Polaris 2014 RZR XP 1000, 2014 RZR XP 4 1000 Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer

technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed August 2013 (PN 9924874 R02)

2014 RZR XP / XP 4 1000

Service Manual

UNDERSTANDING SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCT(S) MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

GENERAL INFORMATION

MAINTENANCE

ENGINE

ELECTRONIC FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

1.1

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION ... . .. . .. . .. . .. . .. . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . 1.2

MODEL NUMBER DESIGNATION. . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . 1.2

ENGINE DESIGNATION NUMBER .. . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. 1.2

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . 1.3

VEHICLE INFORMATION . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . . 1.3

PUBLICATION NUMBERS .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . 1.3

REPLACEMENT KEYS. .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . . 1.4

SPECIAL TOOLS . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. 1.5

GENERAL SPECIFICATIONS. . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. 1.6

MODEL: 2014 RZR XP 1000 / EPS / INT’L .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . . 1.6

2014 RZR XP 1000 / EPS / INT’L . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. 1.7

MODEL: 2014 RZR XP 4 1000.. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. 1.8

2014 RZR XP 4 1000 .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. 1.9

2014 RZR XP / XP 4 1000 CLUTCH CHARTS. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . .1.10

MISC. SPECIFICATIONS AND CHARTS .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. 1.11

MASTER TORQUE TABLE .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. 1.11

CONVERSION TABLE .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .1.14

STANDARD BOLT TORQUE SPECIFICATION. .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . ..1.15

METRIC BOLT TORQUE SPECIFICATION .. . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .1.15

SAE TAP / DRILL SIZES . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . .1.16

METRIC TAP / DRILL SIZES .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . ..1.16

DECIMAL EQUIVALENTS. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .1.17

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

VEHICLE IDENTIFICATION

Model Number Designation

Example: R14ST1EAL

GROUP

MODEL

YEAR

CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION

1st digit

2/3rd

digit

4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit

Z = RZR

11 12 13 14

J = RZR XP

V = RZR

X = Multi-

pass RZR

E = 4x4 Shaft / IRS H = 4x4 Shaft / IRS

T = 4x4 Shaft /

Trailing Arm

Displacement in cc

divided by 10 and

rounded to two digits

(i.e. 50 = 498cc)

A = ORV

E = EU On-road

F = INT’L

M = Military

S =

Scandinavian

V = EU On-road

C = Calif.- - OR - -

5 = 550 6 = 570 7 = 760 8 = 850 9 = 875

E = EPS D = Diesel F = D + E

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.

Engine Designation Number

RZRXP 999-14 High Output 4-Stroke DOHC Twin

Cylinder, Liquid Cooled, Electric Start

Vehicle Identification Number (VIN) Designation

Example: 4XAST1EAXE3000000

World Mfg. ID

Vehicle Descriptors

Vehicle Identifiers

Chassis

Driveline

Engine Size

Engine Modifier

Category

Check Digit

Model Year *

Mfg. Location

Individual Serial No.

1 2

3 4

5 6 7 8 9 10

11 12

15 16

4 X A S T 1 E A X E 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014

GENERAL INFORMATION

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Vehicle and Engine Serial Number Location

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on a portion of the left rear frame, behind the lower shock mounting location. Refer to Figure 1-1.

The engine serial number can be found on a decal applied to the front of the engine crankcase (A) or stamped into the crankcase on the PTO side of the engine (B). Refer to Figure 1-2.

VEHICLE INFORMATION

Publication Numbers

MODEL OWNER’S MANUAL PARTS MANUAL

2014 RZR XP 1000 9924687 9924688

2014 RZR XP 1000 EPS 9924687 9924688

2014 RZR XP 1000 INT’L 9924687 9924688

2014 RZR XP 4 1000 9924687 9924688

NOTE: When ordering service parts be sure to use the correct parts manual.

Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.

GENERAL INFORMATION

1.4

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Replacement Keys

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

GENERAL INFORMATION

1.5

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/

GENERAL INFORMATION

1.6

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

GENERAL SPECIFICATIONS

MODEL: 2014 RZR XP 1000 / EPS / INT’L

CATEGORY DIMENSION / CAPACITY

Length

119″ / 302.2 cm

Width 64″ / 162.5 cm

Height

73.75″ / 187.3 cm

Wheel Base 90″ / 228.6 cm

Ground Clearance 13.5″ / 34.3 cm

Dry Weight 1379 lbs. / 625.5 kg

Gross Vehicle Weight 2168 lbs. / 983 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

740 lbs. / 335.6 kg (Includes riders, cargo and accessories)

Hitch Towing Capacity

This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch.

Hitch Tongue Capacity

GENERAL INFORMATION

1.7

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

2014 RZR XP 1000 / EPS / INT’L

ENGINE

Platform

Domestic Twin Cyl., 4–Stroke, DOHC

Engine Displacement

999cc

Number of Cylinders

Bore & Stroke 93 x 73.6 mm Compression Ratio

10.5:1

Engine Idle Speed

1200 +/- 100 RPM

Engine Max Speed

8800 RPM

Valve Clearance (Intake) 0.005-0.007″ (0.125-0.175 mm)

Valve Clearance (Exhaust) 0.009-0.011″ (0.229-0.275 mm)

Engine Hot Light

Instrument Cluster Indicator

Lubrication

Wet Sump

Oil Requirements

PS4

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 4.9 qt (4.6 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)

Fuel Capacity / Requirement

9.5 gal. (36 L) 87 Octane (minimum)

ELECTRICAL

Alternator Max Output 560 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam LED cluster

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap XG4YCX / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 575 CCA

DC Outlet Standard 12 Volt Relays Fan, EFI, Fuel Pump, Chassis,

EPS (if appl.)

Circuit Breaker 20A Cooling Fan

Fuses 20A EFI

10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS (if appl.)

