Polaris RZR XP4 1000 2015 Manuals

Manuals and User Guides for Polaris RZR XP4 1000 2015. We have 1 Polaris RZR XP4 1000 2015 manual available for free PDF download: Service Manual

Polaris RZR XP4 1000 2015 Service Manual

Polaris RZR XP4 1000 2015 Service Manual (536 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 58.48 MB

Table of Contents

Chapter 1 1 General Information

7
Chapter 2 Maintenance

35
- Break-In Period
  37
- Maintenance Chart Key
  37
- Periodic Maintenance Chart
  37
- Periodic Maintenance Overview
  37
- Pre-Ride / Daily Inspection
  37
- Maintenance Intervals
  38
- Maintenance Quick Reference
  40
- Grease Lubrication Points
  42
- Lubricants / Service Products
  43
  - Lubrication Specifications
    43
- Engine
  44
- Cooling System
  50
  - Cooling System Overview
    50
  - Coolant Strength
    50
  - Coolant Level Inspection
    50
  - Cooling System Pressure Test
    51
  - Cooling System Hoses
    51
  - Radiator Inspection / Cleaning
    52
  - Coolant Drain / Fill
    52
- Fuel System and Air Intake
  53
  - Fuel System Warning
    53
  - Fuel Tank Vent Line
    53
  - Fuel Pump / Fuel Filters
    54
  - Fuel Lines
    54
  - Throttle Pedal Inspection
    55
  - Engine Intake Pre-Filter Service
    55
  - Air Filter Service
    56
  - Intake Duct Drain Inspection
    56
- Pvt / Final Drive / Wheel and Tire
  57
  - Drive Clutch / Driven Clutch / Belt Service
    57
  - Pvt Intake Pre-Filter Service
    57
  - Pvt Drying
    57
  - Drive Shaft Boot Inspection
    58
  - Wheel and Hub Torque Table
    58
  - Wheel Removal
    58
  - Wheel Installation
    59
  - Tire Inspection
    59
- Maintenance
  59
  - Tire Pressure
    59
  - Beadlock Rims (Desert Edition)
    60
- Transmission and Front Gearcase
  61
- Steering
  64
  - Steering Inspection
    64
  - Steering Wheel Free-Play
    64
  - Tie Rod End / Wheel Hub Inspection
    65
  - Wheel Toe Alignment Inspection
    65
  - Wheel Toe Adjustment
    66
- Suspension
  67
- Brake System
  72
- Electrical and Ignition System
  74
  - Battery Maintenance
    74
  - Battery Charging / off Season Storage
    74
  - Battery Removal
    74
  - Battery Installation
    75
  - Engine / Chassis Electrical Ground
    75
  - Spark Plug Service
    76
Chapter 3 Engine / Cooling System

