Polaris RZR XP4 1000 Manuals

Manuals and User Guides for Polaris RZR XP4 1000. We have 1 Polaris RZR XP4 1000 manual available for free PDF download: Service Manual

Polaris RZR XP4 1000 Service Manual

Polaris RZR XP4 1000 Service Manual (539 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 52.82 MB

Table of Contents

Table of Contents

5
- Chapter 1
  8
- Model Number Designation
  8
- Vehicle Identification
  8
- Vehicle Identification Number
  9
- Vehicle Identification Number (Vin) Designation (2015+)
  9
- Vehicle and Engine Serial Number Location
  10
- Vehicle Information
  11
  - Replacement Keys
    11
  - Publication Numbers
    11
  - Special Tools
    12
- General Specifications
  16
  - Rzr Xp 1000 Clutch Chart
    17
  - Rzr Xp 4 1000
    19
  - Rzr 1000 Xp4
    20
  - Rzr Xp 1000 Eps High Lifter
    22
  - 2015 Rzr Xp 1000 High Lifter
    24
  - 2015 Rzr Xp 1000 Desert Edition
    24
  - 2015 Rzr Xp 1000 Desert Edition Clutch Chart
    26
- Misc. Specifications and Charts
  27
  - Master Torque Table
    27
  - Conversion Table
    29
  - Standard Bolt Torque Specification
    30
  - Metric Bolt Torque Specification
    30
  - Sae Tap / Drill Sizes
    31
  - Metric Tap / Drill Sizes
    31
  - Decimal Equivalents
    32
Maintenance Chapter 2 Maintenance

33
- Break-In Period
  35
- Chapter 2
  35
- Maintenance Chart Key
  35
- Periodic Maintenance Chart
  35
- Periodic Maintenance Overview
  35
- Pre-Ride - 50 Hour Maintenance Interval
  36
- 50 - 500 Hour Maintenance Interval
  37
- Maintenance Quick Reference
  38
- Maintenance Quick Reference, Continued
  39
- Grease Lubrication Points
  40
- Lubricants / Service Products
  41
  - Polaris Lubricants, Maintenance and Service Products
    41
- General Vehicle Inspection and Maintenance
  42
  - Pre-Ride / Daily Inspection
    42
  - Shift Cable Inspection / Adjustment
    42
- Fuel System and Air Intake
  44
  - Fuel System
    44
  - Fuel Tank Vent Line
    44
  - Fuel Pump / Fuel Filters
    45
  - Fuel Lines
    45
  - Throttle Pedal Inspection
    46
  - Engine Intake Pre-Filter Service
    46
  - Air Filter Service
    47
  - Intake Duct Drain Inspection
    47
  - Air Box / Air Filter Assembly View
    48
- Engine
  49
- Transmission and Front Gearcase
  55
  - Specification Chart
    55
  - Transmission Lubrication
    55
  - Front Gearcase Lubrication
    56
- Cooling System
  58
  - Cooling System Overview
    58
  - Coolant Strength
    58
  - Coolant Level Inspection
    58
  - Cooling System Pressure Test
    59
  - Cooling System Hoses
    59
- Maintenance
  59
- Radiator Inspection / Cleaning
  60
- Coolant Drain / Fill
  61
- Pvt / Final Drive / Wheel and Tire
  62
  - Drive Clutch / Driven Clutch / Belt Service
    62
    
    Pvt Intake Pre-Filter Service
    62
    
    Pvt Drying
    62
- Pvt System
  62
  - Drive Shaft Boot Inspection
    63
    
    Wheel and Hub Torque Table
    63
    
    Wheel Removal
    63
- Transmission
  63
  - Wheel Installation
    64
    
    Tire Inspection
    64
    
    Tire Pressure
    64
    
    Beadlock Rims (Desert Edition)
    65
  - Electrical and Ignition System
    66
    
    Battery Maintenance
    66
    
    Battery Charging / off Season Storage
    66
    
    Battery Removal
    66
    
    Battery Installation
    67
    
    Engine / Chassis Electrical Ground
    67
    
    Spark Plug Service
    68
- Electrical
  68
  - Steering
    69
    
    Steering Inspection
    69
    
    Steering Wheel Freeplay
    69
    
    Tie Rod End / Wheel Hub Inspection
    70
    
    Wheel Toe Alignment Inspection
    70
- Final Drive
  70
  - Wheel Toe Adjustment
    71
  - Suspension (Walker Evans™)
    72
    
