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Polaris RZR XP 1000 2017, Service Manual, Page: 349 / 535

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Polaris RZR XP 1000 2017 Service Manual Download Page 349

7

9928492 R04 - 2017-2018

RZR

XP 1000 / XP4 1000 Service Manual

© Copyright Polaris Industries Inc.

7.27

FRONT GEARCASE / CENTRALIZED HILLIARD

FRONT GEARCASE ASSEMBLY VIEW

q

Seal

s

Ring Gear

w

Cover Plate

d

Spring

e

AWD Coil

f

Output Hub

r

Backlash Spacer

g

Bearing

t

Nylon Spacer

h

Gearcase Housing

y

Armature Plate

j

Drain Plug

10 ft-lbs (14 Nm)

u

Roller Cage

k

Fill / Check Plug

10 ft-lbs (14 Nm)

i

Roller

l

Pinion Gear

o

Spring Retainer

1(

Snap Ring

a

O-ring

2)

Cover Plate Screws

11 ft-lbs (15 Nm)

FINAL DRIVE

Summary of Contents for RZR XP 1000 2017

Page 1: ...ized 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: ... 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 during disasse...

Page 3: ...Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the nearest Polaris dealer REVISION INDEX REV DATE CHANGES R01 09 19 2017 Initial release R02 11 12 2017 11 21 2017 Corrected oil pressure adapter f...

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: ...T 1 16 2017 RZR XP 4 1000 HIGH LIFTER 1 17 RZR XP 1000 HIGH LIFTER CLUTCH CHART 1 18 2017 RZR XP 1000 LE MATTE GOLD METALLIC 1 19 RZR XP 1000 CLUTCH CHART 1 20 2017 RZR XP 1000 LE RIDE COMMAND 1 21 RZR XP 1000 CLUTCH CHART 1 22 2018 RZR XP 1000 1 23 RZR XP 1000 CLUTCH CHART 1 24 2018 RZR XP 4 1000 1 25 RZR XP 4 1000 CLUTCH CHART 1 26 2018 RZR XP 1000 HIGH LIFTER 1 27 RZR XP 1000 HIGH LIFTER CLUTCH...

Page 8: ...ENTIFICATION 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 15 16 17 4 X A R U E 5 7 3 F G 0 0 0 0 0 0 Model Year A 2010 B 2011 C 2012 D 2013 E 2014 F 2015 G 2016 H 2017 J 2018 VEHICLE AN...

Page 9: ...8 4010321 31 4110141 32 4110148 67 4010278 68 4010278 PUBLICATION NUMBERS YEAR MODEL OWNER S MANUAL 2017 RZR XP 1000 9927194 RZR XP 1000 LE Gold Metallic 9927195 RZR XP 1000 High Lifter 9927193 RZR XP4 1000 9927194 RZR XP4 1000 High Lifter 9927193 RZR XP 1000 INT L EU MD 9927410 ZUG Tractor 9927412 RZR XP4 1000 INT L MD 9927410 2018 RZR XP 1000 LE Gold Metallic High Lifter 9928358 RZR XP4 1000 Hig...

Page 10: ...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 11: ...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 12: ...ing 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 52492 Oil Pressure Gauge Adapter M20 PU 50565 Oil Pressure Gauge Adapter 1 2 NPT PU ...

Page 13: ...eal Protector Sleeve 5 8 PU 51024 Shock Rod Holding Tool PU 51039 Gas Shock Fill Tool PU 51829 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 ...

Page 14: ...anjo Bolts 15 ft lbs 20 Nm Brake Line Flare Fittings 15 ft lbs 20 Nm Brake Pedal Mount Bracket Bolts 16 ft lbs 22 Nm Brake Switch 15 ft lbs 20 Nm Cab Frame Bolts 40 ft lb 54 Nm Cab Frame Mid Hoop Mounting Fasteners 17 ft lb 23 Nm Cam Chain Tensioner 29 ft lb 40 Nm Camshaft Carrier Bolts 7 ft lb 10 Nm Camshaft Sprocket Bolts 14 ft lb 19 Nm ITEM TORQUE Clutch Cover outer Screws 50 in lbs 5 Nm Connec...

Page 15: ...uel Tank Strap Screw 8 ft lbs 11 Nm Hip Bolster Bolts 14 ft lb 19 Nm Hose Clamp 35 in lb 4 Nm ITEM TORQUE Hub Castle Nut 180 ft lbs 244 Nm Intake Plenum Screw 22 ft lb 30 Nm Master Cylinder Mount Bolts 23 ft lbs 31 Nm Oil Cooler Bolts 7 ft lb 10 Nm Oil Pump Mounting Bolts 7 ft lbs 10 Nm Oil Pump Pickup Screws 7 ft lb 10 Nm Oil Sump Cover M8 Bolts 26 ft lb 35 Nm Oil Sump Cover M6 Bolts 106 in lb 12...

Page 16: ...Trailing Arm to Frame 70 ft lb 95 Nm Trailing Arm to Bearing Carrier Fasteners 42 ft lb 54 Nm Trans Bell Crank Nut 18 ft lb 24 Nm Trans Case Screws 20 ft lbs 27 Nm Trans Drain Fill Plugs 14 ft lbs 19 Nm Trans Isolator Bolt rear 40 ft lb 54 Nm Trans Rear Mount Bracket Fasteners 22 ft lb 30 Nm Trans Joint Bracket Bolts 44 ft lb 60 Nm Trans Park Flange Screws 10 ft lb 14 Nm Trans Sector Gear Cover 12...

Page 17: ...e 90 228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1369 lbs 621 kg Gross Vehicle Weight 2200 lbs 997 9 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 Ton...

Page 18: ... Fan EFI Fuel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL 44 oz 1300 mL STEERING SUSPENSION Toe ...

Page 19: ... cm Ground Clearance 13 5 34 3 cm Dry Weight 1565 lbs 709 9 kg Gross Vehicle Weight 2590 lbs 1174 8 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 2 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 Cap...

Page 20: ... Fuel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 15A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 ...

Page 21: ...28 6 cm Ground Clearance 15 0 38 1 cm Dry Weight 1530 lbs 694 0 kg Gross Vehicle Weight 2200 lbs 997 9 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 22: ...l Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 I...

Page 23: ...0 297 2 cm Ground Clearance 15 0 38 1 cm Dry Weight 1752 lbs 783 3 kg Gross Vehicle Weight 2736 lbs 1241 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 2 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 Tongu...

Page 24: ...l Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Key 10A Term 25A EPS 10A Lights 10A Drive 15A Accessory DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 I...

Page 25: ...se 90 228 6 cm Ground Clearance 14 0 35 6 cm Dry Weight 1567 lbs 711 kg Gross Vehicle Weight 2388 lbs 1083 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 Ton...

Page 26: ...ump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type Gated Shift for Park P R N L H 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 ...

Page 27: ...0 228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1379 lbs 626 kg Gross Vehicle Weight 2200 lbs 997 9 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 28: ...uel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 ...

Page 29: ...cm Ground Clearance 13 5 34 3 cm Dry Weight 1369 lbs 621 kg Gross Vehicle Weight 2200 lbs 997 9 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 Capacit...

Page 30: ... Fan EFI Fuel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL 44 oz 1300 mL STEERING SUSPENSION Toe ...

Page 31: ... cm Ground Clearance 13 5 34 3 cm Dry Weight 1565 lbs 709 9 kg Gross Vehicle Weight 2590 lbs 1174 8 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 2 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 Cap...

Page 32: ... Fuel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 15A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 ...

Page 33: ...28 6 cm Ground Clearance 15 0 38 1 cm Dry Weight 1530 lbs 694 0 kg Gross Vehicle Weight 2200 lbs 997 9 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 34: ...l Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 I...

Page 35: ...0 297 2 cm Ground Clearance 15 0 38 1 cm Dry Weight 1752 lbs 783 3 kg Gross Vehicle Weight 2736 lbs 1241 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 2 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 Tongu...

Page 36: ...l Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Key 10A Term 25A EPS 10A Lights 10A Drive 15A Accessory DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 I...

Page 37: ...90 228 6 cm Ground Clearance 14 0 35 6 cm Dry Weight 1567 lbs 711 kg Gross Vehicle Weight 2388 lbs 1083 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 38: ...ump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type Gated Shift for Park P R N L H 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 ...

Page 39: ...228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1379 lbs 626 kg Gross Vehicle Weight 2200 lbs 997 9 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 40: ...uel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 ...

Page 41: ... 297 2 cm Ground Clearance 13 5 34 3 cm Dry Weight 1565 lbs 709 9 kg Gross Vehicle Weight 2590 lbs 1174 8 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 2 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 Tong...

Page 42: ... Fuel Pump Chassis EPS Circuit Breaker 25A Cooling Fan Fuses 10A EFI 10A Unswitched 10A Key 15A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P R N L H 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 ...

Page 43: ...h inch x 2 54 cm 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 ...

Page 44: ...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 45: ... 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 46: ...1 40 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES GENERAL INFORMATION ...

Page 47: ...E INSPECTION 2 32 CAM CHAIN TENSIONER INSPECTION 2 34 HEAT SHIELD INSPECTION 2 35 COOLING SYSTEM 2 36 COOLING SYSTEM OVERVIEW 2 36 COOLANT STRENGTH 2 36 COOLANT LEVEL INSPECTION 2 36 COOLING SYSTEM PRESSURE TEST 2 37 COOLING SYSTEM HOSES 2 37 RADIATOR INSPECTION CLEANING 2 38 COOLANT DRAIN FILL 2 39 FUEL SYSTEM AND AIR INTAKE 2 40 FUEL SYSTEM WARNING 2 40 FUEL TANK VENT LINE 2 40 VENT LINE TERMINA...

Page 48: ...NT LINE ROUTING 2 51 STEERING 2 52 STEERING INSPECTION 2 52 STEERING WHEEL FREE PLAY 2 52 TIE ROD END WHEEL HUB INSPECTION 2 53 WHEEL TOE ALIGNMENT INSPECTION 2 53 WHEEL TOE ADJUSTMENT 2 54 SUSPENSION 2 55 SPRING ADJUSTMENT WALKER EVANS 2 55 SHOCK COMPRESSION ADJUSTMENT WALKER EVANS 2 55 BRAKE SYSTEM 2 57 BRAKE HOSE AND FITTING INSPECTION 2 57 BRAKE FLUID INSPECTION 2 57 BRAKE PAD DISC INSPECTION ...

Page 49: ...ck for proper air pressure in all tires Inspect for tire damage nails in tire Verify there is adequate tread depth Wheels Lug Nuts Ensure rim is not cracked bent Verify proper lug nut torque Headlights Taillights Ensure all lights are operational Adjust headlight aim as required Brake System Check brake fluid level is between MIN and MAX Check brake pedal is not soft when pushed Verify brakes stop...

Page 50: ...on Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it co...

Page 51: ... REMARKS XU D Brake Pads Parking Brake Pads INT L Inspect pad wear Fuel System Turn key on to pressurize fuel pump check lines fittings for leaks and abrasion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Break In Perform a break in oil and filter change at 25 hou...

Page 52: ...L Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonal...

Page 53: ...n XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often...

Page 54: ...ve Belt Inspect replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D Fuel System Check for leaks at fill cap fuel line rail and fuel pump D Spark Plug Inspection Inspect replace as needed torque to s...

Page 55: ...on XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more ofte...

Page 56: ...AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength season...

Page 57: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 58: ...an replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D Fuel System Check for leaks at fill cap fuel line rail and fuel pump D Spark Plug Inspection Inspect replace as needed torque to specification...

Page 59: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 60: ...AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength season...

Page 61: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 62: ...ive Belt Inspect replace as needed D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D Fuel System Check for leaks at fill cap fuel line rail and fuel pump...

Page 63: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 64: ...AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength season...

Page 65: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 66: ...eplace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D Fuel System Check for leaks at fill cap fuel line rail and fuel pump D Spark Plug Inspection Inspect replace as needed torque to specification XU ...

Page 67: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 68: ...GL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D Throttle Pedal Inspect replace if it sticks E Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seaso...

Page 69: ...ion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU Engine Breather Inspect clean Battery Check terminals clean test XU Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more oft...

Page 70: ...cant XU Transmission Lubricant AGL Change lubricant D Fuel System Check for leaks at fill cap fuel line rail and fuel pump D Spark Plug Inspection Inspect replace as needed torque to specification XU Radiator Inspect clean external surfaces XU Cooling Hoses Inspect for leaks pressure test system XU Engine Mounts Inspect torque to specification Exhaust Silencer Pipe Inspect XU Wiring Inspect for we...

Page 71: ...anel 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 op...

Page 72: ...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 73: ...hese areas ITEM METHOD RECOMMENDED LUBE FREQUENCY Front Stabilizer Bar Bushings Grease the fitting on each side of the vehicle w 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 Rear Stabilizer Bar Bushings Grease 2 fittings through the skid plate access holes on each side of the vehicle e ...