79
- Engine Lubrication Specifications
  81
- General Information
  81
- Special Tools
  81
- Oil Pressure Test
  82
- Engine Oil Flow Chart
  83
- Engine Specifications (1000)
  84
- Main Engine Components - Torque Specification and Sequence
  86
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
  87
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
  88
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
  89
- Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
  90
- Intake / Exhaust System
  91
  - Air Box / Air Filter Assembly View
    91
  - Exhaust System Assembly View
    92
- Engine Cooling System
  93
  - Engine Cooling System Specifications
    93
  - Cooling System Pressure Test
    93
  - Cooling System Pressure Cap Test
    94
  - Radiator Removal / Installation
    94
  - Thermostat Replacement
    95
  - Cooling System Assembly View
    97
  - Cooling System Bleeding Procedure
    98
  - Water Pump Removal
    99
  - Water Pump Installation
    99
  - Water Pump Service
    101
- Engine Service
  104
  - Accessible Engine Components
    104
  - Top-End Service (Engine in Chassis)
    104
  - Engine Removal
    104
  - Engine Installation
    108
  - Engine Mounting and Torque Values
    112
  - Engine Break-In Period
    113
  - Engine Lubrication Specifications
    113
- Engine Disassembly / Inspection - Top End
  114
  - Valve Cover Removal
    114
  - Camshaft Removal
    114
  - Camshaft Sprocket Inspection
    116
  - Cylinder Head Removal
    118
  - Cylinder Head Warp Inspection
    118
  - Cylinder Head Disassembly
    119
  - Valve Inspection
    120
  - Combustion Chamber Cleaning
    121
  - Valve Sealing Test
    121
  - Valve Seat Reconditioning (1000)
    122
- Engine Disassembly / Inspection - Bottom End
  125
  - Stator Cover Removal / Inspection
    125
  - Water Pump Housing Removal
    126
  - Flywheel Removal
    127
  - Starter One-Way Clutch Disassembly
    128
  - Crankcase Disassembly / Inspection
    129
  - Balance Shaft Removal / Inspection
    131
  - Crankshaft Removal / Inspection
    132
  - Crankcase Inspection
    134
  - Cylinder Inspection
    135
  - Cylinder / Piston Removal
    136
  - Piston Disassembly / Inspection (1000)
    137
  - Piston Ring Removal
    138
  - Piston Ring to Groove Clearance Inspection
    138
  - Piston Ring Installed Gap (1000)
    139
  - Piston-To-Cylinder Clearance
    139
  - Connecting Rod Inspection
    139
- Engine Assembly - Bottom End
  141
  - Bearing Selection Identification Letters and Numbers
    141
  - Connecting Rod Bearing Selection
    142
  - Crankshaft Main Bearing Selection
    142
  - Upper Crankcase Preparation
    143
  - Piston Ring Installation
    143
  - Piston / Connecting Rod Assembly
    145
  - Cylinder / Piston Installation
    146
  - Crankshaft Installation
    147
  - Balance Shaft Installation
    149
  - Lower Crankcase Preparation
    149
  - Crankcase Assembly
    150
  - Starter One-Way Clutch Assembly
    154
  - Flywheel Installation
    154
  - Stator Cover Installation
    155
- Engine Assembly - Top End
  156
  - Cylinder Head Assembly
    156
  - Cylinder Head Installation
    157
  - Camshaft Installation / Timing
    158
  - Camshaft Timing - Quick Reference
    162
  - Valve Clearance Adjustment
    163
  - Intake Valve Lash - Tappet Selection Matrix
    165
  - Exhaust Valve Lash - Tappet Selection Matrix
    166
  - Valve Cover Installation
    167
- Troubleshooting
  168
  - Engine Cooling System
    168
Chapter 4 Fuel System

171
- General Information
  173
- Special Tools
  173
- Torque Specifications
  174
- Efi Overview
  175
  - Efi Service Notes
    175
  - Efi System Assembly View
    176
  - Efi System Component Locations
    177
  - Principal Components
    178
  - Efi Operation Overview
    178
  - Initial Priming / Starting Procedure
    179
- Electronic Control Unit (Ecu)
  180
  - Operation Overview
    180
  - Ecu Service
    180
  - Ecu Replacement
    180
  - Etc Learn Procedure
    181
- Fuel Injectors
  182
  - Operation Overview
    182
  - Fuel Injector Troubleshooting
    182
  - Fuel Injector Test
    183
  - Fuel Injector Replacement
    183
- Fuel Tank
  186
  - Assembly View
    186
  - Fuel Line Removal / Installation
    187
  - Fuel Tank Removal
    187
  - Fuel Tank Installation
    190
  - Fuel Tank Removal Rzr Xp 4 1000
    191
  - Fuel Tank Installation Rzr Xp 4 1000
    193
- Fuel Pump
  194
  - Operation Overview
    194
  - Fuel Sender Test
    194
  - Fuel Pump Test
    195
  - Fuel Pump Replacement
    196
- Temperature and Manifold Absolute Pressure Sensor (T-Map)
  200
  - Operation Overview
    200
  - T-Map Test / Replacement
    200
- Crankshaft Position Sensor (Cps)
  201
  - Operation Overview
    201
  - Cps Test
    201
  - Cps Replacement
    202
- Electronic Throttle Control (Etc) / Throttle Body
  203
  - Operation Overview
    203
  - Throttle Body Service
    203
  - Throttle Body Removal
    204
  - Etc Test
    205
  - Etc Replacement
    205
  - Etc Learn Procedure
    205
- Pedal Position Sensor (Pps)
  206
  - Operation Overview
    206
  - Location
    206
  - Pps Test
    206
  - Pps Replacement
    206
- Oxygen Sensor (My15-16)
  208
  - Oxygen Sensor Information
    208
  - Oxygen Sensor Replacement
    208
- Efi Diagnostics
  209
  - Cylinder Misfire Detection
    209
  - Trouble Code Display (Etc)
    209
  - Efi Troubleshooting
    217
- Polaris Digital Wrench
  218
  - Digital Wrench® Diagnostic Software Overview
    218
  - Special Tools (Digital Wrench)
    218
  - Digital Wrench Software Version and Update
    219
  - Digital Wrench® Updates
    219
  - Digital Wrench® Communication Errors
    220
  - Digital Wrench® - Diagnostic Connector
    220
  - Guided Diagnostics
    221
  - Digital Wrench® Serial Number Location
    221
  - Digital Wrench® Feature Map
    222
  - Ecu Replacement
    223
  - Etc Learn Procedure
    223
  - Ecu Reprogramming (Reflash)
    223
- Polaris Mobile Digital Wrench (Pmdw)
  226
Chapter 5 Pvt System

