Polaris RZR XP 1000 Service Manual Download Page 399

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9.1

9925724 R01 - 2014-2015

RZR

XP 1000 /

RZR

XP4 1000 Service Manual

BRAKE SYSTEM

CHAPTER 9

BRAKE SYSTEM

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

GENERAL SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

TORQUE SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

BRAKE SYSTEM SERVICE NOTES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

BRAKE NOISE TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

HYDRAULIC BRAKE SYSTEM OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

BRAKE SYSTEM ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

MASTER CYLINDER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

MASTER CYLINDER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

BRAKE BLEEDING / FLUID CHANGE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

BRAKE PEDAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

BRAKE PEDAL REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

BRAKE PEDAL INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

PARKING BRAKE (INT’L MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

PARKING BRAKE ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

PARKING BRAKE INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12

PARKING BRAKE CABLE ADJUSTMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12

PARKING BRAKE CALIPER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13

PARKING BRAKE DISC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19

PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19

PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20

PAD ASSEMBLY / INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21

FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

CALIPER ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

CALIPER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23

CALIPER DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24

CALIPER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25

CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25

CALIPER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.26

FRONT BRAKE DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27

DISC RUNOUT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27

DISC INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27

DISC REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.28

REAR BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.29

PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.29

PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.30

PAD ASSEMBLY / INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.31

Summary of Contents for RZR XP 1000

Page 1: ...zed 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 I...

Page 2: ...tor bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders d...

Page 3: ...y Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the ne...

Page 4: ......

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

Page 6: ......

Page 7: ...PLACEMENT KEYS 1 5 PUBLICATION NUMBERS 1 5 SPECIAL TOOLS 1 6 GENERAL SPECIFICATIONS 1 10 2014 2015 RZR XP 1000 EPS 1 10 RZR XP 1000 CLUTCH CHART 1 11 2014 2015 RZR XP 4 1000 1 13 2014 2015 RZR 1000 XP4 1 14 2015 RZR XP 1000 EPS HIGH LIFTER 1 16 2015 RZR XP 1000 HIGH LIFTER 1 18 2015 RZR XP 1000 DESERT EDITION 1 18 2015 RZR XP 1000 DESERT EDITION CLUTCH CHART 1 20 MISC SPECIFICATIONS AND CHARTS 1 2...

Page 8: ... 760 9 875 E EPS F D E digits that would transfer to 17 digit VIN and are used in digits 4 8 respectively 9th digit will be used on color featured versions of models not including the base First 3 digits and 9th digit are used in model number only They are not used with the 17 digit VIN Model Number Designation Example A15SEA57AD GROUP MODEL YEAR MAKE CHASSIS CODE ENGINE CODE REGION OPTION 1st 2nd...

Page 9: ...NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 F 3 0 0 0 0 0 0 Model Year A 2010 B 2011 C 2012 D 2013 E 2014 F 2015 Vehicle Identification Number VIN Designation 2015 Example 4XARH57A0F3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1 2 3 4 5 6 7 8 9 10 11 12...

Page 10: ...r to the vehicle identification number VIN and the engine serial number The VIN can be found stamped on a portion of the left rear frame behind the lower shock mounting location Refer to Figure 1 1 The engine serial number can be found on a decal applied to the front of the engine crankcase A or stamped into the crankcase on the PTO side of the engine B Refer to Figure 1 2 GENERAL INFORMATION ...

Page 11: ...321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Publication Numbers MODEL OWNER S MANUAL PARTS MANUAL 2014 RZR XP 1000 9924687 9924688 2014 RZR XP 1000 EPS 9924687 9924688 2014 RZR XP 1000 INT L 9924687 9924688 2014 RZR XP 4 1000 9924687 9924688 2015 RZR XP 1000 EPS 9925838 9925754 2015 RZR XP 1000 INT L 9925838 9925858 2015 RZR XP4 1000 9925838 9925795 2015 RZR XP 1000 EPS High Lifter ...

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

Page 13: ...c Pressure 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 Wren...

Page 14: ...k 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 Clutch Compressor PU 50562 Engine Stand Adapter PU 50563 Cylinder Holding Camshaft Timing Plate PU 50564 Water Pump Seal Installer PU 50565 Oil Pressure Gauge Adapter 1 2 NPT PU 50566 Transmission Nut Socket PU 50578 Clutch Spider Nut Socket PU 5...

Page 15: ...or Sleeve 5 8 PU 51024 Shock Rod Holding Tool PU 51039 Gas Shock Fill Tool PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PV 43526 Connector Test Kit PV 43531 Oil Presure gauge PV 43568 Fluke Multimeter PV 43570 Piston Ring Compressor Pliers PV 48656 Fuel Pressure Gauge Adapter PW 47053 Bench Mount Engine Stand PW 47054 Engine Stand Adapter Sleeve 2 3 8 GENERAL INFORMAT...

Page 16: ... Wheel Base 90 228 6 cm Ground Clearance 13 5 34 3 cm Dry Weight 1379 lbs 625 5 kg Gross Vehicle Weight 2200 lbs 998 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 335 6 kg Includes riders cargo and accessories Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads Do not use this vehicle for towing Do not modify the vehicle by adding a hitch...

Page 17: ...hassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 10 73 1 22 79 1 20 41 1 Front Gearcase Lubricant Requirement Demand Drive 8 5 oz 250 ml Transmission Lubricant Requirement Full...

Page 18: ... Inc MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 1800 3700 6000 12000 26 55 1322982 White Orange 7043924 Red 3234452 2015 XP 1000 Meters Feet 0 1800 0 6000 26 63 1323176 Orange Black 1323176 Red 3234452 1800 3700 6000 12000 26 59 1322981 Orange Black 7044338 Red 3234452 GENERAL INFORMATION ...

Page 19: ...117 297 2 cm Ground Clearance 13 5 34 3 cm Dry Weight 1596 lbs 724 kg Gross Vehicle Weight 2560 lbs 1161 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 kg Includes riders cargo and accessories Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads Do not use this vehicle for towing Do not modify the vehicle by adding a hitch Hitch Tongue ...

Page 20: ... Chassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 12 05 1 25 59 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive 8 5 oz 250 ml Transmission Lubricant Requirement Fu...

Page 21: ...Inc MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 1800 3700 6000 12000 26 61 1323098 White Orange 7043924 Red 3234452 2015 XP4 1000 Meters Feet 0 1800 0 6000 26 65 1323260 White Orange 7043924 Red 3234452 1800 3700 6000 12000 26 59 1322981 White Orange 7043924 Red 3234452 GENERAL INFORMATION 1 ...

Page 22: ... Gross Vehicle Weight 2470 lbs 1120 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 335 6 kg Includes riders cargo and accessories Hitch Towing Capacity The tow loop on the rear of the vehicle is provided for recovery use ONLY Tow a vehicle ONLY of equal or lesser size and weight When towing a disabled RZR vehicle place the disabled vehicle s transmission in neutral Do...

Page 23: ...4YCX 0 7 0 8 mm Battery Amp Hr 12v Flooded 575 CCA DC Outlet Standard 12 Volt Relays Fan EFI Fuel Pump Chassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 10A EFI 10A Fuel Pump 5A Brake Light 10A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 12 05 1 25 59 1 22 92 1...

Page 24: ... Copyright 2014 Polaris Industries Inc 2015 RZR XP 1000 High Lifter MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING High Lifter Edition Meters Feet 0 1800 0 6000 26 61 1323260 White Orange 7043924 Red 3234452 2015 RZR XP 1000 Desert Edition GENERAL INFORMATION ...

Page 25: ...round Clearance 13 5 34 3 cm Dry Weight 1379 lbs 625 5 kg Gross Vehicle Weight 2200 lbs 998 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 335 6 kg Includes riders cargo and accessories Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads Do not use this vehicle for towing Do not modify the vehicle by adding a hitch Hitch Tongue Capacity GE...

Page 26: ...appl Circuit Breaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R Transmission Gear Ratios High Low Reverse 10 73 1 22 79 1 20 41 1 Front Gearcase Lubricant Requirement Demand Drive 8 5 oz 250 ml Transmission Lubricant Requirement Full Synthetic AGL...

Page 27: ...Screws INTL 22 ft lb 30 Nm Door Fasteners 8 ft lb 11 Nm Drive Clutch Retaining Bolt 96 ft lb 130 Nm Drive Clutch Cover Plate Screw 9 ft lb 12 Nm ITEM TORQUE Drive Clutch Shift Weight Fasteners 20 in lb 2 Nm Drive Clutch Spider 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 Drive Clutch Spider Jamb Nut 250 ft lb 339 Nm Apply 0 1 mL Loctite 7088 Primer and 0 1 mL Loctite 62...

Page 28: ...er Bar Locating Clamp Bolts 10 ft lb 14 Nm Starter Mounting Bolts 7 ft lb 10 Nm Starter One Way Clutch Screws 9 ft lb 12 Nm Stator Cover Screws 9 ft lb 12 Nm Steering Tilt Shock Fastener 7 ft lb 10 Nm Steering Pivot Tube Fasteners 8 ft lb 11 Nm Steering Rack Mounting Bolts 16 ft lbs 22 Nm ITEM TORQUE Steering Shaft to EPS Unit 15 ft lbs 20 Nm Steering Shaft to Steering Rack 42 ft lb 57 Nm Steering...

Page 29: ...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 x 0 264 US ...

Page 30: ...69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Metric Bolt Torque Specification BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LBS NM DRY THREADS M3 0 3 0 5 0 5 0 7 1 1 3 1 5 2 1 5 2 M4 0 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 18 M8 7 9 5 10 13 18 25 26 35 33 45 M10 14 19 18 25 37 50 55 75 63 85 M12 26 35 ...

Page 31: ... 12 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...

Page 32: ... 64 0 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 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 FRACTION DECIMAL MM TO INCHES 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 18 ...

Page 33: ... ADJUSTMENT 2 10 FUEL SYSTEM AND AIR INTAKE 2 12 FUEL SYSTEM 2 12 FUEL TANK VENT LINE 2 12 FUEL PUMP FUEL FILTERS 2 13 FUEL LINES 2 13 THROTTLE PEDAL INSPECTION 2 14 ENGINE INTAKE PRE FILTER SERVICE 2 14 AIR FILTER SERVICE 2 15 INTAKE DUCT DRAIN INSPECTION 2 15 AIR BOX AIR FILTER ASSEMBLY VIEW 2 16 ENGINE 2 17 ENGINE OIL LEVEL 2 17 ENGINE OIL AND FILTER CHANGE 2 18 ENGINE CRANKCASE BREATHER HOSE I...

Page 34: ... EDITION 2 33 ELECTRICAL AND IGNITION SYSTEM 2 34 BATTERY MAINTENANCE 2 34 BATTERY CHARGING OFF SEASON STORAGE 2 34 BATTERY REMOVAL 2 34 BATTERY INSTALLATION 2 35 ENGINE CHASSIS ELECTRICAL GROUND 2 35 SPARK PLUG SERVICE 2 36 STEERING 2 37 STEERING INSPECTION 2 37 STEERING WHEEL FREEPLAY 2 37 TIE ROD END WHEEL HUB INSPECTION 2 38 WHEEL TOE ALIGNMENT INSPECTION 2 38 WHEEL TOE ADJUSTMENT 2 39 SUSPENS...

Page 35: ...lecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for th...

Page 36: ...mp check lines and fittings for leaks and abrasion Parking Brake Cable Adjustment INT L 25 H Inspect adjust tension after first 25 hours E Air Filter 25 H Monthly 250 400 Inspect replace as needed E Engine Breather Filter if equipped 25 H Monthly 150 250 Inspect replace if necessary Battery 25 H Monthly 250 400 Check terminals clean test E Engine Oil Filter Change Break In Period 25 H 1 M 250 400 ...

Page 37: ...nspect for leaks pressure test system Engine Mounts 100 H 12 M 1000 1600 Inspect torque to specification Exhaust Silencer Pipe 100 H 12 M 1000 1600 Inspect Wiring 100 H 12 M 1000 1600 Inspect for wear routing security inspect connectors subjected to water mud etc Clutches Drive and Driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive Belt 100 H 12 M 1000 1600 Inspect replace as neede...

Page 38: ... Access Panel Polaris PS 4 or Polaris PS 4 Extreme Duty Add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereafter Engine Coolant Under Front Hood Access Panel Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle 4 Check level daily change coolant every two years More often under severe use such as operati...

Page 39: ...er reservoir 1 Check level during pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant until it is visible at the fill hole threads 2 8 5 oz 250 ml Initial level check at 25 hours or 1 month Change lubricant at 100 hours or every 12 months whichever comes first Transmission Polaris AGL Add lubricant until it is visible at the fill hole threads 3 More o...

Page 40: ...ease 3 fittings on each side of the vehicle 1 Polaris All Season Grease Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the vehicle Propshaft Yokes Grease middle and rear fittings 2 Polaris Premium U Joint Grease Front Stabilizer Bar Bushings INT L Grease the fitting on each side of the vehicle 3 Polaris All Season Grease Rear...

Page 41: ...emand Drive 2 5 Gallon 2870465 Oil Pump for 1 Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871329 Dielectric Grease Nyogel Coolant 2871323...

Page 42: ... soapy water and low pressure compressed air if necessary Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Drive Shaft Boots Inspect inner and outer boots for tears or damage on both front and rear drive shafts Check all front ...

Page 43: ...rocedure 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 properly adjusted If transmission still ratchets after cable adjustment the transmission will require service MAINTENANC...

Page 44: ...on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result Fuel Tank Vent Line Symptoms of a restricted fuel tank vent include the following coll...

Page 45: ...dividually Must replace the fuel pump as an assembly Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System Fuel Lines 1 Check the quick connect fuel line 1 at the fuel tank for signs of wear deterioration damage or leakage Replace line s if necessary 2 Locate the fuel supply fitting 2 through the right rear wheel well on the upper right side of the engine...

Page 46: ...s idle position when released Check throttle pedal periodically Engine Intake Pre Filter Service It is recommended that the engine intake pre filter be inspected daily The filter should be inspected using the following procedure 1 The engine intake pre filter is located just above the right rear wheel fender 2 Loosen the knob on top of the assembly and lift up to disengage the tab from the cargo b...

Page 47: ...wel NOTE If the filter has been soaked with fuel or oil it must be replaced 5 Inspect the air filter and replace if necessary NOTE DO NOT attempt to clean the air filter 6 Place the air filter into the air box and reinstall the air box cover NOTE Be sure the lower tabs on the air box cover are properly engaged into the airbox 7 Engage the cover latches 8 Reinstall the cargo box access panel Intake...

Page 48: ... XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Air Box Air Filter Assembly View 1 Intake Airbox Hose 6 Airbox Clip 4 2 Drain Cap 7 Vent Hose 3 Airbox 8 Intake Tubes 4 Air Filter 9 Engine Intake Housing 5 Airbox Cover MAINTENANCE ...

Page 49: ...ce the transmission in PARK 2 Stop the engine and allow it to cool down before removing the dipstick 3 Unlock the dipstick lever 1 Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 5 Remove the dipst...

Page 50: ... this procedure 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 1 Allow the oil to drain completely 5 Remove the seats and engine service panel to access the oil filter 6 Using the Oil Filter Wrench PU 50105 turn the oil filter 2 counter clockwise to remove it Oil Filter Wrench PU 50105 ...

Page 51: ...gine Oil Level page 2 17 16 Reinstall the dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 17 Remove the dipstick and check the oil level 18 Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick Do not overfill 19 When finished r...

Page 52: ...age exceeds service limit inspect the engine for the cause 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 4 Maneuver the outer clutch cover to allow access to the drive clutch in...

Page 53: ...arance using a feeler gauge 10 If the valve clearance is out of specification see Chapter 3 Valve Clearance Adjustment page 3 84 Intake Valve Clearance cold 006 002 0 15 0 05 mm Exhaust Valve Clearance cold 008 002 0 20 0 05 mm 11 Repeat steps 18 20 until all eight valves have been inspected 12 If previously removed apply anti seize compound to the spark plug threads and reinstall the spark plugs ...

Page 54: ...ug and pushed down all the way so they engage onto the spark plugs NOTE The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder 18 Install outer clutch cover and eight retaining screws Torque screws to specification Outer Clutch Cover Screws 50 in lbs 5 Nm 19 Connect the negativ...

Page 55: ...rly 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 1 and check the lubricant level 2 3 If lubricant level is not even with bottom threads add re...

Page 56: ...cked and changed in accordance 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 w...

Page 57: ...face 9 Reinstall the drain plug and torque to specification 10 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole Recommended Front Gearcase Fluid Polaris Demand Drive PN 2877922 Quart Capacity 8 5 oz 250 mL 11 Reinstall the fill plug and torque to specification Front Gearcase Fill Drain Plug Torque 10 ft lbs 14 Nm ...

Page 58: ...stem 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 Premium Pre Mixed Antifreeze PN 2880514 Quart PN 2880513 Gallon Coolant Level Inspection The pressure cap 1 and recovery bottle 2 are located under the front hood of the vehicle The coolant level must be maintained ...

Page 59: ...ixed Antifreeze PN 2871534 Quart PN 2871323 Gallon 9 Reinstall the recovery bottle cap 10 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overheating Cooling System Pressure Test Refer to ENGINE COOLING SYSTEM page 3 13 Cooling System Hoses 1 Inspect all vehicle hoses for cracks deterioration abrasion or leaks Replace if necessary ITEM DESCRIPT...