DRIVETRAIN

Transmission Type

Polaris Automatic PVT

Shift Type

In Line Shift - P/ H / L / N / R

Transmission Gear Ratios: High Low Reverse

10.73:1

22.79:1

20.41:1

Front Gearcase Lubricant Requirement

Demand Drive

8.5 oz. (250 ml)

Transmission Lubricant Requirement

Full Synthetic AGL 44 oz. (1300 ml)

Drive Belt 3211148

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

Walker Evans™ 2.0″

Front Travel 16″ (40.6 cm)

Rear Suspension Independent Trailing Arm

Walker Evans™ 2.5″

Rear Travel 18″ (45.7 cm)

Spring Adjustment Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 6 Rear Rim / Size Aluminum 14 x 8 Front Tire Make / Model /

Size

Maxxis Bighorn 29 x 9 R14

Rear Tire Make / Model / Size

Maxxis Bighorn 29 x 11 R14

Tire Air Pressure

Front 16 psi (110 kPa)

Rear 16 psi (110 kPa)

Brake System Front & Rear

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

Brake Fluid DOT 4

RZR XP 1000 Clutch Chart, page 1.10

GENERAL INFORMATION

1.8

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

MODEL: 2014 RZR XP 4 1000

CATEGORY DIMENSION / CAPACITY

Length

146″ / 370.8 cm

Width 64″ / 162.5 cm

Height

73.75″ / 187.3 cm

Wheel Base 117″ / 297.2 cm

Ground Clearance 13.5″ / 34.3 cm

Dry Weight 1596 lbs. / 724 kg

Gross Vehicle Weight 2560 lbs. / 1161 kg

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

900 lbs. / 408 kg (Includes riders, cargo and accessories)

Hitch Towing Capacity This vehicle is not equipped with

a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch.

Hitch Tongue Capacity

GENERAL INFORMATION

1.9

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

2014 RZR XP 4 1000

ENGINE

Platform

Domestic Twin Cyl., 4–Stroke, DOHC

Engine Displacement

999cc

Number of Cylinders

Bore & Stroke 93 x 73.6 mm Compression Ratio

10.5:1

Engine Idle Speed

1200 +/- 100 RPM

Engine Max Speed

8800 RPM

Valve Clearance (Intake) 0.005-0.007″ (0.125-0.175 mm)

Valve Clearance (Exhaust) 0.009-0.011″ (0.229-0.275 mm)

Engine Hot Light

Instrument Cluster Indicator

Lubrication

Wet Sump

Oil Requirements

PS4

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 6.0 qt (5.6 L)

FUEL SYSTEM

Type Bosch ME17 EFI

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)

Fuel Capacity / Requirement

9.5 gal. (36 L) 87 Octane (minimum)

ELECTRICAL

Alternator Max Output 560 Watts @ 3000 RPM

Lights: Main Headlights Dual Beam LED cluster

Taillights 0.2 Watt LED cluster

Brake Lights 2.9 Watt LED cluster

Ignition System ME17 ECU

Spark Plug / Gap XG4YCX / 0.7–0.8 mm

Battery / Amp Hr 12v Flooded, 575 CCA

DC Outlet Standard 12 Volt Relays Fan, EFI, Fuel Pump, Chassis,

EPS (if appl.)

Circuit Breaker 20A Cooling Fan

Fuses 20A EFI

10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS (if appl.)

DRIVETRAIN

Transmission Type

Polaris Automatic PVT

Shift Type

In Line Shift - P/ H / L / N / R

Transmission Gear Ratios: High Low Reverse

10.73:1

22.79:1

20.41:1

Front Gearcase Lubricant Requirement

Demand Drive

8.5 oz. (250 ml)

Transmission Lubricant Requirement

Full Synthetic AGL 44 oz. (1300 ml)

Drive Belt 3211148

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

Walker Evans™ 2.0″

Front Travel 16″ (40.6 cm)

Rear Suspension Independent Trailing Arm

Walker Evans™ 2.5″

Rear Travel 18″ (45.7 cm)

Spring Adjustment Threaded Spanner Wrench

Adjustment

WHEELS / BRAKES

Front Rim / Size Aluminum 14 x 6 Rear Rim / Size Aluminum 14 x 8 Front Tire Make / Model /

Size

Maxxis Bighorn 29 x 9 R14

Rear Tire Make / Model / Size

Maxxis Bighorn 29 x 11 R14

Tire Air Pressure

Front 19 psi (131 kPa)

Rear 20 psi (138 kPa)

Brake System Front & Rear

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

Brake Fluid DOT 4

2014 RZR XP / XP 4 1000 Clutch Charts, page 1.10

GENERAL INFORMATION

1.10

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

2014 RZR XP / XP 4 1000 CLUTCH CHARTS

CLUTCH CHART (2014 RZR XP 1000 / EPS / INT’L)

ALTITUDE

SHIFT WEIGHT

DRIVE SPRING

DRIVEN SPRING

Meters (Feet)

0-1500 (0-5000)

26-61 (1323098)

White / Orange (7043924)

Red (3234452)

1500-3700 (5000 - 12000)

26-55 (1322982)

White / Orange (7043924)

Red (3234452)

CLUTCH CHART (2014 RZR XP 4 1000)

ALTITUDE

SHIFT WEIGHT

DRIVE SPRING

DRIVEN SPRING

Meters (Feet)

0-1500 (0-5000)

26-67 (1323177)

White / Orange (7043924)

Red (3234452)

1500-3700 (5000 - 12000)

26-61 (1323098)

White / Orange (7043924)

Red (3234452)

GENERAL INFORMATION

1.11

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

MISC. SPECIFICATIONS AND CHARTS

Master Torque Table

ITEM

TORQUE

A-Arm Bolt (front) 42 ft-lb (57 Nm)

Ball Joint Fasteners

42 ft-lbs (57 Nm)

Battery Mount Bracket

Fasteners

8 ft-lbs (11 Nm)

Battery Terminal Fasteners 60 in-lbs (7 Nm)

Brake Disc Mounting Bolts 30 ft-lb (41 Nm)

Brake Bleed Screws

48 in-lb (5 Nm)

Brake Caliper Mounting

Bolts

40 ft-lbs (54 Nm)

Brake Line Banjo Bolts 15 ft-lbs (20 Nm)

Brake Line Flare Fittings 15 ft-lbs (20 Nm)

Brake Pedal Mount Bracket

Bolts

16 ft-lbs (22 Nm)

Brake Switch

15 ft-lbs (20 Nm)

Cab Frame Bolts

40 ft-lb (54 Nm)

Cam Chain Tensioner

29 ft-lb (40 Nm)

Camshaft Carrier Bolts

7 ft-lb (10 Nm)