Page 74: ...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 75: ...ransmission 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 ...

Page 76: ...ION 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 77: ...h a clean cloth see Chapter 2 Engine Oil Level page 2 29 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...

Page 78: ...uilt 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 79: ...Valve Clearance Adjustment page 3 81 MEASUREMENT Intake Valve Clearance cold 006 002 0 15 0 05 mm Exhaust Valve Clearance cold 010 002 0 25 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 I...

Page 80: ...t the negative battery cable to the battery and install the seat 20 Start the engine to ensure proper operation 21 Install the engine access panel CAM CHAIN TENSIONER INSPECTION 1 Locate the cam chain tensioner on the MAG side of the engine near the starter 2 Remove the plunger bolt q and the spring 3 Remove the two tensioner mounting bolts w 4 Push on the tensioner lock e and manually move the pl...

Page 81: ...stries Inc 2 35 HEAT SHIELD INSPECTION Inspect all heat shields to make sure they are not damaged or missing Replace any damaged or missing heat shields q Front Box Shield r Rear Box Shield w Access Panel Shield t Silencer Shield e Side Box Foil Shield y Head Pipe Shield MAINTENANCE ...

Page 82: ...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 83: ...EST 1 Remove the hood from the front cab WARNING Never remove pressure cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 2 Remove pressure cap and pressure test the cooling system using a commercially available pressure tester 3 The system must maintain 10 psi for five minutes or longer If pressure loss is evi...

Page 84: ...ess and condition of all hose spring clamps Replace if necessary RADIATOR INSPECTION CLEANING 1 Check radiator air passages for restrictions or damage q Radiator w Shroud e Fan 2 Carefully straighten any bent radiator fins 3 Remove any obstructions with low pressure compressed air or low pressure water CAUTION Washing the vehicle with a high pressure washer could damage the radiator fins and impai...

Page 85: ...ath 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 completely Properly dispose of the used coolant 6 Reinstall coolant hose and reposition the spring clamp 7 Remove the pressure cap Using a funnel add the recommended coolant to the top of the filler neck and f...

Page 86: ... must be replaced The fitting will not hold properly once it is removed Symptoms of a restricted fuel tank vent include the following collapsing fuel tank engine miss or hesitation loss of engine performance or high exhaust temperatures 1 Remove the seats and the engine service panel 2 Check the fuel tank vent line q for signs of wear deterioration or damage Replace vent line if necessary 3 Be sur...

Page 87: ... 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 rear wheel well on the upper right side of the engine Check the line and quick connect fitting for signs of wear deterioration damage...

Page 88: ...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 Inspect the pre filter If necessary clean with soapy water and dry with low pressure compressed air AIR FILTER SERVICE Inspect the air filter at the interval...

Page 89: ... 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 DRAIN INSPECTION It is recommended that the intake drain be inspected daily 1 Access the intake baffle box drain q through the left rear wheel well 2 Check ...

Page 90: ...sary clean with soapy water and dry with low pressure compressed air PVT DRYING NOTE After operating in water the vehicle s PVTsystem should be checked immediately Use the following instructions to dry it out before operating The 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 d...

Page 91: ...ightly If wheel hub removal is required remove the wheel cap cotter pin and loosen the hub nut slightly 4 Elevate the appropriate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 Verify the transmission is still in PARK 2 Place the wheel in the correct position on the wheel hub t Be sure the valve stem w is toward the...

Page 92: ... proper tire pressure Refer to the warning tire pressure decal applied to the vehicle TIRE PRESSURE INSPECTION COLD Model Front Rear XP 16 psi 110 kPa 16 psi 110 kPa XP4 19 psi 131 kPa 20 psi 138 kPa TIRE PRESSURE INSPECTION COLD High Lifter XP and XP 4 18 psi 124 kPa 18 psi 124 kPa LE Matte Gold Metallic 12 psi 83 kPa 16 psi 110 kPa BEADLOCK RIMS IF EQUIPPED Some RZR XP 1000 LE models comes with ...

Page 93: ...000 Service Manual Copyright Polaris Industries Inc 2 47 TORQUE Beadlock Screws Step 1 24 in lbs 3 Nm Step 2 7 ft lbs 10 Nm NOTE Beadlock bolts should be checked and torqued every 300 miles 450 km 7 Seat bead and inflate to 16 psi MAINTENANCE ...

Page 94: ...y 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 reco...

Page 95: ...with 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 96: ...n 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 m...

Page 97: ...d is retained by a clip w mounted to the cargo box rear bracket The line runs parallel with the fuel supply line and is retained by a zip tie e attached to the cargo box front bracket The line terminates to open air does not terminate to a fitting or hole in the frame FRONT GEARCASE VENT LINE ROUTING The front gearcase vent line starts at the front gearcase q and routes up the right side The vent ...

Page 98: ...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 99: ...Bearing Carrier Inspection Removal page 7 6 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 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible ...

Page 100: ...oe alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both end of the tie rod Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified MEASUREMENT Wheel Toe Out 1 8 to 3 16 3 2 to 4 8 mm After alignment is complete torque jam nuts to specification TORQUE Tie Rod Jam Nut 14 ft lbs 19 Nm CAUTION When tightening the tie rod end ...

Page 101: ...Spreader Tool 2878925 NOTE Polaris does not recommend increasing the spring adjustment by more than one inch 25 4 mm over the factory setting r as it may negatively impact vehicle stability Always return the spring preload to the factory setting after the load is removed from the vehicle Spring Adjustment Factory Setting approx MODEL FRONT REAR RZR XP 1000 0 80 7 97 RZR XP 4 1000 2 04 5 13 RZR XP ...

Page 102: ...ion Factory 6 clicks from softest position Firmest Full clockwise position Walker Evans 2 5 Rear Shock Compression Adjustment Table SETTING COMPRESSION DAMPING Softest Full counter clockwise position Factory 7 clicks from softest position Firmest Full clockwise position The rear shock adjuster can be found on the remote reservoir Clockwise will increase damping and counter clockwise will decrease ...

Page 103: ...Position the vehicle on a level surface 2 Place the transmission in PARK 3 View 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...

Page 104: ...ow 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 use...

Page 105: ...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 106: ...e spark plugs using a 5 8 spark 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...

Page 107: ...12 COOLING SYSTEM ASSEMBLY VIEW 3 14 COOLING SYSTEM BLEEDING PROCEDURE 3 15 WATER PUMP REMOVAL 3 16 WATER PUMP INSTALLATION 3 16 WATER PUMP SERVICE 3 18 ENGINE SERVICE 3 21 ACCESSIBLE ENGINE COMPONENTS 3 21 TOP END SERVICE ENGINE IN CHASSIS 3 21 CRANKSHAFT PTO SEAL REPLACEMENT 3 22 ENGINE REMOVAL 3 24 ENGINE INSTALLATION 3 27 ENGINE MOUNTING AND TORQUE VALUES 3 30 ENGINE BREAK IN PERIOD 3 30 ENGIN...

Page 108: ...D INSPECTION 3 57 ENGINE ASSEMBLY BOTTOM END 3 59 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 59 CONNECTING ROD BEARING SELECTION 3 60 CRANKSHAFT MAIN BEARING SELECTION 3 60 UPPER CRANKCASE PREPARATION 3 61 PISTON RING INSTALLATION 3 61 PISTON CONNECTING ROD ASSEMBLY 3 63 CYLINDER PISTON INSTALLATION 3 64 CRANKSHAFT INSTALLATION 3 65 BALANCE SHAFT INSTALLATION 3 67 LOWER CRANKCASE PREPA...

Page 109: ...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 2 5 qt 2 4 L Oil Type PS 4 Full Syn...

Page 110: ...ide of the engine 4 Remove the plug and insert the oil pressure adapter Torque the adapter to specification TORQUE PU 50565 16 ft lbs 22 Nm PU 52492 22 ft lbs 30 Nm 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 conside...

Page 111: ...3 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 3 5 TORQUE Crankcase Oil Gallery Plug 1 2 NPT 16 ft lbs 22 Nm ENGINE OIL FLOW CHART ENGINE COOLING SYSTEM ...

Page 112: ...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 010 002 0 25 0 05 mm Valve Stem Diameter Intake 2155 2161 5 475 5 490 mm Valve Stem Diameter Exhaus...

Page 113: ...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 114: ...e Manual Copyright Polaris Industries Inc 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 115: ...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 116: ... 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 PRESSURE TEST 1 ...

Page 117: ...p 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 21and Front Bumper page 10 20 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 prop...

Page 118: ...r 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 pa...

Page 119: ...system 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 ENGI...

Page 120: ...LING 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 121: ...ary 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 ...

Page 122: ...nt 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 remove...

Page 123: ...e 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 bol...

Page 124: ...r 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 w...

Page 125: ...ump 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 ...

Page 126: ...Copyright Polaris Industries Inc 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 127: ...lve Cover Water Pump The following components require engine removal for service Camshaft Timing Chain Connecting Rod s Counterbalance Shaft Bearings Crankcase Crankshaft Main Bearings Crankshaft Seal PTO Cylinder Oil Pump Oil Pump Sprocket or Chain Piston Rings TOP END SERVICE ENGINE IN CHASSIS Some top end engine components can be serviced while the engine is mounted in the chassis To service th...

Page 128: ...r 2018 engines and does NOT work with 2017 and older models CRANKSHAFT PTO SEAL REMOVAL 1 Remove the Inner PVT Cover Refer to PVT disassembly to access the crankcase seal 2 Using a commercially available seal puller tool remove crankcase seal from crankcase IMPORTANT Use care not to scratch the crankcase while removing seal 3 Inspect the crankcase and crankshaft surfaces for any burrs or scratches...

Page 129: ... The orientation of the seal is critical Install the seal with the flat side of the seal facing out as shown 2 Tighten the drive bolt e until the cylinder r bottoms out against the crankcase 3 Once the seal is properly installed loosen the drive bolt e and remove special tool PU 52493 from the crankshaft 4 Refer to Inner PVT Cover installation 5 Field test the vehicle before putting back into serv...

Page 130: ...an the engine and chassis 3 Drain the engine oil and coolant prior to engine removal See Chapter 2 Coolant Drain Fill page 2 39 4 Remove the seats 5 Disconnect the negative battery cable from the battery 6 Remove the rear bumper and cargo box see Chapter 10 Cargo Box Assembly Removal page 10 23 7 Remove the air box assembly 8 Elevate the rear of the vehicle off the ground using a suitable lift and...

Page 131: ...g for installation 17 Remove spark plug wires from the engine NOTE The spark plug wires are marked with MAG and PTO Note during installation procedure 18 Remove the breather hose u from the crankcase 19 Remove the six fasteners that attach the exhaust head pipe to the engine Remove the two exhaust springs i that attach the head pipe o to the muffler Remove exhaust head pipe towards the front of th...

Page 132: ...lly out of 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 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 50...

Page 133: ...le 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 front and rear engine mounting locations Install and hand tighten the four front engine mounting nuts q and bolts w NOTE DO NOT torque fasteners at this time 6 Align transmission joint mounting holes with the transmi...

Page 134: ...aining the transmission joint bracket to the engine on the right side Hand tighten the bolts so they remain loose at this time NOTE DO NOT torque fasteners at this time 11 Install the two longer bolts into left side mounting holes Torque left side mounting bolts to specification using the numbered sequence shown 12 Torque right side mounting bolts to specification using the numbered sequence shown...

Page 135: ...box assembly as outlined in the EFI Chapter See Chapter 4 ETC Replacement page 4 41 30 Install the inner clutch cover drive clutch driven clutch drive belt outer clutch cover and clutch outlet duct see Chapter 6 PVT Assembly page 5 11 31 Install the left rear shock lower mounting bolt and new nut Torque to specification TORQUE Rear Shock Mounting Bolt 70 ft lbs 95 Nm 32 Install the left rear wheel...

Page 136: ...ious engine damage and voiding of warranty can result Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unleaded fuel which has a minimum pump octane number of 87 R M 2 2 Refer to Engine Oil Level Check oil level indicated on dipstick Add oil if nece...

Page 137: ...50 2876244 quart 2876245 gallon 35 F to 100 F PS 4 Extreme Duty 2878920 quart 2878919 gallon Oil Filter Wrench PU 50105 or 2 5 64 mm Oil Filter PN 2540086 Oil Pressure Minimum Specification using Polaris engine oil at operating temperature 10 PSI 1200 RPM 40 PSI 7000 RPM Additional oil may be required after complete engine disassembly Check level after filling and add oil as needed ENGINE COOLING ...

Page 138: ...ors w when they are removed and replace valve cover seal 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 s...

Page 139: ...e remaining two bolts that retain the front camshaft carrier t and carefully lift the carrier off the camshafts 5 Hold camshafts y with an open end wrench and remove the top bolt u from the camshaft sprockets i 6 Rotate the 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 Usin...