Page 60: ...ightness and condition of all hose spring clamps Replace if necessary Radiator Inspection Cleaning 1 Check radiator air passages for restrictions or damage ITEM DESCRIPTION 1 Radiator 2 Shroud 3 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 r...

Page 61: ...rneath 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 1 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 an...

Page 62: ...g 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 drain plug 1 and O ring from the outer clutch cover 2 Allow the water to drain out completely 3 Reinstall the drain plug and O ring 4 Place the transmission in PARK apply the brake and start the engine 5 Apply varying throttl...

Page 63: ...l and Hub Torque Table ITEM SPECIFICATION Wheel Nuts Cast Aluminum Wheels 120 ft lbs 163 Nm Hub Retaining Nuts Front and Rear 110 ft lbs 149 Nm Beadlock Screws Step 1 24 in lbs 3 Nm Step 2 7 ft lbs 10 Nm NOTE Do not lubricate the stud or the lug nut Wheel Removal 1 Position the vehicle on a level surface 2 Place the transmission in PARK and stop the engine 3 Loosen the wheel nuts slightly If wheel...

Page 64: ...ly installed it could affect vehicle handling and tire wear On vehicles with tapered wheel nuts make sure tapered end of nut goes into taper on wheel Tire Inspection Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect vehicle handling WARNING Operating with worn tires will...

Page 65: ...ate the tire 2 Remove the beadlock screws and beadlock ring 3 Dismount the tire on the side with the beadlock holes 4 Place the beadlock ring so the tire is sandwiched between the rim and the ring making sure the valve stem is aligned with the slot in the ring 5 Install bolts and thread them to 24 in lbs 3 Nm 6 Tighten in a criss cross pattern to 7 ft lbs 10 Nm NOTE Beadlock bolts should be checke...

Page 66: ...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 or battery l...

Page 67: ...ttery holder and secure with hold down strap 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable s first 5 Connect and tighten the black negative cable s last 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 neces...

Page 68: ...ing 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 the side electr...

Page 69: ...ing to be 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 Freeplay Check steering wheel for specified ...

Page 70: ...l movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to Chapter 7 Final Drive for front hub service procedures Wheel Toe Alignment Inspection 1 Place machine on a smooth level surface and set steering wheel in a straight ahead position Secure the steering wheel in this position 2 Place a chalk mark on the center line of the ...

Page 71: ...the vehicle center This will tell you which tie rod needs adjusting NOTE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold ti...

Page 72: ...strations within this procedure for spring measurement location The factory setting is appropriate for nearly all riding conditions Since this vehicle is equipped with full skid plates adjustment is not necessary If desired the spring setting may be adjusted to maintain vehicle clearance height when carrying loads 1 Raise and safely support front or rear of the vehicle off the ground to allow the ...

Page 73: ...ckwise to decrease compression damping NOTE The recommended factory setting for the front and rear shocks are provided in the following compression adjustment tables Walker Evans 2 0 Front Shock Compression Adjustment Table SETTING COMPRESSION DAMPING Softest Full counter clockwise position Factory 6 clicks from softest position Firmest Full clockwise position Walker Evans 2 5 Rear Shock Compressi...

Page 74: ...tion the vehicle on a level surface 2 Place the transmission in PARK 3 View the brake fluid level in the reservoir 1 The level should be between the MAX and MIN level lines 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the...

Page 75: ...The disc s should be replaced if thickness is less than 0 170 4 32 mm Brake Disc Thickness Service Limit 0 170 4 32 mm Brake Hose and Fitting Inspection Check brake system hoses and fittings for cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts MAINTENANCE ...

Page 77: ...Y VALVE COVER 3 12 ENGINE COOLING SYSTEM 3 13 COOLING SYSTEM PRESSURE TEST 3 13 COOLING SYSTEM PRESSURE CAP TEST 3 14 RADIATOR REMOVAL INSTALLATION 3 14 THERMOSTAT REPLACEMENT 3 15 COOLING SYSTEM ASSEMBLY VIEW 3 17 COOLING SYSTEM BLEEDING PROCEDURE 3 18 WATER PUMP REMOVAL 3 19 WATER PUMP INSTALLATION 3 19 WATER PUMP SERVICE 3 21 ENGINE SERVICE 3 24 ACCESSIBLE ENGINE COMPONENTS 3 24 TOP END SERVICE...

Page 78: ...0 ENGINE ASSEMBLY LOWER END 3 62 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 62 CONNECTING ROD BEARING SELECTION 3 63 CRANKSHAFT MAIN BEARING SELECTION 3 63 UPPER CRANKCASE PREPARATION 3 64 PISTON RING INSTALLATION 3 64 PISTON CONNECTING ROD ASSEMBLY 3 66 CYLINDER PISTON INSTALLATION 3 67 CRANKSHAFT INSTALLATION 3 68 BALANCE SHAFT INSTALLATION 3 70 LOWER CRANKCASE PREPARATION 3 70 CRANK...

Page 79: ...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 Oil Capacity Approx 2 5 Quarts 2 4 L Oil Filter Wrench PU 50105...

Page 80: ...n the MAG side of the engine 4 Remove the crankcase gallery plug 1 and insert the oil pressure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 or PS 4 Extreme Duty at operating temperature and may vary considerably if any other oil is used or if engine is not up to tempe...

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

Page 83: ... Rod Connecting Rod Small End I D 0 7879 0 7885 20 015 20 030 mm 0 7897 20 06 mm 1 Marking Conn Rod Big End Bore I D 1 7318 1 7321 43 989 43 996 mm 2 Marking Conn Rod Big End Bore I D 1 7321 1 7323 43 996 44 003 mm 3 Marking Conn Rod Big End Bore I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D 1 6140 1 6143 40 996 41 004 mm 1 6129 40 970 mm G Marking Main Journal O D 1 613...

Page 84: ...014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc ENGINE DETAIL TORQUE VALUES SEQUENCES ASSEMBLY NOTES Main Engine Components Torque Specification and Sequence ENGINE COOLING SYSTEM ...

Page 85: ...3 3 9 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Balance Shaft Connecting Rods Crankcase Crankshaft Pistons ENGINE COOLING SYSTEM ...

Page 86: ...3 10 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Cylinder Oil Cooler Oil Filter Oil Pump Oil Sump Water Pump ENGINE COOLING SYSTEM ...

Page 87: ...3 3 11 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Camshafts Cylinder Head Flywheel Idler Gears Stator Cover ENGINE COOLING SYSTEM ...

Page 88: ...3 12 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Spark Plugs Starter Thermostat Housing Throttle Body Valve Cover ENGINE COOLING SYSTEM ...

Page 89: ...epending 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 Remove the hood from...

Page 90: ...e cap relief pressure is 13 psi Replace cap if it does not meet this specification Radiator Removal Installation 1 Remove the hood and front bumper See Chapter 10 Hood and Front Body Work page 10 20and Front Bumper page 10 19 2 Remove the four fasteners that secure the front bumper support to the main frame 3 Drain radiator by removing lower radiator hose 1 Be sure to catch and dispose of coolant ...

Page 91: ...hapter 3 Upper Radiator Hose 6 To Radiator Fitting 4 Lower Radiator Hose 7 Fan Motor Assembly 5 Recovery Bottle 8 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 Te...

Page 92: ...bypass system to operate until thermostat opens 9 Install a new thermostat with the bleed hole 4 positioned closest to the engine NOTE Image shown above is with engine removed for clarity 10 Reverse this procedure for installation Torque thermostat cover bolts to specification Thermostat Cover Bolts 7 ft lb 10 Nm 11 Be sure to properly fill and bleed cooling system as outlined in this chapter ENGI...

Page 93: ...Cooling System Assembly View 1 Thermostat housing 6 Filler Neck 11 Oil Cooler Inlet Hose 2 Water Pump 7 Radiator 12 Oil Cooler Outlet Hose 3 Engine Hoses 8 Pressure Cap 13 Bypass Hose 4 Lower Radiator Hose 9 Upper Radiator Hose 14 Water Pump Outlet Hose 5 Fan Assembly 10 Recovery Bottle ENGINE COOLING SYSTEM ...

Page 94: ... the necessary amount of Polaris Premium Antifreeze to the radiator filler neck 5 Remove the seats engine service panel and divider panel heat shield to access the coolant bleed screw 6 Open the bleed screw 3 to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 7 Tighten the bleed screw to specification top off coolant and properly install th...

Page 95: ...coolant 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 1 2 retaining water pump to engine block Note different bolt lengths for installation 12 Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward 13 Maneuver water pump downward and r...

Page 96: ...ole in the skid plate on the RH side of the vehicle 8 Slide water pump into engine crankcase 9 Be sure water pump is fully seated and the drive tab and slot are properly engaged 10 Install the three water pump mounting bolts 5 6 and torque to specification NOTE Install different bolt lengths as shown Water Pump Mounting Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads 11 Install the four cool...

Page 97: ...alled in the engine 1 Remove water pump assembly as outlined in this chapter 2 Remove the three bolts retaining water pump cover 1 to water pump housing 2 Discard cover gasket 3 3 Place the water pump drive tab 4 vertically into a soft jaw vice 4 Remove the bolt and washer retaining the water pump impeller to the shaft Inspect the impeller veins and water pump housing for damage Replace if needed ...

Page 98: ... and oil seal bores 11 Install a NEW oil seal into the water pump housing until fully seated 12 Fully install the water pump shaft and two washers into the housing 13 Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure 14 Install a NEW mechanical seal into the water pump housing using special tool PU 50564 Press the new mechanical seal in until it is flus...

Page 99: ...er Pump Cover Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads 21 Install two new water pump O rings and lubricate them with fresh engine oil 22 Install water pump assembly into engine as shown in the Water Pump Installation procedure 9 Bolt 13 Washers 17 Oil Seal 10 Loctite 204 14 Drive Tab 18 Impeller 11 Mechanical Seal 15 Water Pump Shaft 19 Washer 12 O Rings 16 Water Pump Housing ENGINE C...

Page 100: ...vehicle Refer to Accessible Engine Components page 3 24 for further information The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components WARNING Always wear safety glasses and proper sho...

Page 101: ...kshaft 12 Disconnect the TMAP sensor 3 fuel injector harness leads 4 CPS 5 ECT sensor 6 and ignition coil harness lead Remove wire ties retaining harness to the fuel rail and rear cross member 13 Disconnect the stator harness 14 Remove positive cable from the starter motor 15 Remove negative cable from the starter mounting bolt 16 Disconnect fuel lines and remove throttle body assembly See Chapter...

Page 102: ...retaining the box support bracket 12 Remove the push rivet that attaches the heat shield 13 to the rear cross member 21 Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose 14 and the water pump coolant hose 15 from the engine Dispose of engine coolant properly 22 Use an overhead or portable engine hoist and suitable engine straps to secure engine in its curr...

Page 103: ...nal injury or damage to vehicle components 26 Remove the starter motor bolts 20 and starter motor from the engine 27 Remove the six transmission joint bracket bolts 21 and transmission joint bracket 22 from the engine 28 Install the engine stand adapter PU 50562 onto the engine where the starter motor was located 29 Select the proper engine stand sleeve adapter and install it onto the engine stand...

Page 104: ...steners to specification in sequence Starter Motor Bolts 7 ft lb 10 Nm Trans Joint Bracket Bolts 44 ft lb 60 Nm 4 Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame NOTE Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 5 Align both the...

Page 105: ... holes with transmission joint bracket mounting holes on engine 10 Install the two bolts 6 retaining the transmission joint bracket to the engine on the right side Hand tighten the bolts so they remain loose at this time NOTE DO NOT torque fasteners at this time 11 Install the two longer bolts into left side mounting holes Torque left side mounting bolts to specification using the numbered sequenc...

Page 106: ... cross member 26 Install positive cable to the starter motor 27 Install negative cable to the starter motor mounting bolt 28 Properly route and connect the harness leads for the stator CPS TMAP sensor ECT sensor fuel injectors and ignition coil 29 Install the air box assembly as outlined in the EFI Chapter See Chapter 4 ETC Replacement page 4 36 30 Install the inner clutch cover drive clutch drive...

Page 107: ... the Cooling System Bleeding Procedure page 3 18 as outlined in this chapter 39 Install the seats 40 Start engine and check for any oil or coolant leaks 41 Check the engine oil level 42 Refer customer to Engine Break In Period upon returning vehicle to customer Engine Mounting and Torque Values ENGINE COOLING SYSTEM ...

Page 108: ...um pump octane number of 87 R M 2 2 Refer to Engine Oil Level page 2 17 Check oil level indicated on dipstick Add oil if necessary 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bolt torques 6 Change oil and oil filter...

Page 109: ...ver seal 3 if oil leaks are evident 3 Remove the spark plugs 4 Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber Camshaft Removal NOTE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the PTO cylinder is at Top Dead Center TDC to relieve most of the valve spring pressure The camshaft lobes should face ou...

Page 110: ...he engine using the flywheel and remove the remaining bolt from each camshaft sprocket 7 Lift the chain and sprockets off the camshafts to allow each sprocket to be removed 8 Using a paperclip or other tool hold cam chain up to keep it from falling down into the crankcase NOTE The crankcase has a built in lower guide to prevent the chain from falling off the crankshaft 9 Evenly loosen the four bol...

Page 111: ...linder head if worn beyond service limit or if any surface is pitted or damaged 1 Visually inspect each cam lobe for wear or damage 2 Measure the height of each cam lobe from the base circle to highest point on the lobe using a micrometer Compare to specification NOTE Replace camshafts if damaged or if any part is worn past the service limit Camshaft Lobe Height Intake 1 5390 1 5429 39 09 39 19 mm...

Page 112: ...s to measure the camshaft bore Torque bolts in sequence to specification Replace cylinder head if worn Camshaft Carrier Bolts 89 in lbs 10 Nm 6 Measure camshaft bore and compare to specifications NOTE Replace cylinder head if camshaft journal bores are damaged or if worn past the service limit Camshaft Carrier Bore I D 0 9055 0 9063 23 000 23 021 mm 0 9072 23 044 mm 7 Calculate oil clearance by su...

Page 113: ...ins the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 Refer to Cylinder Piston Removal page 3 56 Cylinder Head Warp Inspection Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care not to damage gasket sealing surface All gasket surfaces must be clean dry and free of any oil or ...

Page 114: ...rside of the bucket 2 Compress the valve spring by hand using valve spring compressor adapter PV 43513 A 3 Push down on spring and remove split keepers 3 4 Slowly release valve spring pressure and remove the compressor adapter 5 Remove the valve retainer 4 valve spring 5 valve stem seal 6 and valve spring seat 7 Discard the valve seal NOTE Replace valve seals whenever cylinder head is disassembled...

Page 115: ...ove for wear or flaring in the keeper seat area NOTE The valves can be re faced or end ground if necessary They must be replaced if extensively worn burnt bent or damaged 5 Measure diameter of valve stem with a micrometer in three places then rotate 90 and measure again take six measurements total Compare to specifications Valve Stem Diameter Intake 0 2155 0 2161 5 475 5 490 mm Exhaust 0 2147 0 21...

Page 116: ...871326 can be used to help remove carbon deposits Do not use a metal scraper a coarse wire brush or abrasive cleaners to clean the cylinder head Damage may result 2 Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage Pay close attention to areas around spark plug and valve seats Valve Sealing Test 1 Clean and dry the combustion chamber area 1 2 Pour a small am...

Page 117: ...seat is too wide seat pressure is reduced causing carbon accumulation and possible compression loss If seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of...

Page 118: ...n contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very narrow and is a normal condition Look...

Page 119: ...g is not required if an interference angle reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the val...

Page 120: ...crews retaining the stator cover CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result 2 Carefully pry the stator cover off the engine using the two pry areas as shown 3 Inspect the condition of the stator windings 1 and outp...

Page 121: ...aring if removed Water Pump Housing Removal NOTE The water pump housing can be serviced with the engine installed in the chassis see Chapter 3 Water Pump Removal page 3 19 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 retaining the water pump housing to the engine 1 3...

Page 122: ...r PA 49316 3 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 3 44and...

Page 123: ... way clutch retaining screws 3 Remove the one way clutch and inspect both sides of drive rollers 1 Inspect the roller contact surface 2 inside the hub for wear damage or uneven surface 4 Inspect drive surface of starter gear 3 and bushing 4 for wear damage or uneven surface If any starter one way clutch component is worn or damaged replace the clutch and starter gear as an assembly ENGINE COOLING ...

Page 124: ...Install the Cylinder Holding Camshaft Timing Plate PU 50563 3 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 5 and three M8 bolts 6 retaining the sump cover 4 to the crankcase 7 Remove the sump cover 7 from the crankcase 8 Remove and clean oil pump pick up 8 9 Remove...

Page 125: ...cess 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 12 for wear or damage Replace oil pump drive chain and sprocket if worn or damaged If any part of the oil pump is damaged the entire assembly must be replaced Replace the oil pump seal 13 during crankcase assembly NOTE Oil pump assembly is no...

Page 126: ...rced 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 48 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 2 and remove it from the crankcase 4 Inspect the balance sh...

Page 127: ...ance shaft assembly Balance Shaft Diameter 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 48 procedure 2 Perform Balance Shaft Removal Inspection page 3 50 procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts 1 Remove the ...

Page 128: ...r worn teeth 8 If the crankshaft gear or sprocket is damaged the crankshaft assembly must be replaced 9 Support crankshaft on V blocks or on centers in a crankshaft stand or lathe Measure crankshaft run out and replace if run out exceeds maximum listed below Crankshaft Maximum Runout Less than 0 001 0 025 mm 10 Visually inspect surface of crankshaft main and connecting rod journals Replace cranksh...