Camshaft Sprocket Bolts 14 ft-lb (19 Nm)

Clutch Cover (outer)

Screws

50 in-lbs (5 Nm)

Connecting Rod Bolts

Step 1: 9 ft-lbs (12 Nm) Step 2: 13 ft-lb (18 Nm)

Step 3: Tighten add’n 105°

Coolant Bleed Screw

89 in-lb (10 Nm)

Coolant Temperature

Sensor

17 ft-lb (23 Nm)

CPS Retaining Bolt 9 ft-lb (12 Nm)

Crankcase Bolts M10

Step 1: 9 ft-lb (12 Nm)

Step 2: 21 ft-lb (28 Nm)

Step 3: Tighten add’n 90°

Crankcase Bolts M8

26 ft-lb (35 Nm)

Crankcase Bolts M6

9 ft-lb (12 Nm)

Crankcase Oil Gallery Plug 11 ft-lbs (15 Nm)

Cylinder Head Bolts

Torque in sequence Step 1: 9 ft-lbs (12 Nm) Step 2: 26 ft-lb (35 Nm) Step 3: Additional 180°

Step 4: M6 bolts: 7 ft-lb (10

Nm)

Differential Cover Screws

(INTL)

22 ft-lb (30 Nm)

Door Fasteners

8 ft-lb (11 Nm)

Drive Clutch Retaining Bolt 96 ft-lb (130 Nm)

ITEM

TORQUE

Drive Clutch Cover Plate

Screw

9 ft-lb (12 Nm)

Drive Clutch Shift Weight

Fasteners

20 in-lb (2 Nm)

Drive Clutch Spider

290 ft-lb (393 Nm)

(Apply 0.4 mL Loctite® 7088

Primer and 0.4 mL Loctite®

620™)

Drive Clutch Spider Jamb

Nut

250 ft-lb (339 Nm)

(Apply 0.1 mL Loctite® 7088

Primer and 0.1 mL Loctite®

620™)

Driven Clutch Retaining

Bolt

55 ft-lb (75 Nm)

Driven Clutch Helix

Retaining Screws

48 in-lb (5 Nm)

ECU Mounting Screws 24 in-lb (3 Nm)

Engine Mount (front) 40 ft-lbs (54 Nm)

Engine Oil Plug 12 ft-lbs (16 Nm)

Engine/Transmission

Mounting Bolts

Step 1-2: 64 ft-lb (87 Nm)

Step 3: 5 ft-lb (7 Nm)

Step 4-7: 44 ft-lb (60 Nm)

*see procedure for illustration

ETC Mounting Bolts 7 ft-lb (10 Nm)

Exhaust Head Pipe Bolts 18 ft-lb (24 Nm)

Floor Screws

8 ft-lb (11 Nm)

Flywheel Bolt 133 ft-lbs (180 Nm)

Frame Bolts (front to rear) 40 ft-lb (54 Nm)

Front Bumper / Fender

Screws

8 ft-ln (11 Nm)

Front Gearcase Cover

Plate Screws

11 ft-lbs (15 Nm)

Front Gearcase Drain/Fill

Plugs

10 ft-lbs (14 Nm)

Front Gearcase Mounting

Bolts

30 ft-lbs (41 Nm)

Fuel Pump PFA Nut 70 ft-lbs (95 Nm)

Fuel Rail Mounting Screws 44 in-lb (5 Nm)

Fuel Tank Block-off Panel

8 ft-lbs (11 Nm)

Fuel Tank Strap Screw 8 ft-lbs (11 Nm)

Hip Bolster Bolts 14 ft-lb (19 Nm)

Hose Clamp 35 in-lb (4 Nm)

Hub Castle Nut (front and

rear)

110 ft-lbs (149 Nm)

GENERAL INFORMATION

1.12

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

ITEM

TORQUE

Intake Plenum Mount

Screw

22 ft-lb (30 Nm)

Master Cylinder Mount

Bolts

23 ft-lbs (31 Nm)

Oil Cooler Bolts

7 ft-lb (10 Nm)

Oil Pump Mounting Bolts 7 ft-lbs (10 Nm)

Oil Pump Pickup Screws 7 ft-lb (10 Nm)

Oil Sump Cover M8 Bolts 26 ft-lb (35 Nm)

Oil Sump Cover M6 Bolts 106 in-lb (12 Nm)

Parking Brake Caliper

Assembly Bolts

37 ft-lb (50 Nm)

Parking Brake Disc

Mounting Bolts (INTL)

14 ft-lb (20 Nm)

Parking Brake Lever

Mounting Bolts

16 ft-lb (22 Nm)

Power Steering Cover

Screws

8 ft-lb (11 Nm)

Power Steering Bracket to

Frame Nuts

16 ft-lb (22 Nm)

Power Steering Unit to

Mount Bracket

30 ft-lb (41 Nm)

Prop Shaft Support Bearing

Fasteners

35 ft-lb (47 Nm)

PVT Inner Cover Bolts

12 ft-lb (16 Nm)

PVT Outer Cover Screws

48 in-lb (5 Nm)

Radius Rod Fasteners

40 ft-lb (54 Nm)

Seat Base to Seat Frame

Fasteners

8 ft-lbs (11 Nm)

Seat Base to Frame (front) 14 ft-lb (19 Nm)

Seat Base to Frame (rear) 30 ft-lb (41 Nm)

Seat Belt Mounting

Fasteners

40 ft-lbs (54 Nm)

Seat Slider Plate Screws

4 ft-lb (5 Nm)

Shift Cable Bracket Bolts

17 ft-lb (23 Nm)

Shock Guard Screws

14 in-lbs (2 Nm)

Shock Mount (front) 44 ft-lb (60 Nm)

Shock Mount (rear) 70 ft-lbs (95 Nm)

Shock Reservoir Mounting

Clamps (rear)

35 in-lb (4 Nm)

Skid Plate Fasteners

8 ft-lbs (11 Nm)

Spark Plug 7 ft-lbs (10 Nm)

Speed Sensor Screw 12 ft-lb (16 Nm)

Stabilizer Bar Linkage

(rear)

40 ft-lbs (54 Nm)

Stabilizer Bar Mounting

Bracket Bolts (rear)

17 ft-lb (23 Nm)

