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

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.5
REFERENCE INFORMATION
REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.)
SERIES# PART NUMBER
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
PUBLICATION NUMBERS
YEAR MODEL OWNER’S
MANUAL
2020 RZR PRO XP 9931012
NOTICE
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.
GENERAL INFORMATION
1

1.6 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier.
Bosch Automotive Service Solutions:
1-800-345-2233 or http://polaris.service-solutions.com/
GENERAL INFORMATION

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.7
2200421
Gas Shock
Recharging Kit
2460761
Hall Sensor Probe
Harness
2870386
Piston Pin Puller
2870630
Timing Light
PU-52522
Live Valve Tool
2870910-A
Roller Pin Tool
2870975
Mity-Vac Pressure
Test Tool
2871226
Clutch Bushing
Replacement Tool Kit
2871282
Transmission Seal
Driver (50 MM)
2871358-B
Drive Clutch Holding
Fixture
2871745
Static Timing Light
Harness
2872085
Drive Clutch Puller
2876389
Combination Pliers
2878925
Spanner Wrench /
Clutch Spreader
8700226
CV Boot Clamp Pliers
(ear)
PA-48838
Fuel Pressure Adapter
PA-49316
Water Pump Drive &
Flywheel Removal
Tool
PU-43506-A
Fuel Pressure Gauge
Kit
PU-47471
Smartlink Module Kit
PU-48951
CV Boot Clamp Pliers
(Stepless)
GENERAL INFORMATION
1

1.8 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
PU-49466
Relay Bypass
PU-50105
Oil Filter Wrench
PU-50296
Battery Tester
PU-50338
Hydrometer
PU-50518-A
Clutch Compressor
PU-50562
Engine Stand Adapter
PU-50563
Cylinder Holding &
Camshaft Timing
Plate
PU-50564
Water Pump Seal
Installer
PU-50569
Oil Pressure Gauge
Adapter (1/4 NPT)
PU-50578
Clutch Spider Nut
Socket
PU-50624
Rolling Engine Stand
PU-50625
Engine Stand Adapter
Sleeve (2″)
PU-50784
Crankshaft Puller/
Installer
PU-51410
Shock Rod Holding
Tool (7/8″)
PU-51039
Gas Shock Fill Tool
PU-51220
Flywheel Holding Tool
PU-51829
Shock Spanner
Wrench 2.5–3.0 Inner
PU-51830
Shock Spanner
Wrench 2.5 Outer
PU-51832
Shock Spanner
Wrench 3.0 Outer
PU-51837
Shock Body Holding
Tool
GENERAL INFORMATION

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.9
PU-51838
Shock Body Holding
Tool
PU-51861
Drive Clutch Holding
Tool
PU-51862
Transmission Snorkel
Tool
PV-1253
Valve Spring
Compressor
PV-43513-A
Valve Spring
Compressor Adapter
PV-43526
Connector Test Kit
PV-43531
Oil Presure gauge
PV-43568
Fluke Multimeter
PV-43570-1
Piston Ring
Compressor Pliers
39800780
IFP Tool (FOX)
GENERAL INFORMATION
1

