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2019-2020 Polaris RZR XP Turbo XP4 Turbo Service Manual PDF
Original price was: $120.00.$30.95Current price is: $30.95.
Official Polaris service manual for the 2019–2020 RZR XP Turbo and XP4 Turbo (including FOX Edition and Dynamix Edition). Covers 12 complete chapters: general information, maintenance, engine/cooling, engine electrical, EFI/fuel system, PVT clutch system, transmission, final drive, steering/suspension, brake system, body/frame, and electrical. Includes complete vehicle specs, torque tables, clutch charts, and wiring schematics. 562 pages — instant PDF download.
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Description
2019-2020 Polaris RZR XP Turbo XP4 Turbo Service Manual PN 9930585 PDF DOWNLOAD
DESCRIPTION:
2019–2020 Polaris RZR XP Turbo / XP4 Turbo — Official Service Manual (PN 9930585 R01)
This is the complete official Polaris factory service manual for the 2019 and 2020 RZR XP Turbo and RZR XP4 Turbo — covering all variants including the FOX Edition and Dynamix Edition. Published by Polaris Industries Inc. (PN 9930585 R01, August 2019, Initial Release R01), this is the same document used by Polaris Master Service Dealer® technicians and is the definitive technical reference for anyone servicing, repairing, or rebuilding these high-performance turbocharged sport side-by-sides.
All 12 chapters are covered in full — from routine maintenance intervals and torque specifications through complete engine tear-down and rebuild, turbocharger service, Bosch ME17 EFI diagnostics, PVT clutch rebuild, Polaris Digital Wrench® procedures, FOX and Walker Evans shock service, Dynamix active suspension calibration, and full wiring schematics.
📋 File Details
| Detail | Information |
|---|---|
| Manual Name | 2019–2020 RZR XP Turbo / XP4 Turbo Service Manual |
| Publication Number | PN 9930585 R01 |
| Models Covered | 2019–2020 RZR XP Turbo, XP4 Turbo, XP Turbo FOX Edition, XP4 Turbo FOX Edition, XP Turbo Dynamix Edition, XP4 Turbo Dynamix Edition |
| Publisher | Polaris Industries Inc. |
| Year | August 2019 (covers 2019 & 2020 model years) |
| PDF Quality | Digitally produced by Servigistics/Arbortext, fully searchable, high resolution |
| Total Pages | 562 |
| File Format | PDF (684×864 pts) |
📑 Complete Table of Contents
Chapter 1 — General Information
- Vehicle Identification (model number decode, VIN designation 2015+)
- VIN and Engine Serial Number Locations
- Replacement Keys (key series chart with part numbers)
- Publication Numbers (Owner’s Manual PN cross-reference)
- Special Tools (complete illustrated tool list with Polaris part numbers: drive clutch puller, clutch compressor, flywheel holder, shock spanner wrenches, CV boot clamp pliers, oil pressure gauge, fuel pressure gauge, Smartlink module, roller pin tool, transmission snorkel tool, and more)
- Master Torque Table (comprehensive alphabetical torque reference — every fastener from A-arm bolts to wheel lug nuts with in-lb / ft-lb / Nm values, including multi-step torque sequences for connecting rod bolts, cylinder head bolts, crankcase bolts, flywheel bolt)
- Vehicle Specifications — full spec sheets for all 10 variants:
- 2019 RZR XP Turbo + Clutch Chart
- 2019 RZR XP4 Turbo + Clutch Chart
- 2019 RZR XP Turbo FOX Edition + Clutch Chart
- 2019 RZR XP4 Turbo FOX Edition + Clutch Chart
- 2019 RZR XP Turbo Dynamix Edition + Clutch Chart
- 2019 RZR XP4 Turbo Dynamix Edition + Clutch Chart
- 2020 RZR XP Turbo + Clutch Chart
- 2020 RZR XP4 Turbo + Clutch Chart
- 2020 RZR XP Turbo / XP4 FOX Edition + Clutch Charts
- 2020 RZR XP Turbo / XP4 Dynamix Edition + Clutch Charts
- Misc. Specifications and Charts (conversion table, SAE and metric tap/drill sizes, decimal equivalents)
Chapter 2 — Maintenance
- Lubricants / Service Products
