Polaris RZR XP 1000 2014 Service Manual
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Polaris RZR XP 1000 2014 Service Manual

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Table of Contents

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2014-2016 RZR XP 1000 / 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 April 2016 (PN 9926816 R07)
© Copyright 2016 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 2014

  • Page 1 Publication Printed April 2016 (PN 9926816 R07) © Copyright 2016 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. REVISION INDEX DATE...
  • Page 5 2014-2016 RZR XP 1000 / XP4 1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM...

  • Page 7: Table Of Contents

    ................1.27 DECIMAL EQUIVALENTS 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 9: Vehicle Identification Number

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright 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 upright , behind the PVT cover.

  • Page 11: Reference 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright 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 8700226 9314177-A Roll Pin Removal Tool Combination Pliers Spanner Wrench / CV Boot Clamp Pliers Drive Clutch Holding (27″) Clutch Spreader (ear) Tool 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 PU-50566 PU-50578 PU-50624 Water Pump Seal Oil Pressure Gauge Transmission Nut Clutch Spider Nut Rolling Engine Stand Installer Adapter (1/2 NPT) Socket Socket 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 PV-48656 PW-47053 PW-47054 Fluke Multimeter Piston Ring Fuel Pressure Gauge Bench Mount Engine Engine Stand Adapter Compressor Pliers Adapter Stand Sleeve (2 3/8″) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 16: General Specifications

    Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.10 © Copyright Polaris Industries Inc.

  • Page 17: 2014-2016 Rzr Xp 1000 Clutch Chart

    20A EPS (if appl.) 0-1800 29-66 Black / white (0-6000) (5633496) Black / Red 2016 XP lettering (7044263) 1000 1800-3700 29-59 (7044506) (6000-12000) (5633319) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 18 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 29-68 20A EPS (if appl.) (0-6000) (5139618) Black / white 2016 XP4 lettering 26-59 1000 1800-3700 (7044506) bushed (6000 - 12000) (1322981) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.13 © Copyright Polaris Industries Inc.
  • Page 20 Hitch Tongue Capacity vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.14 © Copyright Polaris Industries Inc.

  • Page 21: 2015-2016 Rzr Xp 1000 High Lifter Clutch Chart

    200A Terminal Block – (found on lettering XP High 26-59 1800-3700 (7044506) Lifter wiring between battery and bushed (6000-12000) (1322981) terminal block) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.15 © Copyright Polaris Industries Inc.
  • Page 22 Hitch Tongue Capacity vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.16 © Copyright Polaris Industries Inc.
  • Page 23 1800-3700 (7043924) Lifter bushed (6000-12000) 20A EPS (if appl.) (1322981) 200A Terminal Block – (found on wiring between battery and terminal block) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.17 © Copyright Polaris Industries Inc.
  • Page 24 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: 2015 Rzr Xp 1000 Desert Edition Clutch Chart

    (1323176) (3234452) (7043924) 10A Drive Edition 10A Lights 20A EPS 200A Terminal Block – (found on wiring between battery and terminal block) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.19 © Copyright Polaris Industries Inc.
  • Page 26 Do not use this vehicle for towing. Do Hitch Tongue Capacity not modify the vehicle by adding a hitch. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.20 © Copyright Polaris Industries Inc.

  • Page 27: 2015 Rzr Xp 1000 Fox Clutch Chart

    Meters 2015 XP 10A Drive (Feet) (3234452) 1000 Orange / 10A Lights 1800-3700 26-59 Black 20A EPS (if appl.) (6000-12000) (1322981) (7044338) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 28: Misc. Specifications And Charts

    96 ft-lb (130 Nm) Hub Castle Nut (front and Drive Clutch Cover Plate 180 ft-lbs (244 Nm) 9 ft-lb (12 Nm) rear) Screw 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.22 © Copyright Polaris Industries Inc.
  • Page 29 Stabilizer Bar Locating Wheel Lug Nuts 120 ft-lbs (163 Nm) 10 ft-lb (14 Nm) Clamp Bolts Starter Mounting Bolts 7 ft-lb (10 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 30: Conversion Table

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.24 © Copyright Polaris Industries Inc.

  • Page 31: Standard Bolt Torque Specification

    177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.25 © Copyright Polaris Industries Inc.

  • Page 32: Sae Tap / Drill Sizes

    5/16–24 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.26 © Copyright Polaris Industries Inc.

  • Page 33: Decimal Equivalents

    15/32 0.4688″ 12 mm = 0.4724″ 31/32 0.9688″ 25 mm = 0.9843″ 31/64 0.4844″ 63/64 0.9844″ 0.500″ 13 mm = 0.5118″ 1.000″ 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.27 © Copyright Polaris Industries Inc.
  • Page 34 GENERAL INFORMATION NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 1.28 © Copyright Polaris Industries Inc.
  • Page 35 ................. . .2.25 TIRE INSPECTION 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 36 ................. . .2.42 SPARK PLUG SERVICE 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 37: Periodic Maintenance Chart

    Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or Maintenance intervals in the following chart are based death. Have an authorized Polaris dealer perform these upon average riding conditions and an average vehicle services.

  • Page 38: Maintenance Intervals

    Front / Rear Suspension 500 (800) Lubricate (if applicable) 50 H Inspect coolant strength seasonally; pressure test ■ Cooling System 500 (800) 50 H system yearly 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 39 ▶ 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 40: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant bottle * More often under severe use, such as operation in water or under severe loads. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 41 Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 42: Grease Lubrication Points

    Grease middle and rear Propshaft Yokes Polaris Premium U-Joint Grease fittings *There is no grease point on the upper control arm rear mount. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 43: Lubricants / Service Products

    Premium U-Joint Lube 2871551 14 oz cartridge (10 count) NOTE Each item can be purchased separately at your local Polaris dealer. PART NO. DESCRIPTION Additives / Sealants / Thread Locking Agents / Misc. Loctite® Threadlock 242 (6 ml.) (12 count)

  • Page 44: Engine

    Access the oil dipstick through the opening in front of the passenger rear tire. Access the oil fill cap through the cargo box access panel. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. FLUID CAPACITY Recommended Engine Oil: Capacity: 3.0 qt (2.8 L)

  • Page 45: Engine Oil And Filter Change

    TORQUE 5. Remove the seats and engine service panel to Engine Oil Drain Plug: access the oil filter. 12 ft-lbs (16 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.11 © Copyright Polaris Industries Inc.

  • Page 46: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.12 © Copyright Polaris Industries Inc.

  • Page 47: Engine Cylinder Leakdown Test

    Removal of left rear wheel or left rear shock is NOT necessary to perform this procedure. 5. Remove the spark plug wires to gain access to valve cover as shown below. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.13 © Copyright Polaris Industries Inc.
  • Page 48 15. Install the spark plug wires back into their correct location. 16. Install the push rivet that retains the heat shield to the frame cross member. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.14 © Copyright Polaris Industries Inc.
  • Page 49 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.15 © Copyright Polaris Industries Inc.

  • Page 50: Cooling System

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Antifreeze is premixed and ready to use. Do not dilute with water. With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle.

  • Page 51: Cooling System Pressure Test

    Replace if necessary. distilled water as required for freeze protection in your area. Recommended Coolant: Polaris 50/50 Extended Life Anti-freeze 2880514 (quart) 2880513 (gallon) 9. Reinstall the recovery bottle cap. 10. If coolant was required, start engine and check for leaks.

  • Page 52: Radiator Inspection / Cleaning

    MAX level. 8. Refer to Cooling System Bleeding Procedure, page 3.20. Recommended Coolant: Polaris 50/50 Extended Life Anti-freeze 2880514 (quart) 2880513 (gallon) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.18...

  • Page 53: Fuel System And Air Intake

    Never drain the fuel when the engine is hot. Severe burns may result. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.19 © Copyright Polaris Industries Inc.

  • Page 54: Fuel Pump / Fuel Filters

    Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.20 © Copyright Polaris Industries Inc.

  • Page 55: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.21 © Copyright Polaris Industries Inc.

  • Page 56: Air Filter Service

    2. Check the drain to ensure it is not plugged with debris so it can drain properly. If needed, remove the drain from the baffle box during inspection. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.22 © Copyright Polaris Industries Inc.

  • Page 57: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.23 © Copyright Polaris Industries Inc.

  • Page 58: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.24 © Copyright Polaris Industries Inc.

  • Page 59: Wheel Installation

    16 psi (110 kPa) 24 psi (165 kPa) Desert Edition CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.25 © Copyright Polaris Industries Inc.

  • Page 60: Beadlock Rims (Desert Edition)

    5. Install bolts and thread them to 24 in-lbs (3 Nm). 6. Tighten in a criss-cross pattern to 7 ft-lbs (10 Nm). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 61: Transmission And Front Gearcase

    2. Remove the fill plug and check the lubricant level. 8. Clean the drain plug magnetic surface. 9. Reinstall the drain plug and torque to specification. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 62: Front Gearcase Lubrication

    5. Remove the fill plug (see Chapter 2 – Front Gearcase Lubrication, page 2.28). 6. Place a drain pan under the front gearcase drain plug. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 63: Shift Cable Inspection / Adjustment

    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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 64: Steering

    WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.30...

  • Page 65: Tie Rod End / Wheel Hub Inspection

    Removal, page 7.4 and Rear Bearing Carrier Position chalk marks facing rearward, even with the Inspection / Removal, page 7.7 for wheel bearing hub/axle center line. service procedures. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 66: Wheel Toe Adjustment

    • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 67: Suspension

    Suspension springs may be adjusted to suit different riding conditions or vehicle payloads. NOTE Polaris does not recommend increasing the spring WARNING adjustment by more than one inch (25.4 mm) over the Uneven adjustment may cause poor handling of the...