ITEM

TORQUE

Stabilizer Bar Locating

Clamp Bolts

10 ft-lb (14 Nm)

Starter Mounting Bolts 7 ft-lb (10 Nm)

Starter One-Way Clutch

Screws

9 ft-lb (12 Nm)

Stator Cover Screws

9 ft-lb (12 Nm)

Steering Tilt Shock

Fastener

7 ft-lb (10 Nm)

Steering Pivot Tube

Fasteners

8 ft-lb (11 Nm)

Steering Rack Mounting

Bolts

16 ft-lbs (22 Nm)

Steering Shaft to EPS Unit 15 ft-lbs (20 Nm)

Steering Shaft to Steering

Rack

42 ft-lb (57 Nm)

Steering Wheel Nut 65 ft-lbs (88 Nm)

Thermostat Cover Bolts

7 ft-lb (10 Nm)

Throttle Pedal Mounting

Fasteners

18 ft-lb (24 Nm)

Tie Rod End to Knuckle

15 ft-lbs (20 Nm) + 90°

Tie Rod Jamb Nuts

14 ft-lbs (19 Nm)

Trailing Arm to Frame 70 ft-lb (95 Nm)

Trailing Arm to Bearing

Carrier Fasteners

42 ft-lb (54 Nm)

Transmission Bell Crank

Nut

18 ft-lb (24 Nm)

Transmission Case Screws

20 ft-lbs (27 Nm)

Transmission Drain / Fill

Plugs

14 ft-lbs (19 Nm)

Transmission Isolator Bolt

(rear)

40 ft-lb (54 Nm)

Transmission Rear Mount

Bracket Fasteners

17 ft-lb (23 Nm)

Transmission Joint Bracket

Bolts

44 ft-lb (60 Nm)

Transmission Park Flange

Screws

10 ft-lb (14 Nm)

Transmission Sector Gear

Cover

12 ft-lb (16 Nm)

Transmission Shift Fork

Screws

10 ft-lb (14 Nm)

Transmission Snorkel Tube

Locking Screw

10 ft-lb (14 Nm)

Valve Cover Bolts

7 ft-lbs (10 Nm)

Visor Mounting Screws 8 ft-lb (11 Nm)

Voltage Regulator

Fasteners

5 ft-lb (7 Nm)

Water Pump Impeller 7 ft-lb (10 Nm)

GENERAL INFORMATION

1.13

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

ITEM

TORQUE

(Apply Loctite® 204™ to bolt

threads)

Water Pump Cover Bolts

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt

threads)

Wheel Lug Nuts 120 ft-lbs (163 Nm)

GENERAL INFORMATION

1.14

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Conversion Table

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs x 12 = in-lbs

in-lbs x 0.0833 = ft-lbs

ft-lbs

x 1.356 = Nm

in-lbs x 0.0115 = kg-m

Nm x 0.7376

= ft-lbs

kg-m x 7.233

= ft-lbs

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

= mm

x 0.03937 = inch

inch x 2.54

= cm

mile (mi)

x 1.6 = km

km x 0.6214 = mile

ounces (oz)

x 28.35

= grams (g)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

x .03381

= fluid ounces

grams (g)

x 0.035

= ounces

pounds (lb) x 0.454 = kg

kilogram (kg)

x 2.2046 = lbs

cubic inches (cu in)

x 16.387

= cc

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

x 0.946

= liters (L)

liters (L) x 1.057 = US quarts

US gallons x 3.785 = liters (L)

liters (L)

x 0.264

= US gallons

PSI x 6.895 = kilopascals (kPa)

kilopascals (kPa)

x 0.145

PSI

π (3.14) x Radius² x Height =

= cylinder volume

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

GENERAL INFORMATION

1.15

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Standard Bolt Torque Specification

BOLT SIZE

GRADE 2

FT. LBS. (NM)

GRADE 5

FT. LBS. (NM)

GRADE 8

FT. LBS. (NM)

1/4-20

5 (7) 8 (11) 12 (16)

1/4-28

6 (8) 10 (14) 14 (19)

5/16-18

11 (15) 17 (23) 25 (35)

5/16-24

12 (16) 19 (26) 29 (40)

3/8-16

20 (27) 30 (40) 45 (62)

3/8-24

23 (32) 35 (48) 50 (69)

7/16-14

30 (40) 50 (69) 70 (97)

7/16-20

35 (48) 55 (76) 80 (110)

1/2-13

50 (69) 75 (104) 110 (152)

1/2-20

55 (76) 90 (124) 120 (166)

Metric Bolt Torque Specification

BOLT

SIZE

GRADE

4.6 4.8 8.8 / 8.9 10.9 12.9

FT.— LBS. (NM) DRY THREADS

.3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

M10

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

M12

26 (35) 33 (45) 63 (85) 97 (130) 11 (150)

M14

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

M16

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

M18

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

GENERAL INFORMATION

1.16

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

SAE Tap / Drill Sizes

THREAD

SIZE DRILL SIZE

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

1/2–20 29/64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64

5/8–11 17/32

#3–48 5/64 5/8–18 37/64

#3–56

3/4–10 21/32

#4–40

3/4–16 11/16

#4–48

7/8–9 49/64

#5–40 38 7/8–14 13/16

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

1 1/8–7 63/64

#8–32

1 1/8–12 1 3/64

#8–36

1 1/4–7 1 7/64

#10–24

1 1/4–12 1 11/64

#10–32

1 1/2–6 1 11/32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1 3/4–12 1 43/64

