Polaris RZR XP Turbo 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 2017 (PN 9928491 R04)
© Copyright 2017 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.
2017-2018 RZR XP Turbo / XP4 Turbo
Service Manual

SAFETY WARNINGS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE
NOTE 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 09/29/2017 Initial Release; added Dynamix and wiring harness content
R02 11/21/2017 Added door latch and door adjustment procedures
R03 1/10/2018 Add Crankshaft PTO Seal Replacement procedure
2018 RZR XP 4 Turbo Dynamix Edition Vehicle Specifications Added
R04 2/16/2018 Updated Radius Rod Torque Values

2017-2018 RZR XP Turbo / XP4 Turbo
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: FINAL DRIVE
CHAPTER 8: STEERING / SUSPENSION
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL

1
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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2017 RZR XP TURBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2017 RZR XP TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
2017 RZR XP 4 TURBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
2017 RZR XP4 TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
2017 RZR XP TURBO TRACTOR (INT'L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2017 RZR XP TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
2018 RZR XP TURBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
2018 RZR XP TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
2018 RZR XP TURBO FOX EDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2018 RZR XP TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
2018 RZR XP TURBO DYNAMIX EDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
2018 RZR XP TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
2018 RZR XP 4 TURBO DYNAMIX EDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
2017 RZR XP4 TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
2018 RZR XP 4 TURBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
2018 RZR XP 4 TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27
2018 RZR XP 4 TURBO FOX EDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
2018 RZR XP 4 TURBO CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.31
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.31
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32

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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
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 a portion of the left rear frame q, behind the PVT system.
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

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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
2017
RZR XP / XP 4 Turbo 9927198
RZR XP / XP 4 Turbo MD 9927409
RZR XP Turbo TR 9927411
2018
RZR XP / XP 4 Turbo 9928357
RZR XP / XP 4 Turbo MD 9928406
RZR XP Turbo TR 9928405
NOTE
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

1.4 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo 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

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2200421
Gas Shock
Recharging Kit
2460761
Hall Sensor Probe
Harness
2870341-A
Drive Clutch Spider
Remover/Installer
2870386
Piston Pin Puller
2870630
Timing Light
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

1.6 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
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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

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© Copyright Polaris Industries Inc. 1.7
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
GENERAL INFORMATION
1

1.8 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
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MASTER TORQUE TABLE
ITEM TORQUE
A-Arm Fasteners (front) 42 ft-lb (57 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 42 ft-lbs (57 Nm)
Battery Mount Bracket 24 in-lbs (3 Nm)
Terminal Fasteners 60 in-lbs (7 Nm)
Bearing Carrier Mounting Bolts (rear) 42 ft-lb (57 Nm)
Body / Cargo Box Screws 8 ft-lb (11 Nm)
Brake Bleed Screws 48 in-lb (5 Nm)
Brake Caliper Mounting Bolts front 30 ft-lbs (42 Nm)
rear 46 ft-lbs (62 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 Pedal Mount Bracket Fasteners 18 ft-lbs (24 Nm)
Brake Switch 15 ft-lbs (20 Nm)
Cab Frame Bolts 40 ft-lb (54 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)
Cargo Box Bracket Fasteners 14 ft-lb (19 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 Bleed Screw 89 in-lb (10 Nm)
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)
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 11 ft-lbs (15 Nm) apply pipe thread sealant
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)
Door Fasteners 8 ft-lb (11 Nm)
GENERAL INFORMATION

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ITEM TORQUE
Drive Clutch
Mounting Bolt 96 ft-lb (130 Nm)
Cover Plate 9 ft-lb (12 Nm)
Shift Weight 20 in-lb (2 Nm)
Spider Jam Nut 300 ft-lb (407 Nm)
Driven Clutch
Helix Cover 2016-17: 8 ft-lb (11 Nm)
2018: 12 ft-lb (16 Nm)
Mounting Bolt 43 ft-lb (58 Nm)
Slider/Button 35 in-lb (4 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)
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)
Floor Screws 8 ft-lb (11 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 / Fender Screws 8 ft-ln (11 Nm)
Front Gearcase
Cover Plate Screws 11 ft-lbs (15 Nm)
Drain/Fill Plugs 10 ft-lbs (14 Nm)
Mounting Bolts 33 ft-lbs (45 Nm)
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 Strap Screw 8 ft-lbs (11 Nm)
Fuse Box Fasteners 5 ft-lb (7 Nm)
Gear Selector Knob 40 in-lb (5 Nm)
Hip Bolster Bolts 14 ft-lb (19 Nm)
Hose Clamp 35 in-lb (4 Nm)
Hub Castle Nut (front and rear) 180 ft-lbs (244 Nm)
Ignition Coil Mounting Bolt 8 ft-lb (11 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)
Master Cylinder Mount Bolts 23 ft-lbs (31 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)
GENERAL INFORMATION
1