  • Page 68: Shock Compression Adjustment (Walker Evans™)

    Firmest The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counter- clockwise will decrease damping. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 69: Spring Adjustment (Fox®)

    Shock Spanner / Clutch Spreader Tool: 2878925 NOTE DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 70: Shock Compression Adjustment (Fox®)

    Full clockwise position Firmest The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counter-clockwise will decrease damping. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.36 © Copyright Polaris Industries Inc.
  • Page 71 300 lbs (136 kg) Driver +1 6 clicks out 6 clicks out preload, front and rear * shaded cells are factory default settings 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 72: Brake System

    MEASUREMENT Brake Disc Thickness Service Limit: .170″ (4.32 mm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.38 © Copyright Polaris Industries Inc.

  • Page 73: Brake Hose And Fitting Inspection

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 74: Electrical And Ignition System

    “Charging Procedure”, page 11.25. Do not use the vehicle’s stator/alternator to charge a new battery. 5. Lift the battery out of the vehicle. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 75: Battery Installation

    TORQUE Battery Terminal Fasteners: 60 in-lbs (7 Nm) 6. Verify that cables are properly routed and reinstall the driver’s seat. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 76: Spark Plug Service

    Ensure wires are pushed down all the way so head to allow water to drain out. they engage onto the spark plugs. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.42 © Copyright Polaris Industries Inc.
  • Page 77 MAINTENANCE 13. Reinstall the cargo box access panel. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.43 © Copyright Polaris Industries Inc.
  • Page 78 MAINTENANCE NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 2.44 © Copyright Polaris Industries Inc.
  • Page 79 .................3.42 VALVE INSPECTION 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 80 ..................3.91 COOLING SYSTEM 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 81: General Information

    (Use With 2.375” Bore Stand) Oil Filter Flywheel Puller PA-49316 PN 2540086 Mity Vac™ Pressure Test Tool 2870975 Oil Pressure Minimum Specification (using Polaris Oil Filter Wrench PU-50105 engine oil at operating temperature) 10 PSI @ 1200 RPM Oil Pressure Gauge PV-43531...

  • Page 82: Oil Pressure Test

    Oil Pressure Gauge (PV-43531). NOTE Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.

  • Page 83: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 84: Engine Specifications (1000)

    .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 85 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 86: Main Engine Components - Torque Specification And Sequence

    ENGINE / COOLING SYSTEM MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 87: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

    ENGINE / COOLING SYSTEM BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 88: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 89: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 90: Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover

    ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 91: Intake / Exhaust System

    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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 92: Exhaust System Assembly View

    Exhaust Pipe Head Pipe Gasket Muffler / Silencer Head Pipe Bolts Muffler Isolator Mounts 18 ft-lb (24 Nm) Oxygen Sensor13 ft-lb (18 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 93: Engine Cooling System

    CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

  • Page 94: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 95: Thermostat Replacement

    Upper Radiator Hose To Radiator Fitting Lower Radiator Hose Fan Motor Assembly Recovery Bottle Radiator 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.17 © Copyright Polaris Industries Inc.
  • Page 96 Thermostat Cover Bolts: 7 ft-lb (10 Nm) 11. Be sure to properly fill and bleed cooling system as outlined in this chapter. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.18 © Copyright Polaris Industries Inc.

  • Page 97: Cooling System Assembly View

    Oil Cooler Outlet Hose Engine Hoses Pressure Cap Bypass Hose Lower Radiator Hose Upper Radiator Hose Water Pump Outlet Hose Fan Assembly Recovery Bottle 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.19 © Copyright Polaris Industries Inc.

  • Page 98: Cooling System Bleeding Procedure

    10. Remove the pressure cap. Add the necessary to the MAX line. amount of Polaris Premium Antifreeze to the radiator filler neck. 11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

  • Page 99: Water Pump Removal

    14. Plug the water pump drive access hole in the engine block with a clean shop towel. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 100 16. Install the hood, engine service panel and seats. NOTE Install different bolt lengths as shown. TORQUE Water Pump Mounting Bolts: 7 ft-lb (10 Nm)(Apply Loctite® 204™ to bolt threads) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.22 © Copyright Polaris Industries Inc.

  • Page 101: Water Pump Service

    13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 5. Remove impeller from water pump shaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.23 © Copyright Polaris Industries Inc.
  • Page 102 7 ft-lb (10 Nm)(Apply Loctite® 204™ to bolt threads) 18. Clean cover and housing gasket surfaces 19. Install a new water pump cover gasket 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 103 Water Pump Assembly View Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.25 © Copyright Polaris Industries Inc.

  • Page 104: Engine Service

    Serious injury may occur if vehicle tips or falls. 9. Remove lower mounting bolt from the left rear shock and discard the nut. Install a new nut upon assembly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 105 18. Remove the breather hose from the crankcase. NOTE Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.27 © Copyright Polaris Industries Inc.
  • Page 106 NOTE It is not necessary to remove the bolts that retain the bracket to the transmission. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 107 • Sleeve adapter for a 2″ bore engine stand: • (PU-50625) • Sleeve adapter for a 2.375″ bore engine stand: • (PW-47054) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.29 © Copyright Polaris Industries Inc.

  • Page 108: Engine Installation

    6. Align transmission joint mounting holes with the transmission front mounting holes. TORQUE Starter Motor Bolts: 7 ft-lb (10 Nm) Trans Joint Bracket Bolts: 44 ft-lb (60 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.30 © Copyright Polaris Industries Inc.
  • Page 109 9. Align the front transmission mounting holes with transmission joint bracket mounting holes on engine. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.31 © Copyright Polaris Industries Inc.
  • Page 110 26. Install (+) positive cable to the starter motor. TORQUE 27. Install (-) negative cable to the starter motor mounting bolt. Front Engine Mount Fasteners: 40 ft-lbs (54 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 111 (see Chapter 2 – Engine Oil and Filter Change, page 2.11). Rear Shock Mounting Bolt: 37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 70 ft-lbs (95 Nm) or PS-4 Extreme Duty Synthetic Engine Oil to the engine.

  • Page 112: Engine Mounting And Torque Values

    ENGINE / COOLING SYSTEM ENGINE MOUNTING AND TORQUE VALUES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.34 © Copyright Polaris Industries Inc.

  • Page 113: Engine Break-In Period

    Oil Type CAUTION PS-4 Full Synthetic 5W-50 2876244 (quart) Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic 2876245 (gallon) 4-Cycle Engine Oil.Never substitute or mix oil brands. (-35° F to 100° F) Serious engine damage and voiding of warranty can result.Do not operate at full throttle or high speeds for...

  • Page 114: Engine Disassembly / Inspection - Top End

    2. Remove the hydraulic cam chain tensioner from with shop towels to prevent anything from falling into the cylinder. Replace the sealing washer upon the combustion chamber. reassembly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.36 © Copyright Polaris Industries Inc.
  • Page 115 7. Lift the chain and sprockets off the camshafts to allow each sprocket to be removed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 116: Camshaft Sprocket Inspection

    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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.38 © Copyright Polaris Industries Inc.
  • Page 117 Calculated Camshaft Oil Clearance: .0000 - .0026" (0.001 - 0.067 mm) Service Limit: .0039" (0.1 mm) TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 118: Cylinder Head Removal

    DO NOT rotate the engine without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal, page 3.58. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.40 © Copyright Polaris Industries Inc.

  • Page 119: Cylinder Head Disassembly

    7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 120: Valve Inspection

    .2165 - .2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 121: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.43 © Copyright Polaris Industries Inc.

  • Page 122: Valve Seat Reconditioning (1000)

    1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.44 © Copyright Polaris Industries Inc.
  • Page 123 Look for an even and continuous contact Exhaust Seat Cutter Diameter: 1.364″ (34.65 mm) point all the way around the valve face 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.45 © Copyright Polaris Industries Inc.
  • Page 124 12. Thoroughly clean cylinder head and valves. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 125: Engine Disassembly / Inspection - Bottom End

    . If replacement is required, refer to the Electrical chapter. 4. Inspect the ball bearing that supports the starter motor shaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.47 © Copyright Polaris Industries Inc.

  • Page 126: Water Pump Housing Removal

    Water Pump Service, page 3.23. 2. Remove the three long gold colored bolts retaining the water pump housing to the engine. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 127: Flywheel Removal

    5. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel (left hand thread - turn flywheel puller counterclockwise to install). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 128: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.50 © Copyright Polaris Industries Inc.

  • Page 129: Crankcase Disassembly / Inspection

    The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 5. Rotate engine to access the crankcase sump cover. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.51 © Copyright Polaris Industries Inc.
  • Page 130 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 131: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 132: Crankshaft Removal / Inspection

    5. Carefully lift the crankshaft out of the crankcase. 6. Remove the cam chain , oil pump drive chain and PTO main seal from the crankshaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.54 © Copyright Polaris Industries Inc.
  • Page 133 Less than .001″ (0.025 mm) 10. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 134: Crankcase Inspection

    Crankshaft Main Bearing Selection, page 3.64 and Connecting Rod Bearing Selection, page 3.64 procedures. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 135: Cylinder Inspection

    2. Inspect cylinder for wear, scratches, or damage. NOTE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 136: Cylinder / Piston Removal

    (MAG / PTO). 4. Carefully lift the cylinder and pistons from the upper crankcase. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 137: Piston Disassembly / Inspection (1000)

    DO NOT apply heat to piston rings or a loss of radial tension could result. Piston Pin O.D.: .7873 - .7875" (20.000 - 20.005 mm) Service Limit: .7866" (19.98 mm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 138: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 139: Piston Ring Installed Gap (1000)

    Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.61 © Copyright Polaris Industries Inc.
  • Page 140 5. Install matching rod cap on connecting rod (without bearings) and install the bolts. 6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 141: Engine Assembly - Bottom End

    *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 142: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings Blue Blue Green Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 143: Upper Crankcase Preparation

    Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.65 © Copyright Polaris Industries Inc.
  • Page 144 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.66 © Copyright Polaris Industries Inc.

  • Page 145: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 146: Cylinder / Piston Installation

    NOTE Orientation arrow is also located on the bottom side of piston as an additional reference. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 147: Crankshaft Installation

    Press bearing insert firmly into place. is rotated. Repeat for the other connecting rod. 5. Install oil drain diverter into the upper crankcase. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.69 © Copyright Polaris Industries Inc.
  • Page 148 ENGINE / COOLING SYSTEM 6. Apply Polaris PS-4 engine oil to each rod bearing 11. Clean bolt hole threads in connecting rod to remove journal and main bearing journal of crankshaft. all oil. 12. Install matching rod cap on connecting rod with 3 digit serial number stampings aligned &...

