Engine Oil Level
- Engine Oil and Filter Change
- Engine Crankcase Breather Hose
- Engine Cylinder Leakdown Test
- Valve Clearance Adjustment
- Cam Chain Tensioner Inspection
- Spark Arrestor
- Heat Shield Inspection
- COOLING SYSTEM
- Coolant Strength
- Coolant Level Inspection
- Cooling System Pressure Test
- Coolant Hose Inspection
- Radiator Inspection / Cleaning
- Coolant Flush
- Cooling System Bleeding
- FUEL SYSTEM AND AIR INTAKE
- Fuel Tank Vent Inspection
- Throttle Pedal Inspection
- Engine Intake Pre-Filter Service
- Air Filter Service
- Intake Duct Drain Inspection
- PVT / FINAL DRIVE / WHEEL AND TIRE
- PVT Drain
- PVT Intake Pre-Filter Service
- Front Gearcase Lubrication
- Front Gearcase Fluid Level Check
- Front Gearcase Fluid Change
- Drive Shaft Boot Inspection
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
- TRANSMISSION
- Transmission Lubrication
- Transmission Oil Level Check
- Transmission Oil Change
- STEERING
- Steering Inspection
- Steering Wheel Free-play
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
- SUSPENSION
- Suspension Inspection
- Suspension Lubrication
- BRAKE SYSTEM
- Brake Fluid Inspection
- Brake Hose and Fitting Inspection
- Brake Pad Inspection
- Brake Disc Inspection
- ELECTRICAL AND IGNITION SYSTEM
- Battery Maintenance
- Battery Charging / Off Season Storage
- Engine / Chassis Electrical Ground
- Spark Plug Service

3: ENGINE / COOLING SYSTEM
- General Information
- Special Tools
- Engine Lubrication Specifications
- Oil Pressure Test
- Oil Flow Chart
- Engine Service Specifications
- Engine Specifications
- Engine Torque Specifications
- Intake / Exhaust System
- Intake / Turbo System Overview
- Engine Air Intake Assembly View
- Air Box Removal
- Air Box Installation
- Exhaust Assembly View
- Muffler Removal
- Muffler Installation
- Exhaust Pipe Removal
- Head Pipe / Turbo Removal
- Head Pipe / Turbo Installation
- Exhaust Pipe Installation
- Turbocharger Service
- Turbocharger Inspection
- Actuator / Wastegate Inspection
- Actuator Pod Removal
- Oil Drain Tube Service
- Wastegate Flapper Inspection
- Cooling System
- Cooling System Flow
- Cooling System Specifications
- Cooling System Pressure Test
- Charge Air Cooler Removal
- Charge Air Cooler Installation
- Radiator Removal
- Radiator Installation
- Thermostat Replacement
- Water Pump Service
- Engine Service
- Front Engine Mount Isolator Replacement
- Crankshaft PTO Seal Replacement
- Engine Removal
- Engine Installation
- Cam Chain Tensioner Service
- Engine Disassembly / Inspection - Top End
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Seat Reconditioning
- Engine Disassembly / Inspection - Bottom End
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-way Clutch Disassembly
- Crankcase Disassembly
- Balance Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Inspection
- Cylinder / Piston Removal
- Cylinder Inspection
- Piston Disassembly / Inspection
- Piston Ring Removal
- Piston Ring to Groove Clearance
- Piston Ring Installed Gap
- Piston to Cylinder Clearance
- Connecting Rod Inspection
- Engine Assembly - Bottom End
- Bearing Selection Identification
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- Upper Crankcase Preparation
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Piston / Cylinder Installation
- Crankshaft Installation
- Balance Shaft Installation
- Lower Crankcase Preparation
- Crankcase Assembly
- Starter One-way Clutch Assembly
- Flywheel Installation
- Stator Cover Installation
- Engine Assembly - Top End
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing Quick Reference
- Valve Clearance Adjustment
- Valve Lash - Tappet Selection
- Valve Cover Installation
- Troubleshooting
- Engine Troubleshooting
- Cooling Troubleshooting
- Turbocharger Troubleshooting

