Polaris RZR XP 1000 2023 Owner's Manual For Maintenance And Safety
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Polaris RZR XP 1000 2023 Owner's Manual For Maintenance And Safety

Polaris RZR XP 1000 2023 Owner's Manual For Maintenance And Safety

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2023
OWNER'S
For Maintenance and Safety
MANUAL
RZR XP 1000
RZR XP 4 1000

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Summary of Contents for Polaris RZR XP 1000 2023

  • Page 1 2023 OWNER’S For Maintenance and Safety MANUAL RZR XP 1000 RZR XP 4 1000...
  • Page 3 2023 Owner’s Manual RZR XP 1000 RZR XP 4 1000...
  • Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. Recreational Off-Highway Vehicle Association® and ROHVA® are registered trademarks of the Recreational Off-Highway Vehicle Association. WALKER EVANS RACING® is a registered trademark of Walker Evans Enterprises Incorporated. Tread Lightly® is a registered trademark of the United States Department of Agriculture.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation that, if not avoided, will result in death to the operator, bystanders or person(s) inspecting or servicing the vehicle.

  • Page 7: Table Of Contents

    Specifications ....127 Polaris Products ....133 Troubleshooting .

  • Page 9: Introduction

    Additionally, read the product safety labels on the vehicle and follow all rules and regulations concerning the operation of this vehicle in your area. POLARIS recommends anyone who will be operating this vehicle to take a training course. ROHVA® (Recreational Off-Highway Vehicle Association®) provides both an online safety e-course and a hands-on safety course.

  • Page 10: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 11: Safety

    • Reduce the effectiveness of occupant protection systems, including the seatbelts and the Rollover Protective Structure (ROPS). • Make it illegal to own or operate your vehicle. POLARIS-authorized spark arresters, mufflers, and emissions control components are mandatory for ownership or operation in many areas.
  • Page 12 POLARIS recommends that you supervise younger drivers. Set rules and put limits on how, when, and where they are allowed to use this vehicle. For example, young drivers may need to have an adult in the vehicle with them and not be allowed to drive with their friends in the vehicle.
  • Page 13 SAFETY PREPARE VEHICLE FOR THE RIDE Before starting off, always perform the Pre-Ride Inspection. Failure to inspect and verify that the vehicle is in safe operating condition increases the risk of an accident, which can lead to serious injury or death. ITEM REMARK REFERENCE...
  • Page 14 SAFETY ITEM REMARK REFERENCE Exhaust Inspect spark arrester page 107 and clean if needed. – Vehicle Debris Remove grass, leaves, and other flammable material or debris, especially near the exhaust system. Passenger Hand Hold Always adjust the hand page 38 hold to a comfortable position for your passenger before...

  • Page 15: Specification

    Improper tire maintenance can lead to loss of control and an accident, which could result in serious injury or death. To reduce your risk of injury: • Maintain POLARIS recommended tire pressure. Check pressure before operating. Even if your vehicle has only been driven a short distance, the tire pressure readings can become higher.
  • Page 16 Use shatterproof goggles or a shatterproof helmet face shield. Such protective eyewear may reduce the risk of foreign material getting in your eyes and help prevent loss of vision. POLARIS recommends wearing approved Personal Protective Equipment (PPE) that have markings indicating they are designed to standards such as: •...
  • Page 17 SAFETY Always stay completely inside the vehicle and hold the steering wheel or hand holds. Body parts outside of the vehicle can be struck by passing objects or crushed during a rollover. Do not put any part of your body outside of the vehicle for any reason.