  • Page 149: Balance Shaft Installation

    Press bearing insert firmly into place. LOWER CRANKCASE PREPARATION NOTE 3. Apply Polaris PS-4 engine oil to both balance shaft Always replace plain bearings when the crankcase or journals connecting rods have been disassembled. Refer to bearing selection procedures.

  • Page 150: Crankcase Assembly

    8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 3. Apply Polaris PS-4 engine oil to the new bearings installed in the lower crankcase half. 9. Install the eight M10 , two M8 and one M6 lower crankcase bolts.
  • Page 151 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.73 © Copyright Polaris Industries Inc.
  • Page 152 NOTE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.74 © Copyright Polaris Industries Inc.
  • Page 153 TORQUE Oil Cooler bolts: 7 ft-lbs (10 Nm) 27. Proceed to Flywheel Installation, page 3.76 and then Cylinder Head Installation, page 3.79. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 154: Starter One-Way Clutch Assembly

    Loctite cures with time, the longer the unit is let stand before engine starting the better the joint will be. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.76 © Copyright Polaris Industries Inc.

  • Page 155: Stator Cover Installation

    3. Install stator cover and thirteen screws. Torque screws in sequence to specification. TORQUE Stator Cover Screws: 9 ft-lb (12 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.77 © Copyright Polaris Industries Inc.

  • Page 156: Engine Assembly - Top End

    To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers. 9. Install split keepers with gap even on both sides. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 157: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.79 © Copyright Polaris Industries Inc.

  • Page 158: Camshaft Installation / Timing

    3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.80...
  • Page 159 (PU-50563) into the end of camshafts as shown. Use NOTE a 13/16” open-end wrench to rotate camshafts Use new sprocket retaining bolts upon assembly. slightly if needed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.81 © Copyright Polaris Industries Inc.
  • Page 160 18. Install the front camshaft carrier and two outer retaining bolts. 19. Install the fixed cam chain guide and two retaining bolts. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.82 © Copyright Polaris Industries Inc.
  • Page 161 Cam Chain Tensioner: 7 ft-lb (10 Nm) 29 ft-lb (40 Nm) 21. Apply Polaris PS-4 engine oil to the cam chain 23. Rotate crankshaft through two revolutions and verify tensioner bore prior to assembly. Use a new camshaft timing is correct.

  • Page 162: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.84 © Copyright Polaris Industries Inc.

  • Page 163: Valve Clearance Adjustment

    2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes should face out as shown.
  • Page 164 NOTE Lubricate the outer portion of the valve tappet upon installation. 15. Repeat steps 10-14 until all necessary valves have been adjusted. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.86 © Copyright Polaris Industries Inc.

  • Page 165: Intake Valve Lash - Tappet Selection Matrix

    0.926-0.950 520 522 525 528 530 532 535 538 540 542 545 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.87 © Copyright Polaris Industries Inc.

  • Page 166: Exhaust Valve Lash - Tappet Selection Matrix

    0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.88 © Copyright Polaris Industries Inc.

  • Page 167: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts to specification. TORQUE Spark Plugs: 7 ft-lbs (10 Nm) Valve Cover Bolts: 7 ft-lbs (10 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 168: Troubleshooting

    • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring • Lack of lubrication 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.90 © Copyright Polaris Industries Inc.
  • Page 169 Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.91 © Copyright Polaris Industries Inc.
  • Page 170 ENGINE / COOLING SYSTEM NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 3.92 © Copyright Polaris Industries Inc.
  • Page 171 ............... . .4.33 THROTTLE BODY SERVICE 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 172 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........

  • Page 173: General Information

    This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench® diagnostic software. This module kit is used on all 8 pin connector-based Polaris EFI systems. NOTE The EFI fuel system remains under high pressure, even when the engine is not running.

  • Page 174: Torque Specifications

    Fasteners Download Digital Wrench® Updates: NOTE For the most recent information on Digital Wrench® software and update downloads please visit the website: www.polaris.diagsys.com 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 175: Efi Overview

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 176: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 177: Efi System Component Locations

    Located between the air box assembly and rubber cylinder head adapters. • Crankshaft Position Sensor (CPS) Located on top of the stator cover. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 178: Principal Components

    Fuel pressure regulators located in the tank and on the end of the fuel 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 179: Initial Priming / Starting Procedure

    If the engine fails to start, a problem may still exist, and should be diagnosed. NOTE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 180: Electronic Control Unit (Ecu)

    Polaris RZR of the same model may be requirements for the immediate operating conditions. used without system or engine component damage. The ECU then sends output signals to set injector duration and ignition timing.

  • Page 181: Etc Learn Procedure

    3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 182: Fuel Injectors

    Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 183: Fuel Injector Test

    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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.13 © Copyright Polaris Industries Inc.
  • Page 184 5 mm Allen wrench. 11. Upon installation of the new fuel injectors, lightly lubricate the injector O-rings to aid installation. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 185 24. Position the intake hose onto the air box and tighten the hose clamp. 25. Reinstall the cargo box access panel. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 186: Fuel Tank

    Preliminary Filter PFA Nut Fuel Sender Float Arm Fuel Tank Vent PFA Gasket (replace if removed) Fuel Tank Assembly Fuel Pump / Regulator 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.16 © Copyright Polaris Industries Inc.

  • Page 187: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.17 © Copyright Polaris Industries Inc.
  • Page 188 . Remove the rear seat base assembly from the vehicle. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.18 © Copyright Polaris Industries Inc.
  • Page 189 T40 Torx driver. Remove the panel from the vehicle. 12. Remove the nuts retaining the regulator and Torx screws retaining the fuse box. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.19 © Copyright Polaris Industries Inc.

  • Page 190: Fuel Tank Installation

    10. Reinstall right rocker panel and all previously removed fasteners. 11. Reconnect the fuel line and fuel pump electrical harness. Verify connections are secure. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.20 © Copyright Polaris Industries Inc.

  • Page 191: Fuel Tank Removal Rzr Xp 4 1000

    Once removed, place the mechanism in the rear cargo box to keep it out of the way. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.21 © Copyright Polaris Industries Inc.
  • Page 192 11. Remove the nuts retaining the regulator and bolts retaining the fuse box. 12. Remove the fuel tank vent line from the tank fitting. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.22 © Copyright Polaris Industries Inc.

  • Page 193: Fuel Tank Installation Rzr Xp 4 1000

    11. Reconnect the fuel line and fuel pump electrical harness. Verify connections are secure. 12. Reinstall the battery and battery bracket. Torque fastener to specification. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.23 © Copyright Polaris Industries Inc.

  • Page 194: Fuel Pump

    • If the engine fails to start. • If the engine is stopped with the key switch "on" (as in the case of an accident). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 195: Fuel Pump Test

    Turn on the key switch and listen for the pump to activate. NOTE If the pump starts, repeat steps 3, 4 and 5 to verify correct pressure. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.25 © Copyright Polaris Industries Inc.

  • Page 196: Fuel Pump Replacement

    4. Ensure that static has been discharged by touching a ground source such as the engine or frame. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.26 © Copyright Polaris Industries Inc.
  • Page 197 Do not use water or any other chemicals to remove debris. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.27 © Copyright Polaris Industries Inc.
  • Page 198 Cycle the key several times to prime the system. 24. Install the passenger seat / storage box. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.28 © Copyright Polaris Industries Inc.
  • Page 199 FUEL SYSTEM 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.29 © Copyright Polaris Industries Inc.

  • Page 200: Temperature And Manifold Absolute Pressure Sensor (T-Map)

    ECU and compared to its programming for determining the fuel and ignition requirements during engine operation. The T-MAP provides the ECU with engine load data. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.30 © Copyright Polaris Industries Inc.

  • Page 201: Crankshaft Position Sensor (Cps)

    CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage. 5. If the resistance is incorrect, follow the CPS Replacement, page 4.32 procedure. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 202: 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. TORQUE CPS Retaining Bolt: 9 ft-lb (12 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.32 © Copyright Polaris Industries Inc.

  • Page 203: Electronic Throttle Control (Etc) / Throttle Body

    RPM ranges. The ETC controls engine RPM based off input provided by the Pedal Position Sensor (PPS) and Electronic Control Unit (ECU). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.33 © Copyright Polaris Industries Inc.

  • Page 204: Throttle Body Removal

    O-rings to aid installation. Torque the fuel rail mounting screws to specification. TORQUE Fuel Rail Mounting Screws: 44 in-lb (5 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.34 © Copyright Polaris Industries Inc.

  • Page 205: Etc Test

    No internal servicing or adjustments may be 7 ft-lb (10 Nm) performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Intake Boot Clamp: Service Department for specific handling instructions. Do 35 in-lb (4 Nm) not replace the ETC without factory authorization.

  • Page 206: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.36 © Copyright Polaris Industries Inc.
  • Page 207 7. Manually cycle the throttle pedal to verify the throttle pedal moves freely. 8. Connect the negative (-) battery cable and install the drivers seat. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.37 © Copyright Polaris Industries Inc.

  • Page 208: Oxygen Sensor (My15-16)

    3. Install new oxygen sensor. Torque sensor to specification. TORQUE Oxygen Sensor: 13 ft-lb (18 Nm) 4. Connect the harness going to the oxygen sensor. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.38 © Copyright Polaris Industries Inc.