4: ENGINE ELECTRICAL
- Electronic Control Unit (ECU)
- ECU Operation Overview
- ECU Service
- ECU Replacement
- ETC Learn Procedure
- Knock Sensor
- Knock Sensor Overview
- Knock Sensor Testing
- Knock Sensor Replacement
- Crankshaft Position Sensor (CPS)
- Operation Overview
- CPS Test
- CPS Replacement
- Electronic Throttle Control (ETC) / Throttle Body
- ETC Operation Overview
- ETC Test
- ETC / Throttle Body Replacement
- ETC Learn Procedure
- Pedal Position Sensor (PPS)
- Operation Overview
- Location
- PPS Test
- PPS Replacement
- Oxygen Sensor
- Oxygen Sensor Information
- Oxygen Sensor Replacement
- Polaris Digital Wrench
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Digital Wrench)
- Digital Wrench Software Version and Update ID
- Digital Wrench® Updates
- Digital Wrench® Communication Errors
- Digital Wrench Diagnostic Connector
- Guided Diagnostics
- Digital Wrench® Serial Number Location
- Digital Wrench® Feature Map
- ECU Replacement
- ETC Learn Procedure
- ECU Reprogramming (Reflash)
- Polaris Mobile Digital Wrench (PMDW)
- Polaris Mobile Digital Wrench (PMDW)

5: EFI / FUEL SYSTEM
- General Information
- Special Tools
- EFI Overview
- EFI System Components/Locations
- EFI Operation Overview
- EFI Service Notes
- Initial Priming / Starting Procedure
- EVAP SYSTEM
- EVAP System Overview
- EVAP Conditions and Symptoms
- Fuel Injectors
- Fuel Injector Operation Overview
- Fuel Injector O-rings
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement
- Fuel Lines
- Fuel Line Removal / Installation
- Fuel Vent Line Routing
- Fuel Vent Line Routing (EVAP Models)
- Vent Line Termination Fitting
- Fuel Tank / Pump
- Fuel Tank Assembly View
- Fuel Tank Vacuum Test (EVAP Models)
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank Removal (XP4)
- Fuel Tank Installation (XP4)
- Fuel Pump Operation Overview
- Fuel Pressure Test
- Fuel Pressure Test (EVAP Models)
- Fuel Pump Replacement
- Fuel Sender Test
- Pressure Sensors
- BAP Sensor
- Boost Pressure Sensor
- Fuel Pressure Sensor (EVAP Models)
- TMAP Sensor
- Air Temperature Sensor Data
- EFI Diagnostics
- Fuel System Troubleshooting
- Digital Wrench Data Troubleshooting
- Cylinder Misfire Detection

6: PVT SYSTEM
- General Information
- Special Tools
- 2019 RZR XP Turbo Clutch Chart
- 2019 RZR XP 4 Turbo Clutch Chart
- PVT System Overview
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- Drive Belt
- Belt Removal
- Belt Inspection
- Belt Installation
- Belt Break-In
- Drive Clutch Service
- Drive Clutch Removal
- Drive Clutch Assembly View
- Drive Clutch Disassembly / Inspection
- Drive Clutch Assembly
- Drive Clutch Installation
- Driven Clutch Service
- Driven Clutch Removal
- Driven Clutch Assembly View
- Driven Clutch Disassembly / Inspection
- Driven Clutch Assembly
- Driven Clutch Installation
- Troubleshooting
- TROUBLESHOOTING

7: TRANSMISSION
- General Information
- Special Tools
- Shift Lever / Cable
- Shift Lever Removal
- Shift Lever Installation
- Shift Cable Inspection
- Shift Cable Adjustment
- Transmission Service
- Transmission Removal
- Transmission Installation
- Transmission Vent Line Routing
- Transmission Disassembly
- Gear, Shaft, Bearing Inspection
- Transmission Assembly / Snorkel Gear Backlash
- Troubleshooting
- Shifting Difficulty

8: FINAL DRIVE
- General Information
- Special Tools
- Bearing Carrier
- Front Bearing Carrier Removal / Inspection
- Front Bearing Replacement
- Front Bearing Carrier Installation
- Rear Bearing Carrier Inspection / Removal
- Rear Bearing Replacement
- Rear Bearing Carrier Installation
- Drive Shaft
- Front Drive Shaft Removal
- Front Drive Shaft Installation
- Rear Drive Shaft Removal
- Rear Drive Shaft Installation
- Drive Shaft / CV Joint Handling Tips
- Outer CV Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Prop Shaft
- Prop Shaft Removal (XP)
- Prop Shaft Removal (XP4)
- Prop Shaft Assembly View
- Support Bearing Replacement
- U-Joint Disassembly
- U-Joint Assembly
- Prop Shaft Installation (XP)
- Prop Shaft Installation (XP4)
- Front Gearcase / Centralized Hilliard
- Centralized Hilliard Assembly View
- All Wheel Drive Operation
- AWD Diagnosis
- Front Gearcase Removal
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- Front Gearcase Installation
- Front Gearcase Vent Line Routing
- Wheel Hubs
- Front Hub Assembly View
- Rear Hub Assembly View