Page 140: ...r camshaft carrier a and carefully lift the carriers off the camshafts 10 Mark the intake s and exhaust d camshafts to ensure proper assembly 11 Carefully remove camshafts from the cylinder head CAMSHAFT SPROCKET INSPECTION Inspect cam sprocket teeth q for wear or damage Replace timing chain and sprockets if worn or damaged ENGINE COOLING SYSTEM ...

Page 141: ...r if any part is worn past the service limit MEASUREMENT Camshaft Lobe Height Intake 1 5390 1 5429 39 09 39 19 mm Service Limit 1 5370 39 04 mm Exhaust 1 5142 1 5181 38 46 38 56 mm Service Limit 1 5122 38 41 mm 3 Visually inspect each camshaft journal for scoring wear or damage 4 Measure the diameter of the camshaft journals using a micrometer Compare to specification NOTE Replace camshafts if dam...

Page 142: ...0039 0 1 mm CYLINDER HEAD REMOVAL NOTE The cylinder head can be serviced with the engine installed in the chassis 1 Remove the two outer M6 bolts q that retain the cylinder head w to the cylinder 2 Loosen the six cylinder head bolts e evenly 1 8 turn at a time until all are loose 3 Remove and discard the cylinder head bolts 4 Tap cylinder head lightly with a soft faced hammer until loose 5 Tap onl...

Page 143: ...t points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head MEASUREMENT Cylinder Head Warp Limit 0039 0 1 mm CYLINDER HEAD DISASSEMBLY WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs NOTE Keep mated parts together and in or...

Page 144: ...tion 6 Lift up the cylinder head and push the valve i out keeping it in order for reassembly in the same valve guide 7 Repeat the previous steps to remove the remaining valves 8 Clean the combustion chamber and head gasket surface 9 Check the condition of each valve spring Replace if wear or cracking is present on the spring VALVE INSPECTION 1 Remove all carbon from valves with a soft wire wheel o...

Page 145: ...ENT Valve Guide I D 2165 2171 5 500 5 515 mm 7 Be sure to measure each guide and valve combination individually NOTE The valve guides cannot be replaced COMBUSTION CHAMBER CLEANING WARNING Wear eye protection during combustion chamber cleaning 1 Clean all accumulated carbon deposits from combustion chambers and valve seat area q NOTE Carbon Clean Fuel Treatment 2871326 can be used to help remove c...

Page 146: ...a face shield during cylinder head disassembly and reassembly Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions exist the valve seat must be reconditioned If the valve seat is cracked the cylinder head must be replaced Valve seat width and point of contact on the valve face is very important for proper seal...

Page 147: ...ference angle 46 apply black permanent marker to the entire valve face q 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width If the indicated seat contact is at the top edge of the valv...

Page 148: ...des with clean engine oil and apply oil or 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 slig...

Page 149: ...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 150: ...OVAL NOTE The water pump housing can be serviced with the engine installed in the chassis see Chapter 3 Water Pump Removal page 3 16 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 151: ...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 152: ...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 153: ... 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 154: ... 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 155: ...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 47 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 156: ...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 47 procedure 2 Perform Balance Shaft Removal Inspection page 3 49 procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts q Remove the end caps from the crankshaft 5 Carefully li...

Page 157: ...ng 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 Journal 1 Main Bearing f Journal 5 Main Bearing a Journal 2 Rod Bearing g Journal 6 Main Bearing s Journal 3 Main Bearing...

Page 158: ...re installing the original refer to the bearing selection chart provided in the Crankshaft Main Bearing Selection page 3 60 and Connecting Rod Bearing Selection page 3 60 procedures CRANKCASE INSPECTION 1 Remove the oil drain diverter q from the upper crankcase 2 Remove all traces of crankcase sealer from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 3 Be sur...

Page 159: ...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 160: ... the unique cylinder skirt and crankcase design 1 Perform ENGINE DISASSEMBLY INSPECTION TOP END page 3 32 and ENGINE DISASSEMBLY INSPECTION BOTTOM END page 3 43 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 con...

Page 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ... 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 167: ...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 168: ... 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 169: ...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 170: ...ston see Chapter 3 Piston Ring Installation page 3 61 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 171: ...Chapter 3 Crankshaft Main Bearing Selection page 3 60 and Connecting Rod Bearing Selection page 3 60 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 172: ...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 173: ...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 174: ... 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 175: ...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 176: ...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 177: ...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 72 and then Cylinder Head Installat...

Page 178: ...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 179: ...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 180: ... 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 retainer on the spring 8 C...

Page 181: ...linder 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 dry free from oil or gre...

Page 182: ...wheel 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 exhaust markings made during disassembly If installing new camshafts or if ca...

Page 183: ... 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 80 NOTE Intake cam sprocket should have I marks aligned with gasket ...

Page 184: ...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 185: ...SIONER ONLY Install the cam chain tensioner s into the cylinder and torque to specification TORQUE Hydraulic Cam Chain Tensioner 29 ft lb 40 Nm 23 MECHANICAL TENSIONER ONLY Retract the plunger all the way in and install into the cylinder Install the two mounting bolts Torque fasteners to specification TORQUE Tensioner Mounting Bolts 7 ft lb 10 Nm Install the plunger bolt Torque fastener to specifi...

Page 186: ...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 187: ...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 188: ...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 189: ... Lash Specification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3 digit tappet number by 100 i e 450 100 4 5 mm 3 Add the results of step 1 and step 2 i e 0 09 mm 4 5 mm 4 59 mm 4 Multiply that answer by 100 to obtain the correct new tappet i e 4 59 mm x 100 45...

Page 190: ...all 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 191: ...Engine 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 Wo...

Page 192: ...nts 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 thro...

Page 193: ...ETC LEARN PROCEDURE 4 12 FUEL INJECTORS 4 13 OPERATION OVERVIEW 4 13 FUEL INJECTOR O RINGS 4 13 FUEL INJECTOR TROUBLESHOOTING 4 14 FUEL INJECTOR TEST 4 14 FUEL INJECTOR REPLACEMENT 4 15 FUEL LINES TANK 4 18 ASSEMBLY VIEW 4 18 FUEL VENT LINE ROUTING NON HIGHLIFTER 4 19 FUEL VENT LINE ROUTING HIGH LIFTER 4 21 VENT LINE TERMINATION FITTING 4 22 FUEL LINE QUICK CONNECT REMOVAL 4 22 FUEL LINE REMOVAL I...

Page 194: ...ENSOR 4 44 OXYGEN SENSOR INFORMATION 4 44 OXYGEN SENSOR REPLACEMENT 4 44 EFI DIAGNOSTICS 4 46 TROUBLE CODE DISPLAY DTC 4 46 CYLINDER MISFIRE DETECTION 4 53 EFI TROUBLESHOOTING 4 54 POLARIS DIGITAL WRENCH 4 55 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 55 SPECIAL TOOLS DIGITAL WRENCH 4 55 DIGITAL WRENCH SOFTWARE VERSION AND UPDATE ID 4 56 DIGITAL WRENCH UPDATES 4 56 DIGITAL WRENCH COMMUNICATION ...

Page 195: ...ttempting to service any part of the fuel system pressure should be relieved The Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure 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 ...

Page 196: ...d wrap any open joints with 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 ...

Page 197: ...MBLY 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 198: ...e 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 199: ...CU 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 ign...

Page 200: ...ery 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 IN...

Page 201: ...VAP system such as a missing or loose fuel cap No check engine light will illuminate r Fuel Tank The fuel tank has a built in rollover valve to prevent liquid fuel from entering the EVAP system in case of an incident such as the vehicle being upside down t Air Filter and Lines Before incoming air can enter the charcoal canister it needs to be filtered This air filter is located near the fuel tank ...

Page 202: ...es being set A loose fuel cap will NOT trigger a trouble code but may cause a fuel odor Excessive hydrocarbon emissions may be caused by any of the following An ignition misfire Improper ignition timing Excessively lean or rich air fuel mixture Low Compression Worn valves or guides Worn cylinder or piston rings Vacuum leaks Dirty fuel injector Defective sensor or damaged sensor wiring Excessive ca...

Page 203: ...ECU 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 ...

Page 204: ...u 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 205: ... and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length depending on the speed and load requirements of the engine The ECU gathers fuel injection timing information from the Crankshaft Position Sensor CPS and the Pedal Position Sensor PPS to allow for sequential fuel injection FUEL INJECTOR O RINGS 1 Any ti...

Page 206: ...ressure from the leakage can cause hot restart problems and longer cranking times Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pressure the use of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault code...

Page 207: ...ng the intake plenum w to the throttle body 4 Remove the two screws e retaining the intake plenum 5 Remove the driver s seat and disconnect the negative battery cable 6 Disconnect the fuel injector harness leads r 7 Hold a shop towel over the fuel line fitting and remove the fuel supply line t from the fuel rail 8 Remove tie strap retaining the injector harness leads to the fuel rail Remove the tw...

Page 208: ... on the injector and fuel rail as shown above 13 Thoroughly clean the area around the fuel injector ports on the throttle body 14 Lightly lubricate the injector O rings and reinstall the fuel rail injector assembly into the throttle body 15 Install the fuel rail mounting screws and torque to specification TORQUE Fuel Rail Mounting Screws 44 in lb 5 Nm 16 Reinstall the fuel line to the fuel rail 17...

Page 209: ...sure the air box boots fully seat onto the dual throttle body before tightening the hose clamps j TORQUE Hose Clamps 35 in lb 4 Nm Intake Manifold Mount Screw 22 ft lb 30 Nm 22 Reinstall the breather into the air box and tighten the hose clamps retaining the air box to the throttle body assembly 23 Reinstall the two screws retaining the air box assembly 24 Position the intake hose onto the air box...

Page 210: ...4 1000 Service Manual Copyright Polaris Industries Inc FUEL LINES 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 211: ...e Hinge Clip w Panduit Strap r Vent Line Fitting 1 Secure fuel vent line and fuel line together behind the gas tank with a Panduit strap w 2 Retain the fuel vent line to the frame with a hinge clip e and Panduit strap w 3 Route the fuel vent line over the electrical harness and retain fuel vent line to the electrical harness with a Panduit strap w FUEL SYSTEM ...

Page 212: ...nual Copyright Polaris Industries Inc 4 Route the fuel vent line up behind the frame and secure vent line to the frame with two hinge clips e 5 Route the fuel vent line through the shock mount and attach the vent line to the fitting in the frame r FUEL SYSTEM ...

Page 213: ...e 274 cm e Hinge Clip w Panduit Strap 1 Secure fuel vent line and fuel line together behind the gas tank with a Panduit strap w 2 Retain the fuel vent line to the frame with a hinge clip e and Panduit strap w 3 Route the fuel vent line over the electrical harness and retain fuel vent line to the electrical harness with a Panduit strap w FUEL SYSTEM ...

Page 214: ...re proper venting Connect the Mity Vac to the fitting and give it 5 pumps The gauge should return to 0 immediately or there is an obstruction NOTE If the vent line fitting is removed from the frame it must be replaced The ears on the clip arrows will not hold properly once it is removed FUEL LINE QUICK CONNECT REMOVAL When properly used fuel line quick connects can be disconnected and reconnected ...

Page 215: ...fits into the pry slot 2 Gently pry the retaining clip upwards into the open position 3 Remove quick connect from the fuel fitting Hand Method 4 Gently pull outward on retaining tabs to unlock retaining clip CAUTION Do not over pry or excessively bend the retaining tabs This can damage the retaining clip and require replacement of the fuel line assembly 5 Push retaining clip upward into the open p...

Page 216: ...g tabs or any sign of cracks in the retaining clip The retaining clip is responsible for holding the quick connect on the line when under fuel pressure 4 Quick connect has been twisted from its original inserted position or the connector has been damaged FUEL LINE REMOVAL INSTALLATION 1 Place a shop towel around the fuel line to catch any dripping fuel 2 If removing either end of supply line w rel...

Page 217: ...jury or complications 1 Remove the driver and passenger seats 2 Disconnect the negative and positive battery cables from the battery located under the driver s seat Remove the bolt retaining the battery bracket and remove the battery from the vehicle 3 While holding a shop towel over the fuel line connectors disconnect the fuel supply line q from the pump see Chapter 2 Fuel Lines page 2 41 for spe...

Page 218: ...x 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 o retaining the front of the seat base frame and two rear bolts i Remove the rear seat base assembly from the vehicle 10 Remove the T 40 Torx screw a retaining the fuel tank strap to the seat base frame Remove the strap from the othe...

Page 219: ... seat base frame and torque fasteners to specification TORQUE Seat Base Frame fasteners 8 ft lbs 11 Nm 6 Install 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 center console shift knob and screws 9 R...

Page 220: ...e Chapter 2 Fuel Lines page 2 41 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 tank...

