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Polaris RZR XP 1000 2014, Service Manual

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Polaris RZR XP 1000 2014 Service Manual Download Page 97

3

9926816 R07 - 2014-2016

RZR

XP 1000 / XP4 1000 Service Manual

© Copyright Polaris Industries Inc.

3.19

COOLING SYSTEM ASSEMBLY VIEW

q

Thermostat housing

y

Filler Neck

s

Oil Cooler Inlet Hose

w

Water Pump

u

Radiator

d

Oil Cooler Outlet Hose

e

Engine Hoses

i

Pressure Cap

f

Bypass Hose

r

Lower Radiator Hose

o

Upper Radiator Hose

g

Water Pump Outlet Hose

t

Fan Assembly

a

Recovery Bottle

ENGINE / COOLING SYSTEM

Summary of Contents for RZR XP 1000 2014

Page 1: ...rized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Service Manual Service Literature Question Consumers please provide your feedback in writing to Polaris...

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: ...s com purchased from www purepolaris com or by contacting the nearest Polaris dealer REVISION INDEX REV DATE CHANGES R01 08 14 2015 Initial release R02 10 12 2015 Added XP4 High Lifter information 10 30 2015 Call out engine trans centering tool as PU 50658 A R03 11 11 2015 Front and Rear Hub Nut torque changed 11 17 2015 Updated shock spring adjustment procedure table 11 17 2015 Added prop shaft s...

Page 4: ......

Page 5: ...APTER 1 GENERAL INFORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING SYSTEM CHAPTER 4 FUEL SYSTEM CHAPTER 5 PVT SYSTEM CHAPTER 6 TRANSMISSION CHAPTER 7 FINAL DRIVE CHAPTER 8 STEERING SUSPENSION CHAPTER 9 BRAKE SYSTEM CHAPTER 10 BODY FRAME CHAPTER 11 ELECTRICAL ...

Page 6: ......

Page 7: ...1 10 2014 2016 RZR XP 1000 1 10 2014 2016 RZR XP 1000 CLUTCH CHART 1 11 2014 2016 RZR XP 4 1000 1 12 2014 2016 RZR XP4 1000 1 13 2015 2016 RZR XP 1000 HIGH LIFTER 1 14 2015 2016 RZR XP 1000 HIGH LIFTER CLUTCH CHART 1 15 2016 RZR XP4 1000 HIGH LIFTER 1 16 2016 RZR XP4 1000 HIGH LIFTER CLUTCH CHART 1 17 2015 RZR XP 1000 DESERT EDITION 1 18 2015 RZR XP 1000 DESERT EDITION CLUTCH CHART 1 19 2015 RZR X...

Page 8: ... 760 9 875 E EPS 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 MODEL NUMBER DESIGNATION 2015 Example R15RUE57AC GROUP MODEL YEAR MAKE CHASSIS CODE ENGINE CODE REGION OPTION 1s...

Page 9: ... 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 F 3 0 0 0 0 0 0 Model Year A 2010 B 2011 C 2012 D 2013 E 2014 F 2015 VEHICLE IDENTIFICATION NUMBER VIN DESIGNATION 2015 Example 4XARUE573FG000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE CHASSIS MODIFIER ENGINE SIZE ENGINE MODIFIER CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1...

Page 10: ...ut a Polaris ORV refer to the vehicle identification number VIN and the engine serial number The VIN can be found stamped on a portion of the left rear frame upright q behind the PVTcover The engine serial number can be found on a decal applied to the front of the engine crankcase w or stamped into the crankcase on the PTO side of the engine e GENERAL INFORMATION ...

Page 11: ...FW 9924687 9924688 2014 RZR XP 1000 INT L Z14ST1EFX 9924687 9924688 2014 RZR XP 4 1000 Z146T1EAM AW 9924687 9924688 2015 RZR XP 1000 Z15VDE99AO AT AV AW AZ LP EW 9925838 9925754 2015 RZR XP 1000 INT L Z15VDE99FV 9925838 9925858 2015 RZR XP4 1000 Z15VFE99AP AT AV 9925838 9925795 2015 RZR XP 1000 High Lifter Z15VDE99AL 9925836 9925794 2015 RZR XP 1000 Desert Edition Z15VDE99AA 9925838 9925794 2015 R...

Page 12: ...the tools listed or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com GENERAL INFORMATION ...

Page 13: ...ssure Test Tool 2871056 Driven Clutch Puller 2871226 Clutch Bushing Replacement Tool Kit 2871282 Transmission Seal Driver 50 MM 2871351 IFP Depth Tool 2871358 B Drive Clutch Holding Fixture 2871702 Shaft Drive Transmission and Front Gearcase Tool Kit 2871745 Static Timing Light Harness 2872085 Drive Clutch Puller 2872608 Roll Pin Removal Tool 27 2876389 Combination Pliers 2877408 Spanner Wrench Cl...

Page 14: ...Holding Tool PU 47471 Smartlink Module Kit PU 48951 CV Boot Clamp Pliers Stepless PU 49466 Relay Bypass PU 50105 Oil Filter Wrench PU 50296 Battery Tester PU 50338 Hydrometer PU 50518 A Clutch Compressor PU 50562 Engine Stand Adapter PU 50563 Cylinder Holding Camshaft Timing Plate PU 50564 Water Pump Seal Installer PU 50565 Oil Pressure Gauge Adapter 1 2 NPT PU 50566 Transmission Nut Socket PU 505...

Page 15: ...1829 Shock Spanner Wrench 2 5 3 0 Inner PU 51830 Shock Spanner Wrench 2 5 Outer PU 51832 Shock Spanner Wrench 3 0 Outer PU 51837 Shock Body Holding Tool PU 51838 Shock Body Holding Tool PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PV 43526 Connector Test Kit PV 43531 Oil Presure gauge PV 43568 Fluke Multimeter PV 43570 Piston Ring Compressor Pliers PV 48656 Fuel Press...

Page 16: ... Base 90 228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1379 lbs 625 5 kg Gross Vehicle Weight 2200 lbs 998 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 Hitch...

Page 17: ... 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 Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL 44 oz 1300 mL STEERING SUSPENSION Toe Out 1 8 3 16 3 2 4 8 mm Front Suspension Independ...

Page 18: ...297 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 Capa...

Page 19: ...mp 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 12 05 1 25 59 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL 44 oz 1300 mL STEERING SUSPENSION Toe Out 1 8 3 16 3 2 4 8 mm Front Su...

Page 20: ...ss Vehicle Weight 2470 lbs 1120 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 The tow loop on the rear of the vehicle is provided for recovery use ONLY Tow a vehicle ONLY of equal or lesser size and weight When towing a disabled RZR vehicle place the disabled vehicle s transmission in neutral Do not...

Page 21: ...y 10A Drive 10A Lights 20A EPS if appl 200A Terminal Block found on wiring between battery and terminal block DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 12 05 1 25 59 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL 44 oz 1300 mL STEERING SUSPEN...

Page 22: ...ss Vehicle Weight 2735 lbs 1241 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 kg Includes riders cargo and accessories Hitch Towing Capacity The tow loop on the rear of the vehicle is provided for recovery use ONLY Tow a vehicle ONLY of equal or lesser size and weight When towing a disabled RZR vehicle place the disabled vehicle s transmission in neutral Do not o...

Page 23: ...0A Fuel Pump 5A Brake Light 10A Accessory 10A Drive 10A Lights 20A EPS if appl 200A Terminal Block found on wiring between battery and terminal block DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 12 05 1 25 59 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requi...

Page 24: ...0 228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1379 lbs 625 5 kg Gross Vehicle Weight 2200 lbs 998 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 Hitch Tongue...

Page 25: ...eaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS 200A Terminal Block found on wiring between battery and terminal block 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 Demand Drive Fluid 8 5 oz 250 mL...

Page 26: ...8 6 cm Ground Clearance 14 25 36 2 cm Dry Weight 1531 lbs 694 5 kg Gross Vehicle Weight 2271 lbs 1030 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 Hitch Tongue C...

Page 27: ...cuit 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 rear High Low Reverse 12 05 1 25 59 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL 44 oz 1300 ...

Page 28: ...0 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 Drive Clutch Cover Plate Screw 9 ft lb 12 Nm ITEM TORQUE 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 Jamb Nut 250 ft lb 339 Nm Apply 0 1 mL Loctite 7088 Prim...

Page 29: ...m Stabilizer Bar Linkage rear 40 ft lbs 54 Nm Stabilizer Bar Mounting Bracket Bolts rear 17 ft lb 23 Nm Stabilizer Bar Locating Clamp Bolts 10 ft lb 14 Nm Starter Mounting Bolts 7 ft lb 10 Nm ITEM TORQUE 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 Fasteners 8 ft lb 11 Nm Steering Rack Mounting Bolts 16...

Page 30: ...m 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 gall...

Page 31: ...7 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 LB NM DRY THREADS M3 0 3 0 5 0 5 0 7 1 1 3 1 5 2 1 5 2 M4 0 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...

Page 32: ...24 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 ...

Page 33: ... 3906 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 FRACTION DECIMAL MM TO INCHES 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 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 ...

Page 34: ...1 28 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES GENERAL INFORMATION ...

Page 35: ...2 13 VALVE CLEARANCE INSPECTION 2 13 COOLING SYSTEM 2 16 COOLING SYSTEM OVERVIEW 2 16 COOLANT STRENGTH 2 16 COOLANT LEVEL INSPECTION 2 16 COOLING SYSTEM PRESSURE TEST 2 17 COOLING SYSTEM HOSES 2 17 RADIATOR INSPECTION CLEANING 2 18 COOLANT DRAIN FILL 2 18 FUEL SYSTEM AND AIR INTAKE 2 19 FUEL SYSTEM WARNING 2 19 FUEL TANK VENT LINE 2 19 FUEL PUMP FUEL FILTERS 2 20 FUEL LINES 2 20 THROTTLE PEDAL INS...

Page 36: ...D WHEEL HUB INSPECTION 2 31 WHEEL TOE ALIGNMENT INSPECTION 2 31 WHEEL TOE ADJUSTMENT 2 32 SUSPENSION 2 33 SPRING ADJUSTMENT WALKER EVANS 2 33 SHOCK COMPRESSION ADJUSTMENT WALKER EVANS 2 34 SPRING ADJUSTMENT FOX 2 35 SHOCK COMPRESSION ADJUSTMENT FOX 2 36 BRAKE SYSTEM 2 38 BRAKE FLUID INSPECTION 2 38 BRAKE PAD DISC INSPECTION 2 38 BRAKE HOSE AND FITTING INSPECTION 2 39 ELECTRICAL AND IGNITION SYSTEM...

Page 37: ...not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Ra...

Page 38: ...fuel pump check lines and fittings for leaks and abrasion Parking Brake Cable Adjustment INT L 25 H Inspect adjust tension after first 25 hours E Air Filter Weekly Inspect replace as needed E Engine Breather 25 H Monthly 150 250 Inspect clean Battery 25 H Monthly 250 400 Check terminals clean test E Engine Oil Filter Change Break In Period 25 H 1 M Perform a break in oil and filter change at 25 ho...

Page 39: ...eaks pressure test system 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 Front Wheel Bearings 100 H 12 M 1000 1600 Inspect replace as needed ...

Page 40: ...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 50 50 Extended Life Coolant Maintain coolant level in coolant reservoir bottle r Check level daily change coolant every two years More often under severe use such as o...

Page 41: ...el 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 w 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 e More often under severe use su...

Page 42: ...tings on each side of the vehicle q 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 Front Stabilizer Bar Bushings FOX and INT L Grease the fitting on each side of the vehicle w Polaris All Season Grease Rear Stabilizer Bar Bushings Grease 2 fittings through the skid plate access holes on e...

Page 43: ...78068 quart 12 count 2878069 gallon 4 count 2878070 2 5 gallon 2 count Brakes DOT 4 2872189 12 count Grease Fittings Premium All Season Grease 2871322 3 oz cartridge 24 count 2871423 14 oz cartridge 10 count U Joint Lube Premium U Joint Lube 2871515 3 oz cartridge 24 count 2871551 14 oz cartridge 10 count NOTE Each item can be purchased separately at your local Polaris dealer PART NO DESCRIPTION A...

Page 44: ...ansmission in PARK 2 Stop the engine and allow it to cool down before removing the dipstick 3 Unlock the dipstick lever q 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 c...

Page 45: ...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 q 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 w counter clockwise to remove it Oil Filter Wrench PU 50105 2 5 64 mm 7...

Page 46: ...gine Oil Level page 2 10 16 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 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 r...

Page 47: ...built engine will have higher leakdown than an engine with 5 hours of runtime Leakdown should decrease once the rings are broken in VALVE CLEARANCE INSPECTION NOTE Valve clearance inspection should be performed on a cold engine at room temperature 1 Remove the driver s seat Disconnect the negative battery cable 2 Remove the engine access panel 3 Remove eight screws retaining the outer clutch cover...

Page 48: ...alve Clearance Adjustment page 3 85 MEASUREMENT Intake Valve Clearance cold 006 002 0 15 0 05 mm Exhaust Valve Clearance cold 008 002 0 20 0 05 mm 11 Repeat steps 18 20 until all eight valves have been inspected 12 If previously removed apply anti seize compound to the spark plug threads and reinstall the spark plugs Torque spark plugs to specification TORQUE Spark Plug Torque 7 ft lbs 10 Nm 13 In...

Page 49: ...ne will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder 18 Install outer clutch cover and eight retaining screws Torque screws to specification TORQUE Outer Clutch Cover Screws 50 in lbs 5 Nm 19 Connect the negative battery cable to the battery and install the seat 20 Start the engine t...

Page 50: ...m Tap water contains minerals and impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat Recommended Coolant Polaris 50 50 Extended Life Anti freeze 2880514 quart 2880513 gallon COOLANT LEVEL INSPECTION The pressure cap q and recovery bottle w are located under the front hood of the vehicle The coolant level must be maintained betwee...

Page 51: ...d check for leaks Make sure radiator fins are clean to prevent overheating COOLING SYSTEM PRESSURE TEST Refer to Cooling System Specifications page COOLING SYSTEM HOSES 1 Inspect all vehicle hoses for cracks deterioration abrasion or leaks Replace if necessary q Recovery Bottle w Engine Hoses e Radiator Hoses r To Thermostat Housing t To Water Pump y To Radiator 2 Inspect all engine hoses for crac...

Page 52: ...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 q 5 Allow coolant to drain com...

Page 53: ... 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 FUEL TANK VENT LINE Symptoms of a restricted fuel tank vent include the following col...

Page 54: ... damage or leaks NOTE Neither filter is serviceable individually Must replace the fuel pump as an assembly Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System FUEL LINES 1 Check the quick connect fuel line q at the fuel tank for signs of wear deterioration damage or leakage Replace line s if necessary 2 Locate the fuel supply fitting w through the right...

Page 55: ...le position when released Check throttle pedal periodically ENGINE INTAKE PRE FILTER SERVICE It is recommended that the engine intake pre filter be inspected daily The filter should be inspected using the following procedure 1 The engine intake pre filter is located just above the right rear wheel fender 2 Loosen the knob on top of the assembly and lift up to disengage the tab from the cargo box 3...

Page 56: ...OTE If the filter has been soaked with fuel or oil it must be replaced 5 Inspect the air filter and replace if necessary NOTE DO NOTattempt to clean the air filter 6 Place the air filter into the air box and reinstall the air box cover NOTE Be sure the lower tabs on the air box cover are properly engaged into the airbox 7 Engage the cover latches 8 Reinstall the cargo box access panel INTAKE DUCT ...

Page 57: ...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 q 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 throttle f...

Page 58: ...HUB TORQUE TABLE ITEM SPECIFICATION Wheel Nuts Cast Aluminum Wheels 120 ft lbs 163 Nm Hub Retaining Nuts Front and Rear 110 ft lbs 149 Nm Beadlock Screws Step 1 24 in lbs 3 Nm Step 2 7 ft lbs 10 Nm NOTE Do not lubricate the stud or the lug nut WHEEL REMOVAL 1 Position the vehicle on a level surface 2 Place the transmission in PARK and stop the engine 3 Loosen the wheel nuts slightly If wheel hub r...

Page 59: ...CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear TIRE INSPECTION Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect vehicle handling WARNING Operating with worn tires will increase the possibility of the vehicle skidding easily wit...

Page 60: ...ire 2 Remove the beadlock screws and beadlock ring 3 Dismount the tire on the side with the beadlock holes 4 Place the beadlock ring so the tire is sandwiched between the rim and the ring making sure the valve stem is aligned with the slot in the ring 5 Install bolts and thread them to 24 in lbs 3 Nm 6 Tighten in a criss cross pattern to 7 ft lbs 10 Nm TORQUE Beadlock Screws Step 1 24 in lbs 3 Nm ...

Page 61: ...ly and unobstructed Transmission Lubricant 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 q and check the lubricant level 3 If lubricant level is not even with bottom threads w add rec...

Page 62: ...ith the maintenance schedule Be sure 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 ...

Page 63: ...on deceleration Inability to engage into a gear Excessive gear lash noise Gear selector moving out of desired range 1 Locate the shift cable q attached to the transmission case in the right rear wheel well area 2 Inspect shift cable clevis pin pivot bushings r and dust boot e Replace if worn or damaged 3 If adjustment is required loosen the lower jam nut y and pull the cable out of the mount w to ...

Page 64: ...sure the steering mechanism is not restricted or limited NOTE Check front end alignment whenever steering components are replaced WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician STEERING WHEEL FREE PLAY Check steering wheel for specified free play...

Page 65: ...sembly to determine the cause loose wheel nuts or loose front hub nut Refer to Chapter 7 Front Bearing Carrier Inspection Removal page 7 4 and Rear Bearing Carrier Inspection Removal page 7 7 for wheel bearing 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 P...

Page 66: ...ie 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 end to keep it from rotating Loosen jam...

Page 67: ... fully extend 2 Using the shock spanner spreader tool PN 2878925 included in the vehicle s tool kit turn the adjustment collar q to increase or decrease ride height Shock Spanner Clutch Spreader Tool 2878925 NOTE Polaris does not recommend increasing the spring adjustment by more than one inch 25 4 mm over the factory setting w as it may negatively impact vehicle stability Always return the spring...

Page 68: ...ockwise to 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 Compress...