Page 129: ...mit replace the crankshaft assembly CRANKSHAFT BEARING JOURNAL DIAMETERS B Main Bearing Standard 1 6140 1 6143 40 996 41 004 mm Service Limit 1 6129 40 970 mm Conn Rod Bearing Standard 1 6118 1 6122 40 942 40 950 mm Service Limit 1 6104 40 906 mm G Main Bearing Standard 1 6137 1 6140 40 988 40 995 mm Service Limit 1 6129 40 970 mm Conn Rod Bearing Standard 1 6115 1 6118 40 934 40 941 mm Service Li...

Page 130: ...e sure oil passages are clean and free of any cleaning solvent see Chapter 3 Engine Oil Flow Chart page 3 5 5 Remove and discard the plain bearings located in the upper crankcase 2 lower crankcase 3 and connecting rods 4 Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case Refer to bearing selection procedures upon assembly NOTE Always replace p...

Page 131: ... 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 in down from top the middle and 1 54 in up from bottom Record measurements If cylinder is tapered or ...

Page 132: ...ause of the unique cylinder skirt and crankcase design 1 Perform ENGINE DISASSEMBLY INSPECTION TOP END page 3 33 and the ENGINE DISASSEMBLY INSPECTION LOWER END page 3 44 procedures 2 Rotate the engine so the cylinder is facing up 3 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 1 from the cylinder 4 Carefully lift the cylinder and pistons from the upper crankcase 5 Remove the piston c...

Page 133: ...own of the piston slightly with a heat gun if pin cannot be removed by hand Discard circlips CAUTION DO NOTapply heat to piston rings or a loss of radial tension could result 3 Measure piston pin bore I D in two directions 90 apart Replace piston and piston pin if out of specification Piston Pin Bore I D 0 7877 0 7881 20 009 20 018 mm Service Limit 0 7893 20 05 mm 4 Measure piston pin O D in two d...

Page 134: ... open and push up on opposite side Do not scratch ring lands 2 Repeat procedure for second compression ring 2 3 The oil control ring 3 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 1 by placing the ring in th...

Page 135: ...mit replace the rings Piston Ring Installed Gap Top Ring 0 010 0 014 0 25 0 35 mm Service Limit 1 6118 1 6122 40 942 40 950 mm Second Ring 1 6118 1 6122 40 942 40 950 mm Service Limit 0 028 0 70 mm Oil Control Rails 0 008 0 028 0 20 0 70 mm Service Limit 0 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 pi...

Page 136: ... end and big end of connecting rod and matching rod cap for damage galling of surface or pitting 4 Measure small end I D in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service limit specification Connecting Rod Small End I D 0 7879 0 7885 20 015 20 030 mm Service Limit 0 7897 20 06 mm 5 Install matching rod cap on connecting rod...

Page 137: ...able below lists the big end bore diameter specifications Bearing Selection Chart Rod Bearings CONNECTING ROD BIG END BORE DIAMETERS 1 2 3 1 7318 1 7321 43 989 43 996 mm 1 7321 1 7323 43 996 44 003 mm 1 7323 1 7326 44 003 44 010 mm 10 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart provided in the Connecting Rod Bearing Selection page 3 63 ...

Page 138: ...ris Industries Inc ENGINE ASSEMBLY LOWER END Bearing Selection Identification Letters and Numbers 1 Connecting Rod Bearing Identification Number one number 2 Crankcase Bearing Identification Number six numbers 3 Crankshaft Bearing Identification Letters six letters ENGINE COOLING SYSTEM ...

Page 139: ...Chart 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 8 and match that up with the main journal letters on the crankshaft 7 In this example you would use the number 2 as the crankcase codes case journals 1 2 3...

Page 140: ...ugh 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 installed o...

Page 141: ...nstall 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 142: ...connecting rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is recommended they be installed with rods facing the same direction 3 Place piston 1 on connecting rod 2 Push piston pin 3 through rod and piston until it seats against the installed circlip NOTE Do not tap on p...

Page 143: ...re correctly located on each piston see Chapter 3 Piston Ring Installation page 3 64 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 connecting rod assemblies in...

Page 144: ...see Chapter 3 Crankshaft Main Bearing Selection page 3 63 and Connecting Rod Bearing Selection page 3 63 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 1 with the slot in main bearing bore of crankcase Press bearing insert firmly into place Repeat for all m...

Page 145: ... the crankshaft 9 Carefully lower the crankshaft into upper crankcase Guide connecting rods onto the rod journals of crankshaft as necessary 10 Adjust the PTO crankshaft seal so it rests properly in the upper crankcase 11 Clean bolt hole threads in connecting rod to remove all oil 12 Install matching rod cap on connecting rod with 5 digit serial number stampings aligned 13 Install new bolts 11 and...

Page 146: ...E Always 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 bea...

Page 147: ...ces to remove any oil 5 Apply a thin continuous film of Crankcase Sealant PN 2871557 to upper crankcase mating surface 3 as shown Do not allow sealant to dry before assembly NOTE DO NOT block oil passages 4 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...

Page 148: ...M6 Bolts 9 ft lb 12 Nm 11 Rotate the engine so the cylinder is facing up 12 Install the eleven M6 9 and two M8 8 upper crankcase bolts Tighten all bolts lightly by hand 13 Torque the upper crankcase bolts in sequence to specification start with 12 Repeat the sequence to verify final 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 is ...

Page 149: ...fication 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 14 as shown Do not allow sealant to dry before assemb...

Page 150: ... 26 ft lb 35 Nm M6 Bolts 106 in lb 12 Nm 25 Reinstall the crankcase drain plug if previously removed Torque drain plug to specification Crankcase Drain Plug 12 ft lbs 16 Nm 26 Reinstall the oil cooler 18 if previously removed Use new O rings 19 upon installation Torque fasteners to specification Oil Cooler bolts 7 ft lbs 10 Nm 27 Proceed to Flywheel Installation page 3 76 and then Cylinder Head In...

Page 151: ...h on flywheel and install the three screws Torque screws to specification One Way Clutch Retaining Screws 9 ft lb 12 Nm 4 Reassemble starter one way clutch and gear using the following illustration 1 Torque Limit Gear Pin 5 Flywheel 2 Starter Gear 6 Screws 9 ft lb 12 Nm 3 One Way Clutch Asm 7 Torque Limit Gear Asm 4 Bolt 133 ft lbs 180 Nm 5 If starter gear was replaced inspect the torque limit gea...

Page 152: ... and torque the retaining bolt 1 to specification NOTE If the Cylinder Holding Camshaft Timing Plate PU 50563 is installed remove it before tightening the flywheel Flywheel Retaining Bolt 133 ft lbs 180 Nm 7 Install the starter torque limit gear as an assembly Stator Cover Installation 1 Apply gasket tack adhesive to help hold gasket in place during assembly 2 Install a new stator cover gasket ove...

Page 153: ...ly until seated in retaining groove and square with the guide NOTE Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring 3 and retainer 4 in clean engine oil 6 Install the valve spring with widely spaced coils 6 on the top and tightly spaced coils 7 facing down toward the cylinder head NOTE Valve springs to be installed with paint mark f...

Page 154: ... Cylinder Holding Camshaft Timing Plate PU 50563 1 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 ...

Page 155: ...o Camshaft Installation Timing page 3 79 1 Rotate the engine until the flywheel Top Dead Center TDC mark 1 is aligned or centered in the Crankshaft Position Sensor CPS mounting hole 2 This places the PTO cylinder at TDC for camshaft installation NOTE DO NOT use the V mark located on the flywheel opposite of the I mark Only the I mark should be used as a TDC reference 2 Reference the intake and exh...

Page 156: ... end wrench to rotate camshafts slightly if needed 8 Verify the TDC mark on the flywheel is still properly aligned see Step 1 9 Pull cam chain upward making sure it is engaged with the drive sprocket on the crankshaft 10 While lifting the cam chain up engage the cam sprockets into the chain with the I and E marks facing out 11 Install the sprockets onto the camshafts and align the sprocket marks w...

Page 157: ...ocket retaining bolts upon assembly Install the top bolt 8 in each camshaft sprocket 7 Do not torque the bolts at this time NOTE Use new sprocket retaining bolts upon assembly 13 Verify cam timing is correct Flywheel TDC mark should still be aligned see Step 1 and cam sprocket markings should line up as shown ENGINE COOLING SYSTEM ...

Page 158: ...e using the flywheel and torque the remaining sprocket bolts to specification 18 Install the front camshaft carrier 9 and two outer retaining bolts 19 Install the fixed cam chain guide 10 and two retaining bolts 20 Torque the camshaft carriers bolts in sequence to specification Camshaft Carrier Bolts 7 ft lb 10 Nm 21 Apply Polaris PS 4 engine oil to the cam chain tensioner bore prior to assembly U...

Page 159: ...t Timing Quick Reference 1 Intake Cam 4 Align marks with surface 2 Exhaust Cam 5 CPS Mounting Hole 3 Align marks with surface 6 Align Flywheel Mark in Mounting Hole 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 160: ...aft bearing journal surfaces with Polaris PS 4 engine oil prior to installation 3 Carefully install the camshafts into the cylinder head The PTO camshaft lobes 3 should face out as shown 4 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when installed properly 5 Install the four bolts that retain each rear camshaft carrier 4 5 and tighten the...

Page 161: ...onent or place them in an organized rack as you remove them 11 Record the 3 digit number on the bottom of the tappet 8 12 Reference the valve clearance measurement recorded for that valve along with the 3 digit tappet number 13 Refer to the appropriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 14 Install the proper tappet NOTE Lubricate the outer...

Page 162: ...5 528 530 532 535 538 540 542 545 0 376 0 400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 401 0 425 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0 450 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 51...

Page 163: ...5 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 0 451 0 475 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 476 0 500 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 53...

Page 164: ...s 2 Install spark plugs 1 and torque to specification 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Install valve cover seal 2 5 Install the four valve cover shoulder bolts 3 and new isolators 4 using a T40 driver 6 Torque valve cover bolts to specification Spark Plugs 7 ft lbs 10 Nm Valve Cover Bolts 7 ft lbs 10 Nm ENGINE COOLING SYSTEM ...

Page 165: ...icted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression...

Page 166: ...y Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose imp...

Page 167: ... OVERVIEW 4 17 INITIAL PRIMING STARTING PROCEDURE 4 17 ELECTRONIC CONTROL UNIT ECU 4 18 OPERATION OVERVIEW 4 18 ECU SERVICE 4 18 ECU REPLACEMENT 4 18 FUEL INJECTORS 4 20 OPERATION OVERVIEW 4 20 FUEL INJECTOR TROUBLESHOOTING 4 20 FUEL INJECTOR TEST 4 21 FUEL INJECTOR REPLACEMENT 4 21 FUEL PUMP 4 25 OPERATION OVERVIEW 4 25 FUEL SENDER TEST 4 25 FUEL PUMP TEST 4 26 FUEL PUMP REPLACEMENT 4 27 TEMPERAT...

Page 168: ...AGNOSTICS 4 40 TROUBLE CODE DISPLAY ETC 4 40 EFI TROUBLESHOOTING 4 45 DIGITAL WRENCH OPERATION 4 46 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 46 SPECIAL TOOLS ALSO REFER TO THE BEGINNING OF THIS CHAPTER 4 46 DIGITAL WRENCH SOFTWARE VERSION AND UPDATE ID 4 47 DIGITAL WRENCH UPDATES 4 47 DIGITAL WRENCH COMMUNICATION ERRORS 4 48 DIGITAL WRENCH DIAGNOSTIC CONNECTOR 4 48 GUIDED DIAGNOSTICS 4 49 DIG...

Page 169: ... skin or clothing immediately wash with soap and water and change clothing Always stop the engine and refuel outdoors or in a well ventilated area Special Tools PART NUMBER TOOL DESCRIPTION PU 43506 A Fuel Pressure Gauge Kit PV 48656 Fuel Pressure Gauge Adapter PU 47063 B Digital Wrench Diagnostic Software Includes most recent version of software w serial number standard interface cable USB Serial...

Page 170: ...SmartLink Module Kit PU 47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the following kit components separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pin connector based Polaris EFI sy...

Page 171: ...h plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring ha...

Page 172: ...sembly View 1 Electronic Control Unit ECU 7 Fuel Pump Regulator 2 Crankshaft Position Sensor CPS 8 Fuel Level Sender 3 Engine Coolant Temperature Sensor ECT 9 Fuel Filter 4 Dual Throttle Body Assembly 10 Fuel Supply Line 5 Fuel Injectors 11 T MAP Sensor 6 Fuel Rail Regulator 12 Electronic Throttle Control FUEL SYSTEM ...

Page 173: ...Electronic Throttle Control ETC 2 Located on the PTO side of the throttle body assembly Crankshaft Position Sensor CPS 3 Located on top of the stator cover Temperature and Manifold Absolute Pressure TMAP Sensor 4 Located on the Mag side of the throttle body Engine Coolant Temperature Sensor ECT 5 Located on the left side of the thermostat housing The sensor can be accessed with the air box assembl...

Page 174: ...ead adapters Fuel Injectors 7 Located on the top of the throttle body in the intake track retained on top by the fuel rail Fuel Rail Regulator 8 Located on the throttle body on top of the fuel injectors Ignition Coil High Tension Leads 9 Located behind the engine service panel on the driver s side of the vehicle Fuel Pump Regulator Fuel Sender Assembly 10 Under the passenger seat FUEL SYSTEM ...

Page 175: ... XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc FUEL TANK Assembly View 1 PFA Nut 5 Preliminary Filter 2 Fuel Sender Float Arm 6 Fuel Tank Vent 3 PFA Gasket replace if removed 7 Fuel Tank Assembly 4 Fuel Pump Regulator FUEL SYSTEM ...

Page 176: ... Removal NOTE Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications 1 Remove the driver and passenger seats 2 Disconnect the negative and positive battery cables from the battery located under the driver s se...

Page 177: ...chanism to the frame near the right rear portion of the fuel tank Once removed place the mechanism in the rear cargo box to keep it out of the way 7 Remove the shift knob 6 using a flat blade screwdriver and T25 Torx driver Remove the Torx screws retaining the center console Remove the console from the vehicle 8 Remove the shift linkage from the shifter 9 Remove the two bolts 7 and two T40 Torx sc...

Page 178: ...r side of the seat base frame as well 11 Remove the Torx screws 11 and plastic rivets 12 retaining the block off panel using a T40 Torx driver Remove the panel from the vehicle 12 Remove the nuts 13 retaining the regulator and Torx screws 14 retaining the fuse box 13 Remove the fuel tank vent line from the tank fitting 14 Lift the rear of the fuel tank up first Carefully pull the fuel tank out of ...

Page 179: ...Install regulator and fuse box to the block off panel Torque fasteners to specification Regulator Fuse Box fasteners 5 ft lb 7 Nm 7 Install fuel tank strap screw Torque screw to specification Fuel Tank Strap Screw 8 ft lbs 11 Nm 8 Reinstall center console shift knob and screws 9 Reinstall seat belt mechanism Torque bolt to specification Seat Belt Mechanism Bolt 40 ft lbs 54 Nm 10 Reinstall right r...

Page 180: ...Chapter 2 Fuel Lines page 2 13 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 2 5 Remove the right hand rocker panel see Chapter 10 6 Remove the fastener 3 retaining the seat belt mechanism to the frame near the right rear portion of the fuel tank O...

Page 181: ...vets 8 retaining the lower rear close off panel using a T40 Torx driver Remove the panel from the vehicle 11 Remove the nuts 9 retaining the regulator and bolts 10 retaining the fuse box 12 Remove the fuel tank vent line 11 from the tank fitting 13 Lift the rear of the fuel tank up first Carefully pull the fuel tank out of the vehicle FUEL SYSTEM ...

Page 182: ...1 Nm 6 Install regulator and fuse box to the block off panel Torque fasteners to specification Regulator Fuse Box fasteners 5 ft lb 7 Nm 7 Install fuel tank strap screw Torque screw to specification Fuel Tank Strap Screw 8 ft lbs 11 Nm 8 Reinstall rear and front center console shift knob and screws 9 Reinstall seat belt mechanism Torque bolt to specification Seat Belt Mechanism Bolt 40 ft lbs 54 N...

Page 183: ...jectors are on This range can vary depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for...

Page 184: ...y in the 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 R...

Page 185: ...or locking lever and rotate it up until the connector is free from the ECU NOTE Upon removing the ECU connector you should hear a click when the connector is fully open 4 To install reverse the procedure and tighten the mounting screws to specification NOTE Upon installing the ECU connector you should hear a click when the connector is fully closed ECU Retaining Screws 24 in lb 3 Nm FUEL SYSTEM ...

Page 186: ...ional vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel inj...

Page 187: ...y measuring between the two pin terminals 2 Fuel Injector Resistance Specification 11 4 12 6 Ω NOTE Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation Fuel Injector Replacement 1 Remove the cargo box assembly see Chapter 10 Cargo Box Assembly Removal page 10 22 2 Be sure the engine has cooled enough to work on ...

Page 188: ...Remove the two screws 6 that mount the fuel rail to the throttle body using a 5 mm Allen wrench 9 Carefully pull up on the fuel rail 7 and injectors and remove them from the throttle body as an assembly Take care not to damage the fuel injector ends during removal 10 Pull out on the fuel injector retaining clip and pull the injector out of the fuel rail Repeat on the other injector if removal is n...