227
- General Information
  229
- Pvt System Torque Specifications
  229
- Special Tools and Supplies
  229
- Pvt System Overview
  231
  - General Operation
    231
  - Drive Clutch Operation
    231
  - Driven Clutch Operation
    232
  - Pvt Break-In (Drive Belt / Clutches)
    232
  - Maintenance / Inspection
    232
  - Pvt Overheating / Diagnosis
    233
- Pvt System Service
  234
  - Pvt Covers and Duct Components
    234
  - Pvt Covers and Ducting Components (High Lifter)
    236
  - Pvt Disassembly (2014-2015)
    237
  - Pvt Disassembly (2016)
    237
  - Pvt Assembly (2016)
    238
- Drive Belt
  243
  - Belt Removal
    243
  - Belt Inspection
    244
  - Belt Installation
    244
  - Pvt Break-In (Drive Belt / Clutches)
    244
- Drive Clutch Service
  245
  - Drive Clutch Assembly View
    245
  - Drive Clutch Disassembly / Inspection
    246
  - Needle Bearing Inspection
    247
  - Shift Weight Inspection
    248
  - Button to Tower Clearance Inspection
    248
  - Spider Removal
    249
  - Roller, Pin, and Thrust Washer Inspection
    249
  - Clutch Inspection
    250
  - Moveable Sheave Bushing Inspection
    251
  - Bushing Service
    251
  - Drive Clutch Assembly
    253
- Driven Clutch Service (2014-2015)
  256
  - Driven Clutch Disassembly
    256
  - Driven Clutch Bushing Service
    258
    
    Clutch Bushing Removal
    259
    
    Clutch Bushing Installation
    260
  - Driven Clutch Assembly
    260
  - Driven Clutch Assembly View
    263
- Driven Clutch Service (2016)
  264
  - Driven Clutch Slider Inspection
    264
  - Driven Clutch Disassembly
    264
  - Driven Clutch Assembly
    266
  - Assembly View
    268
- Troubleshooting
  269
Chapter 6 Transmission

271
- General Information
  272
- Lubrication
  272
- Special Tools
  272
- Torque Specifications
  272
- Transmission Mounting and Torque Values
  273
- Shift Lever / Cable
  274
  - Shift Lever Removal
    274
  - Shift Lever Installation
    274
  - Shift Cable Inspection
    274
  - Shift Cable Adjustment
    274
- Transmission Service
  276
- Troubleshooting
  304
  - Shifting Difficulty
    304
Chapter 7 Final Drive

305
- Final Drive Torque Specifications
  307
- General Information
  307
- Special Tools
  307
- Bearing Carrier
  308
- Drive Shaft
  316
  - Front Drive Shaft Removal
    316
  - Front Drive Shaft Installation
    317
  - Rear Drive Shaft Removal
    318
  - Rear Drive Shaft Installation
    319
  - Drive Shaft / CV Joint Handling Tips
    321
    
    Outer CV Joint / Boot Replacement
    321
    
    Inner Plunging Joint / Boot Replacement
    324
    
    Outer CV Boot Replacement
    326
    
    Inner Plunging Joint / Boot Replacement
    328
  - Drive Shaft Assembly View
    330
- Prop Shaft Service
  331
  - Front Propshaft Removal
    331
  - Front Prop Shaft Installation
    332
  - Rear Prop Shaft Removal
    332
  - Rear Prop Shaft Installation
    333
  - Rear Prop Shaft Removal Xp 4
    334
  - Rear Prop Shaft Installation
    335
  - Support Bearing Replacement
    336
- Front Gearcase / Centralized Hilliard
  337
  - Centralized Hilliard Assembly View
    337
  - All Wheel Drive Operation
    338
  - Awd Diagnosis
    339
  - Front Gearcase Removal
    340
  - Front Gearcase Disassembly / Inspection
    341
  - Front Gearcase Assembly
    344
  - Front Gearcase Installation
    346
- Wheel Hubs
  348
  - Front Hub Assembly View
    348
  - Rear Hub Assembly View
    348
Chapter 8 Steering / Suspension