Page 69: ...ates 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 spanner spreader tool included in the vehicle s tool kit turn the adjustment collar to increase or decrease ride height Shock Spanner C...

Page 70: ...nter clockwise to decrease compression damping NOTE The recommended factory setting for the front and rear shocks are provided in the following compression adjustment tables FOX 2 5 Front Shock SETTING COMPRESSION DAMPING Softest Full counter clockwise position Factory 12 clicks CCW from full firm setting full clockwise Firmest Full clockwise position FRONT REAR FOX 3 0 Rear Shock SETTING COMPRESS...

Page 71: ...following adjustment table to correctly compensate for weight added to the vehicle NOTE These settings are only guidelines The spring preload and shock clickers can be adjusted further to match personal riding style and location of the weight on the vehicle FOX Internal Bypass Shock Adjustments RIDERS CARGO ACCESSORIES SPRING ADJUSTMENT FRONT SHOCK REAR SHOCK Driver Only 0 Remove 0 2 5 mm preload ...

Page 72: ...ew the brake fluid level in the reservoir q 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 I...

Page 73: ... Service Manual Copyright Polaris Industries Inc 2 39 BRAKE HOSE AND FITTING INSPECTION Check brake system hoses and fittings for cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts MAINTENANCE ...

Page 74: ...low with milk of magnesia beaten egg or vegetable oil Call 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 an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Batteries must be fully charged before us...

Page 75: ...or petroleum jelly 4 Connect and tighten the red positive cable s first 5 Connect and tighten the black negative cable s last Torque terminal fasteners to specification TORQUE Battery Terminal Fasteners 60 in lbs 7 Nm 6 Verify that cables are properly routed and reinstall the driver s seat ENGINE CHASSIS ELECTRICAL GROUND Inspect the ground cable connections Remove ground terminals and clean if ne...

Page 76: ...k plug socket with an extension 6 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 8 Measure gap with a wire gauge Adjust gap if necessary by carefully bending the side electrode 9 If neces...

Page 77: ...2 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 2 43 13 Reinstall the cargo box access panel MAINTENANCE ...

Page 78: ...2 44 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES MAINTENANCE ...

Page 79: ...SYSTEM ASSEMBLY VIEW 3 14 ENGINE COOLING SYSTEM 3 15 ENGINE COOLING SYSTEM SPECIFICATIONS 3 15 COOLING SYSTEM PRESSURE TEST 3 15 COOLING SYSTEM PRESSURE CAP TEST 3 16 RADIATOR REMOVAL INSTALLATION 3 16 THERMOSTAT REPLACEMENT 3 17 COOLING SYSTEM ASSEMBLY VIEW 3 19 COOLING SYSTEM BLEEDING PROCEDURE 3 20 WATER PUMP REMOVAL 3 21 WATER PUMP INSTALLATION 3 21 WATER PUMP SERVICE 3 23 ENGINE SERVICE 3 26 ...

Page 80: ...61 CONNECTING ROD INSPECTION 3 61 ENGINE ASSEMBLY BOTTOM END 3 63 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 63 CONNECTING ROD BEARING SELECTION 3 64 CRANKSHAFT MAIN BEARING SELECTION 3 64 UPPER CRANKCASE PREPARATION 3 65 PISTON RING INSTALLATION 3 65 PISTON CONNECTING ROD ASSEMBLY 3 67 CYLINDER PISTON INSTALLATION 3 68 CRANKSHAFT INSTALLATION 3 69 BALANCE SHAFT INSTALLATION 3 71 LOWER...

Page 81: ...sure 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 FLUID CAPACITY Oil Capacity 3 0 qt 2 8 L Oil Type PS 4 Full Syn...

Page 82: ...G side of the engine 4 Remove the crankcase gallery plug q 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 temperature O...

Page 83: ...3 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 3 5 ENGINE OIL FLOW CHART ENGINE COOLING SYSTEM ...

Page 84: ...ound Limit 001 0 025 mm Cylinder Taper Limit 001 0 025 mm Cylinder to Piston Clearance 0009 0019 0 025 0 050 mm Cylinder Head Cylinder Head Surface Warp Limit 0039 0 1 mm Cylinder Head Standard Height 4 717 0019 119 82 0 05 mm Valve Valve Lash Cold Intake 006 002 0 15 0 05 mm Valve Lash Cold Exhaust 008 002 0 20 0 05 mm Valve Stem Diameter Intake 2155 2161 5 475 5 490 mm Valve Stem Diameter Exhaus...

Page 85: ...Small End I D 7879 7885 20 015 20 030 mm 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 6137 1 6140 40 988 40 995 mm ...

Page 86: ...3 8 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc MAIN ENGINE COMPONENTS TORQUE SPECIFICATION AND SEQUENCE ENGINE COOLING SYSTEM ...

Page 87: ...3 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 3 9 BALANCE SHAFT CONNECTING RODS CRANKCASE CRANKSHAFT PISTONS ENGINE COOLING SYSTEM ...

Page 88: ...3 10 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc CYLINDER OIL COOLER OIL FILTER OIL PUMP OIL SUMP WATER PUMP ENGINE COOLING SYSTEM ...

Page 89: ...3 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 3 11 CAMSHAFTS CYLINDER HEAD FLYWHEEL IDLER GEARS STATOR COVER ENGINE COOLING SYSTEM ...

Page 90: ...3 12 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc SPARK PLUGS STARTER THERMOSTAT HOUSING THROTTLE BODY VALVE COVER ENGINE COOLING SYSTEM ...

Page 91: ...nual Copyright Polaris Industries Inc 3 13 INTAKE EXHAUST SYSTEM AIR BOX AIR FILTER ASSEMBLY VIEW q Intake Airbox Hose y Airbox Clip 4 w Drain Cap u Vent Hose e Airbox i Intake Tubes r Air Filter o Engine Intake Housing t Airbox Cover ENGINE COOLING SYSTEM ...

Page 92: ...EMBLY VIEW q Spark Arrestor Fastener 8 ft lbs 11 Nm u Exhaust Spherical Gasket w Spark Arrestor i Exhaust Stud w Spring 21 ft lb 28 Nm e Exhaust Springs o Exhaust Pipe r Muffler Silencer a Head Pipe Gasket t Muffler Isolator Mounts s Head Pipe Bolts 18 ft lb 24 Nm y Oxygen Sensor13 ft lb 18 Nm ENGINE COOLING SYSTEM ...

Page 93: ...ater in a 50 50 or 60 40 ratio depending on freeze protection required in your area CAUTION Using tap water in the cooling system will lead to 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 PRES...

Page 94: ... relief pressure is 13 psi Replace cap if it does not meet this specification RADIATOR REMOVAL INSTALLATION 1 Remove the hood and front bumper See Chapter 10 Hood and Front Body Work page 10 20and Front Bumper page 10 19 2 Remove the four fasteners that secure the front bumper support to the main frame 3 Drain radiator by removing lower radiator hose q Be sure to catch and dispose of coolant prope...

Page 95: ...er e Upper Radiator Hose y To Radiator Fitting r Lower Radiator Hose u Fan Motor Assembly t Recovery Bottle i Radiator THERMOSTAT REPLACEMENT 1 Remove the hood from the front cab WARNING The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 2 Remove the pressure cap to relieve any system pressure see Chapter 3 Cooling System Pressure Cap Test p...

Page 96: ...ystem to operate until thermostat opens 9 Install a new thermostat with the bleed hole r 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 TORQUE Thermostat Cover Bolts 7 ft lb 10 Nm 11 Be sure to properly fill and bleed cooling system as outlined in this chapter ENGIN...

Page 97: ...OLING SYSTEM ASSEMBLY VIEW q Thermostat housing y Filler Neck s Oil Cooler Inlet Hose w Water Pump u Radiator d Oil Cooler Outlet Hose e Engine Hoses i Pressure Cap f Bypass Hose r Lower Radiator Hose o Upper Radiator Hose g Water Pump Outlet Hose t Fan Assembly a Recovery Bottle ENGINE COOLING SYSTEM ...

Page 98: ...ry 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 e 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 install the pressure c...

Page 99: ...ant hoses 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 q w 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 100: ... drive tab and slot are properly engaged 10 Install the three water pump mounting bolts t y and torque to specification NOTE Install different bolt lengths as shown TORQUE Water Pump Mounting Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads 11 Install the four coolant hoses u a that attach to the water pump Be sure orientation and routing are correct 12 Install the right rear lower shock bolt...

Page 101: ...er pump shaft 6 Using an appropriate arbor press properly support the water pump housing and press out the water pump shaft from the impeller side 7 Extract the mechanical seal and the oil seal from the water pump housing NOTE A 5 32 4 mm diameter punch y will fit in the lubrication slot to aid in the removal of the oil seal Be sure not to damage the water pump shaft bearing surface 8 Inspect the ...

Page 102: ...mp shaft 17 Apply Loctite 204 to the threads of the impeller bolt Install washer and impeller bolt and torque to specification TORQUE Water Pump Impeller Bolt 7 ft lb 10 Nm Apply Loctite 204 to bolt threads 18 Clean cover q and housing gasket surfaces w 19 Install a new water pump cover gasket e 20 Install the water pump cover and three retaining bolts i Torque bolts in sequence to specification T...

Page 103: ...right Polaris Industries Inc 3 25 22 Install water pump assembly into engine Water Pump Assembly View o Bolt f Washers k Oil Seal a Loctite 204 g Drive Tab l Impeller s Mechanical Seal h Water Pump Shaft 1 Washer d O Rings j Water Pump Housing ENGINE COOLING SYSTEM ...

Page 104: ... 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 procedures in this Service M...

Page 105: ...harness leads r CPS t ECT sensor y 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 Chapter 4 Fuel Line Removal Installation page 4 17 Fuel Line...

Page 106: ...taining the box support bracket d Remove the push rivet that attaches the heat shield f to the rear cross member 21 Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose g and the water pump coolant hose h from the engine Dispose of engine coolant properly 22 Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current po...

Page 107: ...injury or damage to vehicle components 26 Remove the starter motor bolts 2 and starter motor from the engine 27 Remove the six transmission joint bracket bolts 2 and transmission joint bracket 2 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 engine stand adapte...

Page 108: ...to specification in sequence TORQUE 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 ...

Page 109: ...U 50658 A HOLE YEAR VEHICLE DESCRIPTION 1 2012 RZR 570 2 2011 14 RZR 900 2014 15 RZR XP 1000 2013 RANGER 900 3 2014 16 ACE 2015 16 ACE 570 2015 16 RGR ETX 2013 16 RZR 570 2014 16 RANGER 570 2015 16 RANGER 570 Full Size 4 2014 16 RANGER 900 2015 16 RZR 900 2016 RZR 1000 2016 ACE 900 5 2015 16 RANGER Diesel i e 2015 RZR 900 uses the holes marked with a 4 8 Loosen the two bolts t retaining transmissi...

Page 110: ...lant hoses onto the engine 17 Install front support bracket u and rear support i onto the vehicle frame Torque fasteners to specification 18 Install push rivet through heat shield o into rear cross member 19 Install the exhaust heat shield and push rivets 20 Replace exhaust gaskets seals Install exhaust head pipe Install the six fasteners that attach the exhaust head pipe to the engine and torque ...

Page 111: ...and cargo box as an assembly NOTE Be sure to connect the engine intake hose and clutch air intake hose to the rear cargo box asm upon installation 34 Connect the negative battery cable 35 Remove the pressure cap and fill the cooling system through the filler neck with properly mixed anti freeze coolant 36 Install a new oil filter Lubricate the seal with engine oil prior to installation see Chapter...

Page 112: ...3 34 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc ENGINE MOUNTING AND TORQUE VALUES ENGINE COOLING SYSTEM ...

Page 113: ... which has a minimum pump octane number of 87 R M 2 2 Refer to Engine Oil Level page 2 10 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 ...

Page 114: ...al e if oil leaks are evident 3 Remove the spark plugs r Stuff spark plug holes with shop towels to prevent 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 q an...

Page 115: ... engine using the flywheel and remove the remaining bolt from each camshaft sprocket 7 Lift the chain and sprockets off the camshafts to allow each sprocket to be removed 8 Using a paperclip or other tool hold cam chain up to keep it from falling down into the crankcase NOTE The crankcase has a built in lower guide to prevent the chain from falling off the crankshaft 9 Evenly loosen the four bolts...

Page 116: ...ad if worn beyond service limit or if any surface is pitted or damaged 1 Visually inspect each cam lobe for wear or damage 2 Measure the height of each cam lobe from the base circle to highest point on the lobe using a micrometer Compare to specification NOTE Replace camshafts if damaged or if any part is worn past the service limit MEASUREMENT Camshaft Lobe Height Intake 1 5390 1 5429 39 09 39 19...

Page 117: ... camshaft bore Torque bolts in sequence to specification Replace cylinder head if worn TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 6 Measure camshaft bore and compare to specifications NOTE Replace cylinder head if camshaft journal bores are damaged or if worn past the service limit MEASUREMENT Camshaft Carrier Bore I D 9055 9063 23 000 23 021 mm Service Limit 9072 23 044 mm 7 Calculate oil cleara...

Page 118: ...linder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 Refer to Cylinder Piston Removal page 3 58 CYLINDER HEAD WARP INSPECTION Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care not to damage gasket sealing surface All gasket surfaces must be clean dry and free of any oil or grease upo...

Page 119: ... of the bucket 2 Compress the valve spring by hand using valve spring compressor adapter PV 43513 A Valve spring compressor PV 1253 or PV 4019 Quick Release can be used if desired to aid in removal 3 Push down on spring and remove split keepers e 4 Slowly release valve spring pressure and remove the compressor adapter 5 Remove the valve retainer r valve spring t valve stem seal y and valve spring ...

Page 120: ...aring in the keeper seat area NOTE The valves can be re faced or end ground if necessary They must be replaced if extensively worn burnt bent or damaged 5 Measure diameter of valve stem with a micrometer in three places then rotate 90 and measure again take six measurements total Compare to specifications MEASUREMENT Valve Stem Diameter Intake 2155 2161 5 475 5 490 mm Exhaust 2147 2153 5 455 5 470...

Page 121: ...se a metal scraper a coarse wire brush or abrasive cleaners to clean the cylinder head Damage may result 2 Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage Pay close attention to areas around spark plug and valve seats VALVE SEALING TEST 1 Clean and dry the combustion chamber area q 2 Pour a small amount of clean solvent into each intake port w and check fo...

Page 122: ...t 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 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of th...

Page 123: ... the valve seat If too low use 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 poi...

Page 124: ...water based lapping compound to the face of the valve NOTE Lapping 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 re...

Page 125: ...he 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 q and output wires w If replacement is required refe...

Page 126: ...OVAL NOTE The water pump housing can be serviced with the engine installed in the chassis see Chapter 3 Water Pump Removal page 3 21 1 Remove the coolant lines 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 q retaining the water pump housing to the engine 3 Remove the water pump assembly from th...

Page 127: ...ywheel Puller PA 49316 e on the threads of the flywheel left hand thread turn flywheel puller counterclockwise to install 6 Hold puller body and tighten the center bolt to remove the flywheel Starter One Way Clutch Inspection NOTE The starter one way clutch can be serviced with the engine installed in the chassis 7 Remove the stator cover and flywheel see Chapter 3 Stator Cover Removal Inspection ...

Page 128: ...clutch retaining screws 3 Remove the one way clutch and inspect both sides of drive rollers q Inspect the roller contact surface w inside the hub for wear damage or uneven surface 4 Inspect drive surface of starter gear e and bushing r 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 ENGINE COOLING SYSTE...

Page 129: ... the oil filter 4 Install the Cylinder Holding Camshaft Timing Plate PU 50563 e onto the cylinder The cylinder holding 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 t and three M8 bolts y retaining the sump cover r to the crankcase 7 Remove the sump cover u from the crankcase 8 Remove and clean oil pump ...

Page 130: ... the 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 d 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 f during crankcase assembly NOTE Oil pump assembly is non serv...

Page 131: ...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 51 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 w and remove it from the crankcase 4 Inspect the balance shaft g...

Page 132: ...MAG PTO 1 4939 1 4946 37 946 37 962 mm Service Limit 1 4921 37 900 mm CRANKSHAFT REMOVAL INSPECTION 1 Perform Crankcase Disassembly Inspection page 3 51 procedure 2 Perform Balance Shaft Removal Inspection page 3 53 procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts q Remove the end caps from the crankshaft 5 Carefully li...

Page 133: ...w MEASUREMENT Crankshaft Maximum Runout Less than 001 0 025 mm 10 Visually inspect surface 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 i MAG End d Journal 4 Rod Bearing o...

Page 134: ...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 page 3 64 and Connecting Rod Bearing Selection page 3 64 procedures CRANKCASE INSPECTION 1 Remove the oil drain diverter q from the upper crankcase 2 Remove all traces of crankcase s...

Page 135: ...exceeds the service limit replace the cylinder MEASUREMENT Cylinder Warp Limit 002 0 05 mm 2 Inspect cylinder for wear scratches or damage NOTE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing 3 Inspect cylinder for taper and out of round with a dial bore gauge Measure in two different directions front to back and side to side on three levels 0 59 down from top the middl...

Page 136: ... the unique cylinder skirt and crankcase design 1 PerformENGINE DISASSEMBLY INSPECTION TOP END page 3 36 and ENGINE DISASSEMBLY INSPECTION BOTTOM END page 3 47 and the procedures 2 Rotate the engine so the cylinder is facing up 3 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 q from the cylinder 4 Carefully lift the cylinder and pistons from the upper crankcase 5 Remove the piston conn...

Page 137: ...he 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 Measure piston pin bore I D in two directions 90 apart Replace piston and piston pin if out of specification MEASUREMENT Piston Pin Bore I D 7877 7881 20 009 20 018 mm Service Limit 7893 20 05 mm 4 Measure piston pin O D in two dir...

Page 138: ...nd push up on opposite side Do not scratch ring lands 2 Repeat procedure for second compression ring w 3 The oil control ring e is a three piece design consisting of a top and bottom steel rail and a center expander section Remove top rail first then bottom rail then the expander PISTON RING TO GROOVE CLEARANCE INSPECTION 1 Measure piston ring to groove clearance q by placing the ring in the ring ...

