Polaris 2014 RZR XP 4 1000 Manuals

Manuals and User Guides for Polaris 2014 RZR XP 4 1000. We have 1 Polaris 2014 RZR XP 4 1000 manual available for free PDF download: Service Manual

Polaris 2014 RZR XP 4 1000 Service Manual

Polaris 2014 RZR XP 4 1000 Service Manual (474 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 44.34 MB

Table of Contents

Table of Contents

4
- Chapter 1
  7
- Engine Designation Number
  7
- General Information
  7
- Model Number Designation
  7
- Vehicle Identification
  7
- Vehicle Identification Number (Vin) Designation
  7
- Vehicle and Engine Serial Number Location
  8
- Vehicle Information
  8
  - Publication Numbers
    8
  - Replacement Keys
    9
- Special Tools
  10
- General Specifications
  11
- Misc. Specifications and Charts
  16
  - Master Torque Table
    16
  - Conversion Table
    19
  - Standard Bolt Torque Specification
    20
  - Metric Bolt Torque Specification
    20
  - Sae Tap / Drill Sizes
    21
  - Metric Tap / Drill Sizes
    21
  - Decimal Equivalents
    22
Maintenance Chapter 2 Maintenance

24
- Maintenance
  24
  - Periodic Maintenance Chart
    26
- Break-In Period
  26
- Chapter 2
  26
- Maintenance Chart Key
  26
- Periodic Maintenance Overview
  26
- Pre-Ride - 50 Hour Maintenance Interval
  27
- 50 - 500 Hour Maintenance Interval
  28
- Maintenance Quick Reference
  29
- Maintenance Quick Reference, Continued
  30
- Grease Lubrication Points
  31
- Lubricants / Service Products
  32
  - Polaris Lubricants, Maintenance and Service Products
    32
- General Vehicle Inspection and Maintenance
  33
  - Pre-Ride / Daily Inspection
    33
  - Shift Cable Inspection / Adjustment
    33
- Fuel System and Air Intake
  34
  - Fuel System
    34
  - Fuel Tank Vent Line
    34
  - Fuel Pump / Fuel Filters
    34
  - Fuel Lines
    35
  - Throttle Pedal Inspection
    35
  - Engine Intake Pre-Filter Service
    36
  - Air Filter Service
    36
  - Intake Duct Drain Inspection
    37
  - Air Box / Air Filter Assembly View
    38
- Engine
  39
- Transmission and Front Gearcase
  44
  - Specification Chart
    44
  - Transmission Lubrication
    44
  - Front Gearcase Lubrication
    45
- Cooling System
  46
  - Cooling System Overview
    46
  - Coolant Strength
    46
  - Coolant Level Inspection
    47
  - Cooling System Pressure Test
    48
  - Cooling System Hoses
    48
  - Radiator Inspection / Cleaning
    49
  - Coolant Drain / Fill
    49
- Pvt / Final Drive / Wheel and Tire
  50
  - Drive Clutch / Driven Clutch / Belt Service
    50
  - Pvt Intake Pre-Filter Service
    50
  - Pvt Drying
    50
  - Drive Shaft Boot Inspection
    51
  - Wheel and Hub Torque Table
    51
  - Wheel Removal
    51
  - Wheel Installation
    51
  - Tire Inspection
    51
  - Tire Pressure
    52
- Electrical and Ignition System
  52
  - Battery Maintenance
    52
  - Battery Charging / off Season Storage
    53
  - Battery Removal
    53
  - Battery Installation
    53
  - Engine / Chassis Electrical Ground
    54
  - Spark Plug Service
    54
- Steering
  55
  - Steering Inspection
    55
  - Steering Wheel Freeplay
    55
  - Tie Rod End / Wheel Hub Inspection
    56
  - Wheel Toe Alignment Inspection
    56
  - Wheel Toe Adjustment
    57
- Suspension (Walker Evans™)
  58
  - Spring Adjustment
    58
  - Shock Compression Adjustment
    59
- Brake System
  60
Engine Chapter 3 Engine