351
- General Information
  353
- Multi-Function Pliers
  353
- Special Tools
  353
- Torque Specifications
  353
- Steering System
  354
  - Assembly View
    354
  - Upper Steering Shaft Removal
    355
  - Steering Wheel Removal
    356
  - Power Steering Unit Removal
    356
  - Lower Steering Shaft Removal
    358
  - Lower Steering Shaft Installation
    358
  - Power Steering Unit Installation
    359
  - Upper Steering Shaft Installation
    360
  - Steering Shaft Bearing Replacement
    361
- Front Suspension
  363
  - Front A-Arm Removal / Replacement
    363
  - Front Stabilizer Bar Removal
    364
  - Front Stabilizer Bar Installation
    365
  - Ball Joint Service Preparation
    365
  - Ball Joint Removal
    366
  - Ball Joint Installation
    366
- Rear Suspension
  367
  - Radius Rod Removal / Installation
    367
  - Trailing Arm Removal / Installation
    367
  - Trailing Arm Spherical Bearing Replacement
    370
  - Rear Suspension Assembly View
    371
  - Stabilizer Bar Removal
    372
  - Stabilizer Bar Installation
    372
- Shocks / Springs
  373
  - Shock Assembly View
    373
  - Shock Removal / Installation
    373
  - Shock / Spring Replacement
    373
- Shock Service
  374
  - Walker Evans™Shock Assembly Views
    374
    
    Walker Evans™ 2.0" Front Shock
    374
    
    Walker Evans™ 2.5" Rear Shock
    375
  - Walker Evans Shock Service
    376
    
    General Service Information
    376
    
    Front Shock Service Information
    376
    
    Rear Shock Service Information
    378
    
    Spring Adjustment (Walker Evans)
    380
    
    Walker Evans™ Shock Rebuild Information
    381
  - Special Tools
    381
  - Valve Shim Arrangement
    381
  - Shock Piston Orientation
    381
  - Walker Evans™ Shock Disassembly
    382
  - Walker Evans™ Shock Assembly
    385
- Fox 2.5" O.e. Podium Bypass
  390
- Fox Shock Assembly Views
  390
- Fox 3.0" O.e. Podium Bypass
  391
- Fox 2.5" Front Shock Information
  392
- Fox Shock Service
  392
- Fox 3.0" Rear Shock Information
  393
  - Spring Adjustment (Fox®)
    394
  - Offset Torque Formula
    395
  - Fox Shock Disassembly
    396
  - Fox Shock Assembly
    403
Chapter 9 Brake System

409
- General Information
  411
- Special Tools
  411
- Torque Specifications
  411
- Brake System Service Notes
  412
- General Specifications
  412
- Brake Noise Troubleshooting
  413
- Hydraulic Brake System Operation
  413
- Brake System Assembly View
  414
- Master Cylinder
  415
  - Master Cylinder Removal
    415
  - Master Cylinder Installation
    416
  - Brake Bleeding / Fluid Change
    416
- Brake Pedal Lever
  418
  - Brake Pedal Removal
    418
  - Brake Pedal Installation
    418
- Parking Brake (Int'l Model)
  419
  - Parking Brake Assembly View
    419
  - Parking Brake Inspection
    420
  - Parking Brake Cable Adjustment
    420
  - Parking Brake Caliper
    421
  - Parking Brake Disc
    424
- Front Brake Pads
  425
  - Pad Removal
    425
  - Pad Inspection
    426
  - Pad Assembly / Installation
    426
  - Brake Burnishing Procedure
    427
- Front Caliper Service
  428
  - Caliper Assembly View
    428
  - Caliper Removal
    429
  - Caliper Disassembly
    430
  - Caliper Inspection
    431
  - Caliper Assembly
    431
  - Caliper Installation
    432
- Front Brake Disc
  433
  - Disc Runout
    433
  - Disc Inspection
    433
  - Disc Replacement
    434
- Rear Brake Pads
  435
  - Pad Removal
    435
  - Pad Inspection
    436
  - Pad Assembly / Installation
    437
- Brake System
  437
  - Brake Burnishing Procedure
    437
- Rear Caliper Service
  438
  - Caliper Assembly View
    438
  - Caliper Removal
    439
  - Caliper Disassembly
    440
  - Caliper Inspection
    440
  - Caliper Assembly
    441
  - Caliper Installation
    441
- Rear Brake Disc
  443
  - Disc Inspection
    443
  - Disc Replacement
    443
- Troubleshooting
  445
  - Poor Brake Performance
    445
  - Pedal Vibration
    445
  - Caliper Overheats (Brakes Drag)
    445
  - Brakes Lock
    445
Chapter 10 Body / Frame