Page 139: ...m Service Limit 1 6118 1 6122 40 942 40 950 mm Second Ring 1 6118 1 6122 40 942 40 950 mm Service Limit 028 0 70 mm Oil Control Rails 008 028 0 20 0 70 mm Service Limit 0354 0 9 mm NOTE Always check piston ring installed gap when installing new rings and or a new cylinder PISTON TO CYLINDER CLEARANCE Measure piston outside diameter at a point 10 mm q up from the bottom of the piston at a right ang...

Page 140: ...20 06 mm 5 Install matching rod cap on connecting rod without bearings and install the bolts 6 Tighten bolts snug then torque to 13 ft lbs 18 Nm 7 Using a dial bore gauge measure big end I D in two directions shown Record measurements and compare to specifications 8 Refer to the number stamped onto the exhaust side of the connecting rod This number represents the bore diameter 9 The table below li...

Page 141: ...IFICATION LETTERS AND NUMBERS q Connecting Rod Bearing Identification Number one number w Crankcase Bearing Identification Number six numbers Some engines may only have 4 digits The extra two digits will refer to the balance shaft bearings which should now all be standard e Crankshaft Bearing Identification Letters six letters ENGINE COOLING SYSTEM ...

Page 142: ... Rod Crankshaft Rod Code B G Y 1 Blue Blue Green 2 Blue Green Yellow 3 Green Yellow Yellow CRANKSHAFT MAIN BEARING SELECTION In order to select the proper main bearings for the crankshaft you must reference the six numbers on the crankcase i and match that up with the main journal letters on the crankshaft u In this example you would use the number 2 as the crankcase codes case journals 1 2 3 4 Yo...

Page 143: ...l paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before assembling the upper crankcase PISTON RING INSTALLATION NOTE Apply clean engine oil to all ring surfaces and ring lands upon installation Always check piston ring installed gap before rings are...

Page 144: ... second ring with marking facing top of piston Rotate ring to position the end gap toward intake side of piston as shown below 5 Install top ring with mark facing top of piston Rotate ring to position the end gap toward exhaust side of piston as shown below 6 Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand ENGINE COOLING SYSTEM ...

Page 145: ...necting 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 recommended they be installed with rods facing the same direction 3 Place piston q on connecting rod w Push piston pin e through rod and piston until it seats against the installed circlip NOTE Do not tap on pin ...

Page 146: ...ston see Chapter 3 Piston Ring Installation page 3 65 3 Note the piston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side NOTE Orientation arrow is also located on the bottom side of piston as an additional reference 4 Carefully compress the piston rings with your fingers and install the piston assemblies into the cylinder from the bottom side Use pisto...

Page 147: ...Chapter 3 Crankshaft Main Bearing Selection page 3 64 and Connecting Rod Bearing Selection page 3 64 1 Rotate the engine so the cylinder is facing down 2 Clean the bearing bore surfaces of upper crankcase main bearings connecting rods and connecting rod caps 3 Align tab of new main bearing q with the slot in main bearing bore of crankcase Press bearing insert firmly into place Repeat for all main ...

Page 148: ...shaft 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 rod to remove all oil 12 Install matching rod cap on connecting rod with 3 digit serial number stampings aligned w e 13 Install new bolts s and tighte...

Page 149: ...ways replace plain bearings when the crankcase or connecting rods have been disassembled Refer to bearing selection procedures 1 Remove all traces of crankcase sealant from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 2 Clean bolt hole threads to remove any oil or crankcase sealant 3 Inspect crankcase bearing bores Replace the crankcase assembly if a bearing...

Page 150: ... remove any oil 5 Apply a thin continuous film of Crankcase Sealant PN 2871557 to upper crankcase mating surface e as shown Do not allow sealant to dry before assembly NOTE DO NOT block oil passages r with crankcase sealant 6 Carefully place lower crankcase on upper case making sure the oil pump drive chain is fed through the lower crankcase 7 Tap lower crankcase with a rubber hammer to seat the c...

Page 151: ...Bolts 9 ft lb 12 Nm 11 Rotate the engine so the cylinder is facing up 12 Install the eleven M6 o and two M8 i 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 torque TORQUE Upper Crankcase Bolts M8 Bolts 26 ft lb 35 Nm M6 Bolts 9 ft lb 12 Nm 14 Rotate the engine so the cylinder...

Page 152: ...on TORQUE 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 free Use care upon assembly to keep oil away 21 Apply a thin continuous film of Crankcase Sealant PN 2871557 to sump cover mating surface g as shown Do not allow sealant to dry before assemb...

Page 153: ...8 Bolts 26 ft lb 35 Nm M6 Bolts 106 in lb 12 Nm 25 Install the crankcase drain plug if previously removed Torque drain plug to specification TORQUE Crankcase Drain Plug 12 ft lbs 16 Nm 26 Install the oil cooler l Use new O rings 1 upon installation Torque fasteners to specification TORQUE Oil Cooler bolts 7 ft lbs 10 Nm 27 Proceed to Flywheel Installation page 3 76 and then Cylinder Head Installat...

Page 154: ...ce damage is present Clean taper of crankshaft to remove all oil or grease 3 Using an applicator apply a 360 degree bead of Loctite 641 Yellow to the internal taper surface on the flywheel Apply Loctite bead 5 6 mm from the center of the taper offset to the larger diameter of the taper on the flywheel 4 Using an applicator apply a 360 degree bead of Loctite 641 Yellow to the external taper surface...

Page 155: ...g assembly 2 Install a new stator cover gasket over alignment pins 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 3 Install stator cover and thirteen screws Torque screws in sequence to specification TORQUE Stator Cove...

Page 156: ...ove 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 e and retainer r in clean engine oil 6 Install the valve spring with widely spaced coils y on the top and tightly spaced coils u facing down toward the cylinder head NOTE Valve springs to be installed with paint mark facing up i 7 Place the valve ret...

Page 157: ...cing up 2 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 q from 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 d...

Page 158: ...r to Camshaft Installation Timing page 3 80 1 Rotate the engine until the flywheel Top Dead Center TDC mark q is aligned or centered in the Crankshaft Position Sensor CPS mounting hole w 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 ...

Page 159: ...rly 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 sprocket marks with the valve cover gasket surface see Chapter 3 Camshaft Timing Quick Reference page 3 84 NOTE Intake ...

Page 160: ...he Cylinder Holding Camshaft Timing Plate PU 50563 from the end of the camshafts 16 Rotate the engine using the flywheel and install the remaining bolt in each camshaft sprocket Torque the sprocket bolts to specification TORQUE Camshaft Sprocket Bolts 14 ft lb 19 Nm 17 Rotate the engine using the flywheel and torque the remaining sprocket bolts to specification 18 Install the front camshaft carrie...

Page 161: ...rrier Bolts 7 ft lb 10 Nm 21 Apply Polaris PS 4 engine oil to the cam chain tensioner bore prior to assembly Use a new tensioner sealing washer d 22 Install the hydraulic cam chain tensioner s into the cylinder and torque to specification TORQUE Cam Chain Tensioner 29 ft lb 40 Nm 23 Rotate crankshaft through two revolutions and verify camshaft timing is correct ENGINE COOLING SYSTEM ...

Page 162: ...ING QUICK REFERENCE q Intake Cam r Align marks with surface w Exhaust Cam t CPS Mounting Hole e Align marks with surface y Align Flywheel Mark in Mounting Hole IMPORTANT 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 ENGINE COOLING SYSTEM ...

Page 163: ...afts Carrier openings should face each other when installed properly 5 Install the four bolts r that retain each rear camshaft carrier t and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 6 Rotate the camshaft until the cam lobes above the valves you are inspecting are facing up y 7 Measure the valve clearance u using a thickness feeler gauge Record the measu...

Page 164: ...propriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 14 Install the proper tappet NOTE Lubricate the outer portion of the valve tappet upon installation 15 Repeat steps 10 14 until all necessary valves have been adjusted 16 Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 f...

Page 165: ... 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 0 450 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 5...

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Page 167: ...tall spark plugs q and torque to specification 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Install valve cover seal w 5 Install the four valve cover shoulder bolts e and new isolators r using a T40 driver 6 Torque valve cover bolts to specification TORQUE Spark Plugs 7 ft lbs 10 Nm Valve Cover Bolts 7 ft lbs 10 Nm ENGINE COOLING SYSTEM ...

Page 168: ...ngine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Cam worn excessively Piston Failure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance Wet sumping Wor...

Page 169: ...ents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose impeller Thermistor failure Cooling fan inoperative or turning too slowly perform current draw test Low oil level Spark plug incorrect heat range Faulty hot light circuit Thermostat stuck closed or not opening completely Radiator is missing its internal diverter plate not allowing coolant to flow thr...

Page 170: ...3 92 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES ENGINE COOLING SYSTEM ...

Page 171: ...2 OPERATION OVERVIEW 4 12 FUEL INJECTOR TROUBLESHOOTING 4 12 FUEL INJECTOR TEST 4 13 FUEL INJECTOR REPLACEMENT 4 13 FUEL TANK 4 16 ASSEMBLY VIEW 4 16 FUEL LINE REMOVAL INSTALLATION 4 17 FUEL TANK REMOVAL 4 17 FUEL TANK INSTALLATION 4 20 FUEL TANK REMOVAL RZR XP 4 1000 4 21 FUEL TANK INSTALLATION RZR XP 4 1000 4 23 FUEL PUMP 4 24 OPERATION OVERVIEW 4 24 FUEL SENDER TEST 4 24 FUEL PUMP TEST 4 25 FUE...

Page 172: ...RE DETECTION 4 39 TROUBLE CODE DISPLAY ETC 4 39 EFI TROUBLESHOOTING 4 47 POLARIS DIGITAL WRENCH 4 48 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 48 SPECIAL TOOLS DIGITAL WRENCH 4 48 DIGITAL WRENCH SOFTWARE VERSION AND UPDATE ID 4 49 DIGITAL WRENCH UPDATES 4 49 DIGITAL WRENCH COMMUNICATION ERRORS 4 50 DIGITAL WRENCH DIAGNOSTIC CONNECTOR 4 50 GUIDED DIAGNOSTICS 4 51 DIGITAL WRENCH SERIAL NUMBER LO...

Page 173: ... relieved The Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure once you have completed the fuel pressure test Fuel Pressure Gauge Adapter PV 48656 Digital Wrench Diagnostic Software PU 47063 B This dealer only software installs on laptop computers equipped with a CD drive and is designed to replace multiple shop tools often used to test EFI com...

Page 174: ...please visit the website www polaris diagsys com TORQUE SPECIFICATIONS ITEM TORQUE VALUE CPS Retaining Bolt 9 ft lb 12 Nm ECU Retaining Screws 24 in lb 3 Nm ETC Housing Retaining Bolts 7 ft lb 10 Nm Fuel Rail Mounting Screw 44 in lb 5 Nm Fuel Tank PFA Nut 70 ft lbs 95 Nm Fuel Tank Strap Screws 8 ft lbs 11 Nm Intake Duct Clamps 35 in lb 4 Nm Intake Manifold Mount Screw lower 22 ft lb 30 Nm Oxygen S...

Page 175: ...ith plastic 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 ...

Page 176: ...BLY VIEW q Electronic Control Unit ECU u Fuel Pump Regulator w Crankshaft Position Sensor CPS i Fuel Level Sender e Engine Coolant Temperature Sensor ECT o Fuel Filter r Dual Throttle Body Assembly a Fuel Supply Line t Fuel Injectors s T MAP Sensor y Fuel Rail Regulator d Electronic Throttle Control FUEL SYSTEM ...

Page 177: ...de of the throttle body assembly Crankshaft Position Sensor CPS e Located on top of the stator cover Temperature and Manifold Absolute Pressure TMAP Sensor r Located on the Mag side of the throttle body Engine Coolant Temperature Sensor ECT t Located on the left side of the thermostat housing The sensor can be accessed with the air box assembly removed Dual Throttle Body Assembly y Located between...

Page 178: ...U Engine Coolant Temperature 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 Temperature and Manifold Pressure Sensor TMAP 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 igni...

Page 179: ...very and ignition timing based on these values During operation the ECU has the ability to re adjust temporarily providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a richer air fuel ratio is automatically calculated by the ECU I...

Page 180: ...CU is operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit is exceeded the ECU suppresses the injection signals cutting off the fuel flow and retards the ignition timing This process repeats it self in rapid succession limiting operation to the preset maximum RPM Limit R...

Page 181: ...ou should hear a click when the connector is fully closed TORQUE ECU Retaining Screws 24 in lb 3 Nm ETC LEARN PROCEDURE IMPORTANT This procedure MUST be performed on the vehicle whenever the ECU is replaced or reflashed or the throttle body is replaced 1 After the reflash ECU replacement throttle body change leave the key on engine not running for 60 seconds Do NOTcrank the engine during this time...

Page 182: ...l 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 fuel injecto...

Page 183: ...suring between the two pin terminals w 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 10 Cargo Box Assembly Removal page 10 22 2 Be sure the engine has cooled enough to work on 3 Loo...

Page 184: ...ve the two screws y that mount the fuel rail to the throttle body using a 5 mm Allen wrench 9 Carefully pull up on the fuel rail u and injectors and remove them from the throttle body as an assembly Take care 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 neces...

Page 185: ... lead to the MAG injector to ensure proper engine operation 18 Use a tie strap to retain the harness leads to the fuel rail 19 Reconnect 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...

Page 186: ... XP4 1000 Service Manual Copyright Polaris Industries Inc FUEL TANK ASSEMBLY VIEW q PFA Nut t Preliminary Filter w Fuel Sender Float Arm y Fuel Tank Vent e PFA Gasket replace if removed u Fuel Tank Assembly r Fuel Pump Regulator FUEL SYSTEM ...

Page 187: ...MOVAL NOTE Syphon 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 ...

Page 188: ...sm to the frame 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 y 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 u and two T40 Torx screws ...

Page 189: ...side of the seat base frame as well 11 Remove the Torx screws s and plastic rivets d retaining the block off panel using a T40 Torx driver Remove the panel from the vehicle 12 Remove the nuts f retaining the regulator and Torx screws g 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 ve...

Page 190: ...lator and fuse box to the block off panel Torque fasteners to specification TORQUE Regulator Fuse Box fasteners 5 ft lb 7 Nm 7 Install fuel tank strap screw Torque screw to specification TORQUE Fuel Tank Strap Screw 8 ft lbs 11 Nm 8 Reinstall center console shift knob and screws 9 Reinstall seat belt mechanism Torque bolt to specification TORQUE Seat Belt Mechanism Bolt 40 ft lbs 54 Nm 10 Reinstal...

Page 191: ...ee Chapter 2 Fuel Lines page 2 20 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 w 5 Remove the right hand rocker panel see Chapter 10 6 Remove the fastener e retaining the seat belt mechanism to the frame near the right rear portion of the fuel tan...

Page 192: ...i retaining the lower rear close off panel using a T40 Torx driver Remove the panel from the vehicle 11 Remove the nuts o retaining the regulator and bolts a retaining the fuse box 12 Remove the fuel tank vent line s from the tank fitting 13 Lift the rear of the fuel tank up first Carefully pull the fuel tank out of the vehicle FUEL SYSTEM ...

Page 193: ...all regulator and fuse box to the block off panel Torque fasteners to specification TORQUE Regulator Fuse Box fasteners 5 ft lb 7 Nm 7 Install fuel tank strap screw Torque screw to specification TORQUE Fuel Tank Strap Screw 8 ft lbs 11 Nm 8 Reinstall rear and front center console shift knob and screws 9 Reinstall seat belt mechanism Torque bolt to specification TORQUE Seat Belt Mechanism Bolt 40 f...

Page 194: ...tches off the pump preventing the continued delivery of fuel in these instances If the key switch is not promptly turned to the start position If the engine fails to start If the engine is stopped with the key switch on as in the case of an accident In these situations the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine is runni...

Page 195: ... and check the system pressure on the gauge If system pressure of 58 2 psi 400 14 kPa is observed the ignition switch ECU fuel pump and pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure Fuel Pressure 58 2 psi 400 14 kPa NOTE If the fuel pressure is out of specification replace the fuel pump assembly 6 If the pu...

Page 196: ...moved WARNING Failure to clean area around fuel pump may lead to debris entering the fuel tank during service Excessive debris in fuel tank may cause premature wear of fuel pump and or clogging of internal fuel filters 4 Ensure that static has been discharged by touching a ground source such as the engine or frame 5 While holding a shop towel over the fuel line connectors disconnect the fuel suppl...

Page 197: ...m and pump pre filter Hold the float arm to the pump body as you lift and tilt the pump to ensure that the float arm is not bent when removed from the tank 9 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 10 Inspect the inside of the fuel tank for debris may require flashlight and mirror If debris like mud or sand is present fuel t...

Page 198: ...e to align the orientation marks may lead to interferences with the fuel level float armand cause incorrect function 17 While maintaining downward pressure thread new PFA nut onto fuel tank and hand tighten Use care when starting PFA nut ensuring threads are properly aligned Verify orientation marks are still aligned between fuel pump and fuel tank 18 Torque PFA nut to specification using the Fuel...

Page 199: ...4 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 4 29 FUEL SYSTEM ...

Page 200: ...se sensor signals comprised of separate intake air temperature and manifold absolute pressure readings are processed by the ECU and compared to its programming for determining the fuel and ignition requirements during engine operation The T MAP provides the ECU with engine load data T MAP TEST REPLACEMENT The T MAP is a non serviceable item and can only be tested using Digital Wrench If the sensor...

Page 201: ...evolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS TEST The CPS is a sealed non serviceable assembly If fault code diagnosis indicates a problem with this sensor test as follows 1 Locate the CPS harness connector above the transmission on the RH side of the vehicl...

Page 202: ...age 4 31 2 Using an 8mm socket remove the CPS retaining bolt q and remove the sensor w from the stator cover 3 Unclip the wire harness retainer e and remove the CPS harness from the retainer to allow replacement 4 Install new sensor using a light coating of oil on the O ring to aid installation 5 Torque the CPS retaining bolt to specification TORQUE CPS Retaining Bolt 9 ft lb 12 Nm FUEL SYSTEM ...

Page 203: ...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 Control Unit ECU THR...

Page 204: ...e body assembly 7 Loosen the two hose clamps y that retain the dual throttle body assembly u to the intake adapters Carefully lift the throttle body assembly out of the intake adapters 8 Remove the two screw retaining the fuel rail to the throttle body Lift the fuel rail and injectors out of the throttle body assembly taking care not to damage the fuel injector ends NOTE It is not necessary to dis...