Page 189: ...jector and the MAG harness lead to the MAG injector to ensure proper engine operation 18 Use a tie strap to retain the harness leads to the fuel rail 19 Reconnect the negative battery cable and reinstall the driver s seat 20 Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks 21 Reinstall the intake plenum assembly and fasten the lower mount to the ...

Page 191: ... ECU switches off the pump preventing the continued delivery of fuel in these instances If the key switch is not promptly turned to the start position If the engine fails to start If the engine is stopped with the key switch on as in the case of an accident In these situations the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine ...

Page 192: ...erved the ignition switch ECU fuel pump and pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure Fuel Pressure 58 2 psi 400 14 kPa NOTE If the fuel pressure is out of specification replace the fuel pump assembly 6 If the pump did not activate Step 5 disconnect the harness connector from the fuel pump Connect a DC ...

Page 193: ... tank during service Excessive debris in fuel tank may cause premature wear of fuel pump and or clogging of internal fuel filters 4 Ensure that static has been discharged by touching a ground source such as the engine or frame 5 While holding a shop towel over the fuel line connectors disconnect the fuel supply line 2 from the pump and the fuel return line B from the tank see Chapter 2 Fuel Lines ...

Page 194: ...t arm and pump pre filter Hold the float arm to the pump body as you lift and tilt the pump to ensure that the float arm is not bent when removed from the tank 9 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 10 Inspect the inside of the fuel tank for debris may require flashlight and mirror If debris like mud or sand is present fu...

Page 195: ... orientation marks on fuel tank to ensure float arm does not get bent or snagged WARNING Failure to align the orientation marks may lead to interferences with the fuel level float arm and cause incorrect function 17 While maintaining downward pressure thread new PFA nut onto fuel tank and hand tighten Use care when starting PFA nut ensuring threads are properly aligned Verify orientation marks are...

Page 196: ...P4 1000 Service Manual Copyright 2014 Polaris Industries Inc 23 Test the fuel pump by turning on the key and listening for the pump to activate Cycle the key several times to prime the system 24 Install the passenger seat storage box FUEL SYSTEM ...

Page 197: ... These 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 se...

Page 198: ...nd crankshaft position takes place during the first two revolutions 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 conn...

Page 199: ...PS Test page 4 32 2 Using an 8mm socket remove the CPS retaining bolt 1 and remove the sensor 2 from the stator cover 3 Unclip the wire harness retainer 3 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 CPS Retaining Bolt 9 ft lb 12 Nm FUEL SYSTEM ...

Page 200: ...a non serviceable component However the fuel rail fuel injectors and the Temperature and Manifold Pressure Sensor TMAP can be serviced separately see Chapter 4 FUEL INJECTORS page 4 20 and Temperature Manifold Absolute Pressure T MAP Sensor page 4 31 Throttle Body Removal 1 Remove the cargo box assembly See Chapter 10 Cargo Box Assembly Removal page 10 22 2 Be sure the engine has cooled enough to ...

Page 201: ...ntake 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 disconnect fuel lines or the injector harnesses to perform this procedure 9 Reverse the previous steps to reinstall the throttle body 10 Upon installation of the fuel rail a...

Page 202: ...ol functions within the ETC are pre set No internal servicing or adjustments may be performed If a problem is encountered and you determine the ETC to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ETC without factory authorization Use Digital Wrench to perform all troubleshooting of this component Use a Volt Ohm meter to test the vehicle har...

Page 203: ...edal assembly PPS Test The PPS can be tested utilizing Digital Wrench by verifying that throttle position readout varies as the pedal is pressed 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 9 6 when the pedal is released With the pedal fully depress...

Page 204: ...m the vehicle ETC Installation 5 Place the throttle pedal assembly on the mounting studs and loosely install the three fasteners 6 Torque the three mounting bolts to specification and connect the PPS harness connection Throttle Pedal Mounting fasteners 18 ft lb 24 Nm 7 Manually cycle the throttle pedal to verify the throttle pedal moves freely 8 Connect the negative battery cable and install the d...

Page 205: ...lack Sensor Ground There are no valid static tests to perform on the oxygen sensor The sensor should be diagnosed using Digital Wrench First verify if there are any stored codes for the oxygen sensor NOTE The ECU must first run though the O2 sensor time delay before a trouble code will be set This may take several minutes at idle to occur Short drive cycles and cold temperatures will both affect t...

Page 206: ...e 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 code present example 2 means there are 3 codes presen...

Page 207: ... Too Low 4 P0117 Temperature Too High 16 P0217 Engine Overheat Shutdown 0 P1217 System Power Battery Potential Power Input Voltage Too High 168 3 P0563 C1063 Voltage Too Low 4 P0562 C1064 Engine Speed This is applicable when the EPS module gets the engine speed from the ECM Error in Engine Speed Computation 190 31 P121C Received Engine Speed Has Error 19 C1066 Engine Speed Error in Engine Speed Co...

Page 208: ... Too Low 4 P0222 Signal Out of Range 2 P0221 All Wheel Drive Control Circuit AWD Driver Circuit Open Grounded 520207 5 P1836 Driver Circuit Short to B 3 P1835 Driver Circuit Grounded 4 P1834 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...

Page 209: ...e 2 P151A Signal Error 8 P151B Deactivated power stages due to 5V sensor supply error 31 P153F Throttle Body Control Return Spring Check Failed Condition Exists 520278 31 P151C Throttle Body Control Adaptation Aborted Condition Exists 520279 31 P151D Throttle Body Control Limp Home Position Check Failed Condition Exists 520280 31 P151E Throttle Body Control Mechanical Stop Adaptation Failure Condi...

Page 210: ...532 Accelerator Sensor Synchronicity Fault Sensor Difference Exceeds Limit Condition Exists 520308 31 P1533 ECU Fault ICO Condition Exists 520309 31 P1534 ECU Fault Hardware Disruption Condition Exists 520311 31 P1537 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 Oxyge...

Page 211: ...r performance 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 a...

Page 212: ...ibration files Perform guided diagnostic procedures Create customer service account records Perform output state control tests some models Special Tools also refer to the beginning of this chapter DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER Digital Wrench Diagnostic Kit PU 47063 B PU 47063 B listed above INCLUDES Digital Wrench Software PU 48731 Standard Interface Cable PU 47151 SmartLink Modul...

Page 213: ...pdates Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through the dealer website at www polarisdealers com NOTE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Locate the Service and Warranty drop down menu 3 Click on Digital Wrench Updates 4 The...

Page 214: ...rmation FAQs downloads and software updates at http polaris diagsys com Digital Wrench Diagnostic Connector Located under the hood connected to a sealed plug 1 Follow these steps to connect the diagnostic interface cable to the vehicle to allow 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 con...

Page 215: ...In addition 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...

Page 216: ...en View 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 Pr...

Page 217: ... to Digital Wrench A laptop that is used by a variety of people and in several applications around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations see Chapter 4 Digital Wrench Updates page 4 47 CLOSE NON ESSENTIAL ...

Page 218: ...con 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 website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be invalid NOTE All characters are letters there are no numbers in a request code NOTE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen 9 Go to www po...

Page 219: ...y 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 process 15 Once the ECU ...

Page 221: ...8 2015 XP XP4 PVT COVERS AND DUCTING COMPONENTS 5 9 PVT COVERS AND DUCTING COMPONENTS HIGH LIFTER 5 10 PVT DISASSEMBLY 5 11 PVT ASSEMBLY 5 13 DRIVE BELT 5 15 BELT REMOVAL 5 15 BELT INSPECTION 5 16 BELT INSTALLATION 5 16 PVT BREAK IN DRIVE BELT CLUTCHES 5 16 DRIVE CLUTCH SERVICE 5 17 DRIVE CLUTCH ASSEMBLY VIEW 5 17 DRIVE CLUTCH DISASSEMBLY INSPECTION 5 18 NEEDLE BEARING INSPECTION 5 19 SHIFT WEIGHT...

Page 222: ... Spanner Clutch Spreader Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com SPECIAL SUPPLIES PART NUMBER Loctite 620 648 and 7088 Primer N A RTV Silicone Sealer 8560054 PVT System Torque Specifications ITEM TORQUE VALUE Drive Clutch Retaining Bolt 96 ft lb 130 Nm Driven Clutch Retaining Bolt 55 ft lb 75 Nm PVT Inner Cover Bolts 12 ft lb 16 Nm PVT Outer Cover Sc...

Page 223: ...0 6000 12000 26 59 1322981 Orange Black 7044338 Red 3234452 2014 2015 RZR 1000 XP4 MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 2014 XP4 1000 Meters Feet 0 1800 0 6000 26 67 1323177 White Orange 7043924 Red 3234452 1800 3700 6000 12000 26 61 1323098 White Orange 7043924 Red 3234452 2015 XP4 1000 Meters Feet 0 1800 0 6000 26 65 1323260 White Orange 7043924 Red 3234452 1800 3700 6000 12000...

Page 224: ...s matched 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 ...

Page 225: ...ll and downhill and throttle settings are constant the drive and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle positio...

Page 226: ...llers and Roller Pins Drive and Driven Clutch Springs 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to the appropriate illustration s on the following pages The PVT system is air cooled by fins on the drive and driven clutch stationary sheaves The fins create a low pressure area in the crankcase casting drawing air into the system through an intake duct The opening for this ...

Page 227: ...rol 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...

Page 228: ...d Duct Components 1 CLUTCH DUCT INTAKE ASSEMBLY 11 BRACKET COVER GUARD 2 CLAMP WORM 12 AIR INLET DUCT 3 DECAL CAUTION 13 SCREW 4 BOLTand WASHER 14 SCREW 5 COVER ASSEMBLY OUTER 15 NUT NYLOK 6 O RING 16 BRACKET BELT SCREEN 7 DRAIN PLUG COVER 17 HOSE AIR OUTLET 8 SEAL COVER 18 INTAKE BOOT 9 SCREW 19 SEAL COVER 10 COVER ASSEMBLY PVT SYSTEM ...

Page 229: ...s 1 Inlet Duct 10 Outer Cover Seal 2 Band Clamp 11 Inner Cover Seal 3 Intake Hose 12 Guard Plate 4 Boot 13 Outlet Duct Screen 5 Clutch Outlet Duct 14 Intake Hose Bracket 6 Inlet Duct 15 Outer Cover Screws 8 ft lbs 11 Nm 7 Outlet Duct 16 Clutch Cover Drain Screw 8 Outer Clutch Cover 17 Inner Cover Screws 8 ft lbs 11 Nm 9 Inner Clutch Cover PVT SYSTEM ...

Page 230: ...t Duct 2 Band Clamp 12 Retaining Bracket Upper Exhaust Hose 3 Upper Intake Hose 13 Inner Cover Seal 4 Upper Exhaust Hose 14 Inner Clutch Cover 5 Middle Intake Hose 15 Guard Plate 6 Lower Intake Hose 16 Inner Clutch Cover Screw 7 7 Lower Exhaust Hose 17 Outer Cover Seal 8 Outlet Duct 18 Outer Clutch Cover 9 Inlet Duct 19 Outer Clutch Cover Screw 8 10 Boot 20 PVT Drain Screw PVT SYSTEM ...

Page 231: ... 1 from the left rear shock Discard the nut 5 Swing shock outward toward the front of the vehicle 6 If servicing a 2015 RZR XP4 1000 Loosen the hose clamp attaching PVT intake hose to the outer clutch cover and disengage the hose from the outer clutch cover 7 Remove the eight clutch cover screws 2 and remove the outer clutch cover from the vehicle 8 Mark the drive belt direction of rotation and re...

Page 232: ...he 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 13 Loosen the hose clamp attaching PVT inlet duct to the inner clutch cover Disengage the hose from the inner clutch cover 14 Loosen hose clamps 3 that attach clutch outlet duct to inner clutch cover Disengag...

Page 233: ... as shown 1 6 Install the protective cover and the four push rivets that secure the cover to the top of the inner PVT cover 7 Install the four inner clutch cover bolts and washers that retain the cover to the transmission Torque bolts to specification 8 Install the three inner clutch cover bolts and washers that retain the cover to the engine Torque bolts to specification Inner Clutch Cover Bolts ...

Page 234: ... 16 If a new belt is installed install so numbers can be easily read 16 Install a new outer clutch cover seal with the colored stripe facing the inner clutch cover 17 Reinstall outer clutch cover and secure with screws Torque screws to specification Outer Clutch Cover Retaining Screws 48 in lb 5 Nm 18 Install inlet and outlet ducts and tighten hose clamps 19 Install the left rear shock lower mount...

Page 235: ...er outward as shown below to access the drive belt NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement 3 Mark the drive belt direction of rotation so that it can be installed in the same direction 4 Insert clutch spreader tool 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 move...

Page 236: ...tion as it was removed 1 With the clutch spreader tool installed 2877408 or 2878925 loop the belt over the drive clutch and over the driven clutch 2 Rotate the driven clutch and walk the belt into the clutch 3 Remove the clutch 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 ...

Page 238: ...nt the 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 1 The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing ...

Page 239: ...spected 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 Drive Clutch Spring Specifications Part Number 7043924 Color White Orange Free Length 3 563 90 50 mm Spring Wire Diameter 0 177 4 50 mm Needle Bearing Inspection 1 Rotate...

Page 240: ... three 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 driv...

Page 241: ...ture PN 2871358 A 2 Loosen and remove the spider counterclockwise using Clutch Spider Removal Installation Tool PN 2870341 Spider Removal Installation Tool 2870341 Clutch Holding Fixture 2871358 A Roller Pin and Thrust Washer Inspection 1 Inspect all rollers roller bushings and roller pins by pulling a flat metal rod across the roller 2 Turn roller with your finger If you notice resistance galling...

Page 242: ...earing 3 and thrust washers 2 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 Shaft Diameter Standard 1 3725 1 3712 34 8615 34 8488 mm Service Limit 1 3704 34...

Page 243: ...quired 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 287...

Page 244: ...s Piston Pin Puller PN 2870386 3 Remove nut from puller rod and set aside 4 Install puller adapter 10 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 T...

Page 245: ... barrel 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 in...

Page 246: ...reads 5 Install the spider assembly onto the shaft threads Be sure all of the alignment marks 8 are in alignment 5 Moveable Sheave Asm 6 Jam Nut 7 Spider 6 Install clutch onto holding fixture PN 2871358 A and secure in a bench vice Tighten the spider using Clutch Spider Tool PN 2870341 Torque spider to specification Spider Assembly 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Locti...

Page 247: ...ch assembly from the holding fixture and inspect the alignment marks made during disassembly NOTE If the marks illustrated below are not in alignment upon assembly the clutch will not be in balance and the drive clutch assembly must be replaced 10 Install the limiter spacer 15 and the clutch spring 14 CAUTION DO NOT reassemble the drive clutch without the limiter spacer Belt life will be greatly r...

Page 248: ...utch Do not attempt disassembly of the driven clutch from the outside snap ring The driven clutch must be disassembled from the helix side 2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in assembly and maintains clutch balance 3 Remove the four screws 1 that secure the cam helix assembly using...

Page 249: ...mbly 6 Remove the spider assembly and spring 3 NOTE Spring is compression only and has no torsional wind 7 Remove the inside spider plate 4 and spider dampener 5 Inspect the spider dampener for wear and replace if needed 8 Remove the E clips 6 washers 7 and the clutch rollers 8 Inspect the rollers for wear replace if worn 9 Remove the clutch assembly from the holding tool 10 Press out the spring p...

Page 250: ...ess 13 Inspect the bearing 12 for wear Spin the bearing if the bearing does not spin smoothly replace it To replace the bearing remove the snap ring 13 from the end of the shaft and press the bearing off the shaft 14 Inspect the cam helix assembly bushing 14 for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam helix assembly 15 Inspect the sheaves for exc...

Page 251: ... 1 5020631 P 90 Driven Clutch Cover Bushing Removal Tool 8 1 5020632 Main Puller Adapter 9 1 5010279 Adapter Reducer 10 1 5020633 Number Two Puller Adapter NOTE Bushings are installed at the factory using Loctite 648 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing Clut...

Page 252: ...hing on installation tool 2 and install assembly into sheave 16 Install left hand thread nut C onto puller rod and hand tighten against installation tool 17 Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 18 Remove nut C from puller rod and set aside 19 Remove installation tool and clutch sheave from puller Clutch Assembly 1 Inst...

Page 253: ...r pin B on both sides 5 Install the roller pin into the sheave assembly on both sides The flat side of the roller pin faces downward when the shaft side is laying flat on the bench 6 Install the spring pins C to secure the roller pins Install until flush with sheave surface 7 Install the spring over the shaft 8 Install the clutch rollers D onto each side of the outside spider Install the washers E...

Page 254: ...assembly pushing the spider onto the shaft 13 Slowly compress the spider into place If the spider appears to bind while compressing stop and make sure the skip tooth on the shaft and the spider are aligned Once the spider passes the retaining ring notch on the shaft install the retaining ring 14 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on the station...

Page 255: ...015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc 15 Use a T25 Torx driver to install the four helix retaining screws 1 and torque to specification Helix Retaining Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 256: ...nual Copyright 2014 Polaris Industries Inc Assembly View 1 Snap Ring 8 Spring 2 Bearing 9 Spider Insert 3 Stationary Sheave 10 Spider Dampener 4 Pin 11 E Clip 5 Roller 12 Washer 6 Moveable Sheave 13 Helix Cam 7 Clutch Shaft 14 Helix Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 257: ...ied operating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift weights Drive clutch binding Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Dr...

Page 258: ... outlined 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 PV...