447
- General Information
  448
- Special Tools
  448
- Torque Specifications
  448
- Body Assembly Views
  449
  - Cab Frame Assembly
    449
  - Cab Frame Assembly Xp
    449
  - Doors
    451
  - Doors (Xp4)
    452
  - Doors High Lifter
    453
  - Dash Instruments / Controls
    454
  - Dash Instruments / Controls High Lifter
    455
  - Hood / Front Body Work
    456
  - Chassis / Main Frame Xp / High Lifter
    457
  - Chassis / Main Frame Xp 4
    458
  - Seat Assembly Front
    459
  - Seat Assembly Rear
    460
  - Floor / Rocker Panels Xp / High Lifter
    461
  - Floor / Rocker Panels Xp 4 / Xp 4 High Lifter
    462
  - Rear Cargo Box / Fenders
    463
  - Rear Bumper
    464
- Body Component Removal
  465
  - Seats
    465
  - Engine Service Panel
    465
  - Front Bumper Xp
    465
  - Rear Bumper
    466
  - Hood and Front Body Work
    466
  - Rear Fender / Fender Flair Removal Xp
    467
  - Rear Fender Flare / Rear Fender Removal Xp
    468
  - Cargo Box Assembly Removal
    468
  - Rocker Panels, Console and Floor Xp
    469
  - Rocker Panels, Rear Console and Floor Xp
    470
  - Decal Replacement
    473
Chapter 11 Electrical

475
- Electrical Service Notes
  478
- General Information
  478
- Special Tools
  478
- Torque Specifications
  478
- Under-Dash Components
  478
- Instrument Cluster
  479
  - Overview
    479
  - Information Display Area
    481
  - Diagnostic Mode
    484
- Switches
  486
  - Brake Light Switch
    486
  - Headlamp Switch
    486
  - Ignition (Key) Switch
    487
  - Awd / 2Wd Switch (Models Without Turf)
    487
  - Transmission (Gear Position) Switch
    488
  - Seat Belt Switch
    489
- All Wheel Drive Coil
  490
  - Operation Overview
    490
  - Diagnosing System Failures
    490
- Vehicle Speed Sensor
  491
  - Speed Sensor Location
    491
  - Speed Sensor Testing
    491
- Ignition Coil
  492
  - Operation Overview
    492
  - Ignition Coil / Ht Lead Replacement
    492
  - Ignition Coil Tests
    492
- Charging System
  493
  - Current Draw - Key off
    493
  - Charging System "Break Even" Test
    493
  - Charging System Stator (Alternator) Tests
    493
  - Stator (Alternator) Replacement
    494
  - Regulator / Rectifier
    495
  - Charging System Testing Flow Chart
    496
- Battery
  497
  - Battery Specifications
    497
  - General Battery Information
    497
  - Battery Removal / Installation
    498
  - Battery off Season Storage
    498
  - Battery Testing
    498
  - Ocv - Open Circuit Voltage Test
    498
  - Load Test
    498
  - Battery Conductance Analyzer
    498
  - Charging Procedure
    499
- Lighting System
  500
  - Headlight Adjustment
    500
  - Headlamp Replacement
    500
  - Headlamp Installation
    501
  - Taillight Replacement
    501
  - Dash Light
    501
- Cooling System
  502
  - Fan Control Circuit Operation / Testing
    502
  - Fan Control Circuit Bypass Test
    502
  - Engine Coolant Temperature Sensor (Ect) Overview
    502
  - Ect Sensor Test
    502
  - Ect Sensor Replacement
    503
- Starting System
  504
  - Troubleshooting
    504
  - Voltage Drop Test
    504
  - Starter Motor Removal
    504
  - Starter Motor Installation
    505
  - Starter Solenoid Bench Test
    505
  - Starter Solenoid Operation
    505
  - Starter Fails to Turn over the Engine
    506
- Electronic Power Steering
  507
- Fuses / Relays
  513
  - Overview / Operation
    513
  - Fuse Box Detail (2014)
    514
  - Fuse Box Detail (2015-2016)
    515
  - Relay Operation
    515
- Can System
  517
  - Can System Overview
    517
  - Can System Testing
    517
- Break-Out Diagrams
  518
  - Awd
    518
  - Vehicle Speed Sensor
    519
  - Cooling System
    520
  - Unswitched Chassis Power
    521
  - Key-On Battery Power
    522
  - Lights
    523

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