1.10 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
MASTER TORQUE TABLE
ITEM TORQUE
A-Arm Fasteners 74 ft-lbs (100 Nm)
Air Box Mounting Bolts 8 ft-lb (11 Nm)
Air Intake Housing Screw (Engine
and PVT) 35 in-lb (4 Nm)
Ball Joint Fasteners 44 ft-lbs (60 Nm)
Battery
Mount
Bracket 53 in-lbs (6 Nm)
Terminal
Fasteners 60 in-lbs (7 Nm)
Bearing Carrier Mounting Bolts
(rear) 44 ft-lbs (60 Nm)
Body Panel Fasteners 7 ft-lbs (10 Nm)
Brake Bleed Screws 48 in-lb (5 Nm)
Brake Caliper
Mounting Bolts
front 33 ft-lbs (45 Nm)
rear 33 ft-lbs (45 Nm)
Brake Junction Block Mounting
Screws 35 in-lb (4 Nm)
Brake Line Banjo Bolts 15 ft-lbs (20 Nm)
Flare Fittings 15 ft-lbs (20 Nm)
Brake Line Guide Fasteners 7 ft-lbs (10 Nm)
Brake Pedal Mount Bracket
Fasteners 18 ft-lbs (24 Nm)
Brake Scraper Fasteners 7 ft-lbs (10 Nm)
Brake Switch 15 ft-lbs (20 Nm)
Box Support Fastener 14 ft-lbs (19 Nm)
Cam Chain
Tensioner
Spring Bolt 15 ft-lb (20 Nm)
Mounting
Bolts 7 ft-lb (10 Nm)
Camshaft Carrier
Carrier Bolts 7 ft-lb (10 Nm)
Sprocket
Bolts 14 ft-lb (19 Nm)
Carbon Canister Fastener 9 ft-lbs (12 Nm)
Carbon Canister Filter Fastener 9 ft-lbs (12 Nm)
Cargo Box Fastener 7 ft-lbs (10 Nm)
Cargo Box Support Bracket
Fasteners 15 ft-lbs (20 Nm)
Charge Air Cooler Bolts Torque in sequence to
7 ft-lb (10 Nm)
Chassis Ground Nut 5 ft-lb (7 Nm)
Connecting Rod Bolts
Step 1: 9 ft-lbs (12
Nm)
Step 2: 22 ft-lb (30
Nm)
Step 3: Tighten
add’n 90°
Coolant Hose Retainer Bolt 8 ft-lb (11 Nm)
Coolant Reservoir 8 ft-lb (11 Nm)
Coolant Temperature Sensor 17 ft-lb (23 Nm)
CPS Retaining Bolt 9 ft-lb (12 Nm)
Crankcase Bolts M6 9 ft-lb (12 Nm)
M8 26 ft-lb (35 Nm)
ITEM TORQUE
M10
Step 1: 9 ft-lb (12
Nm)
Step 2: 21 ft-lb (28
Nm)
Step 3: Tighten
add’n 90°
Crankcase Oil Gallery Plug 12 ft-lbs (16 Nm)
Cylinder Head Bolts
Torque in
sequence
Step 1: 13 ft-lbs (18
Nm)
Step 2: 26 ft-lb (35
Nm)
Step 3: Additional
180°
Step 4: Additional
180°
Step 5: M6 bolts: 7
ft-lb (10 Nm)
Dash Trim Fastener 7 ft-lbs (10 Nm)
Debris Scraper 20 ft-lbs (27 Nm)
Door Frame Fastener 7 ft-lbs (10 Nm)
Door Hinge Fastener 18 ft-lbs (24 Nm)
Door Latch/Actuator Fastener 9 ft-lbs (12 Nm)
Door Panel Fastener 35 in-lbs (4 Nm)
Door Striker Fastener 7 ft-lbs (10 Nm)
Door Trim Bracket Fastener 18 in-lbs (2 Nm)
Drive Clutch
Mounting
Bolt 140 ft-lbs (190 Nm)
Cover Plate 15 ft-lbs (21 Nm)
Shift Weight 20 in-lb (2 Nm)
Driven Clutch
Helix
Fasteners 32 ft-lbs (44 Nm)
Mounting
Bolt 43 ft-lbs (58 Nm)
Driveshaft Boot Guard Screws 14 ft-lb (19 Nm)
ECU Mounting Screws 24 in-lb (3 Nm)
Electric Coolant Pump Bracket
Fasteners 8 ft-lb (11 Nm)
Engine Breather Cover Screws 7 ft-lb (10 Nm)
Engine Mount
Bracket
Fasteners 42 ft-lb (57 Nm)
Isolator Bolt 55 ft-lb (75 Nm)
Engine Mount to Frame 22 ft-lb (30 Nm)
Engine Oil Plug 12 ft-lbs (16 Nm)
EPS-to-Bracket Fasteners 33 ft-lbs (45 Nm)
EPS Bracket Mounting Fasteners
(Lower) 26 ft-lbs (35 Nm)
EPS Bracket Mounting Fasteners
(Upper) 33 ft-lbs (45 Nm)
EPS to Lower Steering Shaft
Fastener 22 ft-lbs (30 Nm)
GENERAL INFORMATION

