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RZR XP4 1000
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
Table of Contents
8
Chapter 1
8
Vehicle Identification
8
Model Number Designation
9
Vehicle Identification Number
9
Vehicle Identification Number (Vin) Designation (2015+)
10
Vehicle and Engine Serial Number Location
11
Vehicle Information
11
Replacement Keys
11
Publication Numbers
12
Special Tools
16
General Specifications
17
Rzr Xp 1000 Clutch Chart
19
Rzr Xp 4 1000
20
Rzr 1000 Xp4
22
Rzr Xp 1000 Eps High Lifter
24
2015 Rzr Xp 1000 High Lifter
24
2015 Rzr Xp 1000 Desert Edition
26
2015 Rzr Xp 1000 Desert Edition Clutch Chart
27
Misc. Specifications and Charts
27
Master Torque Table
29
Conversion Table
30
Standard Bolt Torque Specification
30
Metric Bolt Torque Specification
31
Sae Tap / Drill Sizes
31
Metric Tap / Drill Sizes
32
Decimal Equivalents
33
Maintenance Chapter 2 Maintenance
35
Chapter 2
35
Periodic Maintenance Chart
35
Periodic Maintenance Overview
35
Break-In Period
35
Maintenance Chart Key
36
Pre-Ride - 50 Hour Maintenance Interval
37
50 - 500 Hour Maintenance Interval
38
Maintenance Quick Reference
39
Maintenance Quick Reference, Continued
40
Grease Lubrication Points
41
Lubricants / Service Products
41
Polaris Lubricants, Maintenance and Service Products
42
General Vehicle Inspection and Maintenance
42
Pre-Ride / Daily Inspection
42
Shift Cable Inspection / Adjustment
44
Fuel System and Air Intake
44
Fuel System
44
Fuel Tank Vent Line
45
Fuel Pump / Fuel Filters
45
Fuel Lines
46
Throttle Pedal Inspection
46
Engine Intake Pre-Filter Service
47
Air Filter Service
47
Intake Duct Drain Inspection
48
Air Box / Air Filter Assembly View
49
Engine
49
Engine Oil Level
50
Engine Oil and Filter Change
51
Engine Crankcase Breather Hose Inspection
52
Engine Cylinder Leakdown Test
52
Valve Clearance Inspection
55
Transmission and Front Gearcase
55
Specification Chart
55
Transmission Lubrication
56
Front Gearcase Lubrication
58
Cooling System
58
Cooling System Overview
58
Coolant Strength
58
Coolant Level Inspection
59
Cooling System Pressure Test
59
Cooling System Hoses
59
Maintenance
60
Radiator Inspection / Cleaning
61
Coolant Drain / Fill
62
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
63
Drive Shaft Boot Inspection
63
Wheel and Hub Torque Table
63
Wheel Removal
63
Transmission
64
Wheel Installation
64
Tire Inspection
64
Tire Pressure
65
Beadlock Rims (Desert Edition)
66
Electrical and Ignition System
66
Battery Maintenance
66
Battery Charging / Off Season Storage
66
Battery Removal
67
Battery Installation
67
Engine / Chassis Electrical Ground
68
Spark Plug Service
68
Electrical
69
Steering
69
Steering Inspection
69
Steering Wheel Freeplay
70
Tie Rod End / Wheel Hub Inspection
70
Wheel Toe Alignment Inspection
70
Final Drive
71
Wheel Toe Adjustment
72
Suspension (Walker Evans™)
72
Spring Adjustment
73
Shock Compression Adjustment
74
Brake System
74
Brake Fluid Inspection
74
Brake Pad / Disc Inspection
75
Brake Hose and Fitting Inspection
77
Chapter 3 Engine / Cooling System
79
General Information
79
Special Tools
79
Engine Lubrication Specifications
80
Oil Pressure Test
81
Engine Oil Flow Chart
82
Engine Service Specifications
82
Engine Specifications
84
Engine Detail - Torque Values / Sequences / Assembly Notes
84
Main Engine Components - Torque Specification and Sequence
85
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
86
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
87
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
88
Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