  • Page 18: Driving Guidelines

    SAFETY DRIVING GUIDELINES Drive Responsibly. This vehicle has higher ground clearance and other features to handle rugged terrain. It can be overturned in situations where some other vehicles may not. Abrupt maneuvers or aggressive driving, even on flat, open areas, can cause loss of control, rollovers, severe injury or death.
  • Page 19 While it may be legal locally to drive on some public roads in specific parts of the country, your vehicle was not designed or certified as an on-road motor vehicle. Polaris does not support public road use except as may be necessary to cross roads designated for connecting off highway vehicle trail segments. If you must drive on-road, drive slowly and defensively.
  • Page 20 SAFETY Improperly operating on hills can cause loss of control, rollover, or accident, which can lead to serious injury or death. Use extra care when operating on hills. Plan for rough terrain, ruts, and other changes in traction and terrain. Driving up hills Check the terrain before ascending a hill and make sure it is not too slippery or loose.
  • Page 21 SAFETY Riding in water / Falling into water Operating through deep or fast-flowing water can cause loss of traction, loss of control, overturning, or being swept away in water. You can be seriously injured or killed from entrapment and drowning. Never operate the vehicle in fast-flowing water or in water that exceeds the floor level of the vehicle.
  • Page 22 After any crash, rollover, or other accident, have a POLARIS dealer inspect the vehicle for possible damage, including seat belts, ROPS, brakes, suspension, and steering systems.
  • Page 23 SAFETY After operation, inspect the vehicle for damage and debris to make sure the vehicle can be safely stored and operated again. Some things to inspect include: • Debris that could catch fire, such as mud/grass near the engine or exhaust system •...

  • Page 24: Towing A Rzr

    SAFETY TOWING A RZR Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See the Transporting the Vehicle section for details. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral.
  • Page 25 SAFETY TRAILERING SAFETY The weight distribution of the cargo loaded onto the trailer is important and will have an impact on how the vehicle handles on the road. Ensure the weight of the cargo is distributed properly and the trailer is not rear, front, or side heavy. Improperly trailering or attempting to tow this vehicle can result in serious injury or death.

  • Page 26: Transporting The Vehicle

    5. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.

  • Page 27: Safety Labels And Locations

    If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.  Warning Labels ...
  • Page 28 SAFETY PAYLOAD WARNING WARNING If Total Payload Exceeds Never Exceed 68 MPH (109 km/h) 330 lbs. (150 kg) XP 1000 68 MPH (109 km/h) 860 lbs. (390 kg) XP4 1000 SEAT BELT WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. Be Prepared •...
  • Page 29 SAFETY FUEL TRANSPORT WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. DRIVE RESPONSIBLY WARNING WARNING: Drive Responsibly Rollovers have caused severe injuries and death, even on flat, open areas. Avoid loss of control and rollovers: •...
  • Page 30 Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around the clutch and vent system when replacing the belt. Read owner’s manual or see authorized POLARIS dealer or other authorized person.  Belt Debris Warning...

  • Page 31: Maximum Weight Capacity

    SAFETY LOAD / PASSENGER / TIRE PRESSURE WARNING The Load / Passenger / Tire Pressure  Warning is located at the rear of the vehicle in the cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. •...

  • Page 33: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS   Cargo Box Radiators   ROPS Frame Cab Door  Fuel Tank Cap   Tie-Down Points (4 corners) Gear Selector   Brake Pedal Passenger Hand Hold  Throttle Pedal...
  • Page 34 FEATURES AND CONTROLS SWITCHES Instrument Cluster All Wheel Drive (AWD) Switch Ignition Switch 12V Accessory Outlet Headlight Switch...

  • Page 35: Ignition Switch

    FEATURES AND CONTROLS IGNITION SWITCH The ignition switch is a four-position, key-operated switch. Use the ignition switch to start the engine. See the Starting the Engine section for starting procedures. POSITION FUNCTION The engine is off. Electrical circuits are off, except accessory 12V.
  • Page 36 FEATURES AND CONTROLS ALL WHEEL DRIVE (AWD) SWITCH The AWD Switch has two positions:  All Wheel Drive (AWD)  Two Wheel Drive (2WD) Press the top of the rocker switch to engage All Wheel Drive. Press the bottom of the switch to operate in two wheel drive. See the All Wheel Drive (AWD) System section for AWD operating instructions.

