Polaris 2014 RZR XP 1000 Service Manual Download

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6.2

9924874 R02 - 2014

RZR

XP / XP 4 1000 Service Manual

GENERAL INFORMATION

SPECIAL TOOLS AND SUPPLIES

PART NUMBER

TOOL DESCRIPTION

2872085

Drive Clutch Puller

2871056

Driven Clutch Puller

9314177

Clutch Holding Wrench

2871358-A

Clutch Holding Fixture

PU- 50578

Spider Jam Nut Socket

2870341

Clutch Spider Removal and
Installation Tool

2870910

Roller Pin Tool

2871226

Drive Clutch Bushing Replacement
Tool Kit

2870386

Piston Pin Puller

PU-50518

Driven Clutch Compression Tool

2877408

Shock Spanner / Clutch Spreader

Bosch Automotive Service Solutions:

1-800-345-2233

or http://polaris.service-solutions.com/

SPECIAL SUPPLIES

PART
NUMBER

Loctite® 620™ 648™ and 7088™
Primer

N/A

RTV Silicone Sealer

8560054

PVT System Torque Specifications

ITEM

TORQUE VALUE

Drive Clutch Retaining Bolt

96 ft-lb (130 Nm)

Driven Clutch Retaining Bolt

55 ft-lb (75 Nm)

PVT Inner Cover Bolts

12 ft-lb (16 Nm)

PVT Outer Cover Screws

48 in-lb (5 Nm)

Spider Jamb Nut

250 ft-lb (339 Nm)
(Apply 0.1 mL
Loctite® 7088 Primer
and 0.1 mL Loctite®
620™)

Drive Clutch Spider

290 ft-lb (393 Nm)
(Apply 0.4 mL
Loctite® 7088 Primer
and 0.4 mL Loctite®
620™)

Drive Clutch Cover Plate

9 ft-lb (12 Nm)

ITEM

TORQUE VALUE

Shift Weight Fasteners

20 in-lb (2 Nm)

Driven Clutch Helix
Retaining Screws

48 in-lb (5 Nm)

2014 RZR XP / XP 4 1000 CLUTCH CHARTS

CLUTCH CHART (2014 RZR XP 1000 / EPS / INT’L)

ALTITUDE

SHIFT
WEIGHT

DRIVE
SPRING

DRIVEN
SPRING

Meters
(Feet)

0-1500
(0-5000)

26-61
(1323098)

White /
Orange
(7043924)

Red
(3234452)

1500-3700
(5000 - 12000)

26-55
(1322982)

White /
Orange
(7043924)

Red
(3234452)

CLUTCH CHART (2014 RZR XP 4 1000)

ALTITUDE

SHIFT
WEIGHT

DRIVE
SPRING

DRIVEN
SPRING

Meters
(Feet)

0-1500
(0-5000)

26-67
(1323177)

White /
Orange
(7043924)

Red
(3234452)

1500-3700
(5000 - 12000)

26-61
(1323098)

White /
Orange
(7043924)

Red
(3234452)

CLUTCHING

Summary of Contents for 2014 RZR XP 1000

Page 1: ...ectly 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 yo...

Page 2: ...tor 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 d...

Page 3: ...ty 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 n...

Page 4: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 ELECTRONIC FUEL INJECTION 5 BODY STEERING SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION 9 BRAKES 10 ELECTRICAL ...

Page 5: ......

Page 6: ...ON 1 3 VEHICLE INFORMATION 1 3 PUBLICATION NUMBERS 1 3 REPLACEMENT KEYS 1 4 SPECIAL TOOLS 1 5 GENERAL SPECIFICATIONS 1 6 MODEL 2014 RZR XP 1000 EPS INT L 1 6 2014 RZR XP 1000 EPS INT L 1 7 MODEL 2014 RZR XP 4 1000 1 8 2014 RZR XP 4 1000 1 9 2014 RZR XP XP 4 1000 CLUTCH CHARTS 1 10 MISC SPECIFICATIONS AND CHARTS 1 11 MASTER TORQUE TABLE 1 11 CONVERSION TABLE 1 14 STANDARD BOLT TORQUE SPECIFICATION ...

Page 7: ...60 8 850 9 875 E EPS D Diesel F D E digits that would transfer to 17 digit VIN and are used in digits 4 8 respectively 9th digit will be used on color featured versions of models not including the base First 3 digits and 9th digit are used in model number only They are not used with the 17 digit VIN Engine Designation Number RZRXP 999 14 High Output 4 Stroke DOHC Twin Cylinder Liquid Cooled Electr...

Page 8: ...ngine serial number can be found on a decal applied to the front of the engine crankcase A or stamped into the crankcase on the PTO side of the engine B Refer to Figure 1 2 VEHICLE INFORMATION Publication Numbers MODEL OWNER S MANUAL PARTS MANUAL 2014 RZR XP 1000 9924687 9924688 2014 RZR XP 1000 EPS 9924687 9924688 2014 RZR XP 1000 INT L 9924687 9924688 2014 RZR XP 4 1000 9924687 9924688 NOTE When...

Page 9: ...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 SERIES PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION ...

Page 10: ...d 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 by phone at 1 800 345 2233 or on line at http polaris service solutions com GENERAL INFORMATION 1 ...

Page 11: ...eel Base 90 228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1379 lbs 625 5 kg Gross Vehicle Weight 2168 lbs 983 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 335 6 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 Hi...

Page 12: ...2v Flooded 575 CCA DC Outlet Standard 12 Volt Relays Fan EFI Fuel Pump Chassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 10 73 1 22 79 1 20 41 1 Front Gearcase Lubricant Requir...

Page 13: ...7 2 cm Ground Clearance 13 5 34 3 cm Dry Weight 1596 lbs 724 kg Gross Vehicle Weight 2560 lbs 1161 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 Capaci...

Page 14: ...d 575 CCA DC Outlet Standard 12 Volt Relays Fan EFI Fuel Pump Chassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 10 73 1 22 79 1 20 41 1 Front Gearcase Lubricant Requirement Dem...

Page 15: ...ING DRIVEN SPRING Meters Feet 0 1500 0 5000 26 61 1323098 White Orange 7043924 Red 3234452 1500 3700 5000 12000 26 55 1322982 White Orange 7043924 Red 3234452 CLUTCH CHART 2014 RZR XP 4 1000 ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING Meters Feet 0 1500 0 5000 26 67 1323177 White Orange 7043924 Red 3234452 1500 3700 5000 12000 26 61 1323098 White Orange 7043924 Red 3234452 GENERAL INFORMATION...

Page 16: ...b 35 Nm Step 3 Additional 180 Step 4 M6 bolts 7 ft lb 10 Nm Differential Cover Screws INTL 22 ft lb 30 Nm Door Fasteners 8 ft lb 11 Nm Drive Clutch Retaining Bolt 96 ft lb 130 Nm ITEM TORQUE Drive Clutch Cover Plate Screw 9 ft lb 12 Nm Drive Clutch Shift Weight Fasteners 20 in lb 2 Nm Drive Clutch Spider 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 Drive Clutch Spider J...

Page 17: ...Plug 7 ft lbs 10 Nm Speed Sensor Screw 12 ft lb 16 Nm Stabilizer Bar Linkage rear 40 ft lbs 54 Nm Stabilizer Bar Mounting Bracket Bolts rear 17 ft lb 23 Nm ITEM TORQUE Stabilizer Bar Locating Clamp Bolts 10 ft lb 14 Nm Starter Mounting Bolts 7 ft lb 10 Nm Starter One Way Clutch Screws 9 ft lb 12 Nm Stator Cover Screws 9 ft lb 12 Nm Steering Tilt Shock Fastener 7 ft lb 10 Nm Steering Pivot Tube Fas...

Page 18: ... 4 1000 Service Manual Copyright 2013 Polaris Industries Inc ITEM TORQUE Apply Loctite 204 to bolt threads Water Pump Cover Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads Wheel Lug Nuts 120 ft lbs 163 Nm GENERAL INFORMATION 1 ...

Page 19: ...mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg kilogram kg x 2 2046 lbs cubic inches cu in x 16 387 cc cubic centimeters cc x 0 061 cubic inches US quarts x 0 946 liters L liters L x 1 057 US quarts US gallons x 3 785 liters L liters L x 0 264 US gallon...

Page 20: ... 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Metric Bolt Torque Specification BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LBS NM DRY THREADS M3 3 5 5 7 1 1 3 1 5 2 1 5 2 M4 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 18 M8 7 9 5 10 13 18 25 26 35 33 45 M10 14 19 18 25 37 50 55 75 63 85 M12 26 35 33 45 63 85 ...

Page 21: ... 17 1 1 2 12 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 Metric Tap Drill Sizes TAP SIZE DRILL SIZE DECIMAL NEAREST FRACTION 3 x 50 39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 ...

Page 22: ...906 10 mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 FRACTION DECIMAL MM TO INCHES 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 18 mm 0 70...

Page 24: ...TMENT 2 10 FUEL SYSTEM AND AIR INTAKE 2 11 FUEL SYSTEM 2 11 FUEL TANK VENT LINE 2 11 FUEL PUMP FUEL FILTERS 2 11 FUEL LINES 2 12 THROTTLE PEDAL INSPECTION 2 12 ENGINE INTAKE PRE FILTER SERVICE 2 13 AIR FILTER SERVICE 2 13 INTAKE DUCT DRAIN INSPECTION 2 14 AIR BOX AIR FILTER ASSEMBLY VIEW 2 15 ENGINE 2 16 ENGINE OIL LEVEL 2 16 ENGINE OIL AND FILTER CHANGE 2 17 ENGINE CRANKCASE BREATHER HOSE INSPECT...

Page 25: ... AND IGNITION SYSTEM 2 29 BATTERY MAINTENANCE 2 29 BATTERY CHARGING OFF SEASON STORAGE 2 30 BATTERY REMOVAL 2 30 BATTERY INSTALLATION 2 30 ENGINE CHASSIS ELECTRICAL GROUND 2 31 SPARK PLUG SERVICE 2 31 STEERING 2 32 STEERING INSPECTION 2 32 STEERING WHEEL FREEPLAY 2 32 TIE ROD END WHEEL HUB INSPECTION 2 33 WHEEL TOE ALIGNMENT INSPECTION 2 33 WHEEL TOE ADJUSTMENT 2 34 SUSPENSION WALKER EVANS 2 35 SP...

Page 26: ... in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these com...

Page 27: ...Filter 25 H Monthly 250 400 Inspect replace as needed Battery 25 H Monthly 250 400 Check terminals clean test E Engine Oil Filter Change Break In Period 25 H 1 M 250 400 Perform a break in oil and filter change at 25 hours or one month perform every 50 hours or 6 months thereafter Front Gearcase Lubricant Demand Drive 25 H 1 M 250 400 Initial fluid level inspection add lubricant if needed Transmis...

Page 28: ...tem Engine Mounts 100 H 12 M 1000 1600 Inspect torque to specification Exhaust Silencer Pipe 100 H 12 M 1000 1600 Inspect Wiring 100 H 12 M 1000 1600 Inspect for wear routing security inspect connectors subjected to water mud etc Clutches Drive and Driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive Belt 100 H 12 M 1000 1600 Inspect replace as needed Front Wheel Bearings 100 H 12 M ...

Page 29: ...Access Panel Polaris PS 4 or Polaris PS 4 Extreme Duty Add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereafter Engine Coolant Under Front Hood Access Panel Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Item 4 Check level daily change coolant every two years More often under severe use such as ope...

Page 30: ...tem 1 Check level during pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant until it is visible at the fill hole threads Item 2 8 5 oz 250 ml Initial level check at 25 hours or 1 month Change lubricant at 100 hours or every 12 months whichever comes first Transmission Polaris AGL Add lubricant until it is visible at the fill hole threads Item 3 More ...

Page 31: ...n each side of the vehicle Item 1 Polaris All Season Grease Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the vehicle Propshaft Yokes Grease middle and rear fittings Item 2 Polaris Premium U Joint Grease Front Stabilizer Bar Bushings INT L Grease the fitting on each side of the vehicle Item 3 Polaris All Season Grease Rear T...

Page 32: ...rive 2 5 Gallon 2870465 Oil Pump for 1 Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871329 Dielectric Grease Nyogel Coolant 2871323 60 40 ...

Page 33: ...ssure compressed air if necessary Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Drive Shaft Boots Inspect inner and outer boots for tears or damage on both front and rear drive shafts Check all front and rear suspension comp...

Page 34: ...es or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result...

Page 35: ...ry 2 Locate the fuel supply fitting Item 2 through the right rear wheel well on the upper right side of the engine Check the line and quick connect fitting for signs of wear deterioration damage or leakage Replace line if necessary 3 Be sure fuel lines are routed and retained properly NOTE Make sure lines are not kinked or pinched Throttle Pedal Inspection This vehicle is equipped with Pedal Posit...

Page 36: ... the intervals outlined in the Periodic Maintenance Chart In extremely dusty conditions air filter replacement will be required more often 1 Remove the cargo box access panel Item 1 2 Disengage the four cover latches Item 2 3 Pull cover rearward far enough to remove air filter Item 3 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean shop towel NOTE If the filter h...

Page 37: ...in Inspection It is recommended that the intake drain be inspected daily 1 Access the intake baffle box drain Item 1 through the left rear wheel well 2 Check the drain to ensure it is not plugged with debris so it can drain properly If needed remove the drain from the baffle box during inspection MAINTENANCE ...

Page 38: ...000 Service Manual Copyright 2013 Polaris Industries Inc Air Box Air Filter Assembly View 1 Intake Airbox Hose 6 Airbox Clip 4 2 Drain Cap 7 Vent Hose 3 Airbox 8 Intake Tubes 4 Air Filter 9 Engine Intake Housing 5 Airbox Cover MAINTENANCE ...

Page 39: ...ission in PARK 2 Stop the engine and allow it to cool down before removing the dipstick 3 Unlock the dipstick lever Item 1 Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 5 Remove the dipstick and ...

Page 40: ...dure Do not allow hot engine oil to come into contact with skin as serious burns may result 4 Place a drain pan under the engine crankcase and remove the drain plug Item 1 Allow the oil to drain completely 5 Remove the seats and engine service panel to access the oil filter 6 Using the Oil Filter Wrench PU 50105 turn the oil filter Item 2 counter clockwise to remove it Oil Filter Wrench PU 50105 2...

Page 41: ... consistent 17 Remove the dipstick and check the oil level 18 Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick Do not overfill 19 When finished reinstall the oil fill cap oil dipstick and lock the lever 20 Reinstall the cargo box access panel engine service panel and seats 21 Dispose of used oil and filter properly Engine Crankcase Breather Hose Inspect...

Page 42: ...er clutch cover 4 Maneuver the outer clutch cover to allow access to the drive clutch in order to rotate the engine NOTE Removal of left rear wheel or left rear shock is NOT necessary to perform this procedure 5 Remove the spark plug wires to gain access to valve cover as shown below 6 Remove the four T40 bolts retaining the valve cover 7 The engine will need to be rotated four times to inspect al...

Page 43: ... necessary 14 Install NEW isolators on the valve cover bolts Install the valve cover and the four T40 bolts Torque bolts to specification Valve Cover Bolts 7 ft lbs 10 Nm 15 Install the spark plug wires back into their correct location 16 Install the push rivet that retains the heat shield to the frame cross member 17 Install the spark plug wires Ensure wires are installed on their proper cylinder...

Page 44: ...bricant Level Check The fill plug is located on the rear portion of the transmission gearcase Access the fill plug at the rear of the vehicle Maintain lubricant level even with the bottom of the fill plug hole 1 Position vehicle on a level surface 2 Remove the fill plug Item 1 and check the lubricant level Item 2 3 If lubricant level is not even with bottom threads add recommended lubricant as nee...

Page 45: ...re vehicle is positioned on a level surface when checking or changing the fluid Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located on the bottom right side of the front gearcase Access the fill plug through the right front wheel well Maintain fluid level even with the bottom of the fill plug hole 1 Position vehicle on a level...

Page 46: ...t is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels often during break in period Overheating of en...

Page 47: ...ompletely and check coolant level in the radiator and inspect for signs of trapped air in system WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure cap 5 Remove the pressure cap Using a funnel add coolant to the top of the filler neck 6 Reinstall the pressure cap NOTE Use of a non standard ...

Page 48: ...asion or leaks Replace if necessary ITEM DESCRIPTION 1 Recovery Bottle 2 Engine Hoses 3 Radiator Hoses 4 To Thermostat Housing 5 To Waterpump 6 To Radiator 2 Inspect all engine hoses for cracks deterioration abrasion or leaks Replace if necessary ITEM DESCRIPTION 7 Bypass Hose 8 Waterpump Outlet Hose 9 Oil Cooler Inlet Hose 10 Oil Cooler Outlet Hose 3 Check tightness and condition of all hose spri...

Page 49: ...ne and radiator are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 2 Slowly remove the pressure cap to relieve any cooling system pressure 3 Place a suitable drain pan underneath the radiator fitting on the front right side of the vehicle 4 Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown Item 1 5 Allow coolant to d...

Page 50: ...he PVT drain plug is located at the bottom of the outer clutch cover Access the drain plug through the left rear wheel well 1 Using a flat blade screwdriver remove the PVT drain plug Item 1 and O ring from the outer clutch cover 2 Allow the water to drain out completely 3 Reinstall the drain plug and O ring 4 Place the transmission in PARK apply the brake and start the engine 5 Apply varying throt...

Page 51: ... stand under the frame 5 Remove the wheel nuts and remove the wheel Wheel Installation 1 Verify the transmission is still in PARK 2 Place the wheel in the correct position on the wheel hub Item 5 Be sure the valve stem Item 2 is toward the outside and rotation arrows on the tire point toward forward rotation 3 Attach the wheel nuts Item 1 and finger tighten them 4 Carefully lower the vehicle to th...

Page 52: ...minals with dielectric grease or petroleum jelly WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burn...

Page 53: ...n reinstalling the battery install the black negative cable last 4 Remove the battery hold down bracket Item 2 5 Lift the battery out of the vehicle Battery Installation NOTE Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Refer to Charging Procedure page 10 36before installing the battery 1 Ensure the b...

Page 54: ...lug Service Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart 1 Remove the cargo box access panel Item 1 WARNING A hot engine can cause serious burns Allow engine to cool or wear protective gloves when removing the spark plugs 2 Remove both spark plug caps Item 2 NOTE Note MAG and PTO reference decals on spark plug wires for reassembly 3 Clean out plug...