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.11
ITEM TORQUE
Exhaust Heat Shield Fasteners 8 ft-lb (11 Nm)
Exhaust Manifold Bolts 17 ft-lb (23 Nm)
Nuts 26 ft-lb (35 Nm)
Exhaust Pipe to Muffler Nuts 18 ft-lb (24 Nm)
Exhaust Pipe to Turbo Bolts 18 ft-lb (24 Nm)
Fan Assembly Mounting Fastener 9 ft-lbs (12 Nm)
Front Fascia Fastener 7 ft-lbs (10 Nm)
Fender Flare Fastener 7 ft-lbs (10 Nm)
Floor / Rocker Panel Fastener 7 ft-lbs (10 Nm)
Flywheel Bolt
133 ft-lbs (180 Nm),
loosen 180°, retorque
to 133 ft-lb (180 Nm)
Frame Bolts (front to rear) 40 ft-lb (54 Nm)
Front Bumper Bracket Fastener 30 ft-lbs (40 Nm)
Front Crossbar Fastener 40 ft-lbs (54 Nm)
Front Fascia Fastener 8 ft-lbs (11 Nm)
Front Frame Fastener 148 ft-lbs (200 Nm)
Front Gearcase
Cover Plate
Screws 11 ft-lbs (15 Nm)
Drain/Fill
Plugs 10 ft-lbs (14 Nm)
Front Gearcase Mounting
Fasteners 52 ft-lbs (70 Nm) + 270°
Fuel Pump PFA Nut 70 ft-lbs (95 Nm)
Fuel Rail Mounting Screws 7 ft-lb (10 Nm)
Fuel Tank Block-off Panel 8 ft-lbs (11 Nm)
Fuel Tank Fasteners 15 ft-lbs (20 Nm)
Fuse Box Fasteners 5 ft-lb (7 Nm)
Gear Selector Knob 40 in-lb (5 Nm)
Heat Shield Fastener 9 ft-lbs (12 Nm)
Hip Bolster Bolts 14 ft-lb (19 Nm)
Hood Fastener 7 ft-lbs (10 Nm)
Hose Clamp 35 in-lb (4 Nm)
Hub Castle Nut (front and rear) 180 ft-lbs (244 Nm)
Ignition Coil Fastener 7 ft-lbs (10 Nm)
Instrument Panel Fastener 8 ft-lb (11 Nm)
Intake Cover Fasteners 36 in-lbs (4 Nm)
Intake Clamps 49 in-lb (6 Nm)
Intake Manifold Mounting
Fasteners (lower) 20 ft-lb (27 Nm)
Intake Manifold to Cyl Head
Clamps 6 ft-lb (8 Nm)
Knock / Det Sensor 15 ft-lb (20 Nm)
Main-to-Front Frame Fastener 33 ft-lbs (45 Nm)
Master Cylinder Mount Bolts 18 ft-lbs (25 Nm)
Manifold Pressure Banjo Bolt 7 ft-lb (10 Nm)
Oil Cooler Bolts 7 ft-lb (10 Nm)
Oil Pan Bolts (M8) M6 9 ft-lb (12 Nm)
M8 26 ft-lb (35 Nm)
Oil Pump Mounting
Bolts 7 ft-lbs (10 Nm)
ITEM TORQUE
Pickup
Screws 7 ft-lb (10 Nm)
Oxygen Sensor 13 ft-lb (18 Nm)
Power Steering Unit Shield Screws 15 ft-lb (20 Nm)
Power Steering Bracket to Frame
Nuts 18 ft-lb (24 Nm)
Power Steering Unit to Mount
Bracket 30 ft-lb (41 Nm)
Prop Shaft Roll Hoop Fasteners 13 ft-lbs (18 Nm)
Prop Shaft Support Bearing
Fastener: 30 ft-lbs (40 Nm)
Prop Shaft Mounting Plate
Fastener: 15 ft-lbs (20 Nm)
Prop Shaft to Transmission
Coupler Fasteners 11 ft-lbs (15 Nm)
PVT Inner Cover Baffle Fasteners 7 ft-lbs (10 Nm)
PVT Cover
Fasteners
inner
(see image inEngine
Installation) page for
sequence
STEP 1: Torque to
37 ft-lb (50 Nm)
STEP 2: Torque to
10 ft-lb (14 Nm)
STEP 3: Loosely
install bolts by
hand
STEP 4: Torque to
37 ft-lb (50 Nm)
STEP 5: Torque to
50 ft-lb (68 Nm)
STEP 6: Torque to
37 ft-lb (50 Nm)
outer 36 in-lbs (4 Nm)
PVT Intake Hose Clamp 25 in-lbs (3 Nm)
Radiator Bracket 8 ft-lb (11 Nm)
Radius Rod Fasteners (Inner) 52 ft-lbs (70 Nm) + 45°
Radius Rod Fasteners (Outer) 52 ft-lbs (70 Nm) + 90°
Rear Cargo Box / Fender Fastener 7 ft-lbs (10 Nm)
Rear Fascia/Bumper Fastener 7ft-lbs (10 Nm)
Rear Support Fastener 8 ft-lb (11 Nm)
Rear Fascia Fastener 36 in-lbs (4 Nm)
Rear Fascia Bracket Fastener 36 in-lbs (4 Nm)
ROPS Seat Belt Mount Fastener 40 ft-lbs (54 Nm)
ROPS Fasteners (Front and Rear) 44 ft-lbs (60 Nm)
ROPS Fasteners (Middle) 89 ft-lbs (120 Nm)
Seat Base Support Bracket
Fastener 15 ft-lbs (20 Nm)
Seat Bracket Fastener
(Passenger) 9 ft-lbs (12 Nm)
Seat Frame Fastener (Rear) 30 ft-lbs (40 Nm)
Seat Frame Fastener (Front) M10
x 1.5 x 16 37 ft-lbs (50 Nm)
GENERAL INFORMATION
1

