Polaris RZR XP4 1000 Manuals

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

Polaris RZR XP4 1000 Service Manual (539 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 52.82 MB

Table of Contents
5
Vehicle Identification
8
Model Number Designation
8
Vehicle Identification Number
9
Vehicle Identification Number (Vin) Designation (2015+)
9
Vehicle and Engine Serial Number Location
10
Vehicle Information
11
Replacement Keys
11
Publication Numbers
11
Special Tools
12
General Specifications
16
Rzr Xp 1000 Clutch Chart
17
Rzr Xp 4 1000
19
Rzr 1000 Xp4
20
Rzr Xp 1000 Eps High Lifter
22
2015 Rzr Xp 1000 High Lifter
24
2015 Rzr Xp 1000 Desert Edition
24
2015 Rzr Xp 1000 Desert Edition Clutch Chart
26
Misc. Specifications and Charts
27
Master Torque Table
27
Conversion Table
29
Standard Bolt Torque Specification
30
Metric Bolt Torque Specification
30
Sae Tap / Drill Sizes
31
Metric Tap / Drill Sizes
31
Decimal Equivalents
32
Periodic Maintenance Chart
35
Periodic Maintenance Overview
35
Break-In Period
35
Maintenance Chart Key
35
Pre-Ride - 50 Hour Maintenance Interval
36
50 - 500 Hour Maintenance Interval
37
Maintenance Quick Reference
38
Maintenance Quick Reference, Continued
39
Grease Lubrication Points
40
Lubricants / Service Products
41
Polaris Lubricants, Maintenance and Service Products
41
General Vehicle Inspection and Maintenance
42
Pre-Ride / Daily Inspection
42
Shift Cable Inspection / Adjustment
42
Fuel System and Air Intake
44
Fuel System
44
Fuel Tank Vent Line
44
Fuel Pump / Fuel Filters
45
Fuel Lines
45
Throttle Pedal Inspection
46
Engine Intake Pre-Filter Service
46
Air Filter Service
47
Intake Duct Drain Inspection
47
Air Box / Air Filter Assembly View
48
Engine
49
Engine Oil Level
49
Engine Oil and Filter Change
50
Engine Crankcase Breather Hose Inspection
51
Engine Cylinder Leakdown Test
52
Valve Clearance Inspection
52
Transmission and Front Gearcase
55
Specification Chart
55
Transmission Lubrication
55
Front Gearcase Lubrication
56
Cooling System
58
Cooling System Overview
58
Coolant Strength
58
Coolant Level Inspection
58
Cooling System Pressure Test
59
Cooling System Hoses
59
Maintenance
59
Radiator Inspection / Cleaning
60
Coolant Drain / Fill
61
Pvt / Final Drive / Wheel and Tire
62
Drive Clutch / Driven Clutch / Belt Service
62
Pvt Intake Pre-Filter Service
62
Pvt Drying
62
Pvt System
62
Drive Shaft Boot Inspection
63
Wheel and Hub Torque Table
63
Wheel Removal
63
Transmission
63
Wheel Installation
64
Tire Inspection
64
Tire Pressure
64
Beadlock Rims (Desert Edition)
65
Electrical and Ignition System
66
Battery Maintenance
66
Battery Charging / off Season Storage
66
Battery Removal
66
Battery Installation
67
Engine / Chassis Electrical Ground
67
Spark Plug Service
68
Electrical
68
Steering
69
Steering Inspection
69
Steering Wheel Freeplay
69
Tie Rod End / Wheel Hub Inspection
70
Wheel Toe Alignment Inspection
70
Final Drive
70
Wheel Toe Adjustment
71
Suspension (Walker Evans™)
72
Spring Adjustment
72
Shock Compression Adjustment
73
Brake System
74
Brake Fluid Inspection
74
Brake Pad / Disc Inspection
74
Brake Hose and Fitting Inspection
75
General Information
79
Special Tools
79
Engine Lubrication Specifications
79
Oil Pressure Test
80
Engine Oil Flow Chart
81
Engine Service Specifications
82
Engine Specifications
82
Engine Detail - Torque Values / Sequences / Assembly Notes
84
Main Engine Components - Torque Specification and Sequence
84
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
85
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
86
