Polaris RZR XP XP4 1000 (2014) - Service Repair Manual - Wiring Diagrams

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

- English Service Manual and Wiring Diagrams, for ATV Polaris RZR XP XP4 1000 (2014).

 
CONTENTS:

Vehicle Identification
- Model Number Designation
- Engine Designation Number
- Vehicle Identification Number (Vin) Designation
- Vehicle And Engine Serial Number Location

Vehicle Information
- Publication Numbers
- Replacement Keys

Special Tools

General Specifications
- Model: 2014 Rzr Xp 1000 / Eps / Int’l
- 2014 Rzr Xp 1000 / Eps / Int’l
- Model: 2014 Rzr Xp 4 1000
- 2014 Rzr Xp 4 1000
- 2014 Rzr Xp / Xp 4 1000 Clutch Charts

Misc. Specifications And Charts
- Master Torque Table
- Conversion Table
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- Sae Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

Periodic Maintenance Chart
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 50 Hour Maintenance Interval
- 50 - 500 Hour Maintenance Interval
- Maintenance Quick Reference
- Maintenance Quick Reference, Continued...
- Grease Lubrication Points

Lubricants / Service Products
- Polaris Lubricants, Maintenance And Service Products

General Vehicle Inspection And Maintenance
- Pre-Ride / Daily Inspection
- Shift Cable Inspection / Adjustment

Fuel System And Air Intake
- Fuel System
- 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
- Air Box / Air Filter Assembly View

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

Transmission And Front Gearcase
- Specification Chart
- Transmission Lubrication
- Front Gearcase Lubrication

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

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

Electrical And Ignition System
- Battery Maintenance
- Battery Charging / Off Season Storage
- Battery Removal
- Battery Installation
- Engine / Chassis Electrical Ground
- Spark Plug Service

Steering
- Steering Inspection
- Steering Wheel Freeplay
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment

Suspension (Walker Evans™)
- Spring Adjustment
- Shock Compression Adjustment

Brake System
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose And Fitting Inspection

General Information
- Special Tools
- Engine Lubrication Specifications
- Oil Pressure Test
- Engine Oil Flow Chart

Engine Service Specifications
- Engine Specifications

Engine Detail - Torque Values / Sequences / Assembly Notes
- 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

Engine Cooling System
- Cooling System Pressure Test
- 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
- Cylinder Head Removal
- Cylinder Head Warp Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Sealing Test
- Valve Seat Reconditioning

Engine Disassembly / Inspection - Lower 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
- Piston Ring Removal
- Piston Ring To Groove Clearance Inspection
- Piston Ring Installed Gap
- Piston-To-Cylinder Clearance
- Connecting Rod Inspection

Engine Assembly - Lower 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
- Intake Valve Lash - Tappet Selection Matrix
- Exhaust Valve Lash - Tappet Selection Matrix
- Valve Cover Installation

Troubleshooting
- Engine
- Cooling System

General Information
- Special Tools
- Efi Service Notes
- Efi System Assembly View
- Efi System Component Locations

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

Electronic Fuel Injection
- Principal Components
- Efi Operation Overview
- Initial Priming / Starting Procedure

Electronic Control Unit (Ecu)
- Operation Overview
- Ecu Service
- Ecu Replacement

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

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

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

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

Throttle Body Assembly
- Operation Overview
- Throttle Body Service
- Throttle Body Removal

Electronic Throttle Control (Etc)
- Operation Overview
- Etc Test
- Etc Replacement

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

Efi Diagnostics
- Instrument Cluster Trouble Code Display
- Efi Troubleshooting

Digital Wrench® Operation
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Also Refer To The Beginning Of This Chapter)
- Diagnostic Software Version
- Guided Diagnostic Available
- Digital Wrench® Communication Errors
- Digital Wrench® - Diagnostic Connector
- Digital Wrench® Serial Number Location
- Digital Wrench® Version And Update Id
- Digital Wrench® Updates
- Digital Wrench® Feature Map
- Ecu Replacement
- Engine Controller Reprogramming (Reflash)

General Information
- Special Tools
- Multi-Function Pliers
- Torque Specifications

Body Assembly Views
- Cab Frame Assembly Xp
- Cab Frame Assembly Xp 4
- Doors Xp
- Doors Xp 4
- Dash Instruments / Controls
- Hood / Front Body Work
- Chassis / Main Frame Xp
- Chassis / Main Frame Xp 4
- Seat Assembly Front
- Seat Assembly Rear
- Floor / Rocker Panels Xp
- Floor / Rocker Panels Xp 4
- 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 Flare Removal
- 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

Steering Assembly
- Assembly View (Non-Eps Models)
- Steering Wheel Removal (Non-Eps Models)
- Steering Shaft Removal (Non-Eps Models)
- Steering Shaft Bearing Replacement

Electronic Power Steering Assembly
- Assembly View (Eps Models)
- Upper Steering Shaft Removal (Eps Models)
- Steering Wheel Removal (Eps Models)
- Power Steering Unit Removal
- Lower Steering Shaft Removal (Eps Models)
- Lower Steering Shaft Installation (Eps Models)
- Power Steering Unit Installation
- Upper Steering Shaft Installation (Eps Models)

Front A-Arms
- Removal / Replacement

Ball Joint Service
- Service Preparation
- Ball Joint Removal
- Ball Joint Installation