Page 221: ...l tank to ensure the bracket is inserted properly into the lower fuel tank mount 2 Reinstall the fuel tank bracket and fasteners 3 Install the vent line 4 Reinstall lower rear close off panel Secure with plastic rivets and torque screws to specification TORQUE Block off Panel Screws 8 ft lbs 11 Nm 5 Reinstall the seat base frame and torque fasteners to specification TORQUE Seat Base Frame fastener...

Page 222: ...ously removed fasteners 11 Reconnect the fuel line and fuel pump electrical harness Verify connections are secure 12 Reinstall the battery and battery bracket Torque fastener to specification TORQUE Battery Bracket 8 ft lbs 11 Nm 13 Install seats and test the fuel pump by turning the ignition key on and listening for the pump to activate Check the fuel line fittings for leaks FUEL SYSTEM ...

Page 223: ...e 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 running the fuel pump remains on FUEL SENDER TEST 1 Remove the fuel pump assembly from the fuel tank Refer to Fuel Pump Replacement procedure 2 Using an Ohm meter measure the resistance of ...

Page 224: ... 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 pump did not activate Step 5 disconnect the harness connector from the fuel pump Connect a DC voltmeter across terminals 3 Red Blue and 4 Brown in the plug on the vehicle fuel pump harness Turn on the key switch and observe voltage to ensure a ...

Page 225: ...the fuel supply line w from the pump and the fuel return line B from the tank see Chapter 2 Fuel Lines page 2 41 for specific removal procedures CAUTION It is possible for pressurized fuel to be present when disconnecting the fuel line It is recommended to allow the vehicle to sit for a period of one hour after shutting off the engine before servicing the fuel pump This allows the exhaust to cool ...

Page 226: ...nstallation of new fuel pump assembly NOTE It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel Do not use water or any other chemicals to remove debris 11 Remove new fuel pump assembly t gasket y and PFA nut u from packaging Use care not to bend float arm i during un packaging Do not lift or carry fuel pump assembly by the float arm 12 Use clea...

Page 227: ...etween fuel pump and fuel tank 18 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench TORQUE Fuel Pump PFA Nut 70 ft lbs 95 Nm 19 Verify alignment of fuel pump and tank orientation marks 20 Connect the fuel supply line to the pump see Chapter 2 Fuel Lines page 2 41 for specific installation procedures NOTE Be sure to engage the retainers on each...

Page 228: ...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 229: ...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 230: ...age 4 37 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 231: ...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 232: ...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 233: ...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 234: ...ed 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 t...

Page 235: ...om the vehicle PPS Installation 6 Place the throttle pedal assembly and protective shield on the mounting studs and loosely install the three fasteners 7 Torque the three mounting bolts to specification and connect the PPS harness connection TORQUE Throttle Pedal Mounting fasteners 18 ft lb 24 Nm 8 Manually cycle the throttle pedal to verify the throttle pedal moves freely 9 Connect the negative b...

Page 236: ...r circuit element in the sensor however can be tested with an ohmmeter MEASUREMENT Oxygen Sensor Heater Element Resistance 15 8 18 6 Ohms NOTE This test MUST be performed with the sensor at room temperature 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 i...

Page 237: ...4 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 4 45 TORQUE Oxygen Sensor 13 ft lb 18 Nm 4 Connect the harness going to the oxygen sensor FUEL SYSTEM ...

Page 238: ...de 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 code present example 2 means there are 3 codes present Th...

Page 239: ...tage 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 Below Normal 4 Manifold Absolute Pr...

Page 240: ... 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 Above Normal 3 P0917 Voltage Too Low 4 P0916 Abnormal Rate of Chan...

Page 241: ...30 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 High 3 P16A2 Voltage Too Low 4 P16A1 Valid But Above Normal least severe 16 P16A5...

Page 242: ...rted 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 Failure Condition Exists 520223 31 C1052 Steering Torque Full Failure Condition Exists 520224 31 C1053 EPS Inverter Temperature Greater than 12...

Page 243: ...n 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 Fault 520276 2 P150C Neither Position Sensor Passed Test 12 P150B Throttle Body Control Power Stage Not Plausible 520277 2 P151A Voltage Above Normal 3 P150...

Page 244: ...tion 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 Fault Voltage Condition Exists 520307 31 P1532 Accelerator Sensor...

Page 245: ...iting how far the throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur The check engine light will remain illuminated until there are 4000 engine revolutions i e 4000 RPM for one minute without a significant misfire being detected Once this condition is met the ...

Page 246: ...ormance 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 fil...

Page 247: ... 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 4715...

Page 248: ...s 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 webs...

Page 249: ...C before running the install 8 When the update is complete the version shown on the right side of the Digital Wrench start up screen should match the update you just downloaded NOTE Versions and updates are subject to change DIGITAL WRENCH COMMUNICATION ERRORS If you experience problems connecting to a vehicle or any Digital Wrench related problem visit the Digital Wrench Knowledge Base for the mo...

Page 250: ...low Digital Wrench use 1 Assemble the SmartLink Module and attach the PC Interface Cable to your laptop 2 Remove the protective cap from the Digital Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic connector 4 Turn the ignition key to the ON position select the appropriate vehicle and wait for the status to display Connected in the lower left corner of the sc...

Page 251: ...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 252: ...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 253: ... 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 battery before y...

Page 254: ...l 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 on the dealer web...

Page 255: ...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 256: ...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 257: ...E 5 7 XP XP4 PVT COVERS AND DUCTING COMPONENTS 5 7 PVT COVERS AND DUCTING COMPONENTS HIGH LIFTER 5 8 PVT DISASSEMBLY 5 9 PVT ASSEMBLY 5 11 DRIVE BELT 5 13 BELT REMOVAL 5 13 BELT INSPECTION 5 14 BELT INSTALLATION 5 14 PVT BREAK IN DRIVE BELT CLUTCHES 5 14 DRIVE CLUTCH SERVICE 5 15 DRIVE CLUTCH ASSEMBLY VIEW 5 15 DRIVE CLUTCH DISASSEMBLY INSPECTION 5 16 NEEDLE BEARING INSPECTION 5 17 SHIFT WEIGHT IN...

Page 258: ...5 2 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc TROUBLESHOOTING 5 31 TROUBLESHOOTING 5 31 PVT SYSTEM ...

Page 259: ...800 0 6000 29 75 PM 5633720 Black Red 7044263 Black 7044708 1800 3700 6000 12000 29 68 PM 5139618 RZR XP 4 1000 CLUTCH CHART MODEL ALTITUDE METERS FEET SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING XP4 1000 0 1800 0 6000 29 75 PM 5633720 Black White lettering 7044504 Black 7044708 1800 3700 6000 12000 29 68 PM 5139618 RZR XP 1000 HIGH LIFTER CLUTCH CHART MODEL ALTITUDE METERS FEET SHIFT WEIGHT DRIVE SPR...

Page 260: ...ched 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 compo...

Page 261: ...y operating at slower speeds during the 10 hours as recommended see Chapter 3 Engine Break In Period page 3 30 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 hig...

Page 262: ... 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 th...

Page 263: ...MPONENTS 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 48 in lb 5 Nm u Outlet Duct j Clutch Cover Drain Screw i Outer Clutch Cover k Inner Cover Screws 12 ft lb 16 Nm o Inner Clutch Cover PVT SYSTEM ...

Page 264: ... 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 265: ...tch 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 13 10 Remove the driven clutch retaining bolt and driven clu...

Page 266: ...2085 CAUTION Be sure to use the correct Drive Clutch Puller to prevent damage to crankshaft 13 Remove the four push rivets that secure the upper guard plate to the top of the inner PVT cover 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...

Page 267: ...r and the four push rivets that secure the cover to the top of the inner PVT cover 7 Install the three inner clutch cover bolts and washers that retain the cover to the engine and the four inner clutch cover bolts and washers that retain the cover to the transmission Torque bolts to specification TORQUE Inner Clutch Cover Bolts 12 ft lb 16 Nm 8 Clean the end of the taper on the crankshaft and the ...

Page 268: ...ly read 15 Install a new outer clutch cover seal with the colored stripe facing the inner clutch cover 16 Reinstall outer clutch cover and secure with screws Torque screws to specification TORQUE Outer Clutch Cover Retaining Screws 48 in lb 5 Nm 17 Install inlet and outlet ducts and tighten hose clamps 18 Install the left rear shock lower mounting bolt and the left rear wheel Torque fasteners to s...

Page 269: ...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 270: ...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 271: ... Ring w Washers i Bushing g Cover Bushing e Non braking Bearing o Spring h Drive Clutch Cover r Shift Weight Fastener 20 in lb 2 Nm a Spider 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 j Cover Fasteners 9 ft lb 12 Nm t Shift Weight s Spider Jam Nut 250 ft lb 339 Nm Apply 0 1 mL Loctite 7088 Primer and 0 1 mL Loctite 620 y Moveable Sheave d Spacer PVT SYSTEM ...

Page 272: ...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 273: ... relaxation the 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 The non braking needle bearing should ro...

Page 274: ...e 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 clu...

Page 275: ...ing Fixture PN 2871358 B 2 Loosen and remove the spider e counterclockwise using Clutch Spider Removal Installation Tool r Spider Removal Installation Tool 2870341 A 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 driv...

Page 276: ...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 277: ...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 278: ... Pin Puller 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 puller b...

Page 279: ...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 280: ... 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 281: ...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 282: ...the slider block w Replace the sliders if they are smaller than the service limit MEASUREMENT Slider to Sheave Clearance q Service Limit 0 175 4 5 mm Slider Width w Service Limit 0 975 24 8 mm DRIVEN CLUTCH DISASSEMBLY 1 Remove driven clutch from 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 di...

Page 283: ... Not using a proper compressor may result in personal injury or damage to the clutch 5 Remove the universal clutch compressor 6 Note the alignment of the X s w on the spider and moveable sheave Remove the spider assembly e and spring NOTE Spring is compression only and has no torsional wind 7 Remove the E clips r washers t and the clutch rollers y Inspect the rollers for wear replace if worn 8 Pre...

Page 284: ...f there is heavy wear on the bushings replace the clutch assembly 12 Inspect the sheaves for excessive wear or damage DRIVEN CLUTCH ASSEMBLY 1 Align the X s q on the moveable and stationary sheaves 2 Install the 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 ...

Page 285: ...y the spring Not using a proper compressor may result in personal injury 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 Insta...

Page 286: ...al Copyright Polaris Industries Inc DRIVEN CLUTCH 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 287: ...earance Sheave face grooved 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 mo...

Page 288: ...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 289: ...TER ADJUSTMENT GOLD METALLIC LE 6 5 SHIFT CABLE INSPECTION 6 6 SHIFT CABLE ADJUSTMENT 6 6 TRANSMISSION SERVICE 6 8 TRANSMISSION REMOVAL 6 8 TRANSMISSION INSTALLATION 6 11 TRANSMISSION VENT LINE ROUTING 6 14 TRANSMISSION DISASSEMBLY 6 14 DIFFERENTIAL OPERATION 6 19 PLANETARY DIFFERENTIAL DISASSEMBLY TURF MODE MODELS ONLY 6 22 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT TURF MODE MODELS ONLY 6 23 PLA...

Page 290: ...ar Output Seal Driver 2871699 Part of 2871702 Kit Rear Driveshaft Seal Guide 2871282 Bearing Seal Driver 50 mm PU 50566 Transmission Nut Socket PU 50658 A Clutch Center Distance Tool Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com LUBRICATION FLUID CAPACITY Recommended Transmission Lubricant AGL Capacity Standard 44 oz 1300 mL Capacity INT L 40 5 oz 1200 mL ...

Page 291: ...er and disconnect the cable end from the lever 4 Remove the retaining ring t and slide the shift lever y off the mounting bracket and out from the frame 5 Remove 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 LEVER REMOVAL GOLD METALLIC LE 1 Remove th...

Page 292: ...D METALLIC LE 1 Add Loctite 603 on completely around the outer surface of the spherical bearing Install the spherical bearing into the shift lever NOTE The spherical bearing orientation inside the shift lever is important for proper function Note the alignment o of the marks in the spherical bearing with the marking on the shift lever 2 Once the spherical bearing marks are aligned with the mark on...

Page 293: ...not equal move the bracket until the gaps are equal and tighten the fasteners to specification TORQUE Gated Shifter Bracket Fasteners 14 ft lb 19 Nm 8 Install the shifter boot t spacer r shift knob e retaining screw w and shift knob cover q GATED SHIFTER ADJUSTMENT GOLD METALLIC LE 1 Place the gear selector in REVERSE 2 Remove the shift knob cover q retaining screw w shift knob e and spacer r from...

Page 294: ... Fasteners 14 ft lb 19 Nm 6 Install the shifter boot spacer shift knob retaining screw and shift knob cover SHIFT CABLE INSPECTION Shift cable adjustment may be necessary if symptoms include No gear position or AWD display on instrument cluster Ratcheting noise on deceleration Inability to engage into a gear Excessive gear lash noise Gear selector moving out of desired range Inspect shift cable cl...