  • Page 209: Efi Diagnostics

    • Confirm primary clutch operation (worn/incorrect weights, loose spider/jam nut) • Confirm secondary clutch operation (sliders, rollers, helix) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.39 © Copyright Polaris Industries Inc.
  • Page 210 5. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.40 © Copyright Polaris Industries Inc.
  • Page 211 P0113 Intake Air Temperature (T- Voltage Too Low P0112 MAP) Abnormal rate of Change P0114 Valid But Above Normal P0127 (least severe) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.41 © Copyright Polaris Industries Inc.
  • Page 212 Driver Circuit Short to B+ P0262 Injector 1 (MAG) Driver Circuit Grounded P1262 Driver Circuit Open P0261 Injector 2 (PTO) Driver Circuit Short to B+ P0265 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.42 © Copyright Polaris Industries Inc.
  • Page 213 P17AE Voltage Too High P17AA ECU Output Supply Voltage 3 3599 Voltage Too Low P17AB Valid But Above Normal P17AD (least severe) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.43 © Copyright Polaris Industries Inc.
  • Page 214 Bad Intelligent Device C1070 EPS Software Error 520229 Condition Exists C106F IC CAN Communication with EPS Off Line (EPS DM1 not seen) 520230 U0131 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.44 © Copyright Polaris Industries Inc.
  • Page 215 Throttle Body Control - Mechanical Stop Adaptation Condition Exists 520281 P152A Failure Throttle Body Control - Condition Exists 520282 P152B Repeated Adaptation Failed 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.45 © Copyright Polaris Industries Inc.
  • Page 216 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.46 © Copyright Polaris Industries Inc.

  • Page 217: Efi Troubleshooting

    • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.47 © Copyright Polaris Industries Inc.

  • Page 218: Polaris Digital Wrench

    Refer to Section 2, 3 and 4 in the Instruction Manual • Perform output state control tests (some models) provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the...

  • Page 219: Digital Wrench Software Version And Update

    4. The Digital Wrench® portal website should appear in a new web browser. 5. Click on “Digital Wrench Version Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. NOTE You must already have the current version installed before adding an update.

  • Page 220: Digital Wrench® Communication Errors

    Digital Wrench® related problem, visit the Digital Wrench® Knowledge Base for the most current troubleshooting information, FAQs, downloads and software updates at: http://polaris.diagsys.com/. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.50 © Copyright Polaris Industries Inc.

  • Page 221: Guided Diagnostics

    Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.51 © Copyright Polaris Industries Inc.

  • Page 222: Digital Wrench® Feature Map

    Perform specialized testing and Run the Help System. adjustment functions service reports. Prints the current screen as a Open the ASSERT ASK form. formatted printout. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.52 © Copyright Polaris Industries Inc.

  • Page 223: Ecu Replacement

    ECU. • Proceed to http://polaris.diagsys.com for specific The Digital Wrench® Engine Controller Reprogramming information and FAQs on how to troubleshoot (or “Reflash”) feature allows reprogramming of the ECU communication problems.
  • Page 224 6. Select “Engine Controller Reprogramming”. 9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop- down menu. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.54 © Copyright Polaris Industries Inc.
  • Page 225 12. An “Authorization Key” will appear in the upper left corner of the screen. Copy this key exactly as it appears. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 4.55 © Copyright Polaris Industries Inc.

  • Page 226: Polaris Mobile Digital Wrench (Pmdw)

    (PMDW) • An electronic user’s guide is provided within the app. Polaris Mobile Digital Wrench (PMDW) is a diagnostic To access the user’s guide, launch the app, and then software application (app) designed specifically for click on the “Help” button in the Settings/Preferences Android™...
  • Page 227 ..............5.30 DRIVEN CLUTCH DISASSEMBLY 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 228 ..................5.43 TROUBLESHOOTING 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 229: General Information

    SPECIAL SUPPLIES PART Driven Clutch Helix NUMBER 48 in-lb (5 Nm) Retaining Screws Loctite® 620™ 648™ and 7088™ Primer RTV Silicone Sealer 8560054 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 230 CLUTCH CHART SHIFT DRIVE DRIVEN MODEL ALTITUDE WEIGHT SPRING SPRING White / 2015 Meters 0-1800 26-63 Orange Desert (Feet) (0-6000) (1323176) (3234452) (7043924) Edition 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 231: Pvt System Overview

    The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage.

  • Page 232: Driven Clutch Operation

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 233: Pvt Overheating / Diagnosis

    PVT system. position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty Poor engine performance.

  • Page 234: Pvt System Service

    COVER ASSEMBLY, OUTER NUT, NYLOK O-RING BRACKET, BELT SCREEN DRAIN PLUG, COVER HOSE, AIR OUTLET SEAL, COVER INTAKE BOOT SCREW SEAL, COVER COVER ASSEMBLY 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 235 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 236: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 237: Pvt Disassembly (2014-2015)

    This will damage the clutch. 10. Install the Drive Clutch Holding Tool on the drive clutch. Drive Clutch Holding Tool: 9314177-A 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 238: Pvt Assembly (2016)

    15. Remove the seven bolts that retain inner clutch cover to engine and transmission. Remove inner clutch cover. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.12 © Copyright Polaris Industries Inc.
  • Page 239 Rear Shock Mounting Bolt: 13. Install the drive clutch onto the engine. 70 ft-lbs (95 Nm) TORQUE Wheel Nuts: 120 ft-lbs (163 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.13 © Copyright Polaris Industries Inc.
  • Page 240 PVT inlet and outlet ducts to the clutch cover. Disengage the hoses from the clutch cover and remove the outer cover from the vehicle. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.14 © Copyright Polaris Industries Inc.
  • Page 241 4. Apply silicone around all seven screw holes on the inner clutch cover. IMPORTANT DO NOT apply silicone on drive and driven shaft inner cover donuts. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.15 © Copyright Polaris Industries Inc.
  • Page 242 10. Install the driven clutch, washer and retaining bolt. TORQUE Torque to specification. Wheel Nuts: TORQUE 120 ft-lbs (163 Nm) Driven Clutch Retaining Bolt: 55 ft-lb (75 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 243: Drive Belt

    3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 244: Belt Inspection

    5. Install the outer clutch cover and eight screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws: 48 in-lb (5 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 245: Drive Clutch Service

    PVT SYSTEM DRIVE CLUTCH SERVICE DRIVE CLUTCH ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 246: Drive Clutch Disassembly / Inspection

    Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and Drive Clutch Spring Inspection remove cover plate. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 247: Needle Bearing Inspection

    Check to see that spring coils are parallel to one another using a straight-edge. Distortion of the spring indicates stress fatigue, requiring replacement. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.21 © Copyright Polaris Industries Inc.

  • Page 248: Shift Weight Inspection

    A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Drive Clutch Roller Pin and Button Service”. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 249: Spider Removal

    Rollers, pins, thrust washers and buttons are not using Clutch Spider Removal / Installation Tool serviceable at the time of this publication. Spider Removal / Installation Tool: 2870341 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.23 © Copyright Polaris Industries Inc.

  • Page 250: Clutch Inspection

    3. Lift bearing and thrust washers off the shaft. Replace as an assembly if worn, damaged, or if operational problems were noted prior disassembly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.24 © Copyright Polaris Industries Inc.

  • Page 251: Moveable Sheave Bushing Inspection

    /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.25 © Copyright Polaris Industries Inc.
  • Page 252 3. Remove nut from puller rod and set aside. 12. Place main adapter on puller. 4. Install puller adapter from kit PN 2871226. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.26 © Copyright Polaris Industries Inc.

  • Page 253: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.27 © Copyright Polaris Industries Inc.
  • Page 254 8. Tighten the spider jam nut using Clutch Spider Nut Socket . Torque jam nut to specification. Clutch Spider Nut Socket: PU-50578 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.28 © Copyright Polaris Industries Inc.
  • Page 255 10. Install the limiter spacer and the clutch spring CAUTION DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.29 © Copyright Polaris Industries Inc.

  • Page 256: Driven Clutch Service (2014-2015)

    X’s on the components for reference. This will aid in assembly and maintains clutch balance. Universal Clutch Compressor: PU-50518-A 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.30 © Copyright Polaris Industries Inc.
  • Page 257 Spring is compression only and has no torsional wind. 7. Remove the inside spider plate and spider dampener . Inspect the spider dampener for wear and replace if needed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.31 © Copyright Polaris Industries Inc.

  • Page 258: Driven Clutch Bushing Service

    (helix) assembly. 51325- Puller Nut 51320- Main Adapter 51320- Bushing Removal Tool 15. Inspect the sheaves for excessive wear or damage. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.32 © Copyright Polaris Industries Inc.

  • Page 259: Clutch Bushing Removal

    Piston Pin Puller: 2870386 3. Remove nut from piston pin puller rod and set aside. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.33 © Copyright Polaris Industries Inc.

  • Page 260: Clutch Bushing Installation

    4. Install sheave face down on puller. 5. Install new bushing on installation tool and install assembly into sheave. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.34 © Copyright Polaris Industries Inc.
  • Page 261 9. Install the spider dampener inside the spider and install the inside spider plate 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.35 © Copyright Polaris Industries Inc.
  • Page 262 Helix Retaining Screws: aligned. Once the spider passes the retaining ring 48 in-lb (5 Nm) notch on the shaft, install the retaining ring 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.36 © Copyright Polaris Industries Inc.

  • Page 263: Driven Clutch Assembly View

    Bearing Spider Insert Stationary Sheave Spider Dampener E-Clip Roller Washer Helix (Cam) Moveable Sheave Helix Screws Clutch Shaft 48 in-lb (5 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.37 © Copyright Polaris Industries Inc.

  • Page 264: Driven Clutch Service (2016)

    The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 5. Remove the universal clutch compressor. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.38 © Copyright Polaris Industries Inc.
  • Page 265 12. Inspect the sheaves for excessive wear or damage. 8. Press out the spring pins in the inner sheave. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.39 © Copyright Polaris Industries Inc.

  • Page 266: Driven Clutch Assembly

    3. Install the spring pins to retain the slider pins. 7. Install the universal clutch compressor on the clutch and compress the helix cover. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.40 © Copyright Polaris Industries Inc.
  • Page 267 9. Once back together, verify the grease / tape marks made during disassembly are properly aligned. 10. Install the drive clutch on the vehicle. See PVT Assembly (2016), page 5.15 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.41 © Copyright Polaris Industries Inc.