Page 205: ...oltage at pedal for supply line Troubleshoot wiring 3 Check the pedal for sensor physical damage circuit fault Troubleshoot pedal 1 and 2 vs each other depending on faults ETC REPLACEMENT 1 Remove the cargo box access panel 2 Remove wire harness from the ETC q 3 Remove the four bolts retaining the ETC housing to intake plenum 4 Remove the ETC housing and gasket from intake plenum 5 Reverse these s...

Page 206: ...ted utilizing Digital Wrench by verifying that throttle position readout varies as the pedal is pressed There should not be any dead spots in the reading if using the graph mode in Digital Wrench Reference the Data Display section and be sure Throttle Position is displayed With the ignition key on for at least 15 seconds and engine not running the Throttle Position will read approximately 13 when ...

Page 207: ...ehicle ETC Installation 5 Place the throttle pedal assembly on the mounting studs and loosely install the three fasteners 6 Torque the three mounting bolts to specification and connect the PPS harness connection TORQUE Throttle Pedal Mounting fasteners 18 ft lb 24 Nm 7 Manually cycle the throttle pedal to verify the throttle pedal moves freely 8 Connect the negative battery cable and install the d...

Page 208: ...rench First verify if there are any stored codes for the oxygen sensor NOTE The ECU must first run though the O2 sensor time delay before a trouble code will be set This may take several minutes at idle to occur Short drive cycles and cold temperatures will both affect the delay time of the O2 sensor increases the delay The delay time ensures the oxygen sensor heater has run long enough to provide...

Page 209: ...ndition is met the check engine light will turn off and the code s will show as historic If a misfire code has been set and there is no observed misfire cycle the key and allow 4000 engine revolutions to see if the check engine light turns off If it does not turn off diagnose by verifying the following items Ignition Coil and connections are good Spark plugs wires are secure The correct spark plug...

Page 210: ... 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 one code exists press the MODE button to advance to the next trouble code 5 To exit the diagnostic mode press and hol...

Page 211: ...8 Voltage Above Normal 3 P1507 Voltage Below Normal 4 P1506 Abnormal Frequency or Pulse Width 8 P0501 Abnormal Update Rate 9 P160A Abnormal Rate of Change 10 C1068 C1705 Bad Intelligent Device 12 P3503 Received Vehicle Speed Has Error 19 P106B C1069 Accelerator Position 1 Not Plausible 91 2 P0225 Voltage Too High 3 P0228 Voltage Too Low 4 P0227 Fuel Level Signal Voltage Above Normal 96 3 Voltage B...

Page 212: ...gets the engine speed from the ECM Valid But Above Normal 190 0 P0219 C1059 Valid But Below Normal 1 C1060 Data Erratic or Intermittent 2 C1061 Mechanical System Not Responding 7 P1219 Received Engine Speed Has Error 19 C1066 Error in Engine Speed Computation 31 P121C Engine Speed Error in Engine Speed Computation 400 31 P121D Gear Sensor Signal Date Erratic or Intermittent 523 2 P0914 Voltage Abo...

Page 213: ... 1347 3 P0232 Driver Circuit Grounded 4 P0231 Driver Circuit Open Grounded 5 P0230 Oxygen Sensor 1 Data Erratic Intermittent or Incorrect 3056 2 P0130 Voltage Above Normal or Shorted to High Source 3 P0132 Voltage Below Normal or Shorted to Low Source 4 P0131 Bad Intelligent Device 12 P113A ECU Output Supply Voltage 1 Valid But Above Normal 3597 0 P16A3 Valid But Below Normal 1 P16A6 Voltage Too H...

Page 214: ...ensor Heater 1 Data Erratic or Intermittent 520209 2 P0135 Voltage Above Normal or Shorted to High Source 3 P0032 Voltage Below Normal or Shorted to Low Source 4 P0031 Current below Normal or Open Circuit 5 P0030 Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050 Steering Excessive Current Error Current Above Normal or Grounded 520222 6 C1051 Steering Torque Partial Fa...

Page 215: ...tion 13 P1304 Idle Air Control Valve IAC M17 IAC Stepper Pin 1 Driver Circuit Short to B 520271 3 P1509 Driver Circuit Grounded 4 P1508 Driver Circuit Open Grounded 5 P1505 Mechanical System Not Responding 7 P1549 Out Of Calibration 13 P1301 Accelerator Position Brake Position Interaction Condition Exists 520275 31 P150A Throttle Position Sensor 1 or 2 Indeterminable Position Sensor Correlation Fa...

Page 216: ...evel 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 Angle Not Plausible Condition Exists 520305 31 P1530 ECU Analog to Digital Converter Fault No Load Condition Exists 520306 31 P1531 ECU Analog to Digital Converter Fa...

Page 217: ...formance 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 fi...

Page 218: ...Analyze real time engine data Reflash ECU calibration files Perform guided diagnostic procedures Create customer service account records Perform output state control tests some models SPECIAL TOOLS DIGITAL WRENCH 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...

Page 219: ...is available 3 If a newer update is available it should be downloaded before using Digital Wrench see Chapter 4 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 web...

Page 220: ...r 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 q Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble the Sma...

Page 221: ...dition guided diagnostics are also available for many other electrical sub systems Diagnostic procedures are added to subsequent versions of Digital Wrench as they become available Check your release version often and upgrade when available to be sure you are using the most current software available DIGITAL WRENCH SERIAL NUMBER LOCATION Open the configuration screen by clicking on the wrench icon...

Page 222: ...iew sensor and ECU information in a grid meter or chart format Enter customer and vehicle information and view ECU Identification View information from the main ECU sensors Load the Vehicle Home Page Set up data capture and record functions Open the Software Configuration Screen Perform specialized testing and adjustment functions service reports Run the Help System Open the ASSERT ASK form Prints...

Page 223: ... run Replacement ECUs are programmed as no start and require a reflash for them to work Reprogramming Reflash Tips BATTERY VOLTAGE The majority of problems with reprogramming can be attributed to a low battery Be sure the battery voltage no load is at least 13 volts and at least 12 5 volts with the key ON Connect a battery charger if necessary to bring voltage level above minimum Fully charge the ...

Page 224: ... 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 the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required o...

Page 225: ...An Authorization Key will appear in the upper left corner of the screen Copy this key exactly as it appears 13 Enter or paste the Authorization Key in the box located on the Digital Wrench screen Click the Continue button and follow instructions provided on the screen to complete reprogramming procedure 14 At this point the reflash process will begin Do not touch the vehicle or PC during the proce...

Page 226: ...d Tap on the link to download the app Android Device Minimum Specifications Minimum operating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred Dual core processor 2 GB internal memory external microSD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video Microphone and Voice to text capable Internet and Bluetoot...

Page 227: ...7 PVT SYSTEM SERVICE 5 8 PVT COVERS AND DUCT COMPONENTS 5 8 2015 XP XP4 PVT COVERS AND DUCTING COMPONENTS 5 9 PVT COVERS AND DUCTING COMPONENTS HIGH LIFTER 5 10 PVT DISASSEMBLY 2014 2015 5 11 PVT ASSEMBLY 5 12 PVT DISASSEMBLY 2016 5 14 PVT ASSEMBLY 2016 5 15 DRIVE BELT 5 17 BELT REMOVAL 5 17 BELT INSPECTION 5 18 BELT INSTALLATION 5 18 PVT BREAK IN DRIVE BELT CLUTCHES 5 18 DRIVE CLUTCH SERVICE 5 19...

Page 228: ...5 32 CLUTCH BUSHING REMOVAL 5 33 CLUTCH BUSHING INSTALLATION 5 34 DRIVEN CLUTCH ASSEMBLY 5 34 DRIVEN CLUTCH ASSEMBLY VIEW 5 37 DRIVEN CLUTCH SERVICE 2016 5 38 DRIVEN CLUTCH SLIDER INSPECTION 5 38 DRIVEN CLUTCH DISASSEMBLY 5 38 DRIVEN CLUTCH ASSEMBLY 5 40 ASSEMBLY VIEW 5 42 TROUBLESHOOTING 5 43 TROUBLESHOOTING 5 43 PVT SYSTEM ...

Page 229: ...nner 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...

Page 230: ...000 0 1800 0 6000 26 65 1323260 1800 3700 6000 12000 26 59 1322981 2016 XP4 1000 0 1800 0 6000 29 68 5139618 Black white lettering 7044506 1800 3700 6000 12000 26 59 bushed 1322981 2015 2016 RZR XP 1000 HIGH LIFTER CLUTCH CHART MODEL ALTITUDE METERS FEET SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 2015 RZR XP High Lifter 0 1800 0 6000 26 65 5139758 White Orange 7043924 Red 3234452 2016 RZR XP High Lif...

Page 231: ...tched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning DRIVE CLUTCH OPERATION Drive clutches primarily sense engine RPM The two major comp...

Page 232: ... operating at slower speeds during the 10 hours as recommended see Chapter 3 Engine Break In Period page 3 35 for break in example Avoid aggressive acceleration and high speed operation during the break in period After installation of a new drive belt break in new drive belts by operating at slower speeds during the break in period 50 miles Carry only light loads Avoid aggressive acceleration high...

Page 233: ...l and 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 t...

Page 234: ...ND DUCT COMPONENTS q CLUTCH DUCT INTAKE ASSEMBLY s BRACKET COVER GUARD w CLAMP WORM d AIR INLET DUCT e DECAL CAUTION f SCREW r BOLTand WASHER g SCREW t COVER ASSEMBLY OUTER h NUT NYLOK y O RING j BRACKET BELT SCREEN u DRAIN PLUG COVER k HOSE AIR OUTLET i SEAL COVER l INTAKE BOOT o SCREW 1 SEAL COVER a COVER ASSEMBLY PVT SYSTEM ...

Page 235: ...S q Inlet Duct a Outer Cover Seal w Band Clamp s Inner Cover Seal e Intake Hose d Guard Plate r Boot f Outlet Duct Screen t Clutch Outlet Duct g Intake Hose Bracket y Inlet Duct h Outer Cover Screws 8 ft lbs 11 Nm u Outlet Duct j Clutch Cover Drain Screw i Outer Clutch Cover k Inner Cover Screws 8 ft lbs 11 Nm o Inner Clutch Cover PVT SYSTEM ...

Page 236: ...t Duct w Band Clamp d Retaining Bracket Upper Exhaust Hose e Upper Intake Hose f Inner Cover Seal r Upper Exhaust Hose g Inner Clutch Cover t Middle Intake Hose h Guard Plate y Lower Intake Hose j Inner Clutch Cover Screw 7 u Lower Exhaust Hose k Outer Cover Seal i Outlet Duct l Outer Clutch Cover o Inlet Duct 1 Outer Clutch Cover Screw 8 a Boot 2 PVT Drain Screw PVT SYSTEM ...

Page 237: ...tch cover screws w and remove the outer clutch cover from the vehicle 8 Mark the drive belt direction of rotation and remove drive belt see Chapter 5 Belt Removal page 5 17 9 Remove the driven clutch retaining bolt and driven clutch CAUTION Do not strike the driven clutch to free it from the transmission input shaft This will damage the clutch 10 Install the Drive Clutch Holding Tool on the drive ...

Page 238: ...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 seal q engine side Replace if cracked torn or damaged 4 Apply silicone around all seven screw holes on the inner clutch cover IMPORTANT DO NOT apply silicone on drive and driven s...

Page 239: ...5 ft lb 75 Nm 12 Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch 13 Install the drive clutch onto the engine 14 Install the Drive Clutch Holding Tool 9314177 A and torque the retaining bolt to specification TORQUE Drive Clutch Retaining Bolt 96 ft lb 130 Nm 15 Install the drive belt noting direction of belt rotation see Chapter 5 Belt Installation page 5 1...

Page 240: ...lutch cover screws w and remove the outer clutch cover from the vehicle 8 Loosen the hose clamps e attaching PVT inlet and outlet ducts to the clutch cover Disengage the hoses from the clutch cover and remove the outer cover from the vehicle 9 Mark the drive belt direction of rotation and remove drive belt see Chapter 5 Belt Removal page 5 17 10 Remove the driven clutch retaining bolt and driven c...

Page 241: ... Make note of the routing of the fuel lines vent line battery cable and wire harness for proper assembly 14 Remove the seven bolts r that retain inner clutch cover to engine and transmission Remove inner clutch cover PVT ASSEMBLY 2016 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 seal q ...

Page 242: ...orque to specification TORQUE 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 TORQUE Drive Clutch Retaining Bolt 96 ft lb 130 Nm 14 Install the drive belt noting directi...

Page 243: ...tward as shown below to access the drive belt NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement 3 Mark the drive belt direction of rotation so that it can be installed in the same direction 4 Insert clutch spreader tool w 2877408 or 2878925 into the driven clutch as shown tool included with vehicle s tool kit NOTE Make sure the tool is square with the moveabl...

Page 244: ...t was removed 1 With the clutch spreader tool installed w 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 spreader tool from driven clutch 4 Rotate spin the driven clutch and belt approximately 5 7 times to properly seat the belt in the driven clutch 5 Install the outer clutch cover a...

Page 245: ...5 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 5 19 DRIVE CLUTCH SERVICE DRIVE CLUTCH ASSEMBLY VIEW PVT SYSTEM ...

Page 246: ...he clutch 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 q 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 Refe...

Page 247: ...he spring is subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair Check to see that spring coils are parallel to one another using a straight edge Distortion of the spring indicates stress fatigue requiring replacement NEEDLE BEARING INSPECTION 1 Rotate the clutch bearing in both clockwise and counter clockwise directions Th...

Page 248: ...ree with new bolts and nuts WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Drive Clutch Roller Pin and Button Service BUTTON TO TOWER CLEARANCE INSPECTION 1 Inspect the button to tower clearance as shown Replace the drive c...

Page 249: ...ding Fixture PN 2871358 A 2 Loosen and remove the spider e counterclockwise using Clutch Spider Removal Installation Tool r Spider Removal Installation Tool 2870341 ROLLER PIN AND THRUST WASHER INSPECTION 1 Inspect all rollers roller bushings and roller pins by pulling a flat metal rod across the roller 2 Turn roller with your finger If you notice resistance galling or flat spots replace the drive...

Page 250: ...ust washers w off the shaft Replace as an assembly if worn damaged or if operational problems were noted prior to disassembly 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged MEASUREMENT Shaft Diameter Standard 1 3725 1 3712 34 8615 34 8488 mm Service Limit 1 3704 34 808...

Page 251: ...d 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 Tools QTY PART TOOL DESCRIPTION 1 2871226 Clutch Bushing Replacement Tool Kit 1 2870386 Piston Pin Puller Clutch Bushing Replacement Tool Kit PN 2871226 ...

Page 252: ...ston Pin Puller PN 2870386 3 Remove nut from puller rod and set aside 4 Install puller adapter a from kit PN 2871226 5 Install main adapter Item D onto puller 6 With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave NOTE Use Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn p...

Page 253: ...to increase tension as needed 27 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 28 Remove nut from puller rod and set aside 29 Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 30 Apply Loctite 648 evenly to bushing bore in the cover 31 Working from inside of cover insert new bushing and bushing installati...

Page 254: ... i are in alignment t Moveable Sheave Asm y Jam Nut u Spider 6 Install clutch onto holding fixture and secure in a bench vice Tighten the spider o using Clutch Spider Tool a Torque spider to specification Clutch Holding Fixture 2871358 A Clutch Spider Tool 2870341 TORQUE 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 ...

Page 255: ...e 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 f and the clutch spring g CAUTION DO NOT reassemble the drive clutch without the limiter spacer Belt life will be greatly reduced 11 Install the drive clutch cover h Be sure al...

Page 256: ...e helix side NOTE If driven clutch is difficult to remove use 2871056 Driven clutch puller to remove driven clutch 2 It is important to mark the position of the shaft cam cover and sheave with a grease marker or tape 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 w that secure the cam helix assembly ...

Page 257: ...bly r and spring NOTE Spring is compression only and has no torsional wind 7 Remove the inside spider plate t and spider dampener y Inspect the spider dampener for wear and replace if needed 8 Remove the E clips u washers i and the clutch rollers o Inspect the rollers for wear replace if worn 9 Remove the clutch assembly from the holding tool 10 Press out the spring pins a in the inner sheave 11 P...

Page 258: ... assembly bushing h for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam helix assembly 15 Inspect the sheaves for excessive wear or damage DRIVEN CLUTCH BUSHING SERVICE NOTE Special Tools Required for this service Special Tools PART TOOL DESCRIPTION 2201379 Clutch Bushing Tool Kit see breakdown below 2870386 Piston Pin Puller 2871226 Clutch Bushing Repla...

Page 259: ...he area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing CLUTCH BUSHING REMOVAL 1 Remove the driven clutch as previously outlined 2 Install the handle end of the Piston Pin Puller securely into the bench vise and lightly grease puller threads Piston Pin Puller 2870386 3 Remove nut from piston pin puller rod and set aside 4 Install main puller adapter...

Page 260: ... puller 3 Apply Loctite 648 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller 5 Install new bushing on installation tool w and install assembly into sheave 6 Install left hand thread nut onto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 8 ...

Page 261: ...ether 4 Install the rollers e onto the roller pins r and install on the clutch 5 Install the roller pin into the sheave assembly on both sides The flat side of the roller pin faces towards the sheaves 6 Install the spring pins t to secure the roller pins Install until flush with sheave surface 7 Install the spring over the shaft 8 Install the clutch rollers y onto each side of the spider Install t...

Page 262: ...sure the skip tooth on the shaft and the spider are aligned Once the spider passes the retaining ring notch on the shaft install the retaining ring s 14 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are al...

Page 263: ...yright Polaris Industries Inc 5 37 DRIVEN CLUTCH ASSEMBLY VIEW q Snap Ring i Spring w Bearing o Spider Insert e Stationary Sheave a Spider Dampener r Pin s E Clip t Roller d Washer y Moveable Sheave f Helix Cam u Clutch Shaft g Helix Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 264: ...the transmission input shaft 2 It is important to mark the position of the helix cover sheaves and spider with a tape or grease marker as shown before disassembly Some components will have X s on the components for alignment reference This helps with clutch assembly and maintains clutch balance 3 Place the driven clutch helix side up into the Universal Clutch Compressor Universal Clutch Compressor...