Page 295: ... 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 296: ...rom the transmission output shaft see Chapter 7 Rear Prop Shaft Removal page 7 21 7 Remove rear wheels from the vehicle 8 If internal transmission repair is required drain the transmission lubricant see Chapter 2 Transmission Lubrication page 2 48 9 Remove the lower mounting bolt from the left rear shock Swing shock outward 10 Remove the outer clutch cover drive belt drive clutch driven clutch inn...

Page 297: ...s outward to remove the drive shafts from the transmission 15 Maneuver the drive shafts out of the vehicle frame Reinstall the lower shock bolts e to hold the trailing arms up during the rest of the removal procedure 16 Place a spacer or support between the vehicle frame and engine to hold the engine up in position 17 Remove vent hose from transmission 18 Remove the gear position switch connector ...

Page 298: ... the rear transmission mounting bracket 22 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 23 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 ...

Page 299: ...nsmission 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 Distance Tool onto transmission input shaft and install the drive clutch bolt e to properly position the clutch center distance The picture...

Page 300: ...g 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 right side mounting bolts to specification using the numbered sequence shown TORQUE Engine Transmission Mounting Bolts Step 1 2 64 ...

Page 301: ...teners 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 page 5 11 21 Install new spring ring a on rear drive shafts Apply an anti seize compound to the splines s 22 Swing the rear tra...

Page 302: ... TRANSMISSION VENT LINE ROUTING The transmission vent line connects to a nipple q on the side of the transmission near the transmission switch The vent line routes up through the gap between the MAG and PTO intake runners and is retained by a clip w mounted to the cargo box rear bracket The line runs parallel with the fuel supply line and is retained by a zip tie e attached to the cargo box front ...

Page 303: ... facing outward for reassembly 8 Remove the spacer a 9 Remove the shift shaft s detent pawl d and the shift sector gears f and g NOTE Note the timing marks on the shift gears for reassembly purposes 10 Remove the O rings h from each shaft and discard Use new O rings upon assembly 11 Remove all the transmission case bolts Using suit able pry bars remove the cover using the designated pry points ind...

Page 304: ...idler gear shaft assembly 2 from the transmission housing by pulling both assemblies straight up 16 Place the gear cluster assembly on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly 17 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembly 2 Lift the pinion shaft assembly straight up to remove it from the housing Note the long...

Page 305: ...the retaining ring washer needle bearing and sprocket from the reverse shaft 22 Tilt the two shafts towards each other and remove the silent chain from the two shafts 23 If necessary disassemble the other end of the reverse shaft Remove the bearing engagement dog retaining ring washer low gear d and needle bearing f from the reverse shaft s Reverse Shaft h Washer d Bearing j Low Gear f Engagement ...

Page 306: ...he snorkel shaft to access the snorkel tube 2 for removal 26 Using the Snorkel Tool fully loosen the snorkel tube Snorkel Tool PA 50231 27 Remove the snorkel tube and shaft assembly from the transmission case 28 Remove the snap ring 2 and shim 2 from the snorkel shaft 29 Use an arbor press to remove the snorkel tube from the snorkel shaft 30 Remove the snap ring 3 and shim 3 retaining the bearing ...

Page 307: ...on and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain When Differential Unlock is selected the rear differential becomes unlocked for tighter turns An electrical solenoid mounted in the rear portion of the gearcase actuates the shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the ...

Page 308: ...cted 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 309: ...TION q Ring Gear Assembly w Male Side Gear Assembly e Planet Gear Assembly r Female Gear Assembly t Differential Cover Assembly y Planetary Differential Assembly Fasteners u Engagement Dog i Bearing o Shift Fork Retainer Fastener a Torsion Spring s Retainer d Shift Fork f Solenoid Spring g Solenoid TRANSMISSION ...

Page 310: ... 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 311: ...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 312: ...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 313: ...nd 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 NOTE The are two possible grades for the differential cover screws The grade can be located on the head of the fastener The two possible fasteners are grade 8 8 and grade 10 9 Torque the screws accordin...

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Page 315: ...rkel 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 ...

Page 316: ...over 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 n...

Page 317: ...el 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 instal...

Page 318: ...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 above 3 21 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 22 Insta...

Page 319: ...ounter 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 clean the shift shaft housing 27 Install the sector gear 16T onto the shift drum shaft Install the sh...

Page 320: ... 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 N...

Page 321: ...shings 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 probl...

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Page 323: ...T SERVICE 7 16 OUTER CV BOOT REPLACEMENT 7 16 INNER PLUNGING JOINT BOOT REPLACEMENT 7 18 PROP SHAFT SERVICE 7 20 FRONT PROPSHAFT REMOVAL 7 20 REAR PROP SHAFT REMOVAL 7 21 REAR PROP SHAFT REMOVAL XP 4 7 22 SUPPORT BEARING REPLACEMENT 7 23 U JOINT DISASSEMBLY 7 24 U JOINT ASSEMBLY 7 24 FRONT PROP SHAFT INSTALLATION 7 25 REAR PROP SHAFT INSTALLATION 7 25 REAR PROP SHAFT INSTALLATION XP 4 7 26 FRONT G...

Page 324: ... Industries Inc GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roll Pin Removal Tool 8700226 CV Boot Clamp Pliers earless type PU 48951 Axle Boot Clamp Tool Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com FINAL DRIVE ...

Page 325: ...ont bearing carrier 6 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc 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 bearing car...

Page 326: ... 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 c...

Page 327: ...iper 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...

Page 328: ...alls 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 castle...

Page 329: ...railing 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 corros...

Page 330: ...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 comp...

Page 331: ...ng 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 M10 40 ft lb 54 Nm M12 outer 50 ft lb 90 68 Nm 90 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...

Page 332: ...w 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 333: ...l 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 17 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 disc...

Page 334: ...t Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper and lower ball joint ends into the front bearing carrier 5 Install new pinch bolts and nuts 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 335: ...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 cone washer s e from the rear wheel hub assembly 4 Remove the two bolts r retaining the upper and lower radius rods to the bearing carrier Discard the nuts Let the radius rods swing downward ...

Page 336: ... 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 specification TORQUE Lower Shock Bolt to Trailing Arm 70 ft lbs 95 Nm 5 Insta...

Page 337: ...Castle Nut 180 ft lbs 244 Nm 8 Install the radius rod bolts washers and new nuts Torque fasteners to specification TORQUE Radius Rods to Bearing Carrier M10 40 ft lb 54 Nm M12 outer 50 ft lb 90 68 Nm 90 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 specif...

Page 338: ... other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots CV JOINT SERVICE OUTER CV BOOT REPLACEMENT NOTE Outer CV Joint replacement is...

Page 339: ...ment 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 package 8 Remove excess grease from the CV joint s external surfaces and place the excess grease in the boot 9 Pull the boot over the joint and position the boot lips into the grooves on the...

Page 340: ...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 grease in the joint is obviously contaminated with ...

Page 341: ...n 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 Pull the boot over the joint and position the bo...

Page 342: ...in 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 Prop...

Page 343: ...he frame 3 While moving the prop shaft support bearing assembly slide the rear prop shaft towards the rear until the front prop shaft yoke disengages from the splines 4 Once the front and rear prop shafts have been separated slide the rear prop shaft forward to remove it from the transmission output shaft 5 Remove the support bearing rubber bushing by pulling it off the rear prop shaft 6 Remove th...

Page 344: ...he 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 assembly to the drivers side to slide the rear prop shaft yoke y off the transmission output shaft 7 Slide the prop shaft to the rear of the vehicle until the front of the shaft clears the frame sup...

Page 345: ...n 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 loca...

Page 346: ...to one side and lift out of inner yoke U JOINT ASSEMBLY 1 Install new bearing caps in yoke by hand Carefully install U joint cross Tighten vise or use a press to force bearing caps in 2 Using a suitable arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedur...

Page 347: ...olts that secure the front gearcase to the frame Torque bolts to specification TORQUE Front Gearcase Mounting Bolts 35 ft lbs 47 Nm REAR PROP SHAFT INSTALLATION 1 Reverse the appropriate Rear Prop Shaft Removal procedure to reinstall the rear prop shaft 2 Lubricate the transmission output shaft splines with Polaris All Purpose Grease 3 Lubricate the front and rear prop shaft mid joint with Polaris...

Page 348: ...ropriate Rear Prop Shaft Removal XP 4 page 7 22 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 alig...

Page 349: ...E ASSEMBLY VIEW q Seal s Ring Gear w Cover Plate d Spring e AWD Coil f Output Hub r Backlash Spacer g Bearing t Nylon Spacer h Gearcase Housing y Armature Plate j Drain Plug 10 ft lbs 14 Nm u Roller Cage k Fill Check Plug 10 ft lbs 14 Nm i Roller l Pinion Gear o Spring Retainer 1 Snap Ring a O ring 2 Cover Plate Screws 11 ft lbs 15 Nm FINAL DRIVE ...

Page 350: ... armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels lose traction Once the rear wheels begin to lose traction the front drive will engage by coupling the output hubs r to the ring gear via the rollers The front ...

Page 351: ...case cover u The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the AWD system If this is found replace the cover plate assembly 6 Inspect the roller s...

Page 352: ...nt gearcase and remove the harness from the retaining dart 6 Remove the vent line from the front gearcase and plug vent line fitting 7 Remove the four bolts r securing the front gearcase to the frame 8 Rotate front of gearcase up so the input shaft is facing down Lift and remove the gearcase from the front LH wheel well area and slide it out of the vehicle above the upper A arm FRONT GEARCASE DISA...

Page 353: ... plate assembly NOTE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate r Refer to AWD Diagnosis page 7 28 for detailed inspection process 5 Remove the torsion spring retainer t and torsion spring y from the top of the ring gear 6 Remove the clutch housing ring gear and roll cage assembly u from the gearcase housing FINAL DRIVE ...

Page 354: ... detailed inspection process Replace the cover plate seal f and O ring g 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in order to retain all the rollers NOTE Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 12 Thoroughly clean all parts and inspect the rollers h for nicks and s...

Page 355: ...ct all remaining front gearcase components Check each for excessive wear or damage FRONT GEARCASE ASSEMBLY 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components 2 Install pinion shaft assembly and install internal snap ring NOTE If bearing replacement was required press new bearing onto the pinion shaft and install a new external snap ring 3 Install a new...

Page 356: ...rooves line up with the roll cage windows see below Be sure role cage top groove is facing upward 6 Install the torsion spring r by wrapping each leg of the spring around the dowel pin on the ring gear 7 Align spring retainer dowel pin t with ring gear dowel pin y and install the retainer on top of the torsion spring 8 Check the action of the torsion spring by rotating in both directions to ensure...

Page 357: ...Carefully install the ring gear and roll cage assembly i into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTE Be sure the square O ring is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 12 Carefully install the LH output hub assembly o into the cover plate Take care not to damage the new cover plate seal while installing the output h...

Page 358: ... 35 ft lbs 47 Nm 5 Install the vent line w 6 Connect the AWD wire harness 7 Refer to FRONT DRIVE SHAFT Drive Shaft Installation page 7 12 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 m...

Page 359: ...ustries Inc 7 37 WHEEL HUBS FRONT HUB ASSEMBLY VIEW q Wheel Cap t Cotter Pin o Studs w Wheel Lug Nuts 120 ft lbs 163 Nm y Washers a Snap Ring e Valve Stem u Wheel Hub s Wheel Bearing r Hub Castle Nut 180 ft lbs 244 Nm i Brake Disc d Bearing Carrier REAR HUB ASSEMBLY VIEW FINAL DRIVE ...

Page 360: ... 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 Ste...

Page 361: ...R REMOVAL 8 13 FRONT STABILIZER BAR INSTALLATION 8 14 BALL JOINT SERVICE PREPARATION 8 15 BALL JOINT REMOVAL 8 15 BALL JOINT INSTALLATION 8 15 REAR SUSPENSION 8 16 RADIUS ROD REMOVAL INSTALLATION 8 16 TRAILING ARM REMOVAL INSTALLATION 8 16 TRAILING ARM SPHERICAL BEARING REPLACEMENT 8 19 REAR SUSPENSION ASSEMBLY VIEW 8 20 REAR STABILIZER BAR REMOVAL 8 21 STABILIZER BAR INSTALLATION 8 21 SHOCKS SPRI...

Page 362: ...28492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc SHOCK PISTON ORIENTATION 8 29 WALKER EVANS SHOCK DISASSEMBLY 8 30 WALKER EVANS SHOCK ASSEMBLY 8 33 STEERING SUSPENSION ...

Page 363: ...ass FOX PU 51830 Spanner Wrench 2 5 Outer Internal Bypass FOX PU 51832 Spanner Wrench 3 0 Outer Internal Bypass FOX PU 51837 Shock Body Holding Tool 2 5 FOX PU 51838 Shock Body Bolding Tool 3 0 FOX Walker Evans See Walker Evans Shock Service later in this chapter page 8 29 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com MULTI FUNCTION PLIERS Included in the ...