  • Page 37: Electronic Power Steering (Eps)

    EPS has shut down. If the EPS warning indicator remains on after turning the ignition switch to OFF and then starting the engine, the EPS system is inoperative. See your POLARIS dealer, or another qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

  • Page 38: Seat Adjustments

    FEATURES AND CONTROLS SEATS Before operating the vehicle, always push down on all seat backs to ensure the latches are secure. SEAT ADJUSTMENTS On seats equipped with an adjustment lever under the front edge of the seat, pull the lever to the left. Slide the seat forward or rearward to the desired position.

  • Page 39: Steering Wheel

    Always make sure all cab doors are closed and latched when riding in this vehicle. Always inspect doors and latches for wear and damage before each use of the vehicle. Promptly replace any worn or damaged parts with new parts available from your authorized POLARIS dealer or qualified person.

  • Page 40: Passenger Hand Hold

    FEATURES AND CONTROLS PASSENGER HAND HOLD Always adjust the hand hold to a comfortable position for your passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments.   1. Remove the retainer from the end of the adjustment pin 2.
  • Page 41 FEATURES AND CONTROLS HOOD   Remove the hood to access the radiator pressure cap and pressure tank   1. Turn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the fasteners. 3.

  • Page 42: Seat Belts

    FEATURES AND CONTROLS SEAT BELTS This POLARIS vehicle is equipped with seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 mph (24 km/h) if the seat belt is not secured.

  • Page 43: Seat Belt Inspection

    If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer or qualified person. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.
  • Page 44 FEATURES AND CONTROLS SEAT BELT HEIGHT ADJUSTER (IF EQUIPPED) The seat belt height adjuster reduces neck rub and works as a shock absorber for your shoulder. The   height adjuster consists of an adjuster and a rail Adjustment becomes easier with repeated use. The seat belt height adjuster can be cleaned with water.

  • Page 45: Gear Selector

    L: Low Gear H: High Gear Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer or qualified person can assist in resolving any shifting problems. USING LOW GEAR Always shift into low gear for any of the following conditions: •...

  • Page 46: Service Access Panels

    FEATURES AND CONTROLS SERVICE ACCESS PANELS ENGINE ACCESS PANEL The engine access panel is located behind the seats on the frame of the vehicle. Remove the seats and remove the access panel to reach serviceable engine components. CARGO BOX ACCESS PANEL The cargo box access panel is located on the floor of the cargo box.

  • Page 47: Brake Pedal

    FEATURES AND CONTROLS BRAKE AND THROTTLE PEDALS BRAKE PEDAL  Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. THROTTLE PEDAL  Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released.

  • Page 48: Rollover Protective Structure (Rops)

    FEATURES AND CONTROLS ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on  ROPS Label this vehicle meets OSHA requirements of 29 CFR § 1928.53. Always have your authorized dealer or qualified person thoroughly inspect the ROPS if it ever becomes damaged in any way.

  • Page 49: All-Wheel Drive (Awd) System

    FEATURES AND CONTROLS ALL WHEEL DRIVE (AWD) SYSTEM The All Wheel Drive system is controlled by the AWD switch. Once the vehicle is  in gear, the switch is set to one of two modes. When the switch is on 2X4 , the ...

  • Page 50: Instrument Cluster

    FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.

  • Page 51: Mode Button

    FEATURES AND CONTROLS SPEEDOMETER The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). TACHOMETER The tachometer displays engine speed in revolutions per minute (RPM). MODE BUTTON Press and hold the MODE button to enter or exit the settings menu. Press and release the MODE button to cycle through Area 1 modes and to select an item.