Page 55: ...k plugs 13 Reinstall the cargo box access panel STEERING Steering Inspection The steering components should be checked periodically for loose fasteners worn tie rod ends ball joints and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must be replaced Replace any worn or damaged steering components Steering should move freely through the entire range of t...

Page 56: ...ment is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to Chapter 7 Final Drive for front hub service procedures Wheel Toe Alignment Inspection 1 Place machine on a smooth level surface and set steering wheel in a straight ahead position Secure the steering wheel in this position 2 Place a chalk mark on the center line of the front ...

Page 57: ...icle center This will tell you which tie rod needs adjusting NOTE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold tie rod e...

Page 58: ...easurement location The factory setting is appropriate for nearly all riding conditions Since this vehicle is equipped with full skid plates adjustment is not necessary If desired the spring setting may be adjusted to maintain vehicle clearance height when carrying loads 1 Raise and safely support front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock...

Page 59: ...o decrease compression damping NOTE The recommended factory setting for the front and rear shocks are provided in the following compression adjustment tables Walker Evans 2 0 Front Shock Compression Adjustment Table SETTING COMPRESSION DAMPING Softest Full counter clockwise position Factory 6 clicks from softest position Firmest Full clockwise position Walker Evans 2 5 Rear Shock Compression Adjus...

Page 60: ... Item 1 The level should be between the MAX and MIN level lines 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings Brake Pad Disc Inspection 1 Check the brake pads for...

Page 62: ...3 12 ENGINE COOLING SYSTEM 3 13 COOLING SYSTEM PRESSURE TEST 3 13 PRESSURE CAP TEST 3 13 RADIATOR REMOVAL INSTALLATION 3 14 THERMOSTAT REPLACEMENT 3 15 COOLING SYSTEM ASSEMBLY VIEW 3 17 COOLING SYSTEM BLEEDING PROCEDURE 3 18 WATER PUMP REMOVAL 3 19 WATER PUMP INSTALLATION 3 19 WATER PUMP SERVICE 3 21 ENGINE SERVICE 3 24 ACCESSIBLE ENGINE COMPONENTS 3 24 TOP END SERVICE ENGINE IN CHASSIS 3 24 ENGIN...

Page 63: ...58 ENGINE ASSEMBLY LOWER END 3 60 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 60 CONNECTING ROD BEARING SELECTION 3 61 CRANKSHAFT MAIN BEARING SELECTION 3 61 UPPER CRANKCASE PREPARATION 3 61 PISTON RING INSTALLATION 3 62 PISTON CONNECTING ROD ASSEMBLY 3 63 CYLINDER PISTON INSTALLATION 3 64 CRANKSHAFT INSTALLATION 3 65 BALANCE SHAFT INSTALLATION 3 67 LOWER CRANKCASE PREPARATION 3 67 CRAN...

Page 64: ...ssure Gauge Adapter PU 50565 Piston Ring Compressor Pliers PV 43570 1 Valve Spring Compressor PV 1253 or PV 4019 Quick Release Valve Spring Compressor Adapter PV 43513 A Water Pump Mechanical Seal Installer PU 50564 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Engine Lubrication Specifications Oil Capacity Approx 2 5 Quarts 2 4 L Oil Filter Wrench PU 5010...

Page 65: ... the MAG side of the engine 4 Remove the crankcase gallery plug Item 1 and insert the oil pressure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 or PS 4 Extreme Duty at operating temperature and may vary considerably if any other oil is used or if engine is not up to t...

Page 67: ...ut of Round Limit 0 001 0 025 mm Cylinder Taper Limit 0 001 0 025 mm Cylinder to Piston Clearance 0 0009 0 0019 0 025 0 050 mm Cylinder Head Cylinder Head Surface Warp Limit 0 0039 0 1 mm Cylinder Head Standard Height 4 717 0 0019 119 82 0 05 mm Valve Valve Lash Cold Intake 0 006 0 002 0 15 0 5 mm Valve Lash Cold Exhaust 0 008 0 002 0 20 0 5 mm Valve Stem Diameter Intake 0 2155 0 2161 5 475 5 490 ...

Page 68: ...g Rod Connecting Rod Small End I D 0 7879 0 7885 20 015 20 030 mm 0 7897 20 06 mm 1 Marking Conn Rod Big End Bore I D 1 7318 1 7321 43 989 43 996 mm 2 Marking Conn Rod Big End Bore I D 1 7321 1 7323 43 996 44 003 mm 3 Marking Conn Rod Big End Bore I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D 1 6140 1 6143 40 996 41 004 mm 1 6129 40 970 mm G Marking Main Journal O D 1 61...

Page 69: ... 9924874 R02 2014 RZR XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc ENGINE DETAIL TORQUE VALUES SEQUENCES ASSEMBLY NOTES Main Engine Components Torque Specification and Sequence ENGINE ...

Page 74: ...a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use Cooling System Pressure Test 1 Remove the hood from the front cab WARNING Never remove pressure cap when engine is warm or hot The cooling system is under pressur...

Page 75: ... to the main frame 3 Drain radiator by removing lower radiator hose Item 1 Be sure to catch and dispose of coolant properly WARNING The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 4 Disconnect cooling fan electrical connector 5 Remove the upper radiator hose from the radiator 6 Remove the four upper radiator support fasteners Item 2 and d...

Page 76: ... and serious burns may result Allow the engine to cool before servicing 2 Remove the pressure cap to relieve any system pressure see Pressure Cap Test 3 Drain coolant to a level below the thermostat housing 4 Remove upper coolant hose from thermostat housing Item 1 5 Remove the rear bolt Item 2 retaining the thermostat cover 6 Remove the cargo box access panel 7 Using an 8 mm swivel socket and lon...

Page 77: ...he bleed hole Item 4 positioned closest to the engine NOTE Image shown above is with engine removed for clarity 10 Reverse this procedure for installation Torque thermostat cover bolts to specification Thermostat Cover Bolts 7 ft lb 10 Nm 11 Be sure to properly fill and bleed cooling system as outlined in this chapter ENGINE ...

Page 78: ... Cooling System Assembly View 1 Thermostat housing 6 Filler Neck 11 Oil Cooler Inlet Hose 2 Water Pump 7 Radiator 12 Oil Cooler Outlet Hose 3 Engine Hoses 8 Pressure Cap 13 Bypass Hose 4 Lower Radiator Hose 9 Upper Radiator Hose 14 Water Pump Outlet Hose 5 Fan Assembly 10 Recovery Bottle ENGINE ...

Page 79: ...add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck 5 Remove the seats engine service panel and divider panel heat shield to access the coolant bleed screw 6 Open the bleed screw Item 3 to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 7 Tighten the bleed screw to specification top off coolant and properly in...

Page 80: ...oses that are attached to the water pump Note location and routing for installation Be sure to catch and dispose of coolant properly 11 Remove the three bolts Item 1 2 retaining water pump to engine block Note different bolt lengths for installation 12 Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward 13 Maneuver water pump downward and remov...

Page 81: ...le in the skid plate on the RH side of the vehicle 8 Slide water pump into engine crankcase 9 Be sure water pump is fully seated and the drive tab and slot are properly engaged 10 Install the three water pump mounting bolts Item 5 6 and torque to specification NOTE Install different bolt lengths as shown Water Pump Mounting Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads 11 Install the four ...

Page 82: ... engine 1 Remove water pump assembly as outlined in this chapter 2 Remove the three bolts retaining water pump cover Item 1 to water pump housing Item 2 Discard cover gasket Item 3 3 Place the water pump drive tab Item 4 vertically into a soft jaw vice 4 Remove the bolt and washer retaining the water pump impeller to the shaft Inspect the impeller veins and water pump housing for damage Replace if...

Page 83: ... oil seal bores 11 Install a NEW oil seal into the water pump housing until fully seated 12 Fully install the water pump shaft and two washers into the housing 13 Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure 14 Install a NEW mechanical seal into the water pump housing using special tool PU 50564 Press the new mechanical seal in until it is flush wi...

Page 84: ... Water Pump Cover Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads 21 Install two new water pump O rings and lubricate them with fresh engine oil 22 Install water pump assembly into engine as shown in the Water Pump Installation procedure 9 Bolt 13 Washers 17 Oil Seal 10 Loctite 204 14 Drive Tab 18 Impeller 11 Mechanical Seal 15 Water Pump Shaft 19 Washer 12 O Rings 16 Water Pump Housing ENGI...

Page 85: ...ine Components page 3 24 for further information The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components WARNING Always wear safety glasses and proper shop clothing when performing the ...

Page 86: ... Item 4 CPS Item 5 ECT sensor Item 6 and ignition coil harness lead Remove wire ties retaining harness to the fuel rail and rear cross member 13 Disconnect the stator harness 14 Remove positive cable from the starter motor 15 Remove negative cable from the starter mounting bolt 16 Disconnect fuel lines and remove throttle body assembly See Fuel Line Removal Installation page 4 10 Fuel Line Removal...

Page 87: ...ining the box support bracket Item 12 Remove the push rivet that attaches the heat shield Item 13 to the rear cross member 21 Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose Item 14 and the water pump coolant hose Item 15 from the engine Dispose of engine coolant properly 22 Use an overhead or portable engine hoist and suitable engine straps to secure en...

Page 88: ...l injury or damage to vehicle components 26 Remove the starter motor bolts Item 20 and starter motor from the engine 27 Remove the six transmission joint bracket bolts Item 21 and transmission joint bracket Item 22 from the engine 28 Install the engine stand adapter PU 50562 onto the engine where the starter motor was located 29 Select the proper engine stand sleeve adapter and install it onto the...

Page 89: ...ers to specification in sequence Starter Motor Bolts 7 ft lb 10 Nm Trans Joint Bracket Bolts 44 ft lb 60 Nm 4 Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame NOTE Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 5 Align both the fro...

Page 90: ...unting holes with transmission joint bracket mounting holes on engine 10 Install the two bolts Item 6 retaining the transmission joint bracket to the engine on the right side Hand tighten the bolts so they remain loose at this time NOTE DO NOT torque fasteners at this time 11 Install the two longer bolts into left side mounting holes Torque left side mounting bolts to specification using the numbe...

Page 91: ... harness in the routing clip on the rear cross member 26 Install positive cable to the starter motor 27 Install negative cable to the starter motor mounting bolt 28 Properly route and connect the harness leads for the stator CPS TMAP sensor ECT sensor fuel injectors and ignition coil 29 Install the air box assembly as outlined in the EFI Chapter See ETC Replacement page 4 33 30 Install the inner c...

Page 92: ...w the Cooling System Bleeding Procedure page 3 18 as outlined in this chapter 39 Install the seats 40 Start engine and check for any oil or coolant leaks 41 Check the engine oil level 42 Refer customer to Engine Break In Period upon returning vehicle to customer Engine Mounting and Torque Values ENGINE ...

Page 93: ...mum pump octane number of 87 R M 2 2 Refer to Engine Oil Level page 2 16 Check oil level indicated on dipstick Add oil if necessary 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bolt torques 6 Change oil and oil filte...

Page 94: ...nt anything from falling into the combustion chamber Camshaft Removal NOTE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the PTO cylinder is at Top Dead Center TDC to relieve most of the valve spring pressure The camshaft lobes should face out Item 1 and the slots on the end of the camshafts should line up 2 Remove the hydraulic cam chain tensioner It...

Page 95: ...to prevent the chain from falling off the crankshaft 9 Evenly loosen the four bolts retaining each rear camshaft carrier Item 10 and carefully lift the carriers off the camshafts 10 Mark the intake Item 11 and exhaust Item 12 camshafts to ensure proper assembly 11 Carefully remove camshafts from the cylinder head Camshaft Sprocket Inspection Inspect cam sprocket teeth Item 1 for wear or damage Rep...

Page 96: ...5370 39 04 mm Exhaust 1 5142 1 5181 38 46 38 56 mm Service Limit 1 5122 38 41 mm 3 Visually inspect each camshaft journal for scoring wear or damage 4 Measure the diameter of the camshaft journals using a micrometer Compare to specification NOTE Replace camshafts if damaged or if any part is worn past the service limit Camshaft Journal O D 0 9036 0 9055 22 954 22 999 mm 0 9033 22 944 mm 5 Temporar...

Page 97: ...d Removal NOTE The cylinder head can be serviced with the engine installed in the chassis 1 Remove the two outer M6 bolts Item 1 that retain the cylinder head Item 2 to the cylinder 2 Loosen the six cylinder head bolts Item 3 evenly 1 8 turn at a time until all are loose 3 Remove and discard the cylinder head bolts 4 Tap cylinder head lightly with a soft faced hammer until loose 5 Tap only in rein...

Page 98: ...different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head Cylinder Head Warp Limit 0 0039 0 1 mm Cylinder Head Disassembly WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs NOTE Keep mated parts together and in orde...

Page 99: ...and push the valve Item 8 out keeping it in order for reassembly in the same valve guide 7 Repeat the previous steps to remove the remaining valves 8 Clean the combustion chamber and head gasket surface 9 Check the condition of each valve spring Replace if wear or cracking is present on the spring Valve Inspection 1 Remove all carbon from valves with a soft wire wheel or brush 2 Check valve face f...

Page 100: ...515 mm 7 Be sure to measure each guide and valve combination individually NOTE The valve guides cannot be replaced Combustion Chamber Cleaning WARNING Wear eye protection during combustion chamber cleaning 1 Clean all accumulated carbon deposits from combustion chambers and valve seat area Item 1 NOTE Carbon Clean Fuel Treatment 2871326 can be used to help remove carbon deposits Do not use a metal...

Page 101: ...r the entire circumference of the seat and the seat must be the proper width all the way around If seat is uneven compression leakage will result If seat is too wide seat pressure is reduced causing carbon accumulation and possible compression loss If seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Inst...

Page 102: ...e the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very ...

Page 103: ...g is not required if an interference angle reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the val...

Page 104: ...ws retaining the stator cover CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result 2 Carefully pry the stator cover off the engine using the two pry areas as shown 3 Inspect the condition of the stator windings Item 1 and ou...

Page 105: ...s from the thermostat housing cylinder inlet and oil cooler Leave them all attached to the water pump housing 2 Remove the three long gold colored bolts retaining the water pump housing to the engine 3 Remove the water pump assembly from the engine by using a twisting motion as you pull out on the housing 4 If water pump service is required impeller or mechanical seal refer to Water Pump Service p...

Page 106: ...ne way clutch can be serviced with the engine installed in the chassis 7 Remove the stator cover and flywheel see Stator Cover Removal Inspection and Flywheel Removal 8 Place flywheel on a work bench with the one way clutch facing up Grasp clutch gear and rotate clockwise It should turn smoothly without binding 9 Rotate one way gear counterclockwise Item 5 The gear should immediately lock in posit...

Page 107: ...ear damage or uneven surface 4 Inspect drive surface of starter gear Item 3 and bushing Item 4 for wear damage or uneven surface If any starter one way clutch component is worn or damaged replace the clutch and starter gear as an assembly Crankcase Disassembly Inspection 1 Remove the oil cooler Item 1 from the crankcase 2 Remove the crankcase drain plug Item 2 Drain any oil remaining in the engine...

Page 108: ...tool retains the cylinder and pistons when the engine is rotated 5 Rotate engine to access the crankcase sump cover 6 Remove the thirteen M6 Item 5 and three M8 bolts Item 6 retaining the sump cover Item 4 to the crankcase 7 Remove the sump cover Item 7 from the crankcase 8 Remove and clean oil pump pick up Item 8 9 Remove the three bolts Item 9 that retain the oil pump Item 10 to the crankcase EN...

Page 109: ... sprocket bolt by removing the case plug 11 Lift the oil pump drive chain and remove the oil pump 12 Visually inspect the oil pump and drive sprocket Item 12 for wear or damage Replace oil pump drive chain and sprocket if worn or damaged If any part of the oil pump is damaged the entire assembly must be replaced Replace the oil pump seal Item 13 during crankcase assembly NOTE Oil pump assembly is ...

Page 110: ... reinforced areas with a soft faced hammer to loosen Carefully lift up and remove the lower crankcase half Balance Shaft Removal Inspection 1 Perform Crankcase Disassembly Inspection page 3 46 procedure 2 Note timing marks on balance shaft and crankshaft drive gears Shafts must be properly timed upon assembly 3 Carefully rotate the balance shaft Item 2 and remove it from the crankcase 4 Inspect th...

Page 111: ...rform Crankcase Disassembly Inspection page 3 46 procedure 2 Perform Balance Shaft Removal Inspection page 3 49 procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts Item 1 Remove the end caps from the crankshaft 5 Carefully lift the crankshaft Item 2 out of the crankcase 6 Remove the cam chain Item 3 oil pump drive chain It...

Page 112: ...ce of crankshaft main and connecting rod journals Replace crankshaft if any journal is scratched or pitted 11 Measure each main journal and connecting rod journal in two locations 90 degrees apart Replace crankshaft if any journal is worn below the service limit specification 8 MAG End 12 Journal 4 Rod Bearing 9 Journal 1 Main Bearing 13 Journal 5 Main Bearing 10 Journal 2 Rod Bearing 14 Journal 6...

Page 113: ... 934 40 941 mm Service Limit 1 6104 40 906 mm Y Main Bearing Standard 1 6134 1 6137 40 980 40 987 mm Service Limit 1 6129 40 970 mm Conn Rod Bearing Standard 1 6112 1 6115 40 926 40 933 mm Service Limit 1 6104 40 906 mm 14 Whether installing a new crankshaft or re installing the original refer to the bearing selection chart provided in the Crankshaft Main Bearing Selection and Connecting Rod Beari...

Page 114: ... replace plain bearings when the crankcase or connecting rods have been disassembled Refer to Bearing Selection Identification Letters and Numbers page 3 60 Cylinder Inspection 1 Lay a straight edge Item 1 across the top surface of the cylinder at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder surface If warp exceeds the service lim...

Page 115: ... 0 008 mm Cylinder Piston Removal CAUTION Pistons must be removed from the cylinders with the connecting rods attached DO NOTattempt to service the cylinder or pistons without disassembling the crankcase Although you can remove the cylinder and pistons without disassembly you will not be able to reassemble the engine because of the unique cylinder skirt and crankcase design 1 Perform ENGINE DISASS...

Page 116: ...t but can be placed in either cylinder 1 Note location of the piston circlip gap Item 1 at the top 12 00 position or bottom 6 00 position 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a heat gun if pin cannot be removed by hand Discard circlips CAUTION DO NOTapply heat to piston rings or a loss of radial tension could result 3 Mea...