Page 364: ...Shaft j Lower Steering Shaft e Steering Wheel a Steering Shaft to EPS Fasteners 15 ft lbs 20 Nm k Steering Shaft to Rack Fasteners 42 ft lb 57 Nm r Steering Shaft Bushings s EPS Unit l Tie Rod End Fasteners Do not reuse 30 ft lb 41 Nm 90 t Pivot Tube d EPS Cover 1 Steering Rack Mounting Nuts 16 ft lbs 22 Nm y Pivot Tube Fasteners 8 ft lb 11 Nm f EPS Cover Fasteners 8 ft lb 11 Nm 2 Steering Rack u ...

Page 365: ...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 366: ...he 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 Rem...

Page 367: ...t 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 IMPORTANT Electronic Power Steering EPS units are programmed to be vehicle specific and are not interchangeable between product lines STEERING SUSPENSION ...

Page 368: ...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 369: ...on the power steering 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...

Page 370: ...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 Steering Wheel Nut 65 ft lbs 88 Nm 5 Install a new upper ...

Page 371: ...shaft and press it into the pivot tube by hand IMPORTANT Use care not to allow any of the Loctite to get in the bearing as this may cause the bearing to seize Bearings will be seated in the pivot housing upon tightening the steering wheel nut in step 14 9 Reinstall the upper washers and spacers in the order in which they were removed 10 Install the steering wheel and hand tighten the nut Apply Loc...

Page 372: ...lt removal 7 Loosen and remove the upper A arm front through bolt fastener e and rear though bolt fastener r Remove the upper A arm from the vehicle 8 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 operati...

Page 373: ...19 Examine A arm bushings and pivot tube Replace if worn Discard hardware 20 If not replacing the A arm thoroughly clean the A arm and pivot tube 21 Install new ball joint into A arm Refer to Ball Joint Replacement section 22 Insert new A arm bushings and pivot tube into new A arm A light press force may be needed 23 Install new lower A arm assembly onto vehicle frame Torque new bolt to specificat...

Page 374: ...ue fasteners to specification TORQUE Stabilizer Bar Link Fasteners 40 ft lb 54 Nm 2 Install the stabilizer bar from the side 3 Install the fasteners retaining the stabilizer bar mount to the frame Torque fasteners to specification TORQUE Stabilizer Bar Mount Bracket Fasteners 17 ft lb 23 Nm 4 Install the nut q retaining the front stabilizer bar link w to the upper control arm eon both sides Torque...

Page 375: ...emove the retaining ring q from the ball joint w 2 Place a proper sized driver on the ball joint and place the A arm in a press 3 Carefully press the ball joint out of the A arm and discard the ball joint BALL JOINT INSTALLATION 1 By hand install the NEW ball joint into the A arm 2 Using a press carefully drive in the new ball joint into the A arm 3 After the new ball joint q is fully installed in...

Page 376: ...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 Inner Radius Rod Mounting Bolts 50 ft lb 68 Nm 45 Outer Radius Rod Mounting Bolts 50 ft lbs 68 Nm 90...

Page 377: ...lts 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 Rear Bearing Replacement in the Final Drive chapter 10 Remove the four...

Page 378: ...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 M10 40 ft lb 54 Nm M12 outer 50 ft lb 90 68 Nm 90 Bearing Carrier to Trailing Arm...

Page 379: ...that retains the spherical bearing 4 Properly support the trailing arm and press the spherical bearing out of trailing arm casting 5 Be sure to only press on outer most surface of bearing race do not press on the center spherical bearing 6 Inspect trailing arm bearing housing for wear or damage Replace trailing arm if damaged 7 Press in new bearing until fully seated into trailing arm casting 8 In...

Page 380: ... 95 Nm a Rear Shock Assembly e Radius Rod Fasteners 50 ft lb 68 Nm 45 s Shock Guard r Radius Rod d Stabilizer Bar Link Fasteners 40 ft lbs 54 Nm t Radius Rod Fasteners 50 ft lb 68 Nm 45 f Rear Stabilizer Bar y Rear Bearing Carrier g Stabilizer Bar Mounting Clamp Fasteners 20 ft lb 27 Nm u Bearing Carrier Bolts 40 ft lb 54 Nm h Trailing Arm Mounting Bolts 70 ft lb 95 Nm i Trailing Arm STEERING SUSP...

Page 381: ...t 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 frame Torque fasteners ...

Page 382: ... Bolts Front 40 ft lb 54 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 3 Remove the spring and spring retainer f...

Page 383: ... End 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 Sh...

Page 384: ...n Every 100 hours Visually 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 All models 2 875 73 ...

Page 385: ...TON 1 550 x 0 008 1 500 x 0 010 1 100 x 0 025 1 000 x 0 015 1 100 x 0 010 1 000 x 0 025 1 550 x 0 008 1 450 x 0 010 1 000 x 0 025 1 550 x 0 008 1 300 x 0 010 0 625 x 0 065 1 550 x 0 008 1 200 x 0 010 1 550 x 0 008 1 100 x 0 010 1 550 x 0 008 1 000 x 0 010 1 450 x 0 010 0 900 x 0 010 1 300 x 0 008 0 750 x 0 065 1 200 x 012 1 100 x 012 0 750 x 0 065 Piston Bleed Orifice none RZR XP XP4 1000 High Lif...

Page 386: ...300 x 0 008 1 000 x 0 015 1 550 x 0 008 1 200 x 0 008 0 900 x 0 015 1 500 x 0 010 1 100 x 0 010 0 600 x 0 015 1 450 x 0 010 1 000 x 0 010 0 600 x 0 015 1 300 x 0 010 0 900 x 0 010 1 200 x 0 010 0 750 x 0 065 1 100 x 0 012 0 900 x 0 012 0 800 x 0 012 1 500 x 0 125 No Piston Bleed Orifice Shock Valving RZR XP4 1000 COMPRESSION REBOUND CLICKER ASSEMBLY 1 550 x 0 010 1 500 x 0 010 0 700 x 0 010 1 000 ...

Page 387: ...750 x 0 010 1 450 x 0 010 CLICKER PISTON 1 650 x 0 010 1 300 x 0 010 1 000 x 0 015 1 550 x 0 008 1 200 x 0 010 1 000 x 0 015 1 000 x 0 010 1 100 x 0 010 0 900 x 0 015 1 550 x 0 008 1 000 x 0 010 0 600 x 0 015 1 550 x 0 008 0 900 x 0 010 0 600 x 0 015 1 550 x 0 008 0 800 x 0 010 1 550 x 0 008 1 000 x 0 095 1 550 x 0 008 1 450 x 0 010 1 300 x 0 012 1 200 x 0 012 1 500 x 0 125 Piston Bleed Orifice 0 ...

Page 388: ...ads 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 q to increase w or decrease e 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 ove...

Page 389: ...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 390: ...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 391: ...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 392: ...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 393: ... Shock Seal Protector Sleeve PU 50939 Rear Shock Seal Protector Sleeve PU 50952 4 Install seal head assembly 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 Inform...

Page 394: ...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 395: ...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 396: ...eck 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 Co...

Page 397: ...9 Thread the spring preload adjuster down against the spring and set the preload to the specified measurement see Chapter 2 Spring Adjustment 40 Set the compression adjuster knob to the recommended setting or the original setting upon removal see Chapter 2 Shock Compression Adjustment 41 Remove the shock from the vise 42 Reinstall spherical bearing O rings and polyurethane bushings NOTE After inst...

Page 398: ...8 38 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES STEERING SUSPENSION ...

Page 399: ...LIPERS 9 8 MASTER CYLINDER 9 9 MASTER CYLINDER REMOVAL 9 9 MASTER CYLINDER INSTALLATION 9 9 BRAKE BLEEDING FLUID CHANGE 9 11 BRAKE PEDAL LEVER 9 13 BRAKE PEDAL REMOVAL 9 13 BRAKE PEDAL INSTALLATION 9 13 FRONT BRAKES 9 14 PAD REMOVAL 9 14 PAD INSPECTION 9 14 PAD ASSEMBLY INSTALLATION 9 15 BRAKE BURNISHING PROCEDURE 9 15 FRONT CALIPER ASSEMBLY VIEW 9 16 CALIPER REMOVAL 9 17 CALIPER DISASSEMBLY 9 18 ...

Page 400: ... Polaris Industries Inc CALIPER INSPECTION 9 28 CALIPER ASSEMBLY 9 29 CALIPER INSTALLATION 9 29 DISC INSPECTION 9 30 DISC REPLACEMENT 9 31 TROUBLESHOOTING 9 32 POOR BRAKE PERFORMANCE 9 32 PEDAL VIBRATION 9 32 CALIPER OVERHEATS BRAKES DRAG 9 32 BRAKES LOCK 9 32 BRAKE SYSTEM ...

Page 401: ...AKE SYSTEM SERVICE NOTES Disc brake systems are light weight low maintenance and perform well in 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 f...

Page 402: ...ressure 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 move...

Page 403: ...STEM OVERVIEW BRAKE SYSTEM ASSEMBLY VIEW q Master Cylinder y Flare Fitting 15 ft lbs 20 Nm w LH Front Brake Line u LH Rear Brake Line e RH Front Brake Line i Brake Tee Fitting r MC Rear Brake Line o Bleed Screw 47 in lbs 5 Nm t RH Rear Brake Line a Banjo Fitting 15 ft lbs 20 Nm s Brake Switch BRAKE SYSTEM ...

Page 404: ...017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING RETENTION FRONT BRAKE LINES TO MASTER CYLINDER q Brake Line Retaining Clip w Control Arm Brake Line Retainer BRAKE SYSTEM ...

Page 405: ...9 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 9 7 REAR BRAKE LINE MASTER CYLINDER TO JUNCTION BLOCK q Brake Line Retaining Clip e Zip Tie BRAKE SYSTEM ...

Page 406: ...00 Service Manual Copyright Polaris Industries Inc REAR BRAKE LINES JUNCTION BLOCK TO CALIPERS NOTE Brake lines route inside the stabilizer bar and shock mounts as shown q Brake Line Retaining Clip r Trailing Arm Brake Line Retainer BRAKE SYSTEM ...

Page 407: ...ke 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 re use 5 Remove the two mounting fasteners t that secure the master cylinder to the frame MASTER CYLINDER INSTALLATION 1 I...

Page 408: ...specification ITEM DESCRIPTION ANGLE q Rear Brake Line 20 w Front Right Brake Line 60 e Front Left Brake Line 30 TORQUE Banjo Bolt Brake Pressure Switch 15 ft lbs 20 Nm 4 Install the master cylinder shield and master cylinder retaining bolts and nuts Torque bolts to specification NOTE Hardened washer goes under the head of the bolt not the nut Tighten bolt from head side TORQUE Master Cylinder Mou...

Page 409: ...eservoir q with a Mity Vac pump or similar tool Mity Vac 2870975 3 Add brake fluid to the indicated MAX level of reservoir Polaris DOT 4 Brake Fluid 2872189 4 Bleed the brakes in the following order right rear left rear right front and finally the left front Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure t...

Page 410: ...nder 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 on reservoir Master Cylinder Fluid Level Between MIN and MAX lines on reservoir 11 Install master cylinder reservoir cover 12 Field test machine at low speed before putting into service C...

Page 411: ...e 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 412: ... 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 Remove excess fluid from reservoir as required 6 Push the mounting bracket inward and slip the ou...

Page 413: ...id in the reservoir to prevent air from entering the brake system 5 Install the adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheel and torque wheel nuts to specification T...

Page 414: ...00 Service Manual Copyright Polaris Industries Inc FRONT CALIPER ASSEMBLY VIEW q Socket Set Screw y Pistons w Bleeder Screw 48 in lb 5 Nm u Caliper Mount e Caliper Assembly i Brake Pads r Boots o Brake Scraper t Square O Rings a Bolts BRAKE SYSTEM ...

Page 415: ...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 416: ...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 417: ... 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 418: ...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 419: ...pecification 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 MEASUREMENT Brake Disc Thickness New 0188 4 78 mm Service Limit 0 170 4 32 mm ...

Page 420: ...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 page TORQUE Front Brake Caliper Mounting Bolt...

Page 421: ...ting 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 Brak...

Page 422: ...rd 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 MEASUREMENT Rear Brake Pad Thickness 298 007 7 57 mm 178 mm Service Limit 180 4 6 mm BRAKE SYSTEM ...

Page 423: ...e brake pedal until pressure has been built up Maintain brake fluid in the reservoir between MIN and MAX 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 MA...

Page 424: ...P 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc REAR CALIPER ASSEMBLY VIEW q Socket Set Screw t Pistons w Bleeder Screw 48 in lb 5 Nm y Boots e Caliper Assembly u Caliper Mount r Square O Rings i Brake Pad BRAKE SYSTEM ...