Page 259: ... TURF MODE MODELS ONLY 6 18 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT TURF MODE MODELS ONLY 6 19 PLANETARY DIFFERENTIAL ASSEMBLY TURF MODE MODELS ONLY 6 21 GEAR SHAFT BEARING INSPECTION 6 22 TRANSMISSION ASSEMBLY SNORKEL GEAR BACKLASH PROCEDURE 6 23 TRANSMISSION ASSEMBLY VIEW 6 29 TRANSMISSION SERVICE INT L 6 31 DIFFERENTIAL OPERATION TURF MODE MODELS ONLY 6 31 TRANSMISSION DISASSEMBLY 6 32 PLANE...

Page 260: ...Crank Nut 18 ft lb 24 Nm Fill Drain Plugs 14 ft lbs 19 Nm Gear Sector Cover 12 ft lb 16 Nm Park Brake Disc Mounting Bolt INT L 14 ft lb 20 Nm Park Flange Screws 10 ft lb 14 Nm Rear Transmission Isolator Bolt 40 ft lb 54 Nm ITEM TORQUE VALUE Rear Transmission Mount Bracket Fasteners 17 ft lb 23 Nm Snorkel Tube Refer to Snorkel Gear Backlash Procedure page Snorkel Tube Locking Screw 10 ft lb 14 Nm S...

Page 262: ...d T30 Torx driver Remove the console from the vehicle 3 Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever 4 Remove the retaining ring 5 and slide the shift lever 6 off the mounting bracket and out from the frame 5 Remove both bushings 7 from the shift lever and service as needed Installation 1 Perform the removal steps in reverse or...

Page 263: ...pin pivot bushings and dust boot 2 Replace if worn or damaged 3 If adjustment is required loosen the lower jam nut 4 and pull the cable out of the mount 3 to move the upper jam nut 5 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure...

Page 264: ...shaft from the transmission output shaft see Chapter 7 Rear Prop Shaft Removal page 7 24 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 23 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 clu...

Page 265: ...training arms up and swing trailing arms outward to remove the drive shafts from the transmission 15 Maneuver the drive shafts out of the vehicle frame Reinstall the lower shock bolts 3 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 Rem...

Page 266: ...xhaust springs securing the muffler to the rear transmission mounting bracket 22 Remove the two fasteners 11 attaching the rear transmission mount bracket assembly to the frame Remove the fasteners 12 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...

Page 267: ...unt Torque fasteners to specification Rear Transmission Isolator Fasteners 2 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 PU 50658 onto the crankshaft and transmission input shaft to properly position the clutch center distance IMPORTANT Tool should bottom out on the transmission input...

Page 268: ...lb 87 Nm Step 3 5 ft lb 7 Nm Step 4 7 44 ft lb 60 Nm 12 Remove the clutch center distance tool 13 Remove the spacer or support between the vehicle frame and engine 14 Install and properly route the gear position switch connector 5 speed sensor connector 6 crankshaft position sensor connector 7 shift bracket and shift bracket bolts 8 shift cable clevis pin and washer 9 onto the transmission 15 Torq...

Page 269: ...splines 11 21 Remove lower shock mounting bolt and swing the rear trailing arm out and up Align the splines of the drive shaft with the transmission splines Push inward on the trailing arm assembly until the rear drive shafts lock into the transmission splines 22 Install the rear shocks onto the trailing arms and install the lower mounting bolts with new retaining nuts Torque to specification 23 I...

Page 270: ...8 Quart Capacity Standard 44 oz 1300 ml Capacity INT L 41 oz 1200 ml Transmission Disassembly NOTE Refer to the exploded view at the end of this chapter as a reference 1 Place transmission in High gear before disassembly 2 Drain and properly dispose of the transmission lubricant see Chapter 2 3 Remove the bell crank nut 1 and bell crank 2 4 Remove E clip 3 that retains spring and flat washers 4 an...

Page 271: ...over using the designated pry points indicated by the black arrows in the illus tration below CAUTION Do not pry on case sealing surfaces Use only the designated pry points on the transmission 12 Lift up on the shift shaft rail 16 and move the rail assembly rearward to allow the shift fork pins 17 to be removed from the shift drum 18 Remove the shift drum from the transmission housing 13 Remove th...

Page 272: ...housing Note the longer screw 24 that locks the snorkel tube 18 Remove all seals from the gearcase halves and clean the cases in preparation for assembly Gear Cluster Disassembly 19 Remove the bearing from the reverse shaft using a bearing puller Remove the retaining ring and slide the washers high gear and needle bearing off the reverse shaft 1 Bearing 6 Needle Bearing 2 Reverse Shaft 7 Engagemen...

Page 273: ...assemble the shift shaft rail remove the snap ring 25 from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compressed springs on the shift rail may pop off causing eye or face injury Snorkel Shaft Removal Disassembly CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure to remove pinion shaft will result in ...

Page 274: ...gear from the snorkel shaft Differential Operation Turf Mode Models Only Transmissions equipped with Turf Mode have two traction operational modes Differential Lock and Differential Unlock Locking the rear differential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain When Differential Unlock is selec...

Page 275: ... for tighter turns When Differential Lock is selected power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift fork back into place and mates the engagement dog to the side gear that is part of the planetary differential assembly This locks the rear differential as a solid rear axle increasing traction TRANSMISSION ...

Page 276: ...ng gear 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 repla...

Page 277: ...ial 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 pla...

Page 278: ...fferential 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 ...

Page 279: ...e Models Only 1 Thoroughly clean the differential components 2 Assemble the side gears and place them onto the ring gear along with the six planet gears 3 Align and install the differential cover using the previously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification Differential Cover Screws 22 ft lb 30 Nm...

Page 281: ...e pressed onto the snorkel 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 am...

Page 282: ...earing cover retaining screws 9 Using a 5 mm Allen wrench install only the three screws 15 that secure the pinion shaft assembly as shown below Leave the longer locking screw 16 out at this point Torque the bearing cover retaining screws to specification 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 an...

Page 283: ...e 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 Snorkel Locking Screw 10 ft lb 14 Nm Transmission Assembly NOTE The snorkel shaft and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be instal...

Page 284: ... 20 Install the shift shaft rail 31 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 32 21 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 22 Install the shift drum into the transmission housing Lift up on the shif...

Page 285: ...The input shaft seal 34 should be pressed in until it seats flush with the housing The rear output shaft seals 35 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 shift shaft ...

Page 286: ...rfaces thoroughly 32 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 33 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification Sector Gear Cover Bolts 12 ft lb 16 Nm 34 Install the transmission drain plug and torque to specification Fill Drain Plug 14 ft lbs 19 Nm 35 Install ...

Page 288: ... Sprocket 48T 6 Face 19 1 Retaining Ring Internal 62 1 Gear Low 67T 20 2 Retaining Ring External 63 1 Engagement Dog 6 Face 21 2 Retaining Ring External 64 1 Gear 53T 22 3 Retaining Ring External 65 1 Shaft Pinion 11T 23 1 Retaining Ring External 66 1 Gear 46T 24 2 Washer Thrust 67 1 Gear Snorkel 13T 25 1 Washer Thrust 68 1 Shaft Shift 26 1 Shim 69 1 Weldment Rear Mount Bracket 27 1 Shim 70 1 Brac...

Page 289: ...ed 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 side gear that is part of the planetary differential assembly This unlocks the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When Diffe...

Page 290: ...ubrication page 2 23 3 Remove the bellcrank nut 1 and bellcrank 2 4 Remove E clip 3 that retains spring washer 4 flat washer 4 and gear switch 5 Remove the switch 5 Remove the sector cover bolts 6 and remove the sector cover 7 NOTE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent ...

Page 291: ...ransmission pinion shaft Remove disc from shaft 12 Remove all transmission case bolts Using suitable pry bars remove the cover using the designated pry points indicated by black arrows in illustration below CAUTION Do not pry on case sealing surfaces Use only the designated pry points on the transmission 13 Lift up on the shift shaft rail Q and move the rail assembly rearward to allow the shift fo...

Page 292: ...he idler gear shaft assembly T and gear cluster assembly U on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly 18 Slide engagement dog X off of shift fork guides 19 Remove two screws and retaining plates then lift shift fork Y and torsion spring out of transmission housing 20 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembl...

Page 293: ...bearing and sprocket from the reverse shaft see Figure 8 1 25 Tilt the two shafts towards each other and remove the silent chain from the two shafts 26 If necessary disassemble the other end of the reverse shaft Remove the bearing engagement dog retaining ring washer gear and needle bearing from the reverse shaft see Figure 8 2 27 To disassemble the shift shaft rail remove the snap ring X from the...

Page 294: ...n shaft will result in damage to the snorkel shaft 28 Extract the seal from the snorkel shaft to access the snorkel tube for removal 29 Using the Snorkel Tool PA 50231 fully loosen the snorkel tube 30 Remove the snorkel tube and shaft assembly from the transmission case 31 Remove the snap ring Y and shim Z from the snorkel shaft 32 Use an arbor press to remove the snorkel tube from the snorkel sha...

Page 295: ...Industries Inc 33 Remove the snap ring A and shim B retaining the bearing in the snorkel tube 34 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 35 Remove the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft TRANSMISSION ...

Page 296: ...ng gear 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 repla...

Page 297: ...ial 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 pla...

Page 298: ...fferential 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 ...

Page 299: ...e Models Only 1 Thoroughly clean the differential components 2 Assemble the side gears and place them onto the ring gear along with the six planet gears 3 Align and install the differential cover using the previously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification Differential Cover Screws 22 ft lb 30 Nm...

Page 301: ...r and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 Install the snorkel shaft into the gearcase Using the Snorkel Tool PA 50231 tighten the snorkel tube until it is lightly seated in the transmission housing 6 Inspect the pinion shaft assembly Replace bearings...

Page 302: ...n you should still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel locking screw hole opening to reference your starting point NOTE If you have a hard time seeing into the hole insert a small Allen wrench punch or screwdriver into the hole to feel when the notch is aligned with t...

Page 303: ...he snorkel shaft cannot be installed after assembling the transmission 17 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 18 Install shift fork S and torsion spring into transmission housing as an assembly Load spring as shown in image below 19 Apply Loctite 242 to two screws T and install with retaining plates over shift fork Torque to specification Shi...

Page 304: ...put shaft assembly if previously disassembled see illustrations 22 Install the idler gear shaft assembly A and gear cluster assembly B into the transmission housing all at the same time 23 Install the rear output shaft assembly C Rotate output shaft assembly to align slots with engagement dog Ensure bearing is fully seated upon assembly TRANSMISSION ...

Page 305: ... 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 26 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 27 Install the shift drum E into the transmission housing Lift up on the shift shaft rail D and move the rail assembly towards the shift drum to allow the shif...

Page 306: ... new seals into the transmission case halves The snorkel shaft seal F should be pressed in until it seats against the housing counter bore The input shaft seal G should be pressed in until it seats flush with the housing The rear output shaft seals H and pinion shaft seal J can be installed using a standard bushing installation tool Seals should be installed just past the case lead in chamfer 070 ...

Page 307: ...m 32 Thoroughly clean the shift shaft housing Be sure the transmission is in High gear prior to reassembly 33 Install the sector gear 16T onto the shift drum shaft Install the shift shaft assembly and sector gear 11T into the bushing pocket on the left side Align the timing marks on the gears as shown 34 Install the spacer onto the shift drum shaft 35 Install the detent star onto the shift drum sh...

Page 308: ...urfaces thoroughly 39 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 40 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification Sector Cover Bolts 12 ft lb 16 Nm 41 Install the transmission drain plug and torque to specification Fill Drain Plug 14 ft lbs 19 Nm 42 Install the ...

Page 310: ...87 O Ring 17 Pin Spring 52 Gear Sector 31T 88 O Ring 18 Retaining Ring External 53 Pawl Detent 89 O Ring 19 Snap Ring 54 Star Detent 90 Seal Triple Lip 20 Retaining Ring External 55 Plate Park 12 Face 91 Seal Triple Lip 21 Retaining Ring External 56 Shaft Idler 29T 92 Seal Dual Lip 22 Retaining Ring Internal 57 Shaft Reverse 29T 93 Seal Triple Lip 23 Retaining Ring External 58 Shaft Front Output 9...

Page 311: ...m bushings 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 p...

Page 313: ...CV JOINT HANDLING TIPS 7 16 OUTER CV JOINT BOOT REPLACEMENT 7 17 INNER PLUNGING JOINT BOOT REPLACEMENT 7 19 DRIVE SHAFT ASSEMBLY VIEW 7 22 FRONT PROPSHAFT SERVICE 7 23 FRONT PROPSHAFT REMOVAL 7 23 FRONT PROP SHAFT INSTALLATION 7 24 REAR PROP SHAFT REMOVAL 7 24 REAR PROP SHAFT INSTALLATION 7 25 REAR PROP SHAFT REMOVAL XP 4 7 26 REAR PROP SHAFT INSTALLATION XP 4 7 27 SUPPORT BEARING REPLACEMENT 7 28...

Page 314: ...is service solutions com Final Drive Torque Specifications ITEM SPECIFICATION Wheel Lug Nuts 120 ft lbs 163 Nm Hub Castle Nut front and rear 110 ft lbs 149 Nm Ball Joint Pinch Fasteners 42 ft lbs 57 Nm Brake Caliper Mounting Bolts 40 ft lbs 54 Nm Tie Rod End Fastener 15 ft lbs 20 Nm 90 Propshaft Support Bearing Fasteners 35 ft lb 47 Nm Front Gearcase Cover Plate Screws 11 ft lbs 15 Nm Front Gearca...

Page 315: ...bearing carrier 6 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 7 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 8 Remove the front wheel hub assembly 9 Remove and discard the upper and lower ball joint pinch bolts 4 10 Using a soft faced hammer lightly tap on th...

Page 316: ...wear 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 retaini...

Page 317: ...front wheel hub assembly 2 cone washers 3 and hand tighten the castle nut Install washers with domed side out 6 Install new brake caliper mounting bolts and torque to specification Front Caliper Mounting Bolts 40 ft lbs 54 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 en...

Page 318: ...chine under the frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove the four wheel n...

Page 319: ...the bearing carrier from the rear drive shaft and trailing arm 11 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 corrosion The bearings should turn smoothly ...

Page 320: ...wear 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...

Page 321: ...upper radius rod to the bearing carrier Torque bolts to specification NOTE Use new nuts upon installation of the rear bearing carrier Bearing Carrier to Trailing Arm Bolts 42 ft lb 54 Nm Radius Rod to Bearing Carrier Fasteners 40 ft lb 54 Nm 3 Apply anti seize to drive shaft splines 4 Install rear wheel hub assembly 2 cone washers 3 and hand tighten the castle nut Install washers with domed side o...

Page 322: ...nstall a new cotter pin 5 Tighten nut slightly if necessary to align cotter pin holes Hub Castle Nut 110 ft lbs 149 Nm 7 Install wheel and four wheel nuts Torque wheel nuts to specification Wheel Nuts 120 ft lbs 163 Nm 8 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions FINAL DRIVE ...

Page 323: ...heel hub castle nut 2 Remove the nut and cone washers 3 from the front wheel hub assembly 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 Caliper Removal page 9 23 5 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the front wheel hub assembly 7 Remove and...

Page 324: ...ive shaft 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 3 Torque to specification Ball Joint Pinch Bolts 42 ft lbs 57 Nm 6 Apply Anti Seize to drive shaft axle splines 7 Install front wheel hub assembly...

Page 325: ...fication Wheel Nuts 120 ft lbs 163 Nm 11 Rotate wheel and check for smooth operation Rear Drive Shaft Removal 1 Raise and support the vehicle CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this procedure Always wear eye protection 2 Remove the four wheel nuts and rear wheel 3 Remove the cotter pin 1 and loosen the rear wheel hub castle nut 2 R...

Page 326: ...ion swing the rear trailing arm assembly outward until it is free from the rear drive shaft 13 Lower the trailing arm 14 With a short sharp jerk remove drive shaft from the transmission splines Rear Drive Shaft Installation 1 Install new spring ring 1 on drive shaft Apply an anti seize compound to the splines 2 2 Align splines of drive shaft with transmission splines and reinstall the drive shaft ...

Page 327: ...unting bolt washer and new nut Torque fastener to specification Stabilizer Bar Linkage 40 ft lbs 54 Nm 6 Apply Anti Seize to drive shaft axle splines 7 Install rear wheel hub assembly 3 Install the two cone washers 4 and castle nut Torque castle nut to specification Install new cotter pin 5 Rear Hub Castle Nut 110 ft lbs 149 Nm 8 Install the radius rod bolts washers and new nuts Torque fasteners t...

Page 328: ...te drive shaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the drive shaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot e...

Page 329: ... boot from the CV joint and slide the boot down the shaft 3 Clean the grease from the face of the joint 4 Place the drive shaft in a soft jawed vise Using a soft faced hammer or brass drift strike the inner race of the joint to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure circlip 2 is on the shaft and not l...

Page 330: ...an the splines on the end of the shaft and apply a light coat of grease prior to reassembly 10 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in it s groove machined in the shaft 11 Install a new circlip on the end of the shaft 12 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls a...

Page 331: ...pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the shaft 20 Install and tighten the small clamp 4 on the boot using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 Inner Plunging Joint Boot Replacement 1 Use a sid...

Page 332: ...teristic 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 water and or dirt the joint should be replaced 7 Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 8 ...

Page 333: ...e drive shaft until you reach the end of the splines and the joint locks in place 16 Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft 17 Remove excess grease from the plunging joint s external surfaces and place the excess grease in the boot 18 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and ...