  • Page 52: Indicator Lamps

    Steering (EPS) ON position. If the light remains on, the EPS system is Warning (if inoperative. See your POLARIS dealer, or other qualified equipped) person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

  • Page 53: Rider Information Center

    Service A flashing wrench symbol alerts the operator that the preset  Indicator service interval has been reached. Your POLARIS dealer, or other qualified person, can provide scheduled maintenance. See page 56 for resetting instructions. Fuel Gauge The segments of the fuel gauge show the level of fuel in the ...
  • Page 54 FEATURES AND CONTROLS MODE INFORMATION DISPLAYS The rider information center contains three areas that display mode information. Description Area 1 Modes Engine Temperature Temperature of engine coolant Vehicle Speed Speed of vehicle Tachometer Engine speed (RPM) Description Area 2 Modes Odometer The odometer records and displays the distance traveled by the vehicle.

  • Page 55: Backlight Color

    FEATURES AND CONTROLS ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays. See the Mode Information Displays section for details. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds.

  • Page 56: Backlight Brightness

    FEATURES AND CONTROLS BACKLIGHT BRIGHTNESS The information center backlight can be set to either blue or red. 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the “BL LEVEL” option. Press MODE to select.

  • Page 57: Trip Meter

    FEATURES AND CONTROLS DISPLAY UNITS (STANDARD/METRIC) 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the desired “UNITS” option (distance, temperature or volume). Press MODE to select. 3. Press either toggle button to cycle to the desired setting. 4.

  • Page 58: Programmable Service Interval

    FEATURES AND CONTROLS PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory. As hours of engine operation increase, the counter decreases. The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset.

  • Page 59: Engine Error Codes

    FEATURES AND CONTROLS ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

  • Page 61: Ride Command Display (If Equipped)

    • Familiarize yourself with the features and operations of the Display while the vehicle is stationary. • Download the Polaris RIDE COMMAND App from the Apple® App Store® or Google Play® store and create your personalized account. • Check your display to ensure you have the appropriate maps and trails visible for your area.

  • Page 62: Near-Field Communication (Nfc)

    (IF EQUIPPED) Some Polaris vehicles come equipped with a near-field communication (NFC) chip. The NFC chip is embedded in the Polaris emblem located at the front of the vehicle and seamlessly connects you to a digital platform of vehicle information and tools. See your dealer for more information.

  • Page 63: Radio Compliance Statements

    MANUFACTURER 9200 Series Display RC-7 Polaris Industries Inc. This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
  • Page 64 0.2432 W *Other transmitting radio frequencies may exist outside of EU markets. Hereby, Polaris Industries Inc. declares that the above radio equipment is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address: https://www.polaris.com/en-us/radio-conformity/...
  • Page 65 RIDE COMMAND DISPLAY (IF EQUIPPED) OVERVIEW Ride Command Buttons Icon Bar Driveline Mode Gauge View Mode Widgets Speedometer/Tachometer Settings Gear Status RIDE COMMAND BUTTONS BUTTON DESCRIPTION FUNCTION Menu Button Press the Menu button to access the settings. To reboot the display, press and hold for 5 seconds.
  • Page 66 RIDE COMMAND DISPLAY (IF EQUIPPED) BUTTON DESCRIPTION FUNCTION Map Button Press the Map button to access the map, manage your rides and waypoints, and to see your friends on the map with Group Ride. Phone Button Press the Phone button to access your Bluetooth®...

  • Page 67: Indicator Description

    RIDE COMMAND DISPLAY (IF EQUIPPED) DRIVELINE MODE INDICATOR DESCRIPTION FUNCTION When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When in All-Wheel Drive, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

  • Page 68: Gauge Screens

    To access the Setting menu, press the Menu button You can also navigate to the settings menu by pressing the POLARIS logo at the top of the display screen . This will open the Control Panel. From the Control Panel,...
  • Page 69 RIDE COMMAND DISPLAY (IF EQUIPPED) GAUGE VIEW MODE Press to toggle between the two available gauge view modes, Analog and Digital. While in the digital gauge view mode, press invert the MPH and RPM units.
  • Page 70 RIDE COMMAND DISPLAY (IF EQUIPPED) ICON BAR ICON DESCRIPTION FUNCTION Headset Displays icon if headset is connected Signal Strength Displays current cell signal strength Wireless Internet Displays current wireless internet signal Signal Strength (if strength (if equipped) equipped) Fuel Level Displays current fuel capacity percentage Vehicle Direction...