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
87
Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
88
Engine Cooling System
88
Cooling System Pressure Test
89
Cooling System Pressure Cap Test
90
Radiator Removal / Installation
90
Thermostat Replacement
91
Cooling System Assembly View
93
Cooling System Bleeding Procedure
94
Water Pump Removal
95
Water Pump Installation
95
Water Pump Service
97
Engine Service
100
Accessible Engine Components
100
Top-End Service (Engine in Chassis)
100
Engine Removal
100
Engine Installation
104
Engine Mounting and Torque Values
107
Engine Break-In Period
108
Engine Lubrication Specifications
108
Engine Disassembly / Inspection - Top End
109
Valve Cover Removal
109
Camshaft Removal
109
Camshaft Sprocket Inspection
111
Camshaft / Camshaft Bore Inspection
111
Cylinder Head Removal
113
Cylinder Head Warp Inspection
113
Cylinder Head Disassembly
114
Valve Inspection
115
Combustion Chamber Cleaning
116
Valve Sealing Test
116
Valve Seat Reconditioning
117
Engine Disassembly / Inspection - Lower End
120
Stator Cover Removal / Inspection
120
Water Pump Housing Removal
121
Flywheel Removal
122
Starter One-Way Clutch Disassembly
123
Crankcase Disassembly / Inspection
124
Balance Shaft Removal / Inspection
126
Crankshaft Removal / Inspection
127
Crankcase Inspection
130
Cylinder Inspection
131
Cylinder / Piston Removal
132
Piston Disassembly / Inspection
133
Piston Ring Removal
134
Piston Ring to Groove Clearance Inspection
134
Piston Ring Installed Gap
135
Piston-To-Cylinder Clearance
135
Connecting Rod Inspection
136
Engine Assembly - Lower End
138
Bearing Selection Identification Letters and Numbers
138
Connecting Rod Bearing Selection
139
Crankshaft Main Bearing Selection
139
Upper Crankcase Preparation
140
Piston Ring Installation
140
Piston / Connecting Rod Assembly
142
Cylinder / Piston Installation
143
Crankshaft Installation
144
Balance Shaft Installation
146
Lower Crankcase Preparation
146
Crankcase Assembly
147
Starter One-Way Clutch Assembly
151
Flywheel Installation
152
Stator Cover Installation
152
Engine Assembly - Top End
153
Cylinder Head Assembly
153
Cylinder Head Installation
154
Camshaft Installation / Timing
155
Camshaft Timing - Quick Reference
159
Valve Clearance Adjustment
160
Intake Valve Lash - Tappet Selection Matrix
162
Exhaust Valve Lash - Tappet Selection Matrix
163
Valve Cover Installation
164
Troubleshooting
165
Engine Cooling System
165
General Information
169
Special Tools
169
Efi Service Notes
171
Efi System Assembly View
172
Efi System Component Locations
173
Fuel Tank
175
Assembly View
175
Fuel Line Removal / Installation
176
Fuel Tank Removal
176
Fuel Tank Installation
179
Fuel Tank Removal Rzr Xp 4 1000
180
Fuel Tank Installation Rzr Xp 4 1000
182
Electronic Fuel Injection
183
Principal Components
183
Efi Operation Overview
183
Initial Priming / Starting Procedure
183
Electronic Control Unit (Ecu)
184
Operation Overview
184
Ecu Service
184
Ecu Replacement
184
Fuel Injectors
186
Operation Overview
186
Fuel Injector Troubleshooting
186
Fuel Injector Test
187
Fuel Injector Replacement
187
Fuel Pump
191
Operation Overview
191
Fuel Sender Test
191
Fuel Pump Test
192
Fuel Pump Replacement
193
Temperature / Manifold Absolute Pressure (T-Map) Sensor
197
Operation Overview
197
T-Map Test / Replacement
197
Crankshaft Position Sensor (Cps)
198
Operation Overview
198
Cps Test
198
Cps Replacement
199
Throttle Body Assembly
200
Operation Overview
200
Throttle Body Service
200
Throttle Body Removal
200
Electronic Throttle Control (Etc)
202