Page 335: ...t roll pin and use the Roll Pin Removal Tool PN 2872608 to remove the roll pin Discard roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft Roll Pin Removal Tool PN 2872608 NOTE Right front wheel can be removed to gain better access to the propshaft roll pin 3 Slide the front propshaft 5 off the rear propshaft 6 and remove it from the vehicle 4 Proceed to Fr...

Page 336: ... front and rear prop shafts to aid shaft alignment Reference these marks during installation if still visible 5 When installing the front prop shaft onto the front gearcase use a new roll pin 6 Reposition the front gearcase and install the four bolts that secure the front gearcase to the frame Torque bolts to specification Front Gearcase Mounting Bolts 30 ft lbs 41 Nm Rear Prop Shaft Removal 1 Rem...

Page 337: ...he 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 Slide the rear prop shaft forward from the left rear of the machine just below the PVT cover Install the rear prop shaft on the transmission snorkel shaft 5 Lubricate the support bushing with light oil to ease ins...

Page 338: ... Install a new roll pin Rear Prop Shaft Removal XP 4 1 Remove all seats 2 Remove the front and rear center consoles see Chapter 10 Rocker Panels Rear Console and Floor XP 4 page 10 24 3 Remove the fasteners 1 from center 2 and rear skid plates 3 4 Remove center and rear skid plates 5 Remove the fasteners 4 securing the support bearing cover 5 to the frame 6 Move the prop shaft support bearing asse...

Page 339: ...oval XP 4 page 7 26 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 propshafts to aid shaft alignment Reference these marks d...

Page 340: ...sembly onto the end of the prop shaft NOTE Do not attempt to separate the bearing from the rubber isolated support assembly upon installation 6 Using an appropriate bearing bushing installation sleeve drive the support bearing assembly onto the propshaft until it seats against the shoulder on the shaft NOTE Take care while installing the support bearing assembly Be sure to only drive on the inner ...

Page 341: ... XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Prop Shaft U Joint Service The prop shafts on this unit are not serviceable If a cross or yoke is worn the prop shaft assembly needs to be replaced FINAL DRIVE ...

Page 342: ...tting 1 21 Hub Sub Assembly Male 1 5 Ball Bearing 2 22 Rollers 20 6 Ball Bearing Double Row 1 23 Torsion Spring 1 7 Bushing 1 24 H Clip Spring 20 8 Bushing 1 26 Nylon Spacer 2 9 Oil Seal 2 27 Backlash Spacer 1 10 Oil Seal 1 28 Ring Gear Spacer 1 11 Retaining Ring Internal 1 29 Torsion Spring Retainer 1 12 Retaining Ring 1 30 Pinion Gear 1 13 Cover Screws M6 T30 Torx 7 31 Armature Plate 1 14 Cover ...

Page 343: ...f AWD is engaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts an armature plate 1 that is keyed to the roll cage 2 When the ring gear 3 and roll cage are spinning vehicle is moving the energized coil and arm...

Page 344: ...al page 7 33 and inspect components 4 Inspect armature plate 3 for a consistent wear pattern There should be two distinct wear bands 4 If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the coil 5 i...

Page 345: ...ise and support vehicle 2 Place gear selector in neutral 3 Refer to FRONT DRIVE SHAFT page and remove both front drive shafts from the front gearcase 4 Remove the front section of the prop shaft see Chapter 7 FRONT PROPSHAFT SERVICE page 7 23 5 Disconnect the wire harness for the front gearcase and remove the harness from the retaining dart 6 Remove the vent line from the front gearcase and plug v...

Page 346: ...lug magnet 2 Remove the seven cover screws and remove the cover plate assembly 3 Remove the LH output hub assembly from the clutch housing or outer cover plate assembly NOTE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate Refer to AWD Diagnosis page 7 32 for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from th...

Page 347: ...Remove the RH output hub assembly from the gearcase housing 8 Remove pinion seal internal retaining ring and pinion gear assembly from the gearcase housing Inspect and clean the gearcase housing and replace all oil seals and O rings 9 Inspect the pinion gear for chipped broken or missing teeth Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting FINAL DRIVE ...

Page 348: ...ers A for nicks and scratches The rollers must slide up and down and in and out freely within the roll cage B sliding surfaces and H springs NOTE Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assembly or as a complete kit 13 Inspect clutch housing ring gear C for a consistent wear pattern Inspect the ring gear for chipped broken or missi...

Page 349: ...g 3 Install a new pinion shaft seal into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub into the gearcase housing 5 Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing NOTE Install roll cage so that the ring gear groo...

Page 350: ...y 9 Install armature plate Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer 10 Carefully install the ring gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the c...

Page 351: ... plate screws and torque to specification Cover Plate Screws 11 ft lbs 15 Nm Front Gearcase Installation 1 Install the gearcase back into the vehicle through the LH wheel well area above the upper A arm 2 Lubricate the front gearcase splines with Anti Seize 3 Install the prop shaft onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 4 Install the four bolts 1 that secur...

Page 352: ...T 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 Recommended Front Gearcase Fluid Polaris Demand Drive PN 2877922 Quart Capacity 8 5 oz 250 ml fill on a level surface to bottom of threads on the fill hole FINAL DRIVE ...

Page 354: ...te the tire 2 Remove the beadlock screws and beadlock ring 3 Dismount the tire on the side with the beadlock holes 4 Place the beadlock ring so the tire is sandwiched between the rim and the ring making sure the valve stem is aligned with the slot in the ring 5 Install bolts and thread them to 24 in lbs 3 Nm 6 Tighten in a criss cross pattern to 7 ft lbs 10 Nm NOTE Beadlock bolts should be checked...

Page 355: ...ING SHAFT INSTALLATION EPS MODELS 8 13 POWER STEERING UNIT INSTALLATION 8 14 UPPER STEERING SHAFT INSTALLATION EPS MODELS 8 15 FRONT A ARMS 8 16 FRONT A ARM REMOVAL REPLACEMENT 8 16 BALL JOINT SERVICE 8 19 BALL JOINT SERVICE PREPARATION 8 19 BALL JOINT REMOVAL 8 19 BALL JOINT INSTALLATION 8 20 REAR RADIUS RODS 8 21 RADIUS ROD REMOVAL INSTALLATION 8 21 REAR TRAILING ARM 8 22 TRAILING ARM REMOVAL IN...

Page 356: ...AL SERVICE INFORMATION 8 31 FRONT SHOCK SERVICE INFORMATION 8 31 REAR SHOCK SERVICE INFORMATION 8 33 WALKER EVANS SHOCK REBUILD INFORMATION 8 35 SPECIAL TOOLS 8 36 VALVE SHIM ARRANGEMENT 8 36 SHOCK PISTON ORIENTATION 8 36 WALKER EVANS SHOCK DISASSEMBLY 8 36 WALKER EVANS SHOCK ASSEMBLY 8 39 STEERING SUSPENSION ...

Page 357: ...Shock Spring Preload Spanner Wrench Walker Evans 2876389 Multi Function Pliers Walker Evans See Walker Evans Shock Service later in this chapter page 8 36 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Multi Function Pliers Included in the tool kit the multi function pliers is designed to remove the plastic push rivets used to fasten body components STEERIN...

Page 358: ...lb 54 Nm Rear Stabilizer Bar Linkage 40 ft lbs 54 Nm Rear Shock Reservoir Mounting Clamps 35 in lb 4 Nm Rear Stabilizer Bar Mounting Bracket Bolts 17 ft lb 23 Nm Rear Stabilizer Bar Locating Clamp Bolts 10 ft lb 14 Nm Shock Guard Screws 14 in lbs 2 Nm Tilt Steering Shock Fasteners 7 ft lb 10 Nm Steering Pivot Tube Mounting Fasteners 8 ft lb 11 Nm Steering Wheel Nut 65 ft lbs 88 Nm Steering Shaft t...

Page 360: ...he steering shaft nut NOTE If the steering wheel will not pop loose proceed to Steering Shaft Removal Non EPS Models page 8 6 4 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft Steering Shaft Removal Non EPS Models 1 Remove the pinch bolt 1 retaining the lower portion of the steering shaft 2 to the steering gear box assembly 3 2 Remove the fast...

Page 361: ...shing 4 Bushing 10 Bushing 5 Bushing 11 Bushing 6 Bushing Be sure the lower washers and spacers are still on the steering shaft 8 Apply Loctite 271 Red to the outer circumference of the new upper bearing race Slide the new upper bearing onto the steering shaft and press it into the pivot tube by hand NOTE Use care not to allow any of the Loctite to get in the bearing Bearings will be seated in the...

Page 362: ...front wheels are facing straight forward Remove the steering wheel and align as needed Torque the steering wheel nut to specification Apply Loctite 271 Steering Wheel Nut 65 ft lbs 88 Nm 15 Wipe the pivot tube clean of any excess Loctite 16 Install steering wheel cap and field test steering operation STEERING SUSPENSION ...

Page 363: ... Inc ELECTRONIC POWER STEERING ASSEMBLY Assembly View EPS Models 1 Steering Wheel 5 Steering Box 9 Tilt Steering Shock 2 Upper Steering Shaft 6 Tie Rod End 10 Tie Rod End Bolt Do not reuse 3 EPS Module 7 EPS Mount Bracket 11 Nut Nylok Do not reuse 4 Lower Steering Shaft 8 EPS Cover STEERING SUSPENSION ...

Page 364: ...e the 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 5 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 EPS Models page 8...

Page 365: ...ft 4 Place the 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 Steeri...

Page 366: ... mount 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 4 that retain the power steering unit to the mount bracket WARNING Electronic Power Steering EPS units are programmed to be vehicle specific and are not interchangeable between product lines STEERING SUSPENSION ...

Page 367: ... 11 4 Remove the pinch bolt 1 retaining the lower steering shaft 2 to the steering gear box assembly 3 5 Lift up on the shaft and remove it through the floor panel Lower Steering Shaft Installation EPS Models 1 Install the lower steering shaft onto the gear box and align the marks made during step 2 of the Lower Steering Shaft Removal EPS Models procedure 2 Install the pinch bolt that retains the ...

Page 368: ...eering 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 Lower Steering Shaft to EPS Unit Pinch Bolt 15 ft lbs 20 Nm 5 Torque the four mount bracket nu...

Page 369: ...ing 2 in the upper steering shaft 2 Install the pivot tube and torque fasteners to specification Pivot Tube Fasteners 8 ft lb 11 Nm 3 Install the tilt shock and torque fastener to specification Tilt Shock Fastener 7 ft lb 10 Nm 4 Be sure the front wheels are pointing straight ahead and install the steering wheel and retaining nut Torque the nut to specification and reinstall the plastic wheel cove...

Page 370: ...d from the bearing carrier 5 Remove the front bumper to allow A arm bolt removal 6 Loosen and remove the upper A arm front through bolt fastener 3 and rear though bolt fastener 4 Remove the upper A arm from the vehicle 7 Examine A arm bushings and pivot tube Replace if worn Discard hardware WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serio...

Page 371: ...carrier 16 Loosen and remove the lower A arm front through bolt fastener 6 and rear through bolt fastener 7 Remove the lower A arm from the vehicle 17 Examine A arm bushings and pivot tube Replace if worn Discard hardware 18 If not replacing the A arm thoroughly clean the A arm and pivot tube 19 Install new ball joint into A arm Refer to Ball Joint Replacement section 20 Insert new A arm bushings ...

Page 373: ...ove the caliper from the brake disc see Chapter 9 Caliper Removal page 9 23 5 Remove and discard the upper ball joint pinch bolt 6 If necessary remove the lower front shock fastener from the A arm 7 Remove the upper A Arm to frame mounting bolts and remove the A arm from the chassis 8 To service the lower ball joint 9 Remove and discard the lower ball joint pinch bolt 10 Remove both A arm to frame...

Page 374: ...oint replacements 5 Insert upper lower A arm ball joint end into the bearing carrier Install new pinch bolts and nuts Torque to specification 6 If needed install new brake caliper mounting bolts and torque to specification CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 7 Install wheel and four wheel nuts ...

Page 375: ... nuts and rear wheel 3 Identify mark radius rods upper and lower 4 Remove the nut bolt and washer 1 2 attaching the upper and lower radius rod to the bearing carrier Discard the nuts 5 Remove bolts 3 4 attaching radius rods to the vehicle frame Discard the nuts 6 Remove radius rods from vehicle 7 Examine radius rod shafts boots and spherical bearings Replace entire radius rod if any excessive wear...

Page 376: ...eel nuts and remove the rear wheel 3 Remove the cotter pin 1 and loosen the rear wheel hub castle nut 2 Remove the nut and two cone washers 3 from the rear wheel hub assembly 4 Remove the lower radius rod mounting bolt 4 nut and washer from the bearing carrier Swing radius rod down Discard the nut 5 Remove the two brake caliper mounting bolts 5 6 CAUTION Do not hang the caliper by the brake line U...

Page 377: ...front trailing arm bolt 8 Discard the nut 16 Remove trailing arm from vehicle Visually inspect trailing arm bushings o rings and spherical bearing for wear If bearing requires replacement refer to Trailing Arm Spherical Bearing Replacement page 8 24 17 Replace trailing arm if physically damaged 18 Reverse this procedure to reinstall rear trailing arm NOTE Use new fastener nuts upon installation of...

Page 378: ...2 2 Remove bushings and O rings 3 Remove snap ring 1 that retains the spherical bearing 4 Properly support the trailing arm and press the spherical bearing out of trailing arm casting 5 Be sure to only press on outer most surface of bearing race do not press on the center spherical bearing 6 Inspect trailing arm bearing housing for wear or damage Replace trailing arm if damaged 7 Press in new bear...

Page 379: ...R XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Rear Suspension Assembly View 1 Radius Rod 2 Trailing Arm 3 Spherical Bearing 4 Bushing 5 Shock 6 Spring 7 Bearing Carrier 8 Stabilizer Bar 9 Stabilizer Bar Link STEERING SUSPENSION ...

Page 380: ...pect 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 to specification see below 3 Install stab...

Page 381: ...8 8 27 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc SHOCKS SPRINGS FASTENERS Front Shock Assembly View Rear Shock Assembly View STEERING SUSPENSION ...

Page 382: ...4 ft lb 60 Nm Rear 70 ft lbs 95 Nm Shock Replacement 1 Remove the shock and note the spring preload distance see Chapter 2 Spring Adjustment page 2 40 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spring far enough to remove the spring retainer 3 Remove the spring and spring retainer from the existing shock and in...

Page 383: ...p 28 O Ring 3 Internal Bump Stop 16 Reservoir Body 29 Screw 8 32 4 Shaft Bushing 0 625 17 Washer 1 50 x 0 125 x 0 348 30 O Ring 5 O Ring 18 Crimp Nut 7 16 31 O Ring 6 Seal 19 Snap Ring 32 Detent Spring 7 Wiper 20 Spherical Bearing 33 Detent Ball 8 O Ring 21 Schraeder Valve 34 Shock Body 9 Piston Clicker 22 Snap Ring 35 Spring Adjustment Nut 10 Clicker Bolt 23 Piston Wear Band 1 750 OD 36 Shaft Chr...

Page 384: ...Bearing 18 Spacer 33 O Ring 4 Spring Nut 19 End Cap 34 Wiper 5 Piston 20 Needle Bolt 35 Shaft Seal 6 Reservoir Piston 21 Adjuster Nut 36 Shaft Bushing 0 750 7 Check Valve 22 Reservoir Body 37 O Ring 8 Clicker Bolt 23 Bleed Screw 38 Detent Spring 9 Crimp Nut 24 Bump Stop 39 Detent Ball 10 Adjuster Knob 25 Wear Band 40 O Ring 11 Ball 250 26 O Ring 41 O Ring 12 Retention Nut 27 Screw 42 Screw 13 9 16...

Page 385: ...y 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 mm Extended Length 25 10 63 75 mm IFP Location RZR XP 4 1000 High Lifter 3 375 85 7 mm IFP L...

Page 386: ...x 0 008 0 900 x 0 015 1 10 x 0 025 0 900 x 0 010 0 900 x 0 012 1 00 x 0 025 1 45 x 0 010 1 45 x 0 015 1 00 x 0 025 0 900 x 0 008 1 45 x 0 015 0 625 x 0 065 1 45 x 0 015 1 45 x 0 008 COMPRES SION REBOUND CLICKER 1 30 x 0 015 1 45 x 0 008 1 20 x 0 015 1 30 x 0 010 1 10 x 0 015 1 00 x 0 008 1 00 x 0 015 1 50 x 0 120 0 750 x 0 065 Piston Bleed Orifice none 2015 Front Shock Valving RZR XP 1000 High Lif...

Page 388: ...0 x 0 125 top out Piston Bleed Orifice 0 100 2014 2015 Shock Valving RZR XP 4 1000 COMPRES SION REBOUND CLICKER 1 55 x 0 008 1 50 x 0 01 1 00 x 0 015 1 00 x 0 010 1 45 x 0 01 1 00 x 0 015 1 55 x 0 008 1 30 x 0 01 0 90 x 0 015 1 55 x 0 008 1 20 x 0 01 0 60 x 0 015 1 55 x 0 008 1 10 x 0 01 0 60 x 0 015 1 55 x 0 008 1 00 x 0 01 1 55 x 0 008 0 90 x 0 01 1 45 x 0 010 0 80 x 0 01 1 10 x 0 012 0 75 x 0 0...