Page 265: ...lips r washers t and the clutch rollers y Inspect the rollers for wear replace if worn 8 Press out the spring pins u in the inner sheave 9 Pull out the clutch slider pins i and sliders o 10 Separate the stationary sheave from the moveable sheave Note the X s a on the stationary and fixed sheaves for reassembly 11 Inspect the clutch bushings for wear If there is heavy wear on the bushings replace t...

Page 266: ... square sliders w and slider pins e 3 Install the spring pins r to retain the slider pins 4 If removed install the rollers t washers y and E clips u onto the spider 5 Install the spring so the arm i rests into the notch in the moveable sheave 6 Align the X s o on the spider and moveable sheave 7 Install the universal clutch compressor on the clutch and compress the helix cover PVT SYSTEM ...

Page 267: ...y or damage to the clutch 8 Align the marks previously made on the helix cover and moveable sheave Install the helix cover and the four fasteners a Torque fasteners to specification TORQUE Helix Retaining Screws 48 in lb 5 Nm 9 Once back together verify the grease tape marks made during disassembly are properly aligned 10 Install the drive clutch on the vehicle See PVT Assembly 2016 page 5 15 PVT ...

Page 268: ...ce Manual Copyright Polaris Industries Inc ASSEMBLY VIEW q Shoulder Sleeve i Spring w Bearing o Spider e Spring Pin a Roller r Slider s Washer t Slider Pin d E clip y Stationary Sheave f Helix Cam u Moveable Sheave g Helix Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 269: ...ooved Replace the clutch Engine RPM above specified operating 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 ent...

Page 270: ...lined 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 no...

Page 271: ...TMENT 6 4 TRANSMISSION SERVICE 6 6 TRANSMISSION REMOVAL 6 6 TRANSMISSION INSTALLATION 6 9 TRANSMISSION DISASSEMBLY 6 12 DIFFERENTIAL OPERATION TURF MODE MODELS ONLY 6 16 PLANETARY DIFFERENTIAL DISASSEMBLY TURF MODE MODELS ONLY 6 18 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT TURF MODE MODELS ONLY 6 19 PLANETARY DIFFERENTIAL ASSEMBLY TURF MODE MODELS ONLY 6 22 GEAR SHAFT BEARING INSPECTION 6 23 TRAN...

Page 272: ...UE Bell Crank Nut 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 Rear Transmission Mount Bracket Fasteners 17 ft lb 23 Nm Snorkel Tube Refer to Snorkel Gear Backlash Procedure page Snorkel Tube Locking Screw 10 ft lb 14 Nm Shift Cable...

Page 273: ...6 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 6 3 TRANSMISSION MOUNTING AND TORQUE VALUES TRANSMISSION ...

Page 274: ...ve both bushings u from the shift lever and service as needed SHIFT LEVER INSTALLATION Perform the removal steps in reverse order to install the gear shift lever lever cable console 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 Exces...

Page 275: ... HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount Tighten the lower jam nut against the mount 7 Start engine and shift through all gears to ensure the shift cable is properl...

Page 276: ...om the transmission output shaft see Chapter 7 Rear Prop Shaft Removal page 7 28 3 Remove both rear lower shock bolts and swing shocks outward 4 Remove left sway bar end link lower fasteners from the trailing arm 5 Remove the PVT system from the vehicle see Chapter 5 PVT Disassembly 2016 page 5 14 NOTE CAUTION Be sure to use the correct Drive Clutch Puller to prevent damage to crankshaft Drive Clu...

Page 277: ...fts out of the vehicle frame Reinstall the lower shock bolts e to hold the trailing arms up during the rest of the removal procedure 10 Remove vent hose from transmission 11 Remove the gear position switch connector y speed sensor connector t crankshaft position sensor connector r shift bracket bolts and shift bracket u shift cable clevis pin and washer i from the transmission 12 Remove the wire t...

Page 278: ... the transmission to the engine 16 Remove the two fasteners s attaching the rear transmission mount bracket assembly to the frame Remove the fasteners d that attach the rear mount to the transmission Remove the mount assembly from the vehicle 17 Slide transmission towards the rear of the vehicle Lift and rotate the top of the transmission towards the left side of the vehicle With the help of an as...

Page 279: ...ue nuts to specification TORQUE Rear Transmission Mount Bracket Fasteners q 17 ft lb 23 Nm 4 Install M10 bolt and nut securing the transmission bracket to the rear mount Torque fasteners to specification TORQUE Rear Transmission Isolator Fasteners w 40 ft lb 54 Nm 5 Install the two rear exhaust springs securing the muffler to the rear transmission mounting bracket 6 Install the Clutch Center Dista...

Page 280: ...upler 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 NOTE DO NOT torque fasteners at this time 10 Torque left side mounting bolts to specification in sequence 11 Torque righ...

Page 281: ...stallation page 7 29 19 Install fasteners retaining the intake manifold lower mount to the transmission bracket Torque fasteners to specification TORQUE Intake Manifold 22 ft lb 30 Nm 20 Install inner clutch cover outlet duct drive clutch driven clutch belt and outer clutch cover see Chapter 5 PVT Assembly 2016 page 5 15 21 Install new spring ring a on rear drive shafts Apply an anti seize compoun...

Page 282: ...ty INT L 40 5 oz 1200 mL TRANSMISSION DISASSEMBLY NOTE Refer to the exploded view at the end of this chapter as a reference 1 Place transmission in High gear before disassembly 2 Drain and properly dispose of the transmission lubricant see Chapter 2 3 Remove the bell crank nut q and bell crank w 4 Remove E clip e that retains spring and flat washers r and gear switch t Remove the switch 5 Remove t...

Page 283: ...ve the cover using the designated pry points indicated by the black arrows in the illus tration below CAUTION Do not pry on case sealing surfaces Use only the designated pry points on the transmission 12 Lift up on the shift shaft rail j and move the rail assembly rearward to allow the shift fork pins k to be removed from the shift drum l Remove the shift drum from the transmission housing 13 Remo...

Page 284: ...g Note the longer screw 2 that locks the snorkel tube 18 Remove all seals from the gearcase halves and clean the cases in preparation for assembly Gear Cluster Disassembly 19 Remove the bearing from the reverse shaft using a bearing puller Remove the retaining ring and slide the washers high gear and needle bearing off the reverse shaft q Bearing y Needle Bearing w Reverse Shaft u Engagement Dog e...

Page 285: ...hift shaft rail remove the snap ring 2 from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compressed springs on the shift rail may pop off causing 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 s...

Page 286: ...om the snorkel shaft DIFFERENTIAL OPERATION TURF MODE MODELS ONLY Transmissions equipped with Turf Mode have two traction operational modes Differential Lock and Differential Unlock Locking the rear differential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain When Differential Unlock is selected the...

Page 287: ...tighter turns When Differential Lock is selected power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift fork back into place and mates the engagement dog to the side gear that is part of the planetary differential assembly This locks the rear differential as a solid rear axle increasing traction TRANSMISSION ...

Page 288: ... prior to disassembly 2 Remove the six screws retaining the differential cover and remove the cover 3 Remove the six planet gears and each side gear assembly from the ring gear 4 Inspect the female side gear A male side gear B planet gears C and ring gear D Replace components or bushings as needed Bushing replacement can be performed on all necessary differential components If bushing replacement ...

Page 289: ...Disassembly procedure Ring Gear Bushing Replacement 1 Press the old bushing out of the ring gear 2 Thoroughly clean the bore of the ring gear and check for any unwanted burs 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 ...

Page 290: ...ntial 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 damag...

Page 291: ...6 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 6 21 14 Press the new bushing into the side gear until it bottoms out TRANSMISSION ...

Page 292: ...erential components 2 Assemble the side gears and place them onto the ring gear along with the six 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 TORQUE Differential Cover Screws 22 ft lb 30 Nm TRANSMISSION ...

Page 293: ...6 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 6 23 GEAR SHAFT BEARING INSPECTION TRANSMISSION ...

Page 294: ...kel shaft flush to the shoulder install the washer and new retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly NOTE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium g...

Page 295: ...cover retaining screws 9 Using a 5 mm Allen wrench install only the three screws h that secure the pinion shaft assembly as shown below Leave the longer locking screw j out at this point Torque the bearing cover retaining screws to specification TORQUE Bearing Cover Retaining Screws 10 ft lb 14 Nm IMPORTANT DO NOT install the longer screw Installing the longer screw will lock the snorkel tube and ...

Page 296: ...l If the pinion shaft gear lash appears to be too tight rotate the snorkel shaft clockwise to the next notch 4th notch 14 Once the backlash is set apply Loctite 242 to the threads and install the locking screw to secure the snorkel tube Torque the locking screw to specification TORQUE Snorkel Locking Screw 10 ft lb 14 Nm Transmission Assembly NOTE The snorkel shaft and pinion shaft must be install...

Page 297: ...ift 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 20 Install the shift shaft rail 3 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 towards the input shaft as shown a...

Page 298: ...ission case halves The snorkel shaft seal 3 should be pressed in until it seats against the housing counter bore The input shaft seal 3 should be pressed in until it seats flush with the housing The rear output shaft seals 3 can be installed using a standard bushing installation tool Seals should be installed just past the case lead in chamfer 0 070 or 1 8 mm from outer face of bore 26 Thoroughly ...

Page 299: ...y Crankcase Sealant 3 Bond onto the cover and transmission case mating surface Crankcase 3 Bond Sealant PN 2871557 33 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification TORQUE Sector Gear Cover Bolts 12 ft lb 16 Nm 34 Install the transmission drain plug and torque to specification TORQUE Fill Drain Plug 14 ft lbs 19 ...

Page 300: ...6 30 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc TRANSMISSION ASSEMBLY VIEW TRANSMISSION ...

Page 301: ...al 61 Sprocket 48T 6 Face 19 Retaining Ring Internal 62 Gear Low 67T 20 Retaining Ring External 63 Engagement Dog 6 Face 21 Retaining Ring External 64 Gear 53T 22 Retaining Ring External 65 Shaft Pinion 11T 23 Retaining Ring External 66 Gear 46T 24 Washer Thrust 67 Gear Snorkel 13T 25 Washer Thrust 68 Shaft Shift 26 Shim 69 Weldment Rear Mount Bracket 27 Shim 70 Bracket Rear Mount 28 Bearing Needl...

Page 302: ...6 32 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc TRANSMISSION ASSEMBLY VIEW TURF MODE MODELS TRANSMISSION ...

Page 303: ...O 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 S...

Page 304: ...hings 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 proble...

Page 305: ...15 CV JOINT SERVICE 7 17 OUTER CV JOINT BOOT REPLACEMENT 7 17 INNER PLUNGING JOINT BOOT REPLACEMENT 7 20 2016 CV JOINT SERVICE 7 22 OUTER CV BOOT REPLACEMENT 7 22 INNER PLUNGING JOINT BOOT REPLACEMENT 7 24 DRIVE SHAFT ASSEMBLY VIEW 7 26 PROP SHAFT SERVICE 7 27 FRONT PROPSHAFT REMOVAL 7 27 FRONT PROP SHAFT INSTALLATION 7 28 REAR PROP SHAFT REMOVAL 7 28 REAR PROP SHAFT INSTALLATION 7 29 REAR PROP SH...

Page 306: ...7 2 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc BEADLOCK RIMS DESERT EDITION 7 45 FINAL DRIVE ...

Page 307: ...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 front 30 ft lb 41 Nm Brake Caliper Mounting Bolts rear 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 f...

Page 308: ...ing carrier 6 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 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 front wheel hub assembly 8 Remove and discard the upper and lower ball joint pinch bolts r 9 Using a soft faced hammer lightly tap on the beari...

Page 309: ...r or damage Replace front bearing carrier if damaged Bearing Installation 5 Thoroughly clean the front bearing carrier housing and the outer race on the 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 ...

Page 310: ...er mounting bolts and torque to specification TORQUE Front Caliper Mounting Bolts 30 ft lb 41 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 7 Install the steering tie rod end r onto the front bearing carrier NOTE Refer to the photo below to ensure proper placement of the tie rod end 8 Torque the tie r...

Page 311: ...falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove the four wheel nuts and rear wheel 4 Remove the cotter pin q and loosen the rear wheel hub castl...

Page 312: ...ailing arm Discard the nuts 9 Remove the bearing carrier from the rear drive shaft and trailing arm 10 Rotate bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosi...

Page 313: ... or damage Replace rear bearing carrier if damaged Bearing Installation 5 Thoroughly clean the rear bearing carrier housing and the outer race on the 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 com...

Page 314: ... rod to the bearing carrier Torque bolts to specification NOTE Use new nuts upon installation of the rear bearing carrier TORQUE Bearing Carrier to Trailing Arm Bolts 42 ft lb 54 Nm Radius Rod to Bearing Carrier Fasteners 40 ft lb 54 Nm 3 Apply anti seize to drive shaft splines 4 Install rear wheel hub assembly w cone washers e and hand tighten the castle nut Install washers with domed side out 5 ...

Page 315: ...ew cotter pin t Tighten nut slightly if necessary to align cotter pin holes TORQUE Hub Castle Nut 110 ft lbs 149 Nm 7 Install wheel and four wheel nuts Torque wheel nuts to specification TORQUE 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 FINAL DRIVE ...

Page 316: ... hub castle nut w Remove the nut and cone washers e 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 Caliper Removal page 9 21 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove and disca...

Page 317: ...ft 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 e Torque to specification TORQUE Ball Joint Pinch Bolts 42 ft lbs 57 Nm 6 Apply Anti Seize to drive shaft axle splines 7 Install front wheel hub assembly...

Page 318: ...UTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this procedure Always wear eye protection 2 Remove the four wheel nuts and rear wheel 3 Remove the cotter pin q and loosen the rear wheel hub castle nut w Remove the nut and two cone washers e from the rear wheel hub assembly 4 Remove the two bolts r retaining the upper and lower radius rods to the ...

Page 319: ...gn splines of drive shaft with transmission splines and reinstall the drive shaft Use a rubber mallet to tap on 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 specific...

Page 320: ...t TORQUE Rear Hub Castle Nut 110 ft lbs 149 Nm 8 Install the radius rod bolts washers and new nuts Torque fasteners to specification TORQUE Radius Rods to Bearing Carrier 40 ft lb 54 Nm 9 Install the rear brake caliper assembly and new bolts y Torque to specification TORQUE Rear Caliper Mounting Bolts 40 ft lbs 54 Nm 10 Install wheel and four wheel nuts Torque wheel nuts to specification TORQUE Wh...

Page 321: ...sure surface ground areas and splines of shaft are protected during handling to avoid damage Do 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 prope...

Page 322: ... to one side to expose each ball Severe pitting galling play between the ball and its cage window any cracking or damage to the cage pitting or galling or chips in raceways call for joint replacement 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 otherwis...

Page 323: ...oint housing and shaft Make sure the boot is not dimpled or collapsed 18 Install and tighten the large clamp e using 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 th...

Page 324: ...rom the plunging joint and slide the boot down the shaft 3 Clean the grease from the face of the joint and place the drive shaft in a soft jawed vise 4 Using a soft faced hammer or brass drift strike the inner race of the joint to drive the joint off the shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure the circlip w is on the shaft and not ...

Page 325: ...n the end of the shaft 12 Grease the joint with the special joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability DO NO...

Page 326: ...ousing and lift up to equalize the air pressure in the boot 21 Position the boot lip in its groove Install and tighten the large clamp r using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 2016 CV JOINT SERVICE OUTER CV BOOT REPLACEMENT NOTE Outer CV Joint replacement is not recommended If the outer joint is damaged a new half shaft assembly should be ins...

Page 327: ...balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability DO NOT use substitutes or mix with other lubricants NOTE The amount of grease provided in the boot kit is pre measured Use entire contents of ...

Page 328: ...ng w retaining the cage ball assembly and remove the assembly from the shaft 7 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 IMPORTANT If the gr...

Page 329: ...r lubricants NOTE The amount of grease provided in the boot kit is pre measured Use entire contents of package 14 Slide the joint and shaft into the housing CAUTION DO NOT hammer on the joint to install it in the housing 15 Install the large circlip into the groove of the plunging joint housing 16 Remove excess grease from the CV joint s external surfaces and place the excess grease in the boot 17...

Page 330: ...7 26 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc DRIVE SHAFT ASSEMBLY VIEW FINAL DRIVE ...

Page 331: ...pin and use the Roll Pin Removal Tool PN 2872608 to remove the roll pin Discard roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft Roll Pin Removal Tool PN 2872608 NOTE Right front wheel can be removed to gain better access to the propshaft roll pin 3 Slide the front propshaft t off the rear propshaft y and remove it from the vehicle 4 Proceed to Front Pro...

Page 332: ...op 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 roll pin 6 Reposition the front gearcase and install the four bolts that secure the front gearcase to the frame Torque bolts to specification TORQUE Front Gearcase Mounting Bolts 30 ft lbs 41 Nm REAR PROP SHAFT REMOVAL 1 Remove the cen...

Page 333: ...ear prop shaft 2 Lubricate the transmission output shaft splines with Polaris All Purpose Grease 3 Lubricate the front and rear prop shaft mid joint with Polaris All Purpose Grease 4 Slide the rear prop shaft forward from the left rear of the machine just below the PVTcover Install the rear prop shaft on the transmission snorkel shaft 5 Lubricate the support bushing with light oil to ease installa...

Page 334: ...Install a new roll pin REAR PROP SHAFT REMOVAL XP 4 1 Remove all seats 2 Remove the front and rear center consoles see Chapter 10 Rocker Panels Rear Console and Floor XP 4 page 10 24 3 Remove the fasteners q from center w and rear skid plates e 4 Remove center and rear skid plates 5 Remove the fasteners r securing the support bearing cover t to the frame 6 Move the prop shaft support bearing assem...

Page 335: ... page 7 30 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 shaft mid joint with Polaris All Purpose Grease 4 Align the front and rear prop shafts and slide them together NOTE Paint marks are applied to the front and rear prop shafts to aid shaft alignment Reference these marks during in...

Page 336: ... the shaft and apply Loctite 603 retaining compound to the clean surface 5 Install the new support bearing assembly onto the end of the prop shaft 6 Using an appropriate bearing bushing installation sleeve drive the support bearing assembly onto the prop shaft until it seats against the shoulder on the shaft NOTE Only drive on the inner race of the bearing Driving on the bearing in any other locat...

