Polaris RZR XP 1000 Service Manual
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Polaris RZR XP 1000 Service Manual

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Table of Contents

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2014-2015 RZR XP 1000 / RZR XP4 1000
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized 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 Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed August 2014 (PN 9925724 R01)
© Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RZR XP 1000

  • Page 1 Publication Printed August 2014 (PN 9925724 R01) © Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, 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.
  • Page 3 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 nearest Polaris dealer.

  • Page 5: Table Of Contents

    GENERAL INFORMATION MAINTENANCE ENGINE / COOLING SYSTEM FUEL SYSTEM PVT SYSTEM TRANSMISSION FINAL DRIVE STEERING / SUSPENSION BRAKE SYSTEM BODY / FRAME ELECTRICAL...
  • Page 7 ............... . .1.26 DECIMAL EQUIVALENTS 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 8: Vehicle Identification

    First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 9: Vehicle Identification Number

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 10: Vehicle And Engine Serial Number Location

    GENERAL INFORMATION Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the left rear frame, behind the lower shock mounting location. Refer to Figure 1-1.

  • Page 11: Vehicle Information

    NOTE: When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 12: Special Tools

    Special tools may be required while servicing this vehicle. Some 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.
  • Page 13 Roll Pin Removal Tool Combination Pliers Spanner Wrench / CV Boot Clamp Pliers Drive Clutch Holding (27″) Clutch Spreader (ear) Tool 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 14 Oil Pressure Gauge Transmission Nut Clutch Spider Nut Rolling Engine Stand Engine Stand Adapter Adapter (1/2 NPT) Socket Socket Sleeve (2″) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 15 PV-48656 PW-47053 PW-47054 Piston Ring Fuel Pressure Gauge Bench Mount Engine Engine Stand Adapter Compressor Pliers Adapter Stand Sleeve (2 3/8″) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 16: General Specifications

    Do not use this vehicle for towing. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. 1.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 17: Rzr Xp 1000 Clutch Chart

    SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING Meters 0-1800 26-61 White / Orange 2014 XP 1000 (Feet) (0-6000) (1323098) (7043924) (3234452) 1.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 18 Orange / Black (0-6000) (1323176) (1323176) (3234452) Meters 2015 XP 1000 (Feet) 1800-3700 26-59 Orange / Black (6000-12000) (1322981) (7044338) (3234452) 1.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 19: Rzr Xp 4 1000

    Do not use this vehicle for towing. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. 1.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 20: Rzr 1000 Xp4

    SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING Meters 0-1800 26-67 White / Orange 2014 XP4 1000 (Feet) (0-6000) (1323177) (7043924) (3234452) 1.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 21 (0-6000) (1323260 (7043924) (3234452) Meters 2015 XP4 1000 (Feet) 1800-3700 26-59 White / Orange (6000 - 12000) (1322981) (7043924) (3234452) 1.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 22: Rzr Xp 1000 Eps High Lifter

    Hitch Tongue Capacity vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 1.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 23 20A Cooling Fan Fuses 10A EFI 10A Fuel Pump 5A Brake Light 10A Accessory 10A Drive 10A Lights 20A EPS (if appl.) 1.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 24: 2015 Rzr Xp 1000 High Lifter

    Meters 0-1800 26-61 White / Orange High Lifter (Feet) (0-6000) (1323260) (7043924) (3234452) Edition 2015 RZR XP 1000 Desert Edition 1.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 25 Do not use this vehicle for towing. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. 1.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 26: 2015 Rzr Xp 1000 Desert Edition Clutch Chart

    10A Drive 10A Lights White / 26-61 20A EPS (if appl.) Meters 0-1800 Orange Desert (13231- (323445- (Feet) (0-6000) (70439- Edition 1.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 27: Misc. Specifications And Charts

    7 ft-lb (10 Nm) Drive Clutch Cover Plate 9 ft-lb (12 Nm) Oil Sump Cover M8 Bolts 26 ft-lb (35 Nm) Screw 1.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 28 7 ft-lb (10 Nm) Fastener Steering Pivot Tube 8 ft-lb (11 Nm) Fasteners Steering Rack Mounting 16 ft-lbs (22 Nm) Bolts 1.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 29: Conversion Table

    = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 1.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 30: Standard Bolt Torque Specification

    59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 31: Sae Tap / Drill Sizes

    2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 1.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 32: Decimal Equivalents

    14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 1.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 33 ................2.29 COOLANT DRAIN / FILL 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 34 ............2.43 BRAKE HOSE AND FITTING INSPECTION 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 35: Periodic Maintenance Chart

    ▶ = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.

  • Page 36: Pre-Ride - 50 Hour Maintenance Interval

    ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 37: 50 - 500 Hour Maintenance Interval

    ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 38: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant bottle * More often under severe use, such as operation in water or under severe loads. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 39: Maintenance Quick Reference, Continued

    Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 40: Grease Lubrication Points

    Polaris All Season Grease Bushings each side of the vehicle *There is no grease point on the upper control arm rear mount. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 41: Lubricants / Service Products

    2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count) NOTE: Each item can be purchased separately at your local Polaris dealer. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 42: General Vehicle Inspection And Maintenance

    4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK. 2.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 43 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. 2.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 44: Fuel System And Air Intake

    Never drain the fuel when the engine is hot. Severe burns may result. 2.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 45: Fuel Pump / Fuel Filters

    Make sure lines are not kinked or Refer to Chapter 4 for fuel pump replacement and all pinched. other information related to the EFI System. 2.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 46: Throttle Pedal Inspection

    Check throttle pedal periodically. 3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air. 2.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 47: Air Filter Service

    3. Pull cover rearward far enough to remove air filter . debris so it can drain properly. If needed, remove the drain from the baffle box during inspection. 2.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 48: Air Box / Air Filter Assembly View

    Intake Airbox Hose Airbox Clip (4) Drain Cap Vent Hose Airbox Intake Tubes Air Filter Engine Intake Housing Airbox Cover 2.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 49: Engine

    . Remove the dipstick and wipe it dry with a clean cloth. 8. When finished, reinstall dipstick and lock the lever. 2.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 50: Engine Oil And Filter Change

    5. Remove the seats and engine service panel to access the oil filter. Engine Oil Drain Plug: 12 ft-lbs (16 Nm) 2.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 51: Engine Crankcase Breather Hose Inspection

    20. Reinstall the cargo box access panel, engine service panel and seats. 21. Dispose of used oil and filter properly. 2.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 52: Engine Cylinder Leakdown Test

    NOT necessary to perform this procedure. 5. Remove the spark plug wires to gain access to valve cover as shown below. 2.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 53 14. Install NEW isolators on the valve cover bolts. Install the valve cover and the four T40 bolts. Torque bolts to specification. Valve Cover Bolts: 7 ft-lbs (10 Nm) 2.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 54 19. Connect the negative (-) battery cable to the battery and install the seat. 20. Start the engine to ensure proper operation. 21. Install the engine access panel. 2.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 55: Transmission And Front Gearcase

    9. Reinstall the drain plug and torque to specification. 3. If lubricant level is not even with bottom threads, add recommended lubricant as needed. Do not overfill. 2.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 56: Front Gearcase Lubrication

    5. Remove the fill plug (see Chapter 2 – Front Gearcase Lubrication, page 2.24). 2.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 57 Front Gearcase Fill / Drain Plug Torque: 10 ft-lbs (14 Nm) 12. Check for leaks. Dispose of used fluid properly. 2.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 58: Cooling System

    NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. 7. Remove recovery bottle cap and add coolant using a funnel. 2.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 59: Cooling System Pressure Test

    Make sure radiator fins are clean to prevent overheating. ITEM DESCRIPTION Recovery Bottle Engine Hoses Radiator Hoses To Thermostat Housing To Waterpump To Radiator 2.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 60: Radiator Inspection / Cleaning

    Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended. 2.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 61: Coolant Drain / Fill

    8. Refer to Cooling System Bleeding Procedure, page 3.18. Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2871534) (Quart) (PN 2871323) (Gallon) 2.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 62: Pvt / Final Drive / Wheel And Tire

    PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 2.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 63: Drive Shaft Boot Inspection

    4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 2.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 64: Wheel Installation

    19 psi (131 kPa) 21 psi (145 kPa) wheel. High Lifter 18 psi (124 kPa) 18 psi (124 kPa) 2.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 65: Beadlock Rims (Desert Edition)

