Polaris RZR XP 1000 2017 Service Manual page 135

17. Install front support bracket
onto the vehicle frame.
specification.
18. Install push rivet through heat shield
cross member.
19. Install the exhaust heat shield and push rivets.
20. Replace exhaust gaskets (seals). Install exhaust
head pipe. Install the six fasteners that attach the
exhaust head pipe to the engine and torque to
specification.
TORQUE
Exhaust Head Pipe Bolts:
18 ft-lb (24 Nm)
21. Install the two exhaust springs that attach the head
pipe to the muffler.
22. Install the breather hose to the crankcase.
23. Install the spark plug wires to the appropriate cylinder
by referencing the MAG and PTO spark plug wire
decals.
NOTE
Ensure plug wires caps are pushed down all the way so
they engage onto the spark plugs.
24. Install the throttle body assembly and connect fuel
lines. Install throttle cable retaining clip.
25. Secure wire harness in the routing clip on the rear
cross member.
26. Install (+) positive cable to the starter motor.
27. Install (-) negative cable to the starter motor mounting
bolt.
9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual
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and rear support 28. Properly route and connect the harness leads for the
Torque fasteners to
29. Install the air box assembly as outlined in the EFI
30. Install the inner clutch cover, drive clutch, driven
31. Install the left rear shock lower mounting bolt and new
32. Install the left rear wheel and torque wheel nuts to
o
into rear
33. Install the rear bumper and cargo box as an
34. Connect the (-) negative battery cable.
35. Remove the pressure cap and fill the cooling system
36. Install a new oil filter. Lubricate the seal with engine
37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4
38. Follow the Cooling System Bleeding Procedure, page
39. Install the seats.
40. Start engine and check for any oil or coolant leaks.
41. Turn the key OFF and check the engine oil level.
42. Refer customer to "Engine Break-In Period" upon
ENGINE / COOLING SYSTEM
stator, CPS, TMAP sensor, ECT sensor, fuel injectors
and ignition coil.
Chapter (See Chapter 4 – ETC Replacement, page
4.41).
clutch, drive belt, outer clutch cover and clutch outlet
duct (see Chapter 6 – PVT Assembly, page 5.11).
nut. Torque to specification.
TORQUE
Rear Shock Mounting Bolt:
70 ft-lbs (95 Nm)
specification.
TORQUE
Wheel Nuts:
120 ft-lbs (163 Nm)
assembly.
NOTE
Be sure to connect the engine intake hose and clutch
air intake hose to the rear cargo box asm upon
installation.
through the filler neck with properly mixed anti-freeze
/ coolant.
oil prior to installation (see Chapter 2 – Engine Oil
and Filter Change, page 2.30).
or PS-4 Extreme Duty Synthetic Engine Oil to the
engine. Additional oil may be required after complete
engine disassembly. Check level after filling and add
oil as needed.
3.15 as outlined in this chapter.
returning vehicle to customer.
3
3.29