1/4–28

2–4 1/2 1 25/32

5/16–18

F 2–12

1 59/64

5/16–24

2 1/4–4 1/2 2 1/32

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

U 3–4

2 3/4

7/16–20 25/64

Metric Tap / Drill Sizes

TAP SIZE DRILL SIZE DECIMAL

NEAREST

FRACTION

3 x .50

#39

0.0995

3/32

3 x .60

3/32

0.0937

3/32

4 x .70 #30 0.1285 1/8

4 x .75

1/8 0.125 1/8

5 x .80 #19 0.166 11/64

5 x .90

#20

0.161

5/32

6 x 1.00

0.196

13/64

7 x 1.00

16/64

0.234

15/64

8 x 1.00 J 0.277

9/32

8 x 1.25 17/64 0.265 17/64

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

5/16

0.3125

5/16

10 x 1.25

11/32

0.3437

11/32

10 x 1.50 R 0.339

11/32

11 x 1.50

3/8

0.375

3/8

12 x 1.50

13/32

0.406

13/32

12 x 1.75 13/32 0.406 13/32

GENERAL INFORMATION

1.17

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Decimal Equivalents

FRACTION DECIMAL MM TO INCHES

1/64

0.0156″

1/32 0.0312″ 1 mm = 0.0394″

3/64 0.0469″

1/16

0.0625″

5/64

0.0781″ 2 mm = 0.0787″

3/32 0.0938″

7/64

0.1094″ 3 mm = 0.1181″

1/8

0.1250″

9/64 0.1406″

5/32

0.1563″ 4 mm = 0.1575″

11/64

0.1719″

3/16 0.1875″ 5 mm = 0.1969″

13/64

0.2031″

7/32

0.2188″

15/64

0.2344″ 6 mm = 0.2362″

1/4 0.25″

17/64

0.2656″ 7 mm = 0.2756″

9/32 0.2813″

19/64 0.2969″

5/16

0.3125″ 8 mm = 0.3150″

21/64

0.3281″

11/32 0.3438″ 9 mm = 0.3543″

23/64

0.3594″

3/8

0.375″

25/64 0.3906″ 10 mm = 0.3937″

13/32

0.4063″

27/64

0.4219″ 11 mm = 0.4331″

7/16 0.4375″

29/64

0.4531″

15/32

0.4688″ 12 mm = 0.4724″

31/64

0.4844″

1/2 0.500″ 13 mm = 0.5118″

33/64

0.5156″

17/32

0.5313″

35/64 0.5469″ 14 mm = 0.5512″

9/16

0.5625″

37/64

0.5781″ 15 mm = 0.5906″

19/32

0.5938″

39/64 0.6094″

5/8

0.625″ 16 mm = 0.6299″

FRACTION DECIMAL MM TO INCHES

41/64

0.6406″

21/32 0.6563″ 17 mm = 0.6693″

43/64 0.6719″

11/16

0.6875″

45/64

0.7031″ 18 mm = 0.7087″

23/32 0.7188″

47/64

0.7344″ 19 mm = 0.7480″

3/4

0.750″

49/64 0.7656″

25/32

0.7813″ 20 mm = 0.7874″

51/64

0.7969″

13/16 0.8125″ 21 mm = 0.8268″

53/64

0.8281″

27/32

0.8438″

55/64

0.8594″ 22 mm = 0.8661″

7/8 0.875″

57/64

0.8906″ 23 mm = 0.9055″

29/32

0.9063″

59/64 0.9219″

15/16

0.9375″ 24 mm = 0.9449″

61/64

0.9531″

31/32 0.9688″ 25 mm = 0.9843″

63/64

0.9844″

1 1.000″

GENERAL INFORMATION

1.18

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

NOTES

GENERAL INFORMATION

2.1

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . 2.3

BREAK-IN PERIOD .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . 2.3

MAINTENANCE CHART KEY . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . . 2.3

PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . . 2.4

50 - 500 HOUR MAINTENANCE INTERVAL .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . 2.5

MAINTENANCE QUICK REFERENCE . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . 2.6

MAINTENANCE QUICK REFERENCE, CONTINUED... . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . 2.7

GREASE LUBRICATION POINTS .. . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . . 2.8

LUBRICANTS / SERVICE PRODUCTS. . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. . 2.9

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . .. .. . . . . . .. .. . . . .. .. .. . . . .. . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE . .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . ..2.10

PRE-RIDE / DAILY INSPECTION . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . ..2.10

SHIFT CABLE INSPECTION / ADJUSTMENT . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . ..2.10

FUEL SYSTEM AND AIR INTAKE . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . 2.11

FUEL SYSTEM . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. 2.11

FUEL TANK VENT LINE. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .2.11

FUEL PUMP / FUEL FILTERS .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .2.11

FUEL LINES .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..2.12

THROTTLE PEDAL INSPECTION. . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .2.12

ENGINE INTAKE PRE-FILTER SERVICE . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . 2.13

AIR FILTER SERVICE. . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. ..2.13

INTAKE DUCT DRAIN INSPECTION . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . .2.14

AIR BOX / AIR FILTER ASSEMBLY VIEW . .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .2.15

ENGINE . . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . .2.16

ENGINE OIL LEVEL.. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. ..2.16

ENGINE OIL AND FILTER CHANGE .. . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .2.17

ENGINE CRANKCASE BREATHER HOSE INSPECTION. . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .2.18

ENGINE CYLINDER LEAKDOWN TEST. .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . .2.18

VALVE CLEARANCE INSPECTION . . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . .2.19

TRANSMISSION AND FRONT GEARCASE . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .2.21

SPECIFICATION CHART. . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. ..2.21

TRANSMISSION LUBRICATION .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . .2.21

FRONT GEARCASE LUBRICATION. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. .2.22

COOLING SYSTEM. . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. ..2.23

COOLING SYSTEM OVERVIEW .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. .2.23

COOLANT STRENGTH .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . .2.23

COOLANT LEVEL INSPECTION . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .2.24

COOLING SYSTEM PRESSURE TEST.. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .2.25

COOLING SYSTEM HOSES .. . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . .2.25

RADIATOR INSPECTION / CLEANING . . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. ..2.26

COOLANT DRAIN / FILL .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .2.26

2.2

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

PVT / FINAL DRIVE / WHEEL AND TIRE .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . ..2.27

DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. .2.27

PVT INTAKE PRE-FILTER SERVICE . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . .2.27

PVT DRYING . . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . .2.27

DRIVE SHAFT BOOT INSPECTION . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. ..2.28

WHEEL AND HUB TORQUE TABLE. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . 2.28

WHEEL REMOVAL.. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .2.28

WHEEL INSTALLATION. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . .2.28

TIRE INSPECTION. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . .2.28

TIRE PRESSURE . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. .2.29

ELECTRICAL AND IGNITION SYSTEM .. . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. ..2.29

BATTERY MAINTENANCE . . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . 2.29

BATTERY CHARGING / OFF SEASON STORAGE .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .2.30

BATTERY REMOVAL . .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . .2.30

BATTERY INSTALLATION.. . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. ..2.30