    Spring Adjustment
    72
    
    Shock Compression Adjustment
    73
  - Brake System
    74
    
    Brake Fluid Inspection
    74
    
    Brake Pad / Disc Inspection
    74
    
    Brake Hose and Fitting Inspection
    75
Chapter 3 Engine / Cooling System

77
- Engine Lubrication Specifications
  79
- General Information
  79
- Special Tools
  79
- Oil Pressure Test
  80
- Engine Oil Flow Chart
  81
- Engine Service Specifications
  82
  - Engine Specifications
    82
- Engine Detail - Torque Values / Sequences / Assembly Notes
  84
- Engine Cooling System
  88
  - Cooling System Pressure Test
    89
  - Cooling System Pressure Cap Test
    90
  - Radiator Removal / Installation
    90
  - Thermostat Replacement
    91
  - Cooling System Assembly View
    93
  - Cooling System Bleeding Procedure
    94
  - Water Pump Removal
    95
  - Water Pump Installation
    95
  - Water Pump Service
    97
- Engine Service
  100
  - Accessible Engine Components
    100
  - Top-End Service (Engine in Chassis)
    100
  - Engine Removal
    100
  - Engine Installation
    104
  - Engine Mounting and Torque Values
    107
  - Engine Break-In Period
    108
  - Engine Lubrication Specifications
    108
- Engine Disassembly / Inspection - Top End
  109
  - Valve Cover Removal
    109
  - Camshaft Removal
    109
  - Camshaft Sprocket Inspection
    111
  - Camshaft / Camshaft Bore Inspection
    111
  - Cylinder Head Removal
    113
  - Cylinder Head Warp Inspection
    113
  - Cylinder Head Disassembly
    114
  - Valve Inspection
    115
  - Combustion Chamber Cleaning
    116
  - Valve Sealing Test
    116
  - Valve Seat Reconditioning
    117
- Engine Disassembly / Inspection - Lower End
  120
  - Stator Cover Removal / Inspection
    120
  - Water Pump Housing Removal
    121
  - Flywheel Removal
    122
  - Starter One-Way Clutch Disassembly
    123
  - Crankcase Disassembly / Inspection
    124
  - Balance Shaft Removal / Inspection
    126
  - Crankshaft Removal / Inspection
    127
  - Crankcase Inspection
    130
  - Cylinder Inspection
    131
  - Cylinder / Piston Removal
    132
  - Piston Disassembly / Inspection
    133
  - Piston Ring Removal
    134
  - Piston Ring to Groove Clearance Inspection
    134
  - Piston Ring Installed Gap
    135
  - Piston-To-Cylinder Clearance
    135
  - Connecting Rod Inspection
    136
- Engine Assembly - Lower End
  138
  - Bearing Selection Identification Letters and Numbers
    138
  - Connecting Rod Bearing Selection
    139
  - Crankshaft Main Bearing Selection
    139
  - Upper Crankcase Preparation
    140
  - Piston Ring Installation
    140
  - Piston / Connecting Rod Assembly
    142
  - Cylinder / Piston Installation
    143
  - Crankshaft Installation
    144
  - Balance Shaft Installation
    146
  - Lower Crankcase Preparation
    146
  - Crankcase Assembly
    147
  - Starter One-Way Clutch Assembly
    151
  - Flywheel Installation
    152
  - Stator Cover Installation
    152
- Engine Assembly - Top End
  153
  - Cylinder Head Assembly
    153
  - Cylinder Head Installation
    154
  - Camshaft Installation / Timing
    155
  - Camshaft Timing - Quick Reference
    159
  - Valve Clearance Adjustment
    160
  - Intake Valve Lash - Tappet Selection Matrix
    162
  - Exhaust Valve Lash - Tappet Selection Matrix
    163
  - Valve Cover Installation
    164
- Troubleshooting
  165
  - Engine Cooling System
    165
Chapter 4 Fuel System

