Polaris RZR XP 1000 and XP4 1000 2014 to 2016 - Service Repair Manual

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POLARIS RZR XP 1000 & XP4 1000 (2014-2016) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for ATV Polaris RZR XP 1000 and XP4 1000 2014 to 2016.

 
CONTENTS:

CHAPTER 1: GENERAL INFORMATION

Vehicle Identification
- Model Number Designation (2014 and older)
- Model Number Designation (2015 +)
- Vehicle Identification Number
- Vehicle Identification Number (VIN) Designation (2015+)
- Vehicle and Engine Serial Number Location

Reference Information
- Replacement Keys
- Publication Numbers
- Special Tools
- Master Torque Table

General Specifications
- 2014-2016 RZR XP 1000
- 2014-2016 RZR XP 1000 CLUTCH CHART
- 2014-2016 RZR XP 4 1000
- 2014-2016 RZR XP4 1000
- 2015-2016 RZR XP 1000 High Lifter
- 2015–2016 RZR XP 1000 High Lifter Clutch Chart
- 2016 RZR XP4 1000 High Lifter
- 2016 RZR XP4 1000 High Lifter Clutch Chart
- 2015 RZR XP 1000 Desert Edition
- 2015 RZR XP 1000 Desert Edition Clutch Chart
- 2015 RZR XP 1000 FOX Edition
- 2015 RZR XP 1000 FOX Clutch Chart

Misc. Specifications and Charts
- Conversion Table
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

CHAPTER 2: MAINTENANCE

PERIODIC MAINTENANCE CHART
- Pre-Ride / Daily Inspection
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Intervals
- Maintenance Quick Reference
- Grease Lubrication Points

LUBRICANTS / SERVICE PRODUCTS
- Lubrication Specifications

ENGINE
- Engine Oil Level
- Engine Oil and Filter Change
- Engine Crankcase Breather Hose Inspection
- Engine Cylinder Leakdown Test
- Valve Clearance Inspection

COOLING SYSTEM
- Cooling System Overview
- Coolant Strength
- Coolant Level Inspection
- Cooling System Pressure Test
- Cooling System Hoses
- Radiator Inspection / Cleaning
- Coolant Drain / Fill

FUEL SYSTEM AND AIR INTAKE
- Fuel System Warning
- Fuel Tank Vent Line
- Fuel Pump / Fuel Filters
- Fuel Lines
- Throttle Pedal Inspection
- Engine Intake Pre-Filter Service
- Air Filter Service
- Intake Duct Drain Inspection

PVT / FINAL DRIVE / WHEEL AND TIRE
- Drive Clutch / Driven Clutch / Belt Service
- PVT Intake Pre-Filter Service
- PVT Drying
- Drive Shaft Boot Inspection
- Wheel and Hub Torque Table
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
- Beadlock Rims (if equipped)

TRANSMISSION AND FRONT GEARCASE
- Specification Chart
- Transmission Lubrication
- Front Gearcase Lubrication
- Shift Cable Inspection / Adjustment

STEERING
- Steering Inspection
- Steering Wheel Free-play
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment

SUSPENSION
- Spring Adjustment (Walker Evans)
- Shock Compression Adjustment (WALKER EVANS™)
- Spring Adjustment (FOX®)
- Shock Compression Adjustment (FOX®)

BRAKE SYSTEM
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose and Fitting Inspection

ELECTRICAL AND IGNITION SYSTEM
- Battery Maintenance
- Battery Charging / Off Season Storage
- Battery Removal
- Battery Installation
- Engine / Chassis Electrical Ground
- Spark Plug Service

CHAPTER 3: ENGINE / COOLING SYSTEM

General Information
- Special Tools
- Engine Lubrication Specifications
- Oil Pressure Test
- Engine Oil Flow Chart
- Engine Specifications (1000)
- Main Engine Components - Torque Specification and Sequence
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
- Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover

Intake / Exhaust System
- Air Box / Air Filter Assembly View
- Exhaust System Assembly View

Engine Cooling System
- Engine Cooling System Specifications
- Cooling System Pressure Test
- Cooling System Pressure Cap Test
- Radiator Removal / Installation
- Thermostat Replacement
- Cooling System Assembly View
- Cooling System Bleeding Procedure
- Water Pump Removal
- Water Pump Installation
- Water Pump Service

Engine Service
- Accessible Engine Components
- Top-End Service (Engine in Chassis)
- Engine Removal
- Engine Installation
- Engine Mounting and Torque Values
- Engine Break-In Period
- Engine Lubrication Specifications

Engine Disassembly / Inspection - Top End
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection (1000)
- Cylinder Head Removal
- Cylinder Head Warp Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Sealing Test
- Valve Seat Reconditioning (1000)