88
Engine Cooling System
89
Cooling System Pressure Test
90
Cooling System Pressure Cap Test
90
Radiator Removal / Installation
91
Thermostat Replacement
93
Cooling System Assembly View
94
Cooling System Bleeding Procedure
95
Water Pump Removal
95
Water Pump Installation
97
Water Pump Service
100
Engine Service
100
Accessible Engine Components
100
Top-End Service (Engine in Chassis)
100
Engine Removal
104
Engine Installation
107
Engine Mounting and Torque Values
108
Engine Break-In Period
108
Engine Lubrication Specifications
109
Engine Disassembly / Inspection - Top End
109
Valve Cover Removal
109
Camshaft Removal
111
Camshaft Sprocket Inspection
111
Camshaft / Camshaft Bore Inspection
113
Cylinder Head Removal
113
Cylinder Head Warp Inspection
114
Cylinder Head Disassembly
115
Valve Inspection
116
Combustion Chamber Cleaning
116
Valve Sealing Test
117
Valve Seat Reconditioning
120
Engine Disassembly / Inspection - Lower End
120
Stator Cover Removal / Inspection
121
Water Pump Housing Removal
122
Flywheel Removal
123
Starter One-Way Clutch Disassembly
124
Crankcase Disassembly / Inspection
126
Balance Shaft Removal / Inspection
127
Crankshaft Removal / Inspection
130
Crankcase Inspection
131
Cylinder Inspection
132
Cylinder / Piston Removal
133
Piston Disassembly / Inspection
134
Piston Ring Removal
134
Piston Ring to Groove Clearance Inspection
135
Piston Ring Installed Gap
135
Piston-To-Cylinder Clearance
136
Connecting Rod Inspection
138
Engine Assembly - Lower End
138
Bearing Selection Identification Letters and Numbers
139
Connecting Rod Bearing Selection
139
Crankshaft Main Bearing Selection
140
Upper Crankcase Preparation
140
Piston Ring Installation
142
Piston / Connecting Rod Assembly
143
Cylinder / Piston Installation
144
Crankshaft Installation
146
Balance Shaft Installation
146
Lower Crankcase Preparation
147
Crankcase Assembly
151
Starter One-Way Clutch Assembly
152
Flywheel Installation
152
Stator Cover Installation
153
Engine Assembly - Top End
153
Cylinder Head Assembly
154
Cylinder Head Installation
155
Camshaft Installation / Timing
159
Camshaft Timing - Quick Reference
160
Valve Clearance Adjustment
162
Intake Valve Lash - Tappet Selection Matrix
163
Exhaust Valve Lash - Tappet Selection Matrix
164
Valve Cover Installation
165
Troubleshooting
165
Engine Cooling System
167
Chapter 4 Fuel System
169
General Information
169
Special Tools
171
Efi Service Notes
172
Efi System Assembly View
173
Efi System Component Locations
175
Fuel Tank
175
Assembly View
176
Fuel Line Removal / Installation
176
Fuel Tank Removal
179
Fuel Tank Installation
180
Fuel Tank Removal Rzr Xp 4 1000
182
Fuel Tank Installation Rzr Xp 4 1000
183
Electronic Fuel Injection
183
Principal Components
183
Efi Operation Overview
183
Initial Priming / Starting Procedure
184
Electronic Control Unit (Ecu)
184
Operation Overview
184
Ecu Service
184
Ecu Replacement
186
Fuel Injectors
186
Operation Overview
186
Fuel Injector Troubleshooting
187
Fuel Injector Test
187
Fuel Injector Replacement
191
Fuel Pump
191
Operation Overview
191
Fuel Sender Test
192
Fuel Pump Test
193
Fuel Pump Replacement
197
Temperature / Manifold Absolute Pressure (T-Map) Sensor
197
Operation Overview
197
T-Map Test / Replacement
198
Crankshaft Position Sensor (Cps)
198
Operation Overview
198
Cps Test
199
Cps Replacement
200
Throttle Body Assembly
200
Operation Overview
200
Throttle Body Service
200
Throttle Body Removal
202
Electronic Throttle Control (Etc)
202
Operation Overview
202
Etc Test
202
Etc Replacement
203
Pedal Position Sensor (Pps)