Page 117: ... using a ring removal pliers CAUTION DO NOTexpand the ring more than necessary to remove it from the piston or the ring may break or lose radial tension Piston ring pliers Carefully expand ring and lift it off the piston By hand Placing both thumbs on the ring ends spread the ring open and push up on opposite side Do not scratch ring lands 2 Repeat procedure for second compression ring Item 2 3 Th...

Page 118: ...rence between top and bottom end gap measurements is a general indication of cylinder taper wear The cylinder should be measured for taper and out of round 3 If the installed gap measurement exceeds the service limit replace the rings Piston Ring Installed Gap Top Ring 0 010 0 014 0 25 0 35 mm Service Limit 1 6118 1 6122 40 942 40 950 mm Second Ring 1 6118 1 6122 40 942 40 950 mm Service Limit 0 0...

Page 119: ...ecting rod 3 Inspect the small end and big end of connecting rod and matching rod cap for damage galling of surface or pitting 4 Measure small end I D in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service limit specification Connecting Rod Small End I D 0 7879 0 7885 20 015 20 030 mm Service Limit 0 7897 20 06 mm 5 Install matc...

Page 120: ...table below lists the big end bore diameter specifications Bearing Selection Chart Rod Bearings CONNECTING ROD BIG END BORE DIAMETERS 1 2 3 1 7318 1 7321 43 989 43 996 mm 1 7321 1 7323 43 996 44 003 mm 1 7323 1 7326 44 003 44 010 mm 10 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart provided in the Connecting Rod Bearing Selection page 3 61...

Page 121: ...Polaris Industries Inc ENGINE ASSEMBLY LOWER END Bearing Selection Identification Letters and Numbers 1 Connecting Rod Bearing Identification Number 1 number 2 Crankcase Bearing Identification Number 6 numbers 3 Crankshaft Bearing Identification Letters 6 Letters ENGINE ...

Page 122: ... the crankshaft you must reference the six numbers on the crankcase Item 8 and match that up with the main journal letters on the crankshaft Item 7 In this example you would use the number 2 as the crankcase codes case journals 1 2 3 4 You would use letters G Y G Y as the crankshaft codes crank journals 1 3 5 and 6 Based off the bearing selection chart you would use Green bearing for Main 1 Yellow...

Page 123: ... all ring surfaces and ring lands upon installation Always check piston ring installed gap before rings are installed on piston see Piston Ring Installed Gap Clean accumulated carbon from piston ring grooves and oil ring lube holes if piston has been in service 1 Top Ring 5 Upper Rail 2 Marking Up 6 Spring Expander 3 Marking Up 7 Lower Rail 4 Second Ring 1 Place oil control ring expander in oil ri...

Page 124: ... or deformed during installation 2 Install a new circlip on one side of piston with gap at the top 12 00 position or bottom 6 00 position NOTE Never re use a piston pin circlip If reinstalling the original connecting rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is rec...

Page 125: ...inder bore and direction from which they were removed MAG PTO New pistons are directional intake vs exhaust but can be placed in either cylinder 1 Apply clean engine oil to each piston assembly cylinder bore and bottom tapered portion of each cylinder sleeve 2 Verify that all ring end gaps are correctly located on each piston see Piston Ring Installation 3 Note the piston orientation mark arrow lo...

Page 126: ...ding tool retains the cylinder and pistons when the engine is rotated Crankshaft Installation NOTE Whether installing a new crankshaft or re installing the original refer to the bearing selection charts see Crankshaft Main Bearing Selection page 3 61 and Connecting Rod Bearing Selection page 3 61 procedures in this chapter 1 Rotate the engine so the cylinder is facing down 2 Clean the bearing bore...

Page 127: ...em 8 over crankshaft sprockets 8 Apply Polaris PS 4 engine oil to the new crankshaft oil seal Item 7 and install the seal on the PTO end of the crankshaft 9 Carefully lower the crankshaft into upper crankcase Guide connecting rods onto the rod journals of crankshaft as necessary 10 Adjust the PTO crankshaft seal so it rests properly in the upper crankcase 11 Clean bolt hole threads in connecting r...

Page 128: ...end gear is visible 4 Apply Polaris PS 4 engine oil to both balance shaft journals Item 2 5 Install the balance shaft placing the tooth with the alignment dot Item 3 in line with the dot Item 4 on the crankshaft gear see reference images below Lower Crankcase Preparation NOTE Always replace plain bearings when the crankcase or connecting rods have been disassembled Refer to bearing selection proce...

Page 129: ...s Item 2 with the slot in each bearing bore of the lower crankcase Press bearing inserts firmly into place 3 Apply Polaris PS 4 engine oil to the new bearings installed in the lower crankcase half 4 Clean crankcase mating surfaces to remove any oil 5 Apply a thin continuous film of Crankcase Sealant PN 2871557 to upper crankcase mating surface Item 3 as shown Do not allow sealant to dry before ass...

Page 130: ...Bolts M10 Bolts Step 1 9 ft lb 12 Nm Step 2 21 ft lb 28 Nm Step 3 Tighten add n 90 M8 Bolts 26 ft lb 35 Nm M6 Bolts 9 ft lb 12 Nm 11 Rotate the engine so the cylinder is facing up 12 Install the eleven M6 Item 9 and two M8 Item 8 upper crankcase bolts Tighten all bolts lightly by hand 13 Torque the upper crankcase bolts in sequence to specification start with 12 Repeat the sequence to verify final...

Page 131: ... retain oil pump Item 12 to the crankcase Torque mounting bolts to specification Oil Pump Mounting Bolts 7 ft lbs 10 Nm 19 Reinstall oil pump pick up Item 11 Torque mounting screws to specification Oil Pump Pick Up Retaining Screws 7 ft lb 10 Nm 20 Clean the gasket sealing surfaces on oil sump cover and crankcase to remove old gasket material and any oil NOTE Gasket surfaces must be DRY and oil fr...

Page 132: ...il sump cover Item 15 onto the crankcase 23 Install the thirteen M6 Item 16 and three M8 bolts that retain the oil sump cover Item 17 to the crankcase 24 Torque the oil sump cover bolts in sequence to specification Repeat the sequence to verify final torque Oil Sump Cover Bolts M8 Bolts 26 ft lb 35 Nm M6 Bolts 106 in lb 12 Nm 25 Reinstall the crankcase drain plug if previously removed Torque drain...

Page 133: ... with flange of clutch Item 1 engaged in recess 2 Clean screw threads in flywheel to remove all oil or grease 3 Place one way clutch on flywheel and install the three screws Torque screws to specification One Way Clutch Retaining Screws 9 ft lb 12 Nm 4 Reassemble starter one way clutch and gear using the following illustration 1 Torque Limit Gear Pin 5 Flywheel 2 Starter Gear 6 Screws 9 ft lb 12 N...

Page 134: ... If the Cylinder Holding Camshaft Timing Plate PU 50563 is installed remove it before tightening the flywheel Flywheel Retaining Bolt 133 ft lbs 180 Nm 6 Install the starter torque limit gear as an assembly Stator Cover Installation 1 Apply gasket tack adhesive to help hold gasket in place during assembly 2 Install a new stator cover gasket over alignment pins CAUTION The flywheel contains powerfu...

Page 135: ...eated in retaining groove and square with the guide NOTE Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring Item 3 and retainer Item 4 in clean engine oil 6 Install the valve spring with widely spaced coils Item 6 on the top and tightly spaced coils Item 7 facing down toward the cylinder head NOTE Valve springs to be installed with pa...

Page 136: ...m the cylinder NOTE Once the cylinder head is removed nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 3 Prepare cylinder head gasket sealing surfaces by cleaning thoroughly to remove all residue The head gasket must be installed clean and dry free from oil or grease NOTE Do not touch sealing surfaces of gasket 4 ...

Page 137: ...engine until the flywheel Top Dead Center TDC mark Item 1 is aligned or centered in the Crankshaft Position Sensor CPS mounting hole Item 2 This places the PTO cylinder at TDC for camshaft installation NOTE DO NOT use the V mark located on the flywheel opposite of the I mark Only the I mark should be used as a TDC reference 2 Reference the intake and exhaust markings made during disassembly If ins...

Page 138: ...a 13 16 open end wrench to rotate camshafts slightly if needed 8 Verify the TDC mark on the flywheel is still properly aligned see Step 1 9 Pull cam chain upward making sure it is engaged with the drive sprocket on the crankshaft 10 While lifting the cam chain up engage the cam sprockets into the chain with the I and E marks facing out 11 Install the sprockets onto the camshafts and align the spro...

Page 139: ... retaining bolts upon assembly Install the top bolt Item 8 in each camshaft sprocket Item 7 Do not torque the bolts at this time NOTE Use new sprocket retaining bolts upon assembly 13 Verify cam timing is correct Flywheel TDC mark should still be aligned see Step 1 and cam sprocket markings should line up as shown ENGINE ...

Page 140: ...the flywheel and torque the remaining sprocket bolts to specification 18 Install the front camshaft carrier Item 9 and two outer retaining bolts 19 Install the fixed cam chain guide Item 10 and two retaining bolts 20 Torque the camshaft carriers bolts in sequence to specification Camshaft Carrier Bolts 7 ft lb 10 Nm 21 Apply Polaris PS 4 engine oil to the cam chain tensioner bore prior to assembly...

Page 141: ...1000 Service Manual Copyright 2013 Polaris Industries Inc Camshaft Timing Quick Reference 1 Intake Cam 4 Align marks with surface 2 Exhaust Cam 5 CPS Mounting Hole 3 Align marks with surface 6 Align Flywheel Mark in Mounting Hole ENGINE ...

Page 142: ...204784 Exhaust Camshaft PN 1204786 2 Lubricate the camshaft bearing journal surfaces with Polaris PS 4 engine oil prior to installation 3 Carefully install the camshafts into the cylinder head The PTO camshaft lobes Item 3 should face out as shown 4 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when installed properly 5 Install the four bol...

Page 143: ...t or place them in an organized rack as you remove them 11 Record the 3 digit number on the bottom of the tappet Item 8 12 Reference the valve clearance measurement recorded for that valve along with the 3 digit tappet number 13 Refer to the appropriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 14 Install the proper tappet NOTE Lubricate the oute...

Page 144: ...525 528 530 532 535 538 540 542 545 0 376 0 400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 401 0 425 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0 450 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 ...

Page 145: ...5 518 520 522 525 528 530 532 535 538 540 542 0 401 0 425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0 450 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 451 0 475 465 468 470 472 475 478 480 482 485 488 49...

Page 146: ...all spark plugs Item 1 and torque to specification 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Install valve cover seal Item 2 5 Install the four valve cover shoulder bolts Item 3 and new isolators Item 4 using a T40 driver 6 Torque valve cover bolts to specification Spark Plugs 7 ft lbs 10 Nm Valve Cover Bolts 7 ft lbs 10 Nm ENGINE ...

Page 147: ...icted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression...

Page 148: ...key Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose i...

Page 150: ...ERATION OVERVIEW 4 16 INITIAL PRIMING STARTING PROCEDURE 4 17 ELECTRONIC CONTROL UNIT ECU 4 17 OPERATION OVERVIEW 4 17 ECU SERVICE 4 18 ECU REPLACEMENT 4 18 FUEL INJECTORS 4 19 OPERATION OVERVIEW 4 19 FUEL INJECTOR TROUBLESHOOTING 4 19 FUEL INJECTOR TEST 4 20 FUEL INJECTOR REPLACEMENT 4 20 FUEL PUMP 4 23 OPERATION OVERVIEW 4 23 FUEL SENDER TEST 4 24 FUEL PUMP TEST 4 24 FUEL PUMP REPLACEMENT 4 25 T...

Page 151: ...TING 4 39 DIGITAL WRENCH OPERATION 4 40 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 40 SPECIAL TOOLS ALSO REFER TO THE BEGINNING OF THIS CHAPTER 4 40 DIAGNOSTIC SOFTWARE VERSION 4 41 GUIDED DIAGNOSTIC AVAILABLE 4 41 DIGITAL WRENCH COMMUNICATION ERRORS 4 41 DIGITAL WRENCH DIAGNOSTIC CONNECTOR 4 41 DIGITAL WRENCH SERIAL NUMBER LOCATION 4 41 DIGITAL WRENCH VERSION AND UPDATE ID 4 42 DIGITAL WRENCH ...

Page 152: ...h Diagnostic Software Includes most recent version of software w serial number standard interface cable USB Serial Adaptor cable and SmartLink Module Kit PU 47471 Digital Wrench SmartLink Module Kit PU 47470 PU 47469 PU 47468 PU 47470 Digital Wrench PC Interface Cable PU 47469 Digital Wrench Vehicle Interface Cable PU 47468 Digital Wrench SmartLink Module Bosch Automotive Service Solutions 1 800 3...

Page 153: ...Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pin connector based Polaris EFI systems This kit is available to Polaris dealers through our tool supplier Bosch at http polaris service solutions com or 1 800 345 2233 Digital Wrench Diagnostic Connector Located under the hood connected to a sealed plug Digital Wrench Download Website Located at www polaris diagsys co...

Page 154: ... if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness con...

Page 155: ... Electronic Control Unit ECU 7 Fuel Pump Regulator 2 Crankshaft Position Sensor CPS 8 Fuel Level Sender 3 Engine Coolant Temperature Sensor ECT 9 Fuel Filter 4 Dual Throttle Body Assembly 10 Fuel Supply Line 5 Fuel Injectors 11 T MAP Sensor 6 Fuel Rail Regulator 12 Electronic Throttle Control ELECTRONIC FUEL INJECTION ...

Page 156: ...ontrol ETC Item 2 Located on the PTO side of the throttle body assembly Crankshaft Position Sensor CPS Item 3 Located on top of the stator cover Temperature and Manifold Absolute Pressure TMAP Sensor Item 4 Located on the Mag side of the throttle body Engine Coolant Temperature Sensor ECT Item 5 Located on the left side of the thermostat housing The sensor can be accessed with the air box assembly...

Page 157: ...ectors Item 7 Located on the top of the throttle body in the intake track retained on top by the fuel rail Fuel Rail Regulator Item 8 Located on the throttle body on top of the fuel injectors Ignition Coil High Tension Leads Item 9 Located behind the engine service panel on the driver s side of the vehicle Fuel Pump Regulator Fuel Sender Assembly Item 10 Under the passenger seat ELECTRONIC FUEL IN...

Page 158: ...ice Manual Copyright 2013 Polaris Industries Inc FUEL TANK Assembly View 1 PFA Nut 5 Preliminary Filter 2 Fuel Sender Float Arm 6 Fuel Tank Vent 3 PFA Gasket replace if removed 7 Fuel Tank Assembly 4 Fuel Pump Regulator ELECTRONIC FUEL INJECTION ...

Page 159: ...hon as much fuel from the tank as possible before attempting to remove it from the vehicle WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications 1 Remove the driver and passenger seats 2 Disconnect the negative and positive battery cables from the battery located under the driver s seat Remove the bol...

Page 160: ...me near the right rear portion of the fuel tank Once removed place the mechanism in the rear cargo box to keep it out of the way 7 Remove the shift knob Item 6 using a flat blade screwdriver and T25 Torx driver Remove the Torx screws retaining the center console Remove the console from the vehicle 8 Remove the shift linkage from the shifter 9 Remove the two bolts Item 7 and two T40 Torx screws Ite...

Page 161: ...aining the regulator and Torx screws Item 14 retaining the fuse box 13 Remove the fuel tank vent line from the tank fitting 14 Lift the rear of the fuel tank up first Carefully pull the fuel tank out of the vehicle Fuel Tank Installation 1 Carefully reinstall the fuel tank assembly Install the inner tank bracket with the fuel tank to ensure the bracket is inserted properly into the lower fuel tank...

Page 162: ...crew 8 ft lbs 11 Nm 8 Reinstall center console shift knob and screws 9 Reinstall seat belt mechanism Torque bolt to specification Seat Belt Mechanism Bolt 40 ft lbs 54 Nm 10 Reinstall right rocker panel and all previously removed fasteners 11 Reconnect the fuel line and fuel pump electrical harness Verify connections are secure 12 Reinstall the battery and battery bracket Torque fastener to specif...

Page 163: ... see Fuel Lines Quick Connect Fittings for specific removal procedure NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 4 Disconnect the fuel pump electrical harness Item 2 5 Remove the right hand rocker panel see Chapter 5 6 Remove the fastener Item 3 retaining the seat belt mechanism to the frame near the right rear portion o...

Page 164: ... 13 Lift the rear of the fuel tank up first Carefully pull the fuel tank out of the vehicle Fuel Tank Installation RZR XP 4 1000 1 Carefully reinstall the fuel tank assembly Install the inner tank bracket with the fuel tank to ensure the bracket is inserted properly into the lower fuel tank mount 2 Reinstall the fuel tank bracket and fasteners 3 Install the vent line 4 Reinstall lower rear close o...

Page 165: ...ture Sensor ECT Fuel Filter s Fuel Injectors Fuel Pressure Regulators Fuel Pump Fuel Rail Fuel Supply Return Lines Idle Air Control Valve IAC Ignition Coil Manifold Air Quality Sensor MAQS Wire Harness Assembly EFI Operation Overview The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are elec...

Page 166: ...ECTRONIC CONTROL UNIT ECU Operation Overview The ECU Item 1 is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition power on off intake air temperature manifold absolute pressure load engine coolant ...

Page 167: ...is required to ensure that all essential data contained within the original ECU is transferred to the replacement ECU NOTE Refer to this procedure and carefully follow all instructions provided in Digital Wrench 1 Carefully follow the ECU replacement instructions provided in Digital Wrench to ensure that all essential data contained within the original ECU is transferred to the replacement ECU 2 R...

Page 168: ...r operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the ...

Page 169: ... terminals Item 1 Fuel Injector Resistance Specification 11 4 12 6 Ω NOTE Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation Fuel Injector Replacement 1 Remove the cargo box assembly see chapter 5 2 Be sure the engine has cooled enough to work on 3 Loosen the hose clamps Item 1 retaining the intake plenum Item ...

Page 170: ...e not to damage the fuel injector ends during removal 10 Pull out on the fuel injector retaining clip and pull the injector out of the fuel rail Repeat on the other injector if removal is necessary 11 Upon installation of the new fuel injectors lightly lubricate the injector O rings to aid installation 12 Install the new injector s into the fuel rail and reinstall the retaining clip NOTE Be sure t...