Operation Overview
202
Etc Test
202
Etc Replacement
202
Pedal Position Sensor (Pps)
203
Operation Overview
203
Location
203
Pps Test
203
Pps Replacement
203
Oxygen Sensor (My15 Only)
205
Oxygen Sensor Information
205
Efi Diagnostics
206
Trouble Code Display (Etc)
206
Efi Troubleshooting
211
Digital Wrench® Operation
212
Digital Wrench® Diagnostic Software Overview
212
Special Tools (Also Refer to the Beginning of this Chapter)
212
Digital Wrench Software Version and Update
213
Digital Wrench® Updates
213
Digital Wrench® Communication Errors
214
Digital Wrench® - Diagnostic Connector
214
Guided Diagnostics
215
Digital Wrench® Serial Number Location
215
Digital Wrench® Feature Map
216
Ecu Replacement
217
Ecu Reprogramming (Reflash)
217
General Information
222
Special Tools and Supplies
222
Pvt System Torque Specifications
222
Rzr Xp 1000 Clutch Chart
223
Pvt System Overview
224
General Operation
224
Drive Clutch Operation
224
Driven Clutch Operation
225
Pvt Break-In (Drive Belt / Clutches)
225
Maintenance / Inspection
226
Overheating / Diagnosis
227
Pvt System Service
228
Pvt Covers and Ducting Components (High Lifter)
230
Pvt Disassembly
231
Pvt Assembly
233
Drive Belt
235
Belt Removal
235
Belt Inspection
236
Belt Installation
236
Pvt Break-In (Drive Belt / Clutches)
236
Drive Clutch Service
237
Drive Clutch Assembly View
237
Drive Clutch Disassembly / Inspection
238
Needle Bearing Inspection
239
Shift Weight Inspection
240
Button to Tower Clearance Inspection
240
Spider Removal
241
Roller, Pin, and Thrust Washer Inspection
241
Clutch Inspection
242
Moveable Sheave Bushing Inspection
243
Bushing Service
243
Drive Clutch Assembly
245
Driven Clutch Service
248
Clutch Disassembly
248
Bushing Service
251
Clutch Assembly
252
Assembly View
256
Troubleshooting
257
Specifications
260
Special Tools
260
Torque Specifications
260
Lubrication
260
Transmission Mounting and Torque Values
261
Shift Lever
262
Removal
262
Installation
262
Shift Cable
263
Inspection
263
Adjustment
263
Transmission Service
264
Transmission Removal
264
Transmission Installation
267
Transmission Disassembly
270
Differential Operation (Turf Mode Models Only)
274
Planetary Differential Disassembly (Turf Mode Models Only)
276
Planetary Differential Bushing Replacement (Turf Mode Models Only)
277
Planetary Differential Assembly (Turf Mode Models Only)
279
Gear / Shaft / Bearing Inspection
280
Transmission Assembly / Snorkel Gear Backlash Procedure
281
Transmission Assembly View
287
Transmission Service (Int
289
Differential Operation (Turf Mode Models Only)
289
Transmission Disassembly
290
Planetary Differential Disassembly (Turf Mode Models Only)
296
Planetary Differential Bushing Replacement (Turf Mode Models Only)
297
Planetary Differential Assembly (Turf Mode Models Only)
299
Gear / Shaft / Bearing Inspection
300
Snorkel Gear Backlash Procedure
301
Transmission Assembly View (Turf Mode Models)
309
Troubleshooting
311
Shifting Difficulty
311
General Information
314
Special Tools
314
Final Drive Torque Specifications
314
Bearing Carrier
315
Front Bearing Carrier Inspection / Removal
315
Front Bearing Replacement
316
Front Bearing Carrier Installation
317
Rear Bearing Carrier Inspection / Removal
318
Rear Bearing Replacement
320
Rear Bearing Carrier Installation
321
Drive Shaft
323
Front Drive Shaft Removal
323
Front Drive Shaft Installation
324
Rear Drive Shaft Removal
325
Rear Drive Shaft Installation
326
Drive Shaft / CV Joint Handling Tips
328
Outer CV Joint / Boot Replacement
329
Inner Plunging Joint / Boot Replacement
331