  • Page 268: Assembly View

    Bearing Spider Spring Pin Roller Slider Washer E-clip Slider Pin Stationary Sheave Helix (Cam) Helix Screws Moveable Sheave 48 in-lb (5 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.42 © Copyright Polaris Industries Inc.

  • Page 269: Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.43 © Copyright Polaris Industries Inc.
  • Page 270 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 5.44 © Copyright Polaris Industries Inc.
  • Page 271 ................6.34 SHIFTING DIFFICULTY 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 272: General Information

    Shift Fork Screws 20 ft-lbs (27 Nm) Transmission Case Screws Speed Sensor Screw 12 ft-lb (16 Nm) 22 ft-lb (30 Nm) Differential Cover Screw 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 273: Transmission Mounting And Torque Values

    TRANSMISSION TRANSMISSION MOUNTING AND TORQUE VALUES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 274: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 275 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 276: Transmission Service

    4. Remove left sway bar end link lower fasteners from the trailing arm. 5. Remove the PVT system from the vehicle (see Chapter 5 – PVT Disassembly (2016), page 5.14 NOTE 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 277 10. Remove vent hose from transmission. overhead lift. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 278 Remove the fasteners that attach the rear mount to the transmission. Remove the mount assembly from the vehicle. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 279: Transmission Installation

    4. Install M10 bolt and nut securing the transmission bracket to the rear mount. Torque fasteners to specification. TORQUE Rear Transmission Isolator Fasteners 40 ft-lb (54 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 280 13. Remove the spacer or support between the vehicle frame and engine. 8. Align front transmission mounting holes with transmission joint bracket mounting holes on engine. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.10 © Copyright Polaris Industries Inc.
  • Page 281 17. Install and properly route the vent hose. 18. Lubricate the transmission splines and mid prop shaft joint splines with Polaris All Purpose Grease. Install the prop shaft onto the transmission output shaft (see Chapter 7 – Rear Prop Shaft Installation, page 7.29).

  • Page 282: Transmission Disassembly

    . Remove the switch. 27. If transmission lubricant was drained, fill the 5. Remove the sector cover bolts and remove the transmission with the specified amount of Polaris sector cover AGL (see Chapter 2 – Transmission Lubrication, NOTE page 2.27).
  • Page 283 Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.13 © Copyright Polaris Industries Inc.
  • Page 284 Gear Cluster Disassembly 22. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.14 © Copyright Polaris Industries Inc.
  • Page 285 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 286: Differential Operation (Turf Mode Models Only)

    This unlocks the rear differential. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 287 When “Differential-Lock” is selected, power is removed from the electrical solenoid allowing the solenoid plunger 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.17 © Copyright Polaris Industries Inc.

  • Page 288: Planetary Differential Disassembly (Turf Mode Models Only)

    Planetary Differential Bushing Replacement (Turf Mode Models Only), page 6.19. 2. Remove the six screws retaining the differential cover and remove the cover. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 289: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 290 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 291 TRANSMISSION 14. Press the new bushing into the side gear until it bottoms out. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 292: Planetary Differential Assembly (Turf Mode Models Only)

    5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification. TORQUE Differential Cover Screws: 22 ft-lb (30 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.22 © Copyright Polaris Industries Inc.

  • Page 293: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.23 © Copyright Polaris Industries Inc.

  • Page 294: Transmission Assembly / Snorkel Gear Backlash Procedure

    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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.24 © Copyright Polaris Industries Inc.
  • Page 295 8. Apply Loctite ® ™ to the threads of the bearing and may have some tight spots. cover retaining screws. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.25 © Copyright Polaris Industries Inc.
  • Page 296 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.26 © Copyright Polaris Industries Inc.
  • Page 297 Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.27 © Copyright Polaris Industries Inc.
  • Page 298 Be sure to install the detent star with Transmission Case Bolts: the raised edge facing outward and skip-tooth 20 ft-lbs (27 Nm) aligned. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 299 18 ft-lb (24 Nm) 36. Refer to Transmission Installation, page complete the repair. 31. Clean the transmission and gear sector cover mating surfaces thoroughly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.29 © Copyright Polaris Industries Inc.

  • Page 300: Transmission Assembly View

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.30 © Copyright Polaris Industries Inc.
  • Page 301 Sensor, Speed Cover, Sector Gears Bearing, Ball Case, RH Spring, Wave Case, LH Bracket, Wire Harness Drum, Shift Collar Sleeve, Input Shaft 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.31 © Copyright Polaris Industries Inc.

  • Page 302: Transmission Assembly View (Turf Mode Models)

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW (TURF MODE MODELS) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.32 © Copyright Polaris Industries Inc.
  • Page 303 Shift Dog, Park Bearing, Plain Bearing, Ball Gear, 44T Collar Sleeve, Input Shaft Bearing, Ball Fork, Shift Bearing, Needle Cage Sprocket, 48T, 6-Face 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.33 © Copyright Polaris Industries Inc.

  • Page 304: Troubleshooting

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 6.34 © Copyright Polaris Industries Inc.
  • Page 305 ............... .7.44 REAR HUB ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 306 ..............7.45 BEADLOCK RIMS (DESERT EDITION) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 307: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 308: Bearing Carrier

    12. 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 309: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 310: Front Bearing Carrier Installation

    6. Install new brake caliper mounting bolts and torque to specification. TORQUE Front Caliper Mounting Bolts: TORQUE 30 ft-lb (41 Nm) Wheel Hub Castle Nut: 110 ft-lbs (149 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 311: Rear Bearing Carrier Inspection / Removal

    5. Remove the lower radius rod outer mounting bolt nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 312 11. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 313: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 314: Rear Bearing Carrier Installation

    Bearing Carrier to Trailing Arm Bolts: 42 ft-lb (54 Nm) Radius Rod to Bearing Carrier Fasteners: 40 ft-lb (54 Nm) 3. Apply anti-seize to drive shaft splines. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.10 © Copyright Polaris Industries Inc.
  • Page 315 120 ft-lbs (163 Nm) 8. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 316: Drive Shaft

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.12 © Copyright Polaris Industries Inc.

  • Page 317: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.13 © Copyright Polaris Industries Inc.

  • Page 318: Rear Drive Shaft Removal

    Always wear eye protection. drive shaft is parallel with the ground. 2. Remove the four wheel nuts and rear wheel. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.14 © Copyright Polaris Industries Inc.

  • Page 319: Rear Drive Shaft Installation

    Torque fastener to specification. TORQUE Stabilizer Bar Linkage: 40 ft-lbs (54 Nm) 6. Apply Anti-Seize to drive shaft axle splines. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.15 © Copyright Polaris Industries Inc.
  • Page 320 8. Install the radius rod bolts, washers and new nuts. Torque fasteners to specification. TORQUE Radius Rods to Bearing Carrier: 40 ft-lb (54 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 321: Drive Shaft / Cv Joint Handling Tips

    CV joints and CV joint boots. 3. Clean the grease from the face of the joint. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 322 Use entire contents of package. If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 323 18. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 324: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 325 18. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.21 © Copyright Polaris Industries Inc.

  • Page 326: Outer Cv Boot Replacement

    3. Clean the grease from the face of the joint. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 327 9. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 328: Inner Plunging Joint / Boot Replacement

    4. Clean the grease from the face of the joint. 5. Pull the shaft / joint straight out from the housing. 9. Visually inspect the joint for damage. Replace if needed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.24 © Copyright Polaris Industries Inc.
  • Page 329 17. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 330: Drive Shaft Assembly View

    FINAL DRIVE DRIVE SHAFT ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 331: Prop Shaft Service

    Roll Pin Removal Tool: PN 2872608 NOTE Right front wheel can be removed to gain better access to the propshaft roll pin. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 332: Front Prop Shaft Installation

    Torque bolts to specification. TORQUE Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.28 © Copyright Polaris Industries Inc.

  • Page 333: Rear Prop Shaft Installation

    Paint marks are applied to the front and rear prop shafts to aid shaft alignment. Reference these marks during installation if still visible. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.29 © Copyright Polaris Industries Inc.

  • Page 334: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.30 © Copyright Polaris Industries Inc.

  • Page 335: Rear Prop Shaft Installation

    Reference these marks during installation if still visible. 5. Torque the support bearing fasteners to specification. TORQUE Support Bearing Fasteners: 35 ft-lb (47 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.31 © Copyright Polaris Industries Inc.

  • Page 336: Support Bearing Replacement

    Chapter 7 – Rear Prop Shaft Installation, page 7.29). 5. Install the new support bearing assembly onto the end of the prop shaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.32 © Copyright Polaris Industries Inc.

  • Page 337: Front Gearcase / Centralized Hilliard

    Cover Screws, M6 (T30 Torx) Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.33 © Copyright Polaris Industries Inc.

  • Page 338: All Wheel Drive Operation

    “over- running” condition for the rollers upon disengagement. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.34 © Copyright Polaris Industries Inc.

  • Page 339: Awd Diagnosis

    Should have a minimum of 11 Vdc. 3. If electrical tests are within specification, remove gearcase (see Chapter 7 – Front Gearcase Removal, page 7.36) and inspect components. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.35 © Copyright Polaris Industries Inc.

  • Page 340: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.36 © Copyright Polaris Industries Inc.

  • Page 341: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.37 © Copyright Polaris Industries Inc.
  • Page 342 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.38 © Copyright Polaris Industries Inc.
  • Page 343 Refer to the “Electronic Parts Catalog” for individual part availability. Most parts are to be replaced as an assembly or as a complete kit. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.39 © Copyright Polaris Industries Inc.

  • Page 344: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.40 © Copyright Polaris Industries Inc.
  • Page 345 NOTE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.41 © Copyright Polaris Industries Inc.

  • Page 346: Front Gearcase Installation

    TORQUE Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 5. Install the vent line TORQUE Cover Plate Screws: 11 ft-lbs (15 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.42 © Copyright Polaris Industries Inc.
  • Page 347 Demand Drive Fluid 2877922 (quart) Capacity:8.5 oz (250 mL) (fill on a level surface to bottom of threads on the fill hole) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.43 © Copyright Polaris Industries Inc.