9: STEERING / SUSPENSION
- General Information
- Special Tools
- Steering System
- Steering System Assembly View
- Upper Steering Shaft Removal
- Steering Wheel Removal
- Power Steering Unit Removal
- Lower Steering Shaft Removal
- Lower Steering Shaft Installation
- Power Steering Unit Installation
- Upper Steering Shaft Installation
- Steering Shaft Bushing Replacement
- Front Suspension
- Front Suspension Assembly View
- Front A-arm Removal / Replacement
- Front Stabilizer Bar Removal
- Front Stabilizer Bar Installation
- Ball Joint Service Preparation
- Ball Joint Removal
- Ball Joint Installation
- Rear Suspension
- Rear Suspension Assembly View (Remote Reservoir)
- Trailing Arm Removal / Installation
- Trailing Arm Spherical Bearing Replacement
- Radius Rod Removal / Installation
- Rear Stabilizer Bar Removal
- Stabilizer Bar Installation
- Shocks / Springs
- Shock Assembly View
- Shock Removal / Installation
- Shock / Spring Replacement
- Spring Adjustment
- Shock Compression Adjustment (FOX®)
- FOX 2.5″ Front Shock Information
- FOX 3.0″ Rear Shock Information
- Shock Service
- FOX SHOCK SERVICE
- FOX 2.5″ O.E. Podium Bypass
- FOX 3.0″ O.E. Podium Bypass
- Offset Torque Formula
- FOX Shock Disassembly
- FOX Shock Assembly
- WALKER EVANS SHOCK SERVICE
- Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
- General Service Information
- Spring Adjustment (Walker Evans)
- Walker Evans™ Shock Rebuild Information
- Special Tools
- Valve Shim Arrangement
- Shock Piston Orientation
- Walker Evans™ Shock Disassembly
- Walker Evans™ Shock Assembly
- DYNAMIX ACTIVE SUSPENSION (if equipped)
- Dynamix Shocks Disassembly / Assembly
- Dynamix Overview
- Demonstration Mode
- Suspension Control Module (SCM)
- DYNAMIX™ System Features
- Vehicle Speed Sensitivity
- Cornering Control
- Braking
- Acceleration
- Airborne Detection
- Advanced Diagnostics
- Processing Capability
- Suspension Mode Switch (Dynamix models)
- Dynamix Troubleshooting
- Shock Valve Power Supply
- SCM System Voltage
- SCM Shock Valve Diagnostics
- SCM Mode Switch
- SCM CAN Diagnostics
- SCM Steering Angle Adapted Offset Diagnostics
- SCM / Inertial Measurement Unit

10: BRAKE SYSTEM
- General Information
- Special Tools
- Brake System Specifications
- Brake System Overview
- Brake System View
- Brake Line Routing / Retention
- BRAKE SYSTEM SERVICE NOTES
- HYDRAULIC BRAKE SYSTEM OPERATION
- Master Cylinder
- Master Cylinder Removal
- Master Cylinder Installation
- BRAKE BLEEDING / FLUID CHANGE
- Brake Pedal
- Brake Pedal Removal
- Brake Pedal Installation
- SECONDARY HAND BRAKE (INT'L)
- Secondary Brake System Overview
- Secondary Brake Fluid Reservoir
- Secondary Brake Master Cylinder
- Front Brake Service
- Brake Caliper / Pad Removal
- Front Caliper Assembly View
- Front Caliper Disassembly / Inspection
- Brake Pad Inspection
- Front Caliper Assembly
- Brake Disc Inspection
- Front Brake Disc Replacement
- Brake Caliper / Pad Installation
- Brake Burnishing Procedure
- Rear Brake Service
- Brake Caliper / Pad Removal
- Rear Caliper Disassembly / Inspection
- Brake Pad Inspection
- Rear Caliper Assembly
- Rear Brake Disc Inspection
- Rear Brake Disc Replacement
- Rear Brake Caliper / Pad Installation
- Brake Burnishing Procedure
- Troubleshooting
- BRAKE NOISE TROUBLESHOOTING
- Poor Brake Performance
- Brake Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
- Brake Warning System (INTL Models)
- Brake Warning System Inspection (INTL Models)
- Brake Pedal Switch Inspection