    NOTE: Beadlock bolts should be checked and retorqued every 300 miles (450 km). 7. Seat bead and inflate to 16 psi. 2.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 66: Electrical And Ignition System

    Procedure”, page 11.37. Do not use the vehicle’s stator/alternator to charge a new battery. 5. Lift the battery out of the vehicle. 2.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 67: Battery Installation

    2. Inspect the chassis ground terminals. Be sure the grounds are clean and tight. 6. Verify that cables are properly routed and reinstall the driver’s seat. 2.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 68: Spark Plug Service

    4. Rinse plug wells with water and dry with compressed air. NOTE: Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 2.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 69: Steering

    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. 2.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 70: Tie Rod End / Wheel Hub Inspection

    (loose wheel nuts or loose front hub nut). hub/axle center line. • Refer to Chapter 7 “Final Drive” for front hub service procedures. 2.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 71: Wheel Toe Adjustment

    • After alignment is complete, torque jam nuts to specification. Tie Rod Jamb Nut: 14 ft-lbs (19 Nm) 2.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 72: Suspension (Walker Evans™)

    The increased suspension height will negatively impact vehicle stability when operating without a load. 2.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 73: Shock Compression Adjustment

    The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counter- clockwise will decrease damping. 2.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 74: Brake System

    2.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 75: Brake Hose And Fitting Inspection

    Tighten any loose fittings and replace any worn or damaged parts. Brake Disc Thickness Service Limit: 0.170” (4.32 mm) 2.43 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 76 MAINTENANCE NOTES 2.44 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 77 ................3.40 VALVE SEALING TEST 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 78 ..................3.90 COOLING SYSTEM 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 79: General Information

    (Quick Release) Valve Spring Compressor PV-43513-A Adapter Water Pump Mechanical Seal PU-50564 Installer Bosch Automotive Service Solutions: 1-800-345- 2233 or http://polaris.service-solutions.com/ 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 80: Oil Pressure Test

    MAG side of the engine. 4. Remove the crankcase gallery plug and insert the oil pressure adapter. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 81: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM Engine Oil Flow Chart 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 82: Engine Service Specifications

    0.0590 ± 0.0039" (1.5 ± 0.10 mm) 0.0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 83 Crankshaft Runout Limit (PTO and MAG) (0.025 mm) Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm) Shaft 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 84: Engine Detail - Torque Values / Sequences / Assembly Notes

    ENGINE / COOLING SYSTEM ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES Main Engine Components - Torque Specification and Sequence 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 85: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

    ENGINE / COOLING SYSTEM Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 86: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

    ENGINE / COOLING SYSTEM Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump 3.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 87: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE / COOLING SYSTEM Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover 3.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 88: Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover

    ENGINE / COOLING SYSTEM Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover 3.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 89: Cooling System Pressure Test

    3.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 90: Cooling System Pressure Cap Test

    Allow the engine to cool before servicing. 4. Disconnect cooling fan electrical connector. 5. Remove the upper radiator hose from the radiator. 3.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 91: Thermostat Replacement

    Upper Radiator Hose To Radiator Fitting Lower Radiator Hose Fan Motor Assembly Recovery Bottle Radiator 3.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 92 Thermostat Cover Bolts: 7 ft-lb (10 Nm) 11. Be sure to properly fill and bleed cooling system as outlined in this chapter. 3.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 93: Cooling System Assembly View

    Engine Hoses Pressure Cap Bypass Hose Lower Radiator Hose Upper Radiator Hose Water Pump Outlet Hose Fan Assembly Recovery Bottle 3.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 94: Cooling System Bleeding Procedure

    5. Remove the seats, engine service panel and divider panel heat shield to access the coolant bleed screw. 3.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 95: Water Pump Removal

    14. Plug the water pump drive access hole in the engine block with a clean shop towel. 3.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 96 12. Install the right rear lower shock bolt and new nut. Torque mounting bolt to specification. Rear Shock Mounting Bolt: 70 ft-lbs (95 Nm) 3.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 97: Water Pump Service

    6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 3.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 98 19. Install a new water pump cover gasket 13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 3.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 99 “Water Pump Installation” procedure. Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 3.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 100: Engine Service

    Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 3.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 101 NOTE: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 3.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 102 NOTE: It is not necessary to remove the bolts that retain the bracket to the transmission. 3.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 103 • Sleeve adapter for a 2″ bore engine stand: • (PU-50625) • Sleeve adapter for a 2.375″ bore engine stand: • (PW-47054) 3.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 104: Engine Installation

    6. Align transmission joint mounting holes with the transmission front mounting holes. Starter Motor Bolts: 7 ft-lb (10 Nm) Trans Joint Bracket Bolts: 44 ft-lb (60 Nm) 3.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 105 13. Remove the clutch center distance tool. 9. Align the front transmission mounting holes with transmission joint bracket mounting holes on engine. 3.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 106 Check level after filling and add all the way so they engage onto the spark plugs. oil as needed. 3.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 107: Engine Mounting And Torque Values

    40. Start engine and check for any oil or coolant leaks. Engine Mounting and Torque Values 3.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 108: Engine Break-In Period

    6. Change oil and oil filter after 25 hour break-in period. * Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed. 3.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 109: Engine Disassembly / Inspection - Top End

    Replace the sealing washer upon the combustion chamber. reassembly. 3.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 110 6. Rotate the engine using the flywheel and remove the remaining bolt from each camshaft sprocket. 3.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 111: Camshaft Sprocket Inspection

    Exhaust: 1.5142 - 1.5181" (38.46 - 38.56 mm) Service Limit: 1.5122" (38.41 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 3.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 112 Calculated Camshaft Oil Clearance: 0.0000 - 0.0026" (0.001 - 0.067 mm) 0.0039" (0.1 mm) Camshaft Carrier Bolts: 89 in-lbs (10 Nm) 3.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 113: Cylinder Head Removal

    Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal, page 3.56. Cylinder Head Warp Limit: 0.0039″ (0.1 mm) 3.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 114: Cylinder Head Disassembly

    8. Clean the combustion chamber and head gasket surface. 9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring. 3.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 115: Valve Inspection

    They must be replaced if extensively worn, burnt, bent or damaged. Valve Guide I.D.: 0.2165 - 0.2171" (5.500 - 5.515 mm) 3.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 116: Combustion Chamber Cleaning

    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. 3.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 117: Valve Seat Reconditioning

    2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 3.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 118 Intake: 0.0393 ± 0.0039" (1.0 ± 0.10 mm) Service Limit: 0.0551" (1.4 mm) Exhaust: 0.0590 ± 0.0039" (1.5 ± 0.10 mm) Service Limit: 0.0748" (1.9 mm) 3.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 119 12. Thoroughly clean cylinder head and valves. 3.43 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 120: Engine Disassembly / Inspection - Lower End

    3. Inspect the condition of the stator windings output wires . If replacement is required, refer to Chapter 10. 3.44 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 121: Water Pump Housing Removal

    Water Pump Service, page 3.21. 2. Remove the three long gold colored bolts retaining the water pump housing to the engine 3.45 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 122: Flywheel Removal

    5. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel (left hand thread - turn flywheel puller counterclockwise to install). 3.46 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 123: Starter One-Way Clutch Disassembly

    3. Remove the one-way clutch and inspect both sides of drive rollers . Inspect the roller contact surface inside the hub for wear, damage or uneven surface. 3.47 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 124: Crankcase Disassembly / Inspection

    The cylinder holding to the crankcase. tool retains the cylinder and pistons when the engine is rotated. 3.48 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 125 14. Remove the eleven M6 and two M8 upper pump. crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 3.49 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 126: Balance Shaft Removal / Inspection

    3. Carefully rotate the balance shaft and remove it from the crankcase. 4. Inspect the balance shaft gear teeth for damage. 3.50 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 127: Crankshaft Removal / Inspection

    1.4939 - 1.4946" (37.946 - 37.962 mm) 5. Carefully lift the crankshaft out of the crankcase. Service Limit: 1.4921" (37.900 mm) 3.51 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 128 8. If the crankshaft gear or sprocket is damaged, the crankshaft assembly must be replaced. 3.52 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 129 Crankshaft Main Bearing Selection, page 3.63 and Connecting Rod Bearing Selection, page 3.63 procedures. 3.53 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 130: Crankcase Inspection