  • Page 348: Wheel Hubs

    FINAL DRIVE WHEEL HUBS FRONT HUB ASSEMBLY VIEW REAR HUB ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.44 © Copyright Polaris Industries Inc.
  • Page 349 5. Install bolts and thread them to 24 in-lbs (3 Nm). 6. Tighten in a criss-cross pattern to 7 ft-lbs (10 Nm). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.45 © Copyright Polaris Industries Inc.
  • Page 350 FINAL DRIVE NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 7.46 © Copyright Polaris Industries Inc.
  • Page 351 ......... . .8.31 WALKER EVANS™ SHOCK REBUILD INFORMATION 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 352 ................8.53 FOX SHOCK ASSEMBLY 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 353: General Information

    Power Steering Bracket to 16 ft-lb (22 Nm) Frame Nuts Steering Rack Mounting 16 ft-lbs (22 Nm) Bolts Hip Bolster Bolts 14 ft-lb (19 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 354: Steering System

    Nut, Nylok (Do not reuse) 30 ft-lb (41 Nm) Tie Rod End Steering Wheel Nut 14 ft-lbs (19 Nm) 65 ft-lbs (88 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 355: Upper Steering Shaft Removal

    2. Remove the pinch bolt retaining the upper steering shaft to the power steering unit. 3. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 356: Steering Wheel Removal

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 357 WARNING Electronic Power Steering (EPS) units are programmed to be vehicle specific and are not interchangeable between product lines. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 358: Lower Steering Shaft Removal

    5. Lift up on the shaft and remove it through the floor panel. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 359: Power Steering Unit Installation

    Torque to specification. TORQUE Lower Steering Shaft to EPS Unit Pinch Bolt: 15 ft-lbs (20 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 360: Upper Steering Shaft Installation

    8 ft-lb (11 Nm) 3. Install the tilt shock and torque fastener to specification. TORQUE Tilt Shock Fastener: 7 ft-lb (10 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 361: Steering Shaft Bearing Replacement

    9. Reinstall the upper washers and spacers in the order in which they were removed. 10. Install the steering wheel and hand tighten the nut. Apply Loctite ® ™. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.11 © Copyright Polaris Industries Inc.
  • Page 362 65 ft-lbs (88 Nm) 15. Wipe the pivot tube clean of any excess Loctite ® 16. Install steering wheel cap and field test steering operation. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 363: Front Suspension

    5. Remove the front bumper to allow A-arm bolt removal. TORQUE Front Ball Joint Pinch Bolts: 42 ft-lbs (57 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 364: Front Stabilizer Bar Removal

    18. If not replacing the A-arm, thoroughly clean the A- arm and pivot tube. 19. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 365: Front Stabilizer Bar Installation

    4. Install the nut retaining the front stabilizer bar link to the upper control arm on both sides. Torque fasteners to specification. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 366: Ball Joint Removal

    Front Shock Mounting Bolts: 42 ft-lb (57 Nm) Front Caliper Mounting Bolts: 30 ft-lbs (42 Nm) Wheel Nuts (Alum): 120 ft-lbs (163 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 367: Rear Suspension

    6. Remove radius rods from vehicle. 7. Examine radius rod shafts, boots and spherical bearings. Replace entire radius rod if any excessive wear is evident. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.17 © Copyright Polaris Industries Inc.
  • Page 368 11. Remove the lower stabilizer bar linkage fastener. Discard the nut. 12. Support trailing arm with suitable jack stand or support. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.18 © Copyright Polaris Industries Inc.
  • Page 369 17. Reverse this procedure to reinstall rear trailing arm. NOTE Use new fastener nuts upon installation of the rear trailing arm and bearing carrier. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 370: Trailing Arm Spherical Bearing Replacement

    8. Install new snap ring, O-rings (not required) and 4. Properly support the trailing arm and press the bushings. spherical bearing out of trailing arm casting. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 371: Rear Suspension Assembly View

    Shock Guard Screws Trailing Arm Mounting Bolts 42 ft-lb (57 Nm) 14 in-lbs (2 Nm) 70 ft-lb (95 Nm) Rear Shock Assembly Radius Rod 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 372: Stabilizer Bar Removal

    7. Carefully remove the stabilizer from the LH wheel well area of the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 373: Shocks / Springs

    Step 1 (see Chapter 2 – Spring Adjustment (WALKER EVANS™), page 6. Reinstall the shock onto the vehicle and torque new fasteners to specification. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 374: Shock Service

    Piston Wear Band (1.750" OD) 36. Shaft, Chrome Clicker Bolt Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 375: Walker Evans™ 2.5" Rear Shock

    Wear Band Ball (.250") O-Ring O-Ring 2& Retention Nut Screw Screw 9/16 Heim Shaftloop O-Ring Snap Ring Shock Body Needle O-Ring Hose 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 376: Walker Evans Shock Service

    IFP Location RZR XP 2.875″ (73.02 cm) 1000 / Desert Edition Nitrogen Pressure 125 psi (862 kPa) +/- 5% 2874124 (qt.) Gas Shock Oil 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 377 1.00 x 0.025 0.900 x 0.008 1.45 x 0.015 0.625 x 0.065 1.45 x 0.015 1.45 x 0.008 1.30 x 0.015 1.45 x 0.008 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 378: Rear Shock Service Information

    1000 / High Lifter Piston Bleed Orifice: 0.100″ Nitrogen Pressure 125 psi (862 kPa) +/- 5% 2874124 (qt.) Gas Shock Oil P/N 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 379 1.55 x 0.008 1.00 x 0.095 1.45 x 0.010 (top-out) 1.30 x 0.012 1.20 x 0.012 1.50 x 0.125 (top-out) Piston Bleed Orifice: 0.100″ 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.29 © Copyright Polaris Industries Inc.

  • Page 380: Spring Adjustment (Walker Evans)

    Suspension springs may be adjusted to suit different riding conditions or vehicle payloads. NOTE Polaris does not recommend increasing the spring WARNING adjustment by more than one inch (25.4 mm) over the Uneven adjustment may cause poor handling of the...

  • Page 381: Walker Evans™ Shock Rebuild Information

    The rebound and compression valve stacks will always be positioned as shown in the illustration, regardless of how the shock assembly is installed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.31 © Copyright Polaris Industries Inc.

  • Page 382: Walker Evans™ Shock Disassembly

    Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.32 © Copyright Polaris Industries Inc.
  • Page 383 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.33 © Copyright Polaris Industries Inc.
  • Page 384 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 385: Walker Evans™ Shock Assembly

    8. Place a new lock nut onto the shock rod. Torque the new lock nut to specification. NOTE Do not over torque the nut or damage to the valve stack can occur. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.35 © Copyright Polaris Industries Inc.
  • Page 386 15. Screw IFP Tool (PS-45908) onto the floating piston. FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.36 © Copyright Polaris Industries Inc.
  • Page 387 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 388 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 389 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.39 © Copyright Polaris Industries Inc.

  • Page 390: Fox Shock Assembly Views

    Valving Assembly Retaining Ring Bearing Assembly Retaining Ring Reservoir End Cap Assembly Bearing Cap Damping Adjust Assembly Body Cap Sparing Hardware Assembly Body 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.40 © Copyright Polaris Industries Inc.

  • Page 391: Fox 3.0" O.e. Podium Bypass

    Reservoir End Cap Assembly O-ring Remote Reservoir Adjust Port Damping Adjust Assembly 3& O-ring Eyelet Spring Hardware Assembly O-ring Reducer O-ring Reservoir 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.41 © Copyright Polaris Industries Inc.

  • Page 392: Fox Shock Service

    1.230 x 0.082 (Top Out) 1.350 x 0.015 0.875 x 0.100 (Back Up) 1.250 x 0.015 1.100 x 0.015 1.570 x 0.128 (Top Out) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.42 © Copyright Polaris Industries Inc.

  • Page 393: Fox 3.0" Rear Shock Information

    1.100 x 0.012 1.230 x 0.082 (Top Out) 1.100 x 0.012 0.875 x 0.100 (Back Up) 0.950 x 0.012 1.950 x 0.188 (Top Out) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.43 © Copyright Polaris Industries Inc.

  • Page 394: Spring Adjustment (Fox®)

    Shock Spanner / Clutch Spreader Tool: 2878925 NOTE DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.44 © Copyright Polaris Industries Inc.

  • Page 395: Offset Torque Formula

    L = 13.750″ Will equal 30 ft-lb of torque applied to the reservoir. E = 3.750″ or 2.500″ *depending on body cap 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.45 © Copyright Polaris Industries Inc.

  • Page 396: Fox Shock Disassembly

    Ensure you have obtained the correct rebuild kit and oil prior to disassembly. 1. Clamp the shock body securely in a vice. 4. Remove reservoir end cap from reservoir. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.46 © Copyright Polaris Industries Inc.
  • Page 397 8. Press down on bearing assembly and remove retaining ring. 12. Remove IFP. 13. Dump out used shock oil. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.47 © Copyright Polaris Industries Inc.
  • Page 398 16. Use the IFP tool to remove LSC. IFP Tool: commercially available also available from FOX 398-00-394 17. Use a strap wrench to remove the reservoir. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.48 © Copyright Polaris Industries Inc.
  • Page 399 29. Note the bleed shim orientation on compression valve stack. 30. Remove compression valve stack and cable tie together. Clean with contact cleaner. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.49 © Copyright Polaris Industries Inc.
  • Page 400 Loctite residue left in the eyelet and shaft threads. Clean thoroughly with contact cleaner and lint-free 36. Clean all surfaces of the bearing housing and cinch towel. ring. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.50 © Copyright Polaris Industries Inc.
  • Page 401 38. To remove the remote hose assembly, de-pressurize reservoir, push hose in and remove retaining ring with a small pick. 39. Remove hose o-rings. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.51 © Copyright Polaris Industries Inc.
  • Page 402 STEERING / SUSPENSION 2.5 Bypass Piston 3.0 Bypass Piston Compression Side Compression Side Rebound Side Rebound Side 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.52 © Copyright Polaris Industries Inc.