Engine Disassembly / Inspection - Bottom End
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-Way Clutch Disassembly
- Crankcase Disassembly / Inspection
- Balance Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Inspection
- Cylinder Inspection
- Cylinder / Piston Removal
- Piston Disassembly / Inspection (1000)
- Piston Ring Removal
- Piston Ring to Groove Clearance Inspection
- Piston Ring Installed Gap (1000)
- Piston-to-Cylinder Clearance
- Connecting Rod Inspection

Engine Assembly - Bottom End
- Bearing Selection Identification Letters and Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- Upper Crankcase Preparation
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Cylinder / Piston Installation
- Crankshaft Installation
- Balance Shaft Installation
- Lower Crankcase Preparation
- Crankcase Assembly
- Starter One-Way Clutch Assembly
- Flywheel Installation
- Stator Cover Installation

Engine Assembly - Top End
- Cylinder Head Assembly
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Clearance Adjustment
- Valve Lash - Tappet Selection
- Valve Cover Installation

Troubleshooting
- Engine
- Cooling System

CHAPTER 4: FUEL SYSTEM

General Information
- Special Tools
- Torque Specifications

EFI Overview
- EFI Service Notes
- EFI System Assembly View
- EFI System Component Locations
- Principal Components
- EFI Operation Overview
- Initial Priming / Starting Procedure

Electronic Control Unit (ECU)
- Operation Overview
- ECU Service
- ECU Replacement
- ETC Learn Procedure

Fuel Injectors
- Operation Overview
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement

Fuel Tank
- Assembly View
- Fuel Line Removal / Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank Removal RZR XP 4 1000
- Fuel Tank Installation RZR XP 4 1000

Fuel Pump
- Operation Overview
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump Replacement

Temperature and Manifold Absolute Pressure Sensor (T-MAP)
- Operation Overview
- T-MAP Test / Replacement

Crankshaft Position Sensor (CPS)
- Operation Overview
- CPS Test
- CPS Replacement

Electronic Throttle Control (ETC) / Throttle Body
- Operation Overview
- Throttle Body Service
- Throttle Body Removal
- ETC Test
- ETC Replacement
- ETC Learn Procedure

Pedal Position Sensor (PPS)
- Operation Overview
- Location
- PPS Test
- PPS Replacement

Oxygen Sensor (MY15-16)
- Oxygen Sensor Information
- Oxygen Sensor Replacement

EFI Diagnostics
- Trouble Code Display (DTC)
- Cylinder Misfire Detection
- EFI Troubleshooting

Polaris Digital Wrench
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Digital Wrench)
- Digital Wrench Software Version and Update ID
- Digital Wrench® Updates
- Digital Wrench® Communication Errors
- Digital Wrench® - Diagnostic Connector
- Guided Diagnostics
- Digital Wrench® Serial Number Location
- Digital Wrench® Feature Map
- ECU Replacement
- ETC Learn Procedure
- ECU Reprogramming (Reflash)

Polaris Mobile Digital Wrench (PMDW)
- Polaris Mobile Digital Wrench (PMDW)

CHAPTER 5: PVT SYSTEM

General Information
- SPECIAL TOOLS AND SUPPLIES
- PVT System Torque Specifications
- 2014-2016 RZR XP 1000 CLUTCH CHART
- 2014-2016 RZR XP4 1000
- 2015–2016 RZR XP 1000 High Lifter Clutch Chart
- 2015 RZR XP 1000 Desert Edition Clutch Chart
- 2015 RZR XP 1000 FOX Clutch Chart

PVT System Overview
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In (Drive Belt / Clutches)
- Maintenance / Inspection
- PVT Overheating / Diagnosis

PVT System Service
- PVT Covers and Duct Components
- XP / XP4 PVT Covers and Ducting Components
- PVT Covers and Ducting Components (High Lifter)
- PVT Disassembly (2014–2015)
- PVT Assembly
- PVT Disassembly
- PVT Assembly

Drive Belt
- Belt Removal
- Belt Inspection
- Belt Installation
- PVT Break-In (Drive Belt / Clutches)

Drive Clutch Service
- Drive Clutch Assembly View
- Drive Clutch Disassembly / Inspection
- Needle Bearing Inspection
- Shift Weight Inspection
- Button To Tower Clearance Inspection
- Spider Removal
- Roller, Pin, and Thrust Washer Inspection
- Clutch Inspection
- Moveable Sheave Bushing Inspection
- Bushing Service
- Drive Clutch Assembly

Driven Clutch Service (2014-2015)
- Driven Clutch Disassembly
- Driven Clutch Bushing Service
- Driven Clutch Assembly
- Driven Clutch Assembly View