1.12 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
ITEM TORQUE
Seat Frame Fastener (Front) M8 x
1.25 x 45 18 ft-lbs (25 Nm)
Seat Frame Fastener (Front) M8 x
1.25 x 50 15 ft-lbs (20 Nm)
Seat Hinge Bracket Fastener 7 ft-lbs (10 Nm)
Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm)
Seat Slide/Tilt Bracket Fastener 7 ft-lbs (10 Nm)
Seat Slide/Tilt Receiver Fastener 15 ft-lbs (20 Nm)
Shift Cable
to shifter 13 ft-lb (18 Nm)
Transmis-
sion Bracket 37 ft-lb (50 Nm)
Jam Nut 16 ft-lb (22 Nm)
Shift Knob Fastener 35 in-lbs (4 Nm)
Shift Linkage Support Bracket
Fastener 15 ft-lbs (20 Nm)
Shock Guard Screws 30 ft-lbs (40 Nm)
Shock
Body Cap 100 ft-lb (135 Nm)
Bearing Asm 35 ft-lb (47 Nm)
Bleed Screw 14 in-lb (2 Nm)
Eyelet 50 ft-lb (68 Nm)
Shaft Nut 22 ft-lb (30 Nm)
Shock Access Panel Fasteners 36 in-lbs (4 Nm)
Shock Mount (Front) 44 ft-lbs (60 Nm)
Shock Mount (Rear) 74 ft-lbs (100 Nm)
Shock Reservoir Mounting Clamps
(rear) 35 in-lb (4 Nm)
Skid Plate Fasteners 9 ft-lbs (12 Nm)
Slider Rail Fastener 30 ft-lbs (40 Nm)
Snorkel Shaft Coupler Jam Nut 140 ft-lb (190 Nm)
Spark Arrestor 8 ft-lb (11 Nm)
Spark Plug 9 ft-lbs (12 Nm)
Speed Sensor Screw 12 ft-lb (16 Nm)
Stabilizer Bar Linkage (Front) 74 ft-lbs (100 Nm)
Stabilizer Bar Linkage (Rear) 44 ft-lbs (60 Nm)
Stabilizer Bar
Mounting Brackets
front 44 ft-lbs (60 Nm)
rear 30 ft-lbs (40 Nm)
Starter Cable Nuts 40 in-lb (5 Nm)
Starter Mounting Bolts 7 ft-lb (10 Nm)
Starter One-Way Clutch Screws 9 ft-lb (12 Nm)
Starter Solenoid
Cable Nuts 35 in-lb (4 Nm)
Mounting
Bolts 7 ft-lbs (10 Nm)
Stator Cover Screws 9 ft-lb (12 Nm)
Steering Tilt Shock Fastener 9 ft-lbs (12 Nm)
Steering Cast Mounting Fasteners
(Lower) 42 ft-lbs (57 Nm)
Steering Cast Mounting Fasteners
(Upper) 22 ft-lbs (30 Nm)
Steering Column Mounting
Fasteners 33 ft-lbs (45 Nm)
Steering Rack Mounting Bolts 44 ft-lbs (60 Nm)
ITEM TORQUE
Steering Shaft to EPS Unit 22 ft-lbs (30 Nm)
Steering Shaft to Steering Rack 48 ft-lbs (65 Nm)
Steering Wheel Nut 66 ft-lbs (90 Nm)
Support Bearing Fastener 30 ft-lbs (40 Nm)
Suspension Control Module (SCM)
Fasteners 8 ft-lb (11 Nm)
Taillight Mounting Nuts 24 in-lb (3 Nm)
Terminal Block Nuts 30 in-lb (3 Nm)
Thermostat Cover Bolts 7 ft-lb (10 Nm)