  • Page 403: Fox Shock Assembly

    30 ft-lb (42 Nm) 3. With body prepared with Loctite primer add a layer of Loctite 638 2 threads up, 2 threads wide 360°. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.53 © Copyright Polaris Industries Inc.
  • Page 404 18. Install 1st T-seal back-up ring. 19. Install 2nd T-seal back-up ring 20. Install wiper seal. 21. Lubricate all seals with Slick Honey. 22. Install external o-ring. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.54 © Copyright Polaris Industries Inc.
  • Page 405 28. Install shaft nut and torque to specification. 34. Install shaft assembly into inner body. TORQUE Shaft Nut: 22 ft-lb (30 Nm) 29. Install all Bypass check valves. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.55 © Copyright Polaris Industries Inc.
  • Page 406 40. Install retaining ring, ensuring that it is fully seated in ring gland. 41. Holding cinch ring spanner, torque bearing assembly to specification. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.56 © Copyright Polaris Industries Inc.
  • Page 407 49. Stroke shock absorber and inspect shock for leaks. 50. Install body cap. 51. Clean oil residue from shock. 52. Install o-ring and reducers in eyelet and body. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.57 © Copyright Polaris Industries Inc.
  • Page 408 STEERING / SUSPENSION NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 8.58 © Copyright Polaris Industries Inc.
  • Page 409 ..............9.29 PAD ASSEMBLY / INSTALLATION 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 410 ................... .9.37 BRAKES LOCK 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 411: General Information

    37 ft-lb (50 Nm) Bolts 110 ft-lbs (149 Nm) Wheel Hub Castle Nuts Aluminum: 120 ft-lbs Wheel Lug Nuts (163 Nm) Steel: 60 ft-lb (81 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 412: General 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 413: 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 414: Brake System Assembly View

    BRAKE SYSTEM BRAKE SYSTEM ASSEMBLY VIEW BRAKE SYSTEM ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 415: Master Cylinder

    2. Remove the clip from the clevis pin that attaches the master cylinder to the brake pedal lever. the master cylinder to the frame. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 416: Master Cylinder Installation

    Mity Vac™: 2870975 3. Add brake fluid to the indicated MAX level of reservoir. Polaris DOT 4 Brake Fluid 2872189 4. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container.
  • Page 417 Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 418: Brake Pedal Lever

    2. Remove the E-clip from the pedal mount and remove the brake pedal lever from the vehicle. Brake Pedal Free-play: 0.090″ (2.28 mm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 419: Parking Brake (Int'l Model)

    BRAKE SYSTEM PARKING BRAKE (INT’L MODEL) PARKING BRAKE ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 420: Parking Brake Inspection

    See Chapter 10 – Parking Brake Switch (INT’L Model), 3. If the vehicle moves, adjustment is necessary. page for more information on the parking brake switch. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 421: Parking Brake Caliper

    BRAKE SYSTEM PARKING BRAKE CALIPER 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.13 © Copyright Polaris Industries Inc.
  • Page 422 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. Caliper Disassembly / Inspection 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.14 © Copyright Polaris Industries Inc.
  • Page 423 Anti-Seize Lubricant to the thrust washer and shims. 4. Torque the caliper assembly bolts to specification. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 424: Parking Brake Disc

    2. Using a 1/2″ socket and ratchet, remove the brake disc retaining bolt and flat washer. 3. Remove the disc from the transmission shaft. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 425: Front Brake Pads

    When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 7. Remove the inner pad from the bracket and caliper. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 426: Pad Inspection

    Use only new, clean 7. Install wheel and torque wheel nuts to specification. pads. TORQUE Wheel Nuts: 120 ft-lbs (163 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 427: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 428: Front Caliper Service

    BRAKE SYSTEM FRONT CALIPER SERVICE CALIPER ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 429: Caliper Removal

    . Remove brake line from caliper. 5. Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 430: Caliper Disassembly

    Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 431: Caliper Inspection

    Replace if damaged or worn beyond may drag upon assembly. service limit. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing MEASUREMENT inward. Piston should slide in and out of bore smoothly, with light resistance.

  • Page 432: Caliper Installation

    NOTE If new pads are installed, refer to Brake Burnishing Procedure, page 9.19. TORQUE Banjo Bolt 15 ft-lbs (20 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 433: Front Brake Disc

    Service Limit: 0.170″ (4.32 mm) Brake Disc Thickness Variance Service Limit: 0.002″ (.051 mm) Brake Disc Runout: Service Limit: .010″ (0.254 mm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 434: Disc Replacement

    30 ft-lb (41 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 435: Rear Brake Pads

    Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 436: Pad Inspection

    8. Remove the inner brake pad. Rear Brake Pad Thickness: .298 ± .007″ (7.57 mm ± .178 mm) Service Limit: .180″ (4.6 mm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.28 © Copyright Polaris Industries Inc.

  • Page 437: Pad Assembly / Installation

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 438: Rear Caliper Service

    BRAKE SYSTEM REAR CALIPER SERVICE CALIPER ASSEMBLY VIEW 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.30 © Copyright Polaris Industries Inc.

  • Page 439: Caliper Removal

    Discard nut. 5. Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 440: Caliper Disassembly

    Rear Caliper Piston O.D.: Standard: 1.500″ (38.10 mm) Service Limit: 1.498″ (38.05 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.32 © Copyright Polaris Industries Inc.

  • Page 441: Caliper Assembly

    Torque mounting bolts to specification. may drag upon assembly. TORQUE 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion Rear Caliper Mount Bolt while pushing inward. Piston should slide in and out 40 ft-lbs (54 Nm) of bore smoothly with light resistance.
  • Page 442 6. Install wheel and torque wheel nuts to specification. TORQUE Wheel Nuts: 120 ft-lbs (163 Nm) NOTE If new pads are installed, refer to Brake Burnishing Procedure, page 9.29. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.34 © Copyright Polaris Industries Inc.

  • Page 443: Rear Brake Disc

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Brake Disc Mounting Bolts: 30 ft-lb (41 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.35 © Copyright Polaris Industries Inc.
  • Page 444 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.36 © Copyright Polaris Industries Inc.

  • Page 445: Troubleshooting

    • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.37 © Copyright Polaris Industries Inc.
  • Page 446 BRAKE SYSTEM NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 9.38 © Copyright Polaris Industries Inc.
  • Page 447 ................10.27 DECAL REPLACEMENT 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.1 © Copyright Polaris Industries Inc.

  • Page 448: General Information

    8 ft-lb (11 Nm) Seat Base to Frame (Front 14 ft-lb (19 Nm) Bolts) Seat Base to Frame (Rear 30 ft-lb (41 Nm) Bolts) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 449: Body Assembly Views

    Visor Screws 8 ft-lb (11 Nm) Front ROPS Bracket 40 ft-lb (54 Nm) Cab Frame Extenders Hip Bolster Lower Fasteners 14 ft-lb (19 Nm) Hip Bolster 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.3 © Copyright Polaris Industries Inc.
  • Page 450 . Torque to 40 ft-lb (54 Nm) 8. Install visor panel on front ROPS with M10 x 1.25 x 20 bolts. Torque to 8 ft-lb (11 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 451: Doors

    Latch Striker 8 ft-lb (11 Nm) Door Latch Screws Hinge Pin 8 ft-lb (11 Nm) Striker Screws Latch Release 8 ft-lb (11 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 452: Doors (Xp4)

    BODY / FRAME DOORS (XP4) Door Panel Latch Release Door Frame Latch Door panel (Rear) Latch Striker Hinge Pin Door Frame (Rear) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.6 © Copyright Polaris Industries Inc.

  • Page 453: Doors High Lifter

    Latch Striker Upper Door Frame Latch Striker Screws (8 ft-lbs, 11 Nm) Lower Door Frame Hinge Screws (8 ft-lbs, 11 Nm) Hinge Pin 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 454: Dash Instruments / Controls

    BODY / FRAME DASH INSTRUMENTS / CONTROLS Headlight Switch Instrument Cluster Key Switch AWD Switch 12V Accessory Port Bezel 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.8 © Copyright Polaris Industries Inc.

  • Page 455: Dash Instruments / Controls High Lifter

    BODY / FRAME DASH INSTRUMENTS / CONTROLS HIGH LIFTER Instrument Cluster AWD Switch Key Switch Winch Switch 12V Accessory Port Bezel Headlight Switch 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.9 © Copyright Polaris Industries Inc.

  • Page 456: Hood / Front Body Work

    8 ft-lb (11 Nm) Lower Radiator Mount Screws Passenger Front Fender Flair 8 ft-lb (11 Nm) Fan Shroud Screws Hood 8 ft-lb (11 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 457: Chassis / Main Frame Xp / High Lifter

    BODY / FRAME CHASSIS / MAIN FRAME XP / HIGH LIFTER 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.11 © Copyright Polaris Industries Inc.

  • Page 458: Chassis / Main Frame Xp 4

    BODY / FRAME CHASSIS / MAIN FRAME XP 4 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 459: Seat Assembly Front

    4 ft-lb (5 Nm) Screw Seat Back 4 ft-lb (5 Nm) Seat Base Seat Base Pad Seat Base Slider Assembly Seat Latch Lever 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.13 © Copyright Polaris Industries Inc.

  • Page 460: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 461: Floor / Rocker Panels Xp / High Lifter

    RH Rocker T27 Screws Push Rivots LH Rocker Console Cover U-Type Nuts Seat Belt Boot Block Off Flap Shifter Boot Lower Floor 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 462: Floor / Rocker Panels Xp 4 / Xp 4 High Lifter

    Block Off Flap Console Rear Main Floor Lower Lower Rear Close-off Panel Upper Rear Close-off Panel Rocker RH B-Pillar Cover RH Floor Rear 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 463: Rear Cargo Box / Fenders

    Rear Fascia Support Brackets Shock Panel Bracket Fasteners Passenger Side Cargo Box Half 8 ft-lb (11 Nm) Driver Side Cargo Box Half Fender Flair 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 464: Rear Bumper

    Rear Fascia Fasteners Exhaust Cover/Bumper 8 ft-lb (11 Nm) Exhaust Cover Bracket (lower) Rear Fascia Fascia Support Brackets Exhaust Cover Bracket (upper) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 465: 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 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 466: 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.. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 467: Rear Fender / Fender Flair Removal Xp

    12. Remove the front portion of the cab frame assembly. Refer to appropriate Cab Frame Assembly XP, page 10.3 procedure for assembly torque specifications. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.21 © Copyright Polaris Industries Inc.