62
- Chapter 3
  64
- Engine Lubrication Specifications
  64
- General Information
  64
- Special Tools
  64
- Oil Pressure Test
  65
- Engine Oil Flow Chart
  66
- Engine Service Specifications
  67
  - Engine Specifications
    67
- Engine Detail - Torque Values / Sequences / Assembly Notes
  69
- Engine Cooling System
  74
  - Cooling System Pressure Test
    74
  - Pressure Cap Test
    74
  - Radiator Removal / Installation
    75
  - Thermostat Replacement
    76
  - Cooling System Assembly View
    78
  - Cooling System Bleeding Procedure
    79
  - Water Pump Removal
    80
  - Water Pump Installation
    80
  - Water Pump Service
    82
- Engine Service
  85
  - Accessible Engine Components
    85
  - Top-End Service (Engine in Chassis)
    85
  - Engine Removal
    85
  - Engine Installation
    89
  - Engine Mounting and Torque Values
    92
  - Engine Break-In Period
    93
  - Engine Lubrication Specifications
    93
- Engine Disassembly / Inspection - Top End
  94
  - Valve Cover Removal
    94
  - Camshaft Removal
    94
  - Camshaft Sprocket Inspection
    95
  - Camshaft / Camshaft Bore Inspection
    95
  - Cylinder Head Removal
    97
  - Cylinder Head Warp Inspection
    98
  - Cylinder Head Disassembly
    98
  - Valve Inspection
    99
  - Combustion Chamber Cleaning
    100
  - Valve Sealing Test
    100
  - Valve Seat Reconditioning
    101
- Engine Disassembly / Inspection - Lower End
  104
  - Stator Cover Removal / Inspection
    104
  - Water Pump Housing Removal
    105
  - Flywheel Removal
    105
  - Starter One-Way Clutch Disassembly
    106
  - Crankcase Disassembly / Inspection
    107
  - Balance Shaft Removal / Inspection
    110
  - Crankshaft Removal / Inspection
    111
  - Crankcase Inspection
    113
  - Cylinder Inspection
    114
  - Cylinder / Piston Removal
    115
  - Piston Disassembly / Inspection
    116
  - Piston Ring Removal
    117
  - Piston Ring to Groove Clearance Inspection
    118
  - Piston Ring Installed Gap
    118
  - Piston-To-Cylinder Clearance
    118
  - Connecting Rod Inspection
    119
- Engine Assembly - Lower End
  121
  - Bearing Selection Identification Letters and Numbers
    121
  - Connecting Rod Bearing Selection
    122
  - Crankshaft Main Bearing Selection
    122
  - Upper Crankcase Preparation
    122
  - Piston Ring Installation
    123
  - Piston / Connecting Rod Assembly
    124
  - Cylinder / Piston Installation
    125
  - Crankshaft Installation
    126
  - Balance Shaft Installation
    128
  - Lower Crankcase Preparation
    128
  - Crankcase Assembly
    129
  - Starter One-Way Clutch Assembly
    133
  - Flywheel Installation
    134
  - Stator Cover Installation
    134
- Engine Assembly - Top End
  135
  - Cylinder Head Assembly
    135
  - Cylinder Head Installation
    136
  - Camshaft Installation / Timing
    137
  - Camshaft Timing - Quick Reference
    141
  - Valve Clearance Adjustment
    142
  - Intake Valve Lash - Tappet Selection Matrix
    144
  - Exhaust Valve Lash - Tappet Selection Matrix
    145
  - Valve Cover Installation
    146
- Troubleshooting
  147
  - Engine
    147
  - Cooling System
    148
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

150
- Chapter 4
  152
- General Information
  152
- Special Tools
  152
- Efi Service Notes
  154
- Efi System Assembly View
  155
- Efi System Component Locations
  156
- Fuel Tank
  158
  - Assembly View
    158
  - Fuel Line Removal / Installation
    159
  - Fuel Tank Removal
    159
  - Fuel Tank Installation
    161
  - Fuel Tank Removal Rzr Xp 4 1000
    163
  - Fuel Tank Installation Rzr Xp 4 1000
    164
- Electronic Fuel Injection
  165
  - Principal Components
    165
  - Efi Operation Overview
    165
  - Initial Priming / Starting Procedure
    166
- Electronic Control Unit (Ecu)
  166
  - Operation Overview
    166
  - Ecu Service
    167
  - Ecu Replacement
    167
- Fuel Injectors
  168
  - Operation Overview
    168
  - Fuel Injector Troubleshooting
    168
  - Fuel Injector Test
    169
  - Fuel Injector Replacement
    169
- Fuel Pump
  172
  - Operation Overview
    172
  - Fuel Sender Test
    173
  - Fuel Pump Test
    173
  - Fuel Pump Replacement
    174
- Crankshaft Position Sensor (Cps)
  178
  - Cps Test
    179
  - Cps Replacement
    179
- Temperature / Manifold Absolute Pressure (T-Map) Sensor
  178
  - Operation Overview
    178
  - T-Map Test / Replacement
    178
- Throttle Body Assembly
  180
  - Operation Overview
    180
  - Throttle Body Service
    180
  - Throttle Body Removal
    180
- Electronic Throttle Control (Etc)
  181
  - Operation Overview
    181
  - Etc Test
    181
  - Etc Replacement
    182
- Pedal Position Sensor (Pps)
  182
  - Operation Overview
    182
  - Location
    182
  - Pps Test
    182
  - Pps Replacement
    183
- Efi Diagnostics
  184
  - Instrument Cluster Trouble Code Display
    184
  - Diagnostic Trouble Code Table
    184
  - Efi Troubleshooting
    188
- Digital Wrench® Operation
  189
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

