What kind of problems does a Polaris RZR Pro XP normally have? In this blog, we’ve outlined all the most important things you should watch for when you’re in the market for a Polaris RZR Pro XP. In the rest of the article, we’ll discuss every single problem in detail. Furthermore, we’ll tell you how to identify it, fix it and how much it costs to fix. Read on!

Also read: Are Polaris ATVs Reliable, Check Your Model Here!

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1. Air Intake Problems

The RZR PRO XP is unquestionably a powerful machine. However, the air filters, have a history of being problematic. The issue with filters is that dust can get in. Dust doesn’t go well with motors. The filters’ seals appear to be letting dust in, which is against their intended function.

An enthusiast reports,

“The RZR Pro XP’s OEM intake tube collapses under boost because it is molded rubber, a very brittle material. When we first looked at this model, we identified this as a weakness.…. as soon as we increased the boost pressure past 22 psi, the airflow abruptly shut off. This has been a recognized problem even at stock boost settings because warmer outside air temperatures will make rubber softer than cold air temperatures.”

You can use aftermarket parts to fix the problem. Reliable RZR PRO XP replacement air filter costs around $75.00

2. Belt Slip Issues 

Belt slips are a common RZR Pro XP problem, with many new RZR Pro XP experiencing belt slip issues under heavy throttle. With larger tires or more power, this situation will only worsen. The problem is that these P90X clutches are ineffective at grabbing the belt at higher RPMs compared to the older 2016–2020 RZR clutches.

For example, a customer says,

“I recently acquired a new 2021 RZR Pro XP. When I first got it, I broke the belt in properly, even going beyond what was advised. When I drive it, it performs flawlessly and launches hard if I want it to, but when I hit 40 mph, I can feel the belt slip. I believe the recall was done, which, I thought, would fix it; I believe they replaced the whole primary, but the belt still feels like it’s slipping at that speed and still looks pretty good. Any ideas why this might be happening?”

Replace the belt and see if that will cure the issue. If not, you can consider upgrading the clutch kits. The kits’ firmer springs provide additional belt tension, and the weights’ changeable settings let you tune your RPM for optimum belt grip. Also, get the belt aligned well because a misaligned belt will grip one sheave more strongly than the other and may lead to slipping.

If the primary weights are sticking, use scotch brite on the pin to clear the surface rust. Moreover, ensure the clutches are clean, including the secondary rollers. Good replacement belt price ranges from $150 to $199.99.

3. Clutch Failures/Recalls

The issue was with the quality of RZR PRO XP clutches. The UTV is notorious for clutch issues. CPSC and Polaris issued a recall for approximately 18,400 RZR vehicles, including the RZR Pro XP2020-2021 model year, for clutch failure. Polaris found that the units have a high risk of drive clutch failure under certain operating conditions.

Customers may be at risk for injury because of primary clutch failures that can send debris and clutch components flying from the clutch casing. This scenario frequently arises during high-load, low-speed situations, including high boost vehicle launches, high RPM belt slip, and launches with simultaneous throttle and brake application.

The clutch systems may also have an over-shift problem. When the shift is fully engaged, the belt rises too high out of the primary clutch, losing belt traction and possibly even colliding with the inner clutch cover. Also, this will cause the upper cogs of the belt to wear out faster.

Also read: 5 x Most Common Polaris Clutch Problems!

4. Non-Durable Frame

The RZR PRO XP is designed to endure extreme pressure. Isn’t it what makes off-roading so much fun? But the frame tells the difference. Unfortunately, the structure is not as sturdy as it ought to be.

For example, a customer reports,

“I was out riding my RZR PRO XP when I came across a hurdle that my friends and I had crossed numerous times on other vehicles. Each of them had successfully navigated the hurdle by bumping their bellies. As I had done with other machines, I gave the belly a hump and bent all the frames supports at the bottom toward the back.

The drive shaft was pushed up against the safety loop and the transmission at the back by the support that holds the carrier bearing, which was severely twisted. I was traveling at a reasonable 5 mph, so nothing wild.”

You will become more aware of this after you see the roll cage. We adore it because it is lovely. But it won’t provide as much safety as you think it will. If you are hitting fast, your likelihood of seeing a doctor is high.

5. Weak Front Differential

The front differential often makes a sound and is comparatively weaker considering the type of use the vehicle is subject to.

For example, a customer complains,

“This morning I grabbed up my Pro XP and drove up to the mountain. I tipped over on a ledge on the last trail of the afternoon, and it generated a dreadful “clattering” or “clunking” sound. It repeatedly locked the front tires up as I gingerly hobbled it back to the trailer. The front differential is clearly to blame. And there is no doubt that it’s seriously flawed.”

The front differential of the 2WD RZR PRO XP may also make a rattling sound. The problem usually stems from a bad prop shaft. However, the front differential issue isn’t even traceable by some users, which is baffling. You can fix the problem with some aftermarket parts.

6. Hard Shift/Transmission Issues

A customer asks,

“I have a 2020 RZR Pro XP. I adjusted the rear linkage for the shift cable and still find it rough shifting it into gear. Does anyone have any ideas?”

Typically, shifting difficulties or harsh shifting arises from the Transmission or PVT Systems. The transmission’s robustness is the key problem here. It is not sturdy, and there have been bearing failure issues. Polaris is aware of this fact, but has not yet expressed any opinion.

You can experience shifting difficulties to shift only with the engine running, then check your PVT System. Worn pivot arm bushing rod ends, or clevis pins can also cause PVT misalignment. Loose fasteners on sector gear cover can impact the shift cable adjustment. Worn, damaged, or broken internal transmission parts can lead to transmission leaks, low fluid levels, and hard shifts.

Isolate the transmission to see if shifting problems arise from internal transmission issues or external causes. Unplug the shift cable from the bellcrank. After that, use the shift lever to shift the UTV with the shift cable detached from the transmission. The shift cable is probably to blame if the shift lever keeps binding. Replace the cable.  

If the shift lever moves smoothly while unplugged, select each gear range manually at the transmission bellcrank. If the bellcrank fails to turn freely, it is most likely an internal transmission problem. If the bellcrank moves freely, have a test drive after manually selecting each gear range at the transmission bellcrank. If it works as it should, the problem probably stems from something external.

Also read: 6 x Most Common Polaris Transmission Problems!

7. Suspension Spring Issues

The lowest you can go on your ride is 13 inches, which is not impressive.

A customer laments,

“Many RZR Pro XP model owners, at least in my experience, complain about the rear ride height. Even with the rear tender spring fully lowered, the ride height is 13.”

Polaris said they know of the problem and will try to fix it. The company will notify the dealers once they resolve the issue. So, anyone with this problem should get help from their dealers.

8. Fire Hazard Recall

Polaris and CPSC recalled around 2,000 RZR Pro XP and RZR Pro XP 4 2021 model year vehicles for a fire hazard because some vehicles may suffer an oil leak. It is because they have a raised edge at the oil supply line’s sealing surface of the turbocharger castings machined surface.

Featured image: https://www.polaris-orv.media/