203
Operation Overview
203
Location
203
Pps Test
203
Pps Replacement
205
Oxygen Sensor (My15 Only)
205
Oxygen Sensor Information
206
Efi Diagnostics
206
Trouble Code Display (Etc)
211
Efi Troubleshooting
212
Digital Wrench® Operation
212
Digital Wrench® Diagnostic Software Overview
212
Special Tools (Also Refer to the Beginning of This Chapter)
213
Digital Wrench Software Version and Update
213
Digital Wrench® Updates
214
Digital Wrench® Communication Errors
214
Digital Wrench® - Diagnostic Connector
215
Guided Diagnostics
215
Digital Wrench® Serial Number Location
216
Digital Wrench® Feature Map
217
Ecu Replacement
217
Ecu Reprogramming (Reflash)
221
Pvt System Chapter 5 Pvt System
222
Chapter 5
222
General Information
222
Special Tools and Supplies
222
Pvt System Torque Specifications
223
Rzr Xp 1000 Clutch Chart
224
Pvt System Overview
224
General Operation
224
Drive Clutch Operation
225
Driven Clutch Operation
225
Pvt Break-In (Drive Belt / Clutches)
226
Maintenance / Inspection
227
Overheating / Diagnosis
228
Pvt System Service
230
Pvt Covers and Ducting Components (High Lifter)
231
Pvt Disassembly
233
Pvt Assembly
235
Drive Belt
235
Belt Removal
236
Belt Inspection
236
Belt Installation
236
Pvt Break-In (Drive Belt / Clutches)
237
Drive Clutch Service
237
Drive Clutch Assembly View
238
Drive Clutch Disassembly / Inspection
239
Needle Bearing Inspection
240
Shift Weight Inspection
240
Button to Tower Clearance Inspection
241
Spider Removal
241
Roller, Pin, and Thrust Washer Inspection
242
Clutch Inspection
243
Moveable Sheave Bushing Inspection
243
Bushing Service
245
Drive Clutch Assembly
248
Driven Clutch Service
248
Clutch Disassembly
251
Bushing Service
252
Clutch Assembly
256
Assembly View
257
Troubleshooting
259
Chapter 6 Transmission
260
Specifications
260
Special Tools
260
Torque Specifications
260
Lubrication
261
Transmission Mounting and Torque Values
262
Shift Lever
262
Removal
262
Installation
263
Shift Cable
263
Inspection
263
Adjustment
264
Transmission Service
264
Transmission Removal
267
Transmission Installation
270
Transmission Disassembly
274
Differential Operation (Turf Mode Models Only)
276
Planetary Differential Disassembly (Turf Mode Models Only)
277
Planetary Differential Bushing Replacement (Turf Mode Models Only)
279
Planetary Differential Assembly (Turf Mode Models Only)
280
Gear / Shaft / Bearing Inspection
281
Transmission Assembly / Snorkel Gear Backlash Procedure
287
Transmission Assembly View
289
Transmission Service (Int
289
Differential Operation (Turf Mode Models Only)
290
Transmission Disassembly
296
Planetary Differential Disassembly (Turf Mode Models Only)
297
Planetary Differential Bushing Replacement (Turf Mode Models Only)
299
Planetary Differential Assembly (Turf Mode Models Only)
300
Gear / Shaft / Bearing Inspection
301
Snorkel Gear Backlash Procedure
309
Transmission Assembly View (Turf Mode Models)
311
Troubleshooting
311
Shifting Difficulty
313
Final Drive Chapter 7 Final Drive
314
Chapter 7
314
General Information
314
Special Tools
314
Final Drive Torque Specifications
315
Bearing Carrier
315
Front Bearing Carrier Inspection / Removal
316
Front Bearing Replacement
317
Front Bearing Carrier Installation
318
Rear Bearing Carrier Inspection / Removal
320
Rear Bearing Replacement
321
Rear Bearing Carrier Installation
323
Drive Shaft
323
Front Drive Shaft Removal
324
Front Drive Shaft Installation
325
Rear Drive Shaft Removal
326
Rear Drive Shaft Installation
328
Drive Shaft / CV Joint Handling Tips
329
Outer CV Joint / Boot Replacement
331