Page 171: ...the negative battery cable and reinstall the driver s seat 20 Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks 21 Reinstall the intake plenum assembly and fasten the lower mount to the transmission mount bracket Be sure the lower air box post is placed properly into the rubber grommet Be sure the air box boots fully seat onto the dual throttle bo...

Page 172: ... regulator and fuel gauge sender The pump is rated for a minimum output of 25 liters per hour at 58 2 psi 400 14 kPa and has two non serviceable fuel filters 1 Fuel Line Connection 4 Pump Sending Unit Electrical Connection 2 Fuel Pump 5 Regulator 3 Preliminary Filter When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off t...

Page 173: ...If during starting the battery voltage drops below 7 0 volts the ECU will fail to operate the system WARNING Fuel is extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 1 Remove the passenger seat from the vehicle 2 Cover the fuel line connection at the fuel tank with a shop towel...

Page 174: ...and listen for the pump to activate NOTE If the pump starts repeat steps 3 4 and 5 to verify correct pressure 9 If the pump still does not operate check for correct ECU operation by plugging in a known good ECU of the same model NOTE If the pump still does not operate replace the fuel pump assembly Fuel Pump Replacement 1 Move the vehicle to a well ventilated area Shift the transmission into Park ...

Page 175: ...o allow the vehicle to sit for a period of one hour after shutting off the engine before servicing the fuel pump This allows the exhaust to cool and fuel pressure to drop NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 6 Disconnect the fuel pump electrical harness Item 3 7 Place the Fuel Pump Service Tool PU 50326 over the fu...

Page 176: ...uel pump assembly NOTE It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel Do not use water or any other chemicals to remove debris 11 Remove new fuel pump assembly Item 5 gasket Item 6 and PFA nut Item 7 from packaging Use care not to bend float arm Item 8 during un packaging Do not lift or carry fuel pump assembly by the float arm 12 Use clea...

Page 177: ...uel pump and fuel tank 18 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench Fuel Pump PFA Nut 70 ft lbs 95 Nm 19 Verify alignment of fuel pump and tank orientation marks 20 Connect the fuel supply line to the pump see Fuel Lines Quick Connect Fittings for specific installation procedures NOTE Be sure to engage the retainers on each fuel line u...

Page 178: ...ANKSHAFT POSITION SENSOR CPS Operation Overview Mounted on top of the stator cover the crankshaft position sensor Item 1 is essential to engine operation constantly monitoring the rotational speed RPM and position of the crankshaft A ferromagnetic 35 tooth encoder ring with a missing tooth is built onto the flywheel The inductive speed sensor is mounted 1 0 0 26 mm 0 059 0 010 in away from the enc...

Page 179: ...d the corresponding pin terminals at the ECU see wiring diagram Check the sensor mounting air gap flywheel encoder ring for damage or runout and flywheel key Follow the CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage 4 If the resistance is incorrect follow the CPS Replacement procedure CPS Replacement 1 If not done already disconnect the CPS harness connector see CPS ...

Page 180: ...tors The Manifold Air Quality Sensor MAQS attached to the end of the throttle body is non serviceable If the sensor is faulty the entire throttle body assembly must be replaced Refer to Throttle Body Removal procedure Throttle Body Removal 1 Remove the cargo box assembly See Cargo Box Assembly Removal page 5 21 2 Be sure the engine has cooled enough to work on 3 Loosen the hose clamps Item 1 retai...

Page 181: ...d using Digital Wrench If the ETC is faulty the entire assembly must be replaced Mounted to the intake plenum the ETC acts as an electronically controlled throttle body The ETC controls engine throttle operation to provide the proper air fuel ratio needed for engine operation at all RPM ranges The ETC controls engine RPM based off input provided by the Pedal Position Sensor PPS and Electronic Cont...

Page 182: ...rottle pedal assembly the PPS acts as a throttle position sensor The PPS provides throttle pedal position to the Electronic Control Unit ECU to increase or decrease engine RPM using the Electronic Throttle Control ETC The PPS is the primary input used to control engine speed during vehicle operation Location The ETC switch Item 1 is located in the drivers foot control area mounted on the top of th...

Page 183: ... The Pedal Position Sensor is calibrated to the throttle pedal If the PPS is faulty the throttle pedal assembly must be replaced see PPS Replacement PPS Replacement NOTE The PPS is calibrated to the throttle pedal If the PPS is faulty the throttle pedal assembly must be replaced 1 Disconnect the PPS harness connection Item 2 located on the throttle pedal 2 Remove the drivers seat and disconnect th...

Page 184: ...mber located far left can range from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes present The second number located top right can be 2 to 6 digits in length This number equates to the suspected area of fault SPN The third number located bottom right can be 1 to 2 digits in length This number equates to the fault mode FMI 4 If more than on...

Page 185: ... ECU Memory EEPROM Read Write Failure 628 12 C1073 Calibration Checksum CRC Error 630 13 C1074 Crankshaft Position Sensor CPS Plausibility Fault 636 2 P0335 Injector 1 MAG Driver Circuit Open Grounded 651 5 P0261 Driver Circuit Short to B 3 P0262 Driver Circuit Grounded 4 P1262 Injector 2 PTO Driver Circuit Open Grounded 652 5 P0264 Driver Circuit Short to B 3 P0265 Driver Circuit Grounded 4 P1265...

Page 186: ... 31 C1053 EPS Inverter Temperature Greater than 110 C 230 F 520225 16 C1054 Greater than 120 C 248 F 0 C1055 EPS CAN Communications Receive Error No RX Message for 2 Seconds 520226 2 U0100 EPS CAN Communications Transmit Error No TX Message for 2 Seconds 520227 2 U1100 Position Encoder Error Position Encoder Error 520228 11 C1065 EPS Software Error Software Error 520229 12 C1070 IC CAN Communicati...

Page 187: ...0285 2 P153E ECU Monitoring Error Condition Exists 520286 31 P1540 ECU Monitoring Error Level 3 Condition Exists 520287 31 P1541 ECU Monitoring of Injection Cut Off Level 1 Condition Exists 520288 31 P1542 ECU Monitoring of Injection Cut Off Level 2 Condition Exists 520289 31 P1543 Controller Option Setting Not Programmed Out of Calibration 520290 13 P1544 Throttle Body Control Requested Throttle ...

Page 188: ...bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug Injector failure Poor Idle Symptom Idle Too High if 1400 RPM when warm Throttle stop screw tampering Throttle cable sticking improperly adjusted routed incorrectly Faulty electrical connection Symptom Idle Too Low if 1100 RPM when warm Plugged air filter Leak...

Page 189: ...s Perform guided diagnostic procedures Create customer service account records Perform output state control tests some models Special Tools also refer to the beginning of this chapter DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER Digital Wrench Diagnostic Kit PU 47063 B PU 47063 B listed above INCLUDES Digital Wrench Software PU 48731 Standard Interface Cable PU 47151 SmartLink Module Kit PU 4747...

Page 190: ...e most current software available Digital Wrench Communication Errors If you experience problems connecting to a vehicle or any Digital Wrench related problem visit the Digital Wrench Knowledge Base for the most current troubleshooting information FAQs downloads and software updates at http polaris diagsys com Digital Wrench Diagnostic Connector Located under the hood connected to a sealed plug It...

Page 191: ... Digital Wrench Updates NOTE Always operate with the latest update Digital Wrench Updates Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through the dealer website at www polarisdealers com NOTE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Loc...

Page 192: ...ink shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or open the file from where they are Select save and download them to your PC before running the install 8 When the update is complete the version shown on the right side of the Digital Wrench start up screen should match the update you just downloaded NOTE Versions and update...

Page 194: ...e minimum Fully charge the battery before you attempt to reprogram DEDICATED LAPTOP Best results are obtained using a laptop computer that is dedicated to Digital Wrench A laptop that is used by a variety of people and in several applications around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Repro...

Page 195: ...o Digital Wrench See page 4 42 2 Connect SmartLink Module cables to PC and vehicle See page 4 41 3 Open the Digital Wrench program 4 Select the model year product line and vehicle description by selecting the Change Vehicle Type icon 5 Select the Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to th...

Page 196: ...uthorization from the Service and Warranty drop down menu 10 Enter or paste CTRL V the Request Code into the box 11 Select the same file type from the list that you selected previously while in Digital Wrench Enter the VIN along with the customer s name and address When completed click the Authorize button once to proceed 12 An Authorization Key will appear in the upper left corner of the screen C...

Page 197: ...ustries Inc 14 At this point the reflash process will begin Do not touch the vehicle or PC during the process 15 Once the ECU reprogramming procedure is complete click the Finish button on the screen Verify the reflash was a success by starting the vehicle ELECTRONIC FUEL INJECTION ...

Page 198: ...5 17 REAR BUMPER 5 18 BODY COMPONENT REMOVAL 5 19 SEATS 5 19 ENGINE SERVICE PANEL 5 19 FRONT BUMPER XP 5 19 REAR BUMPER 5 19 HOOD AND FRONT BODY WORK 5 20 REAR FENDER FENDER FLARE REMOVAL 5 21 REAR FENDER FLARE REAR FENDER REMOVAL XP 4 5 21 CARGO BOX ASSEMBLY REMOVAL 5 21 ROCKER PANELS CONSOLE AND FLOOR XP 5 22 ROCKER PANELS REAR CONSOLE AND FLOOR XP 4 5 23 DECAL REPLACEMENT 5 26 STEERING ASSEMBLY...

Page 199: ...T 5 43 REAR SUSPENSION ASSEMBLY VIEW 5 44 REAR STABILIZER BAR 5 45 STABILIZER BAR REMOVAL 5 45 STABILIZER BAR INSTALLATION 5 45 SHOCKS SPRINGS FASTENERS 5 46 FRONT SHOCK ASSEMBLY VIEW 5 46 REAR SHOCK ASSEMBLY VIEW 5 46 SHOCK REMOVAL INSTALLATION 5 47 SHOCK REPLACEMENT 5 47 WALKER EVANS SHOCK ASSEMBLY VIEWS 5 48 WALKER EVANS 2 0 FRONT SHOCK 5 48 WALKER EVANS 2 5 REAR SHOCK 5 49 WALKER EVANS SHOCK S...

Page 200: ...ing Preload Spanner Wrench Walker Evans 2876389 Multi Function Pliers Walker Evans See Walker Evans Shock Service later in this chapter page 5 52 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Multi Function Pliers Included in the tool kit the multi function pliers is designed to remove the plastic push rivets used to fasten body components BODY STEERING SU...

Page 201: ...r Mounting Clamps 35 in lb 4 Nm Rear Stabilizer Bar Mounting Bracket Bolts 17 ft lb 23 Nm Rear Stabilizer Bar Locating Clamp Bolts 10 ft lb 14 Nm Seat Belt Mounting Hardware 40 ft lbs 54 Nm Seat Slider Plate 4 ft lb 5 Nm Shock Guard Screws 14 in lbs 2 Nm Skid Plate Screws 8 ft lbs 11 Nm Front to Rear Frame Bolts 40 ft lb 54 Nm Tilt Steering Shock Fasteners 7 ft lb 10 Nm Steering Pivot Tube Mountin...

Page 202: ...nstall ROPS hoop to the hip bolster and frame with M10 x 1 25 x 55 bolts and nuts Tighten fasteners to 40 ft lb 54 Nm 3 Install the front ROPS to the frame with M10 x 1 5 x 45 screws and nuts Install front ROPS to ROPS hoop with M10 x 1 5 x 20 screws Torque fasteners to 40 ft lb 54 Nm 4 Install rear ROPS to the ROPS hoop with M10 x 1 5 x 25 screws Install rear ROPS to frame with M10 x 1 5 x 45 scr...

Page 203: ...nstall ROPS rear hoop to frame with M10 x 1 25 x 55 bolts and nuts item 3 Torque to 40 ft lb 54 Nm 4 Attach ROPS main to the mid ROPS hoop and front main frame with M10 x 1 5 x 45 screws item 4 Torque to 40 ft lb 54 Nm 5 Install rear ROPS to rear ROPS hoop and rear frame with M10 x 1 5 x 45 screws item 5 Torque to 40 ft lb 54 Nm 6 Install ROPS brace to ROPS mid hoop and ROPS rear hoop with M10 x 1...

Page 204: ... 5 7 9924874 R02 2014 RZR XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc Doors XP 1 Door Panel 4 Hinge Pin 2 Door Frame 5 Latch Release 3 Latch Striker 6 Latch BODY STEERING SUSPENSION ...

Page 205: ...4 RZR XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc Doors XP 4 1 Door Panel 4 Hinge Pin 2 Door Frame 5 Latch Release 3 Latch Striker 6 Latch 7 Door Panel Rear 8 Door Frame Rear BODY STEERING SUSPENSION ...

Page 206: ...2014 RZR XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc Dash Instruments Controls 1 Instrument Cluster 4 Headlight Switch 2 Key Switch 5 AWD Switch 3 12V Accessory Port 6 Bezel BODY STEERING SUSPENSION ...

Page 207: ...nual Copyright 2013 Polaris Industries Inc Hood Front Body Work 1 Front Bumper 6 Hood 2 Right Front Fender 7 Grill 3 Right Front Fender Flair 8 Front Bumper Cover 4 Left Front Fender 9 Radiator Shroud 5 Left Front Fender Flair BODY STEERING SUSPENSION ...

Page 210: ...lange Nut Nylok 3 Seat Base Assembly Slider 14 Slider Adjustment Plate 4 Seat Latch Lever 15 Carriage Bolt 5 Spring Seat Latch 16 Shoulder Bolt 6 Plate Seat Latch 17 Seat Slider Mounting Plate 7 Screw 4 ft lb 5 Nm 18 Spring 8 Screw 4 ft lb 5 Nm 19 Seat Slider Lever 9 Shoulder Bolt 20 Seat Bottom 10 Spring Lock Washer 21 Seat Back 11 Flat Washer BODY STEERING SUSPENSION ...

Page 211: ...ht 2013 Polaris Industries Inc Seat Assembly Rear 1 Seat Frame 7 Plate Seat Latch 2 Screw 4 ft lb 5 Nm 8 Screw 4 ft lb 5 Nm 3 Seat Base Assembly 9 Bolt 4 Seat Latch Lever 10 Seat Bottom 5 Spring Seat Latch 11 Seat Back 6 Plate Seat Latch BODY STEERING SUSPENSION ...

Page 212: ...anual Copyright 2013 Polaris Industries Inc Floor Rocker Panels XP 1 Upper Floor 7 RH Rocker 2 T27 Screws 8 Push Rivots 3 LH Rocker 9 Console Cover 4 U Type Nuts 10 Seat Belt Boot 5 Block Off Flap 11 Shifter Boot 6 Lower Floor BODY STEERING SUSPENSION ...

Page 213: ... 4 1 Main Floor Upper 9 B Pillar Cover LH 2 Rocker LH 10 Console Front 3 Rivet 11 Shifter Boot 4 U Type Nuts 12 Seat Belt Boot Front 5 Block Off Flap 13 Console Rear 6 Main Floor Lower 14 Lower Rear Close off Panel 7 Rocker RH 15 Upper Rear Close off Panel 8 B Pillar Cover RH 16 Floor Rear BODY STEERING SUSPENSION ...

Page 216: ...el Item 1 Front Bumper XP 1 Remove the ten T 40 Torx screws retaining the front bumper 2 Disconnect the front headlight connectors 3 Remove the ten Torx screws retaining the upper middle and lower portion of the bumper 4 Pull out on the front bumper to remove the bumper headlights and radiator deflector as an assembly 5 If replacing the front bumper remove both headlights and the radiator deflecto...

Page 217: ... from the lower dash 7 Remove the two T 40 Torx screws retaining the dash and the one T 40 retaining the back of the dash to the bracket 8 Remove the dash assembly from the vehicle NOTE The lower dash is also held by clips Pull the dash straight out to disengage the clips Front Fender Flair Removal 9 Remove the six T40 Torx screws and remove fender flairs Item 1 from the dash assembly NOTE Two of ...

Page 218: ...rivets on the lower fender flare Item 1 Remove the four T40 Torx screws Item 2 2 Remove the fender flare from the vehicle 3 Remove air intake cover Item 3 if removing left side fender 4 Remove the plastic rivets Item 4 and one T40 Torx fastener Item 5 retaining the rear fender 5 Remove fender from the vehicle Cargo Box Assembly Removal 1 Remove both seats 2 Remove the PVT pre filter driver side an...

Page 219: ...ss panel and the panel locking pin Item 1 8 Remove the 17 Torx screws in the bed of the cargo box 9 Remove the seven T 40 Torx screws on the cab side of cargo box 10 Remove the cargo box half from the vehicle Rocker Panels Console and Floor XP Rocker Panel Removal 1 Remove the push rivets and Torx screws retaining the rocker panel and remove panel from the vehicle Console and Lower Floor Removal 2...

Page 220: ...l 1 Remove rear fender flare See Rear Fender Flare Removal 2 Remove rear fender See Rear Fender Removal 3 Remove the four Torx T40 rear door mounting fasteners Item 1 and remove door 4 Remove two push rivets Item 2 Remove two Torx T40 door striker fasteners Item 3 and remove striker Remove one Torx T27 fastener Item 4 retaining the b pillar cover and remove cover 5 Remove three Torx T40 fasteners ...

Page 221: ...loor 3 Remove shift handle knob and remove the front console 4 Remove the Torx T40 screws item 3 and push rivets item 4 retaining the rear console to the rear floor 5 Remove the rear console 6 Remove two M10x1 25x20 bolts from the rear seat frame Item 5 and two M10x1 50x55 Item 6 bolts from the rear seat frame assembly 7 Remove the seat frame 8 Disconnect negative and positive battery cables Remov...

Page 222: ...ing the upper rear close off panel Remove the upper close off panel 13 Disconnect the shift cable Item 11 from the front seat base Remove two M8x1 25x20 bolts Item 12 and two M10x1 25x55 bolts Item 13 from the front seat base Remove front seat base assembly 14 Remove four Torx T40 screws Item 14 retaining the rear floor and remove the rear floor 15 Remove the Torx screws Item 15 retaining the main...

Page 223: ...reating procedure can also be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted plastic components Painted plastic surfaces should only be wiped clean prior to decal adhesion To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the de...

Page 225: ...ain the pivot tube 4 Remove the steering shaft pivot tube and steering wheel from the vehicle as an assembly 5 Refer to steps 11 13 of the Steering Shaft Bearing Replacement procedure for installation Steering Shaft Bearing Replacement NOTE Replacement pivot tube assembly comes with new upper and lower bearings installed Use this procedure if replacing just the bearings only 1 Perform the Steering...