1.10 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
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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 16 ft-lb (22 Nm)
Power Steering Unit to Mount Bracket 30 ft-lb (41 Nm)
Prop Shaft Support Bearing Fasteners 33 ft-lbs (45 Nm)
Prop Shaft to Transmission Fasteners 22 ft-lb (30 ft-lb)
PVT Inner Cover Fasteners inner
(see image inEngine Installation), page 3.46 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 35 in-lb (3 Nm)
Radiator Bracket 8 ft-lb (11 Nm)
Radius Rod Fasteners (Inner) 50 ft-lb (68 Nm) + 45°
Radius Rod Fasteners (Outer) 50 ft-lbs (68 Nm) + 90°
Seat Frame to Main Frame
T-40 8 ft-lb (11 Nm)
M8 14 ft-lb (19 Nm)
M10 30 ft-lb (41 Nm)
Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm)
Seat Slider Plate Screws 4 ft-lb (5 Nm)
Shift Cable
to shifter 13 ft-lb (18 Nm)
Transmission Bracket 37 ft-lb (50 Nm)
Jam Nut 16 ft-lb (22 Nm)
Shock Guard Screws 14 in-lbs (2 Nm)
Shock (FOX)
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 Mount front 42 ft-lbs (57 Nm)
rear 70 ft-lbs (95 Nm)
Shock Reservoir Mounting Clamps (rear) 35 in-lb (4 Nm)
Skid Plate Fasteners 8 ft-lbs (11 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 42 ft-lbs (57 Nm)
Stabilizer Bar Mounting Clamps front 20 ft-lb (27 Nm)
rear 30 ft-lb (42 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 8 ft-lb (11 Nm)
GENERAL INFORMATION

9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc. 1.11
ITEM TORQUE
Stator Cover Screws 9 ft-lb (12 Nm)
Steering Tilt Shock Fastener 7 ft-lb (10 Nm)
Steering Column Mounting Fasteners 40 ft-lb (54 Nm)
Steering Rack Mounting Bolts 16 ft-lbs (22 Nm)
Steering Shaft to EPS Unit 25 ft-lb (34 Nm)
Steering Shaft to Steering Rack 50 ft-lb (68 Nm)
Steering Wheel Nut 65 ft-lbs (88 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 (41 Nm) + 90°
Tie Rod Jam Nuts 14 ft-lbs (19 Nm)
TMAP Fastener 7 ft-lb (10 Nm)
Trailing Arm to Frame Bolts 70 ft-lb (95 Nm)
Trailing Arm to Bearing Carrier Fasteners 42 ft-lb (54 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 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 Clamps 35 in-lb (4 Nm)
Valve Cover Bolts 7 ft-lbs (10 Nm)
Visor Mounting Screws 8 ft-lb (11 Nm)
Voltage Regulator Fasteners 8 ft-lb (11 Nm)
Water Pump Impeller
Impeller 7 ft-lb (10 Nm)
(Apply Loctite® 204™ to bolt threads)
Cover Bolts 7 ft-lb (10 Nm)
(Apply Loctite® 204™ to bolt threads)
Wheel Lug Nuts 120 ft-lbs (163 Nm)
GENERAL INFORMATION
1

1.12 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc.
VEHICLE SPECIFICATIONS
2017 RZR XP TURBO
CATEGORY DIMENSION / CAPACITY
Length 119″ / 302.3 cm
Width 64″ / 162.5 cm
Height 73.75″ / 187.3 cm
Wheel Base 90″ / 228.6 cm
Ground Clearance 13.5″ / 34.3 cm
Dry Weight 1478 lbs. / 670.4 kg
Gross Vehicle Weight 2335 lbs. / 1059 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