    NOTE: Always replace plain bearings when the crankcase connecting rods have been disassembled. Refer to Bearing Selection Identification Letters and Numbers, page 3.62. 3.54 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 131: Cylinder Inspection

    0.001″ (0.025 mm) Cylinder Out of Round: 0.001″ (0.025 mm) Standard Bore Size: 3.6614 ± 0.0003" (93 mm ± 0.008 mm) 3.55 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 132: Cylinder / Piston Removal

    (MAG / PTO). 4. Carefully lift the cylinder and pistons from the upper crankcase. 3.56 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 133: Piston Disassembly / Inspection

    DO NOT apply heat to piston rings or a loss of radial tension could result. Piston Pin O.D.: 0.7873 - 0.7875" (20.000 - 20.005 mm) Service Limit: 0.7866" (19.98 mm) 3.57 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 134: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. 3.58 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 135: Piston Ring Installed Gap

    Service Limit: 0.0354" (0.9 mm) NOTE: Always check piston ring installed gap when installing new rings and/or a new cylinder. 3.59 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 136: Connecting Rod Inspection

    3. Inspect the small end and big end of connecting rod (and matching rod cap) for damage, galling of surface or pitting. 3.60 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 137 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 procedure. 3.61 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 138: Engine Assembly - Lower End

    Connecting Rod Bearing Crankcase Bearing Identification Crankshaft Bearing Identification Identification Number ( one number) Number (six numbers) Letters (six letters) 3.62 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 139: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 3.63 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 140: Upper Crankcase Preparation

    NOTE: Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 3.64 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 141 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. 3.65 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 142: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 3.66 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 143: Cylinder / Piston Installation

    NOTE: Orientation arrow is also located on the bottom side of piston as an additional reference. 3.67 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 144: Crankshaft Installation

    5. Install oil drain diverter into the upper crankcase. 3.68 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 145 Connecting Rod Bolts: Step 1: 9 ft-lbs (12 Nm) Step 2: 13 ft-lb (18 Nm) Step 3: Tighten add’n 105° 3.69 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 146: Balance Shaft Installation

    Rinse with clear, warm water and dry with compressed air. 7. Be sure passages are clean and dry before assembling the crankcase. 3.70 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 147: Crankcase Assembly

    Do not allow sealant to dry before assembly. NOTE: Install new M10 lower crankcase bolts. NOTE: DO NOT block oil passages with crankcase sealant. 3.71 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 148 11. Rotate the engine so the cylinder is facing up. 12. Install the eleven M6 and two M8 upper crankcase bolts. Tighten all bolts lightly by hand. 3.72 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 149 NOTE: Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 3.73 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 150 25. Reinstall the crankcase drain plug if previously removed. Torque drain plug to specification. Crankcase Drain Plug: 12 ft-lbs (16 Nm) 3.74 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 151: Starter One-Way Clutch Assembly

    5. If starter gear was replaced, inspect the torque limit gear. 6. After assembly, be sure the starter gear rotates in the clockwise direction only. 3.75 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 152: Flywheel Installation

    3. Install stator cover and thirteenscrews. Torque screws in sequence to specification. Flywheel Retaining Bolt: 133 ft-lbs (180 Nm) Stator Cover Screws: 9 ft-lb (12 Nm) 3.76 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 153: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 3.77 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 154: Cylinder Head Installation

    5. Carefully set the cylinder head in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder head bolts evenly. 3.78 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 155: Camshaft Installation / Timing

    Exhaust Camshaft - PN 1204786 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3.79 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 156 Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 3.80 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 157 . Do not torque the bolts at this time. markings should line up as shown. NOTE: Use new sprocket retaining bolts upon assembly. 3.81 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 158 Cam Chain Tensioner: 29 ft-lb (40 Nm) 23. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 3.82 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 159: Camshaft Timing - Quick Reference

    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 3.83 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 160: Valve Clearance Adjustment

    7. Measure the valve clearance using a thickness (feeler) gauge. Record the measurement if clearance is out of specification. 3.84 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 161 Camshaft Installation / Timing, page 3.79. 3.85 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 162: Intake Valve Lash - Tappet Selection Matrix

    0.951-0.975 522 525 528 530 532 535 538 540 542 545 0.976-1.000 525 528 530 532 535 538 540 542 545 3.86 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 163: Exhaust Valve Lash - Tappet Selection Matrix

    0.951-0.975 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 512 515 518 520 522 525 528 530 532 535 538 540 542 545 3.87 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 164: Valve Cover Installation

    6. Torque valve cover bolts to specification. Spark Plugs: 7 ft-lbs (10 Nm) Valve Cover Bolts: 7 ft-lbs (10 Nm) 3.88 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 165: Troubleshooting

    Engine Idles But Will Not Accelerate • Air filter dirty or contaminated • Spark plug fouled/weak spark Low Compression • Broken throttle cable 3.89 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 166 Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 3.90 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 167 ELECTRONIC THROTTLE CONTROL (ETC) ............4.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual...
  • Page 168 ..............4.51 ECU REPROGRAMMING (REFLASH) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 169: General Information

    Fuel Pressure Gauge Adapter - PV-48656 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 170 (1-800-345-2233). NOTE: For the most recent information on Digital Wrench® software and update downloads please visit the website: www.polaris.diagsys.com 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 171: Efi Service Notes

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 172: Efi System Assembly View

    Engine Coolant Temperature Sensor (ECT) Fuel Filter Dual Throttle Body Assembly Fuel Supply Line Fuel Injectors T-MAP Sensor Fuel Rail / Regulator Electronic Throttle Control 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 173: Efi System Component Locations

    Located on the left side of the thermostat housing. assembly. The sensor can be accessed with the air box assembly removed. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 174 • Fuel Rail / Regulator Located on the throttle body, on top of the fuel injectors. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 175: Fuel Tank

    PFA Nut Fuel Sender Float Arm Fuel Tank Vent PFA Gasket (replace if removed) Fuel Tank Assembly Fuel Pump / Regulator 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 176: Fuel Line Removal / Installation

    3. Pull on the fuel line for removal. 4. To install the line, verify the connections are clean and free of debris. 4.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 177 . Remove the rear seat base assembly from the vehicle. 4.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 178 Remove the panel from the vehicle. 12. Remove the nuts retaining the regulator and Torx screws retaining the fuse box. 4.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 179: Fuel Tank Installation

    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) 4.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 180: Fuel Tank Removal Rzr Xp 4 1000

    Once removed, place the mechanism in the rear cargo box to keep it out of the way. 4.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 181 12. Remove the fuel tank vent line from the tank fitting. 4.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 182: Fuel Tank Installation Rzr Xp 4 1000

    8. Reinstall rear and front center console, shift knob and screws. 9. Reinstall seat belt mechanism. Torque bolt to specification. 4.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 183: Electronic Fuel Injection

    4- stroke cycle. When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned. 4.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 184: Electronic Control Unit (Ecu)

    This process repeats it self in rapid succession, limiting operation to the preset maximum. RPM Limit: 8300 4.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 185 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) 4.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 186: Fuel Injectors

    Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 187: Fuel Injector Test

    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. 4.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 188 5 mm Allen wrench. 11. Upon installation of the new fuel injectors, lightly lubricate the injector O-rings to aid installation. 4.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 189 23. Reinstall the two screws retaining the air box assembly. 24. Position the intake hose onto the air box and tighten the hose clamp. 4.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 190 FUEL SYSTEM 25. Reinstall the cargo box access panel. 4.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 191: Fuel Pump

    • If the key switch is not promptly turned to the "start" position. • If the engine fails to start. 4.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 192: Fuel Pump Test

    ECU operation by plugging in a known-good ECU of the same model. NOTE: If the pump still does not operate, replace the fuel pump assembly. 4.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 193: Fuel Pump Replacement

    4. Ensure that static has been discharged by touching a ground source such as the engine or frame. 4.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 194 Do not use water or any other chemicals to remove debris. 4.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 195 21. Install the fuel tank vent line onto the tank fitting. flange is centered. 22. Connect the fuel pump electrical harness. 4.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 196 Cycle the key several times to prime the system. 24. Install the passenger seat / storage box. 4.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 197: Temperature / Manifold Absolute Pressure (T-Map) Sensor

    The T-MAP provides the ECU with engine load data. 4.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 198: Crankshaft Position Sensor (Cps)