ENGINE / CHASSIS ELECTRICAL GROUND . .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .2.31

SPARK PLUG SERVICE . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .2.31

STEERING .. . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .2.32

STEERING INSPECTION .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .2.32

STEERING WHEEL FREEPLAY. . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . .2.32

TIE ROD END / WHEEL HUB INSPECTION .. . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. ..2.33

WHEEL TOE ALIGNMENT INSPECTION . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .2.33

WHEEL TOE ADJUSTMENT .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . .2.34

SUSPENSION (WALKER EVANS™) . . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . .2.35

SPRING ADJUSTMENT. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . .2.35

SHOCK COMPRESSION ADJUSTMENT. . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . .2.36

BRAKE SYSTEM. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. ..2.37

BRAKE FLUID INSPECTION . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . .2.37

BRAKE PAD / DISC INSPECTION . .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .2.37

BRAKE HOSE AND FITTING INSPECTION . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. ..2.37

MAINTENANCE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Break-In Period

The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 25 hours or one month.

• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

■ = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an

authorized Polaris dealer.

▶ = SEVERE USE ITEM: See information provided above.

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

MAINTENANCE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Pre-Ride - 50 Hour Maintenance Interval

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

REMARKS

HOURS CALENDAR

MILES

(KM)

Steering

Pre-Ride

Inspect or adjust as needed. See Pre-Ride Checklist on Page 2.10.

Front / Rear Suspension

- -

Tires

- -

Brake Fluid Level

- -

Brake Pedal Travel

- -

Brake System

- -

Wheels / Fasteners

- -

Frame Fasteners

- -

Engine Oil Level

- -

Engine Intake Pre-Filter

Daily

Inspect and clean often

PVT Intake Pre-Filter

Daily

Inspect and clean often

▶

Intake Baffle Box Drain

Daily

Inspect drain at the bottom of the air intake baffle box for obstructions

Coolant Level

Daily

Check level daily

Head Lights / Tail Lights

Daily

Check operation

▶

■

Brake Pad Wear / Inspect Parking Brake Pads (INT’L)

10 H

Monthly 100 (160) Inspect periodically

▶

■

Parking Brake Cable Adjustment (INT’L)

25 H

- -

Inspect; adjust tension after first 25 hours

▶

Air Filter 25 H

Monthly 250 (400) Inspect; replace as needed

Battery

25 H

Monthly 250 (400)

Check terminals; clean; test

▶

Engine Oil & Filter Change (Break-In Period)

25 H 1 M

250 (400)

Perform a break-in oil and filter change at 25 hours or one month; perform every 50 hours or 6 months thereafter

▶

Front Gearcase Lubricant (Demand Drive)

25 H 1 M

250 (400) Initial fluid level inspection; add lubricant if needed

▶

Transmission Lubricant (AGL)

25 H 1 M

250 (400) Initial fluid level inspection; add lubricant if needed

▶

General Lubrication 50 H 3 M

500 (800) Lubricate all fittings, pivots, cables, etc.

■

Throttle Cable / Throttle Pedal

50 H 6 M

500 (800) Inspect; adjust; replace if necessary

Throttle Body Intake Boots

50 H 6 M

500 (800) Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage

50 H 6 M

500 (800) Inspect; adjust as needed

■

Steering

50 H 6 M

500 (800) Lubricate (if applicable)

▶

Front / Rear Suspension

50 H 6 M

500 (800) Lubricate (if applicable)

▶ Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

■ Have an authorized Polaris dealer perform these services.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

50 - 500 Hour Maintenance Interval

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

REMARKS

HOURS CALENDAR

MILES

(KM)

■

Cooling System

50 H 6 M

500 (800)

Inspect coolant strength seasonally; pressure test system yearly

▶

Engine Oil/Filter Change

50 H 6 M

1000 (1600)

Perform a break-in oil change at 25 hours or one month

▶

■

Parking Brake Cable Adjustment (INT’L)

100 H 6 M

1000 (1600) Inspect; adjust tension as needed

▶

Front Gearcase Lubricant (Demand Drive)

100 H 12 M

1000 (1600) Change lubricant

▶

Transmission Lubricant (AGL)

100 H 12 M

1000 (1600) Change lubricant

■

Fuel System

100 H 12 M

1000 (1600)

Check for leaks at fill cap, fuel line / rail, and fuel pump.

■

Spark Plug Inspection

100 H 12 M

1000 (1600) Inspect; replace as needed; torque to specification

▶

Radiator 100 H 12 M

1000 (1600) Inspect; clean external surfaces

▶

Cooling Hoses

100 H 12 M

1000 (1600) Inspect for leaks; pressure test system

▶

Engine Mounts

100 H 12 M

1000 (1600) Inspect, torque to specification

Exhaust Silencer / Pipe

100 H 12 M

1000 (1600) Inspect

▶

Wiring

100 H 12 M

1000 (1600)

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

■

Clutches (Drive and Driven)

100 H 12 M

1000 (1600) Inspect; clean; replace worn parts

■

Drive Belt 100 H 12 M

1000 (1600) Inspect; replace as needed

■

Front Wheel Bearings

100 H 12 M

1000 (1600) Inspect; replace as needed

▶

Shocks 100 H

- -

Visually inspect shock seals

■

Valve Clearance 100 H

1000 (1600) Inspect; adjust as needed

▶

■

Shocks

12 M

1500 (2400) Change shock oil and inspect seals

▶

Coolant

24 M

Replace coolant

■

Brake Fluid 200 H 24 M

2000 (3200) Change every two years (DOT 4)

Spark Arrestor

200 H 24 M

2000 (3200)

Clean out

■

Valve Clearance 200 H

2000 (3200) Inspect; adjust as needed

■

Spark Plug Replacement

500 H 36 M

5000 (8000) Replace; torque to specification

■

Toe Adjustment

Inspect periodically; adjust when parts are replaced

Headlight Aim

Adjust as needed

▶ Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

■ Have an authorized Polaris dealer perform these services.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Maintenance Quick Reference

ITEM LUBE REC. METHOD

FREQUENCY*

Oil Fill Cap (Item 1):

- Under Cargo Box Access Panel

Oil Filter (Item 2) / Dipstick (Item 3):

- Behind Engine Access Panel

Polaris PS-4 or Polaris PS-4 Extreme Duty

Add oil to proper level on dipstick

Perform a break-in oil and filter change at 25 hrs or one month; perform every 50 hrs thereafter

Engine Coolant

- Under Front Hood / Access Panel

Polaris 60/40 Coolant

Maintain coolant level in coolant reservoir bottle (Item 4).