Page 337: ...ose Fitting 2 Hub Sub Assembly Male t Ball Bearing 2 Rollers y Ball Bearing Double Row 2 Torsion Spring u Bushing 2 H Clip Spring i Bushing 2 Nylon Spacer o Oil Seal 2 Backlash Spacer a Oil Seal 2 Ring Gear Spacer s Retaining Ring Internal 2 Torsion Spring Retainer d Retaining Ring 3 Pinion Gear f Cover Screws M6 T30 Torx 3 Armature Plate g Cover Plate Assembly 3 AWD Coil h Gearcase Housing 3 Fill...

Page 338: ...is engaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts an armature plate q that is keyed to the roll cage w When the ring gear e and roll cage are spinning vehicle is moving the energized coil and armature ...

Page 339: ...age 7 36 and inspect components 4 Inspect armature plate e for a consistent wear pattern There should be two distinct wear bands r If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the coil t is se...

Page 340: ...and support vehicle 2 Place gear selector in neutral 3 Refer to FRONT DRIVE SHAFT page and remove both front drive shafts from the front gearcase 4 Remove the front section of the prop shaft see Chapter 7 FRONT PROPSHAFT SERVICE page 5 Disconnect the wire harness for the front gearcase and remove the harness from the retaining dart 6 Remove the vent line from the front gearcase and plug vent line ...

Page 341: ... 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 not be removed 4 Remove and inspect the armature plate Refer to AWD Diagnosis page 7 35 for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the t...

Page 342: ...e the RH output hub assembly from the gearcase housing 8 Remove pinion seal internal retaining ring and pinion gear assembly from the gearcase housing Inspect and clean the gearcase housing and replace all oil seals and O rings 9 Inspect the pinion gear for chipped broken or missing teeth Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting FINAL DRIVE ...

Page 343: ... A for nicks and scratches The rollers must slide up and down and in and out freely within the roll cage B sliding surfaces and H springs NOTE Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assembly or as a complete kit 13 Inspect clutch housing ring gear C for a consistent wear pattern Inspect the ring gear for chipped broken or missing ...

Page 344: ...nstall a new pinion shaft seal into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub into the gearcase housing 5 Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing NOTE Install roll cage so that the ring gear grooves l...

Page 345: ...Install armature plate Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer 10 Carefully install the ring gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover...

Page 346: ... and torque to specification TORQUE Cover Plate Screws 11 ft lbs 15 Nm FRONT GEARCASE INSTALLATION 1 Install the gearcase back into the vehicle through the LH wheel well area above the upper A arm 2 Lubricate the front gearcase splines with Anti Seize 3 Install the prop shaft onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 4 Install the four bolts q that secure the ...

Page 347: ...Shaft Installation page 7 13 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 change information FLUID CAPACITY Recommended Front Gearcase Fluid Demand Drive Fluid 2877922 quart Capacity 8 5 oz 250 mL fill on a level surface to bottom of threads on the fill hole FINAL DRIVE ...

Page 348: ...7 44 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc WHEEL HUBS FRONT HUB ASSEMBLY VIEW REAR HUB ASSEMBLY VIEW FINAL DRIVE ...

Page 349: ...tire 2 Remove the beadlock screws and beadlock ring 3 Dismount the tire on the side with the beadlock holes 4 Place the beadlock ring so the tire is sandwiched between the rim and the ring making sure the valve stem is aligned with the slot in the ring 5 Install bolts and thread them to 24 in lbs 3 Nm 6 Tighten in a criss cross pattern to 7 ft lbs 10 Nm TORQUE Beadlock Screws Step 1 24 in lbs 3 Nm...

Page 350: ...7 46 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES FINAL DRIVE ...

Page 351: ...BAR REMOVAL 8 14 FRONT STABILIZER BAR INSTALLATION 8 15 BALL JOINT SERVICE PREPARATION 8 15 BALL JOINT REMOVAL 8 16 BALL JOINT INSTALLATION 8 16 REAR SUSPENSION 8 17 RADIUS ROD REMOVAL INSTALLATION 8 17 TRAILING ARM REMOVAL INSTALLATION 8 17 TRAILING ARM SPHERICAL BEARING REPLACEMENT 8 20 REAR SUSPENSION ASSEMBLY VIEW 8 21 STABILIZER BAR REMOVAL 8 22 STABILIZER BAR INSTALLATION 8 22 SHOCKS SPRINGS...

Page 352: ...ER EVANS SHOCK DISASSEMBLY 8 32 WALKER EVANS SHOCK ASSEMBLY 8 35 FOX SHOCK ASSEMBLY VIEWS 8 40 FOX 2 5 O E PODIUM BYPASS 8 40 FOX 3 0 O E PODIUM BYPASS 8 41 FOX SHOCK SERVICE 8 42 FOX 2 5 FRONT SHOCK INFORMATION 8 42 FOX 3 0 REAR SHOCK INFORMATION 8 43 SPRING ADJUSTMENT FOX 8 44 OFFSET TORQUE FORMULA 8 45 FOX SHOCK DISASSEMBLY 8 46 FOX SHOCK ASSEMBLY 8 53 STEERING SUSPENSION ...

Page 353: ...Nm Steering Wheel Nut 65 ft lbs 88 Nm Steering Shaft to Power Steering Unit upper lower EPS models 15 ft lbs 20 Nm EPS Cover Screws 8 ft lb 11 Nm Power Steering Unit to Mount Bracket Bolts 30 ft lb 41 Nm Lower Steering Shaft to Steering Rack 42 ft lb 57 Nm Power Steering Bracket to Frame Nuts 16 ft lb 22 Nm Steering Rack Mounting Bolts 16 ft lbs 22 Nm Hip Bolster Bolts 14 ft lb 19 Nm SPECIAL TOOLS...

Page 354: ...ering Shaft to EPS Fasteners 15 ft lbs 20 Nm e EPS Module o Tilt Steering Shock h Steering Rack Mounting Nuts 16 ft lbs 22 Nm r Lower Steering Shaft a Tie Rod End Bolt Do not reuse 2014 15 ft lbs 20 Nm 90 2015 30 ft lb 41 Nm 90 j Steering Shaft to Rack Fasteners 42 ft lb 57 Nm t Steering Box s Nut Nylok Do not reuse k EPS to Bracket Fasteners 30 ft lb 41 Nm y Tie Rod End 14 ft lbs 19 Nm d Steering...

Page 355: ...he cover from the vehicle 2 Remove the pinch bolt retaining the upper steering shaft to the power steering unit 3 Lift the steering wheel up and remove the four fasteners t that retain the pivot tube 4 Remove the steering shaft pivot tube and steering wheel from the vehicle as an assembly 5 If replacing the upper steering shaft or steering wheel refer to Steering Wheel Removal page 8 6 STEERING SU...

Page 356: ...e assembly in a vise 5 Using a large bronze drift and hammer strike the steering shaft nut to pop the steering wheel off the shaft taper 6 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft POWER STEERING UNIT REMOVAL 1 Remove the upper steering shaft pivot tube and steering wheel from the vehicle as an assembly Refer to Upper Steering Shaft Remo...

Page 357: ...nt bracket 5 Carefully remove the power steering unit and mount bracket from the vehicle as an assembly 6 If replacing the power steering unit remove the three bolts r that retain the power steering unit to the mount bracket WARNING Electronic Power Steering EPS units are programmed to be vehicle specific and are not interchangeable between product lines STEERING SUSPENSION ...

Page 358: ...ove the pinch bolt q retaining the lower steering shaft w to the steering gear box assembly e 5 Lift up on the shaft and remove it through the floor panel LOWER STEERING SHAFT INSTALLATION 1 Install the lower steering shaft onto the gear box and align the marks made during step 2 of the Lower Steering Shaft Removal EPS Models procedure 2 Install the pinch bolt that retains the lower steering shaft...

Page 359: ... stub shaft with the opening in the lower steering shaft 3 Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts 4 Position the lower steering shaft on the power steering unit stub shaft and install the pinch bolt Torque to specification TORQUE Lower Steering Shaft to EPS Unit Pinch Bolt 15 ft lbs 20 Nm 5 Torque the four mount bracket n...

Page 360: ...shaft 2 Install the pivot tube and torque fasteners to specification TORQUE Pivot Tube Fasteners 8 ft lb 11 Nm 3 Install the tilt shock and torque fastener to specification TORQUE 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 TORQUE Steer...

Page 361: ...r circumference of the new lower bearing race Slide the new lower bearing onto the steering shaft and install the steering shaft through the pivot tube Be sure the lower washers and spacers are still on the steering shaft q Cap u Bearing w Nut i Bearing e Steering Hub Insert o Bushing r Bushing a Bushing t Bushing s Bushing y Bushing NOTE Use care not to allow any of the Loctite to get in the bear...

Page 362: ...e 5 17 Torque fasteners to specification TORQUE Pivot Tube Bolts 8 ft lb 11 Nm 13 Install the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube see Figure 5 17 Torque fastener to specification TORQUE Tilt Shock Bolt 7 ft lb 10 Nm 14 Be sure the front wheels are facing straight forward Remove the steering wheel and align as needed Torque the steering wheel nut ...

Page 363: ...r A arm front through bolt fastener e and rear though bolt fastener r 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 injury or death could result if fasteners come loose during operation 8 If not replacing the A arm thoroug...

Page 364: ...placing 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 and pivot tube into new A arm A light press force may be needed 21 Install new lower A arm assembly onto vehicle frame Torque new bolt to specification 22 Insert lower A arm ball joint end into the bearing carrier Install lower ball j...

Page 365: ... to specification TORQUE Stabilizer Bar Link Fasteners 40 ft lb 54 Nm BALL JOINT SERVICE PREPARATION NOTE Do not reuse a ball joint if it has been removed If removed it must be replaced Use this removal procedure only when replacing the ball joint 1 Properly lift and support the vehicle by the frame 2 Remove the appropriate front wheel 3 To service the upper ball joint Remove and discard the two f...

Page 366: ... w install a new retaining ring e 4 Repeat the ball joint service procedure for any additional A arm ball joint replacements 5 Insert upper lower A arm ball joint end into the bearing carrier Install new pinch bolts and nuts Torque to specification 6 If needed install new brake caliper mounting bolts and torque to specification CAUTION New bolts have a pre applied locking agent which is destroyed ...

Page 367: ... 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 8 Reverse this procedure to reinstall the radius rods 9 Torque all fasteners to specification NOTE Use new attaching nuts upon installation of the rear radius rods TORQUE Radius Rod Mounting Bolts 40 ft lb 54 Nm WARNING Upon radius rod inst...

Page 368: ...emove the five remaining bolts y that attach the rear bearing carrier to trailing arm Discard the nuts 8 Remove the bearing carrier from the rear drive shaft and trailing arm 9 Rotate bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion Replace bearing if moisture dirt corrosion or roughness is evident see Chapter 7 Rear Bearing Replacement page 7 9...

Page 369: ...cedure to reinstall rear trailing arm NOTE Use new fastener nuts upon installation of the rear trailing arm and bearing carrier 18 Torque all fasteners to specification TORQUE Trailing Arm to Main Frame Trailing arm spherical bearing bolt 70 ft lb 95 Nm Rear Shock Mounting Bolts 70 ft lbs 95 Nm Rear Stabilizer Bar Linkage 40 ft lbs 54 Nm Radius Rod Mounting Bolts 40 ft lb 54 Nm Bearing Carrier to ...

Page 370: ...hat 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 into trailing arm casting 8 Ins...

Page 371: ...ring Carrier g Stabilizer Bar Link Fasteners 42 ft lbs 57 Nm e Reservoir Mounting Clamp o Bearing Carrier Bolts 42 ft lb 57 Nm h Rear Stabilizer Bar r Shock Bolts 70 ft lbs 95 Nm a Trailing Arm j Stabilizer Bar Mounting Clamp Fasteners 30 ft lb 42 Nm t Radius Rod Fasteners 42 ft lb 57 Nm s Shock Guard Screws 14 in lbs 2 Nm k Trailing Arm Mounting Bolts 70 ft lb 95 Nm y Radius Rod d Rear Shock Asse...

Page 372: ...of the vehicle 8 Inspect the stabilizer bar for straightness Inspect the 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 ...

Page 373: ...k Assembly View page TORQUE Shock Mounting Bolts Front 42 ft lb 57 Nm Rear 70 ft lbs 95 Nm SHOCK SPRING REPLACEMENT 1 Remove the shock and note the spring preload distance see Chapter 2 Spring Adjustment WALKER EVANS page 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...

Page 374: ...Cap 28 O Ring 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 C...

Page 375: ...Spherical Bearing l Spacer 3 O Ring r Spring Nut 1 End Cap 3 Wiper t Piston 2 Needle Bolt 3 Shaft Seal y Reservoir Piston 2 Adjuster Nut 3 Shaft Bushing 0 750 u Check Valve 2 Reservoir Body 3 O Ring i Clicker Bolt 2 Bleed Screw 3 Detent Spring o Crimp Nut 2 Bump Stop 3 Detent Ball a Adjuster Knob 2 Wear Band 4 O Ring s Ball 250 2 O Ring 4 O Ring d Retention Nut 2 Screw 4 Screw f 9 16 Heim Shaftloo...

Page 376: ...ually inspect shock seals Every 1500 miles or Annually Change shock oil and replace seals NOTE If leakage from a remote shock reservoir hose fitting is evident check for a loose fitting and seal threads with Three Bond 1215 PN 2871557 FRONT SHOCK SERVICE INFORMATION FRONT SHOCK DESIGN DETAILS Travel 8 42 21 39 cm Extended Length 25 10 63 75 cm IFP Location RZR XP 4 1000 High Lifter 3 375 85 7 cm I...

Page 377: ...008 0 900 x 0 015 1 10 x 0 025 0 900 x 0 010 0 900 x 0 012 1 00 x 0 025 1 45 x 0 010 1 45 x 0 015 1 00 x 0 025 0 900 x 0 008 1 45 x 0 015 0 625 x 0 065 1 45 x 0 015 1 45 x 0 008 1 30 x 0 015 1 45 x 0 008 COMPRESSION REBOUND CLICKER 1 20 x 0 015 1 30 x 0 010 1 10 x 0 015 1 00 x 0 008 1 00 x 0 015 1 50 x 0 120 0 750 x 0 065 Piston Bleed Orifice none 2015 2016 Front Shock Valving RZR XP 1000 High Lif...

Page 378: ... 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 0 065 top out 1 20 x 0 012 1 50 x 0 125 top out Piston Bleed Orifice 0 100 2014 2016 Shock Valving RZR XP 4 1000 COMPRESSION REBOUND CLICKER 1 55 x 0 008 1 50 x 0 01 1 00 x 0 015 1 00 x 0 010 1 45 ...

Page 379: ...1 75 x 0 010 1 45 x 0 010 1 00 x 0 015 1 65 x 0 010 1 30 x 0 010 0 90 x 0 015 1 55 x 0 008 1 20 x 0 010 0 600 x 0 015 1 00 x 0 010 1 10 x 0 010 0 600 x 0 015 1 55 x 0 008 1 00 x 0 010 1 55 x 0 008 0 90 x 0 010 1 55 x 0 008 0 80 x 0 010 1 55 x 0 008 1 55 x 0 008 1 45 x 0 010 1 00 x 0 095 top out 1 30 x 0 012 1 20 x 0 012 1 50 x 0 125 top out Piston Bleed Orifice 0 100 2015 Shock Valving RZR XP 1000...

Page 380: ...end 2 Using the shock spanner spreader tool PN 2878925 included in the vehicle s tool kit turn the adjustment collar q to increase or decrease ride height Shock Spanner Clutch Spreader Tool 2878925 NOTE Polaris does not recommend increasing the spring adjustment by more than one inch 25 4 mm over the factory setting w as it may negatively impact vehicle stability Always return the spring preload t...

Page 381: ...ngly 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 Front PU 50938 Shock Body Holding Tool Rear 2872429 Shock Rod Holding Tool Front PS 50931 Shock Rod Holding Tool Rear PU 50939 Shock Seal Protector Sleeve Front PU 50952 Shock Seal Protector Sle...

Page 382: ...embly 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...

Page 383: ...PS 45908 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 ...

Page 384: ...wear band and replace if damaged or worn 18 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 Body Holding Tool PU 50938 19 Front Shocks Only Using a 9 16 socket w extension remove the fastener retaining the clicker valve stack Place the valve stack on a clean shop towel in order of removal NO...

Page 385: ...embly onto the shock shaft 5 Remove the Shock Seal Protector Sleeve 6 Place the compression valve stack on the rod in the reverse order of disassembly 7 Place valve piston on top of the compression stack NOTE If unsure of the valve stack order refer to Shock Valving under the Shock Service Information provided earlier in this section 8 Place a new lock nut onto the shock rod Torque the new lock nu...

Page 386: ...dy Holding Tool PU 50979 Rear Shock Body Holding Tool PU 50938 12 Fill the shock body and remote reservoir 1 2 full of the recommended gas shock oil FLUID CAPACITY Recommended Shock Oil Racing Gas Shock Oil PN 2874124 Quart 10 Weight for Walker Evans 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 co...

Page 387: ...ep damping piston at least 1 4 below the surface of the oil during this process While holding 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 ...

Page 388: ...heck to make 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 C...

Page 389: ...preload adjuster down against the spring and set the preload to the specified measurement see Chapter 2 Spring Adjustment WALKER EVANS page 40 Set the compression adjuster knob to the recommended setting or the original setting upon removal see Chapter 2 Shock Compression Adjustment WALKER EVANS page 2 34 41 Remove the shock from the vise 42 Reinstall spherical bearing O rings and polyurethane bus...

Page 390: ...Screw 2 Reservoir t Reservoir Decal 2 Shaft y Band Decal 2 Spring Adjuster Ring u O ring 2 Spring Adjuster Ring Backup i O ring 2 Screw Assembly o O ring 2 Piston Assembly a O ring 2 Internal Bypass Body Assembly s Retaining Ring 2 Valving Assembly d Retaining Ring 2 Bearing Assembly f Retaining Ring 2 Reservoir End Cap Assembly g Bearing Cap 3 Damping Adjust Assembly h Body Cap 3 Sparing Hardware...