Driven Clutch Service (2016)
- Driven Clutch Slider Inspection
- Driven Clutch Disassembly
- Driven Clutch Assembly
- Driven Clutch Assembly View

Troubleshooting
- TROUBLESHOOTING

CHAPTER 6: TRANSMISSION

General Information
- Special Tools
- Torque Specifications
- Lubrication
- Transmission Mounting and Torque Values

Shift Lever / Cable
- Shift Lever Removal
- Shift Lever Installation
- Shift Cable Inspection
- Shift Cable Adjustment

Transmission Service
- Transmission Removal
- Transmission Installation
- Transmission Disassembly
- Differential Operation
- Planetary Differential Disassembly (Turf Mode Models Only)
- Planetary Differential Bushing Replacement (Turf Mode Models Only)
- Planetary Differential Assembly (Turf Mode Models Only)
- Gear / Shaft / Bearing Inspection
- Transmission Assembly / Snorkel Gear Backlash Procedure
- TRANSMISSION ASSEMBLY VIEW
- TRANSMISSION ASSEMBLY VIEW (Turf Mode Models)

Troubleshooting
- Shifting Difficulty

CHAPTER 7: FINAL DRIVE

General Information
- SPECIAL TOOLS
- Final Drive Torque Specifications

Bearing Carrier
- Front Bearing Carrier Inspection / Removal
- Front Bearing Replacement
- Front Bearing Carrier Installation
- Rear Bearing Carrier Inspection / Removal
- Rear Bearing Replacement
- Rear Bearing Carrier Installation

Drive Shaft
- Front Drive Shaft Removal
- Front Drive Shaft Installation
- Rear Drive Shaft Removal
- Rear Drive Shaft Installation
- Drive Shaft / CV Joint Handling Tips
- 2014-2015 CV Joint Service
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- 2016 CV Joint Service
- Outer CV Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Assembly View

Prop Shaft Service
- Front Prop Shaft Removal
- Front Prop Shaft Installation
- Rear Prop Shaft Removal
- Rear Prop Shaft Installation
- Rear Prop Shaft Removal XP 4
- Rear Prop Shaft Installation XP 4
- Support Bearing Replacement

Front Gearcase / Centralized Hilliard
- Centralized Hilliard Assembly View
- All Wheel Drive Operation
- AWD Diagnosis
- Front Gearcase Removal
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- Front Gearcase Installation

Wheel Hubs
- Front Hub Assembly View
- Rear Hub Assembly View
- Beadlock Rims (if equipped)

CHAPTER 8: STEERING / SUSPENSION

General Information
- SPECIAL TOOLS
- Multi-Function Pliers

Steering System
- Steering System Assembly View
- Upper Steering Shaft Removal
- Steering Wheel Removal
- Power Steering Unit Removal
- Lower Steering Shaft Removal
- Lower Steering Shaft Installation
- Power Steering Unit Installation
- Upper Steering Shaft Installation
- Steering Shaft Bearing Replacement

Front Suspension
- Front A-arm Removal / Replacement
- Front Stabilizer Bar Removal
- Front Stabilizer Bar Installation
- Ball Joint Service Preparation
- Ball Joint Removal
- Ball Joint Installation

Rear Suspension
- Radius Rod Removal / Installation
- Trailing Arm Removal / Installation
- Trailing Arm Spherical Bearing Replacement
- Rear Suspension Assembly View
- Rear Stabilizer Bar Removal
- Stabilizer Bar Installation

Shocks / Springs
- Shock Assembly View
- Shock Removal / Installation
- Shock / Spring Replacement

Shock Service
- WALKER EVANS™SHOCK ASSEMBLY VIEWS
- Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
- Walker Evans™ 2.5" Rear Shock
- WALKER EVANS SHOCK SERVICE
- General Service Information
- Front Shock Service Information
- Rear Shock Service Information
- Spring Adjustment (Walker Evans)
- Walker Evans™ Shock Rebuild Information
- Special Tools
- Valve Shim Arrangement
- Shock Piston Orientation
- Walker Evans™ Shock Disassembly
- Walker Evans Shock Assembly
- FOX SHOCK ASSEMBLY VIEWS
- FOX 2.5" O.E. Podium Bypass
- FOX 3.0" O.E. Podium Bypass
- FOX SHOCK SERVICE
- Fox 2.5" Front Shock Information
- FOX 3.0" Rear Shock Information
- Spring Adjustment (FOX®)
- Offset Torque Formula
- FOX Shock Disassembly
- FOX Shock Assembly

CHAPTER 9: BRAKE SYSTEM

General Information
- SPECIAL TOOLS
- GENERAL SPECIFICATIONS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OPERATION