    CPS and flywheel encoder ring for damage. 4. If the resistance is incorrect, follow the Replacement, page 4.33 procedure. 4.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 199: Cps 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) 4.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 200: Throttle Body Assembly

    INJECTORS, page 4.20 and Temperature / Manifold Absolute Pressure (T-MAP) Sensor, page 4.31). 5. Remove the driver’s seat and disconnect the negative battery cable. 4.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 201 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. 4.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 202: Electronic Throttle Control (Etc)

    ETC Housing Retaining Bolts: 7 ft-lb (10 Nm) Intake Boot Clamp: 35 in-lb (4 Nm) 4.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 203: Pedal Position Sensor (Pps)

    1. Disconnect the PPS harness connection located on the throttle pedal. 2. Remove the drivers seat and disconnect the negative (-) battery cable. 4.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 204 7. Manually cycle the throttle pedal to verify the throttle pedal moves freely. 8. Connect the negative (-) battery cable and install the drivers seat. 4.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 205: Oxygen Sensor (My15 Only)

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 4.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 206: Efi Diagnostics

    5. To exit the diagnostic mode, press and hold the diagnostics code menu. MODE button or turn the ignition key OFF once the codes are recorded. 4.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 207 P0265 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 4.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 208 Idle Air Control Valve (IAC) 520268 Driver Circuit Short to B+ P1519 M17; IAC Stepper Pin 3 Driver Circuit Grounded P1518 4.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 209 ECU Monitoring of Injection Condition Exists 520289 P1543 Cut Off (Level 2) Controller Option Setting Not Out of Calibration 520290 P1544 Programmed 4.43 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 210 Voltage Below Normal or Shorted Oxygen Sensor Heater 1 520209 P0031 to Low Source Current below Normal or Open P0030 Circuit 4.44 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 211: Efi Troubleshooting

    • Air Leaks, dirty injector • TMAP damaged (check with Digital Wrench®) • Tight valves (low compression or high leakdown) 4.45 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 212: Digital Wrench® Operation

    PV-43546 (Fluke 77: PV-43568) Commercially Available (refer to diagnostic software Laptop or Desktop Computer user manual or HELP section for minimum requirements) 4.46 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 213: Digital Wrench Software Version And Update

    NOTE: Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the install. 4.47 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 214: Digital Wrench® Communication Errors

    ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 4.48 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 215: Guided Diagnostics

    Check your release version often and upgrade when available to be sure you are using the most current software available. 4.49 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 216: Digital Wrench® Feature Map

    Run the Help System. adjustment functions service reports. Prints the current screen as a Open the ASSERT ASK form. formatted printout. 4.50 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 217: Ecu Replacement

    2. Connect SmartLink Module cables to PC and Chapter 4 – Digital Wrench® Updates, page 4.47. vehicle. See, page 4.48 3. Open the Digital Wrench® program. 4.51 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 218 7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 4.52 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 219 Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 4.53 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 220 FUEL SYSTEM NOTES 4.54 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 221 TROUBLESHOOTING................. . .5.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual...

  • Page 222: General Information

    Driven Clutch Helix 48 in-lb (5 Nm) Retaining Screws SPECIAL SUPPLIES PART NUMBER Loctite® 620™ 648™ and 7088™ Primer RTV Silicone Sealer 8560054 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 223: Rzr Xp 1000 Clutch Chart

    ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING Meters 0-1800 26-61 White / Orange High Lifter (Feet) (0-6000) (1323260) (7043924) (3234452) Edition 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 224: Pvt System Overview

    Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 225: Driven Clutch Operation

    Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 226: Maintenance / Inspection

    PVT area. This is especially critical on units subjected to frequent water forging. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 227: Overheating / Diagnosis

    NOTE: Using High gear for heavy loads, hilly terrain, sand/dune environments, or in wet, muddy conditions will increase the chance of drive belt burning. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 228: Pvt System Service

    NUT, NYLOK O-RING BRACKET, BELT SCREEN DRAIN PLUG, COVER HOSE, AIR OUTLET SEAL, COVER INTAKE BOOT SCREW SEAL, COVER COVER ASSEMBLY 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 229 Outer Cover Screws (8 ft-lbs, 11 Nm) Outlet Duct Clutch Cover Drain Screw Outer Clutch Cover Inner Cover Screws (8 ft-lbs, 11 Nm) Inner Clutch Cover 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 230: Pvt Covers And Ducting Components (High Lifter)

    Lower Exhaust Hose Outer Cover Seal Outlet Duct Outer Clutch Cover Inlet Duct Outer Clutch Cover Screw (8) Boot PVT Drain Screw 5.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 231: Pvt Disassembly

    PVT intake hose to the outer clutch cover and disengage the hose from the outer clutch cover. Drive Clutch Holding Tool 9314177-A 5.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 232 15. Remove the seven bolts that retain inner clutch cover to engine and transmission. Remove inner clutch cover. 5.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 233: Pvt Assembly

    12. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 13. Install the drive clutch onto the engine. 5.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 234 Torque screws to specification. Outer Clutch Cover Retaining Screws: 48 in-lb (5 Nm) 18. Install inlet and outlet ducts and tighten hose clamps. 5.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 235: Drive Belt

    NOT necessary for belt replacement. 3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 5.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 236: Belt Inspection

    5. Install the outer clutch cover and eight screws. Torque screws to specification. Outer Clutch Cover Retaining Screws: 48 in-lb (5 Nm) 5.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 237: Drive Clutch Service

    PVT SYSTEM DRIVE CLUTCH SERVICE Drive Clutch Assembly View 5.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 238: Drive Clutch Disassembly / Inspection

    Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. Drive Clutch Spring Inspection 5.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 239: Needle Bearing Inspection

    Drive Clutch Spring Specifications Part Number 7043924 White / Orange Color Free Length 3.563″ (90.50 mm) Spring Wire Diameter 0.177″ (4.50 mm) 5.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 240: Shift Weight Inspection

    Button to Tower Clearance: 0.000-.012″ (.000-.304 mm) 2. Inspect the tower sheave surfaces. Replace the drive clutch if worn, damaged or cracked. 5.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 241: Spider Removal

    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 5.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 242: Clutch Inspection

    Replace as an assembly if worn, damaged, or if operational problems were noted prior disassembly. 5.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 243: Moveable Sheave Bushing Inspection

    P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 5.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 244 Piston Pin Puller: PN 2870386 3. Remove nut from puller rod and set aside. 4. Install puller adapter from kit PN 2871226. 5.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 245: Drive Clutch Assembly

    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. 5.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 246 Loctite® 7088™ Primer in 90° apart to the threads of the spider jamb nut. Install spider jamb nut onto stationary shaft threads. Moveable Sheave Spider 5.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 247 12. Install cover bolts and torque in a cross pattern evenly to specification. Drive Clutch Cover Bolts: 9 ft-lb (12 Nm) 5.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 248: Driven Clutch Service

    X’s on the components for reference. This will aid in assembly and maintains clutch balance. 5.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 249 9. Remove the clutch assembly from the holding tool. 10. Press out the spring pins in the inner sheave. 5.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 250 5.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 251: Bushing Service

    Turn puller barrel for further tension if needed. 7. Turn clutch sheave counterclockwise until bushing is removed and sheave comes free. 5.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 252: Clutch Assembly

    18. Remove nut (C) from puller rod and set aside. 19. Remove installation tool and clutch sheave from puller. 5.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 253 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 5.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 254 (helix) side down. Press down on the moveable sheave belt face with both hands and the helix will release. 5.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 255 15. Use a T25 Torx driver to install the four helix retaining screws and torque to specification. Helix Retaining Screws: 48 in-lb (5 Nm) 5.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 256: Assembly View

    Spider Insert Stationary Sheave Spider Dampener E-Clip Roller Washer Helix (Cam) Moveable Sheave Helix Screws Clutch Shaft 48 in-lb (5 Nm) 5.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 257: Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 5.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 258 Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 5.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 259 ................6.53 SHIFTING DIFFICULTY 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 260: Specifications

    Capacity (INT’L): 41 oz. (1200 ml) Mounting Bolt (INT’L) Park Flange Screws 10 ft-lb (14 Nm) Rear Transmission 40 ft-lb (54 Nm) Isolator Bolt 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 261: Transmission Mounting And Torque Values