Page 391: ...ng Backup r Lock Nut k Retaining Ring 3 Screw Assembly t Screw l Retaining Ring 3 Piston Assembly y Hose 1 Bearing Cap 3 Internal Bypass Body Assembly u Reservoir Decal 2 Body Cap 3 Valving Assembly i Band Decal 2 Outer Body 3 Bearing Assembly o O ring 2 Low Speed Adjuster Knob 3 Reservoir End Cap Assembly a O ring 2 Remote Reservoir Adjust Port 3 Damping Adjust Assembly s O ring 2 Eyelet 3 Spring...

Page 392: ...pression Adjustment factory r 12 clicks CCW from full firm setting full clockwise Spring Adjustment Setting t 2 18 5 54 cm 2015 Front FOX Shock Valving COMPRESSION REBOUND 1 600 x 0 006 SB 1 425 x 0 008 1 600 x 0 015 1 425 x 0 008 1 600 x 0 015 1 425 x 0 008 1 600 x 0 015 0 700 x 0 006 1 600 x 0 015 1 425 x 0 012 0 950 x 0 010 1 350 x 0 012 1 600 x 0 015 1 250 x 0 012 1 425 x 0 015 1 100 x 0 012 1...

Page 393: ...24 qt Compression Adjustment factory r 12 clicks CCW from full stop Spring Adjustment Setting t 10 63 26 99 cm 2015 Rear FOX Shock Valving COMPRESSION REBOUND 1 800 x 0 006 SB 1 600 x 0 008 1 800 x 0 012 1 600 x 0 008 1 800 x 0 012 1 600 x 0 008 1 800 x 0 012 0 750 x 0 010 1 600 x 0 012 1 600 x 0 012 1 425 x 0 012 1 425 x 0 012 1 350 x 0 012 1 350 x 0 012 1 250 x 0 012 1 100 x 0 012 1 100 x 0 012 ...

Page 394: ...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 spanner spreader tool included in the vehicle s tool kit turn the adjustment collar to increase or decrease ride height Shock Spanner Clutch...

Page 395: ...lb Run down Body Cap on Reservoir Place reservoir in Body Clamps 803 00 XXXX in a Vise Use Body Cap Socket 398 00 XXX to torque the body cap with a torque wrench to 24 ft lb of torque Torque T 30 ft lb of desired torque Example A Y Unknown Torque Value Set Torque Wrench to 24 ft lb L 13 750 Will equal 30 ft lb of torque applied to the reservoir E 3 750 or 2 500 depending on body cap STEERING SUSPE...

Page 396: ...onents Example if the eyelet is tight to the shaft it may not require removal or if the shock body and body cap do not show any signs of oil leakage and they are tight they may not require removal Record compression adjuster settings by counting the number of clicks in clockwise until the adjuster stops Once you have recorded the numbers back all adjusters out counter clockwise to the full soft po...

Page 397: ...heat to the bearing assembly to break the Loctite bond between the cinch ring and the bearing assembly NOTE The seal will be destroyed from the heat and must be replaced 7 Hold cinch ring with spanner and rotate bearing assembly counter clockwise to release pressure on retaining ring 8 Press down on bearing assembly and remove retaining ring 9 Remove the shaft assembly and body assembly 10 Use the...

Page 398: ...f medium taps with the hammer Tap the pin punch out and remove the reducer from the tapered pin punch 19 Remove both internal retaining rings 20 Press out the spherical bearing with mandrel or socket press only on the bearing race 21 Ensure reservoir o ring has been removed 22 With the body of the shock placed in clamp block and secured in vise apply a sufficient amount of heat to the body cap wit...

Page 399: ...th contact cleaner and lint free towel inside and out 26 Remove lock nut from the shaft assembly 27 Remove rebound valve stack from the assembly and cable tie together Clean with contact cleaner NOTE Damping pistons are directional Rebound side shown 28 Remove damping piston 29 Note the bleed shim orientation on compression valve stack 30 Remove compression valve stack and cable tie together Clean...

Page 400: ... the eyelet with the correct body cap socket 33 Use a wire brush heat and a pick to remove any Loctite residue left in the eyelet and shaft threads Clean thoroughly with contact cleaner and lint free towel 34 Apply Loctite primer 7649 to eyelet threads q Wipe over spray off any external surface 35 Remove all seals and o rings from bearing assembly NOTE If the DU bearing needs replacement replace t...

Page 401: ...ng a 5 64 hex wrench NOTE Observe location size and thickness of bypass valves 38 To remove the remote hose assembly de pressurize reservoir push hose in and remove retaining ring with a small pick 39 Remove hose o rings 40 Pistons are equipped with an energizing o ring under piston bearing Clean the surface with contact cleaner STEERING SUSPENSION ...

Page 402: ...9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 2 5 Bypass Piston Compression Side Rebound Side 3 0 Bypass Piston Compression Side Rebound Side STEERING SUSPENSION ...

Page 403: ...ffset formula See Offset Torque Formula page 8 45 TORQUE Body Cap step 1 30 ft lb 42 Nm 3 With body prepared with Loctite primer add a layer of Loctite 638 2 threads up 2 threads wide 360 4 Apply a thin layer of Slick Honey to body cap o rings 5 Install both o rings in body cap Ensuring no Slick Honey is on threads 6 Torque body cap to final specified torque with body cap socket TORQUE Body Cap st...

Page 404: ...reads up 2 threads wide 360 14 Torque eyelet to specification with shaft secured in clamp blocks TORQUE Shock Eyelet 50 ft lb 68 Nm 15 Install 398 00 095 B Bullet tool on shaft to install bumper 16 Install body cap 17 Install T seal 18 Install 1st T seal back up ring 19 Install 2nd T seal back up ring 20 Install wiper seal 21 Lubricate all seals with Slick Honey 22 Install external o ring 23 Insta...

Page 405: ...ll all Bypass check valves 30 Use Loctite 242 Blue on bypass screws Torque bypass screws to specification TORQUE Bypass Screw 14 in lb 2 Nm 31 Install assembled internal body Ensure that body is seated properly in body cap 32 Fill reservoir assembly with oil and install lubricated IFP 33 Ensuring oil level is above IFP install bleed screw with o ring Torque bleed screw to specification TORQUE Blee...

Page 406: ...7 Nm 42 On 2 5 Bypass shocks with Aluminum body apply 290 wicking Loctite to bearing assembly threads 3 0 Bypass shocks with steel outer bodies do not require 290 Loctite on the bearing assembly threads NOTE On remote reservoir assemblies lubricate o rings with Slick Honey prior to installing hose assembly With hose fully seated install retaining ring Ensure retaining ring is fully seated by pulli...

Page 407: ...7 47 Install retaining ring ensure that it is fully seated in ring gland 48 Fill reservoir with specified nitrogen pressure 49 Stroke shock absorber and inspect shock for leaks 50 Install body cap 51 Clean oil residue from shock 52 Install o ring and reducers in eyelet and body STEERING SUSPENSION ...

Page 408: ...8 58 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES STEERING SUSPENSION ...

Page 409: ...AL LEVER 9 10 BRAKE PEDAL REMOVAL 9 10 BRAKE PEDAL INSTALLATION 9 10 PARKING BRAKE INT L MODEL 9 11 PARKING BRAKE ASSEMBLY VIEW 9 11 PARKING BRAKE INSPECTION 9 12 PARKING BRAKE CABLE ADJUSTMENT 9 12 PARKING BRAKE CALIPER 9 13 PARKING BRAKE DISC 9 16 FRONT BRAKE PADS 9 17 PAD REMOVAL 9 17 PAD INSPECTION 9 18 PAD ASSEMBLY INSTALLATION 9 18 BRAKE BURNISHING PROCEDURE 9 19 FRONT CALIPER SERVICE 9 20 C...

Page 410: ... 9 30 CALIPER ASSEMBLY VIEW 9 30 CALIPER REMOVAL 9 31 CALIPER DISASSEMBLY 9 32 CALIPER INSPECTION 9 32 CALIPER ASSEMBLY 9 33 CALIPER INSTALLATION 9 33 REAR BRAKE DISC 9 35 DISC INSPECTION 9 35 DISC REPLACEMENT 9 35 TROUBLESHOOTING 9 37 POOR BRAKE PERFORMANCE 9 37 PEDAL VIBRATION 9 37 CALIPER OVERHEATS BRAKES DRAG 9 37 BRAKES LOCK 9 37 BRAKE SYSTEM ...

Page 411: ...b 5 Nm Brake Disc to Hub Bolts 18 ft lb 24 Nm Master Cylinder Mounting Bolts 23 ft lbs 31 Nm Brake Pedal Mounting Bracket to Frame 18 ft lb 24 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 Wheel Hub Castle Nuts 110 ft lbs 149 Nm Wheel Lug Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm SPECIAL TOOLS...

Page 412: ...n the conditions this vehicle will routinely encounter There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life DO NOTover fill the master cylinder fluid reservoir Make sure the brake pedal returns freely and completely Adjust stop pin on brake caliper s after pad service Check and adjust mast...

Page 413: ...pressure on the piston within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads These pads contact the brake discs and mov...

Page 414: ...9 6 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc BRAKE SYSTEM ASSEMBLY VIEW BRAKE SYSTEM ASSEMBLY VIEW BRAKE SYSTEM ...

Page 415: ...brake pedal lever 3 Place a container to catch brake fluid under the master cylinder brake line banjo bolts r CAUTION Brake fluid 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 and allow fluid to drain NOTE Dispose of fluid properly Do not r...

Page 416: ...ng the brakes or replacing the fluid always start with the furthest caliper from the master cylinder This procedure should be used to change fluid or bleed brakes during regular maintenance CAUTION Always wear safety glasses when handling chemicals and fluids CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 1 Clean master cylinder...

Page 417: ...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 TORQUE 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 MIN and MAX lines on reservoir 11 Ins...

Page 418: ... brake pedal lever w and remove the clip q and master cylinder clevis pin r 2 Remove the E clip e from the pedal mount and remove the brake pedal lever w from the vehicle BRAKE PEDAL INSTALLATION 1 Reverse the Removal steps to install brake pedal lever Compare brake pedal free play to specification Brake Pedal Free play 0 090 2 28 mm BRAKE SYSTEM ...

Page 419: ...9 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 9 11 PARKING BRAKE INT L MODEL PARKING BRAKE ASSEMBLY VIEW BRAKE SYSTEM ...

Page 420: ...porarily 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 n...

Page 421: ...9 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 9 13 PARKING BRAKE CALIPER BRAKE SYSTEM ...

Page 422: ...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 b...

Page 423: ...1 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 TORQUE Parking Brake Caliper Assembly Bolts 37 ft lb 50 Nm 5 Ensure the parking brake assembly functions properly by actuating the lever Install the mounting sleeves D before installation Brak...

Page 424: ...sc is less than specified replace the brake disc see Chapter 9 Disc Replacement page Disc Replacement 1 Remove the parking brake caliper from the disc see Chapter 9 2 Using a 1 2 socket and ratchet remove the brake disc retaining bolt and flat washer 3 Remove the disc from the transmission shaft 4 Install the new brake disc Install the mounting bolt and flat washer Torque the mounting bolt to spec...

Page 425: ... bolts and remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper...

Page 426: ...nated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper onto front hub and torque mounting bolts w to specification TORQUE Front Caliper Mount Bolt 30 ft lb 41 Nm 4 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 5 Install the adjustm...

Page 427: ... 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 BRAKE SYSTEM ...

Page 428: ...9 20 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc FRONT CALIPER SERVICE CALIPER ASSEMBLY VIEW BRAKE SYSTEM ...

Page 429: ...n 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 q Remove brake line from caliper 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts w and remove the caliper a...

Page 430: ...r 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 standard pliers The piston sealing surfaces will become damaged if a standard pliers is used 5 Once the pistons are removed use a pick to carefully remove the square O rings e from the caliper O rings should be replaced during caliper service 6 Cl...

Page 431: ... mm Service Limit 1 368 34 75 mm 3 Inspect the brake disc and pads as outlined in this chapter CALIPER ASSEMBLY 1 Install new O rings w in the caliper body Be sure the grooves q are clean and free of residue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and out of bore smoothly...

Page 432: ...cation TORQUE Banjo Bolt 15 ft lbs 20 Nm 4 Install the adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 5 Perform brake bleeding procedure as outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification TORQUE Wheel Nuts 120 ft lbs 163 Nm 7 Field test unit for proper braking action before putting into serv...

Page 433: ...unout exceeds specification Brake Disc Runout Service Limit 010 0 254 mm DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace disc if deep scratches are evident 2 Use a 0 1 micrometer and measure disc thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit Brake Disc Thickness New 0188 4 78 mm Service Limit 0 170 4 32 ...

Page 434: ...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 hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Castle Nut 110 ft lbs 149 Nm 7 Install the front brake caliper see Chapter 9 FRONT CALIPER SERVICE TORQUE Front Brake Caliper Mounting Bolts ...

Page 435: ...unting bolt q nut and washer from the bearing carrier Swing radius rod down Discard the nut 5 Remove the two caliper mounting bolts w 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 Br...

Page 436: ...t 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 298 007 7 57 mm 178 mm Service Limit 180 4 6 mm BRAKE SYSTEM ...

Page 437: ... 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 turn clockwise until the stationary pad contacts the disc then back off 1 2 turn 7 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside r...

Page 438: ...9 30 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc REAR CALIPER SERVICE CALIPER ASSEMBLY VIEW BRAKE SYSTEM ...

Page 439: ... 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 q Remove brake line from caliper 4 Remove the lower radius rod outer mounting bolt w nut and washer from the bearing carrier Swing radius rod down Discard nut 5 Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is re...

Page 440: ...piston and retaining bracket a with brake cleaner or alcohol NOTE Be sure to clean caliper body seal grooves CALIPER INSPECTION 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit MEASUREMENT Rear Caliper Piston Bore I D Standard 1 505 38 23 mm Service Limit 1 507 38 28 mm 2 Inspect piston f...

Page 441: ...smoothly with light resistance 3 Lubricate the mounting bracket pins r with silicone grease and install the rubber dust seal boots t 4 Compress the mounting bracket and make sure the dust seals 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 rear caliper with new mounti...

Page 442: ...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 TORQUE Wheel Nuts 120 ft lbs 163 Nm NOTE If new pads are installed refer to Brake Burnishing Procedure page 9 29 BRAKE SYSTEM ...

Page 443: ... 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 010 0 254 mm DISC REPLACEMENT 1 Remove rear brake caliper see Chapter 9 Caliper Removal page 9 31 2 Remove wheel hub cotter pin r castle nut e and washers w 3 Remove the hub assembly from the vehicle and remove the four bolts q re...

Page 444: ...TORQUE Rear Wheel Hub Castle Nut 110 ft lbs 149 Nm 7 Install rear caliper see Chapter 9 REAR CALIPER SERVICE Bleed the brake system See Chapter 9 BRAKE BLEEDING FLUID CHANGE page 9 8 8 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure brakes do not drag when pedal is released If the brakes drag re check assembly and installation...

Page 445: ...or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging PEDAL VIBRATION Disc damaged Disc worn runout or thickness variance exceeds service limit CALIPER OVERHEATS BRAKES DRAG Compensating port plugged Pad clearance set incorrectly Parking brake lever incorrectly adjusted INT L Model Brake pedal binding or unable to return fully Parking brake left on INT L Model ...

Page 446: ...9 38 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES BRAKE SYSTEM ...

Page 447: ...10 CHASSIS MAIN FRAME XP HIGH LIFTER 10 11 CHASSIS MAIN FRAME XP 4 10 12 SEAT ASSEMBLY FRONT 10 13 SEAT ASSEMBLY REAR 10 14 FLOOR ROCKER PANELS XP HIGH LIFTER 10 15 FLOOR ROCKER PANELS XP 4 XP 4 HIGH LIFTER 10 16 REAR CARGO BOX FENDERS 10 17 REAR BUMPER 10 18 BODY COMPONENT REMOVAL 10 19 SEATS 10 19 ENGINE SERVICE PANEL 10 19 FRONT BUMPER XP 10 19 REAR BUMPER 10 20 HOOD AND FRONT BODY WORK 10 20 R...

Page 448: ...alker Evans See Walker Evans Shock Service later in this chapter page 8 31 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com TORQUE SPECIFICATIONS ITEM TORQUE VALUE Front A Arm Bolt 42 ft lb 57 Nm Door Hinge Mount Nuts 8 ft lb 11 Nm Door Latch Screws 8 ft lb 11 Nm Front Bumper Fender Screws 8 ft ln 11 Nm Floor Screws 8 ft lb 11 Nm Trailing Arm to Frame Bolt 70...

Page 449: ...ghten 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 screws and nuts Torque fasteners to 40 ft lb 54 Nm 5 Install visor on front ROPS with M...

Page 450: ...4 ft lb 19 Nm 3 Install ROPS rear hoop to frame with M10 x 1 25 x 55 bolts and nuts e 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 r 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 t Torque to 40 ft lb 54 Nm 6 Install ROPS brace to ROPS mid hoop and ROPS rear hoop with M10 x...

Page 451: ...Copyright Polaris Industries Inc 10 5 DOORS XP q Door Panel y Latch w Door Frame u Hinge Screws 8 ft lb 11 Nm e Latch Striker i Door Panel Screws 8 ft lb 11 Nm r Hinge Pin o Door Latch Screws 8 ft lb 11 Nm t Latch Release a Striker Screws 8 ft lb 11 Nm BODY FRAME ...

Page 452: ...07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc DOORS XP4 q Door Panel t Latch Release w Door Frame y Latch e Latch Striker u Door panel Rear r Hinge Pin i Door Frame Rear BODY FRAME ...

Page 453: ...Polaris Industries Inc 10 7 DOORS HIGH LIFTER q Upper Door Panel u Latch Release w Lower Door Panel i Latch e Hip Bolster Panel o Latch Striker r Upper Door Frame a Latch Striker Screws 8 ft lbs 11 Nm t Lower Door Frame s Hinge Screws 8 ft lbs 11 Nm y Hinge Pin BODY FRAME ...

Page 454: ...R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc DASH INSTRUMENTS CONTROLS q Instrument Cluster r Headlight Switch w Key Switch t AWD Switch e 12V Accessory Port y Bezel BODY FRAME ...

Page 455: ... XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 10 9 DASH INSTRUMENTS CONTROLS HIGH LIFTER q Instrument Cluster t AWD Switch w Key Switch y Winch Switch e 12V Accessory Port u Bezel r Headlight Switch BODY FRAME ...