Check level daily; change coolant every two years

* More often under severe use, such as operation in water or under severe loads.

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Maintenance Quick Reference, Continued...

ITEM LUBE REC. METHOD

FREQUENCY*

Brake Fluid

Polaris DOT 4 Brake Fluid

Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir (Item

Check level during pre-ride inspection; change fluid every two years

Front Gearcase

Polaris Demand Drive

Add lubricant until it is visible at the fill hole threads (Item 2) (

8.5 oz. (250 ml))

Initial level check at 25 hours or 1 month; Change lubricant at 100 hours or every 12 months, whichever comes first

Transmission Polaris AGL

Add lubricant until it is visible at the fill hole threads (Item 3)

* More often under severe use, such as operation in water or under severe loads.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Grease Lubrication Points

There are grease fittings at each front A-arm pivot point, each rear torsion bar bushing and on the front propshaft yokes. Apply grease until all traces of water have been purged out at each of these areas.

ITEM METHOD RECOMMENDED LUBE

FREQUENCY

Front A-arm Pivot Bushings

Grease 3 fittings on each side of the vehicle (Item 1)

Polaris All Season Grease

Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle

Propshaft Yokes

Grease middle and rear fittings (Item 2)

Polaris Premium U-Joint Grease

Front Stabilizer Bar Bushings (INT’L)

Grease the fitting on each side of the vehicle (Item 3)

Polaris All Season Grease

Rear Torsion Bar Bushings

Grease 2 fittings through the skid plate access holes on each side of the vehicle (Item

Polaris All Season Grease

*There is no grease point on the upper control arm rear mount.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

PART NO.

DESCRIPTION

Engine Lubricant

2870791

Fogging Oil (12 oz. Aerosol)

2876244

PS-4 Synthetic 4-Cycle Engine Oil (Quart)

2876245

PS-4 Synthetic 4-Cycle Engine Oil (Gallon)

2878920

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Quart)

2878919

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Gallon)

2540086

Engine Oil Filter

2879723

Engine Oil Change Kit (PS-4)

2879324

Engine Oil Change Kit (PS-4 Extreme Duty)

Gearcase / Transmission Lubricants

2878068

AGL (1 Qt.) (12 Count)

2878069

AGL (1 Gal.) (4 Count)

2878070

AGL Gearcase Lubricant (2.5 Gal.) (2 Count)

2877922

Demand Drive (Quart)

2877923

Demand Drive (2.5 Gallon)

2870465

Oil Pump for 1 Gallon Jug

Grease / Specialized Lubricants

2871312 Grease Gun Kit

2871322

Premium All Season Grease (3 oz. cartridge) (24 Count)

2871423

Premium All Season Grease (14 oz. cartridge) (10 Count)

2871460

Starter Drive Grease (12 Count)

2871515

Premium U-Joint Lube (3 oz.) (24 Count)

2871551

Premium U-Joint Lube (14 oz.) (10 Count)

2871329

Dielectric Grease (Nyogel™)

Coolant

2871323

60/40 Coolant (Gallon) (6 Count)

2871534

60/40 Coolant (Quart) (12 Count)

NOTE: Each item can be purchased separately at your local Polaris dealer.

PART NO.

DESCRIPTION

Additives / Sealants / Thread Locking Agents / Misc.

2871950

Loctite® Threadlock 242 (6 ml.) (12 count)

2871326

Premium Carbon Clean (12 oz.) (12 count)

2870652

Fuel Stabilizer (16 oz.) (12 count)

2872189

DOT 4 Brake Fluid (12 count)

2871557

Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

MAINTENANCE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Engine Oil - Check for proper level on dipstick (refer to “Engine Oil Level” procedure)

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation and fluid level and adjustment (includes parking brake on INT’L Model)

• Headlights/Taillights/Brakelights - also check operation of all indicator lights, instrument cluster and switches

• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Engine Intake Pre-Filter - Inspect pre-filter and clean with soapy water and low pressure compressed air if necessary

• PVT Intake Pre-Filter - Inspect pre-filter and clean with soapy water and low pressure compressed air if necessary

• Steering - check for free operation noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

• Drive Shaft Boots - Inspect inner and outer boots for tears or damage on both front and rear drive shafts

• Check all front and rear suspension components for wear or damage.

Shift Cable Inspection / Adjustment

Shift cable adjustment may be necessary if symptoms include:

• No gear position or AWD display on instrument cluster

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear lash (noise)

• Gear selector moving out of desired range

1. Locate the shift cable (Item 1) attached to the transmission case in the right rear wheel well area.

2. Inspect shift cable, clevis pin, pivot bushings (Item

4), and dust boot (Item 3). Replace if worn or damaged.

3. If adjustment is required, loosen the lower jam nut (Item 6) and pull the cable out of the mount (Item 2) to move the upper jam nut (Item 5).

4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK.

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5. Thread the upper or lower jam nut as required to obtain proper cable adjustment.

NOTE: This procedure may require a few attempts to obtain the proper adjustment.

6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount.

7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service.

FUEL SYSTEM AND AIR INTAKE

Fuel System

WARNING

Gasoline is extremely flammable and explosive under

certain conditions.

Always stop the engine and refuel outdoors or in a well

ventilated area.

Do not smoke or allow open flames or sparks in or near

the area where refueling is performed or where

gasoline is stored.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow

gasoline, seek medical attention immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water

and change clothing.

Never start the engine or let it run in an enclosed area.

Engine exhaust fumes are poisonous and can result in

loss of consciousness or

death in a short time.

Never drain the fuel when the engine is hot.

Severe burns may result.

Fuel Tank Vent Line

Symptoms of a restricted fuel tank vent include the following: collapsing fuel tank, engine miss or hesitation, loss of engine performance or high exhaust temperatures.