Page 226: ...tall the lower portion of the steering shaft onto the steering gear box assembly see Figure 5 16 Torque the lower pinch bolt to specification Lower Steering Pinch Bolt 30 ft lbs 41 Nm 12 Install the two fasteners that retain the pivot tube see Figure 5 17 Torque fasteners to specification Pivot Tube Bolts 23 ft lbs 31 Nm 13 Install the fastener retaining the upper portion of the steering wheel til...

Page 227: ...TRONIC POWER STEERING ASSEMBLY Assembly View EPS Models 1 Steering Wheel 5 Steering Box 9 Tilt Steering Shock 2 Upper Steering Shaft 6 Tie Rod End 10 Tie Rod End Bolt Do not reuse 3 EPS Module 7 EPS Mount Bracket 11 Nut Nylok Do not reuse 4 Lower Steering Shaft 8 EPS Cover BODY STEERING SUSPENSION ...

Page 228: ...ing wheel from the vehicle as an assembly 5 If replacing the upper steering shaft or steering wheel refer to Steering Wheel Removal EPS Models page 5 31 Steering Wheel Removal EPS Models 1 Remove the upper steering shaft pivot tube and steering wheel as an assembly before attempting to remove the steering wheel Refer to Upper Steering Shaft Removal EPS Models page 5 31 CAUTION Striking the steerin...

Page 229: ...m the vehicle as an assembly Refer to Upper Steering Shaft Removal EPS Models page 5 31 CAUTION Striking the steering wheel or steering shaft while installed in the vehicle can permanently damage the EPS unit and cause a power steering fault 2 Disconnect the two electrical harnesses from the power steering unit 3 Remove the pinch bolt retaining the lower steering shaft to the power steering unit 4...

Page 230: ...ub shaft and gear box to aid installation 3 Remove the power steering unit see Power Steering Unit Removal procedure 4 Remove the pinch bolt Item 1 retaining the lower steering shaft Item 2 to the steering gear box assembly Item 3 5 Lift up on the shaft and remove it through the floor panel Lower Steering Shaft Installation EPS Models 1 Install the lower steering shaft onto the gear box and align ...

Page 231: ...hten the four nuts 4 Position the lower steering shaft on the power steering unit stub shaft and install the pinch bolt Torque to specification Lower Steering Shaft to EPS Unit Pinch Bolt 15 ft lbs 20 Nm 5 Torque the four mount bracket nuts Item 6 to specification Power Steering Unit Mount Bracket Nuts 16 ft lb 22 Nm 6 Proceed to Upper Steering Shaft Installation EPS Models page 5 34 to complete t...

Page 232: ...to specification Tilt Shock Fastener 7 ft lb 10 Nm 4 Be sure the front wheels are pointing straight ahead and install the steering wheel and retaining nut Torque the nut to specification and reinstall the plastic wheel cover Steering Wheel Nut 65 ft lbs 88 Nm 5 Install a new upper steering shaft pinch bolt and nut Torque pinch bolt to specification Upper Steering Shaft Pinch Bolt 15 ft lbs 20 Nm 6...

Page 233: ...ing carrier 5 Remove the front bumper to allow A arm bolt removal 6 Loosen and remove the upper A arm front through bolt fastener Item 3 and rear though bolt fastener Item 4 Remove the upper A arm from the vehicle 7 Examine A arm bushings and pivot tube Replace if worn Discard hardware WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious in...

Page 234: ...Loosen and remove the lower A arm front through bolt fastener Item 6 and rear through bolt fastener Item 7 Remove the lower A arm from the vehicle 17 Examine A arm bushings and pivot tube Replace if worn Discard hardware 18 If not replacing the A arm thoroughly clean the A arm and pivot tube 19 Install new ball joint into A arm Refer to Ball Joint Replacement section 20 Insert new A arm bushings a...

Page 236: ... ring Item 7 from the ball joint Item 8 2 Place a proper sized driver on the ball joint and place the A arm in a press 3 Carefully press the ball joint out of the A arm and discard the ball joint Ball Joint Installation 1 By hand install the NEW ball joint into the A arm 2 Using a press carefully drive in the new ball joint into the A arm 3 After the new ball joint Item 7 is fully installed into t...

Page 237: ...3 Identify mark radius rods upper and lower 4 Remove the nut bolt and washer Item 1 2 attaching the upper and lower radius rod to the bearing carrier Discard the nuts 5 Remove bolts Item 3 4 attaching radius rods to the vehicle frame Discard the nuts 6 Remove radius rods from vehicle 7 Examine radius rod shafts boots and spherical bearings Replace entire radius rod if any excessive wear is evident...

Page 238: ... rear wheel 3 Remove the cotter pin Item 1 and loosen the rear wheel hub castle nut Item 2 Remove the nut and two cone washers Item 3 from the rear wheel hub assembly 4 Remove the lower radius rod mounting bolt Item 4 nut and washer from the bearing carrier Swing radius rod down Discard the nut 5 Remove the two brake caliper mounting bolts Item 5 6 CAUTION Do not hang the caliper by the brake line...

Page 239: ...t Item 8 Discard the nut 16 Remove trailing arm from vehicle Visually inspect trailing arm bushings o rings and spherical bearing for wear If bearing requires replacement refer to Trailing Arm Spherical Bearing Replacement 17 Replace trailing arm if physically damaged 18 Reverse this procedure to reinstall rear trailing arm NOTE Use new fastener nuts upon installation of the rear trailing arm and ...

Page 240: ...ngs 3 Remove snap ring Item 1 that retains the spherical bearing 4 Properly support the trailing arm and press the spherical bearing out of trailing arm casting 5 Be sure to only press on outer most surface of bearing race do not press on the center spherical bearing 6 Inspect trailing arm bearing housing for wear or damage Replace trailing arm if damaged 7 Press in new bearing until fully seated ...

Page 241: ... Service Manual Copyright 2013 Polaris Industries Inc Rear Suspension Assembly View 1 Radius Rod 2 Trailing Arm 3 Spherical Bearing 4 Bushing 5 Shock 6 Spring 7 Bearing Carrier 8 Stabilizer Bar 9 Stabilizer Bar Link BODY STEERING SUSPENSION ...

Page 242: ...e pivot bushings and replace if needed Stabilizer Bar Installation 1 Carefully install stabilizer bar through the LH wheel well area NOTE Be sure fuel lines and shift cable are routed ABOVE the stabilizer bar 2 Fully install stabilizer bar bushings bracket and bracket fasteners and stabilizer links Center stabilizer bar in the frame Torque fasteners to specification see below 3 Install stabilizer ...

Page 243: ...5 46 9924874 R02 2014 RZR XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc SHOCKS SPRINGS FASTENERS Front Shock Assembly View Rear Shock Assembly View BODY STEERING SUSPENSION ...

Page 244: ...m Shock Replacement 1 Remove the shock and note the spring preload distance see Chapter 2 for factory settings 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spring far enough to remove the spring retainer 3 Remove the spring and spring retainer from the existing shock and install components onto the new shock 4 In...

Page 245: ...g 3 Internal Bump Stop 16 Reservoir Body 29 Screw 8 32 4 Shaft Bushing 0 625 17 Washer 1 50 x 0 125 x 0 348 30 O Ring 5 O Ring 18 Crimp Nut 7 16 31 O Ring 6 Seal 19 Snap Ring 32 Detent Spring 7 Wiper 20 Spherical Bearing 33 Detent Ball 8 O Ring 21 Schraeder Valve 34 Shock Body 9 Piston Clicker 22 Snap Ring 35 Spring Adjustment Nut 10 Clicker Bolt 23 Piston Wear Band 1 750 OD 36 Shaft Chrome 11 Cli...

Page 246: ...18 Spacer 33 O Ring 4 Spring Nut 19 End Cap 34 Wiper 5 Piston 20 Needle Bolt 35 Shaft Seal 6 Reservoir Piston 21 Adjuster Nut 36 Shaft Bushing 0 750 7 Check Valve 22 Reservoir Body 37 O Ring 8 Clicker Bolt 23 Bleed Screw 38 Detent Spring 9 Crimp Nut 24 Bump Stop 39 Detent Ball 10 Adjuster Knob 25 Wear Band 40 O Ring 11 Ball 250 26 O Ring 41 O Ring 12 Retention Nut 27 Screw 42 Screw 13 9 16 Heim Sh...

Page 247: ... Oil 2874124 qt Front Shock Valving RZR XP 1000 COMPRES SION REBOUND CLICKER 1 55 x 0 008 1 50 x 0 01 1 10 x 0 025 1 00 x 0 015 1 10 x 0 01 1 00 x 0 025 1 55 x 0 008 1 45 x 0 01 1 00 x 0 025 1 55 x 0 008 1 30 x 0 01 0 625 x 0 065 1 55 x 0 008 1 20 x 0 01 1 55 x 0 008 1 10 x 0 01 1 55 x 0 008 1 00 x 0 01 1 45 x 0 010 0 90 x 0 01 1 30 x 0 008 0 75 x 0 065 Piston Bleed Orifice none Front Shock Valvin...

Page 248: ...Pressure 125 psi 862 kPa 5 Gas Shock Oil P N 2874124 qt Shock Valving RZR XP 1000 COMPRES SION REBOUND CLICKER 1 55 x 0 008 1 500 x 0 01 1 00 x 0 015 1 00 x 0 010 1 45 x 0 01 1 00 x 0 015 1 55 x 0 008 1 30 x 0 01 0 90 x 0 015 1 55 x 0 008 1 20 x 0 01 0 70 x 0 015 1 55 x 0 008 1 10 x 0 01 0 70 x 0 015 1 55 x 0 008 1 00 x 0 01 1 55 x 0 008 0 90 x 0 01 1 45 x 0 010 0 80 x 0 01 1 30 x 0 012 0 75 x 0 0...

Page 249: ...eme caution must be used while handling and working with Walker Evans shocks and related high pressure service equipment The pressure must be released from the shock before disassembly It is strongly recommended you wear safety glasses and ear protection during these procedures Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit PS 45908 IFP Tool PU 50979 Shock Body Holding Tool...

Page 250: ...ly It is strongly recommended you wear safety glasses and ear protection during these procedures 1 Clean and carefully remove shock from the vehicle 2 Back preload adjuster all the way down and carefully remove spring retainer and spring s 3 Use the appropriate shock body holding tool to properly secure the shock assembly into a vice for service Front Shock Body Holding Tool PU 50979 Rear Shock Bo...

Page 251: ...08 and cycle the Internal Floating Piston IFP a few times to purge the shock oil from the reservoir 11 Remove the floating piston from the shock reservoir using the IFP Tool PS 45908 12 Clean and inspect ALL parts and replace as needed NOTE Seal kits are available and should be installed at this time if seals or O rings are damaged or worn 13 Use the appropriate shock rod holding tool and a vise t...

Page 252: ...he clicker valve stack Place the valve stack on a clean shop towel in order of removal NOTE Keep the valve stack in the order it was removed If unsure of order refer to Shock Valving under the Shock Service Information provided earlier in this section 20 Inspect the valves for kinks waves pits or foreign material 21 Thoroughly clean all shock components and shock body prior to assembly Walker Evan...

Page 253: ... to the valve stack can occur Lock Nut 14 ft lbs 19 Nm NOTE Make sure Top Out washers are orientated as shown 9 Front Shocks Only Assemble the clicker valve stack on top of the fastener and install the assembly into the reservoir body Tighten the valve stack fastener securely 10 Turn the compression adjuster knob counter clockwise soft until it stops so damping is in the full open position 11 Use ...

Page 254: ... Shocks 13 Using a 3 32 Allen wrench remove IFP bleed screw 14 Apply a thin film of oil to IFP O ring and wear band Insert IFP into reservoir until completely submerged Allow air to escape as you install the piston 15 Screw IFP Tool PS 45908 onto the floating piston 16 Slowly cycle the IFP up and down Be sure to bottom out piston in the reservoir body Allow time for the bubbles to dissipate Repeat...

Page 255: ...the shock rod apply 2 3 sharp blows to the rod eyelet with a rubber mallet driving the piston down into the shock body This opens the valves on the damping piston You will see the released air bubbles come to the surface of the oil 20 Add oil to the body tube until the surface of the oil is at the top of the shock body threads NOTE During installation some shock oil will over flow Wrap a shop clot...

Page 256: ...ke sure retaining ring is seated properly 31 Push the shock rod assembly completely into the shock body It should go all the way down smoothly without interference If it does not disassemble and reassemble per this procedure 32 Secure the shock body in a vise by its lower mount 33 Pressurize the shock reservoir through the Schrader valve using the Gas Shock Recharging Kit PN 2200421 34 Continue fi...

Page 257: ...spring and set the preload to the specified measurement see Chapter 2 40 Set the compression adjuster knob to the recommended setting or the original setting upon removal see Chapter 2 41 Remove the shock from the vise 42 Reinstall spherical bearing O rings and polyurethane bushings NOTE After installation be sure to RIDE SLOWLY initially to ensure the shock and the vehicle s suspension is perform...

Page 258: ...D DUCT COMPONENTS 6 6 PVT DISASSEMBLY 6 7 PVT ASSEMBLY 6 8 DRIVE BELT 6 10 BELT REMOVAL 6 10 BELT INSPECTION 6 11 BELT INSTALLATION 6 11 PVT BREAK IN DRIVE BELT CLUTCHES 6 11 DRIVE CLUTCH SERVICE 6 12 DRIVE CLUTCH ASSEMBLY VIEW 6 12 DRIVE CLUTCH DISASSEMBLY INSPECTION 6 13 NEEDLE BEARING INSPECTION 6 14 SHIFT WEIGHT INSPECTION 6 14 BUTTON TO TOWER CLEARANCE INSPECTION 6 15 SPIDER REMOVAL 6 15 ROLL...

Page 259: ...ive Clutch Retaining Bolt 96 ft lb 130 Nm Driven Clutch Retaining Bolt 55 ft lb 75 Nm PVT Inner Cover Bolts 12 ft lb 16 Nm PVT Outer Cover Screws 48 in lb 5 Nm Spider Jamb Nut 250 ft lb 339 Nm Apply 0 1 mL Loctite 7088 Primer and 0 1 mL Loctite 620 Drive Clutch Spider 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 Drive Clutch Cover Plate 9 ft lb 12 Nm ITEM TORQUE VALUE S...

Page 260: ...hes primarily sense torque opening and closing according to the forces applied to it from the drive belt and the transmission input shaft If the torque resistance at the transmission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driven clutch sheaves As engine RPM and horsepower increase the load from the drive belt increases resulting...

Page 261: ...and Roller Pins Drive and Driven Clutch Springs 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to the appropriate illustration s on the following pages The PVT system is air cooled by fins on the drive and driven clutch stationary sheaves The fins create a low pressure area in the crankcase casting drawing air into the system through an intake duct The opening for this intake...

Page 262: ...d vehicle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVTsystem Remove the PVT drain plug Shift the transmission to neutral Using the throttle vary the e...

Page 263: ... Components 1 CLUTCH DUCT INTAKE ASSEMBLY 11 BRACKET COVER GUARD 2 CLAMP WORM 12 AIR INLET DUCT 3 DECAL CAUTION 13 SCREW 4 BOLTand WASHER 14 SCREW 5 COVER ASSEMBLY OUTER 15 NUT NYLOK 6 O RING 16 BRACKET BELT SCREEN 7 DRAIN PLUG COVER 17 HOSE AIR OUTLET 8 SEAL COVER 18 INTAKE BOOT 9 SCREW 19 SEAL COVER 10 COVER ASSEMBLY CLUTCHING ...

Page 264: ... the nut 5 Swing shock outward toward the front of the vehicle 6 Remove the eight clutch cover screws Item 2 and remove the outer clutch cover from the vehicle 7 Mark the drive belt direction of rotation and remove drive belt see DRIVE BELT Belt Removal 8 Remove the driven clutch retaining bolt and driven clutch 9 Install the Drive Clutch Holding Tool 9314177 A on the drive clutch Drive Clutch Hol...

Page 265: ...Loosen hose clamps Item 3 that attach clutch outlet duct to inner clutch cover Disengage hose from the cover 14 Remove the seven bolts Item 4 that retain inner clutch cover to engine and transmission Remove inner clutch cover PVT Assembly 1 Inspect inner clutch cover Replace if cracked or damaged 2 Inspect the seal on the transmission input shaft Replace if damaged 3 Inspect inner clutch cover sea...

Page 266: ... the driven clutch washer and retaining bolt Torque to specification Driven Clutch Retaining Bolt 55 ft lb 75 Nm 11 Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch 12 Install the drive clutch onto the engine 13 Install the Drive Clutch Holding Tool 9314177 A and torque the retaining bolt to specification Drive Clutch Retaining Bolt 96 ft lb 130 Nm 14 Insta...

Page 267: ...spect the entire clutch outlet duct including the outlet duct screen when replacing a drive belt Remove any debris found in the outlet duct or outlet duct screen Item 1 1 Remove the eight screws that retain the outer clutch cover 2 Maneuver the outer clutch cover outward as shown below to access the drive belt NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement...

Page 268: ...tion or erratic PVT operation See the Troubleshooting Chart at the end of this chapter for possible causes Belt Installation NOTE Be sure to install belt in the same direction as it was removed 1 With the clutch spreader tool installed 2877408 or 2878925 loop the belt over the drive clutch and over the driven clutch 2 Rotate the driven clutch and walk the belt into the clutch 3 Remove the clutch s...

Page 270: ...h will not be in balance and the assembly MUST be replaced 3 Remove cover bolts evenly in a cross pattern and remove cover plate 4 Inspect cover bushing Item 1 The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer t...

Page 271: ...ange Free Length 3 563 90 50 mm Spring Wire Diameter 0 177 4 50 mm Needle Bearing Inspection 1 Rotate the clutch bearing in both clockwise and counter clockwise directions The non braking needle bearing should rotate in both directions on the shaft with only a slight amount of drag 2 Verify there is no binding or rough spots If problems are noted continue with disassembly Shift Weight Inspection 1...

Page 272: ...ve the spider jam nut counterclockwise using the Clutch Spider Nut Socket PU 50578 Clutch Spider Nut Socket PU 50578 Clutch Holding Fixture PN 2871358 A 2 Loosen and remove the spider counterclockwise using Clutch Spider Removal Installation Tool PN 2870341 Spider Removal Installation Tool 2870341 Clutch Holding Fixture 2871358 A Roller Pin and Thrust Washer Inspection 1 Inspect all rollers roller...