  • Page 71: Update Software

    1. Go to ridecommand.polaris.com/update. 2. Log into your account, or create a new account. 3. Using the Vehicle Identification Number (VIN), add your new Polaris vehicle to your Garage. 4. Locate and download the latest software to a USB flash drive (8+ GB).

  • Page 72: Software Updates

    RIDE COMMAND DISPLAY (IF EQUIPPED) UPDATE MAPS To update the maps on your display, do the following: 1. Go to ridecommand.polaris.com/update and download the map update to a USB flash drive. 2. Insert USB flash drive into the USB port on your vehicle.

  • Page 73: Operation

    OPERATION OPERATION VEHICLE BREAK-IN ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with the recommended fuel. See the Refueling section for details. Always exercise extreme caution whenever handling fuel. 2. Check the oil level. See the Oil Check section for details. Add the recommended oil as needed to maintain the oil level in the safe operating range.

  • Page 74: Pvt Break-In (Clutches / Belt)

    OPERATION PVT BREAK-IN (CLUTCHES / BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. If a belt fails, always clean any debris from the duct and from the engine compartment. STANDARD BREAK-IN Drive at slower speeds for the first 50 miles (80 km) of operation.
  • Page 75 OPERATION OPERATING GUIDELINES STARTING THE ENGINE NOTICE Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2.

  • Page 76: Driving In Reverse

    OPERATION DRIVING IN REVERSE WARNING Before shifting into reverse, use extra care to make sure the area is clear of people or obstacles. When it’s safe to proceed, back slowly. Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2.

  • Page 77: Emission Control Systems

    OPERATION ON PUBLIC LANDS IN THE U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 79: Maintenance

    Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your POLARIS dealer or other authorized person can assist.
  • Page 80 The items outlined in this service interval only need to be performed at the first 25 hours of operation. They do not need to be performed every 25 hours. * It is recommended to have an authorized Polaris dealer perform these services.
  • Page 81 Inspect hoses for damage. Replace as necessary. Locate all applicable fittings and grease. General Lubrication Inspect; Adjust pressure level as needed; Tires Inspect wear and replace as needed. * Have an authorized Polaris dealer or other qualified person perform these services.
  • Page 82 MAINTENANCE Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation. EVERY 50 HOURS / 1000 MILES (1600 KM) OR YEARLY FOLLOWING INITIAL BREAK-IN SERVICE Inspect air filter;...
  • Page 83 Components/Alignment Inspect; replace as needed. Shock Absorbers * Have an authorized Polaris dealer or other qualified person perform these services. Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.

  • Page 84: Lubrication Recommendations

    MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 78, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
  • Page 85 MAINTENANCE  Middle Prop Shaft Grease Fitting  Stabilizer Bar Bushings (one on each side of vehicle)  Rear Prop Shaft Grease Fitting...

  • Page 86: Engine Oil

    (-18 °C) to (+49 °C) 10W-50 4-Cycle Oil Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. Follow the manufacturer's recommendations for ambient temperature operation. Part numbers can be found in the POLARIS Products chapter.

  • Page 87: Oil Check

    MAINTENANCE OIL CHECK Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull.  Access the oil check dipstick through the right rear wheel well. Access the oil ...

  • Page 88: Oil And Filter Change

    MAINTENANCE OIL AND FILTER CHANGE Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page . Always change the oil filter whenever changing oil. Access the oil check dipstick through the right rear wheel well. Access the oil fill cap through the service access panel on the floor of the cargo box.
  • Page 89 MAINTENANCE 9. Remove the oil fill cap and add 2.5 quarts (2.4 l) of recommended oil. Reinstall the fill cap. 10. Start the engine and allow it to idle for 30 seconds. 11. Stop the engine. Wait 15 seconds before removing the dipstick. 12.