Page 425: ... 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 426: ...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 427: ...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 428: ...m NOTE If new pads are installed refer to Brake Burnishing Procedure page 9 25 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 MEASUREMENT Brake Disc Thickness New 0 188 4 78 mm Servic...

Page 429: ...w brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal TORQUE Brake Disc Mounting Bolts 30 ft lb 41 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Rear Wheel Hub Castle Nut 110 ft lbs 149 Nm 7 Install rear caliper see Chapter 9 REAR CALIPER SERVICE page Bleed the brake sys...

Page 430: ...r 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 R...

Page 431: ... HIGH LIFTER 10 12 CHASSIS MAIN FRAME XP 4 10 13 SEAT ASSEMBLY FRONT 10 14 SEAT ASSEMBLY REAR 10 15 FLOOR ROCKER PANELS XP HIGH LIFTER 10 16 FLOOR ROCKER PANELS XP 4 XP 4 HIGH LIFTER 10 17 REAR CARGO BOX FENDERS 10 18 REAR BUMPER 10 19 BODY COMPONENT REMOVAL 10 20 SEATS 10 20 ENGINE SERVICE PANEL 10 20 FRONT BUMPER XP 10 20 REAR BUMPER 10 21 HOOD AND FRONT BODY WORK 10 21 REAR FENDER FENDER FLAIR ...

Page 432: ...lammable residue CAUTION Do not flame treat components that are installed on the vehicle Remove the component from the vehicle before flame treating The body cab components are plastic polyethylene material Therefore they must be flame treated prior to installing a decal to ensure good adhesion The flame treating procedure can also be used to reduce or eliminate the whitish stress marks that are s...

Page 433: ...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 434: ...ntil cab frame is completely assembled on vehicle then tighten to specification q ROPS Rear u ROPS Front w ROPS Rear Hoop i Cab Frame Fasteners 40 ft lb 54 Nm e ROPS Brace o Cab Frame Mid Hoop Mounting Fasteners 17 ft lb 23 Nm r ROPS Mid Hoop a Hip Bolster Bottom Fasteners 14 ft lb 19 Nm t Hip Bolster s Visor Fasteners 8 ft lb 11 Nm y ROPS Main BODY FRAME ...

Page 435: ...olts and nuts i 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 i 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 i Torque to 40 ft lb 54 Nm 6 Install ROPS brace to ROPS mid hoop and ROPS rear hoop with M10 x 1 5 x 45 screws i Torque to 40 ft lb 54 Nm 7 Install ROPS front to RO...

Page 436: ...al Copyright Polaris Industries Inc 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 437: ...017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 10 7 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 438: ...ght Polaris Industries Inc 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 439: ... 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 10 9 DASH INSTRUMENTS CONTROLS q Instrument Cluster r Headlight Switch w Key Switch t AWD Switch e 12V Accessory Port y Bezel BODY FRAME ...

Page 440: ... RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 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 441: ...BODY 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 442: ... XP HIGH LIFTER q Frame Bolts 40 ft lb 54 Nm y Rear Support s Front Frame w Seat Frame Fasteners rear 30 ft lb 41 Nm u Seat Frame d Suspension Mount Bracket e M8 Fasteners14 ft lb 19 Nm i Dash Frame f Front Skid Plate r T 40 Torx Fasteners8 ft lbs 11 Nm o Rear Frame t Cargo Box Brackets a Rear Skid Plate BODY FRAME ...

Page 443: ...10 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 10 13 CHASSIS MAIN FRAME XP 4 BODY FRAME ...

Page 444: ...XP4 1000 Service Manual Copyright Polaris Industries Inc 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 445: ...vice Manual Copyright Polaris Industries Inc 10 15 SEAT ASSEMBLY REAR q Seat Back Screws 4 ft lb 5 Nm r Seat Latch Fasteners 4 ft lb 5 Nm w Seat Base Assembly t Seat Bottom Screws 4 ft lb 5 Nm e Seat Latch y Seat Base Fasteners 4 ft lb 5 Nm BODY FRAME ...

Page 446: ...Service Manual Copyright Polaris Industries Inc 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 447: ...ELS 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 448: ...m 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 449: ...1000 Service Manual Copyright Polaris Industries Inc 10 19 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 450: ...ANEL 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 b...

Page 451: ... 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 l...

Page 452: ...t 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 t...

Page 453: ...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 bolts retaining each rear ca...

Page 454: ...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 16 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 retaining the upper floor i to the low...

Page 455: ... q 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 r...

Page 456: ...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 the lower rear close off panel 11 Remove two Torx T40 screws u an...

Page 457: ...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 458: ...specification TORQUE Door Latch Fasteners 8 ft lb 11 Nm 4 Install the door panel onto the door frame Torque fasteners to specification TORQUE Door Panel Fasteners 22 in lb 2 Nm 5 Adjust the door so it properly opens and latches Refer to Door Adjustment page 10 28 DOOR ADJUSTMENT 1 Remove the T 25 fasteners retaining the door panel to the door frame Remove the door panel 2 Close the door and keep i...

Page 459: ...cally and horizontally loosen striker assembly fasteners w for extra adjustment Torque striker fasteners once aligned TORQUE Striker Fasteners 8 ft lb 11 Nm 5 Holding the door in position tighten the top hinge bracket M8 fasteners e and then bottom fasteners r Torque to specification TORQUE Door Hinge Fasteners 8 ft lb 11 Nm 6 Install the door panel onto the door frame Torque fasteners to specific...

Page 460: ...10 30 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc NOTES BODY FRAME ...

Page 461: ...1 7 TESTING CONTINUITY RESISTANCE 11 8 TESTING FOR A SHORT TO GROUND 11 8 TESTING FOR A SHORT TO VOLTAGE 11 9 TESTING FOR INTERMITTENT CONDITIONS 11 9 TESTING CURRENT FLOW AMPERAGE 11 10 TESTING PARASITIC DRAW 11 11 TESTING VOLTAGE DROP 11 11 INSTRUMENT CLUSTER 11 12 OVERVIEW 11 12 INFORMATION DISPLAY AREA 11 14 DIAGNOSTIC MODE 11 17 INSTRUMENT CLUSTER PINOUTS 11 18 INSTRUMENT CLUSTER REMOVAL 11 1...

Page 462: ...RN LIGHTS 11 38 FLASHER MODULE INT L TRACTOR 11 38 BRAKE ALARM INT L TRACTOR 11 39 DIFFERENTIAL SOLENOID OVERVIEW 11 39 DIFFERENTIAL SOLENOID CIRCUIT OPERATION 11 39 ALL WHEEL DRIVE COIL 11 40 OPERATION OVERVIEW 11 40 DIAGNOSING SYSTEM FAILURES 11 40 VEHICLE SPEED SENSOR 11 41 SPEED SENSOR LOCATION 11 41 SPEED SENSOR TESTING 11 41 IGNITION COIL 11 42 OPERATION OVERVIEW 11 42 IGNITION COIL HT LEAD ...

Page 463: ... 53 VOLTAGE DROP TEST 11 53 STARTER MOTOR REMOVAL 11 53 STARTER MOTOR INSTALLATION 11 54 STARTER SOLENOID BENCH TEST 11 54 STARTER SOLENOID OPERATION 11 54 ELECTRONIC POWER STEERING 11 55 EPS OPERATION 11 55 PROPER EPS SYSTEM DIAGNOSING 11 55 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON 11 56 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF 11 57 EPS TROUBLESHOOTING ...

Page 464: ...nsor Probe Harness 2871745 Static Timing Light Harness PU 50296 Battery Conductance Analyzer MDX 610P PU 49466 Relay Bypass Digital Wrench see Chapter 4 DIGITAL WRENCH OPERATION page Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com UNDER DASH COMPONENTS The following switches and components can be accessed underneath the instrument dash panel Speedometer AWD ...

Page 465: ... The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 D...

Page 466: ...rs beside a DMM will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge STATIC AND DYNAMIC TESTING There are many methods for testing a DC circuit These methods fall into one of two categories either static or dynamic STATIC TESTING The two most common fo...

Page 467: ...onnector is held upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the terminal or attempting to adjust tighten the tang in the female terminal For a video demonstration scan the QR code below or right click it and select open in new tab BACK PROBING Bac...

Page 468: ... so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There are many possible causes of a short to ground here are some The harness rubbing against a component that is grounded such as the frame chassis component or engine A component s internal circuitry contacting it s ...

Page 469: ...d to either end of the disconnected circuit Ensure you are using the correct adapter Connector Probing Guidelines page 11 7 9 If there is voltage present the harness is damaged and should be repaired or replaced You may need to remove the protective tape and tubing to inspect 10 If the DMM reads 0 volts the concern may be in a component related to the circuit If so checking internal continuity of ...

Page 470: ...lexing certain areas Pulling at or near the suspected connector Pushing in different directions to flex the connector body and try to isolate poor connections Changing the temperature This can be accomplished with either heat guns or cold air guns WARNING Always exercise caution when using these tools and use them for short periods of time when changing the temp of an area Failure to do so can lea...

Page 471: ...ne fuse at a time until the value drops indicating the circuit that requires attention TESTING VOLTAGE DROP NOTE If you disconnect the connector at the load and measure voltage with one lead on the power supply wire and one to ground you will be measuring available voltage This is a static test and not dynamic voltage drop testing Refer to page Static and Dynamic Testing page 11 6 The measurement ...

Page 472: ...r 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 473: ...ator 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...

Page 474: ...p 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 appe...

Page 475: ... until 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 a...

Page 476: ...ndicates 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 ba...

Page 477: ... 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 ...

Page 478: ...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 easily 2 Be sure the rubbe...

Page 479: ...18 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 19 RIDE COMMAND SYSTEM RIDE COMMAND DISPLAY 1 Gauge Screen Button 2 Audio Button 3 Map Button 4 Device Manager Button 5 App Screen Button ELECTRICAL ...

Page 480: ...2 time traveled total hours and total miles To reset trip 1 2 or time traveled press and hold this icon on whichever output you wish to reset 4 Pressing the MPH RPM button will change whether miles per hour or RPM is shown on top 5 Press on the coolant icon to cycle to battery voltage and turbo boost pressure if applicable then back to engine temperature 6 Swipe down from the top of the screen or ...

Page 481: ... the arrows on either side of the favorites to view all 18 favorite slots MAP 1 Press the Map Screen button shown above to display the map screen 2 The map should center you based on the location of the GPS 3 Use the plus and minus signs on the left side of the screen or pinch the screen with your fingers to zoom in and out on the map 4 The compass icon on the right side of the screen toggles nort...

Page 482: ...s 9 You can also save a ride on your Display by clicking on the Record icon shown below to start recording your ride When you are finished recording your ride press the Stop icon to stop recording 10 You can manage rides on your Display by clicking on the Ride icon as shown below Managing Rides or Waypoints 1 To navigate to a waypoint go to the waypoint menu on your display select the waypoint you...

Page 483: ...flash drive rather than in a folder Export Rides and Waypoints 1 To export rides waypoints from your USB drive plug the USB drive in to the USB pigtail port and press the USB export icon 2 Press the down arrow icon to the left of the ride or waypoint that you would like to download The ride waypoint should then be saved on the USB NOTE You must be on the waypoint manager screen to import or export...

Page 484: ...ings When your phone appears on the display press the button next to it 2 A prompt will appear on your iPhone requesting Polaris RZR to pair with your phone 3 Ensure the conformation code on the screen and your phone are the same then press Pair on your phone 4 For optimal experience turn on show notifications from Polaris RZR within your smartphone s Bluetooth settings Android 1 From your smartph...

Page 485: ...uested to access contacts and messages 6 The display will now show a list of previously connected phones on the display If it is unpaired click on your phone from the list 7 Once the display says connected paired your phone is now connected to the display via Bluetooth 8 After a phone is connected the Device Manager Screen will appear as shown below ELECTRICAL ...

Page 486: ... plug a USB charge cable for your smartphone into the USB pigtail port NOTE USB music playback is not available on all devices Connecting Your Bluetooth Headset With The Display The Display can connect with Polaris approved Bluetooth headsets to listen to music take phone calls and talk with other riders Use the following steps to connect your Bluetooth headset to the Display 1 From the Device Man...

Page 487: ...e Manual Copyright Polaris Industries Inc 11 27 APPS SCREEN Press the Apps Menu button shown above to display the Apps Menu From this menu Settings Diagnostics Lock Screen GPS Satellite Status Ride Stats and GoPro features can all be accessed ELECTRICAL ...

Page 488: ...audio tab on the left side of the display allows access to automatic volume control as well as stereo adjustments This menu is also available from the settings button on the audio screen Use the equalizer to adjust Bass Mid and Treble To do this drag the dot above the desired adjustment up to increase band frequency and down to decrease band frequency Use the Fade Balance screen to adjust sound ou...