Page 273: ... or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged Shaft Diameter Standard 1 3725 1 3712 34 8615 34 8488 mm Service Limit 1 3704 34 8088 mm 5 Visually inspect the thrust washers for damage Measure the thickness and compare to specification Replace if worn or damaged Thrust Washer Thickness Standard 030 76 mm Service L...

Page 274: ... 2 1 5020628 P 90 Drive Driven Clutch Bushing Install Tool 3 1 5020629 Drive Clutch Cover Bushing Removal Installation Tool 5 1 5020631 P 90 Driven Clutch Cover Bushing Removal Tool 8 1 5020632 Main Puller Adapter ITEM QTY PART TOOL DESCRIPTION 9 1 5010279 Adapter Reducer 10 1 5020633 Number Two Puller Adapter NOTE Bushings are installed at the factory using Loctite 648 In order to remove bushings...

Page 275: ... until tiny smoke tailings appear 9 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Moveable Sheave Bushing Installation 12 Place main adapter Item 8 on puller 13 Apply Loctite 648 evenly to bushing bore inside moveable shea...

Page 276: ...of cover insert new bushing and bushing installation tool into center of clutch cover 32 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 33 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 34 Turn clutch cover counterclockwise on puller rod until bushing is seated 35 Remove nut from puller rod Take installation too...

Page 277: ...sure all of the alignment marks Item 8 are in alignment 5 Moveable Sheave Asm 6 Jam Nut 7 Spider 6 Install clutch onto holding fixture PN 2871358 A and secure in a bench vice Tighten the spider using Clutch Spider Tool PN 2870341 Torque spider to specification Spider Assembly 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 in 90 apart in vertical stripes to the shaft threa...

Page 278: ...om the holding fixture and inspect the alignment marks made during disassembly NOTE If the marks illustrated below are not in alignment upon assembly the clutch will not be in balance and the drive clutch assembly must be replaced 10 Install the limiter spacer Item 15 and the clutch spring Item 14 CAUTION DO NOT reassemble the drive clutch without the limiter spacer Belt life will be greatly reduc...

Page 279: ...not attempt disassembly of the driven clutch from the outside snap ring The driven clutch must be disassembled from the helix side 2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in assembly and maintains clutch balance 3 Remove the four screws Item 1 that secure the cam helix assembly using a ...

Page 280: ...Remove the spider assembly and spring B NOTE Spring is compression only and has no torsional wind 7 Remove the inside spider plate D and spider dampener E Inspect the spider dampener E for wear and replace if needed 8 Remove the E clips F washers G and the clutch rollers H Inspect the rollers for wear replace if worn 9 Remove the clutch assembly from the holding tool 10 Press out the spring pins I...

Page 281: ...ot fit snug into the bushing replace the cam helix assembly 15 Inspect the sheaves for excessive wear or damage Bushing Service NOTE Special Tools Required EBS Clutch Bushing Tool Kit 2201379 ITEM QTY PART TOOL DESCRIPTION A B 1 5132027 EBS Puller Tool C 1 5132501 EBS Puller Nut D 1 5132029 EBS Main Adapter E 1 5132028 EBS Bushing Removal Tool Instructions 1 9915111 Instructions Additional Special...

Page 282: ...ler 2 Install adapter reducer Item 9 3 Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 4 Flip sheave over so bushing faces downward and install onto puller 5 Install bushing tool Item 2 6 Install left hand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed 7 Turn clutch sheave counterclockwise ...

Page 283: ...ch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 18 Remove nut C from puller rod and set aside 19 Remove installation tool and clutch sheave from puller Clutch Assembly 1 Install a new bearing onto the clutch shaft using an arbor press Once bearing is fully seated install a new snap ring 2 Install the shaft and bearing assembly into the ou...

Page 284: ...B on both sides 5 Install the roller pin into the sheave assembly on both sides The flat side of the roller pin faces downward when the shaft side is laying flat on the bench 6 Install the spring pins C to secure the roller pins Install until flush with sheave surface 7 Install the spring over the shaft 8 Install the clutch rollers D onto each side of the outside spider Install the washers E and E...

Page 285: ...gn the skip tooth spider or use the X on top of the spider and align it with the skip tooth on the shaft 11 Place the driven clutch into the Universal Clutch Compressor PU 50518 12 Press down on the top of the spider assembly pushing the spider onto the shaft 13 Slowly compress the spider into place If the spider appears to bind while compressing stop and make sure the skip tooth on the shaft and ...

Page 286: ...ade before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveable sheave belt face with both hands and the helix will release 15 Use a T25 Torx driver to install the four helix retaining screws and torque to specification Heli...

Page 288: ...erating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift weights Drive clutch binding Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Driven c...

Page 289: ...ned in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Find leak and repair as necessary Operator error Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Replace belt Water ingestion Inspect and seal PVTsystem Belt contaminated with oil or grease Inspect and clean PVT nois...

Page 290: ...7 12 SUPPORT BEARING REPLACEMENT 7 13 PROP SHAFT U JOINT SERVICE 7 15 FRONT GEARCASE CENTRALIZED HILLIARD 7 16 CENTRALIZED HILLIARD ASSEMBLY VIEW 7 16 ALL WHEEL DRIVE OPERATION 7 17 AWD DIAGNOSIS 7 17 FRONT GEARCASE REMOVAL 7 18 FRONT GEARCASE DISASSEMBLY INSPECTION 7 19 FRONT GEARCASE ASSEMBLY 7 22 FRONT GEARCASE INSTALLATION 7 25 REAR BEARING CARRIER 7 26 BEARING CARRIER INSPECTION REMOVAL 7 26 ...

Page 291: ...ice solutions com Final Drive Torque Specifications ITEM SPECIFICATION Wheel Lug Nuts 120 ft lbs 163 Nm Hub Castle Nut front and rear 110 ft lbs 149 Nm Ball Joint Pinch Fasteners 42 ft lbs 57 Nm Brake Caliper Mounting Bolts 40 ft lbs 54 Nm Tie Rod End Fastener 15 ft lbs 20 Nm 90 Propshaft Support Bearing Fasteners 35 ft lb 47 Nm Front Gearcase Cover Plate Screws 11 ft lbs 15 Nm Front Gearcase Moun...

Page 292: ... 6 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 Caliper Removal page 9 14 7 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 8 Remove the front wheel hub assembly 9 Remove and discard the upper and lower ball joint pinch bolts Item 4 10 Using a soft faced hammer l...

Page 293: ...he new bearing Be sure that all oil residue has been removed from each surface 6 Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 7 Apply Loctite 603 retaining compound to the outer circumference of the new bearing Item 2 race and carefully press the new bearing into the bearing carrier housing NOTE Use care ...

Page 294: ...upon assembly 7 Install the steering tie rod end Item 4 onto the front bearing carrier NOTE Refer to the photos below to ensure proper placement of the tie rod end 8 Torque the tie rod end fastener Item 5 to specification and install a new cotter pin Item 5 Tie Rod End Fastener 15 ft lbs 20 Nm 90 9 Torque wheel hub nut Item 6 to specification and install a new cotter pin Item 7 Tighten nut slightl...

Page 295: ...heel hub castle nut Item 2 Remove the nut and cone washers Item 3 from the front wheel hub assembly 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 5 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the front wheel hub assembly 7 Remove and discard the upp...

Page 296: ...t Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper and lower ball joint ends into the front bearing carrier 5 Install new pinch bolts and nuts Torque to specification Ball Joint Pinch Bolts 42 ft lbs 57 Nm 6 Apply Anti Seize to drive shaft axle splines 7 Install front wheel hub assembly Item 4 co...

Page 297: ...locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 10 Install wheel and four wheel nuts Torque wheel nuts to specification Wheel Nuts 120 ft lbs 163 Nm 11 Rotate wheel and check for smooth operation FRONT PROPSHAFT SERVICE Front Propshaft Removal 1 Remove the center console 1 Cap 3 Torx Screw 2 Shifter 4 Push Rivet 2 Locate the prop shaft roll p...

Page 298: ... with Anti Seize 3 Lubricate the front and rear prop shaft mid joint with Polaris All Purpose Grease 4 Align the front and rear prop shafts as shown below and slide them together NOTE Paint marks are applied to the front and rear prop shafts to aid shaft alignment Reference these marks during installation if still visible 5 When installing the front prop shaft onto the front gearcase use a new rol...

Page 299: ... output shaft 5 Remove the support bearing rubber bushing by pulling it off the rear prop shaft 6 Remove the rear prop shaft out of the left rear of the vehicle Rear Prop Shaft Installation 1 Reverse the appropriate Rear Prop Shaft Removal procedure to reinstall the rear prop shaft 2 Lubricate the transmission output shaft splines with Polaris All Purpose Grease 3 Lubricate the front and rear prop...

Page 300: ...E Paint marks are applied to the front and rear prop shafts to aid shaft alignment Reference these marks during installation if still visible 7 Torque the support bearing fasteners to specification Support Bearing Fasteners 35 ft lb 47 Nm 8 Align the front propshaft paint mark with the front gearcase input shaft mark so the pin holes align Install a new roll pin FINAL DRIVE ...

Page 301: ... the prop shaft support bearing assembly to the drivers side to slide the rear prop shaft yoke Item 6 off the transmission output shaft 7 Slide the prop shaft to the rear of the vehicle until the front of the shaft clears the frame support and slide the prop shaft forward out of the vehicle Rear Prop Shaft Installation XP 4 1 Reverse the appropriate Rear Prop Shaft Removal procedure to reinstall t...

Page 302: ...the rear prop shaft from the vehicle see Rear Propshaft Removal procedure 2 Using a rubber mallet remove the rubber isolated bearing support from the shaft to expose the bearing 3 Using a commercially available 2 jaw puller remove the bearing from the end of the propshaft 4 Clean the bearing mounting surface on the shaft and apply Loctite 603 retaining compound to the clean surface 5 Install the n...

Page 303: ...E Take care while installing the support bearing assembly Be sure to only drive on the inner race of the bearing Driving on the bearing or support in any other location will damage the bearing or support assembly 7 Wipe the bearing and shaft clean of any excess retaining compound NOTE Use care to not allow any of the Loctite compound to get in the bearing 8 Install the rear prop shaft into the veh...

Page 304: ...R XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc Prop Shaft U Joint Service The prop shafts on this unit are not serviceable If a cross or yoke is worn the prop shaft assembly needs to be replaced FINAL DRIVE ...

Page 305: ...1 21 Hub Sub Assembly Male 1 5 Ball Bearing 2 22 Rollers 20 6 Ball Bearing Double Row 1 23 Torsion Spring 1 7 Bushing 1 24 H Clip Spring 20 8 Bushing 1 26 Nylon Spacer 2 9 Oil Seal 2 27 Backlash Spacer 1 10 Oil Seal 1 28 Ring Gear Spacer 1 11 Retaining Ring Internal 1 29 Torsion Spring Retainer 1 12 Retaining Ring 1 30 Pinion Gear 1 13 Cover Screws M6 T30 Torx 7 31 Armature Plate 1 14 Cover Plate ...

Page 306: ...hat is keyed to the roll cage When the ring gear and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels lose traction Once the rear wheels begin to...

Page 307: ...armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the AWD system If this is found replace the cover plate assembly 6 Inspect the rollers for nicks and scratches The rollers must slide up down in and out freely within the roll cage sliding surfaces and H springs 7 Inspect the roll cage assembly for cracks or excessive wear If damaged r...

Page 308: ...nd slide it out of the vehicle above the upper A arm Front Gearcase Disassembly Inspection 1 Drain and properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the seven cover screws and remove the cover plate assembly 3 Remove the LH output hub assembly from the clutch housing or outer cover plate assembly NOTE Nylon spacer is non serviceable and should no...

Page 309: ... armature plate Refer to AWD Diagnosis for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the top of the ring gear 6 Remove the clutch housing ring gear and roll cage assembly from the gearcase housing 7 Remove the RH output hub assembly from the gearcase housing FINAL DRIVE ...

Page 310: ...cover plate seal and O ring 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in order to retain all the rollers NOTE Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 12 Thoroughly clean all parts and inspect the rollers A for nicks and scratches The rollers must slide up and down a...

Page 311: ...se components Check each for excessive wear or damage Front Gearcase Assembly 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components 2 Install pinion shaft assembly and install internal snap ring NOTE If bearing replacement was required press new bearing onto the pinion shaft and install a new external snap ring 3 Install a new pinion shaft seal into the p...

Page 312: ...grooves line up with the roll cage windows see below Be sure role cage top groove is facing upward 6 Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear 7 Align spring retainer dowel pin with ring gear dowel pin and install the retainer on top of the torsion spring 8 Check the action of the torsion spring by rotating in both directions to ensure the ...

Page 313: ...10 Carefully install the ring gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTE Be sure the square O ring is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 12 Carefully install the LH output hub assembly into the cover plate Take care not to damage the new cover plate seal while installing the output hu...

Page 314: ...all the four bolts Item 1 that secure the front gearcase to the frame and torque to specification Front Gearcase Mounting Bolts 30 ft lbs 41 Nm 5 Install the vent line Item 2 6 Connect the AWD wire harness 7 Refer to FRONT DRIVE SHAFT Drive Shaft Installation and install both front drive shafts into the gearcase 8 Add the proper lubricant to the front gearcase Refer to Chapter 2 for fluid fill and...

Page 315: ...hout binding or rough spots 3 Remove the four wheel nuts and rear wheel 4 Remove the cotter pin Item 1 and loosen the rear wheel hub castle nut Item 2 Remove the nut and 2 cone washers Item 3 from the rear wheel hub assembly 5 Remove the lower radius rod outer mounting bolt Item 4 nut and washer from the bearing carrier Swing radius rod down Discard the nut 6 Remove the two brake caliper mounting ...

Page 316: ...ring if moisture dirt corrosion or roughness is evident Bearing Replacement Bearing Removal 1 Remove the outer snap ring Item 1 2 From the back side of the bearing carrier tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4 In...

Page 317: ...stallation 1 Install drive shaft through the backside of the bearing carrier 2 Install the four fasteners Item 1 that attach the rear bearing carrier to the trailing arm Install the 1 fastener Item 2 that attaches the upper radius rod to the bearing carrier Torque bolts to specification NOTE Use new nuts upon installation of the rear bearing carrier Bearing Carrier to Trailing Arm Bolts 42 ft lb 5...

Page 318: ... ft lbs 54 Nm 6 Torque wheel hub nut to specification and install a new cotter pin Item 5 Tighten nut slightly if necessary to align cotter pin holes Hub Castle Nut 110 ft lbs 149 Nm 7 Install wheel and 4 wheel nuts Torque wheel nuts to specification Wheel Nuts 120 ft lbs 163 Nm 8 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions...

Page 319: ...ds swing downward 5 Remove the brake caliper mounting bolts Item 5 Remove the rear brake caliper assembly 6 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 7 Remove the rear hub assembly from the bearing carrier 8 Support the trailing arm from underneath 9 Remove the lower shock mounting bolt and nut Item 6 Swing the shock inward Disca...

Page 320: ... the outboard end of the drive shaft if necessary 3 Swing the rear trailing arm assembly outward and upward until the rear axle can be inserted into the bearing carrier Support the trailing arm from underneath 4 Install the lower shock mounting bolt and new nut Torque fastener to specification Lower Shock Bolt to Trailing Arm 70 ft lbs 95 Nm 5 Install the stabilizer bar mounting bolt washer and ne...

Page 321: ...w cotter pin Item 5 Rear Hub Castle Nut 110 ft lbs 149 Nm 8 Install the radius rod bolts washers and new nuts Torque fasteners to specification Radius Rods to Bearing Carrier 40 ft lb 54 Nm 9 Install the rear brake caliper assembly and new bolts Item 6 Torque to specification Rear Caliper Mounting Bolts 40 ft lbs 54 Nm 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification Wheel Nuts...

Page 322: ...o not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints ar...

Page 323: ...placement NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 9 Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly 10 Slide the small boot clamp and boot small end first onto the drive shaft a...

Page 324: ...sing the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 19 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you ...

Page 325: ...he circlip Item 2 is on the shaft and not left in the joint 6 Remove the boot from the shaft CAUTION Complete disassembly of the plunging joint is NOT recommended The internal components are precision fit and develop their own characteristic wear patterns Intermixing the internal components could result in looseness binding and or premature failure of the joint NOTE If the grease in the joint is o...

Page 326: ...rive shaft firmly into the inner race 14 Align the circlip with the lead in chamfer 15 Use a soft faced hammer to tap the joint onto the drive shaft until you reach the end of the splines and the joint locks in place 16 Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft 17 Remove excess grease from the plunging joint s external surfaces and pl...

Page 330: ...5 TRANSMISSION INSTALLATION 8 8 TRANSMISSION SERVICE 8 12 TRANSMISSION DISASSEMBLY 8 12 GEAR SHAFT BEARING INSPECTION 8 17 SNORKEL GEAR BACKLASH PROCEDURE 8 18 TRANSMISSION SERVICE INT L 8 25 DIFFERENTIAL OPERATION 8 25 TRANSMISSION DISASSEMBLY 8 26 PLANETARY DIFFERENTIAL DISASSEMBLY 8 31 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT 8 32 PLANETARY DIFFERENTIAL ASSEMBLY 8 35 GEAR SHAFT BEARING INSPEC...

Page 331: ... 18 ft lb 24 Nm Fill Drain Plugs 14 ft lbs 19 Nm Gear Sector Cover 12 ft lb 16 Nm Park Brake Disc Mounting Bolt INT L 14 ft lb 20 Nm Park Flange Screws 10 ft lb 14 Nm Rear Transmission Isolator Bolt 40 ft lb 54 Nm ITEM TORQUE VALUE Rear Transmission Mount Bracket Fasteners 17 ft lb 23 Nm Snorkel Tube Refer to Snorkel Gear Backlash Procedure page 8 18 Snorkel Tube Locking Screw 10 ft lb 14 Nm Shift...

Page 332: ... Remove the shift knob cover Item 1 retaining screw Item 2 and shift knob Item 3 from the shift lever Item 4 2 Remove the screws retaining the center console using a T27 and T30 Torx driver Remove the console from the vehicle 3 Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever TRANSMISSION ...

Page 333: ...sole shift knob SHIFT CABLE Inspection Shift cable adjustment may be necessary if symptoms include No gear position or AWD display on instrument cluster Ratcheting noise on deceleration Inability to engage into a gear Excessive gear lash noise Gear selector moving out of desired range Inspect shift cable clevis pins and pivot bushings and replace if worn or damaged Adjustment 1 Locate the shift ca...