Drive Shaft Assembly View
334
Front Propshaft Service
335
Front Propshaft Removal
335
Front Prop Shaft Installation
336
Rear Prop Shaft Removal
336
Rear Prop Shaft Installation
337
Rear Prop Shaft Removal XP 4
338
Rear Prop Shaft Installation
339
Support Bearing Replacement
340
Prop Shaft U-Joint Service
341
All Wheel Drive Operation
343
Awd Diagnosis
344
Front Gearcase Removal
345
Front Gearcase Disassembly / Inspection
346
Front Gearcase Assembly
349
Front Gearcase Installation
351
Wheel Hubs
353
Front Hub Assembly View
353
Rear Hub Assembly View
353
Beadlock Rims (Desert Edition)
354
General Information
357
Special Tools
357
Multi-Function Pliers
357
Steering / Suspension
357
Steering Assembly
359
Assembly View (Non-Eps Models)
359
Steering Wheel Removal (Non-Eps Models)
360
Steering Shaft Removal (Non-Eps Models)
360
Steering Shaft Bearing Replacement
361
Electronic Power Steering Assembly
363
Assembly View (Eps Models)
363
Steering Wheel Removal (Eps Models)
365
Power Steering Unit Removal
365
Lower Steering Shaft Removal (Eps Models)
367
Lower Steering Shaft Installation (Eps Models)
367
Power Steering Unit Installation
368
Upper Steering Shaft Installation (Eps Models)
369
Front A-Arms
370
Front A-Arm Removal / Replacement
370
Ball Joint Service
373
Ball Joint Service Preparation
373
Ball Joint Removal
373
Ball Joint Installation
374
Rear Radius Rods
375
Radius Rod Removal / Installation
375
Rear Trailing Arm
376
Trailing Arm Removal / Installation
376
Trailing Arm Spherical Bearing Replacement
378
Rear Suspension Assembly View
379
Rear Stabilizer Bar
380
Stabilizer Bar Removal
380
Stabilizer Bar Installation
380
Shocks / Springs / Fasteners
381
Front Shock Assembly View
381
Rear Shock Assembly View
381
Shock Removal / Installation
382
Shock Replacement
382
Walker Evans™Shock Assembly Views
383
Walker Evans™ 2.0" Front Shock
383
Walker Evans™ 2.5" Rear Shock
384
Walker Evans™ Shock Service
385
General Service Information
385
Front Shock Service Information
385
Rear Shock Service Information
387
Special Tools
390
Valve Shim Arrangement
390
Shock Piston Orientation
390
Walker Evans™ Shock Disassembly
390
Walker Evans™ Shock Assembly
393
General Information
401
Special Tools
401
General Specifications
401
Torque Specifications
402
Brake System Service Notes
402
Brake Noise Troubleshooting
403
Hydraulic Brake System Operation
403
Brake System
403
Brake System Assembly View
404
Master Cylinder
405
Master Cylinder Removal
405
Master Cylinder Installation
406
Brake Bleeding / Fluid Change
406
Brake Pedal Lever
408
Brake Pedal Removal
408
Brake Pedal Installation
408
Parking Brake (Int'l Model)
409
Parking Brake Assembly View
409
Parking Brake Inspection
410
Parking Brake Cable Adjustment
410
Parking Brake Caliper
411
Parking Brake Disc
414
Front Brake Pads
417
Pad Removal
417
Pad Inspection
418
Pad Assembly / Installation
418
Brake Burnishing Procedure
419
Front Caliper Service
420
Caliper Assembly View
420
Caliper Removal
421
Caliper Disassembly
422
Caliper Inspection
423
Caliper Assembly
423
Caliper Installation
424
Front Brake Disc
425
Disc Runout
425
Disc Inspection
425
Disc Replacement
426
Rear Brake Pads
427
Pad Removal
427
Pad Inspection
428
Pad Assembly / Installation
429
Brake Burnishing Procedure
430
Rear Caliper Service
431
Caliper Assembly View
431
Caliper Removal
432
Caliper Disassembly
433
Caliper Inspection
433
Caliper Assembly
434
Caliper Installation
434
Rear Brake Disc
436
Disc Inspection
436
Disc Replacement
436
Troubleshooting
438
Poor Brake Performance
438
Pedal Vibration