198
- Body / Steering / Suspension
  198
  - General Information
    200
- Chapter 5
  200
- Multi-Function Pliers
  200
- Special Tools
  200
- Torque Specifications
  201
- Body Assembly Views
  202
  - Cab Frame Assembly Xp
    202
  - Cab Frame Assembly Xp 4
    203
  - Doors Xp
    204
  - Doors XP 4
    205
  - Dash Instruments / Controls
    206
  - Hood / Front Body Work
    207
  - Chassis / Main Frame Xp
    208
  - Chassis / Main Frame
    209
  - Seat Assembly Front
    210
  - Seat Assembly Rear
    211
  - Floor / Rocker Panels
    212
  - Floor / Rocker Panels
    213
  - Rear Cargo Box / Fenders
    214
  - Rear Bumper
    215
- Body Component Removal
  216
  - Seats
    216
  - Engine Service Panel
    216
  - Front Bumper
    216
  - Rear Bumper
    216
  - Hood and Front Body Work
    217
  - Rear Fender / Fender Flare Removal
    218
  - Rear Fender Flare / Rear Fender Removal Xp
    218
  - Cargo Box Assembly Removal
    218
  - Rocker Panels, Console and Floor
    219
  - Rocker Panels, Rear Console and Floor Xp
    220
  - Decal Replacement
    223
- Steering Assembly
  224
- Electronic Power Steering Assembly
  227
- Front A-Arms
  233
  - Removal / Replacement
    233
- Ball Joint Service
  236
  - Service Preparation
    236
  - Ball Joint Removal
    236
  - Ball Joint Installation
    236
- Rear Radius Rods
  237
  - Removal / Installation
    237
- Rear Trailing Arm
  238
- Rear Stabilizer Bar
  242
  - Stabilizer Bar Removal
    242
  - Stabilizer Bar Installation
    242
- Shocks / Springs / Fasteners
  243
  - Front Shock Assembly View
    243
  - Rear Shock Assembly View
    243
  - Shock Removal / Installation
    244
  - Shock Replacement
    244
- Walker Evans™Shock Assembly Views
  245
  - Walker Evans™ 2.0" Front Shock
    245
  - Walker Evans™ 2.5" Rear Shock
    246
- Walker Evans™ Shock Service
  247
  - General Service Information
    247
  - Front Shock Service Information
    247
  - Rear Shock Service Information
    248
  - Walker Evans™ Shock Rebuild Information
    249
  - Special Tools
    249
  - Valve Shim Arrangement
    249
  - Piston Orientation
    249
  - Walker Evans™ Shock Disassembly
    250
  - Walker Evans™ Shock Assembly
    252
Clutching Chapter 6 Clutching

258
- Clutching
  258
  - General Information
    259
- Chapter 6
  259
- Pvt System Torque Specifications
  259
- Special Tools and Supplies
  259
- Pvt System Overview
  260
  - General Operation
    260
  - Drive Clutch Operation
    260
  - Driven Clutch Operation
    260
  - Pvt Break-In (Drive Belt / Clutches)
    260
  - Maintenance / Inspection
    261
  - Overheating / Diagnosis
    262
- Pvt System Service
  263
  - Pvt Covers and Duct Components
    263
  - Pvt Disassembly
    264
  - Pvt Assembly
    265
- Drive Belt
  267
  - Belt Removal
    267
  - Belt Inspection
    268
  - Belt Installation
    268
  - Pvt Break-In (Drive Belt / Clutches)
    268
- Drive Clutch Service
  269
  - Drive Clutch Assembly View
    269
  - Drive Clutch Disassembly / Inspection
    270
  - Needle Bearing Inspection
    271
  - Shift Weight Inspection
    271
  - Button to Tower Clearance Inspection
    272
  - Spider Removal
    272
  - Roller, Pin, and Thrust Washer Inspection
    272
  - Clutch Inspection
    273
  - Moveable Sheave Bushing Inspection
    273
  - Bushing Service
    274
  - Drive Clutch Assembly
    276
- Driven Clutch Service
  279
  - Clutch Disassembly
    279
  - Bushing Service
    281
  - Clutch Assembly
    283
  - Assembly View
    287
- Troubleshooting
  288
Final Drive Chapter 7 Final Drive