- Pre-Ride Inspection
- Maintenance Intervals (hour-based service schedule)
- Maintenance Quick Reference
- Grease Lubrication Points
- Engine / Exhaust: oil level check, oil and filter change, crankcase breather, cylinder leakdown test, valve clearance adjustment, cam chain tensioner inspection, spark arrestor, heat shield
- Cooling System: coolant strength, level inspection, pressure test, hose inspection, radiator cleaning, coolant flush, cooling system bleeding
- Fuel System and Air Intake: tank vent, throttle pedal, pre-filter, air filter service, intake duct drain
- PVT / Final Drive / Wheels: PVT drain, PVT pre-filter, front gearcase fluid check and change, driveshaft boot inspection, wheel removal/installation, tire inspection/pressure
- Transmission: oil level check, oil change
- Steering: inspection, free-play check, tie rod/hub inspection
- Brake System: fluid inspection, hose/fitting check, pad and disc inspection
- Electrical and Ignition System inspection
Chapter 3 — Engine / Cooling System
- Engine Specifications (925cc, 2-cylinder, DOHC, turbocharged, 9:1 CR, bore & stroke 93×68 mm)
- Engine Removal / Installation
- Engine Disassembly — Bottom End:
- Starter, flywheel, stator, oil pump disassembly
- Crankcase disassembly / inspection (crankshaft, balance shaft, connecting rods, pistons)
- Cylinder bore measurement and honing
- Bearing selection (connecting rod and main bearing selection tables)
- Piston ring and piston installation
- Crankshaft, balance shaft, lower crankcase assembly
- Starter one-way clutch assembly
- Flywheel / stator cover installation
- Engine Assembly — Top End:
- Cylinder head assembly (valve sealing test)
- Cylinder head installation
- Camshaft installation and timing (timing quick reference chart)
- Valve clearance adjustment and Valve Lash / Tappet Selection tables
- Valve cover installation
- Cooling System: water pump service, thermostat, electric coolant pump, coolant temperature sensor, radiator, charge air cooler (intercooler), hoses and routing
- Turbocharger: oil feed/drain lines, actuator, boost control valve, removal and installation
- Troubleshooting: Engine, Cooling, and Turbocharger fault tables
Chapter 4 — Engine Electrical
- ECU (Bosch ME17): operation overview, ECU service, replacement, ETC learn procedure, ECU reprogramming (reflash)
- Knock Sensor: overview, testing, replacement
- Crankshaft Position Sensor (CPS): overview, test, replacement
- Electronic Throttle Control (ETC) / Throttle Body: operation, test, replacement, ETC learn procedure
- Pedal Position Sensor (PPS): overview, location, test, replacement
- Oxygen Sensor: information and replacement
- Polaris Digital Wrench®: diagnostic software overview, special tools, software version/update, communication errors, diagnostic connector location, Guided Diagnostics, serial number location, feature map
- Digital Wrench procedures: ECU replacement, ETC learn, ECU reprogramming/reflash
- Polaris Mobile Digital Wrench (PMDW)
Chapter 5 — EFI / Fuel System
- EFI system components/locations, operation overview, service notes
- Initial priming / starting procedure
- EVAP System: overview, conditions and symptoms, vacuum testing
- Fuel Injectors: operation, O-rings, troubleshooting, testing, replacement
- Fuel Lines: removal/installation, vent line routing (XP and XP4 — standard and EVAP models)
- Fuel Tank / Pump: assembly view, vacuum test, removal/installation (XP and XP4 procedures separate)
- Fuel pump operation overview, fuel pressure test (standard and EVAP models — 58 ± 2 PSI spec), fuel pump replacement, fuel sender test
- Pressure Sensors: BAP, boost pressure, fuel pressure (EVAP), TMAP sensor, air temperature data table
- EFI Diagnostics: fuel system troubleshooting, Digital Wrench data troubleshooting, cylinder misfire detection