    TRANSMISSION Transmission Mounting and Torque Values 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 262: Shift Lever

    5. Remove both bushings from the shift lever and service as needed. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 263: Shift Cable

    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. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 264: Transmission Service

    (see Chapter 5 – PVT Disassembly, page 5.11). NOTE: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 265 15. Maneuver the drive shafts out of the vehicle frame. Reinstall the lower shock bolts to hold the trailing arms up during the rest of the removal procedure. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 266 21. Remove the two rear exhaust springs securing the muffler to the rear transmission mounting bracket. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 267: Transmission Installation

    NOTE: DO NOT torque fasteners at this time. Rear Transmission Mount Bracket Fasteners 17 ft-lb (23 Nm) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 268 Step 4-7: 44 ft-lb (60 Nm) Shift Cable Bracket Bolts: 17 ft-lb (23 Nm) 12. Remove the clutch center distance tool. 6.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 269 Wheel Nuts: nuts. Torque to specification. 120 ft-lbs (163 Nm) 26. Properly lower the vehicle. 6.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 270: Transmission Disassembly

    . Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly. 8. Remove the spacer 6.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 271 Do not pry on case sealing surfaces. opposite side. Use only the designated pry points on the transmission. 6.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 272 Gear Cluster Disassembly 22. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 6.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 273 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 6.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 274: Differential Operation (Turf Mode Models Only)

    This unlocks the rear differential. 6.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 275 When “Differential-Lock” is selected, power is removed from the electrical solenoid allowing the solenoid plunger 6.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 276: Planetary Differential Disassembly (Turf Mode Models Only)

    Replacement (Turf Mode Models Only), page 6.19. 2. Remove the six screws retaining the differential cover and remove the cover. 6.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 277: Planetary Differential Bushing Replacement (Turf Mode Models Only)

    5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 6.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 278 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 6.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 279: Planetary Differential Assembly (Turf Mode Models Only)

    5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification. Differential Cover Screws: 22 ft-lb (30 Nm) 6.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 280: Gear / Shaft / Bearing Inspection

    TRANSMISSION Gear / Shaft / Bearing Inspection 6.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 281: Transmission Assembly / Snorkel Gear Backlash Procedure

    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. 6.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 282 6.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 283 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 6.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 284 Lift up on the shift shaft rail and move the rail assembly towards the shift drum to allow the shift fork ends to be installed into the shift drum. 6.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 285 28. Install the spacer and then the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 6.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 286 36. Refer to Transmission Installation, page complete the repair. 31. Clean the transmission and gear sector cover mating surfaces thoroughly. 6.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 287: Transmission Assembly View

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW 6.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 288 Bearing, Ball Cover, Sector Gears Spring, Wave Case, RH Case, LH Bracket, Wire Harness Drum, Shift Collar Sleeve, Input Shaft 6.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 289: Transmission Service (Int

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 6.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 290: Transmission Disassembly

    . Remove the switch. outward for reassembly. 8. Remove the spacer (J). 6.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 291 CAUTION Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 6.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 292 If disassembly is required, refer to “Gear Cluster Disassembly”. Gear Cluster Disassembly 18. Slide engagement dog (X) off of shift fork guides. 6.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 293 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 6.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 294 29. Using the Snorkel Tool (PA-50231), fully loosen the snorkel tube. 32. Use an arbor press to remove the snorkel tube from the snorkel shaft. 6.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 295 34. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 6.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 296: Planetary Differential Disassembly (Turf Mode Models Only)

    Replacement (Turf Mode Models Only), page 6.19. 2. Remove the six screws retaining the differential cover and remove the cover. 6.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 297: Planetary Differential Bushing Replacement (Turf Mode Models Only)

    5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 6.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 298 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 6.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 299: Planetary Differential Assembly (Turf Mode Models Only)

    5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification. Differential Cover Screws: 22 ft-lb (30 Nm) 6.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 300: Gear / Shaft / Bearing Inspection

    TRANSMISSION Gear / Shaft / Bearing Inspection 6.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 301: Snorkel Gear Backlash Procedure

    8. Apply Loctite® 242™ to the threads of the bearing cover retaining screws. 6.43 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 302 Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 6.44 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 303 18. Install shift fork (S) and torsion spring into transmission housing as an assembly. Load spring as shown in image below 6.45 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 304 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. 6.46 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 305 Sealant (PN 2871557) to the left hand transmission mating surface. NOTE: Shift fork pins should be offset towards the input shaft as shown above. 6.47 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 306 (.070" or 1.8 mm from outer face of bore). Transmission Case Screws: 20 ft-lbs (27 Nm) 6.48 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 307 35. Install the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 6.49 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 308 Bell Crank Nut: 18 ft-lb (24 Nm) 43. Refer to TRANSMISSION INSTALLATION, page 6.9 to complete the repair. 6.50 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 309: Transmission Assembly View (Turf Mode Models)

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW (Turf Mode Models) 6.51 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 310 108. Bearing, Ball Gear, 44T Collar Sleeve, Input Shaft 109. Bearing, Ball Fork, Shift Bearing, Needle Cage Sprocket, 48T, 6-Face 6.52 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 311: Troubleshooting

    (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 6.53 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 312 TRANSMISSION NOTES 6.54 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 313 ............7.42 BEADLOCK RIMS (DESERT EDITION) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 314: General Information

    30 ft-lbs (41 Nm) Mounting Bolts Bearing Carrier to 42 ft-lb (54 Nm) Trailing Arm Bolts Radius Rod 40 ft-lb (54 Nm) Fasteners 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 315: Bearing Carrier

    13. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 316: Front Bearing Replacement

    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. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 317: Front Bearing Carrier Installation

    8. Torque the tie rod end fastener to specification and install a new cotter pin Tie Rod End Fastener: 15 ft-lbs (20 Nm) + 90° 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 318: Rear Bearing Carrier Inspection / Removal

    Swing radius rod down. Discard the nut. 6. Remove the two brake caliper mounting bolts Remove the rear brake caliper assembly. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 319 Discard the nuts. 10. Remove the bearing carrier from the rear drive shaft and trailing arm. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 320: Rear Bearing Replacement

    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. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 321: Rear Bearing Carrier Installation

    42 ft-lb (54 Nm) Radius Rod to Bearing Carrier Fasteners: 40 ft-lb (54 Nm) 3. Apply anti-seize to drive shaft splines. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 322 8. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 7.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 323: Drive Shaft

    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. 7.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 324: Front Drive Shaft Installation

    3. Install drive shaft into the front bearing carrier. 4. Install the upper and lower ball joint ends into the front bearing carrier. 7.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 325: Rear Drive Shaft Removal

    120 ft-lbs (163 Nm) 7. Remove the rear hub assembly from the bearing 11. Rotate wheel and check for smooth operation. carrier. 7.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 326: Rear Drive Shaft Installation

    3. Swing the rear trailing arm assembly outward and upward until the rear axle can be inserted into the bearing carrier. Support the trailing arm from underneath. 7.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 327 8. Install the radius rod bolts, washers and new nuts. Torque fasteners to specification. Radius Rods to Bearing Carrier: 40 ft-lb (54 Nm) 7.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 328: Drive Shaft / Cv Joint Handling Tips

    Refer to text for grease capacity of CV joints and CV joint boots. Wheel Nuts: 120 ft-lbs (163 Nm) 7.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 329: Outer Cv Joint / Boot Replacement

    3. Clean the grease from the face of the joint. 7.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 330 11. Install a new circlip on the end of the shaft. 7.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 331: Inner Plunging Joint / Boot Replacement

    3. Clean the grease from the face of the joint and place the drive shaft in a soft-jawed vise. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 332 11. Install a new circlip on the end of the shaft. 7.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 333 Make sure the boot is not dimpled or collapsed. CV Boot Clamp Pliers: 8700226 7.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 334: Drive Shaft Assembly View

    FINAL DRIVE Drive Shaft Assembly View 7.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 335: Front Propshaft Service

    Roll Pin Removal Tool: PN 2872608 NOTE: Right front wheel can be removed to gain better access to the propshaft roll pin. 7.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 336: Front Prop Shaft Installation

    3. While moving the prop shaft support bearing assembly, slide the front prop shaft off the rear prop shaft and remove it from the vehicle. 7.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 337: Rear Prop Shaft Installation