290
- Final Drive
  290
  - General Information
    291
- Chapter 7
  291
- Final Drive Torque Specifications
  291
- Special Tools
  291
- Front Bearing Carrier
  292
  - Bearing Carrier Inspection / Removal
    292
  - Bearing Replacement
    293
  - Bearing Carrier Installation
    293
- Front Drive Shaft
  295
  - Drive Shaft Removal
    295
  - Drive Shaft Installation
    296
- Front Propshaft Service
  297
  - Front Propshaft Removal
    297
  - Front Prop Shaft Installation
    298
  - Rear Prop Shaft Removal
    299
  - Rear Prop Shaft Installation
    299
- Transmission
  299
  - Rear Prop Shaft Removal Xp
    301
    
    Rear Prop Shaft Installation Xp
    301
    
    Support Bearing Replacement
    302
    
    Prop Shaft U-Joint Service
    304
  - Front Gearcase / Centralized Hilliard
    305
    
    Centralized Hilliard Assembly View
    305
    
    All Wheel Drive Operation
    306
    
    Awd Diagnosis
    306
    
    Front Gearcase Removal
    307
    
    Front Gearcase Disassembly / Inspection
    308
    
    Front Gearcase Assembly
    311
    
    Front Gearcase Installation
    314
  - Rear Bearing Carrier
    315
    
    Bearing Carrier Inspection / Removal
    315
- Brakes
  315
  - Bearing Replacement
    316
    
    Bearing Carrier Installation
    317
  - Rear Drive Shaft
    319
    
    Drive Shaft Removal
    319
    
    Drive Shaft Installation
    320
  - Drive Shaft CV Joint / Boot Replacement
    322
    
    Drive Shaft / CV Joint Handling Tips
    322
    
    Outer CV Joint / Boot Replacement
    322
    
    Inner Plunging Joint / Boot Replacement
    324
    
    Drive Shaft Assembly View
    327
  - Wheel Hubs
    328
    
    Front Hub Assembly View
    328
    
    Rear Hub Assembly View
    328
Transmission Chapter 8 Transmission

330
- Chapter 8
  331
- Lubrication
  331
- Special Tools
  331
- Specifications
  331
- Torque Specifications
  331
- Shift Lever
  332
  - Removal
    332
  - Installation
    333
- Transmission Mounting and Torque Values
  332
- Shift Cable
  333
  - Inspection
    333
  - Adjustment
    333
- Transmission Removal
  334
- Transmission Installation
  337
- Transmission Service
  341
  - Transmission Disassembly
    341
  - Gear / Shaft / Bearing Inspection
    346
  - Snorkel Gear Backlash Procedure
    347
- Electrical
  354
  - Transmission Disassembly
    355
    
    Planetary Differential Disassembly
    360
    
    Planetary Differential Bushing Replacement
    361
    
    Planetary Differential Assembly
    364
    
    Gear / Shaft / Bearing Inspection
    365
    
    Snorkel Gear Backlash Procedure
    366
  - Troubleshooting
    374
    
    Troubleshooting Checklist
    374
  - Transmission Assembly View
    375
  - Transmission Assembly View (Int
    377
- Transmission Service (Int
  354
  - Differential Operation
    354
Brakes Chapter 9 Brakes

380
- Brake System Service Notes
  382
- Chapter 9
  382
- General Information
  382
- General Specifications
  382
- Special Tools
  382
- Torque Specifications
  382
- Brake Noise Troubleshooting
  383
- Hydraulic Brake System Operation
  383
- Brake System
  386
  - Assembly View
    386
- Master Cylinder
  387
  - Removal
    387
  - Installation
    387
- Brake Bleeding / Fluid Change
  388
- Brake Pedal Lever
  388
  - Pedal Removal
    388
  - Pedal Installation
    388
- Parking Brake (Int'l Model)
  390
  - Assembly View
    390
  - Parking Brake Inspection
    391
  - Parking Brake Cable Adjustment
    391
- Parking Brake Caliper Service (Int'l Model)
  392
  - Caliper Assembly View
    392
  - Caliper Removal
    393
  - Caliper Disassembly / Inspection
    393
  - New Brake Pad Installation
    394
  - Caliper Installation
    395
- Parking Brake Disc (Int'lmodel)
  395
  - Disc Inspection
    395
  - Disc Replacement
    396
- Front Brake Pads
  396
  - Pad Removal
    396
  - Pad Inspection
    397
  - Pad Assembly / Installation
    398
  - Brake Burnishing Procedure
    398
- Front Caliper Service
  399
  - Caliper Assembly View
    399
  - Caliper Removal
    399
  - Caliper Disassembly
    400
  - Caliper Inspection
    401
  - Caliper Assembly
    402
  - Caliper Installation
    402
- Front Brake Disc
  403
  - Disc Runout
    403
  - Disc Inspection
    404
  - Disc Replacement
    404
- Rear Brake Pads
  405
  - Pad Removal
    405
  - Pad Inspection
    406
  - Pad Assembly / Installation
    407
  - Brake Burnishing Procedure
    408
- Rear Caliper Service
  409
  - Caliper Assembly View
    409
  - Caliper Removal
    409
  - Caliper Disassembly
    410
  - Caliper Inspection
    411
  - Caliper Assembly
    411
  - Caliper Installation
    412
- Rear Brake Disc
  413
  - Disc Inspection
    413
  - Disc Replacement
    413
- Troubleshooting
  414
  - Brakes Squeal / Poor Brake Performance
    414
  - Pedal Vibration
    414
  - Caliper Overheats (Brakes Drag)
    414
  - Brakes Lock
    414
Electrical Chapter 10 Electrical