Inner Plunging Joint / Boot Replacement
334
Drive Shaft Assembly View
335
Front Propshaft Service
335
Front Propshaft Removal
336
Front Prop Shaft Installation
336
Rear Prop Shaft Removal
337
Rear Prop Shaft Installation
338
Rear Prop Shaft Removal XP 4
339
Rear Prop Shaft Installation
340
Support Bearing Replacement
341
Prop Shaft U-Joint Service
343
All Wheel Drive Operation
344
Awd Diagnosis
345
Front Gearcase Removal
346
Front Gearcase Disassembly / Inspection
349
Front Gearcase Assembly
351
Front Gearcase Installation
353
Wheel Hubs
353
Front Hub Assembly View
353
Rear Hub Assembly View
354
Beadlock Rims (Desert Edition)
355
Steering / Suspension Chapter 8 Steering / Suspension
357
Chapter 8
357
General Information
357
Special Tools
357
Multi-Function Pliers
357
Steering / Suspension
359
Steering Assembly
359
Assembly View (Non-Eps Models)
360
Steering Wheel Removal (Non-Eps Models)
360
Steering Shaft Removal (Non-Eps Models)
361
Steering Shaft Bearing Replacement
363
Electronic Power Steering Assembly
363
Assembly View (Eps Models)
365
Steering Wheel Removal (Eps Models)
365
Power Steering Unit Removal
367
Lower Steering Shaft Removal (Eps Models)
367
Lower Steering Shaft Installation (Eps Models)
368
Power Steering Unit Installation
369
Upper Steering Shaft Installation (Eps Models)
370
Front A-Arms
370
Front A-Arm Removal / Replacement
373
Ball Joint Service
373
Ball Joint Service Preparation
373
Ball Joint Removal
374
Ball Joint Installation
375
Rear Radius Rods
375
Radius Rod Removal / Installation
376
Rear Trailing Arm
376
Trailing Arm Removal / Installation
378
Trailing Arm Spherical Bearing Replacement
379
Rear Suspension Assembly View
380
Rear Stabilizer Bar
380
Stabilizer Bar Removal
380
Stabilizer Bar Installation
381
Shocks / Springs / Fasteners
381
Front Shock Assembly View
381
Rear Shock Assembly View
382
Shock Removal / Installation
382
Shock Replacement
383
Walker Evans™Shock Assembly Views
383
Walker Evans™ 2.0" Front Shock
384
Walker Evans™ 2.5" Rear Shock
385
Front Shock Service Information
385
General Service Information
385
Walker Evans™ Shock Service
387
Rear Shock Service Information
390
Shock Piston Orientation
390
Special Tools
390
Valve Shim Arrangement
390
Walker Evans™ Shock Disassembly
393
Walker Evans™ Shock Assembly
399
Brake System Chapter 9 Brake System
401
Chapter 9
401
General Information
401
Special Tools
401
General Specifications
402
Torque Specifications
402
Brake System Service Notes
403
Brake Noise Troubleshooting
403
Hydraulic Brake System Operation
403
Brake System
404
Brake System Assembly View
405
Master Cylinder
405
Master Cylinder Removal
406
Master Cylinder Installation
406
Brake Bleeding / Fluid Change
408
Brake Pedal Lever
408
Brake Pedal Removal
408
Brake Pedal Installation
409
Parking Brake (Int'l Model)
409
Parking Brake Assembly View
410
Parking Brake Inspection
410
Parking Brake Cable Adjustment
411
Parking Brake Caliper
414
Parking Brake Disc
417
Front Brake Pads
417
Pad Removal
418
Pad Inspection
418
Pad Assembly / Installation
419
Brake Burnishing Procedure
420
Front Caliper Service
420
Caliper Assembly View
421
Caliper Removal
422
Caliper Disassembly
423
Caliper Inspection
423
Caliper Assembly
424
Caliper Installation
425
Front Brake Disc
425
Disc Runout
425
Disc Inspection
426
Disc Replacement
427
Rear Brake Pads
427
Pad Removal
428
Pad Inspection
429
Pad Assembly / Installation
430
Brake Burnishing Procedure
431
Rear Caliper Service
431
Caliper Assembly View
432
Caliper Removal
433
Caliper Disassembly
433
Caliper Inspection
434
Caliper Assembly
434
Caliper Installation