Page 389: ... 55 x 0 010 1 45 x 0 008 0 900 x 0 015 1 20 x 0 008 1 30 x 0 008 0 700 x 0 015 1 55 x 0 008 1 20 x 0 008 0 700 x 0 015 1 50 x 0 010 1 10 x 0 008 1 45 x 0 010 1 00 x 0 008 1 30 x 0 010 0 900 x 0 008 1 20 x 0 010 0 750 x 0 065 top out 1 10 x 0 012 0 900 x 0 012 0 800 x 0 012 1 50 x 0 125 top out COMPRES SION REBOUND CLICKER No Piston Bleed Orifice Walker Evans Shock Rebuild Information When performi...

Page 390: ...orts will always face the rebound valve stack Walker Evans Shock Disassembly NOTE To prevent damage or marks to the shock the use of special tools and a soft jaw vise is recommended WARNING Walker Evans shocks contain high pressure nitrogen gas Extreme caution must be used while handling and working with Walker Evans shocks and related high pressure service equipment The pressure must be released ...

Page 391: ...ize the shock 6 Using a snap ring pliers remove the retaining ring from the reservoir 7 Carefully remove the cap from the reservoir body 8 Using a 1 open end wrench or adjustable wrench loosen and remove the bearing cap from the shock body 9 Slowly lift up and remove the shock rod assembly from the shock body STEERING SUSPENSION ...

Page 392: ...mount the shock rod vertically with the threaded end upward Front Shock Rod Holding Tool 2872429 Rear Shock Rod Holding Tool PU 50931 14 Using an 11 16 socket remove the nut retaining the valve stack and piston NOTE Keep the rebound and compression valve stacks in the order they were removed If unsure of order refer to Shock Valving under the Shock Service Information provided earlier in this sect...

Page 393: ...Assembly 1 Install new seals and O rings on the seal head assembly 2 Use the appropriate shock rod holding tool and a vise to mount the shock rod vertically with the threaded end upward Front Shock Rod Holding Tool 2872429 Rear Shock Rod Holding Tool PU 50931 3 Install the appropriate Shock Seal Protector Sleeve over the shaft threads Front Shock Seal Protector Sleeve PU 50939 Rear Shock Seal Prot...

Page 394: ...he fastener and install the assembly into the reservoir body Tighten the valve stack fastener securely 10 Turn the compression adjuster knob counter clockwise soft until it stops so damping is in the full open position 11 Use 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 5...

Page 395: ...tall the IFP bleed screw NOTE When the IFP Tool is removed the IFP must remain submerged in shock oil to prevent air from getting under the floating piston 18 Fill the shock body with oil approximately 1 4 below the threads 19 Apply a thin film of oil to the wear band on the damping piston Slowly insert the shock rod assembly into the body until the damping piston assembly is approximately 1 below...

Page 396: ...4 Using a 1 open end wrench tighten the bearing cap 25 Using a 3 32 Allen wrench remove the IFP bleed screw 26 Set the IFP depth to the specified length from the top of the reservoir IFP Depth FRONT 3 375 85 7 mm REAR RZR XP 1000 6 25 158 8 mm REAR RZR XP 4 1000 7 25ʺ 184 2 mm 27 Using a long 3 32 Allen wrench install the IFP bleed screw NOTE Apply grease to the end of the Allen wrench so the blee...

Page 397: ...ressure compressed air in a well ventilated area 37 Check shock for any leaks 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 38 Reinstall the compression spring and the spring retainer 39 Thread the spring preload adjuster down against the spring and set the preload to the specified measurement see Ch...

Page 399: ...LEVER 9 10 BRAKE PEDAL REMOVAL 9 10 BRAKE PEDAL INSTALLATION 9 10 PARKING BRAKE INT L MODEL 9 11 PARKING BRAKE ASSEMBLY VIEW 9 11 PARKING BRAKE INSPECTION 9 12 PARKING BRAKE CABLE ADJUSTMENT 9 12 PARKING BRAKE CALIPER 9 13 PARKING BRAKE DISC 9 16 FRONT BRAKE PADS 9 19 PAD REMOVAL 9 19 PAD INSPECTION 9 20 PAD ASSEMBLY INSTALLATION 9 20 BRAKE BURNISHING PROCEDURE 9 21 FRONT CALIPER SERVICE 9 22 CALI...

Page 400: ...VICE 9 33 CALIPER ASSEMBLY VIEW 9 33 CALIPER REMOVAL 9 34 CALIPER DISASSEMBLY 9 35 CALIPER INSPECTION 9 35 CALIPER ASSEMBLY 9 36 CALIPER INSTALLATION 9 36 REAR BRAKE DISC 9 38 DISC INSPECTION 9 38 DISC REPLACEMENT 9 38 TROUBLESHOOTING 9 40 POOR BRAKE PERFORMANCE 9 40 PEDAL VIBRATION 9 40 CALIPER OVERHEATS BRAKES DRAG 9 40 BRAKES LOCK 9 40 BRAKE SYSTEM ...

Page 401: ...ront Brake Pad Thickness 0 297 007 7 54 178 mm 180 4 6 mm Front Brake Disc Thickness 0 188 4 78 mm 170 4 32 mm Front Brake Disc Runout 010 254 mm REAR BRAKE SYSTEM Item Standard Service Limit Rear Brake Pad Thickness 298 007 7 57 178 mm 180 4 6 mm Rear Brake Disc Thickness 188 4 78 mm 170 4 32 mm Rear Brake Disc Runout 010 254 mm PARK BRAKE SYSTEM INT L MODEL Item Standard Service Limit Park Brake...

Page 402: ...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 freely and completely Adjust stop pin on brake caliper s after pad service Che...

Page 403: ...ies pressure on the piston within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads These pads contact the brake discs and...

Page 405: ... the brake pedal lever 3 Place a container to catch brake fluid under the master cylinder brake line banjo bolts 4 CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Make note of front and rear brake line locations to master cylinder 4 Loosen the brake line banjo bolts and allow fluid to drain NOTE Dispose of fluid properly Do ...

Page 406: ...akes during regular maintenance CAUTION Always wear safety glasses when handling chemicals and fluids CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 1 Clean master cylinder reservoir cover thoroughly and remove the cover 2 2 If changing fluid remove old fluid from reservoir 1 with a Mity Vac pump or similar tool Mity Vac PN 2870...

Page 407: ... maintain level in reservoir CAUTION Maintain at least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to specification Bleeder Screw 48 in lb 5 Nm 9 Repeat steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir Master Cylinder Fluid Level Betwee...

Page 408: ...e brake pedal lever 2 and remove the clip 1 and master cylinder clevis pin 4 2 Remove the E clip 3 from the pedal mount and remove the brake pedal lever 2 from the vehicle Brake Pedal Installation 1 Reverse the Removal steps to install brake pedal lever Brake pedal free play should not exceed 0 090 2 28 mm Brake Pedal Free play 0 090 2 28 mm BRAKE SYSTEM ...

Page 410: ...n temporarily disconnect the parking brake switch electrical connector Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension 1 Pull back on parking brake lever located in the dash 2 After 3 to 4 clicks BRAKE should display on the instrument cluster and the wheels should not rotate when turning by hand After 8 full clicks of lever travel the vehicle sho...

Page 412: ... disc and remove it from the vehicle Caliper Disassembly Inspection NOTE Refer to the Electronic Parts Catalog for parking brake caliper replacement parts information 1 Remove the two caliper assembly bolts C 2 Slide the brake pads and springs from the assembly NOTE Retain the lever and ball bearings for reassembly 3 Inspect brake pads for excessive wear Replace as needed 4 Check the three steel b...

Page 413: ... Anti Seize Lubricant to the thrust washer and shims 4 Torque the caliper assembly bolts to specification Parking Brake Caliper Assembly Bolts 37 ft lb 50 Nm 5 Ensure the parking brake assembly functions properly by actuating the lever Install the mounting sleeves D before installation Brake Caliper Installation 1 Install the parking brake caliper over the brake disc Align the caliper mounting sle...

Page 414: ...ce the brake disc see Chapter 9 Disc Replacement page Disc Replacement 1 Remove the parking brake caliper from the disc see Chapter 9 2 Using a 1 2 socket and ratchet remove the brake disc retaining bolt and flat washer 3 Remove the disc from the transmission shaft 4 Install the new brake disc Install the mounting bolt and flat washer Torque the mounting bolt to specification Parking Brake Disc Mo...

Page 417: ...ting bolts and remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into cal...

Page 418: ...sembly Installation 1 Lubricate mounting bracket pins 1 with a light film of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper onto front hub and ...

Page 419: ...AX 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 Wheel Nuts 120 ft lbs 163 Nm Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph G...

Page 421: ... when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removing the line 1 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 2 and remove the calip...

Page 422: ...ea for disassembly 4 Use a commercially available caliper piston pliers to extract the pistons from the caliper NOTE Do not remove the caliper pistons with a 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 from the caliper O rings should be replaced during caliper service 6...

Page 423: ...vice 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 2 in the caliper body Be sure the grooves 1 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 with l...

Page 424: ... specification 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 Wheel Nuts 120 ft lbs 163 Nm 7 Field test unit for proper braking action before putting into service In...

Page 425: ... specification Brake Disc Runout Service Limit 0 010 0 254 mm Disc Inspection 1 Visually inspect disc for scoring scratches or gouges Replace disc if deep scratches are evident 2 Use a 0 1 micrometer and measure disc thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit Brake Disc Thickness New 0188 4 78 mm Service Limit 0 170 4 32 mm Brake Di...

Page 426: ...ke Disc Mounting Bolts 5 30 ft lb 41 Nm CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin Castle Nut 110 ft lbs 149 Nm 7 Install the front brake caliper see Chapter 9 FRONT CALIPER SERVICE page 9 22 8 Follow bl...

Page 427: ...uter mounting bolt nut and washer from the bearing carrier Swing radius rod down Discard the nut 5 Remove the two caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 6 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE...

Page 428: ...ket inward and slip outer brake pad past the edge to remove 8 Remove the inner brake pad Pad Inspection 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Rear Brake Pad Thickness 0 298 0 007 7 57 mm 178 mm Service Limit 0 180 4 6 mm BRAKE SYSTEM ...

Page 429: ...olts 3 to specification Rear Caliper Mount Bolt 1 40 ft lbs 54 Nm 4 Install lower radius rod bolt washer and new nut Torque to specification Radius Rod to Bearing Carrier Bolt 40 ft lb 54 Nm 5 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 6 Install the adjustment set screw and...

Page 430: ...med after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping may result Repeat this procedure 10 times Do not make more than 3 stops per 1 mile 1 6 km BRAKE SYSTEM ...

Page 432: ... four wheel nuts and rear wheel Clean caliper area before removal 3 Place a container below the caliper to catch the brake fluid when removing the line 1 Remove brake line from caliper 4 Remove the lower radius rod outer mounting bolt 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...

Page 433: ...rom the caliper body 8 5 Clean the caliper body piston and retaining bracket 10 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 Rear Caliper Piston Bore I D Standard 1 505 38 23 mm Service Li...

Page 434: ...Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins 4 with silicone grease and install the rubber dust seal boots 5 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 I...

Page 435: ...adius Rod to Bearing Carrier Bolt 40 ft lb 54 Nm 4 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 5 Follow bleeding procedure outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification Wheel Nuts 120 ft lbs 163 Nm NOTE If new pads are installed refer to Brake Burnishing Procedure page 9 32 BRAKE SYSTEM ...

Page 436: ...nt a dial indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 0 010 0 254 mm Disc Replacement 1 Remove rear brake caliper see Chapter 9 Caliper Removal page 9 34 2 Remove wheel hub cotter pin 4 castle nut 3 and washers 2 3 Remove the hub assembly from the vehicle and r...

Page 437: ...pin Rear Wheel Hub Castle Nut 110 ft lbs 149 Nm 7 Install rear caliper see Chapter 9 REAR CALIPER SERVICE page 9 33 Bleed the brake system See Chapter 9 BRAKE BLEEDING FLUID CHANGE page 9 8 8 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure brakes do not drag when pedal is released If the brakes drag re check assembly and insta...

Page 438: ...er or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Parking brake lever incorrectly adjusted INT L Model Brake pedal binding or unable to return fully Parking brake left on INT L Mod...

Page 439: ...WORK 10 10 CHASSIS MAIN FRAME XP HIGH LIFTER 10 11 CHASSIS MAIN FRAME XP 4 10 12 SEAT ASSEMBLY FRONT 10 13 SEAT ASSEMBLY REAR 10 14 FLOOR ROCKER PANELS XP HIGH LIFTER 10 15 FLOOR ROCKER PANELS XP 4 10 16 REAR CARGO BOX FENDERS 10 17 REAR BUMPER 10 18 BODY COMPONENT REMOVAL 10 19 SEATS 10 19 ENGINE SERVICE PANEL 10 19 FRONT BUMPER XP 10 19 REAR BUMPER 10 20 HOOD AND FRONT BODY WORK 10 20 REAR FENDE...

Page 440: ...2233 or http polaris service solutions com Torque Specifications ITEM TORQUE VALUE Front A Arm Bolt 42 ft lb 57 Nm Door Hinge Mount Nuts 8 ft lb 11 Nm Door Latch Screws 8 ft lb 11 Nm Front Bumper Fender Screws 8 ft ln 11 Nm Floor Screws 8 ft lb 11 Nm Trailing Arm to Frame Bolt 70 ft lb 95 Nm Seat Belt Mounting Hardware 40 ft lbs 54 Nm Seat Slider Plate 4 ft lb 5 Nm Skid Plate Screws 8 ft lbs 11 Nm...

Page 441: ...o 14 ft lb 19 Nm 2 Install ROPS hoop to the hip bolster and frame with M10 x 1 25 x 55 bolts and nuts Tighten fasteners to 40 ft lb 54 Nm 3 Install the front ROPS to the frame with M10 x 1 5 x 45 screws and nuts Install front ROPS to ROPS hoop with M10 x 1 5 x 20 screws Torque fasteners to 40 ft lb 54 Nm 4 Install rear ROPS to the ROPS hoop with M10 x 1 5 x 25 screws Install rear ROPS to frame wit...

Page 442: ...to 14 ft lb 19 Nm 3 Install ROPS rear hoop to frame with M10 x 1 25 x 55 bolts and nuts 3 Torque to 40 ft lb 54 Nm 4 Attach ROPS main to the mid ROPS hoop and front main frame with M10 x 1 5 x 45 screws 4 Torque to 40 ft lb 54 Nm 5 Install rear ROPS to rear ROPS hoop and rear frame with M10 x 1 5 x 45 screws 5 Torque to 40 ft lb 54 Nm 6 Install ROPS brace to ROPS mid hoop and ROPS rear hoop with M...

Page 443: ... 10 5 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Doors XP 1 Door Panel 4 Hinge Pin 2 Door Frame 5 Latch Release 3 Latch Striker 6 Latch BODY FRAME ...

Page 444: ...14 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Doors XP 4 1 Door Panel 5 Latch Release 2 Door Frame 6 Latch 3 Latch Striker 7 Door panel Rear 4 Hinge Pin 8 Door Frame Rear BODY FRAME ...

Page 445: ...ght 2014 Polaris Industries Inc Doors High Lifter 1 Upper Door Panel 7 Latch Release 2 Lower Door Panel 8 Latch 3 Hip Bolster Panel 9 Latch Striker 4 Upper Door Frame 10 Latch Striker Screws 8 ft lbs 11 Nm 5 Lower Door Frame 11 Hinge Screws 8 ft lbs 11 Nm 6 Hinge Pin BODY FRAME ...

Page 446: ...2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Dash Instruments Controls 1 Instrument Cluster 4 Headlight Switch 2 Key Switch 5 AWD Switch 3 12V Accessory Port 6 Bezel BODY FRAME ...

Page 447: ...R XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Dash Instruments Controls High Lifter 1 Instrument Cluster 5 AWD Switch 2 Key Switch 6 Winch Switch 3 12V Accessory Port 7 Bezel 4 Headlight Switch BODY FRAME ...

Page 448: ...000 Service Manual Copyright 2014 Polaris Industries Inc Hood Front Body Work 1 Front Bumper 6 Hood 2 Right Front Fender 7 Grill 3 Right Front Fender Flair 8 Front Bumper Cover 4 Left Front Fender 9 Radiator Shroud 5 Left Front Fender Flair BODY FRAME ...

Page 451: ...lbs 5 4 Nm 13 Flange Nut Nylok 3 Seat Base Assembly Slider 14 Slider Adjustment Plate 4 Seat Latch Lever 15 Carriage Bolt 5 Spring Seat Latch 16 Shoulder Bolt 6 Plate Seat Latch 17 Seat Slider Mounting Plate 7 Screw 4 ft lb 5 Nm 18 Spring 8 Screw 4 ft lb 5 Nm 19 Seat Slider Lever 9 Shoulder Bolt 20 Seat Bottom 10 Spring Lock Washer 21 Seat Back 11 Flat Washer BODY FRAME ...

Page 452: ...Manual Copyright 2014 Polaris Industries Inc Seat Assembly Rear 1 Seat Frame 7 Plate Seat Latch 2 Screw 4 ft lb 5 Nm 8 Screw 4 ft lb 5 Nm 3 Seat Base Assembly 9 Bolt 4 Seat Latch Lever 10 Seat Bottom 5 Spring Seat Latch 11 Seat Back 6 Plate Seat Latch BODY FRAME ...

Page 453: ...Service Manual Copyright 2014 Polaris Industries Inc Floor Rocker Panels XP High Lifter 1 Upper Floor 7 RH Rocker 2 T27 Screws 8 Push Rivots 3 LH Rocker 9 Console Cover 4 U Type Nuts 10 Seat Belt Boot 5 Block Off Flap 11 Shifter Boot 6 Lower Floor BODY FRAME ...