Throttle Body / ETC Bolts 7 ft-lb (10 Nm)
Throttle Pedal Mounting Fasteners 8 ft-lb (11 Nm)
Tie Rod End to Knuckle 30 ft-lbs (40 Nm) + 90°
Tie Rod Jam Nuts 44 ft-lbs (60 Nm)
TMAP Fastener 7 ft-lb (10 Nm)
Trailing Arm to Frame Bolts 74 ft-lbs (100 Nm)
Trailing Arm to Bearing Carrier
Fasteners 44 ft-lbs (60 Nm)
Transmission
Bell Crank
Nut 18 ft-lb (24 Nm)
Case
Screws 20 ft-lbs (27 Nm)
Drain/FIll
Plugs 14 ft-lbs (19 Nm)
Isolator Bolt
(rear) 33 ft-lb (45 Nm)
Rear Mount
to Frame 22 ft-lb (30 Nm)
Park Flange
Screws 10 ft-lb (14 Nm)
Sector Gear
Cover 12 ft-lb (16 Nm)
Snorkel
Tube
Locking
Screw
10 ft-lb (14 Nm)
Turbo Actuator Rod Heim Joint
Fasteners 7 ft-lb (10 Nm)
Turbo Boost Control Valve Bolts 8 ft-lb (11 Nm)
Turbo Coolant Line Fasteners 7 ft-lbs (10 Nm)
Turbo Mounting Bolts 18 ft-lb (24 Nm)
Turbo Oil Banjo Bolt 33 ft-lb (45 Nm)
Turbo Oil Drain Tube Fasteners 11 ft-lb (15 Nm)
Turbo Oil Line Clamp (Lower) 35 in-lb (4 Nm)
Turbo Oil Line Clamp (Upper) 7 ft-lbs (10 Nm)
U-Joint Strap Fastener 11 ft-lbs (15 Nm)
Valve Cover Bolts 7 ft-lbs (10 Nm)
Visor Mounting Screws 8 ft-lb (11 Nm)
Voltage Regulator Bracket
Fasteners 7 ft-lbs (10 Nm)
Voltage Regulator Fasteners 8 ft-lb (11 Nm)
Water Pump
Impeller Impeller
7 ft-lb (10 Nm)
(Apply Loctite®
204™ to bolt
threads)
GENERAL INFORMATION

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc. 1.13
ITEM TORQUE
Cover Bolts
7 ft-lb (10 Nm)
(Apply Loctite®
204™ to bolt
threads)
Winch Cover Fastener 22 in-lb ( 3 Nm)
Winch Mounting Plate Fasteners 18 ft-lbs (24 Nm)
Wheel Lug Nuts 120 ft-lbs (163 Nm)
GENERAL INFORMATION
1

1.14 9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
VEHICLE SPECIFICATIONS
2020 RZR PRO XP
CATEGORY DIMENSION / CAPACITY
Length 126.1″ / 320.4 cm
Width 64″ / 162.6 cm
Height 71.7″ / 182.1 cm
Wheel Base 96″ / 243.8 cm
Ground Clearance 14″ / 35.6 cm
Dry Weight 1785 lbs. / 810 kg
Gross Vehicle Weight 2623 lbs. / 1190 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity
(Payload)
740 lbs. / 336 kg
(Includes riders, cargo and
accessories)
Hitch Towing Capacity This vehicle is not equipped with
a hitch for towing loads. Do not
use this vehicle for towing. Do
not modify the vehicle by adding
a hitch.
Hitch Tongue Capacity
GENERAL INFORMATION