    NOTE: Paint marks are applied to the front and rear prop shafts shaft alignment. Reference these marks during installation if still visible. 7.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 338: Rear Prop Shaft Removal Xp 4

    6. Move the prop shaft support bearing assembly to the drivers side to slide the rear prop shaft yoke off the transmission output shaft. 7.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 339: Rear Prop Shaft Installation

    5. Torque the support bearing fasteners to specification. Support Bearing Fasteners: 35 ft-lb (47 Nm) 7.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 340: Support Bearing Replacement

    NOTE: Do not attempt to separate the bearing from the rubber isolated support assembly upon installation. 7.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 341: 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. 7.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 342 Cover Screws, M6 (T30 Torx) Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic 7.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 343: All Wheel Drive Operation

    Torsion Spring Operation: The torsion spring acts as a return mechanism to help disengage the coupling of 7.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 344: Awd Diagnosis

    3. If electrical tests are within specification, remove gearcase (see Chapter 7 – Front Gearcase Removal, page 7.33) and inspect components. 7.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 345: Front Gearcase Removal

    Lift and remove the gearcase from the front LH wheel well area and slide it out of the vehicle above the upper A-arm. 7.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 346: Front Gearcase Disassembly / Inspection

    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. 7.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 347 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. 7.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 348 13. Inspect clutch housing / ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 7.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 349: Front Gearcase Assembly

    6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 4. Install the RH output hub into the gearcase housing. 7.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 350 NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 7.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 351: Front Gearcase Installation

    Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 5. Install the vent line Cover Plate Screws: 11 ft-lbs (15 Nm) 7.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 352 (PN 2877922) (Quart) Capacity: 8.5 oz. (250 ml) (fill on a level surface to bottom of threads on the fill hole) 7.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 353: Wheel Hubs

    FINAL DRIVE WHEEL HUBS Front Hub Assembly View Rear Hub Assembly View 7.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 354: Beadlock Rims (Desert Edition)

    NOTE: Beadlock bolts should be checked and retorqued every 300 miles (450 km). 7. Seat bead and inflate to 16 psi. 7.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 355 WALKER EVANS™ SHOCK SERVICE ..............8.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual...
  • Page 356 ............. . .8.39 WALKER EVANS™ SHOCK ASSEMBLY 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 357: General Information

    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 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 358 Mount Bracket Bolts Lower Steering Shaft to 42 ft-lb (57 Nm) Steering Rack Power Steering Bracket to 16 ft-lb (22 Nm) Frame Nuts 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 359: Steering Assembly

    STEERING / SUSPENSION STEERING ASSEMBLY Assembly View (Non-EPS Models) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 360: Steering Wheel Removal (Non-Eps Models)

    5. Refer to steps 11-13 of the Steering Shaft Bearing Replacement, page 8.7 procedure for installation. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 361: Steering Shaft Bearing Replacement

    Bushing 7 ft-lb (10 Nm) Bushing Bushing Bushing Be sure the lower washers and spacers are still on the steering shaft. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 362 15. Wipe the pivot tube clean of any excess Loctite ® 16. Install steering wheel cap and field test steering operation. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 363: Electronic Power Steering Assembly

    Tie Rod End Bolt (Do not reuse) EPS Module EPS Mount Bracket Nut, Nylok (Do not reuse) Lower Steering Shaft EPS Cover 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 364 3. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. 8.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 365: Steering Wheel Removal (Eps Models)

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 8.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 366 WARNING Electronic Power Steering (EPS) units are programmed to be vehicle specific and are not interchangeable between product lines. 8.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 367: Lower Steering Shaft Removal (Eps Models)

    . 5. Lift up on the shaft and remove it through the floor panel. 8.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 368: Power Steering Unit Installation

    Torque to specification. Lower Steering Shaft to EPS Unit Pinch Bolt: 15 ft-lbs (20 Nm) 8.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 369: Upper Steering Shaft Installation (Eps Models)

    8 ft-lb (11 Nm) 3. Install the tilt shock and torque fastener to specification. Tilt Shock Fastener: 7 ft-lb (10 Nm) 8.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 370: Front A-Arms

    A-arm. Completely remove the ball joint end from the bearing carrier. 5. Remove the front bumper to allow A-arm bolt removal. 8.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 371 Lower A-arm Bolts: 44 ft-lb (60 Nm) Front Ball Joint Pinch Bolts: 42 ft-lbs (57 Nm) 8.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 372 STEERING / SUSPENSION 8.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 373: Ball Joint Service

    9. Remove and discard the lower ball joint pinch bolt. 10. Remove both A-arm to frame mounting bolts and remove the A-arm from the chassis. 8.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 374: Ball Joint Installation

    Front Shock Mounting Bolts: 44 ft-lb (60 Nm) Front Caliper Mounting Bolts: 40 ft-lbs (54 Nm) Wheel Nuts (Alum): 120 ft-lbs (163 Nm) 8.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 375: Rear Radius Rods

    5. Remove bolts & attaching radius rods to the vehicle frame. Discard the nuts. 6. Remove radius rods from vehicle. 8.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 376: Rear Trailing Arm

    Swing radius rod down. Discard the nut. 5. Remove the two brake caliper mounting bolts 8.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 377 Rear Brake Caliper Mounting Bolts: 40 ft-lbs (54 Nm) Rear Wheel Hub Castle Nut: 110 ft-lbs (149 Nm) Wheel Nuts: 120 ft-lbs (163 Nm) 8.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 378: Trailing Arm Spherical Bearing Replacement

    7. Press in new bearing until fully seated into trailing arm casting. 8. Install new snap ring, O-rings (not required) and bushings. 8.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 379: Rear Suspension Assembly View

    Rear Suspension Assembly View Radius Rod Trailing Arm Spherical Bearing Bushing Shock Spring Bearing Carrier Stabilizer Bar Stabilizer Bar Link 8.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 380: Rear Stabilizer Bar

    (if replacing stabilizer bar). 9. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 8.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 381: Shocks / Springs / Fasteners

    STEERING / SUSPENSION SHOCKS / SPRINGS / FASTENERS Front Shock Assembly View Rear Shock Assembly View 8.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 382: Shock Removal / Installation

    44 ft-lb (60 Nm) 6. Reinstall the shock onto the vehicle and torque new Rear: fasteners to specification. 70 ft-lbs (95 Nm) 8.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 383: Walker Evans™Shock Assembly Views

    Piston Wear Band (1.750" OD) 36. Clicker Bolt Shaft, Chrome Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 8.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 384: Walker Evans™ 2.5" Rear Shock

    Wear Band Ball (.250") O-Ring O-Ring Retention Nut Screw Screw 9/16 Heim Shaftloop O-Ring Snap Ring Shock Body Needle O-Ring Hose 8.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 385: Walker Evans™ Shock Service

    IFP Location RZR XP 4 3.375″ (85.7 mm) 1000 / High Lifter IFP Location RZR XP 2.875” (73.02 mm) 1000 / Desert Edition 8.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 386 0.750 x 0.065 0.900 x 0.008 1.45 x 0.015 0.625 x 0.065 Piston Bleed Orifice: none 1.45 x 0.015 1.45 x 0.008 8.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 387: Rear Shock Service Information

    STEERING / SUSPENSION Rear Shock Service Information 8.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 388 0.75 x 0.065 1.10 x 0.012 (top-out) 0.900 x 0.012 0.800 x 0.012 1.50 x 0.125 (top-out) No Piston Bleed Orifice 8.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 389 0.750 x 0.065 1.20 x 0.010 (top-out) 1.10 x 0.012 0.900 x 0.012 0.800 x 0.012 1.50 x 0.125 (top-out) 8.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 390: Special Tools

    Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 8.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 391 9. Slowly lift up and remove the shock rod assembly from the shock body. 7. Carefully remove the cap from the reservoir body. 8.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 392 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 8.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 393: Walker Evans™ Shock Assembly

    NOTE: If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 8.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 394 Tighten the valve stack fastener securely. Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 8.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 395 You will see the released air bubbles come to the surface of the oil. 8.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 396 If it does not, disassemble and reassemble per this procedure. 32. Secure the shock body in a vise by its lower mount. 8.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 397 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 8.43 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 398 STEERING / SUSPENSION NOTES 8.44 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 399 ..............9.31 PAD ASSEMBLY / INSTALLATION 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 400 ..................9.40 BRAKES LOCK 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 401: General Information

    Outboard - 0.250” (6.35 mm) 0.190" (4.83 mm) Park Brake Disc Thickness 0.175” - 0.185” (4.44 - 4.70 mm) 0.150" (3.81 mm) 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 402: Torque Specifications

    • Perform a brake burnishing procedure after installing new pads to maximize service life. • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 403: Brake Noise Troubleshooting

    Inspect and repair as necessary HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.