Page 456: ...DY WORK q Front Fascia u Grill w Driver s Front Fender i Front Bumper Cover e Driver s Front Fender Flair o Radiator Shroud r Passenger Front Fender a Front Fascia Screws 8 ft lb 11 Nm t Passenger Front Fender Flair s Lower Radiator Mount Screws 8 ft lb 11 Nm y Hood d Fan Shroud Screws 8 ft lb 11 Nm BODY FRAME ...

Page 457: ...10 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 10 11 CHASSIS MAIN FRAME XP HIGH LIFTER BODY FRAME ...

Page 458: ...10 12 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc CHASSIS MAIN FRAME XP 4 BODY FRAME ...

Page 459: ...000 Service Manual Copyright Polaris Industries Inc 10 13 SEAT ASSEMBLY FRONT q Seat Frame t Seat Slider Screws 4 ft lb 5 Nm w Screw 4 ft lb 5 Nm y Seat Back e Seat Base u Seat Base Pad r Seat Latch Lever i Seat Base Slider Assembly BODY FRAME ...

Page 460: ...e Manual Copyright Polaris Industries Inc SEAT ASSEMBLY REAR q Seat Frame u Plate Seat Latch w Screw 4 ft lb 5 Nm i Screw 4 ft lb 5 Nm e Seat Base Assembly o Bolt r Seat Latch Lever a Seat Bottom t Spring Seat Latch s Seat Back y Plate Seat Latch BODY FRAME ...

Page 461: ...ce Manual Copyright Polaris Industries Inc 10 15 FLOOR ROCKER PANELS XP HIGH LIFTER q Upper Floor u RH Rocker w T27 Screws i Push Rivots e LH Rocker o Console Cover r U Type Nuts a Seat Belt Boot t Block Off Flap s Shifter Boot y Lower Floor BODY FRAME ...

Page 462: ...LS XP 4 XP 4 HIGH LIFTER q Main Floor Upper o B Pillar Cover LH w Rocker LH a Console Front e Rivet s Shifter Boot r U Type Nuts d Seat Belt Boot Front t Block Off Flap f Console Rear y Main Floor Lower g Lower Rear Close off Panel u Rocker RH h Upper Rear Close off Panel i B Pillar Cover RH j Floor Rear BODY FRAME ...

Page 463: ... Nm w Rear Fascia Screws 8 ft lb 11 Nm a Rear Fender e Intake Cover s Cargo Box Screws 8 ft lb 11 Nm r Intake Pre filter d Cargo Box Panel t Shock Panel Screw 14 in lbs 2 Nm f Intake Cover Retainer y Shock Panel g Rear Fascia Support Brackets u Passenger Side Cargo Box Half h Bracket Fasteners 8 ft lb 11 Nm i Fender Flair j Driver Side Cargo Box Half BODY FRAME ...

Page 464: ... XP4 1000 Service Manual Copyright Polaris Industries Inc REAR BUMPER q Rear Fascia Fasteners 8 ft lb 11 Nm r Exhaust Cover Bumper w Rear Fascia t Exhaust Cover Bracket lower e Fascia Support Brackets y Exhaust Cover Bracket upper BODY FRAME ...

Page 465: ... PANEL 1 Remove the seats Remove the driver and passenger seats 2 Lift the panel upward and towards the front of the vehicle to remove the panel q 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...

Page 466: ...latches q to disengage the rear portion of the hood 2 Lift rear of hood and slide forward to disengage the front tabs and remove the hood from the vehicle Dash Removal 3 Remove the hood as previously described 4 Remove the two T 40 Torx screws retaining the Upper Dash cover between the front fenders w 5 Disconnect the instrument cluster AWD switch headlight switch and ignition switch Note their lo...

Page 467: ...at were hidden beneath the fender flair one on the outside of the fender and one on the inside 12 Remove the front portion of the cab frame assembly Refer to appropriate Cab Frame Assembly XP page 10 3 procedure for assembly torque specifications 13 Remove the front fender REAR FENDER FENDER FLAIR REMOVAL XP Fender Flair Removal 1 Remove the three Torx screws q 2 Remove the four plastic rivets on ...

Page 468: ...move both seats 2 Remove the PVT pre filter driver side and air intake pre filter passenger side assembly 3 Remove the T 25 Torx screw retaining each shock reservoir hose cover and remove the cover 4 Loosen the shock reservoir clamps and maneuver the reservoir through the hole in the box NOTE Do NOT let the reservoir hang by the hose Use a wire or string to restrain the reservoir 5 Remove the four...

Page 469: ...P 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 Remove both seats and rocker panels see Chapter 10 Floor Rocker Panels XP High Lifter page 10 15 3 Remove the T27 screws q retaining the console t to the floor 4 Remove shift handle knob and remove the console 5 Remove the Torx screws retain...

Page 470: ... and remove door 4 Remove two push rivets w Remove two Torx T40 door striker fasteners e and remove striker Remove one Torx T27 fastener r retaining the b pillar cover and remove cover 5 Remove three Torx T40 fasteners t from top of fender flare Remove two torx T40 fasteners y u Note length and location of fasteners Remove fender flare 6 Remove three push rivets i and five Torx T40 fasteners o ret...

Page 471: ...ar floor 5 Remove the rear console 6 Remove two M10x1 25x20 bolts from the rear seat frame t and two M10x1 50x55 y bolts from the rear seat frame assembly 7 Remove the seat frame 8 Disconnect negative and positive battery cables Remove the battery 9 Remove two fasteners retaining the fuse panel to the lower rear close off panel 10 Remove two fasteners retaining the voltage regulator to the back of...

Page 472: ...Remove the upper close off panel 13 Disconnect the shift cable s from the front seat base Remove two M8x1 25x20 bolts d and two M10x1 25x55 bolts f from the front seat base Remove front seat base assembly 14 Remove four Torx T40 screws g retaining the rear floor and remove the rear floor 15 Remove the Torx screws h retaining the main floor and remove the main floor from the vehicle BODY FRAME ...

Page 473: ...The flame treating 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 w...

Page 474: ...10 28 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES BODY FRAME ...

Page 475: ...S WITHOUT TURF 11 13 TRANSMISSION GEAR POSITION SWITCH 11 14 SEAT BELT SWITCH 11 15 ALL WHEEL DRIVE COIL 11 16 OPERATION OVERVIEW 11 16 DIAGNOSING SYSTEM FAILURES 11 16 VEHICLE SPEED SENSOR 11 17 SPEED SENSOR LOCATION 11 17 SPEED SENSOR TESTING 11 17 IGNITION COIL 11 18 OPERATION OVERVIEW 11 18 IGNITION COIL HT LEAD REPLACEMENT 11 18 IGNITION COIL TESTS 11 18 CHARGING SYSTEM 11 19 CURRENT DRAW KEY...

Page 476: ... REMOVAL 11 30 STARTER MOTOR INSTALLATION 11 31 STARTER SOLENOID BENCH TEST 11 31 STARTER SOLENOID OPERATION 11 31 STARTER FAILS TO TURN OVER THE ENGINE 11 32 ELECTRONIC POWER STEERING 11 33 EPS OPERATION 11 33 EPS TORQUE OFFSET PROCEDURE 11 33 PROPER EPS SYSTEM DIAGNOSING 11 34 EPS SYSTEM BREAKOUT 11 35 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON 11 36 EPS TROUBLESHOOTING POWER ...

Page 477: ...11 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 3 CHARGING SYSTEM 11 50 ELECTRICAL ...

Page 478: ...ons When measuring resistance of a component that has a resistance value under 10 Ohms 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 ...

Page 479: ...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 any gasoline that splashes on the instrument cluster The rider information display is located in the instrument cluster All segments will light...

Page 480: ...or 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 o Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system a AWD Indicator Illuminated when the AWD 2WD switch is in the AWD position s Differential Unlocked Indicator If equipped w...

Page 481: ...ip 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 3 Toggle the MODE button until the wrench icon is displayed in the information area Battery Voltage Cycle through the instrument cluster menu using the mode button until dc app...

Page 482: ...ntil 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 1 Toggle the MODE button until the odometer is displayed 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to adv...

Page 483: ...indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle 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 b...

Page 484: ...the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics 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 c...

Page 485: ...hile securely holding the dash q and rubber mount w NOTE Do not remove the rubber mount from the dash panel Only remove the rubber mount if necessary The bezel r 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 more ...

Page 486: ...an 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 switch to HIGH There s...

Page 487: ... be continuity between switch pins C and D Turn the ignition key to START There should be continuity between switch pins A and B C and D AWD 2WD SWITCH MODELS WITHOUT TURF 1 Disconnect the AWD 2WD switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 2 sets of outputs AWD 2WD If any of the tests fail replace the switch assembly M...

Page 488: ...n be accessed through the RH wheel well area 2 Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector Do not pull on the wiring 3 Test the transmission switch continuity readings for each gear position and compare to the specification table below GEAR POSITION RESISTANCE VALUE WHEN MEASURED AT SWITCH TERMINALS A AND B HIGH 24 Ω LOW 75 Ω NEU 160 Ω REV ...

Page 489: ...unctionality If the circuit is open buckle undone vehicle speed will be limited to 15mph If the circuit is closed buckle inserted the vehicle will function normally Testing 1 Disconnect the harness q running to the seat belt 2 Using a multi meter measure between both pins on switch SEAT BELT DISENGAGED SEAT BELT ENGAGED Between both pins on switch OL 1 Ω ELECTRICAL ...

Page 490: ... 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 properly Verify continuity of wire connections with a know...

Page 491: ... well SPEED SENSOR TESTING 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires from the Static Timing Light Harness 2871745 to the sensor 3 pin connector using the Hall Sensor Probe Harness 2460761 3 Pass a screwdriver back and forth in front of the sensor tip 4 Be sure connections are good and 9V battery is in good condition If the...

Page 492: ... HT LEAD REPLACEMENT NOTE The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG from the factory and should be installed to the corresponding cylinder and ignition coil post 1 Remove the seats and engine service panel to access the ignition coil 2 Disconnect the ignition coil harness and remove the high tension leads from the coi...

Page 493: ...em loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test WARNING Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will result Do not run test for extended period of time Do not run test with high amperage acces...

Page 494: ...l indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 4 Set the selector dial to measure AC Voltage 5 Start the engine and let it idle 6 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 7 Re...

Page 495: ...area in front of the left rear shock It is mounted under the LH panel divider NOTE If the regulator rectifier case temperature exceeds 230 F or 110 C the unit will turn itself off to cool down The unit will turn on again after it has cooled down to at least 212 F or 100 C If it turns off verify the cooling fins are clean free from debris and that adequate airflow is present ELECTRICAL ...

Page 496: ...nual Copyright 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 497: ...s 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 space Always shield eyes when w...

Page 498: ...ed 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 remove spark plug h...

Page 499: ... the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging STATE OF CHARGE VOLTAGE DC ACTION CHARG E TIME 100 12 8 or more None check again in 3 mo...

Page 500: ...g this procedure 5 Adjust the beam to the desired position by loosening or tightening the three T 25 adjustment screws q and moving the lamp to the appropriate height 6 Adjust the beam to desired position Repeat the procedure to adjust the other headlight WARNING Due to the nature of light utility vehicles and where they are operated headlight lenses become dirty Frequent washing is necessary to m...

Page 501: ...ntil 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 TAILLIGHT REPLACEMENT Before replacing the taillight s use a digital multi meter to test the har...

Page 502: ...k 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 temperature sensor and connector terminals ENGINE COOLANT TEMPERATURE SENSOR ECT OVERVIEW Mounted in the thermostat housing the engine temperature sen...

Page 503: ... 1 Remove the throttle body see Chapter 4 Throttle Body Removal page 4 34 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 sensor see Chapter 2 Coolant Drain Fill page 2 18 5 Using a wrench remove and replace the sensor applying a light coating of thread sealant to the sensor threads q to aid installatio...

Page 504: ...r or loose flywheel VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 0 1 VDC per connection or component To perform the test place the meter on ...

Page 505: ...fication 7 Install negative battery cable to the upper starter mounting bolt stud Torque nut to specification TORQUE Starter Mounting Bolts and Nut 7 ft lb 10 Nm STARTER SOLENOID BENCH TEST Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds With the solenoid energized resistance should read about 0 0 5 Ω between terminals A and B If resistance measure...

Page 506: ...11 32 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc STARTER FAILS TO TURN OVER THE ENGINE ELECTRICAL ...

Page 507: ...e 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 instrument cluster will illuminate During this time the vehicle will have no power steering operation You will be able to connect and communicate with the vehicle s Engine Controller but not the Power Steering Contro...

Page 508: ...PER EPS SYSTEM DIAGNOSING READ BEFORE YOU REPLACE THE EPS UNIT NOTE Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS unit If not update to the latest version for each and follow the guided diagnostic procedure s available in Digital Wrench ELECTRICAL ...

Page 509: ...11 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 35 EPS SYSTEM BREAKOUT ELECTRICAL ...

Page 510: ...11 36 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON ELECTRICAL ...

Page 511: ...11 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 37 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF ELECTRICAL ...

Page 512: ...11 38 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING USING DIGITAL WRENCH ELECTRICAL ...

Page 513: ... 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 function o...

Page 514: ...11 40 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc FUSE BOX DETAIL 2014 ELECTRICAL ...

Page 515: ...heel well The Headlight Relay INT L and Flash to Pass Relay INT L are also mounted separately located under the dash CHASSIS RELAY provides power to the following systems Lights Headlights Taillights Drive AWD Accessory 12V Receptacles Accessory Options COLOR FUNCTION Red Chassis fuse protected 12 Vdc constant battery voltage Brown Relay coil ground Orange 12 Vdc power input from key switch to ena...

Page 516: ...s 12 Vdc power for EPS operation REAR DIFF SOLENOID RELAY INT L provides power to the following system Rear Differential Solenoid COLOR FUNCTION Red Dark Green 10 Amp fuse protected 12 Vdc battery voltage Dark Green White ECU input to enable relay Brown Relay coil ground Red Relay switched power to operate the Rear Diff Solenoid Blue Ground to energize the Rear Diff Solenoid HEADLIGHT RELAY INT L ...

Page 517: ...en and a yellow wire CAN SYSTEM TESTING A component not displaying information correctly could be the cause of damaged CAN wiring or a faulty component The easiest location to test the CAN system is at the Diagnostic Connector Turn the key to the ON position Using a multimeter ohm across the Green and Yellow wires at the diagnostic connector A RZR equipped with a PIDD should have a reading of 120 ...

Page 518: ...11 44 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc BREAK OUT DIAGRAMS AWD ELECTRICAL ...

Page 519: ...11 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 45 VEHICLE SPEED SENSOR ELECTRICAL ...

Page 520: ...11 46 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc COOLING SYSTEM ELECTRICAL ...

Page 521: ...11 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 47 UNSWITCHED CHASSIS POWER ELECTRICAL ...

Page 522: ...11 48 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc KEY ON BATTERY POWER ELECTRICAL ...

Page 523: ...11 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 49 LIGHTS ELECTRICAL ...

Page 524: ...11 50 9926816 R07 2014 2016 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc CHARGING SYSTEM ELECTRICAL ...

Page 525: ... Brake System Assembly View 9 6 Brake Hose and Fitting Inspection 2 39 Troubleshooting 9 37 Brakes Bleeding Fluid Change 9 8 Brake Burnishing Procedure 9 29 Brakes Lock 9 37 Hydraulic Brake System Operation 9 5 Master Cylinder Installation 9 8 Master Cylinder Removal 9 7 Overheating 9 37 Pedal Vibration 9 37 Performance Issues 9 37 Special Tools 9 3 Torque Specifications 9 3 Troubleshooting Brake ...

Page 526: ...gnostics 4 51 Overview 4 48 Serial Number 4 51 Updates 4 49 Doors 10 5 Doors XP4 10 6 Drive Belt Inspection 5 18 Installation 5 18 Removal 5 17 Drive Clutch Assembly 5 27 Bushing Service 5 25 Button to Tower Clearance 5 22 Cover Bushing 5 25 Disassembly 5 20 Moveable Sheave Inspection 5 25 Needle Bearing 5 21 Operation 5 5 Roller and Pin Inspection 5 23 Shift Weights 5 22 Spider Removal 5 23 Sprin...

Page 527: ...olant Temp Sensor ECT 11 28 Engine Serial Number Location 1 4 Engine Service Panel 10 19 Engine Camshaft Timing Quick Reference 3 84 Engine Valve Cover Installation 3 89 EPS Breakout Diagram 11 35 Operation 11 33 Torque Offset Procedure 11 33 Troubleshooting 11 36 ETC Testing 4 35 ETC Learn Procedure 4 11 4 35 4 53 Exhaust Assembly View 3 14 Exhaust Valve Lash Tappet Matrix 3 88 F Fan Control Circ...

Page 528: ...n 9 8 Removal 9 7 Master Torque Table 1 22 Metric Bolt Torque Specification 1 25 Misfire Detection 4 39 Model Number Designation 1 2 N ne Valve Clearance Adjustment 3 85 O Oil Pressure Test 3 4 Open Circuit Voltage Test 11 24 Oxygen Sensor 4 38 Replacement 4 38 P Parking Brake Adjustment INT L 9 12 Assembly View INT L 9 11 Caliper INT L 9 13 Disc INT L 9 16 Inspection INT L 9 12 Pedal Position Sen...

Page 529: ...ientation Walker Evans 8 31 Shock Walker Evans 2 5 Assembly View 8 25 Shock Walker Evans Assembly 8 35 Spark Plug Service 2 42 Special Tools Body Steering Suspension 8 3 10 2 Brakes 9 3 Clutching 5 3 EFI 4 3 Electrical 11 4 Engine 3 3 Final Drive 7 3 Master 1 6 Shock 8 31 Transmission 6 2 Specification Wheel Toe Out 2 31 Specifications Brakes 9 4 Cooling System 3 15 Engine Lubrication 3 3 3 35 Eng...

Page 530: ...es 6 3 Output Shaft Backlash Procedure 6 24 Removal 6 6 Snorkel Shaft Removal 6 12 Troubleshooting 6 34 Transmission Lubrication 6 2 Transmission Switch 11 14 Trouble Codes Instrument Cluster ETC 4 39 Troubleshooting Brake Noise 9 5 Brake System 9 37 Clutch 5 43 Cooling System 3 91 Engine 3 90 Fuel Injector 4 12 Fuel System 4 47 Misfire Detection 4 39 Transmission Shifting Difficulty 6 34 U Upper ...

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