  • Page 90: Transmission (Main Gearcase)

    MAINTENANCE TRANSMISSION (MAIN GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart section for recommended lubricants, capacities and torque specifications. FLUID CHECK The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.

  • Page 91: Fluid Change

    MAINTENANCE FLUID CHANGE  The drain plug is located on the bottom of the gearcase. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3.
  • Page 92 MAINTENANCE DEMAND DRIVE UNIT (FRONT GEARCASE) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. DEMAND DRIVE FLUID CHECK  The fill plug is located on the bottom right side of the demand drive unit.
  • Page 93 MAINTENANCE DEMAND DRIVE FLUID CHANGE The demand drive drain plug is located on the bottom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4.

  • Page 94: Gearcase Specification Chart

    MAINTENANCE GEARCASE SPECIFICATION CHART Use of other fluids may result in improper operation of components. See the Polaris Products section for the part numbers. Fill Plug Drain Plug Capacity Gearcase Lubricant Torque Torque Transmission 44 oz. 10-14 ft. lbs. 10-14 ft. lbs.

  • Page 95: Spark Plugs

    NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. Refer to the specifications section of this manual. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.

  • Page 96: Spark Plug Removal And Replacement

    MAINTENANCE SPARK PLUG REMOVAL AND REPLACEMENT  1. Remove the cargo box access panel to access the spark plugs 2. Clean the area around the spark plugs before removing the plugs. 3. Remove the spark plug caps. 4. Using the spark plug wrench provided in the tool kit, remove the plugs by rotating them counterclockwise.

  • Page 97: Spark Plug Condition

    MAINTENANCE SPARK PLUG CONDITION NORMAL PLUG The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTICE The tip should not be white.
  • Page 98 MAINTENANCE FUSE / RELAY CENTER If the engine stops or will not start, if the power steering stops working (if equipped), or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.

  • Page 99: Cooling System

    ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See the Polaris Products section for the part numbers.
  • Page 100 MAINTENANCE RADIATOR COOLANT LEVEL / CHANGING COOLANT This procedure is required only if the cooling system has been drained for  maintenance and/or repair. If the overflow bottle has run dry, the level in the radiator should also be inspected. CAUTION Escaping steam can cause burns.

  • Page 101: Overflow Bottle Coolant Level

    5. Reinstall the cap. If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer or authorized person.
  • Page 102 • See your dealer or other qualified service person as recommended in the owner’s manual and on safety labels. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 103 MAINTENANCE BELT REPLACEMENT / DEBRIS REMOVAL If a belt fails, always clean any debris from the PVT ducting and from the clutch and engine compartments when replacing the belt. WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
  • Page 104 MAINTENANCE 3. Remove the clutch cover screws and open the clutch cover. (It does not have to be removed from the vehicle.) Remove all debris wrapped in and around the PVT system. Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation.

  • Page 105: Pvt Drying

    5. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer or other qualified person can assist. Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.
  • Page 106 MAINTENANCE 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your POLARIS dealer or authorized person can assist.

  • Page 107: Filter Systems

    MAINTENANCE FILTER SYSTEMS INTAKE PRE-FILTERS  The engine intake pre-filter is located on the right side of the vehicle. The  clutch air intake is located on the left side of the vehicle. Inspect the engine pre-filter before each use of the vehicle to ensure adequate air flow.
  • Page 108 7. Reinstall the air filter (if clean) or install a new air filter (if soiled). Do not attempt to clean the air filter. NOTICE Use of a non-POLARIS-approved air filter may cause engine damage. Always use a POLARIS-approved replacement filter. Replacement filters are available at your POLARIS dealer.

  • Page 109: Spark Arrester

    MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrestor. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
  • Page 110 MAINTENANCE BRAKES WARNING Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal. The front and rear brakes are hydraulic disc type brakes activated by the brake pedal.