167
- General Information
  169
- Special Tools
  169
- Efi Service Notes
  171
- Efi System Assembly View
  172
- Efi System Component Locations
  173
- Fuel Tank
  175
  - Assembly View
    175
  - Fuel Line Removal / Installation
    176
  - Fuel Tank Removal
    176
  - Fuel Tank Installation
    179
  - Fuel Tank Removal Rzr Xp 4 1000
    180
  - Fuel Tank Installation Rzr Xp 4 1000
    182
- Electronic Fuel Injection
  183
  - Principal Components
    183
  - Efi Operation Overview
    183
  - Initial Priming / Starting Procedure
    183
- Electronic Control Unit (Ecu)
  184
  - Operation Overview
    184
  - Ecu Service
    184
  - Ecu Replacement
    184
- Fuel Injectors
  186
  - Operation Overview
    186
  - Fuel Injector Troubleshooting
    186
  - Fuel Injector Test
    187
  - Fuel Injector Replacement
    187
- Fuel Pump
  191
  - Operation Overview
    191
  - Fuel Sender Test
    191
  - Fuel Pump Test
    192
  - Fuel Pump Replacement
    193
- Temperature / Manifold Absolute Pressure (T-Map) Sensor
  197
  - Operation Overview
    197
  - T-Map Test / Replacement
    197
- Crankshaft Position Sensor (Cps)
  198
  - Operation Overview
    198
  - Cps Test
    198
  - Cps Replacement
    199
- Throttle Body Assembly
  200
  - Operation Overview
    200
  - Throttle Body Service
    200
  - Throttle Body Removal
    200
- Electronic Throttle Control (Etc)
  202
  - Operation Overview
    202
  - Etc Test
    202
  - Etc Replacement
    202
- Pedal Position Sensor (Pps)
  203
  - Operation Overview
    203
  - Location
    203
  - Pps Test
    203
  - Pps Replacement
    203
- Oxygen Sensor (My15 Only)
  205
  - Oxygen Sensor Information
    205
- Efi Diagnostics
  206
  - Trouble Code Display (Etc)
    206
  - Efi Troubleshooting
    211
- Digital Wrench® Operation
  212
Pvt System Chapter 5 Pvt System

221
- Chapter 5
  222
- General Information
  222
- Pvt System Torque Specifications
  222
- Special Tools and Supplies
  222
- Rzr Xp 1000 Clutch Chart
  223
- Pvt System Overview
  224
  - General Operation
    224
  - Drive Clutch Operation
    224
  - Driven Clutch Operation
    225
  - Pvt Break-In (Drive Belt / Clutches)
    225
  - Maintenance / Inspection
    226
  - Overheating / Diagnosis
    227
- Pvt System Service
  228
  - Pvt Covers and Ducting Components (High Lifter)
    230
  - Pvt Disassembly
    231
  - Pvt Assembly
    233
- Drive Belt
  235
  - Belt Removal
    235
  - Belt Inspection
    236
  - Belt Installation
    236
  - Pvt Break-In (Drive Belt / Clutches)
    236
- Drive Clutch Service
  237
  - Drive Clutch Assembly View
    237
  - Drive Clutch Disassembly / Inspection
    238
  - Needle Bearing Inspection
    239
  - Shift Weight Inspection
    240
  - Button to Tower Clearance Inspection
    240
  - Spider Removal
    241
  - Roller, Pin, and Thrust Washer Inspection
    241
  - Clutch Inspection
    242
  - Moveable Sheave Bushing Inspection
    243
  - Bushing Service
    243
  - Drive Clutch Assembly
    245
- Driven Clutch Service
  248
  - Clutch Disassembly
    248
  - Bushing Service
    251
  - Clutch Assembly
    252
  - Assembly View
    256
- Troubleshooting
  257
Chapter 6 Transmission

259
- Lubrication
  260
- Special Tools
  260
- Specifications
  260
- Torque Specifications
  260
- Transmission Mounting and Torque Values
  261
- Shift Lever
  262
  - Removal
    262
  - Installation
    262
- Shift Cable
  263
  - Inspection
    263
  - Adjustment
    263
- Transmission Service
  264
- Transmission Service (Int
  289
- Troubleshooting
  311
  - Shifting Difficulty
    311
Final Drive Chapter 7 Final Drive