BRAKE SYSTEM ASSEMBLY VIEW
- Brake System Assembly View

MASTER CYLINDER
- Master Cylinder Removal
- Master Cylinder Installation
- BRAKE BLEEDING / FLUID CHANGE

BRAKE PEDAL LEVER
- Brake Pedal Removal
- Brake Pedal Installation

PARKING BRAKE (INT’L MODEL)
- Parking Brake Assembly View
- Parking Brake Inspection
- Parking Brake Cable Adjustment
- Parking Brake Caliper
- Parking Brake Disc

FRONT BRAKE PADS
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure

FRONT CALIPER SERVICE
- Front Caliper Assembly View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation

FRONT BRAKE DISC
- Disc Runout
- Disc Inspection
- Disc Replacement

REAR BRAKE PADS
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure

REAR CALIPER SERVICE
- Rear Caliper Assembly View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation

REAR BRAKE DISC
- Disc Inspection
- Disc Replacement

TROUBLESHOOTING
- Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock

CHAPTER 10: BODY / FRAME

General Information
- SPECIAL TOOLS
- Torque Specifications

Body Assembly Views
- Cab Frame Assembly XP
- Cab Frame Assembly XP 4
- Doors XP
- Doors (XP4)
- Doors High Lifter
- Dash Instruments / Controls
- Dash Instruments / Controls High Lifter
- Hood / Front Body Work
- Chassis / Main Frame XP / High Lifter
- Chassis / Main Frame XP 4
- Seat Assembly Front
- Seat Assembly Rear
- Floor / Rocker Panels XP / High Lifter
- Floor / Rocker Panels XP 4 / XP 4 High Lifter
- Rear Cargo Box / Fenders
- Rear Bumper

Body Component Removal
- Seats
- Engine Service Panel
- Front Bumper XP
- Rear Bumper
- Hood and Front Body Work
- Rear Fender / Fender Flair Removal XP
- Rear Fender Flare / Rear Fender Removal XP 4
- Cargo Box Assembly Removal
- Rocker Panels, Console and Floor XP
- Rocker Panels, Rear Console and Floor XP 4
- DECAL REPLACEMENT

Doors
- Door Panel / Latch Replacement
- Door Adjustment

CHAPTER 11: ELECTRICAL

General Information
- Special Tools
- Torque Specifications
- Electrical Service Notes
- Under-Dash Components

Instrument Cluster
- Overview
- Information Display Area
- Diagnostic Mode
- Instrument Cluster Pinouts
- Instrument Cluster Removal
- Instrument Cluster Installation

Switches
- Brake Light Switch
- Headlamp Switch
- Ignition (Key) Switch
- AWD / 2WD Switch (no Turf mode)
- Transmission (Gear Position) Switch
- Seat Belt Switch

All Wheel Drive Coil
- Operation Overview
- Diagnosing System Failures

Vehicle Speed Sensor
- Speed Sensor Location
- Speed Sensor Testing

Ignition Coil
- Operation Overview
- Ignition Coil / HT Lead Replacement
- Ignition Coil Tests

Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Charging System Stator (Alternator) Tests
- Stator (Alternator) Replacement
- Regulator / Rectifier
- Charging System Testing Flow Chart

Battery
- Battery Specifications
- General Battery Information
- Battery Removal / Installation
- Battery Off Season Storage
- Battery Testing
- OCV - Open Circuit Voltage Test
- Load Test
- Battery Conductance Analyzer
- Charging Procedure

Lighting System
- Headlight Adjustment
- Headlamp Replacement
- Headlamp Installation
- Taillight Replacement
- Dash Light

Cooling System
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- Engine Coolant Temperature Sensor (ECT) Overview
- ECT Sensor Test
- ECT Sensor Replacement

Starting System
- Troubleshooting
- Voltage Drop Test
- Starter Motor Removal
- Starter Motor Installation
- Starter Solenoid Bench Test
- Starter Solenoid Operation
- Starter fails to turn over the engine.

Electronic Power Steering
- EPS Operation
- EPS Torque Offset Procedure
- Proper EPS System Diagnosing
- EPS System Breakout
- EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
- EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
- EPS Troubleshooting (Using Digital Wrench®)

Fuses / Relays
- Overview / Operation
- Fuse Box Detail (2014)
- Fuse Box Detail (2015-2016)
- Relay Operation

CAN SYSTEM
- CAN System Overview
- CAN System Testing

Break-Out Diagrams
- AWD
- Vehicle Speed Sensor
- Cooling System
- Unswitched Chassis Power
- Key-On Battery Power
- Lights
- Charging System