If you have an RZR turbo, Turbo S, Pro XP, or Turbo R you’ve most likely heard about issues with the OEM intercooler. This was mainly on the 2016-2019 models until Polaris upgraded the damper/seal to a thicker version(Part number 5814884) for 2020 models. This upgraded damper/seal helps support the intercooler better for less risk of failure. Polaris has this damper part number listed as a superseding part number for all year XPT/Turbo S models.
When an intercooler fails it allows coolant to enter the intake plenum and motor. When the intercooler fails you will have white smoke out the exhaust, possible engine misfire, and low coolant level. Some small leaks will simply build up coolant in the intake plenum, then dump it into the motor when going down hill, or hitting a large bump/jump. While the coolant can hydro lock the motor and cause head gasket issues among others, it’s normally passed through without issue. Simply replace the intercooler core(also upgrade damper if you are driving a 2016-2019 model year), change spark plugs, and change your oil.
Aftermarket intercooler cores have been around for a bit. The problem is, many did not use the OEM damper/seal and air could bypass the intercooler and create very hot intake temps and rapid loss in performance as boost is pulled back based on this temp. For this reason, we only suggest using an intercooler core that uses the damper/seal.
We have had great luck with the OEM intercooler since the upgraded damper, but have still seen a few failures. There are a few aftermarket options that use the OEM damper (or at least the bottom of it) that work great and will have less risk of failure.