  • Page 468: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 469: Rocker Panels, Console And Floor Xp

    10. Remove the cargo box half from the vehicle. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 470: Rocker Panels, Rear Console And Floor Xp

    1. Remove seats and rocker panels (see Chapter 10 – Floor / Rocker Panels XP 4 / XP 4 High Lifter, page 10.16). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.24 © Copyright Polaris Industries Inc.
  • Page 471 11. Remove two Torx T40 screws and four push rivets retaining the lower rear close off panel. 5. Remove the rear console. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.25 © Copyright Polaris Industries Inc.
  • Page 472 Remove front seat base assembly. 14. Remove four Torx T40 screws retaining the rear floor and remove the rear floor. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.26 © Copyright Polaris Industries Inc.

  • Page 473: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.27 © Copyright Polaris Industries Inc.
  • Page 474 BODY / FRAME NOTES 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 10.28 © Copyright Polaris Industries Inc.
  • Page 475 ................11.24 BATTERY TESTING 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.1 © Copyright Polaris Industries Inc.
  • Page 476 ....................11.49 LIGHTS 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.2 © Copyright Polaris Industries Inc.
  • Page 477 ..................11.50 CHARGING SYSTEM 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 478: General Information

    13 ft-lb (18 Nm) • Speedometer • AWD Switch • Headlamp Switch • 12 Vdc Accessory Power Point • Ignition Switch • LED Ambiance Light 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 479: Instrument Cluster

    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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.5 © Copyright Polaris Industries Inc.
  • Page 480 Hours Indicator - Illuminates when Hours are being displayed on the Information Display Mode Button - Used to move through the menu features. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 481: Information Display Area

    Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. Engine Hours 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.7 © Copyright Polaris Industries Inc.
  • Page 482 4. To turn off the service interval function, toggle the 2. Press and hold the MODE button while turning the MODE button until “OFF” is displayed. key to the ON position. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.8 © Copyright Polaris Industries Inc.
  • Page 483 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 484: Diagnostic Mode

    MIL will illuminate and blink in place of the check engine MIL. 2. Press and hold the MODE button to enter the diagnostics code menu. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.10 © Copyright Polaris Industries Inc.
  • Page 485 1. Disconnect the wire harness connector from the back side of the instrument cluster. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 486: Switches

    4. For switch replacement, refer to Chapter 9 “Brakes”. NOTE Pins 7 and 8 provide power and ground to light the switch lamp. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 487: Ignition (Key) Switch

    A and B; C and D. • Move the switch to 2WD (NONE / OFF). There should ONLY be continuity between pins 3 and 7. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 488: Transmission (Gear Position) Switch

    GEAR WHEN MEASURED AT POSITION SWITCH TERMINALS A AND B HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 489: Seat Belt Switch

    2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT DISENGAGED ENGAGED Between both ∞ (OL) < 1 Ω pins on switch 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 490: All Wheel Drive Coil

    80% of all electrical issues are caused by bad/failed connections and grounds. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 491: Vehicle Speed Sensor

    4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 492: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Mounting Bolt: 8 ft-lb (11 Nm) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 493: Charging System

    The battery should be fully charged before performing this test. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 494: Stator (Alternator) Replacement

    7. Refer to the following table for approximate AC Voltage readings according to RPM. Test each leg at the specified RPM in the table. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 495: Regulator / Rectifier

    212° F or 100° C. If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.21 © Copyright Polaris Industries Inc.

  • Page 496: 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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 497: Battery

    ELECTRICAL BATTERY BATTERY SPECIFICATIONS GENERAL BATTERY INFORMATION Polaris / Johnson Controls 575 WARNING Type Sealed - Maintenance Free CALIFORNIA PROPOSITION 65 WARNING:Batteries, Voltage 12 Vdc battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known...

  • Page 498: Battery Removal / Installation

    NOTE To perform this test, use a load testing device that has an Battery charge can be maintained by using a Polaris adjustable load. Apply a load of three times the ampere- battery tender or by charging once a month to make up hour rating.

  • Page 499: Charging Procedure

    Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 500: Lighting System

    The front bumper can be removed and placed face down on a suitable workbench to ease headlamp replacement (see Chapter 10 – Front Bumper XP, page 10.19). 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.26 © Copyright Polaris Industries Inc.

  • Page 501: Headlamp Installation

    6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlight Adjustment” procedure as shown in this chapter. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.27 © Copyright Polaris Industries Inc.

  • Page 502: Cooling System

    “Check Engine” indicator should display on the instrument cluster. This indicates all other components are working properly. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.28 © Copyright Polaris Industries Inc.

  • Page 503: Ect Sensor Replacement

    Refer to Chapter 3 and 10 for additional ECT sensor 8. Add the required amount of coolant and bleed the information. Polaris dealers can test the sensor by using system (see Chapter 3 – Cooling System Bleeding Digital Wrench® Diagnostic Software (dealer only).

  • Page 504: Starting System

    Refer to the voltage drop tests on the starter system in this chapter. Voltage should not exceed 0.1 DC volts per connection 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.30 © Copyright Polaris Industries Inc.

  • Page 505: Starter Motor Installation

    12V power via the Green / White wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.31 © Copyright Polaris Industries Inc.

  • Page 506: Starter Fails To Turn Over The Engine

    ELECTRICAL STARTER FAILS TO TURN OVER THE ENGINE. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.32 © Copyright Polaris Industries Inc.

  • Page 507: Electronic Power Steering

    If the steering wheel pulls to one side when the vehicle is to a normal mechanically coupled steering system. The driven in a straight line and there is no damage to the system is Polaris Digital Wrench® compatible for steering or suspension components, perform the simplified...

  • Page 508: Proper Eps System Diagnosing

    EPS unit. If not, update to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.34 © Copyright Polaris Industries Inc.

  • Page 509: Eps System Breakout

    ELECTRICAL EPS SYSTEM BREAKOUT 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.35 © Copyright Polaris Industries Inc.

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

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.36 © Copyright Polaris Industries Inc.

  • Page 511: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.37 © Copyright Polaris Industries Inc.

  • Page 512: Eps Troubleshooting (Using Digital Wrench®)

    ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.38 © Copyright Polaris Industries Inc.

  • Page 513: Fuses / Relays

    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. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.39 © Copyright Polaris Industries Inc.

  • Page 514: Fuse Box Detail (2014)

    ELECTRICAL FUSE BOX DETAIL (2014) 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.40 © Copyright Polaris Industries Inc.

  • Page 515: Fuse Box Detail (2015-2016)

    12 Vdc power input from key Orange switch to enable relay. Provides 12 Vdc power for lights, White drive and accessory circuits. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.41 © Copyright Polaris Industries Inc.
  • Page 516 Yellow in order to operate high beam headlights momentarily. “Normally closed” relay output to Dark Green operate low-beam headlights. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.42 © Copyright Polaris Industries Inc.

  • Page 517: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.43 © Copyright Polaris Industries Inc.

  • Page 518: Break-Out Diagrams

    ELECTRICAL BREAK-OUT DIAGRAMS 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.44 © Copyright Polaris Industries Inc.

  • Page 519: Vehicle Speed Sensor

    ELECTRICAL VEHICLE SPEED SENSOR 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.45 © Copyright Polaris Industries Inc.

  • Page 520: Cooling System

    ELECTRICAL COOLING SYSTEM 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.46 © Copyright Polaris Industries Inc.

  • Page 521: Unswitched Chassis Power

    ELECTRICAL UNSWITCHED CHASSIS POWER 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.47 © Copyright Polaris Industries Inc.

  • Page 522: Key-On Battery Power

    ELECTRICAL KEY-ON BATTERY POWER 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.48 © Copyright Polaris Industries Inc.

  • Page 523: Lights

    ELECTRICAL LIGHTS 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.49 © Copyright Polaris Industries Inc.
  • Page 524 ELECTRICAL CHARGING SYSTEM 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual 11.50 © Copyright Polaris Industries Inc.
  • Page 525 Test ..............11.28 Removal (Front) .............9.17 Cooling Fan Brake Pedal Bypass Test ............11.28 Installation ............9.10 Circuit Breaker............. 11.39 Removal...............9.10 Cooling System 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 526 Assembly View ..........3.9–3.12 Updates ...............4.49 Balance Shaft Removal / Inspection ......3.53 Doors ..............10.5 Bearing Selection Identification .........3.63 Doors (XP4) .............10.6 Break-In Period............3.35 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 527 Exhaust Valve Lash - Tappet Matrix .......3.88 Fuse Box ............... 11.39 Details (2015–2016) ..........11.41 Fuse Box Detail ............11.40 Control Circuit Bypass Test........11.28 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 528 Replacement............1.5 Ring Removal / Inspection........3.60 Piston to Cylinder Clearance........3.61 Plunging Joint / Boot Replacement (Inner) ........7.20, 7.24 Polaris Mobile Digital Wrench (PMDW) ......4.56 Leakdown Test ............2.13 Power Steering Unit Lower Steering Shaft Installation ............. 8.9 Installation ............. 8.8 Removal..............
  • Page 529 Shock Piston Orientation, Walker Evans......8.31 Rear – Assembly View..........8.21 Shock, Walker Evans 2.5, Assembly View ......8.25 Spring Adjustment (WALKER EVANS™) ..... 2.33, 8.30 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 530 Instrument Cluster (ETC) .........4.39 Troubleshooting Brake Noise ............9.5 Brake System ............9.37 Clutch ..............5.43 Cooling System............3.91 Engine ..............3.90 Fuel Injector ............4.12 Fuel System ............4.47 9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual IX.6 © Copyright Polaris Industries Inc.

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