Page 334: ...sion will require service TRANSMISSION REMOVAL CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this procedure Always wear eye protection 1 Remove the seats console cover and engine service panel see Chapter 5 2 Disconnect the negative battery cable from the battery 3 Remove the rear bumper and cargo box as an assembly see Chapter 5 4 Remove the...

Page 335: ...ur bolts Item 2 attaching the upper and lower radius rods to the bearing carriers left and right side Discard nuts and replace with new upon assembly Allow the radius rods swing downward 14 Remove both lower shock bolts left and right side while supporting the trailing arms from underneath Lift training arms up and swing trailing arms outward to remove the drive shafts from the transmission 15 Man...

Page 336: ...ensor connector Item 5 crankshaft position sensor connector Item 4 shift bracket bolts and shift bracket Item 7 shift cable clevis pin and washer Item 8 from the transmission 19 Remove the wire ties retaining harness to transmission and mounts 20 Using a 15mm socket remove the four bolts from the left side Item 9 and right side Item 10 securing the transmission to the engine 21 Remove the two rear...

Page 337: ...he transmission towards the left side of the vehicle With the help of an assistant remove transmission from the left rear wheel well area TRANSMISSION INSTALLATION 1 With the help of an assistant position the transmission into the vehicle frame through the left rear wheel well area 2 Slide transmission towards rear of the vehicle and rotate the top of the transmission toward the right side of the ...

Page 338: ...t on the transmission input shaft and lay flush on the crankshaft 7 Loosen the two bolts retaining the transmission coupler bracket to the engine on the right side 8 Align front transmission mounting holes with transmission joint bracket mounting holes on engine 9 Loosely install the two longer bolts into left side mounting holes and two shorter bolts with washers into right side mounting holes NO...

Page 339: ...erly route the vent hose 18 Lubricate the transmission splines and mid propshaft joint splines with Polaris All Purpose Grease Install the propshaft onto the transmission output shaft see Chapter 7 19 Install inner clutch cover outlet duct drive clutch driven clutch belt and outer clutch cover see Chapter 6 20 Install new spring ring Item 10 on rear drive shafts Apply an anti seize compound to the...

Page 340: ...ft lb 54 Nm Stabilizer Bar Linkage 40 ft lbs 54 Nm Wheel Nuts 120 ft lbs 163 Nm 26 Properly lower the vehicle 27 Install the air box assembly as outlined in the EFI Chapter see Chapter 4 ECT Sensor Replacement 28 Install the rear bumper and cargo box as an assembly see Chapter 5 29 Connect the negative battery cable 30 Install the engine service panel console cover and seats 31 If transmission lub...

Page 341: ... aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J 9 Remove the shift shaft K detent pawl L and the shift sector gears M and N NOTE Note the timing marks on the shi...

Page 342: ...emove the shift shaft rail Q and shift forks from the transmission housing as an assembly 14 Remove the rear output shaft assembly S by lifting underneath the gear or by tapping the shaft from the opposite side 15 Remove the idler gear shaft assembly T and gear cluster assembly U from the transmission housing by pulling both assemblies straight up 16 Place the gear cluster assembly on a clean surf...

Page 343: ...bearing from the reverse shaft using a bearing puller Remove the retaining ring and slide the washers 53T gear and needle bearing off the reverse shaft see Figure 8 1 20 Remove the retaining ring and engagement dog from the reverse shaft see Figure 8 1 21 Remove the retaining ring washer needle bearing and sprocket from the reverse shaft see Figure 8 1 22 Tilt the two shafts towards each other and...

Page 344: ...ausing eye or face injury Snorkel Shaft Removal Disassembly CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure to remove pinion shaft will result in damage to the snorkel shaft 25 Extract the seal from the snorkel shaft to access the snorkel tube for removal 26 Using the Snorkel Tool PA 50231 fully loosen the snorkel tube 27 Remove the snorkel tube and sh...

Page 345: ...ve the snorkel tube from the snorkel shaft 30 Remove the snap ring A and shim B retaining the bearing in the snorkel tube 31 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 32 Remove the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft TRANSMISSION ...

Page 347: ...etaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 Install the snorkel shaft into the gearcase Using the Snorkel Tool PA 50231 tighten the snorkel tube until it is lightly seated in the transmission housing 6 Inspect the pinion shaft assembly Replace bearings if nee...

Page 348: ...hould still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel locking screw hole opening to reference your starting point NOTE If you have a hard time seeing into the hole insert a small Allen wrench punch or screwdriver into the hole to feel when the notch is aligned with the hole...

Page 349: ... Assembly NOTE The snorkel shaft and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after assembling the transmission 17 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 18 Assemble the reverse shaft assembly and input shaft assembly if previously disassembled see illustrations TRANSMISSION ...

Page 350: ...t assembly C 21 Assemble the shift shaft rail if previously disassembled NOTE Both shift forks need to be orientated the same way so that the shift fork pins are both offset to the same side of the rail 22 Install the shift shaft rail D and shift forks into the transmission housing as an assembly Be sure the shift forks are engaged into the engagement dogs NOTE Shift fork pins should be offset tow...

Page 351: ... 3 Bond Sealant PN 2871557 to left hand transmission mating surface 26 Install the transmission case cover and retaining bolts Torque bolts to specification Transmission Case Bolts 20 ft lbs 27 Nm 27 Install new seals into the transmission case halves The snorkel shaft seal F should be pressed in until it seats against the housing counter bore The input shaft seal G should be pressed in until it s...

Page 352: ...um shaft Install the shift shaft assembly and sector gear 11T into the bushing pocket on the left side Align the timing marks on the gears as shown 30 Install the spacer onto the shift drum shaft 31 Install the detent star onto the shift drum shaft Be sure to install the detent star with the raised edge facing outward and skip tooth aligned 32 Install the detent pawl onto the shift shaft and caref...

Page 353: ...d PN 2871557 onto the cover and transmission case mating surface 36 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification Sector Gear Cover Bolts 12 ft lb 16 Nm 37 Install the transmission drain plug and torque to specification Fill Drain Plug 14 ft lbs 19 Nm 38 Install the bellcrank onto the shift shaft Note the key sp...

Page 354: ...ectrical solenoid mounted in the rear portion of the gearcase actuates the shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly This unlocks the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When Differential Lock is selected p...

Page 355: ...nut Item 1 and bellcrank Item 2 4 Remove E clip Item 3 that retains spring washer Item 4 flat washer Item 4 and gear switch Item 5 Remove the switch 5 Remove the sector cover bolts Item 6 and remove the sector cover Item 7 NOTE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent star...

Page 356: ...sion pinion shaft Remove disc from shaft 12 Remove all transmission case bolts Using suitable pry bars remove the cover using the designated pry points indicated by black arrows in illustration below CAUTION Do not pry on case sealing surfaces Use only the designated pry points on the transmission 13 Lift up on the shift shaft rail Q and move the rail assembly rearward to allow the shift fork pins...

Page 357: ...er gear shaft assembly T and gear cluster assembly U on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly 18 Slide engagement dog X off of shift fork guides 19 Remove 2 screws and retaining plates then lift shift fork Y and torsion spring out of transmission housing 20 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembly V Lift...

Page 358: ...g and sprocket from the reverse shaft see Figure 8 1 25 Tilt the two shafts towards each other and remove the silent chain from the two shafts 26 If necessary disassemble the other end of the reverse shaft Remove the bearing engagement dog retaining ring washer gear and needle bearing from the reverse shaft see Figure 8 2 27 To disassemble the shift shaft rail remove the snap ring X from the end o...

Page 359: ...t will result in damage to the snorkel shaft 28 Extract the seal from the snorkel shaft to access the snorkel tube for removal 29 Using the Snorkel Tool PA 50231 fully loosen the snorkel tube 30 Remove the snorkel tube and shaft assembly from the transmission case 31 Remove the snap ring Y and shim Z from the snorkel shaft 32 Use an arbor press to remove the snorkel tube from the snorkel shaft TRA...

Page 360: ...bearing from the opposite side to remove it from the snorkel tube 35 Remove the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft Planetary Differential Disassembly NOTE If the gearcase is completely assembled perform the Gearcase Disassembly and Inspection procedure 1 Use a scribe to mark the differential cover and ring gear prior to disassembly TRANSMISSION ...

Page 361: ...r D Replace components or bushings as needed Bushing replacement can be performed on all necessary differential components If bushing replacement is required proceed to Planetary Differential Bushing Replacement Planetary Differential Bushing Replacement NOTE If the differential is completely assembled perform the Planetary Differential Disassembly procedure Ring Gear Bushing Replacement 1 Press t...

Page 362: ...tries Inc 3 Press the new bushing into the ring gear housing 4 Install the bushing to the specified depth as shown Planet Gear Bushing Replacement 5 Press the old bushing out of the planet gear 6 Thoroughly clean the bore of the planet gear and check for any unwanted burs TRANSMISSION ...

Page 363: ...ial cover 9 Thoroughly clean the bore of the differential cover and check for any unwanted burs 10 Press the new bushing into the differential cover 11 Install the bushing to the specified depth as shown Female Side Gear Bushing Replacement 12 Locate the bushing split Using a small chisel or flat blade screwdriver peel back and remove the old bushing from the side gear being careful not to damage ...

Page 364: ...Thoroughly clean the differential components 2 Assemble the side gears and place them onto the ring gear along with the 6 planet gears 3 Align and install the differential cover using the previously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification Differential Cover Screws 22 ft lb 30 Nm TRANSMISSION ...

Page 366: ...retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 Install the snorkel shaft into the gearcase Using the Snorkel Tool PA 50231 tighten the snorkel tube until it is lightly seated in the transmission housing 6 Inspect the pinion shaft assembly Replace bearings if ne...

Page 367: ...ould still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel locking screw hole opening to reference your starting point NOTE If you have a hard time seeing into the hole insert a small Allen wrench punch or screwdriver into the hole to feel when the notch is aligned with the hole ...

Page 368: ...orkel shaft cannot be installed after assembling the transmission 17 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 18 Install shift fork S and torsion spring into transmission housing as an assembly Load spring as shown in image below 19 Apply Loctite 242 to 2 screws T and install with retaining plates over shift fork Torque to specification Shift Fork...

Page 369: ...aft assembly if previously disassembled see illustrations 22 Install the idler gear shaft assembly A and gear cluster assembly B into the transmission housing all at the same time 23 Install the rear output shaft assembly C Rotate output shaft assembly to align slots with engagement dog Ensure bearing is fully seated upon assembly TRANSMISSION ...

Page 370: ... assembly Be sure the shift forks are engaged into the engagement dogs NOTE Shift fork pins should be offset towards the input shaft as shown above 26 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 27 Install the shift drum E into the transmission housing Lift up on the shift shaft rail D and move the rail assembly towards the shift drum to allow the shift fork...

Page 371: ...eals into the transmission case halves The snorkel shaft seal F should be pressed in until it seats against the housing counter bore The input shaft seal G should be pressed in until it seats flush with the housing The rear output shaft seals H and pinion shaft seal J can be installed using a standard bushing installation tool Seals should be installed just past the case lead in chamfer 070 or 1 8...

Page 372: ...horoughly clean the shift shaft housing Be sure the transmission is in High gear prior to reassembly 33 Install the sector gear 16T onto the shift drum shaft Install the shift shaft assembly and sector gear 11T into the bushing pocket on the left side Align the timing marks on the gears as shown 34 Install the spacer onto the shift drum shaft 35 Install the detent star onto the shift drum shaft Be...

Page 373: ...faces thoroughly 39 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 40 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification Sector Cover Bolts 12 ft lb 16 Nm 41 Install the transmission drain plug and torque to specification Fill Drain Plug 14 ft lbs 19 Nm 42 Install the be...

Page 374: ...ushings Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the prob...

Page 376: ...ket 48T 6 Face 19 1 Retaining Ring Internal 62 1 Gear Low 67T 20 2 Retaining Ring External 63 1 Engagement Dog 6 Face 21 2 Retaining Ring External 64 1 Gear 53T 22 3 Retaining Ring External 65 1 Shaft Pinion 11T 23 1 Retaining Ring External 66 1 Gear 46T 24 2 Washer Thrust 67 1 Gear Snorkel 13T 25 1 Washer Thrust 68 1 Shaft Shift 26 1 Shim 69 1 Weldment Rear Mount Bracket 27 1 Shim 70 1 Bracket Re...

Page 378: ...Ring 17 Pin Spring 52 Gear Sector 31T 88 O Ring 18 Retaining Ring External 53 Pawl Detent 89 O Ring 19 Snap Ring 54 Star Detent 90 Seal Triple Lip 20 Retaining Ring External 55 Plate Park 12 Face 91 Seal Triple Lip 21 Retaining Ring External 56 Shaft Idler 29T 92 Seal Dual Lip 22 Retaining Ring Internal 57 Shaft Reverse 29T 93 Seal Triple Lip 23 Retaining Ring External 58 Shaft Front Output 95 Sen...

Page 380: ...KING BRAKE INT L MODEL 9 11 ASSEMBLY VIEW 9 11 PARKING BRAKE INSPECTION 9 12 PARKING BRAKE CABLE ADJUSTMENT 9 12 PARKING BRAKE CALIPER SERVICE INT L MODEL 9 13 CALIPER ASSEMBLY VIEW 9 13 CALIPER REMOVAL 9 14 CALIPER DISASSEMBLY INSPECTION 9 14 NEW BRAKE PAD INSTALLATION 9 15 CALIPER INSTALLATION 9 16 PARKING BRAKE DISC INT L MODEL 9 16 DISC INSPECTION 9 16 DISC REPLACEMENT 9 17 FRONT BRAKE PADS 9 ...

Page 381: ...STALLATION 9 28 BRAKE BURNISHING PROCEDURE 9 29 REAR CALIPER SERVICE 9 30 CALIPER ASSEMBLY VIEW 9 30 CALIPER REMOVAL 9 30 CALIPER DISASSEMBLY 9 31 CALIPER INSPECTION 9 32 CALIPER ASSEMBLY 9 32 CALIPER INSTALLATION 9 33 REAR BRAKE DISC 9 34 DISC INSPECTION 9 34 DISC REPLACEMENT 9 34 TROUBLESHOOTING 9 35 BRAKES SQUEAL POOR BRAKE PERFORMANCE 9 35 PEDAL VIBRATION 9 35 CALIPER OVERHEATS BRAKES DRAG 9 3...

Page 382: ...e Banjo Bolts 15 ft lbs 20 Nm Brake Switch 15 ft lbs 20 Nm Brake Bleeder Screw 48 in lb 5 Nm Brake Disc to Hub Bolts 30 ft lb 41 Nm Master Cylinder Mounting Bolts 23 ft lbs 31 Nm Brake Pedal Mounting Bracket to Frame 16 ft lbs 22 Nm Park Brake Disc Mounting Bolt 14 ft lb 20 Nm Park Brake Lever Mount Bolts 16 ft lb 22 Nm Park Brake Caliper Assembly Bolts 37 ft lb 50 Nm BRAKE SYSTEM SERVICE NOTES Di...

Page 383: ...RAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies brake pedal master cylinder hydraulic brake lines brake calipers brake pads and brake discs which are secured to the drive line When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder As the master cylinder piston moves inward it closes a small openi...

Page 384: ...e what is necessary and discard the rest in accordance with local laws Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury BRAKES ...

Page 387: ...d will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Make note of front and rear brake line locations to master cylinder 4 Loosen the brake line banjo bolts Item 4 and allow fluid to drain NOTE Dispose of fluid properly Do not re use 5 Remove the two mounting fasteners Item 5 that secure the master cylinder to the frame Installation 1 Reverse Step...

Page 388: ...from the master cylinder This procedure should be used to change fluid or bleed brakes during regular maintenance CAUTION Always wear safety glasses CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 1 Clean master cylinder reservoir cover thoroughly and remove the cover Item 2 2 If changing fluid remove old fluid from reservoir Ite...

Page 389: ...aintain level in reservoir CAUTION Maintain at least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to specification Bleeder Screw 48 in lb 5 Nm 9 Repeat steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir Master Cylinder Fluid Level Between ...

Page 391: ...y disconnect the parking brake switch electrical connector Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension 1 Pull back on parking brake lever located in the dash 2 After 3 to 4 clicks BRAKE should display on the instrument cluster and the wheels should not rotate when turning by hand After 8 full clicks of lever travel the vehicle should not roll...

Page 393: ... mount shift cable bracket 3 Lift the parking brake caliper off the brake disc and remove it from the vehicle Caliper Disassembly Inspection NOTE Refer to the Electronic Parts Catalog for parking brake caliper replacement parts information 1 Remove the two caliper assembly bolts C 2 Slide the brake pads and springs from the assembly NOTE Retain the lever and ball bearings for reassembly 3 Inspect ...

Page 394: ...easure gap for the brake disc and compare to gap specification Disassemble and add shim s between thrust washer and the inside brake pad as needed to close the gap to 207 217 in 5 25 5 51 mm 3 Once you have determined the correct amount of shims to use reassemble the caliper and apply an Anti Seize Lubricant to the thrust washer and shims 4 Torque the caliper assembly bolts to specification Parkin...

Page 395: ...unt bracket 2 Install and tighten the two caliper mount shift cable bracket fasteners to specification Parking Brake Caliper Mount Bracket Bolts 37 ft lb 50 Nm 3 Install the cable pin and clip pin Test the park brake for proper function PARKING BRAKE DISC INT L MODEL Disc Inspection 1 Measure the brake disc with a micrometer If the thickness of the disc is less than specified replace the brake dis...

Page 396: ...er Torque the mounting bolt to specification Parking Brake Disc Mounting Bolt 14 ft lb 20 Nm FRONT BRAKE PADS Pad Removal 1 Elevate and support front of vehicle CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the wheel nuts and front wheel 3 Loosen the pad adjuster screw 2 3 turns 4 Remove the upper and lower calipe...

Page 397: ...ter cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Push the mounting bracket inward and slip the outer brake pad out between the bracket and caliper body 7 Remove the inner pad from the bracket and caliper Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn beyond the service limit Front Brake Pad Thickn...

Page 398: ...ke fluid in the reservoir to prevent air from entering the brake system 5 Install the adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheel and torque wheel nuts to specifica...

Page 399: ...evate and safely support the front of the vehicle 2 Remove the four wheel nuts and the front wheel CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removing the line Item 1 Remove brake line from caliper BRAKES ...