436
Rear Brake Disc
436
Disc Inspection
436
Disc Replacement
438
Troubleshooting
438
Poor Brake Performance
438
Pedal Vibration
438
Caliper Overheats (Brakes Drag)
438
Brakes Lock
439
Body / Frame Chapter 10 Body / Frame
440
Chapter 10
440
General Information
440
Special Tools
440
Torque Specifications
441
Body Assembly Views
441
Cab Frame Assembly Xp / High Lifter
442
Cab Frame Assembly XP 4
443
Doors
444
Doors
445
Doors High Lifter
446
Dash Instruments / Controls
447
Dash Instruments / Controls High Lifter
448
Hood / Front Body Work
449
Chassis / Main Frame Xp / High Lifter
450
Chassis / Main Frame XP 4
451
Seat Assembly Front
452
Seat Assembly Rear
453
Floor / Rocker Panels Xp / High Lifter
454
Floor / Rocker Panels XP 4
455
Rear Cargo Box / Fenders
456
Rear Bumper
457
Body Component Removal
457
Seats
457
Engine Service Panel
457
Front Bumper Xp
458
Rear Bumper
458
Hood and Front Body Work
459
Rear Fender / Fender Flare Removal Xp / High Lifter
460
Rear Fender Flare / Rear Fender Removal Xp
460
Cargo Box Assembly Removal
461
Rocker Panels, Console and Floor Xp / High Lifter
462
Rocker Panels, Rear Console and Floor Xp
465
Decal Replacement
467
Chapter 11 Electrical
469
General Information
469
Special Tools
469
Electrical Service Notes
469
Under-Dash Components
470
Instrument Cluster
470
Overview
472
Rider Information Display
473
Information Display Area
476
Diagnostic Mode
478
Instrument Cluster Removal
478
Instrument Cluster Installation
479
Switches
479
Brake Light Switch
479
Headlamp Switch
480
Ignition (Key) Switch
480
Awd / 2Wd Switch (Models Without Turf)
481
Transmission (Gear Position) Switch
482
Seat Belt Switch
483
All Wheel Drive Coil
483
Operation Overview
483
Diagnosing System Failures
484
Vehicle Speed Sensor
484
Speed Sensor Location
484
Speed Sensor Testing
485
Ignition Coil
485
Operation Overview
485
Ignition Coil / Ht Lead Replacement
486
Ignition Coil Tests
487
Lighting System
487
Headlight Adjustment
488
Headlamp Replacement
489
Headlamp Installation
489
Taillight Replacement
490
Dash Light
491
Cooling System
491
Fan Control Circuit Operation / Testing
491
Fan Control Circuit Bypass Test
491
Engine Coolant Temperature Sensor (Ect) Overview
492
Ect Sensor Test
492
Ect Sensor Replacement
493
Fuse / Relay Box
493
Overview / Operation
494
Fuse Box Detail
495
Relay Operation
497
Charging System
497
Current Draw - Key Off
497
Charging System "Break Even" Test
498
Charging System Stator (Alternator) Tests
499
Stator (Alternator) Replacement
499
Regulator / Rectifier
500
Charging System Testing Flow Chart
501
Battery
501
Battery Specifications
501
General Battery Information
502
Battery Removal / Installation
502
Battery Off Season Storage
502
Battery Testing
502
Ocv - Open Circuit Voltage Test
503
Load Test
503
Battery Conductance Analyzer
503
Charging Procedure
504
Starting System
504
Troubleshooting
504
Voltage Drop Test
505
Starter Motor Removal
505
Starter Motor Installation
506
Starter Solenoid Bench Test
506
Starter Solenoid Operation
506
Condition: Starter Fails to Turn Over the Engine
507
Electronic Power Steering (Eps)
507
Eps Operation
507
Proper Eps System Diagnosing
508
Eps System Breakout
509
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
510
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
511
Eps Troubleshooting (Using Digital Wrench®)
512
Electrical System Breakout Diagrams
512
Awd
513
Vehicle Speed Sensor
514
Cooling System
515
Unswitched Chassis Power
516
Key-On Battery Power
517
Lights
518
Charging System
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