313
- Chapter 7
  314
- Final Drive Torque Specifications
  314
- General Information
  314
- Special Tools
  314
- Bearing Carrier
  315
- Drive Shaft
  323
  - Front Drive Shaft Removal
    323
  - Front Drive Shaft Installation
    324
  - Rear Drive Shaft Removal
    325
  - Rear Drive Shaft Installation
    326
  - Drive Shaft / CV Joint Handling Tips
    328
  - Outer CV Joint / Boot Replacement
    329
  - Inner Plunging Joint / Boot Replacement
    331
  - Drive Shaft Assembly View
    334
- Front Propshaft Service
  335
  - Front Propshaft Removal
    335
  - Front Prop Shaft Installation
    336
  - Rear Prop Shaft Removal
    336
  - Rear Prop Shaft Installation
    337
  - Rear Prop Shaft Removal XP 4
    338
  - Rear Prop Shaft Installation
    339
  - Support Bearing Replacement
    340
  - Prop Shaft U-Joint Service
    341
  - All Wheel Drive Operation
    343
  - Awd Diagnosis
    344
  - Front Gearcase Removal
    345
  - Front Gearcase Disassembly / Inspection
    346
  - Front Gearcase Assembly
    349
  - Front Gearcase Installation
    351
- Wheel Hubs
  353
  - Front Hub Assembly View
    353
  - Rear Hub Assembly View
    353
  - Beadlock Rims (Desert Edition)
    354
Steering / Suspension Chapter 8 Steering / Suspension

355
- Chapter 8
  357
- General Information
  357
- Multi-Function Pliers
  357
- Special Tools
  357
- Steering / Suspension
  357
- Steering Assembly
  359
- Electronic Power Steering Assembly
  363
- Front A-Arms
  370
  - Front A-Arm Removal / Replacement
    370
- Ball Joint Service
  373
  - Ball Joint Service Preparation
    373
  - Ball Joint Removal
    373
  - Ball Joint Installation
    374
- Rear Radius Rods
  375
  - Radius Rod Removal / Installation
    375
- Rear Trailing Arm
  376
- Rear Stabilizer Bar
  380
  - Stabilizer Bar Removal
    380
  - Stabilizer Bar Installation
    380
- Shocks / Springs / Fasteners
  381
  - Front Shock Assembly View
    381
  - Rear Shock Assembly View
    381
  - Shock Removal / Installation
    382
  - Shock Replacement
    382
- Walker Evans™Shock Assembly Views
  383
  - Walker Evans™ 2.0" Front Shock
    383
  - Walker Evans™ 2.5" Rear Shock
    384
- Front Shock Service Information
  385
- General Service Information
  385
- Walker Evans™ Shock Service
  385
- Rear Shock Service Information
  387
- Shock Piston Orientation
  390
- Special Tools
  390
- Valve Shim Arrangement
  390
- Walker Evans™ Shock Disassembly
  390
- Walker Evans™ Shock Assembly
  393
Brake System Chapter 9 Brake System

399
- Chapter 9
  401
- General Information
  401
- General Specifications
  401
- Special Tools
  401
- Brake System Service Notes
  402
- Torque Specifications
  402
- Brake Noise Troubleshooting
  403
- Brake System
  403
  - Brake System Assembly View
    404
- Hydraulic Brake System Operation
  403
- Master Cylinder
  405
  - Master Cylinder Removal
    405
  - Master Cylinder Installation
    406
  - Brake Bleeding / Fluid Change
    406
- Brake Pedal Lever
  408
  - Brake Pedal Removal
    408
  - Brake Pedal Installation
    408
- Parking Brake (Int'l Model)
  409
  - Parking Brake Assembly View
    409
  - Parking Brake Inspection
    410
  - Parking Brake Cable Adjustment
    410
  - Parking Brake Caliper
    411
  - Parking Brake Disc
    414
- Front Brake Pads
  417
  - Pad Removal
    417
  - Pad Inspection
    418
  - Pad Assembly / Installation
    418
  - Brake Burnishing Procedure
    419
- Front Caliper Service
  420
  - Caliper Assembly View
    420
  - Caliper Removal
    421
  - Caliper Disassembly
    422
  - Caliper Inspection
    423
  - Caliper Assembly
    423
  - Caliper Installation
    424
- Front Brake Disc
  425
  - Disc Runout
    425
  - Disc Inspection
    425
  - Disc Replacement
    426
- Rear Brake Pads
  427
  - Pad Removal
    427
  - Pad Inspection
    428
  - Pad Assembly / Installation
    429
  - Brake Burnishing Procedure
    430
- Rear Caliper Service
  431
  - Caliper Assembly View
    431
  - Caliper Removal
    432
  - Caliper Disassembly
    433
  - Caliper Inspection
    433
  - Caliper Assembly
    434
  - Caliper Installation
    434
- Rear Brake Disc
  436
  - Disc Inspection
    436
  - Disc Replacement
    436
- Troubleshooting
  438
  - Poor Brake Performance
    438
  - Pedal Vibration
    438
  - Caliper Overheats (Brakes Drag)
    438
  - Brakes Lock
    438
Body / Frame Chapter 10 Body / Frame