9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc. 1.13
ENGINE
Platform Turbocharged., 4–Stroke,
DOHC
Engine Displacement 925cc
Number of Cylinders 2
Bore & Stroke 93 x 68 mm
Compression Ratio 9:1
Engine Idle Speed 1200 +/- 100 RPM
Engine Max Speed 8800 RPM
Valve Clearance (Intake) .006 ± .002" (0.15 ± 0.05 mm)
Valve Clearance (Exhaust) .010 ± .002" (0.25 ± 0.05 mm)
Engine Hot Light Instrument Cluster Indicator
Lubrication Wet Sump
Oil Requirements
PS-4 Full Synthetic 5W-50 or
PS-4 Extreme Duty Full
Synthetic 10W-50
Oil Capacity 2.75 qt (2.6 L)
Coolant Type Polaris 50/50 Extended Life
Anti-freeze
Coolant Capacity 10.8 qt (10.22 L)
FUEL SYSTEM
Type Bosch ME17 EFI
Fuel Delivery Electronic Fuel Pump (in-tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Fuel Capacity /
Requirement
9.5 gal. (36 L)
91 Octane (minimum)
ELECTRICAL
Alternator Max Output 660 Watts @ 3000 RPM
Lights: Main Headlights Dual Beam LED cluster
Taillights 0.2 Watt LED cluster
Brake Lights 2.9 Watt LED cluster
Ignition System ME17 ECU
Spark Plug / Gap MR9F / 0.7–0.8 mm
Battery / Amp Hr 12v Flooded, 575 CCA / 44 A/hr
DC Outlet Standard 12 Volt
Relays Fan, EFI, Fuel Pump, Chassis,
EPS
Fuses
10A Accy
10A Drive
10A EFI
10A Fuel
10A Instr
10A Key
10A Lights
10A Term
10A Unsw
10A Water
25A EPS
30A Fan
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Type In Line Shift - P/ R / N / L / H
Front Gearcase Lubricant Demand Drive Fluid
Front Gearcase Capacity 8.5 oz (250 mL)
Transmission Lubricant AGL Synthetic Gearcase
Lubricant
Transmission Capacity 64 oz (1900 mL)
STEERING / SUSPENSION
Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)
Front Suspension Independent Dual A-arm
FOX Internal Bypass 2.5″
Front Travel 16″ (40.6 cm)
Rear Suspension Independent Trailing Arm
FOX Internal Bypass 3.0″
Rear Travel 18″ (45.7 cm)
Spring Adjustment Threaded Spanner Wrench
Adjustment
WHEELS / BRAKES
Front Rim / Size Aluminum 14 x 6
Rear Rim / Size Aluminum 14 x 8
Front Tire Make / Model /
Size
Maxxis Bighorn
29 x 9 R14
Rear Tire Make / Model /
Size
Maxxis Bighorn
29 x 11 R14
Tire Air Pressure Front 18 psi (125 kPa)
Rear 19 psi (130 kPa)
Brake System
4 Wheel Hydraulic
Front: Triple Bore Caliper
Rear – Double Bore Caliper
Brake Fluid DOT 4
2017 RZR XP TURBO CLUTCH CHART
MODEL ALTITUDE SHIFT
WEIGHT
DRIVE
SPRING
DRIVEN
SPRING
2017
RZR XP
Turbo
0-1800 Meters
(0-6000 Feet)
W-31-70
(5140832) Black
(7044762)
Black / white
lettering
(7044369)
1800-3700 Meters
(6000–12000 Feet)
W-31-64
(5141004)
GENERAL INFORMATION
1

1.14 9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc.
2017 RZR XP 4 TURBO
CATEGORY DIMENSION / CAPACITY
Length 146″ / 370.8 cm
Width 64″ / 162.6 cm
Height 73.75″ / 187.3 cm
Wheel Base 117″ / 297.2 cm
Ground Clearance 13.5″ / 34.3 cm
Dry Weight 1689 lbs. / 766 kg
Gross Vehicle Weight 2700 lbs. / 1225 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity
(Payload)
900 lbs. / 408 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