  • Page 404: Brake System Assembly View

    BRAKE SYSTEM BRAKE SYSTEM Brake System Assembly View 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 405: Master Cylinder

    2. Remove the clip from the clevis pin that attaches the master cylinder to the brake pedal lever. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 406: Master Cylinder Installation

    Be sure the hose fits tightly on fitting. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 407 10. Add brake fluid to MAX level inside reservoir. Master Cylinder Fluid Level Between MIN and MAX lines on reservoir. 11. Install master cylinder reservoir cover. 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 408: Brake Pedal Lever

    2. Remove the E-clip from the pedal mount and 0.090″ (2.28 mm) remove the brake pedal lever from the vehicle. 9.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 409: Parking Brake (Int'l Model)

    BRAKE SYSTEM PARKING BRAKE (INT’L MODEL) Parking Brake Assembly View 9.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 410: Parking Brake Inspection

    4. Adjust the parking brake cable where it attaches to the caliper mount / shift cable bracket. The mount bracket is located on the right-hand side of the transmission. 9.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 411: Parking Brake Caliper

    BRAKE SYSTEM Parking Brake Caliper 9.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 412 Caliper Disassembly / Inspection NOTE: Refer to the “Electronic Parts Catalog” for parking brake caliper replacement parts information. 9.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 413 37 ft-lb (50 Nm) 5. Ensure the parking brake assembly functions properly by actuating the lever. Install the mounting sleeves (D) before installation. 9.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 414: Parking Brake Disc

    4. Install the new brake disc. Install the mounting bolt and flat washer. Torque the mounting bolt to specification. Parking Brake Disc Mounting Bolt: 14 ft-lb (20 Nm) 9.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 415 BRAKE SYSTEM 9.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 416 BRAKE SYSTEM 9.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 417: Front Brake Pads

    Support caliper to avoid kinking or bending brake line. 7. Remove the inner pad from the bracket and caliper. 9.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 418: Pad Inspection

    0.297 ± 0.007" (7.5 ± .178 mm) Service Limit: 0.180" (4.6 mm) Front Caliper Mount Bolt: 40 ft-lbs (54 Nm) 9.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 419: Brake Burnishing Procedure

    Up to MAX line inside reservoir 7. Install wheel and torque wheel nuts to specification. Wheel Nuts: 120 ft-lbs (163 Nm) 9.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 420: Front Caliper Service

    BRAKE SYSTEM FRONT CALIPER SERVICE Caliper Assembly View 9.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 421: Caliper Removal

    5. Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 9.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 422: Caliper Disassembly

    NOTE: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 423: Caliper Inspection

    Front Caliper Piston O.D.: Std: 1.370” (34.80 mm) Service Limit: 1.368” (34.75 mm) 9.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 424: Caliper Installation

    NOTE: If new pads are installed, refer to Brake Burnishing Procedure, page 9.21. Banjo Bolt 15 ft-lbs (20 Nm) 9.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 425: Front Brake Disc

    Brake Disc Thickness Variance Service Limit: 0.002″ (.051 mm) difference between measurements Brake Disc Runout: Service Limit: 0.010″ (0.254 mm) 9.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 426: Disc Replacement

    5. Install new bolts and torque to specification. Brake Disc Mounting Bolts 30 ft-lb (41 Nm) 9.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 427: Rear Brake Pads

    Remove excess fluid from reservoir as required. 9.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 428: Pad Inspection

    8. Remove the inner brake pad. Rear Brake Pad Thickness: 0.298 ± 0.007″ (7.57 mm ± .178 mm) Service Limit: 0.180″ (4.6 mm) 9.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 429: Pad Assembly / Installation

    8. Install wheel and torque wheel nuts to specification. Wheel Nuts: 120 ft-lbs (163 Nm) Rear Caliper Mount Bolt 40 ft-lbs (54 Nm) 9.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 430: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 431: Rear Caliper Service

    BRAKE SYSTEM REAR CALIPER SERVICE Caliper Assembly View 9.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 432: Caliper Removal

    Discard nut. 5. Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 433: Caliper Disassembly

    Measure diameter and replace if damaged or worn beyond service limit. Rear Caliper Piston O.D.: Standard: 1.500″ (38.10 mm) Service Limit: 1.498″ (38.05 mm) 9.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 434: Caliper Assembly

    Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. 9.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 435 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. 9.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 436: Rear Brake Disc

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. Brake Disc Mounting Bolts: 30 ft-lb (41 Nm) 9.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 437 Inspect for fluid leaks and firm brakes. Make sure brakes do not drag when pedal is released. If the brakes drag, re-check assembly and installation. 9.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 438: Troubleshooting

    • Operator riding brakes Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 439 ............... . 10.27 DECAL REPLACEMENT 10.1 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 440: General Information

    Seat Base to Frame (Front 14 ft-lb (19 Nm) Bolts) Seat Base to Frame (Rear 30 ft-lb (41 Nm) Bolts) 10.2 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 441: Body Assembly Views

    5. Install deflector on front ROPS with M10 x 1.25 x 20 bolts. Torque bolts to 8 ft-lb (11 Nm) 10.3 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 442: Cab Frame Assembly Xp 4

    8. Install visor panel on front ROPS with M10 x 1.25 x 20 bolts. Torque to 8 ft-lb (11 Nm) 10.4 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 443: Doors

    BODY / FRAME Doors XP Hinge Pin Door Panel Door Frame Latch Release Latch Striker Latch 10.5 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 444: Doors

    Doors XP 4 Door Panel Latch Release Door Frame Latch Door panel (Rear) Latch Striker Hinge Pin Door Frame (Rear) 10.6 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 445: Doors High Lifter

    Upper Door Frame Latch Striker Screws (8 ft-lbs, 11 Nm) Lower Door Frame Hinge Screws (8 ft-lbs, 11 Nm) Hinge Pin 10.7 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 446: Dash Instruments / Controls

    BODY / FRAME Dash Instruments / Controls Headlight Switch Instrument Cluster Key Switch AWD Switch 12V Accessory Port Bezel 10.8 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 447: Dash Instruments / Controls High Lifter

    Dash Instruments / Controls High Lifter Instrument Cluster AWD Switch Key Switch Winch Switch 12V Accessory Port Bezel Headlight Switch 10.9 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 448: Hood / Front Body Work

    Right Front Fender Grill Right Front Fender Flair Front Bumper Cover Left Front Fender Radiator Shroud Left Front Fender Flair 10.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 449: Chassis / Main Frame Xp / High Lifter

    BODY / FRAME Chassis / Main Frame XP / High Lifter 10.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 450: Chassis / Main Frame Xp 4

    BODY / FRAME Chassis / Main Frame XP 4 10.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 451: Seat Assembly Front

    Spring Screw 4 ft-lb (5 Nm) Seat Slider Lever Shoulder Bolt Seat Bottom Spring Lock Washer Seat Back Flat Washer 10.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 452: Seat Assembly Rear

    Screw 4 ft-lb (5 Nm) Seat Base Assembly Bolt Seat Latch Lever Seat Bottom Spring Seat Latch Seat Back Plate Seat Latch 10.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 453: Floor / Rocker Panels Xp / High Lifter

    T27 Screws Push Rivots LH Rocker Console Cover U-Type Nuts Seat Belt Boot Block Off Flap Shifter Boot Lower Floor 10.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 454: Floor / Rocker Panels Xp 4

    Console Rear Main Floor Lower Lower Rear Close-off Panel Upper Rear Close-off Panel Rocker RH B-Pillar Cover RH Floor Rear 10.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 455: Rear Cargo Box / Fenders

    BODY / FRAME Rear Cargo Box / Fenders 10.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 456: Rear Bumper

    BODY / FRAME Rear Bumper 10.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 457: Body Component Removal

    • Remove the driver and passenger seats 2. Lift the panel upward and towards the front of the vehicle to remove the panel 10.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 458: Rear Bumper