  • Page 111: Brake Inspection

    MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40® or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.

  • Page 112: Brake Fluid

    Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See the Polaris Products section for the part numbers. Change the brake fluid every two years and any time the fluid becomes...

  • Page 113: Suspension Settings

    WARNING Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer or qualified person perform the adjustments.
  • Page 114 MAINTENANCE WALKER EVANS RACING® SHOCKS  Front Shock Preload Measurement  Rear Shock Preload Measurement FACTORY DEFAULT PRELOAD SETTINGS FACTORY DEFAULT PRELOAD SETTINGS 1.49 inches (38 mm) Front RZR XP 1000 7.75 inches (197 mm) Rear 2.04 inches (51 mm) Front RZR XP 4 1000 5.83 inches (148 mm)

  • Page 115: Tire Tread Depth

    Cracking of the tread and sidewall rubber and/or deformation is evidence of aging. Tires should be inspected for aging before use. If signs of aging or damage are found, see your Polaris dealer or other qualified person for assistance.

  • Page 116: Axle And Wheel Nut Torque Specifications

    MAINTENANCE AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. 120 ft-lbs Lug Nut Front and Rear (Aluminum Wheels) (162.7 Nm) 180 ft.

  • Page 117: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer or other qualified person can assist. Right Rear Wheel 1.

  • Page 118: Taillight / Brake Light Replacement

    MAINTENANCE LIGHTS Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. LED LAMPS If an LED headlamp appears to have moisture or fogging inside the lens, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out.

  • Page 119: Headlight Beam Adjustment

    MAINTENANCE HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted slightly upward or downward and to the left or right. NOTICE Rider weight must be included on the seat while performing this procedure. 1. Position the vehicle on a level surface. The headlight should be approximately 25 ft.

  • Page 120: Vehicle Immersion

    If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer or other qualified person can provide this service. If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

  • Page 121: Steering Wheel Inspection

    MAINTENANCE 8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer or other qualified person can provide the required service. 9. If water has been ingested into the PVT follow the procedure on page 103 for drying.

  • Page 122: Battery Installation

    If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer.
  • Page 123 MAINTENANCE If you plan to store the vehicle for ONE MONTH or longer, remove the battery from the vehicle, then store the battery in a cool and dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP charger. When using an automatic charger other than a BatteryMINDer®...

  • Page 124: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 125: Washing Tips

    MAINTENANCE Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system. WASHING TIPS • Avoid the use of harsh cleaners, which can scratch the finish. •...

  • Page 126: Polishing The Vehicle

    MAINTENANCE POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

  • Page 127: Inspect And Lubricate

    6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug caps to the spark plugs.

  • Page 128: Storage Area / Covers

    STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 129: Specifications

    SPECIFICATIONS SPECIFICATIONS RZR XP 1000 Gross Vehicle Weight RZR XP 1000: 2270 lbs (1031 kg) RZR XP 1000 without Ride Command Package: 2259 lbs (1025 kg) Dry Weight* RZR XP 1000: 1460 lbs. (662 kg) RZR XP 1000 with Ride Command Package: 1472 lbs.
  • Page 130 Rear Suspension Independent trailing arms with 18 in. (45.7 cm) travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Tire Size - Front 29x9-14 Tire Size - Rear 29x11-14 Tire Pressure...
  • Page 131 SPECIFICATIONS RZR XP 4 1000 Gross Vehicle Weight RZR XP 4 1000: 2640 lbs. (1200 kg) RZR XP 4 1000 without Ride Command Package: 2625 lbs. (1191 kg) Dry Weight* RZR XP 4 1000: 1671 lbs. (758 kg) RZR XP 4 1000 with Ride Command Package: 1683 lbs.
  • Page 132 Rear Suspension Independent trailing arms with 18 in. (45.7 cm) travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Tire Size - Front 29x9-14 Tire Size - Rear 29x11-14 Tire Pressure...
  • Page 133 SPECIFICATIONS OUTPUT GEAR RATIOS OUTPUT GEAR RATIOS RZR XP RZR XP 4 Rear High Gear 10.73 12.05 Low Gear 18.77 18.79 Reverse 20.41 22.92 Front (including front drive) High Gear 11.42 12.82 Low Gear 19.98 19.98 Reverse 21.73 24.41 Drive Ratio - Front 3.182:1 3.182:1 CLUTCHING...