Chapter 6 — PVT System
- PVT system overview, general and drive/driven clutch operation
- Drive Belt: removal, inspection, installation, break-in procedure
- Drive Clutch Service: removal, assembly view, disassembly/inspection (shift weights, rollers, spider, helix, spring), assembly, installation (300 ft-lb spider jam nut torque)
- Driven Clutch Service: removal, assembly view, disassembly/inspection, assembly, installation
- Altitude-based clutch charts (shift weight and spring selection 0–6000 ft vs. 6000–12000 ft)
- Troubleshooting (belt wear, clutch slip, engagement RPM issues)
Chapter 7 — Transmission
- Shift Lever / Cable: removal, installation, inspection, adjustment
- Transmission Service: removal, installation, vent line routing
- Transmission Disassembly (gear, shaft, bearing inspection)
- Transmission Assembly / Snorkel Gear Backlash procedure
- Troubleshooting: Shifting Difficulty
Chapter 8 — Final Drive
- Bearing Carriers: front removal/inspection/bearing replacement/installation; rear inspection/removal/bearing replacement/installation
- Drive Shafts: front and rear removal/installation; CV joint handling tips; outer CV boot replacement; inner plunging joint/boot replacement
- Prop Shaft: removal/installation (XP and XP4 separate procedures); assembly view; support bearing replacement; U-joint disassembly and assembly
- Front Gearcase / Centralized Hilliard AWD: assembly view, all-wheel drive operation, AWD diagnosis, gearcase removal/disassembly/inspection/assembly/installation, vent line routing
- Wheel Hubs: front and rear hub assembly views
Chapter 9 — Steering / Suspension
- Steering System: assembly view; upper/lower steering shaft removal/installation; steering wheel removal; power steering unit (EPS) removal/installation; steering shaft bushing replacement
- Front Suspension: assembly view; front A-arm removal/replacement; front stabilizer bar removal/installation; ball joint service, removal, and installation
- Rear Suspension: assembly view; trailing arm removal/installation; spherical bearing replacement; radius rod removal/installation; rear stabilizer bar removal/installation
- Shocks / Springs: shock assembly view; removal/installation; spring replacement; spring adjustment
- FOX Shock Service: compression adjustment; FOX 2.5″ front and 3.0″ rear shock information; FOX Podium Bypass 2.5″/3.0″ disassembly and assembly (with offset torque formula)
- Walker Evans Shock Service: 2.0″ front / 2.5″ rear service; spring adjustment; shock rebuild (valve shim arrangement, piston orientation, disassembly and assembly)
- Dynamix Active Suspension (if equipped): Dynamix overview; Suspension Control Module (SCM); Dynamix system features (vehicle speed sensitivity, cornering control, braking); demonstration mode; shock disassembly/assembly
Chapter 10 — Brake System
- Brake system specifications (DOT 4, front triple bore caliper, rear double bore caliper)
- Brake system overview and system view; brake line routing/retention
- Brake system service notes; bleeding / fluid change
- Brake pedal removal/installation
- Front Brake Caliper: pad removal/inspection, disc inspection, caliper/pad installation, burnishing procedure
- Rear Brake Caliper: pad removal/inspection, disc inspection, caliper installation, burnishing procedure
- Troubleshooting: brake noise, brake vibration, brakes lock
- Brake warning system inspection (International models); brake pedal switch inspection
Chapter 11 — Body / Frame
- Body assembly views (XP and XP4)
- Body component removal (front/rear fascia, fenders, doors, visor, floor, skid plate, cargo box, hip bolsters, seats, seat belts, cab frame)
- Frame inspection
Chapter 12 — Electrical
- Electrical service notes; component locations
- Electrical Diagnostics: test procedures, service notes