11: BODY / FRAME
- General Information
- Special Tools
- DECAL REPLACEMENT
- Body Assembly Views
- Cab Frame Assembly XP
- Cab Frame Assembly XP 4
- Doors XP
- Doors (XP4)
- Dash Instruments / Controls
- Dash Instruments / Controls (Ride Command)
- Hood / Front Body Work
- Chassis / Main Frame (XP)
- Chassis / Main Frame (XP4)
- Seat Assembly Front
- Floor / Rocker Panels
- Floor / Rocker Panels (XP4)
- Rear Cargo Box / Fenders
- Rear Bumper
- Body Component Removal
- Seats
- Engine Service Panel
- Front Fascia
- Rear Fascia
- Hood and Front Body Work
- Rear Fender / Fender Flair Removal
- Cargo Box Assembly Removal
- Rocker Panels, Console and Floor XP
- Doors
- Door Panel / Latch Replacement
- Door Adjustment

12: ELECTRICAL
- General Information
- Special Tools
- Under-Dash Components
- Electrical Service Notes
- Electrical Component Locations
- Electrical Diagnostics
- Electrical Service Notes
- Digital Multi-Meter (DMM) Notes
- Static and Dynamic Testing
- Connector Probing Guidelines
- Testing Continuity / Resistance
- Testing For A Short To Ground
- Testing For A Short To Voltage
- Testing for Intermittent Conditions
- Testing Current Flow (Amperage)
- Testing Parasitic Draw
- Testing Voltage Drop
- INSTRUMENT CLUSTER
- Overview
- Indicator Lamps
- Display Area 1
- Display Area 2
- Options Menu
- Unit Selection Distance
- Unit Selection Temperature
- Clock
- Back Light Color
- Back Light Level
- Service Hours
- Diagnostic Code
- Instrument Cluster Pinouts
- Instrument Cluster Removal
- Instrument Cluster Installation
- Switches / Controls
- Headlamp Switch
- Ignition / Key Switch
- AWD / 2WD Switch (no Turf mode)
- Seat Belt Switch
- Transmission / Gear Position Switch
- Brake Pressure Switch
- Boost Control Solenoid / Valve
- Hazard Switch (INT'L / Tractor)
- Turn/Lights/Horn Switch (INT'L/Tractor)
- Horn
- Turn Lights
- Flasher Module (INT'L/Tractor)
- Brake Alarm (INT'L/Tractor)
- Parking Brake Switch (INT’L/Tractor)
- Suspension Mode Switch (Dynamix models)
- Steering Angle Sensor Centering (Dynamix)
- Ignition Coil
- Operation Overview
- Ignition Coil / HT Lead Replacement
- Ignition Coil Tests
- Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Stator Testing
- Voltage Regulator (Non-Dynamix)
- Voltage Regulator (Dynamix)
- Battery
- Battery Specifications
- General Battery Information
- Battery Removal
- Battery Installation
- Battery Off Season Storage
- Battery Testing
- OCV - Open Circuit Voltage Test
- Load Test
- Battery Conductance Analyzer
- Charging Procedure
- Lighting System
- Headlight Adjustment
- Headlamp Replacement
- Headlamp Installation
- Taillight Replacement
- Dash Light
- Cooling System
- Cooling Fan Description and Operation
- Cooling Fan Testing
- Fan Control Circuit Bypass Test
- Cooling Fan Replacement
- Electric Coolant Pump
- ECT Sensor Test
- Starting System
- Starter Solenoid Replacement
- Starter Solenoid Bench Test
- Starter Solenoid Operation
- Electronic Power Steering (EPS)
- EPS Operation
- Proper EPS System Diagnosing
- EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
- EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
- EPS Troubleshooting (Using Digital Wrench®)
- Fuses / Relays
- Fuse / Relay Center (All except Dynamix)
- Relay / Fuse Details
- Fuse / Relay Box (Dynamix)
- Voltage Regulator Fusible Link
- CAN SYSTEM
- CAN System Overview
- CAN System Testing
- Wiring Harness
- Main Harness Routing
- Main Harness Retention Locations
- Wiring Harness Replacement
- Break-Out Diagram viewing
- Diagnostic Trouble Code List


WIRING DIAGRAMS

RZR XP Turbo
- Sheet 1
- Sheet 2
- Sheet 3

RZR XP Turbo with EVAP
- Sheet 1
- Sheet 2
- Sheet 3

RZR XP Turbo Dynamix
- Sheet 1
- Sheet 2
- Sheet 3
- Sheet 4
- Sheet 5

RZR XP Turbo Dynamix with EVAP
- Sheet 1
- Sheet 2
- Sheet 3
- Sheet 4
- Sheet 5

RZR XP 4 Turbo
- Sheet 1
- Sheet 2
- Sheet 3

RZR XP 4 Turbo with EVAP
- Sheet 1
- Sheet 2
- Sheet 3

RZR XP 4 Turbo Dynamix with EVAP
- Sheet 1
- Sheet 2
- Sheet 3
- Sheet 4
- Sheet 5