Polaris RZR PRO XP 2020 User manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer®technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2020 (PN 9850068 R01)
© Copyright 2020 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2020-2021 RZR PRO XP / XP 4
Service Manual

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.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.

REVISION INDEX
REV DATE CHANGES
R01 11/10/2020 Initial Release.

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

2020-2021 RZR PRO XP / XP 4
Service Manual
Chapter Summary
CHAPTER 1 : GENERAL INFORMATION
CHAPTER 2 : MAINTENANCE
CHAPTER 3 : ENGINE / COOLING SYSTEM
CHAPTER 4 : ENGINE ELECTRICAL
CHAPTER 5 : EFI / FUEL SYSTEM
CHAPTER 6 : PVT SYSTEM
CHAPTER 7 : TRANSMISSION
CHAPTER 8 : FINAL DRIVE
CHAPTER 9 : STEERING / SUSPENSION
CHAPTER 10 : BRAKE SYSTEM
CHAPTER 11 : BODY / FRAME
CHAPTER 12 : ELECTRICAL

1
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.1
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VIN AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
2020 RZR PRO XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
2020-21 RZR PRO XP CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
2020 RZR PRO XP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2020-21 RZR PRO XP 4 CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
2021 RZR PRO XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
2020-21 RZR PRO XP CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
2021 RZR PRO XP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2020-21 RZR PRO XP 4 CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
GENERAL DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
GENERAL DIAGNOSTICS INFORMATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
GUIDED SYMPTOM DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
GUIDED SYMPTOM REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27
ENGINE CRANKS BUT DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
NO CRANK NO START OR SLOW CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
OVER HEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33
WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34
ENGINE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
COOLING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37
DIGITAL WRENCH® SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38
GUIDED DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.39
DIGITAL WRENCH® COMMUNICATION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41

1.2 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
POLARIS MOBILE DIGITAL WRENCH® (PMDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
DIAGNOSTIC TROUBLE CODES OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
MASTER TROUBLE CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.47
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59
FLUID INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59
FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62
PVT SYSTEM OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
TRANSMISSION ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
ALL WHEEL DRIVE (AWD) CONCERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
BRAKE VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68
POOR BRAKE PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . . . . . . .1.69
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . . . . . . .1.70
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74
TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
TESTING FOR A SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
TESTING FOR INTERMITTENT CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.77
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.77
CURRENT DRAW - KEY OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78
GENERAL INFORMATION

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.3
VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5R U E 57A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)
Example: 4XARUE573FG000000
WORLD MFG. ID
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
CHASSIS
DRIVELINE
CHASSIS
MODIFIER
ENGINE SIZE
ENGINE MODIFIER
CHECK DIGIT
MODEL YEAR *
MFG. LOCATION
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A R U E 5 7 3 F G 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J = 2018; K = 2019, L = 2020,
M = 2021
VIN AND ENGINE SERIAL NUMBER LOCATIONS
Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial
number.
The VIN can be found stamped on the rear left vertical shock support tube q.
The engine serial number can be found on a decal applied to the front of the engine crankcase wor stamped into the
crankcase on the PTO side of the engine.
GENERAL INFORMATION
1

1.4 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
GENERAL INFORMATION