Page 400: ... hub Caliper Disassembly 1 Remove both brake pads from the caliper see FRONT BRAKE PADS Pad Removal 2 Remove mount bracket assembly Item 1 and dust boots Item 2 3 Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly 4 Use a commercially available caliper piston pliers to extract the pistons from the caliper NOTE Do not remove the caliper pistons with a stan...

Page 401: ...or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches pitting or wear Measure bore size and compare to specifications Replace if damaged or worn beyond service limit Front Caliper Piston Bore I D Std 1 373 34 87 mm Service Limit 1 375 34 93 mm 2 Inspect piston for nicks scratches pitting or wear Measure piston diameter and repla...

Page 402: ...ate the mounting bracket pins Item 3 with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seal boots are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper Installation 1 Install the brake line onto the caliper taking care not to allow any de...

Page 403: ...lbs 163 Nm 7 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation NOTE If new pads are installed refer to Brake Burnishing Procedure page 9 19 FRONT BRAKE DISC Disc Runout 1 Mount dial indicator as shown to measure disc runout Slo...

Page 404: ...sembly from the vehicle and remove the 4 bolts Item 1 retaining the disc to the hub 4 Clean the wheel hub mating surface and install new disc on wheel hub 5 Install new bolts Item 5 and torque to specification Brake Disc Mounting Bolts Item 5 30 ft lb 41 Nm CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 Install wheel hu...

Page 405: ...mounting bolt nut and washer from the bearing carrier Swing radius rod down Discard the nut 5 Remove the two caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 6 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brak...

Page 406: ... inward and slip outer brake pad past the edge to remove 8 Remove the inner brake pad Pad Inspection 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Rear Brake Pad Thickness 0 298 0 007 7 57 mm 178 mm Service Limit 0 180 4 6 mm BRAKES ...

Page 407: ...to specification Rear Caliper Mount Bolt Item 1 40 ft lbs 54 Nm 4 Install lower radius rod bolt washer and new nut Torque to specification Radius Rod to Bearing Carrier Bolt 40 ft lb 54 Nm 5 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 6 Install the adjustment set screw and t...

Page 408: ...d after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping may result Repeat this procedure 10 times Do not make more than 3 stops per 1 mile 1 6 km BRAKES ...

Page 409: ...levate and safely support the rear of the vehicle CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 2 Remove the four wheel nuts and rear wheel Clean caliper area before removal 3 Place a container below the caliper to catch the brake fluid when removing the line Item 1 Remove brake line from caliper BRAKES ...

Page 410: ...nd remove the caliper Caliper Disassembly 1 Remove brake pad adjustment set screw Item 9 2 Push upper pad retainer pin inward and slip brake pads Item 1 past the edge and remove from the caliper 3 Remove mount bracket Item 2 and dust boots Item 6 and 7 4 Using a hammer and a small punch remove the piston Item 5 from the caliper body Item 8 Remove the square O rings Item 4 and Item 3 from the calip...

Page 411: ... 498 38 05 mm 3 Inspect the brake disc and pads as outlined in this chapter Caliper Assembly 1 Install new caliper seals Item 1 in the caliper body Item 2 Be sure groove is clean and free of residue or brakes may drag upon assembly 2 Coat piston with clean Polaris DOT 4 Brake Fluid PN 2872189 Install piston Item 3 with a twisting motion while pushing inward Piston should slide in and out of bore s...

Page 412: ...ue to specification NOTE Banjo Bolts 15 ft lbs 20 Nm 3 Install lower radius rod bolt washer and new nut Torque to specification Radius Rod to Bearing Carrier Bolt 40 ft lb 54 Nm 4 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 5 Follow bleeding procedure outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification Whee...

Page 413: ... indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 0 010 0 254 mm Disc Replacement 1 Remove rear brake caliper see REAR CALIPER SERVICE 2 Remove wheel hub cotter pin Item 4 castle nut Item 3 and washers Item 2 3 Remove the hub assembly from the vehicle and remove the...

Page 414: ...e Performance Air in system Water in system brake fluid contaminated Caliper or disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or th...

Page 416: ...RAKE LIGHT SWITCH 10 13 HEADLAMP SWITCH 10 13 IGNITION KEY SWITCH 10 14 IGNITION KEY SWITCH INT L 10 14 AWD 2WD SWITCH 10 15 AWD 2WD TURF SWITCH INT L 10 15 TURN SIGNAL SWITCH INT L 10 16 HAZARD SWITCH INT L 10 16 TRANSMISSION GEAR POSITION SWITCH 10 16 PARKING BRAKE SWITCH INT L MODEL 10 17 REAR DIFF SOLENOID INT L 10 18 DIFFERENTIAL SOLENOID OVERVIEW 10 18 DIFFERENTIAL SOLENOID CIRCUIT OPERATION...

Page 417: ...OR RECTIFIER 10 32 CHARGING SYSTEM TESTING FLOW CHART 10 33 BATTERY SERVICE 10 34 BATTERY SPECIFICATIONS 10 34 GENERAL BATTERY INFORMATION 10 34 BATTERY REMOVAL INSTALLATION 10 35 BATTERY OFF SEASON STORAGE 10 35 BATTERY TESTING 10 35 OCV OPEN CIRCUIT VOLTAGE TEST 10 35 LOAD TEST 10 35 BATTERY CONDUCTANCE ANALYZER 10 35 CHARGING PROCEDURE 10 36 STARTING SYSTEM 10 36 TROUBLESHOOTING 10 36 VOLTAGE D...

Page 418: ...013 Polaris Industries Inc EPS TROUBLESHOOTING USING DIGITAL WRENCH 10 43 ELECTRICAL SYSTEM BREAKOUTS 10 44 AWD 10 44 VEHICLE SPEED SENSOR 10 45 COOLING SYSTEM 10 46 UNSWITCHED CHASSIS POWER 10 47 KEY ON BATTERY POWER 10 48 LIGHTS 10 49 CHARGING SYSTEM 10 50 ELECTRICAL ...

Page 419: ...s remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter ...

Page 420: ...t 2013 Polaris Industries Inc EFI DIAGNOSTICS EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4 Refer to Chapter 4 Electronic Fuel Injection System EFI when diagnosing an EFI system or component ELECTRICAL ...

Page 421: ...OTE Some features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off...

Page 422: ...and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory and adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 9 Check Engine MIL Illuminated when the ECM has detected a Dia...

Page 423: ...rds and displays the total distance traveled by the vehicle The odometer can not be reset Trip Meter The trip meter records the miles traveled by the vehicle on each trip To reset the trip meter 1 Toggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Tachometer RPM Engine RPM can be displayed digitally Engine Temperature Engine tempe...

Page 424: ... OFF is displayed Clock The clock displays the time in a 12 hour or 24 hour format Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour To set the clock follow these steps 7 Toggle the MODE button until the odometer is displayed 8 Press and hold the MODE button until the hour segment flashes Release the button 9 With the segment flashing tap the MODE button to advance...

Page 425: ...and a high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If voltage drops below 8 5 volts LCD backlighting and icons will turn off If battery voltage rises above 15 volts a warning screen will display OV and provide the present battery voltage If voltage rises above...

Page 426: ...iagnostics code menu 3 A set of three numbers will appear in the information area The first number located far left can range from 0 to 9 This number represents the total number of trouble codes present example 2 means there are 3 codes present The second number located top right can be 2 to 6 digits in length This number equates to the suspected area of fault SPN The third number located bottom r...

Page 427: ...rely holding the dash Item 1 and rubber mount Item 2 NOTE Do not remove the rubber mount from the dash panel Only remove the rubber mount if necessary The bezel Item 4 is a snap on assembly and is a serviceable part Instrument Cluster Installation 1 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount...

Page 428: ...r than 0 5 ohms clean the switch terminals Re test and replace switch if necessary 4 For switch replacement refer to Chapter 9 Brakes Headlamp Switch 1 Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs OFF LOW HIGH If any of the tests fail replace headlamp switch assembly Move the swi...

Page 429: ...ignition key to START There should be continuity between switch pins A and B C and D Ignition Key Switch INT L 1 Disconnect the key switch harness by lifting the connector lock and pulling on the connector Do not pull on the wiring 2 Test between the 4 sets of outputs OFF ON LIGHTS ON START If any of the tests fail replace ignition switch assembly Turn the ignition key to ON LIGHTS There should be...

Page 430: ...pins 2 and 3 Move the switch to 2WD NONE OFF There should be no continuity between any pins AWD 2WD TURF Switch INT L 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs AWD 2WD TURF If any of the tests fail replace the switch assembly Move the switch to AWD There should be contin...

Page 431: ...isconnect wires or harness from the Hazard switch 2 Test between the outputs ON NONE OFF If any of the tests fail replace the switch assembly Move switch to ON There should be continuity between switch pins 2 and 3 Move switch to NONE OFF There should be no continuity between switch pins Transmission Gear Position Switch 1 The transmission gear position switch is located on the RH side of the tran...

Page 432: ... parking brake lever to locate the internally mounted switch The switch remains in the open position when the park brake lever is not applied When the parking brake lever is applied the switch makes contact and sends voltage to the ECU to illuminate BRAKE in the instrument cluster rider information display area see Park Brake Indicator NOTE If the parking brake is applied the ECU will rev limit th...

Page 433: ...he differential solenoid is located on the rear portion of the transmission case The solenoid actuates a shift fork with an engagement dog which locks and unlocks the rear differential Refer to Chapter 8 for more information Differential Solenoid Circuit Operation The Rear Diff Solenoid Relay is attached to the lower airbox bracket and can be accessed through the right rear wheel well When the swi...

Page 434: ...ystem must be grounded to operate Diagnosing System Failures Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below AWD Hub Coil Resistance 24 Ω 5 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connect properl...

Page 435: ...n sensor for each passing tooth on the flywheel s encoder ring The encoder ring missing tooth creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the p...

Page 436: ...nt The headlight beams are adjustable 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 With the machine in Park start the engine and turn the headlight switch to the LOW position 4 The most intense part of the LOW beam headlight beam s...

Page 437: ...essary to maintain lighting quality Riding with poor lighting can result in severe injury or death Headlamp Replacement 1 Disconnect wire harness from headlamp assembly Be sure to pull on the connector not on the wiring 2 Remove the three T 25 headlamp mounting screws Item 1 and three adjustment preload springs Item 2 NOTE The front bumper can be removed and placed face down on a suitable workbenc...

Page 438: ...e headlamp screws until the headlamp assembly is fully seated Back headlamp mounting screws off 1 8 to 1 4 2 3 turns 5 Install the front bumper as shown in Chapter 5 if previously removed 6 Connect headlamp electrical connector to the headlamp assembly 7 Perform the Headlight Adjustment procedure as shown in this chapter TAIL BRAKE LIGHTS Taillight Replacement Before replacing the taillight s use ...

Page 439: ...r should display on the instrument cluster This indicates all other components are working properly 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition circuit breaker and mechanical relay for proper operation Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant tempe...

Page 440: ...2 5 k Ω 6 86 F 30 C 1 7 k Ω 6 104 F 40 C 1 2 k Ω 6 122 F 50 C 834 Ω 6 140 F 60 C 596 Ω 6 158 F 70 C 435 Ω 6 176 F 80 C 323 Ω 6 194 F 90 C 243 Ω 6 212 F 100 C 186 Ω 6 ECT Sensor Replacement 1 Remove the throttle body see Chapter 4 Throttle Body Removal 2 Be sure the engine has cooled enough to work on 3 Disconnect the vehicle harness from ECTsensor 4 Drain the coolant so the level is below the sens...

Page 441: ...in the empty position and compare to specification Fuel Sender Empty 90 4 5 Ω 4 Slowly move the sender float to the full position and compare to specification Fuel Sender Full 6 1 Ω 5 If the readings are out of specification or if the reading is erratic or LCD display sticks check the following before replacing the fuel pump assembly Loose float Float contact with tank Bent float rod 6 If none of ...

Page 442: ...wiring and components such as the instrument cluster ECU EFI system main harness lights accessories and power steering The relays assist with component operation like the cooling fan fuel pump EFI system drive system and electronic power steering A separate 20 amp circuit breaker protects the fan motor circuit Two separate relays located under the dash operate the headlights and the flash to pass ...

Page 444: ... Amp fuse protected 12 Vdc constant battery voltage Dark Green Yellow ECU ground input to enable relay Red White 20 Amp fuse protected 12 Vdc constant battery voltage Red Dark Blue Provides 12 Vdc power for EFI system circuits FAN RELAY provides power to the following system Fan Motor COLOR FUNCTION Red 20 Amp circuit breaker protected 12 Vdc constant battery power Orange White ECU ground input to...

Page 445: ...er to operate high beam headlights momentarily Dark Green Normally closed relay output to operate low beam headlights CHARGING SYSTEM Current Draw Key Off CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw...

Page 446: ...e stator alternator TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2 to Y3 Each test should measure 0 07 0 13 Ω TEST CONNECT METER LEADS TO OHMS READING Battery Charge Coil Y1 to Y2 0 07 0 13 Ω Battery Charge Coil Y1 to Y3 0 07 0 13 Ω Battery Charge Coil Y2 to Y3 0 07 0 13 Ω NOTE If there are any significant variati...

Page 447: ... Removal Inspection procedure to service the stator NOTE The stator cover can be removed with the engine installed in the chassis Be sure to thoroughly clean the area around the stator cover prior to removal Regulator Rectifier The regulator rectifier Item 1 is located in the left rear wheel well area in front of the left rear shock It is mounted under the LH panel divider NOTE If the regulator re...

Page 448: ...opyright 2013 Polaris Industries Inc Charging System Testing Flow Chart Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not exposed or pinched ELECTRICAL ...

Page 449: ...from contact with the skin eyes or clothing ANTIDOTE External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in closed s...

Page 450: ...battery is stored or used at a low state of charge hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery Use a volt ohm meter to test battery voltage OPEN CIRCUIT VOLTAGE STATE OF CHARGE VOLTAGE 100 12 8 V and up 75 Charged 12 6 V 50 Charged 12 3 V 25 Charged 12 0 V 0 Charged 11 8 V or less Load Test CAUTION To prevent shock or component damage remo...

Page 451: ... connections switch positions and when to connect the charger to an outlet STARTING SYSTEM Troubleshooting Starter Motor Does Not Run Battery discharged Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty ...

Page 452: ...ottom hole acts as a pilot hole to properly align the starter drive bendix with the flywheel This helps prevent binding and starter damage 6 Torque upper starter mounting screw to specification 7 Install negative battery cable to the upper starter mounting bolt stud Torque nut to specification Starter Mounting Bolts and Nut 7 ft lb 10 Nm Starter Solenoid Bench Test Test the start solenoid by power...

Page 453: ...10 38 9924874 R02 2014 RZR XP XP 4 1000 Service Manual Copyright 2013 Polaris Industries Inc STARTING SYSTEM TESTING FLOW CHART Condition Starter fails to turn over the engine ELECTRICAL ...

Page 454: ...ration NOTE To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction Indicator Light will illuminate to indicate the EPS has shut down and will set a fault code in Digital Wrench The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indicator Light MIL on the instrumen...

Page 466: ... and Fitting Inspection 2 37 Brake Light Switch 10 13 Brake Pad Installation Front 9 19 Thickness 9 18 Brake Pad Inspection 2 37 Brake Pads Rear 9 26 Removal Front 9 17 Brake Pedal Installation 9 9 Removal 9 9 Brake System Assembly View 9 7 Bleeding 9 9 Operation 9 4 Troubleshooting 9 35 Brakes Torque Specifications 9 3 Break Even Test 10 30 Break In Period 2 3 C Cab Frame Assembly Removal 5 5 5 6...

Page 467: ...6 13 Moveable Sheave Inspection 6 16 Needle Bearing 6 14 Operation 6 3 Roller and Pin Inspection 6 15 Shift Weights 6 14 Spider Removal 6 15 Spring 6 13 Drive Shaft Boot Inspection 2 28 CV Joint Handling 7 33 Installation Front 7 7 Installation Rear 7 31 Removal Front 7 6 Removal Rear 7 30 Service Rear 7 33 Driven Clutch Assembly 6 26 Assembly View 6 30 Bushing Service 6 24 Disassembly 6 22 Operat...

Page 468: ...gnation Number 1 2 Engine Serial Number Location 1 3 Engine Service Panel 5 19 Engine Camshaft Timing Quick Reference 3 80 Engine Cooling System Troubleshooting 3 87 Engine Troubleshooting 3 86 Engine Valve Cover Installation 3 85 EPS Breakout Diagram 10 40 Operation 10 39 Troubleshooting 10 41 ETC 4 32 Exhaust Valve Lash Tappet Matrix 3 84 F Fan Control Circuit Bypass Test 10 24 Fan Control Circu...

Page 469: ...nstallation 9 8 Metric Bolt Torque Specification 1 15 N ne Valve Clearance Adjustment 3 81 O Oil Pressure Test 3 4 Open Circuit Voltage Test 10 35 Outer CV Joint Boot Replacement 7 33 P Parking Brake Adjustment INT L 9 12 Assembly View INT L 9 11 Inspection INT L 9 12 Parking Brake Caliper Assembly View INT L 9 13 Disassembly INT L 9 14 Installation INT L 9 16 Pad Installation INT L 9 15 Removal I...

Page 470: ...8 Spark Plug Service 2 31 Special Tools 1 5 Body Steering Suspension 5 3 Brakes 9 3 Clutching 6 2 EFI 4 3 Electrical 10 4 Engine 3 3 Final Drive 7 2 Shock 5 52 Transmission 8 2 Specification Wheel Toe Out 2 33 Specifications Brakes 9 3 Camshaft 3 34 Cooling System 3 13 Engine 3 6 Engine Lubrication 3 3 3 32 Engine Oil Pressure 3 4 General 1 6 Transmission and Front Gearcase 2 21 Specifications Wal...

Page 471: ...e Values 8 3 Output Shaft Backlash INT L 8 37 Output Shaft Backlash Procedure 8 18 Removal 8 5 Snorkel Shaft Removal 8 12 Troubleshooting 8 45 Transmission Lubrication 8 2 Transmission Switch 10 16 Trouble Codes 4 35 Troubleshooting Brake Noise 9 4 Brake System 9 35 Clutch 6 31 Fuel Injector 4 19 Transmission 8 45 Turn Signal Switch INT L 10 16 U Upper Steering Shaft EPS Installation 5 34 Removal ...

Page 472: ...HARNESS CHASSIS RZR XP 1000 ...

Page 473: ...HARNESS CHASSIS RZR XP 1000 ...

Page 474: ...HARNESS BOX RZR XP 1000 ...

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