Page 454: ...cker Panels XP 4 1 Main Floor Upper 9 B Pillar Cover LH 2 Rocker LH 10 Console Front 3 Rivet 11 Shifter Boot 4 U Type Nuts 12 Seat Belt Boot Front 5 Block Off Flap 13 Console Rear 6 Main Floor Lower 14 Lower Rear Close off Panel 7 Rocker RH 15 Upper Rear Close off Panel 8 B Pillar Cover RH 16 Floor Rear BODY FRAME ...

Page 457: ...vice Panel 1 Remove the seats Remove the driver and passenger seats 2 Lift the panel upward and towards the front of the vehicle to remove the panel 1 Front Bumper XP 1 Remove the ten T 40 Torx screws retaining the front bumper 2 Disconnect the front headlight connectors 3 Remove the ten Torx screws retaining the upper middle and lower portion of the bumper 4 Pull out on the front bumper to remove...

Page 458: ...urn latches 1 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 2 5 Disconnect the instrument cluster AWD switch headlight switch and ignition switch Note thei...

Page 459: ... Remove the two T 40 Torx screw that 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 High Lifter page 10 3 procedure for assembly torque specifications 13 Remove the front fender Rear Fender Fender Flare Removal XP High Lifter 1 Remove the four T27 Torx screw...

Page 460: ... 1 Remove both seats 2 Remove the PVT pre filter driver side and air intake pre filter passenger side assembly 3 Remove the T 25 Torx screw retaining each shock reservoir hose cover and remove the cover 4 Loosen the shock reservoir clamps and maneuver the reservoir through the hole in the box NOTE Do NOT let the reservoir hang by the hose Use a wire or string to restrain the reservoir 5 Remove the...

Page 461: ...High Lifter Rocker Panel Removal 1 Remove the push rivets and Torx screws retaining the rocker panel and remove panel from the vehicle Console and Lower Floor Removal 2 Remove both seats and rocker panels see Chapter 10 Floor Rocker Panels XP High Lifter page 10 15 3 Remove the T27 screws 1 retaining the console 5 to the floor 4 Remove shift handle knob and remove the console 5 Remove the Torx scr...

Page 462: ...g fasteners 1 and remove door 4 Remove two push rivets 2 Remove two Torx T40 door striker fasteners 3 and remove striker Remove one Torx T27 fastener 4 retaining the b pillar cover and remove cover 5 Remove three Torx T40 fasteners 5 from top of fender flare Remove two torx T40 fasteners 6 7 Note length and location of fasteners Remove fender flare 6 Remove three push rivets 8 and five Torx T40 fa...

Page 463: ...he rear floor 5 Remove the rear console 6 Remove two M10x1 25x20 bolts from the rear seat frame 5 and two M10x1 50x55 6 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 ba...

Page 464: ...el Remove the upper close off panel 13 Disconnect the shift cable 11 from the front seat base Remove two M8x1 25x20 bolts 12 and two M10x1 25x55 bolts 13 from the front seat base Remove front seat base assembly 14 Remove four Torx T40 screws 14 retaining the rear floor and remove the rear floor 15 Remove the Torx screws 15 retaining the main floor and remove the main floor from the vehicle BODY FR...

Page 465: ...sion The flame treating procedure can also be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted plastic components Painted plastic surfaces should only be wiped clean prior to decal adhesion To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the a...

Page 467: ...3 IGNITION KEY SWITCH 11 14 AWD 2WD SWITCH MODELS WITHOUT TURF 11 14 TRANSMISSION GEAR POSITION SWITCH 11 15 SEAT BELT SWITCH 11 16 ALL WHEEL DRIVE COIL 11 17 OPERATION OVERVIEW 11 17 DIAGNOSING SYSTEM FAILURES 11 17 VEHICLE SPEED SENSOR 11 18 SPEED SENSOR LOCATION 11 18 SPEED SENSOR TESTING 11 18 IGNITION COIL 11 19 OPERATION OVERVIEW 11 19 IGNITION COIL HT LEAD REPLACEMENT 11 19 IGNITION COIL TE...

Page 468: ...36 LOAD TEST 11 37 BATTERY CONDUCTANCE ANALYZER 11 37 CHARGING PROCEDURE 11 37 STARTING SYSTEM 11 38 TROUBLESHOOTING 11 38 VOLTAGE DROP TEST 11 38 STARTER MOTOR REMOVAL 11 39 STARTER MOTOR INSTALLATION 11 39 STARTER SOLENOID BENCH TEST 11 40 STARTER SOLENOID OPERATION 11 40 CONDITION STARTER FAILS TO TURN OVER THE ENGINE 11 40 ELECTRONIC POWER STEERING EPS 11 41 EPS OPERATION 11 41 PROPER EPS SYST...

Page 469: ...ance of a component that has a resistance value under 10 Ohms remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current re...

Page 470: ...nd or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster The rider information display is located in the instrument cluster All segments will li...

Page 471: ...tor that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 9 Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system 10 AWD Indicator Illuminated when the AWD 2WD switch is in the AWD position 11 Differential Unlocked Indicator If equippe...

Page 472: ... lit and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory and adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 9 Check Engine MIL Illuminated when the ECM has detected ...

Page 473: ...ter records and displays the total distance traveled by the vehicle The odometer can not be reset Trip Meter The trip meter records the miles traveled by the vehicle on each trip To reset the trip meter 1 Toggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Tachometer RPM Engine RPM can be displayed digitally Engine Temperature Engi...

Page 474: ...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 7 Toggle the MODE button until the odometer is displayed 8 Press and hold the MODE button until the hour segment flashes Release the button 9 With the segment flashing tap the MODE button to ad...

Page 475: ...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 battery voltage rises above 15 volts a warning screen will display OV and provide the present battery voltage If voltage ris...

Page 476: ...the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off 1 If the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the informat...

Page 477: ...e FMI 4 Use the trouble code reference table in the EFI Chapter for a description of each code see Chapter 4 Trouble Code Display ETC page 4 40 5 If more than one code exists press the MODE button to advance to the next trouble code 6 To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded NOTE If there is a diagnostic problem with the po...

Page 478: ...e rubber mount if necessary The bezel 4 is a snap on assembly and is a serviceable part Instrument Cluster Installation 1 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily 2 Be sure the rubber mount inside the dash is fully installed and that the indexing key on the rubber mount is line...

Page 479: ... than 0 5 ohms clean the switch terminals Re test and replace switch if necessary 4 For switch replacement refer to Chapter 9 Brakes Headlamp Switch 1 Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs OFF LOW HIGH If any of the tests fail replace headlamp switch assembly Move the swit...

Page 480: ...ON There should be continuity between switch pins C and D Turn the ignition key to START There should be continuity between switch pins A and B C and D AWD 2WD Switch models without Turf 1 Disconnect the AWD 2WD switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 2 sets of outputs AWD 2WD If any of the tests fail replace the sw...

Page 481: ...and can be accessed through the RH wheel well area 2 Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector Do not pull on the wiring 3 Test the transmission switch continuity readings for each gear position and compare to the specification table below GEAR POSITION RESISTANCE VALUE WHEN MEASURED AT SWITCH TERMINALS A AND B HIGH 24 Ω LOW 75 Ω NEU 160 ...

Page 482: ...nctionality If the circuit is open buckle undone vehicle speed will be limited to 15mph If the circuit is closed buckle inserted the vehicle will function normally Testing 1 Disconnect the harness 1 running to the seat belt 2 Using a multi meter measure between both pins on switch SEAT BELT DISENGAGED SEAT BELT ENGAGED Measure between both pins on switch OL 1 Ω ELECTRICAL ...

Page 483: ...System Failures Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below AWD Hub Coil Resistance 24 Ω 5 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connect properly Verify continuity of wire connections with ...

Page 484: ...eel 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 ...

Page 485: ...between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plugs Ignition Coil 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...

Page 486: ...can be tested by using an ohm meter Use the following illustration and specification table to test the ignition coil resistance TEST PIN CONNECTION RESIST ANCE Primary Between 1 2 Between 2 3 0 4 Ω Secondary PTO Between High Tension Lead Caps 7 0 k Ω 5 Secondary MAG Between High Tension Lead Caps 7 4 k Ω 5 Primary Test Secondary Test ELECTRICAL ...

Page 487: ...on 4 The most intense part of the LOW beam headlight beam should be aimed 2 in 5 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included in the seat while performing this procedure 5 Adjust the beam to the desired position by loosening or tightening the three T 25 adjustment screws and moving the lamp to the appropriate height 6 Adjust the beam to desired position Repeat ...

Page 488: ...embly Be sure to pull on the connector not on the wiring 2 Remove the three T 25 headlamp mounting screws 1 and three adjustment preload springs 2 NOTE The front bumper can be removed and placed face down on a suitable workbench to ease headlamp replacement see Chapter 10 Front Bumper XP page 10 19 3 Carefully lift and remove headlamp assembly from the bumper ELECTRICAL ...

Page 489: ...hten all three headlamp screws until the headlamp assembly is fully seated Back headlamp mounting screws off 1 8 to 1 4 2 3 turns 5 Install the front bumper as shown in Chapter 5 if previously removed 6 Connect headlamp electrical connector to the headlamp assembly 7 Perform the Headlight Adjustment procedure as shown in this chapter Taillight Replacement Before replacing the taillight s use a dig...

Page 490: ...1 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc Dash Light The LED light will remain ON for approximately 30 seconds after key has been switched to the OFF position ELECTRICAL ...

Page 491: ...Check Engine indicator should display on the instrument cluster This indicates all other components are working properly 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition circuit breaker and mechanical relay for proper operation Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot ch...

Page 492: ...86 F 30 C 1 7 k Ω 6 104 F 40 C 1 2 k Ω 6 122 F 50 C 834 Ω 6 140 F 60 C 596 Ω 6 158 F 70 C 435 Ω 6 176 F 80 C 323 Ω 6 194 F 90 C 243 Ω 6 212 F 100 C 186 Ω 6 ECT Sensor Replacement 1 Remove the throttle body see Chapter 4 Throttle Body Removal page 4 34 2 Be sure the engine has cooled enough to work on 3 Disconnect the vehicle harness from ECTsensor 4 Drain the coolant so the level is below the sens...

Page 493: ...g and components such as the instrument cluster ECU EFI system main harness lights accessories and power steering The relays assist with component operation like the cooling fan fuel pump EFI system drive system and electronic power steering A separate 20 amp circuit breaker protects the fan motor circuit Two separate relays located under the dash operate the headlights and the flash to pass funct...

Page 495: ...hite 20 Amp fuse protected 12 Vdc constant battery voltage Dark Green Yellow ECU ground input to enable relay Red White 20 Amp fuse protected 12 Vdc constant battery voltage Red Dark Blue Provides 12 Vdc power for EFI system circuits FAN RELAY provides power to the following system Fan Motor COLOR FUNCTION Red 20 Amp circuit breaker protected 12 Vdc constant battery power Orange White ECU ground i...

Page 496: ...20 Amp fuse protected 12 Vdc battery voltage White Red Key switch input to enable relay Brown Relay coil ground Yellow Dark Green Relay switched power to operate the Headlights FLASH TO PASS RELAY INT L provides power to the following system Momentary High Beam Headlight Operation COLOR FUNCTION Dark Green 12 Vdc switched power from headlight relay used to operate low beam headlights during normal...

Page 497: ...the charging system is the point at which the alternator overcomes all system 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 ru...

Page 498: ... to Ground Y3 to Ground 3 Each test should measure Open Line OL TEST CONNECT METER LEADS TO OHMS READING Battery Charge Coil Y1 Y2 or Y3 to Ground Open Line Infinity NOTE Any measurement other than Infinity open will 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...

Page 499: ...ly clean the area around the stator cover prior to removal Regulator Rectifier The regulator rectifier 1 is located in the left rear wheel well area in front of the left rear shock It is mounted under the LH panel divider NOTE If the regulator rectifier case temperature exceeds 230 F or 110 C the unit will turn itself off to cool down The unit will turn on again after it has cooled down to at leas...

Page 500: ...ual Copyright 2014 Polaris Industries Inc Charging System Testing Flow Chart Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not exposed or pinched ELECTRICAL ...

Page 501: ...lothing 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 working...

Page 502: ...if the voltage drops below a pre determined point Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first The following are two tests which can easily be made on a sealed Maintenance Free battery to determine its condition OCV Test and a Load Test OCV Open Circuit Voltage Test Battery voltage should be checked with a di...

Page 503: ...rized Polaris dealers distributors are required to use the conductance analyzer when testing 12V Polaris batteries Polaris MDX 610P Bosch PN PU 50296 Charging Procedure If battery voltage is 12 6 Vdc or less the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging Do not exceed 6 amps when charging the 4011224 battery NOTE Char...

Page 504: ...pter 11 Voltage Drop Test page 11 38 Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are ...

Page 505: ...bolt stud 6 Remove the starter from the engine Starter Motor Installation 1 Inspect and replace starter motor O ring if needed 2 Lubricate starter motor O ring with fresh engine oil 3 Install the starter motor onto the engine case 4 Hand tighten the upper starter mounting bolt stud 5 Install and torque the lower mounting bolt to specification NOTE Tighten the lower starter bolt first as the bottom...

Page 506: ...cation replace the starter solenoid Starter Solenoid Operation To energize the Starter Solenoid the following must occur The brake must be applied to provide a ground path via the Orange wire The key switch must be turned to the start position to provide 12V power via the Green White wire Once the pull in coil is energized the solenoid provides a current path for 12V power to reach the starter mot...

Page 507: ...ing operation 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 in...

Page 509: ...11 11 43 9925724 R01 2014 2015 RZR XP 1000 RZR XP4 1000 Service Manual Copyright 2014 Polaris Industries Inc EPS Troubleshooting Power Steering Non Functional with MIL ON ELECTRICAL ...

Page 519: ...19 Brake Pedal Installation 9 10 Removal 9 10 Brake System Assembly View 9 6 Troubleshooting 9 40 Brakes Bleeding Fluid Change 9 8 Brake Burnishing Procedure 9 32 Brake Hose and Fitting Inspection 2 43 Brakes Lock 9 40 Hydraulic Brake System Operation 9 5 Master Cylinder Installation 9 8 Master Cylinder Removal 9 7 Overheating 9 40 Pedal Vibration 9 40 Performance Issues 9 40 Special Tools 9 3 Tor...

Page 520: ...Assembly 5 25 Assembly View 5 17 Bushing Service 5 23 Button to Tower Clearance 5 20 Cover Bushing 5 23 Disassembly 5 18 Moveable Sheave Inspection 5 23 Needle Bearing 5 19 Roller and Pin Inspection 5 21 Shift Weights 5 20 Spider Removal 5 21 Spring 5 18 Drive Shaft Boot Inspection 2 31 CV Joint Handling 7 16 Installation Front 7 12 Installation Rear 7 14 Removal Front 7 11 Removal Rear 7 13 Drive...

Page 521: ...ection 3 39 Valve Sealing Test 3 40 Valve Seat Reconditioning 3 41 Engine Coolant Temp Sensor ECT 11 25 Engine Serial Number Location 1 4 Engine Service Panel 10 19 Engine Camshaft Timing Quick Reference 3 83 Engine Valve Cover Installation 3 88 EPS Breakout Diagram 11 42 Operation 11 41 Troubleshooting 11 43 ETC 4 36 Exhaust Valve Lash Tappet Matrix 3 87 F Fan Control Circuit Bypass Test 11 25 Fa...

Page 522: ...t 2 3 Master Torque Table 1 21 Metric Bolt Torque Specification 1 24 Model Number Designation 1 2 N ne Valve Clearance Adjustment 3 84 O Oil Pressure Test 3 4 Open Circuit Voltage Test 11 36 Oxygen Sensor 4 39 P Parking Brake Adjustment INT L 9 12 Assembly View INT L 9 11 Caliper INT L 9 13 Disc INT L 9 16 Inspection INT L 9 12 Pedal Position Sensor PPS 4 37 Piston Disassembly Inspection 3 57 Inst...

Page 523: ...alker Evans Assembly 8 39 Shocks 8 27 Spark Plug Service 2 36 Special Tools 1 6 Body Steering Suspension 8 3 10 2 Brakes 9 3 Clutching 5 2 EFI 4 3 Electrical 11 3 Engine 3 3 Final Drive 7 2 Shock 8 36 Transmission 6 2 Specification Wheel Toe Out 2 38 Specifications Brakes 9 3 Camshaft 3 35 Cooling System 3 13 Engine 3 6 Engine Lubrication 3 3 3 32 Engine Oil Pressure 3 4 Transmission and Front Gea...

Page 524: ...cklash INT L 6 43 Output Shaft Backlash Procedure 6 23 Removal 6 6 Snorkel Shaft Removal 6 12 Troubleshooting 6 53 Transmission Lubrication 6 2 Transmission Switch 11 15 Trouble Codes 4 40 Instrument Cluster ETC 4 40 Troubleshooting Brake Noise 9 5 Brake System 9 40 Clutch 5 37 Cooling System 3 90 Engine 3 89 Fuel Injector 4 20 Fuel System 4 45 Transmission 6 53 Transmission Shifting Difficulty 6 ...

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Page 533: ...2015 RZR XP4 1000 Chassis ...

Page 534: ...2015 RZR XP 1000 Chassis ...

Page 535: ...2015 RZR XP 1000 Chassis ...

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