Rear Radius Rods
- Removal / Installation

Rear Trailing Arm
- Trailing Arm Removal / Installation
- Trailing Arm Spherical Bearing Replacement
- Rear Suspension Assembly View

Rear Stabilizer Bar
- Stabilizer Bar Removal
- Stabilizer Bar Installation

Shocks / Springs / Fasteners
- Front Shock Assembly View
- Rear Shock Assembly View
- Shock Removal / Installation
- Shock Replacement

Walker Evans™Shock Assembly Views
- Walker Evans™ 2.0" Front Shock
- Walker Evans™ 2.5" Rear Shock

Walker Evans™ Shock Service
- General Service Information
- Front Shock Service Information
- Rear Shock Service Information
- Walker Evans™ Shock Rebuild Information
- Special Tools
- Valve Shim Arrangement
- Piston Orientation
- Walker Evans™ Shock Disassembly
- Walker Evans™ Shock Assembly

General Information
- Special Tools And Supplies
- Pvt System Torque Specifications
- 2014 Rzr Xp / Xp 4 1000 Clutch Charts

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

Pvt System Service
- Pvt Covers And Duct Components
- 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
- Clutch Disassembly
- Bushing Service
- Clutch Assembly
- Assembly View

Troubleshooting

General Information
- Special Tools
- Final Drive Torque Specifications

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

Front Drive Shaft
- Drive Shaft Removal
- Drive Shaft Installation

Front Propshaft Service
- Front Propshaft 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
- Prop Shaft U-Joint Service

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

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

Rear Drive Shaft
- Drive Shaft Removal
- Drive Shaft Installation

Drive Shaft Cv Joint / Boot Replacement
- Drive Shaft / Cv Joint Handling Tips
- Outer Cv Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Assembly View

Wheel Hubs
- Front Hub Assembly View
- Rear Hub Assembly View

Specifications
- Special Tools
- Torque Specifications
- Lubrication
- Transmission Mounting And Torque Values

Shift Lever
- Removal
- Installation

Shift Cable
- Inspection
- Adjustment

Transmission Removal

Transmission Installation

Transmission Service
- Transmission Disassembly
- Gear / Shaft / Bearing Inspection
- Snorkel Gear Backlash Procedure

Transmission Service (Int’l)
- Differential Operation
- Transmission Disassembly
- Planetary Differential Disassembly
- Planetary Differential Bushing Replacement
- Planetary Differential Assembly
- Gear / Shaft / Bearing Inspection
- Snorkel Gear Backlash Procedure

Troubleshooting
- Troubleshooting Checklist

Transmission Assembly View

Transmission Assembly View (Int’l)

General Information
- Special Tools
- General Specifications
- Torque Specifications
- Brake System Service Notes
- Brake Noise Troubleshooting
- Hydraulic Brake System Operation

Brake System
- Assembly View

Master Cylinder
- Removal
- Installation

Brake Pedal Lever
- Pedal Removal
- Pedal Installation

Brake Bleeding / Fluid Change

Parking Brake (Int’l Model)
- Assembly View
- Parking Brake Inspection
- Parking Brake Cable Adjustment

Parking Brake Caliper Service (Int’l Model)
- Caliper Assembly View
- Caliper Removal
- Caliper Disassembly / Inspection
- New Brake Pad Installation
- Caliper Installation

Parking Brake Disc (Int’l Model)
- Disc Inspection
- Disc Replacement

Front Brake Pads
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure

Front Caliper Service
- 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
- Caliper Assembly View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation

Rear Brake Disc
- Disc Inspection
- Disc Replacement

Troubleshooting
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock

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

Efi Diagnostics
- Efi Component Testing

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

Switches / Controls
- Brake Light Switch
- Headlamp Switch
- Ignition (Key) Switch
- Ignition (Key) Switch (Int’l)
- Awd / 2wd Switch
- Awd / 2wd / Turf Switch (Int’l)
- Turn Signal Switch (Int’l)
- Hazard Switch (Int’l)
- Transmission (Gear Position) Switch
- Parking Brake Switch (Int’l Model)

Rear Diff Solenoid (Int’l)
- Differential Solenoid Overview
- Differential Solenoid Circuit Operation

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

Head Lights
- Headlight Adjustment
- Headlamp Replacement
- Headlamp Installation

Tail / Brake Lights
- Taillight Replacement

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

Fuel Sender
- Testing

Fuse Box: Fuses / Relays / Circuit Breaker
- Overview / Operation
- Fuse Box Detail
- Relay Operation

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 Service
- 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

Starting System
- Troubleshooting
- Voltage Drop Test
- Starter Motor Removal
- Starter Motor Installation
- Starter Solenoid Bench Test
- Starter Solenoid Operation

Starting System Testing Flow Chart
- Condition: Starter Fails To Turn Over The Engine.

Electronic Power Steering (Eps)
- Eps Operation
- 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®)

Electrical System Breakouts
- Awd
- Vehicle Speed Sensor
- Cooling System
- Unswitched Chassis Power
- Key-On Battery Power
- Lights
- Charging System

2014 Rzr 1000 Wiring Harnesses
- 2014 Ranger Rzr Xp 1000 (Chassis)
- 2014 Ranger Rzr Xp 1000 (Box).Pdf