438
Caliper Overheats (Brakes Drag)
438
Brakes Lock
438
General Information
440
Special Tools
440
Torque Specifications
440
Body Assembly Views
441
Cab Frame Assembly Xp / High Lifter
441
Cab Frame Assembly XP 4
442
Doors
443
Doors
444
Doors High Lifter
445
Dash Instruments / Controls
446
Dash Instruments / Controls High Lifter
447
Hood / Front Body Work
448
Chassis / Main Frame Xp / High Lifter
449
Chassis / Main Frame XP 4
450
Seat Assembly Front
451
Seat Assembly Rear
452
Floor / Rocker Panels Xp / High Lifter
453
Floor / Rocker Panels XP 4
454
Rear Cargo Box / Fenders
455
Rear Bumper
456
Body Component Removal
457
Seats
457
Engine Service Panel
457
Front Bumper Xp
457
Rear Bumper
458
Hood and Front Body Work
458
Rear Fender / Fender Flare Removal Xp / High Lifter
459
Rear Fender Flare / Rear Fender Removal Xp
460
Cargo Box Assembly Removal
460
Rocker Panels, Console and Floor Xp / High Lifter
461
Rocker Panels, Rear Console and Floor Xp
462
Decal Replacement
465
General Information
469
Special Tools
469
Electrical Service Notes
469
Under-Dash Components
469
Instrument Cluster
470
Overview
470
Rider Information Display
472
Information Display Area
473
Diagnostic Mode
476
Instrument Cluster Removal
478
Instrument Cluster Installation
478
Switches
479
Brake Light Switch
479
Headlamp Switch
479
Ignition (Key) Switch
480
Awd / 2Wd Switch (Models Without Turf)
480
Transmission (Gear Position) Switch
481
Seat Belt Switch
482
All Wheel Drive Coil
483
Operation Overview
483
Diagnosing System Failures
483
Vehicle Speed Sensor
484
Speed Sensor Location
484
Speed Sensor Testing
484
Ignition Coil
485
Operation Overview
485
Ignition Coil / Ht Lead Replacement
485
Ignition Coil Tests
486
Lighting System
487
Headlight Adjustment
487
Headlamp Replacement
488
Headlamp Installation
489
Taillight Replacement
489
Dash Light
490
Cooling System
491
Fan Control Circuit Operation / Testing
491
Fan Control Circuit Bypass Test
491
Engine Coolant Temperature Sensor (Ect) Overview
491
Ect Sensor Test
492
Ect Sensor Replacement
492
Fuse / Relay Box
493
Overview / Operation
493
Fuse Box Detail
494
Relay Operation
495
Charging System
497
Current Draw - Key off
497
Charging System "Break Even" Test
497
Charging System Stator (Alternator) Tests
498
Stator (Alternator) Replacement
499
Regulator / Rectifier
499
Charging System Testing Flow Chart
500
Battery
501
Battery Specifications
501
General Battery Information
501
Battery Removal / Installation
502
Battery off Season Storage
502
Battery Testing
502
Ocv - Open Circuit Voltage Test
502
Load Test
503
Battery Conductance Analyzer
503
Charging Procedure
503
Starting System
504
Troubleshooting
504
Voltage Drop Test
504
Starter Motor Removal
505
Starter Motor Installation
505
Starter Solenoid Bench Test
506
Starter Solenoid Operation
506
Condition: Starter Fails to Turn over the Engine
506
Electronic Power Steering (Eps)
507
Eps Operation
507
Proper Eps System Diagnosing
507
Eps System Breakout
508
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
509
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
510
Eps Troubleshooting (Using Digital Wrench®)
511
Electrical System Breakout Diagrams
512
Awd
512
Vehicle Speed Sensor
513
Cooling System
514
Unswitched Chassis Power
515
Key-On Battery Power
516
Lights
517
Charging System
518

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Polaris RZR XP4 1000 Manuals

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

Polaris RZR XP4 1000 Service Manual (539 pages)

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