416
- Chapter 10
  419
- Electrical Service Notes
  419
- General Information
  419
- Special Tools
  419
- Torque Specifications
  419
- Under-Dash Components
  419
- Efi Diagnostics
  420
  - Efi Component Testing
    420
- Instrument Cluster
  421
  - Overview
    421
  - Rider Information Display
    422
  - Information Display Area
    423
  - Diagnostic Mode
    426
- Switches / Controls
  428
  - Brake Light Switch
    428
  - Headlamp Switch
    428
  - Ignition (Key) Switch
    429
  - Ignition (Key) Switch (Int'l)
    429
  - Awd / 2Wd Switch
    430
  - Awd / 2Wd / Turf Switch (Int'l)
    430
  - Turn Signal Switch (Int'l)
    431
  - Hazard Switch (Int'l)
    431
  - Transmission (Gear Position) Switch
    431
  - Parking Brake Switch (Int'l Model)
    432
- Rear Diff Solenoid (Int'l)
  433
  - Differential Solenoid Overview
    433
  - Differential Solenoid Circuit Operation
    433
- All Wheel Drive Coil
  434
  - Operation Overview
    434
  - Diagnosing System Failures
    434
- Ignition Coil
  435
  - Operation Overview
    435
  - Ignition Coil / Ht Lead Replacement
    435
  - Ignition Coil Tests
    436
- Vehicle Speed Sensor
  435
  - Speed Sensor Location
    435
  - Speed Sensor Testing
    435
- Head Lights
  436
  - Headlight Adjustment
    436
  - Headlamp Replacement
    437
  - Headlamp Installation
    438
- Tail / Brake Lights
  438
  - Taillight Replacement
    438
- Cooling System
  439
  - Fan Control Circuit Operation / Testing
    439
  - Fan Control Circuit Bypass Test
    439
  - Engine Coolant Temperature Sensor (Ect) Overview
    439
  - Ect Sensor Test
    440
  - Ect Sensor Replacement
    440
- Fuel Sender
  441
  - Testing
    441
- Fuse Box: Fuses / Relays / Circuit Breaker
  442
  - Overview / Operation
    442
  - Fuse Box Detail
    443
  - Relay Operation
    444
- Charging System
  445
  - Current Draw - Key off
    445
  - Charging System "Break Even" Test
    445
  - Charging System Stator (Alternator) Tests
    446
  - Stator (Alternator) Replacement
    447
  - Regulator / Rectifier
    447
  - Charging System Testing Flow Chart
    448
- Battery Service
  449
  - Battery Specifications
    449
  - General Battery Information
    449
  - Battery Removal / Installation
    450
  - Battery off Season Storage
    450
  - Battery Testing
    450
  - Ocv - Open Circuit Voltage Test
    450
  - Load Test
    450
  - Battery Conductance Analyzer
    450
  - Charging Procedure
    451
- Starting System
  451
  - Troubleshooting
    451
  - Voltage Drop Test
    451
  - Starter Motor Removal
    452
  - Starter Motor Installation
    452
  - Starter Solenoid Bench Test
    452
  - Starter Solenoid Operation
    452
- Starting System Testing Flow Chart
  453
  - Condition: Starter Fails to Turn over the Engine
    453
- Electronic Power Steering (Eps)
  454
- Electrical System Breakouts
  459
  - Awd
    459
  - Vehicle Speed Sensor
    460
  - Cooling System
    461
  - Unswitched Chassis Power
    462
  - Key-On Battery Power
    463
  - Lights
    464
  - Charging System
    465

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