  • Page 135: Polaris Products

    POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PART NUMBER DESCRIPTION Engine Lubricant 2870791 Fogging Oil — 12 fl oz (355 mL) Aerosol 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil — 1 qt (0.95 L) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil — 1 gal (3.8 L) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil —...

  • Page 136: Part Number Description

    U-Joint Grease — 3 fl oz (89 mL) Cartridge 2871551 U-Joint Grease — 14 fl oz (414 mL) Cartridge 2871329 Dielectric Grease (Nyogel®) Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite® 565 Thread Sealant 2830438 POLARIS Battery Trickle Charger...

  • Page 137: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR / BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall trailer in Use low gear during loading. high gear Starting out going up a steep incline Use low gear. Driving at low RPM or ground speed Drive at a higher speed or use low (3-7 MPH/ 5-11 km/h) gear more frequently.

  • Page 138: Possible Cause

    TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Clutch malfunction Your POLARIS dealer or other qualified person can assist. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. Your POLARIS dealer or other qualified person can assist.

  • Page 139: Engine Turns Over, Fails To Start

    ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel Refuel Clogged fuel filter Your POLARIS dealer or other qualified person can assist. Water is present in fuel Drain the fuel system and refuel Old or non-recommended fuel Replace with fresh recommended...

  • Page 140: Engine Pings Or Knocks

    TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Incorrect ignition timing Your POLARIS dealer or other qualified person can assist. Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Exhaust leak Check all connections Mechanical failure Your POLARIS dealer or other qualified person can assist.

  • Page 141: Engine Stops Or Loses Power

    Clogged intake pre-filter Inspect and clean (with soapy water) or replace Other mechanical failure Your POLARIS dealer or other qualified person can assist Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel...
  • Page 142 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Worn or defective spark plug wires Your POLARIS dealer or other qualified person can assist. Incorrect spark plug gap or heat Set gap to specs or replace plug range Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC...

  • Page 143: Limited Warranty

    This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.

  • Page 144: Warranty Coverage And Exclusions

    WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.

  • Page 145: Lubricants And Fluids

    MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.

  • Page 146: How To Obtain Warranty Service

    If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

  • Page 147: Exported Products

    IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.

  • Page 148: U.s.a. Epa Emissions Limited Warranty

    U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 149 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...

  • Page 150: California Residents

    California regulations and may void this limited emissions warranty offered by the manufacturer. POLARIS Inc. warrants that at the time is first purchased, this vehicle is: 1. Designed, built, and equipped so as to conform, at the time of sale, with all applicable California evaporative emissions regulations.

  • Page 151: Manufacturer's Warranty Coverage

    As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
  • Page 152 WARRANTY United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334...

  • Page 153: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 155 3-Point Seat Belt ..... . . 40 Demand Drive Fluid Check ..90 Demand Drive Unit (Front Gearcase) .
  • Page 156 Polaris Maintenance Schedule ..78 Polaris Products ..... . 133 Ignition Switch ......33 POLARIS Variable Indicator Lamps .
  • Page 157 Safe Operating Guidelines U.S.A. EPA Emissions Limited Stopping the Engine and Parking Warranty ......146 the Vehicle.
  • Page 158 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Inc. 2100 Highway 55 Part No. 9940912 Rev 01 Medina, MN 55340 Printed in USA...
  • Page 159 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR Code® with your smartphone.

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Rzr xp 4 1000 2023

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