439
- Chapter 10
  440
- General Information
  440
- Special Tools
  440
- Torque Specifications
  440
- Body Assembly Views
  441
  - Cab Frame Assembly Xp / High Lifter
    441
  - Cab Frame Assembly XP 4
    442
  - Doors
    443
  - Doors
    444
  - Doors High Lifter
    445
  - Dash Instruments / Controls
    446
  - Dash Instruments / Controls High Lifter
    447
  - Hood / Front Body Work
    448
  - Chassis / Main Frame Xp / High Lifter
    449
  - Chassis / Main Frame XP 4
    450
  - Seat Assembly Front
    451
  - Seat Assembly Rear
    452
  - Floor / Rocker Panels Xp / High Lifter
    453
  - Floor / Rocker Panels XP 4
    454
  - Rear Cargo Box / Fenders
    455
  - Rear Bumper
    456
- Body Component Removal
  457
  - Seats
    457
  - Engine Service Panel
    457
  - Front Bumper Xp
    457
  - Rear Bumper
    458
  - Hood and Front Body Work
    458
  - Rear Fender / Fender Flare Removal Xp / High Lifter
    459
  - Rear Fender Flare / Rear Fender Removal Xp
    460
  - Cargo Box Assembly Removal
    460
  - Rocker Panels, Console and Floor Xp / High Lifter
    461
  - Rocker Panels, Rear Console and Floor Xp
    462
  - Decal Replacement
    465
Chapter 11 Electrical

467
- Electrical Service Notes
  469
- General Information
  469
- Special Tools
  469
- Under-Dash Components
  469
- Instrument Cluster
  470
  - Overview
    470
  - Rider Information Display
    472
  - Information Display Area
    473
  - Diagnostic Mode
    476
  - Instrument Cluster Removal
    478
  - Instrument Cluster Installation
    478
- Switches
  479
  - Brake Light Switch
    479
  - Headlamp Switch
    479
  - Ignition (Key) Switch
    480
  - Awd / 2Wd Switch (Models Without Turf)
    480
  - Transmission (Gear Position) Switch
    481
  - Seat Belt Switch
    482
- All Wheel Drive Coil
  483
  - Operation Overview
    483
  - Diagnosing System Failures
    483
- Vehicle Speed Sensor
  484
  - Speed Sensor Location
    484
  - Speed Sensor Testing
    484
- Ignition Coil
  485
  - Operation Overview
    485
  - Ignition Coil / Ht Lead Replacement
    485
  - Ignition Coil Tests
    486
- Lighting System
  487
  - Headlight Adjustment
    487
  - Headlamp Replacement
    488
  - Headlamp Installation
    489
  - Taillight Replacement
    489
  - Dash Light
    490
- Cooling System
  491
  - Fan Control Circuit Operation / Testing
    491
  - Fan Control Circuit Bypass Test
    491
  - Engine Coolant Temperature Sensor (Ect) Overview
    491
  - Ect Sensor Test
    492
  - Ect Sensor Replacement
    492
- Fuse / Relay Box
  493
  - Overview / Operation
    493
  - Fuse Box Detail
    494
  - Relay Operation
    495
- Charging System
  497
  - Current Draw - Key off
    497
  - Charging System "Break Even" Test
    497
  - Charging System Stator (Alternator) Tests
    498
  - Stator (Alternator) Replacement
    499
  - Regulator / Rectifier
    499
  - Charging System Testing Flow Chart
    500
- Battery
  501
  - Battery Specifications
    501
  - General Battery Information
    501
  - Battery Removal / Installation
    502
  - Battery off Season Storage
    502
  - Battery Testing
    502
  - Ocv - Open Circuit Voltage Test
    502
  - Load Test
    503
  - Battery Conductance Analyzer
    503
  - Charging Procedure
    503
- Starting System
  504
  - Troubleshooting
    504
  - Voltage Drop Test
    504
  - Starter Motor Removal
    505
  - Starter Motor Installation
    505
  - Starter Solenoid Bench Test
    506
  - Starter Solenoid Operation
    506
  - Condition: Starter Fails to Turn over the Engine
    506
- Electronic Power Steering (Eps)
  507
- Electrical System Breakout Diagrams
  512
  - Awd
    512
  - Vehicle Speed Sensor
    513
  - Cooling System
    514
  - Unswitched Chassis Power
    515
  - Key-On Battery Power
    516
  - Lights
    517
  - Charging System
    518

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