- Instrument Cluster: display overview, pinouts, removal/installation
- Ignition / Key Switch: testing and replacement
- Brake Pressure Switch and Brake Alarm (International)
- Ignition Coil: replacement, coil tests (primary and secondary resistance specs)
- Charging System: overview, “break-even” test, stator test, voltage regulator test, charging procedure (660W @ 3000 RPM alternator)
- Lighting System: LED headlight cluster, taillights, brake lights
- Starting System: starter motor test, solenoid test, starter removal/installation
- Fuses / Relays: fuse/relay center layout (standard and Dynamix) — all fuse assignments
- Wiring Schematics
⚡ Key Technical Specifications at a Glance
| Specification | 2019–2020 RZR XP Turbo | 2019–2020 RZR XP4 Turbo |
|---|---|---|
| Engine | 925cc, DOHC, Turbocharged, 4-Stroke | 925cc, DOHC, Turbocharged, 4-Stroke |
| Cylinders / Bore×Stroke | 2 / 93×68 mm | 2 / 93×68 mm |
| Compression Ratio | 9:1 | 9:1 |
| Max Engine Speed | 8800 RPM | 8800 RPM |
| Fuel System | Bosch ME17 EFI, 58 ±2 PSI, 91 Octane min | Same |
| Fuel Capacity | 9.5 gal. (36 L) | 9.5 gal. (36 L) |
| Oil Capacity | 2.75 qt (2.6 L) — PS-4 5W-50 / 10W-50 | 2.75 qt |
| Coolant Capacity | 10.8 qt (10.22 L) | 11.7 qt (11.07 L) |
| Transmission | Polaris Automatic PVT / P-R-N-L-H | Same |
| Drivetrain | AWD (Centralized Hilliard) | Same |
| Front Suspension | Dual A-arm, Walker Evans 2″ Needle | Same |
| Front Travel | 16″ (40.6 cm) | 16″ |
| Rear Suspension | Independent Trailing Arm, Walker Evans 2.5″ | Same |
| Rear Travel | 18″ (45.7 cm) | 18″ |
| Tires (Front/Rear) | Maxxis Bighorn 29×9 R14 / 29×11 R14 | Same |
| Brakes | 4-Wheel Hydraulic, DOT 4, Triple/Double Bore | Same |
| Alternator | 660W @ 3000 RPM | Same |
| Battery | 12V Flooded, 575 CCA / 44 A/hr | Same |
| Length | 119″ / 302.3 cm | 146″ / 370.8 cm |
| Width | 64″ / 162.5 cm | 64″ / 162.6 cm |
| Dry Weight | 1,478 lbs. / 670.4 kg | 1,689 lbs. / 766 kg |
| Payload Capacity | 740 lbs. (336 kg) | 900 lbs. (408 kg) |
| Ground Clearance | 13.5″ / 34.3 cm | 13.5″ |
🔑 Why RZR Technicians and Serious Owners Need This Manual
- ✅ Covers all 2019–2020 variants in one document — XP Turbo, XP4 Turbo, FOX Edition, and Dynamix Edition for both model years
- ✅ Complete engine rebuild — bottom end and top end with bearing selection tables, valve lash/tappet selection, camshaft timing quick reference, and step-by-step illustrated assembly
- ✅ Turbocharger service — oil lines, actuator, boost control valve, removal and installation with correct torque specs
- ✅ Bosch ME17 EFI diagnostics — Digital Wrench® procedures, fault isolation, ECU reprogramming (reflash), ETC learn procedure, sensor testing
- ✅ PVT clutch system — complete drive and driven clutch disassembly, inspection, assembly with altitude-based clutch charts for performance tuning
- ✅ FOX and Walker Evans shock rebuild — full service procedures for both shock types including valve shim arrangement and piston orientation
- ✅ Dynamix active suspension — SCM programming, system features, shock disassembly/assembly (Dynamix Edition)
- ✅ Master torque table — every fastener on the vehicle in one alphabetical reference table, including multi-step torque sequences
- ✅ Complete wiring schematics — all circuits with component locations for fast electrical diagnosis
- ✅ AWD / Hilliard front gearcase — complete disassembly, inspection, assembly with AWD diagnosis procedure
💬 Sales Pitch
The RZR XP Turbo is built hard — and eventually it needs hard maintenance. Whether you’re pulling the engine, rebuilding clutches after hard use, reflashing the ECU, or rebuilding FOX shocks after a season of riding, this is the exact manual Polaris dealerships use. Stop guessing torque specs and start working confidently — download this official Polaris factory service manual instantly after purchase.