Page 489: ...ne or more of the faults in this list is an active fault LOCK TOUCHSCREEN By pressing the Lock Touchscreen icon you will see the display below This screen is useful for clearing your screen of debris To get out of this screen press any of the hard buttons below the screen SATELLITE STATUS In the Apps Menu select GPs Satellite Status The screen displays all available satellites in the area RIDE STA...

Page 490: ...view previously taken images and still images of videos press the Media icon To add and delete GoPros press the Camera icon The icons in the bottom right corner allow the camera mode to be changed between video picture burst and time lapse NOTE Preview image will be disabled when traveling at speeds over 15 MPH ENGINE OVERHEAT INDICATORS The engine temperature scale at the right side of the Displa...

Page 491: ...sage occurs perform one or all of the following actions to resolve the issue Remove and reconnect the USB flash drive securely Make sure the Display files are not inside a folder on the flash drive Make sure only Display files are on the flash drive Remove any other files if necessary Try using a different USB flash drive 7 The display will then initiate the update and restart with the new softwar...

Page 492: ...p 8 Go to Step 5 5 Refer to the wiring schematic and check circuits without voltage for continuity and proper operation Did you find any problems in the circuit Go to Step 7 Go to Step 1 and repeat diagnosis 6 Replace display with known good display Did you find and repair the condition Go to Step 8 Go to Step 1 and repeat diagnosis 7 Repair replace and check all affected power ground circuits Che...

Page 493: ...known good display Did you find and repair the condition Go to Step 2 Repeat Diagnosis GPS Antenna Troubleshooting 1 Unplug connector from GPS antenna and verify all contacts are securely seated in the connector 2 Turn ignition on and make the following measurements on the antenna connector WIRING CONNECTION TO MEASURE VOLTAGE SPECIFICATION Power Between Pins 4 and 3 12Vdc Battery Voltage 3 If ant...

Page 494: ...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 495: ...ld be contunity between switch pins A and B Turn the key to ON position There should be continuity between switch pins A B and D Turn the key to START position There should be continuity between all the pins on the switch AWD 2WD SWITCH NO TURF MODE 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 ...

Page 496: ... 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 620 Ω LOW 300 Ω NEU 160 Ω REV 75 Ω PARK 24 Ω SEAT BELT SWITCH Location Found on the driver s seat belt latch Functionality If the circuit is open buckle undone vehicle speed will be limited to 15mph If the circuit is closed buckle in...

Page 497: ...TCH INT L TRACTOR Testing 1 Disconnect the Turn Lights Horn switch by depressing the connector locks and pulling on the connector Do NOT pull on the wiring 2 Test between the sets of outputs If any of the tests fail replace the switch assembly Turn on the High Beam There should be continuity between switch pins 2 and 5 Turn on the Low Beam There should be continuity between switch pins 2 and 6 Tur...

Page 498: ...ined to the front bumper by a single faster q accessible through the front grill Rear The rear turn lights are integrated into the rear taillight If the taillights are functioning properly but there is no blinker check the wiring connections and the flasher module FLASHER MODULE INT L TRACTOR The flasher module q is located on the front floor assembly near the master cylinder The module and fasten...

Page 499: ...N The Rear Diff Solenoid Relay is attached to the lower airbox bracket and can be accessed through the right rear wheel well When the switch is pushed to activate TURF a ground signal is provided to the ECU from the AWD 2WD TURF Switch Depending on engine speed and gear position criteria the ECU energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid If the rear diff...

Page 500: ... 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 501: ... 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 502: ... 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 503: ...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 504: ...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 505: ...e negative battery terminal 2 Push the locking tabs down on the front fascia grill and remove the grill 3 Disconnect both regulator connectors q 4 Remove the two regulator mounting fasteners w and remove the regulator through the grill opening 5 Install regulator onto the mounting plate Torque mounting fasteners to specification TORQUE Regulator Mounting Fasteners 5 ft lb 7 Nm 6 Connect the regula...

Page 506: ...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 wor...

Page 507: ...ored 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...

Page 508: ...he 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 mont...

Page 509: ...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 maintain lighting quality Ridin...

Page 510: ...ly 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 harness to ensure the lamp is receiv...

Page 511: ...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 sensor q measures c...

Page 512: ...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 39 5 Using a wrench remove and replace the sensor applying a light coating of thread sealant to the sensor threads q to aid installation 6 Torque the new ECT sensor to specification and connect the vehicle harness ...

Page 513: ...ar 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 514: ...cation 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 measureme...

Page 515: ...peration NOTE To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction Indicator Light will illuminate to indicate the EPS has shut down and will set a fault code in Digital Wrench The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indicator Light MIL on the instrum...

Page 516: ...11 56 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON ELECTRICAL ...

Page 517: ...11 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 57 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF ELECTRICAL ...

Page 518: ...11 58 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING USING DIGITAL WRENCH ELECTRICAL ...

Page 519: ...er In 16 Power Out EFI 10A Fuse 17 Power In 21 Power Out Lights 15A Fuse 18 Power In 22 Power Out EFI Relay 19 Coil High 20 Power In 23 Power Out 24 Coil Low Fuel Pump Relay 25 Coil High 26 Power In 29 Power Out 30 Coil Low Unsw 10A Fuse 27 Power In 31 Power Out CIRCUIT PIN FUNCTION Drive 10A Fuse 28 Power In 32 Power Out Chassis Relay 33 Coil High 34 Power In 37 Power Out 38 Coil Low Term Relay 3...

Page 520: ...er Out EFI 10A Fuse 17 Power In 21 Power Out Lights 15A Fuse 18 Power In 22 Power Out EFI Relay 19 Coil High 20 Power In 23 Power Out 24 Coil Low Fuel Pump Relay 25 Coil High 26 Power In 29 Power Out 30 Coil Low Unsw 10A Fuse 27 Power In 31 Power Out Drive 10A Fuse 28 Power In 32 Power Out Chassis Relay 33 Coil High CIRCUIT PIN FUNCTION 34 Power In 37 Power Out 38 Coil Low Term Relay 35 Coil High ...

Page 521: ...In 16 Power Out EFI Relay 17 Coil High 18 Power In 21 Power Out 22 Coil Low EFI 10A Fuse 19 Power In 23 Power Out Lights 10A Fuse 20 Power In 24 Power Out Fuel Pump Relay 25 Coil High 26 Power In 29 Power Out 30 Coil Low Key 10A Fuse 27 Power In 31 Power Out Drive 10A Fuse 28 Power In 32 Power Out Chassis Relay 33 Coil High CIRCUIT PIN FUNCTION 34 Power In 37 Power Out 38 Coil Low Term 10A Fuse 35...

Page 522: ...16 Power Out EFI Relay 17 Coil High 18 Power In 21 Power Out 22 Coil Low EFI 10A Fuse 19 Power In 23 Power Out Lights 10A Fuse 20 Power In 24 Power Out Fuel Pump Relay 25 Coil High 26 Power In 29 Power Out 30 Coil Low Key 10A Fuse 27 Power In 31 Power Out Drive 10A Fuse 28 Power In 32 Power Out Chassis Relay 33 Coil High CIRCUIT PIN FUNCTION 34 Power In 37 Power Out 38 Coil Low Term 10A Fuse 35 Po...

Page 523: ...Fuel Injectors ECU Seatbelt Switch Brake Pressure Switch Ignition Power Splice Ignition Coil EFI B Splice 2 Fan Relay coil high Fuel Pump Relay coil high Chassis Relay coil high Fuel Pump Relay Fuel Pump Sender Unsw 10A Fuse B Unswitched Fused Splice 1 EFI Relay coil high B Unswitched Fused Splice 2 Instrument Cluster Diagnostic Plug Drive 10A Fuse AWD Coil Chassis Relay Chassis Splice Lights 10A ...

Page 524: ... B Splice 2 Fan Relay coil high Fuel Pump Relay coil high Chassis Relay coil high EFI 10A Fuse EFI Relay power in Lights 10A Fuse Lights B Splice Taillight Harness Headlight Switch LED Dash Light s Fuel Pump Relay Fuel Pump Sender Key 10A Fuse B Unswitched Fused Splice 1 EFI Relay coil high B Unswitched Fused Splice 2 Key Switch Instrument Cluster Diagnostic Plug Drive 10A Fuse AWD Coil Chassis Re...

Page 525: ...R XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc 11 65 WIRING HARNESS MAIN HARNESS RETENTION LOCATIONS Front q Zip Tie Retention Locations The white tape on a harness signifies a retention point Rear ELECTRICAL ...

Page 526: ...11 66 9928492 R04 2017 2018 RZR XP 1000 XP4 1000 Service Manual Copyright Polaris Industries Inc MAIN HARNESS ROUTING ELECTRICAL ...

Page 527: ...ual in with the main wiring diagrams To access the interactive break out diagrams 1 Open the wiring diagram PDF and open the left side menu 2 If the wiring diagram does not open the Adobe navigation bars click on the Adobe Icon 3 Click on the Layers Icon 4 Click on the box next to the breakout diagram you want to see Deselect any other diagram that may be selected 5 Click on the Wiring Diagram bla...

Page 528: ... 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 OFF 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 Ω...

Page 529: ...14 Brake Pads Removal Front 9 14 Brake Pedal Installation 9 13 Removal 9 13 Brake System Assembly View 9 5 Brake Hose and Fitting Inspection 2 57 Troubleshooting 9 32 Brakes Bleeding Fluid Change 9 11 Brake Burnishing Procedure 9 25 Brakes Lock 9 32 Hydraulic Brake System Operation 9 4 Master Cylinder Installation 9 9 Master Cylinder Removal 9 9 Overheating 9 32 Pedal Vibration 9 32 Performance Is...

Page 530: ...down Test 2 32 D Dash Removal 10 21 Dash Instruments Controls 10 9 Dash Light 11 50 Decal Replacement 10 2 Decimal Equivalent Chart 1 39 Diagnostic Trouble Codes ETC 4 46 Differential Assembly 6 25 Bushing Replacement 6 23 Disassembly 6 22 Operation 6 19 Differential Solenoid 11 39 Digital Wrench Communication Errors 4 57 Diagnostic Connector 4 58 ECU Reprogramming 4 61 Guided Diagnostics 4 59 Ove...

Page 531: ...Installation 3 73 Troubleshooting 3 85 Valve Cover Removal 3 32 Valve Inspection 3 38 Valve Lash Tappet Selection 3 83 Valve Sealing Test 3 40 Valve Seat Reconditioning 1000 3 40 Engine Coolant Temp Sensor ECT 11 51 Engine Serial Number Location 1 2 Engine Service Panel 10 20 Engine Camshaft Timing Quick Reference 3 80 Engine Valve Cover Installation 3 84 EPS Operation 11 55 Troubleshooting 11 56 ...

Page 532: ...ment 1 3 L Leakdown Test 2 32 Lower Steering Shaft Installation 8 8 Removal 8 8 Lubrication Specifications 2 28 Lubrication Grease Points 2 27 Lubrication Specifications 3 3 3 31 M Main Frame 10 12 10 13 Main Harness Routing 11 66 Maintenance Battery 2 58 Quick Reference Chart 2 25 Steering System 2 52 Maintenance Intervals 2 5 Master Cylinder Installation 9 9 Removal 9 9 Master Torque Table 1 8 M...

Page 533: ... 24 10 25 Rocker Panels 10 16 Rocker Panels XP 4 10 17 S Seat Rear 10 15 Removal 10 20 Seat Assembly 10 14 Seat Belt Switch 11 36 Sensor Crankshaft Position 4 37 Oxygen 4 44 Service 11 6 Service Intervals Maintenance 2 5 Service Panel 10 20 Shift Cable Adjustment 6 6 Inspection 6 6 Inspection and Adjustment 2 50 Shift Lever Installation 6 3 Installation Gated Gold Metallic LE 6 4 Removal 6 3 Remov...

Page 534: ...nspection 2 53 Tire Inspection 2 46 Pressure 2 46 TMAP 4 36 Toe Adjustment 2 54 Torque Specifications Master 1 8 Wheel and Hub 2 45 Trailing Arm Spherical Bearing Replacement 8 19 Transmission Assembly 6 27 Disassembly 6 14 Gear Shaft Bearing Inspection 6 26 Installation 6 11 Lubrication 2 48 Lubrication Specifications 6 2 Output Shaft Backlash Procedure 6 27 Removal 6 8 Snorkel Shaft Removal 6 14...

Page 535: ...Inc IX 7 W Water Pump Housing Removal 3 44 Installation 3 16 Removal 3 16 Service 3 18 Wheel Installation 2 45 Removal 2 45 Wheel Alignment 2 53 Wheel Bearing Replacement front 7 4 Replacement rear 7 8 Wheel Hub Assembly View front 7 37 Assembly View rear 7 37 Wheel Toe Adjustment 2 54 INDEX ...

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