    7. Remove the two T-40 Torx screws retaining the dash and the one T-40 retaining the back of the dash to the bracket.. 10.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 459: Rear Fender / Fender Flare Removal Xp / High Lifter

    Refer to appropriate Cab Frame Assembly XP / High Lifter, page 10.3 procedure for assembly torque specifications. 13. Remove the front fender. 10.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 460: Rear Fender Flare / Rear Fender Removal Xp

    6. Remove the eight fasteners retaining the rear cab frame to the frame and to the front cab frame. Remove the rear cab frame from the vehicle. 10.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 461: Rocker Panels, Console And Floor Xp / High Lifter

    10. Remove the cargo box half from the vehicle. 10.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 462: Rocker Panels, Rear Console And Floor Xp

    Console and Lower Floor Removal 1. Remove seats and rocker panels (see Chapter 10 – Floor / Rocker Panels XP 4, page 10.16). 10.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 463 11. Remove two Torx T40 screws and four push rivets retaining the lower rear close off panel. 5. Remove the rear console. 10.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 464 Remove front seat base assembly. 14. Remove four Torx T40 screws retaining the rear floor and remove the rear floor. 10.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 465: Decal Replacement

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 10.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 466 BODY / FRAME NOTES 10.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 467 ..............11.26 ECT SENSOR REPLACEMENT 11.1 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 468 ................11.52 CHARGING SYSTEM 11.2 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 469: General Information

    13 ft-lb (18 Nm) • Headlamp Switch • 12 Vdc Accessory Power Point • Ignition Switch • LED Ambiance Light 11.3 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 470: Instrument Cluster

    NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 11.4 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 471 Hours Indicator - Illuminates when Hours are being displayed on the Information Display Mode Button - Used to move through the menu features. 11.5 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 472: Rider Information Display

    TURF position (INT’L Model Only). 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 11.6 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 473: Information Display Area

    1. Toggle the MODE button to TRIP 1. Engine hours are logged anytime the engine is running. Total hours can not be reset. 11.7 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 474 (Standard 12-hour / Metric-24 hour). To set the clock, follow these steps: 7. Toggle the MODE button until the odometer is displayed. 11.8 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 475 When the park brake is fully engaged, “BRAKE” appears in the rider information display. Engine speed is limited to 1500 RPM in all gears, except 11.9 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 476: Diagnostic Mode

    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. 11.10 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 477 NOTE: If there is a diagnostic problem with the power steering system, the power steering MIL will illuminate and blink in place of the check engine MIL. 11.11 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 478: Instrument Cluster Removal

    Only remove the rubber mount if instrument cluster. necessary. The bezel is a snap-on assembly and is a serviceable part. 11.12 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 479: Switches

    4. For switch replacement, refer to Chapter 9 “Brakes”. NOTE: Pins 7 and 8 provide power and ground to light the switch lamp. 11.13 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 480: Ignition (Key) Switch

    • Turn the ignition key to START. There should be should be no continuity between any pins. continuity between switch pins A and B; C and D. 11.14 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 481: Transmission (Gear Position) Switch

    WHEN MEASURED AT POSITION SWITCH TERMINALS A AND B HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 11.15 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 482: Seat Belt Switch

    2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT DISENGAGED ENGAGED Measure between both ∞ (OL) < 1 Ω pins on switch 11.16 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 483: All Wheel Drive Coil

    80% of all electrical issues are caused by bad/failed connections and grounds. 11.17 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 484: Vehicle Speed Sensor

    4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 11.18 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 485: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 11.19 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 486: Ignition Coil Tests

    7.0 k Ω ± 5% (PTO) Lead Caps Secondary Between High Tension 7.4 k Ω ± 5% (MAG) Lead Caps Primary Test Secondary Test 11.20 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 487: Lighting System

    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. 11.21 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 488: Headlamp Replacement

    (see Chapter 10 – Front Bumper XP, page 10.19). 11.22 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 489: Headlamp Installation

    6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlight Adjustment” procedure as shown in this chapter. 11.23 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 490: Dash Light

    Dash Light The LED light will remain ON for approximately 30 seconds after key has been switched to the OFF position. 11.24 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 491: Cooling System

    11.25 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 492: Ect Sensor Test

    243 Ω ± 6% system (see Chapter 3 – Cooling System Bleeding Procedure, page 3.18). 212 °F (100 °C) 186 Ω ± 6% 11.26 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 493: Fuse / Relay Box

    20-amp circuit breaker protects the fan motor circuit. Two separate relays located under the dash operate the headlights and the “flash to pass” function on INT’L models. 11.27 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 494: Fuse Box Detail

    ELECTRICAL Fuse Box Detail 11.28 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 495: Relay Operation

    Provides 12 Vdc power for EFI Red / Dark Blue system circuits. FAN RELAY provides power to the following system: • Fan Motor 11.29 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 496 Yellow in order to operate high beam headlights momentarily. “Normally closed” relay output to Dark Green operate low-beam headlights. 11.30 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 497: Charging System

    5. With lights and other electrical loads off, the “break even” point should occur at approximately 1500 RPM or lower. 11.31 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 498: Charging System Stator (Alternator) Tests

    2. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 11.32 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 499: Stator (Alternator) Replacement

    It is mounted under the LH panel divider. 11.33 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 500: 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. 11.34 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 501: Battery

    Circuit Voltage Test, page 11.36). 5. Charge the battery as recommended (see Chapter 11 – Charging Procedure , page 11.37). 11.35 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 502: Battery Removal / Installation

    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. 11.36 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 503: Load Test

    Polaris MDX-610P Bosch PN: PU-50296 11.37 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 504: Starting System

    • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 11.38 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 505: Starter Motor Removal

    NOTE: The (-) negative battery cable is mounted to the engine using the upper starter mounting bolt / stud. 6. Remove the starter from the engine. 11.39 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 506: Starter Solenoid Bench Test

    “ELECTRICAL SYSTEM BREAOUTS: Starter-Interlock” provided in this chapter for starter solenoid operation. Condition: Starter fails to turn over the engine. 11.40 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 507: Electronic Power Steering (Eps)

    Engine Controller, but not the Power Steering Controller, while using Digital Wrench®. NOTE: DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS. 11.41 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 508: Eps System Breakout

    ELECTRICAL EPS System Breakout 11.42 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 509: Eps Troubleshooting (Power Steering Non-Functional With Mil On)

    ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL ON) 11.43 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 510: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 11.44 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 511: Eps Troubleshooting (Using Digital Wrench®)

    ELECTRICAL EPS Troubleshooting (Using Digital Wrench®) 11.45 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 512: Electrical System Breakout Diagrams

    ELECTRICAL ELECTRICAL SYSTEM BREAKOUT DIAGRAMS 11.46 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 513: Vehicle Speed Sensor

    ELECTRICAL Vehicle Speed Sensor 11.47 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 514: Cooling System

    ELECTRICAL Cooling System 11.48 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 515: Unswitched Chassis Power

    ELECTRICAL Unswitched Chassis Power 11.49 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 516: Key-On Battery Power

    ELECTRICAL Key-On Battery Power 11.50 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 517: Lights

    ELECTRICAL Lights 11.51 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.

  • Page 518: Charging System

    ELECTRICAL Charging System 11.52 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 519 Assembly View ..........3.17 Rear..............9.29 Bleeding Procedure..........3.18 Removal (Front) ..........9.19 Coolant Strength and Type........2.26 Brake Pedal Hoses..............2.27 IX.1 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 520 Connecting Rod Bearing Selection ...... 3.63 Assembly............5.25 Cooling System Troubleshooting ......3.90 Assembly View ..........5.17 Crankcase Assembly.......... 3.71 IX.2 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 521 Fan Control Circuit Bypass Test ......11.25 Removal............10.20 Fan Control Circuit Operation ....... 11.25 Hood / Front Body..........10.10 Final Drive IX.3 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 522 Model Number Designation ........1.2 Radiator Removal / Installation ......... 3.14 Radiator Inspection / Cleaning ........ 2.28 Valve Clearance Adjustment ....... 3.84 IX.4 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 523 Seat Belt............11.16 Brakes..............9.3 Switches Clutching ............. 5.2 AWD/2WD ............11.14 EFI..............4.3 Gear Position ........... 11.15 Electrical ............11.3 IX.5 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
  • Page 524 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 IX.6 9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual © Copyright 2014 Polaris Industries Inc.
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