1. Remove the seats and the engine service panel.

2. Check the fuel tank vent line for signs of wear, deterioration or damage. Replace vent line if necessary.

3. Be sure the vent line is routed properly and secured with cable tie(s).

NOTE: Make sure vent line is not kinked or pinched.

Fuel Pump / Fuel Filters

The fuel pump assembly (Item 1) is located in the fuel tank under the passenger seat.

The RZR XP 1000 EFI engine uses a serviceable, highvolume, high-pressure, fuel pump that includes a preliminary filter (Item 2) and an internal fine filter (Item

3) located before the pump regulator.

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NOTE: Neither filter is serviceable individually. Must replace the fuel pump as an assembly.

Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System.

Fuel Lines

1. Check the quick-connect fuel line (Item 1) at the fuel tank for signs of wear, deterioration, damage or leakage. Replace line(s) if necessary.

2. Locate the fuel supply fitting (Item 2) through the right rear wheel well on the upper right side of the engine. Check the line and quick-connect fitting for signs of wear, deterioration, damage or leakage. Replace line if necessary.

3. Be sure fuel lines are routed and retained properly.

NOTE: Make sure lines are not kinked or pinched.

Throttle Pedal Inspection

This vehicle is equipped with Pedal Position Sensor (Item 1) used to detect when the throttle pedal (Item 2) is pushed or released.

The throttle pedal should move freely and always return back to its idle position when released.

Check throttle pedal periodically.

MAINTENANCE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Engine Intake Pre-Filter Service

It is recommended that the engine intake pre-filter be inspected daily. The filter should be inspected using the following procedure:

1. The engine intake pre-filter is located just above the right rear wheel fender.

2. Loosen the knob on top of the assembly and lift up to disengage the tab from the cargo box.

3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air.

Air Filter Service

Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often.

1. Remove the cargo box access panel (Item 1).

2. Disengage the four cover latches (Item 2).

3. Pull cover rearward far enough to remove air filter (Item 3).

4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean shop towel.

NOTE: If the filter has been soaked with fuel or oil it must be replaced.

5. Inspect the air filter and replace if necessary.

NOTE: DO NOT attempt to clean the air filter.

6. Place the air filter into the air box and reinstall the air box cover.

NOTE: Be sure the lower tabs on the air box cover are properly engaged into the airbox.

7. Engage the cover latches.

8. Reinstall the cargo box access panel.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Intake Duct Drain Inspection

It is recommended that the intake drain be inspected daily.

1. Access the intake baffle box drain (Item 1) through the left rear wheel well.

2. Check the drain to ensure it is not plugged with debris so it can drain properly. If needed, remove the drain from the baffle box during inspection.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Air Box / Air Filter Assembly View

1. Intake Airbox Hose 6. Airbox Clip (4)

2. Drain Cap

7. Vent Hose

3. Airbox 8. Intake Tubes

4. Air Filter 9. Engine Intake Housing

5. Airbox Cover

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ENGINE

Engine Oil Level

The 2014 RZR XP 1000 engine has a wet-sump design, meaning the engine oil is contained in the bottom of the crankcase. To check the oil level, follow the procedure listed below:

Access the oil dipstick through the opening in front of the passenger rear tire.

Access the oil fill cap through the cargo box access panel.

Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil.

Recommended Engine Oil:

PS-4 (PN 2876244)

Ambient Temp Range: -35° F to 100° F

PS-4 Extreme Duty (PN 2878920)

Ambient Temp Range: 0° F to 120° F

Capacity: 2.5 Quarts (2.4 L)

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down before removing the dipstick.

3. Unlock the dipstick lever (Item 1). Remove the dipstick and wipe it dry with a clean cloth.

4. Reinstall the dipstick and push it into place. Do not lock the dipstick

NOTE: Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.

5. Remove the dipstick and check the oil level.

6. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill (see NOTE below).

NOTE: A rising oil level between checks during cold weather operation can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the upper mark, change the oil immediately.

7. Add engine oil through the oil fill cap (Item 2) located on top of the valve cover, under the cargo box access panel.

8. When finished, reinstall dipstick and lock the lever.

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Engine Oil and Filter Change

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

The engine oil dipstick is located on the front side of the engine. Access the dipstick through the engine service panel.

The engine oil fill cap is located on top of the valve cover. Access the oil fill cap through the cargo box access panel.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase.

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down.

3. Clean the area around the crankcase drain plug.

CAUTION

Use caution when performing this procedure.

Do not allow hot engine oil to come into contact with

skin, as serious burns may result.

4. Place a drain pan under the engine crankcase and remove the drain plug (Item 1). Allow the oil to drain completely.

5. Remove the seats and engine service panel to access the oil filter.

6. Using the Oil Filter Wrench (PU-50105), turn the oil filter (Item 2) counter-clockwise to remove it.

Oil Filter Wrench:

PU-50105: 2.5″ (64 mm)

7. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase.

8. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it by hand until the O-ring contacts the sealing surface, then turn an additional 1/2 turn.

Oil Filter Torque:

Turn by hand until filter O-ring contacts sealing surface,

then turn an additional 1/2 turn.

9. Replace the sealing washer on drain plug.

NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.

10. Reinstall the engine crankcase drain plug. Torque drain plug to specification.

Engine Oil Drain Plug:

12 ft-lbs (16 Nm)

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11. Remove oil fill cap (see “Engine Oil Level”). Fill engine with 2.5 quarts (2.4 L) of recommended engine oil.

Recommended Engine Oil:

PS-4 (PN 2876244)

Ambient Temp Range: -35° F to 100° F

PS-4 Extreme Duty (PN 2878920)

Ambient Temp Range: 0° F to 120° F

Capacity: 2.5 Quarts (2.4 L)

12. Verify the transmission is still in PARK.

13. Start the engine and allow it to idle for 30 seconds.

14. Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.

15. Unlock the dipstick lever. Remove the dipstick and wipe it dry with a clean cloth (see “Engine Oil Level”).

16. Reinstall the dipstick and push it into place. Do not lock the dipstick

NOTE: Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.

17. Remove the dipstick and check the oil level.

18. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

19. When finished, reinstall the oil fill cap, oil dipstick and lock the lever.

20. Reinstall the cargo box access panel, engine service panel and seats.

21. Dispose of used oil and filter properly.

Engine Crankcase Breather Hose Inspection

The engine crankcase is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is form fitted for proper fit.

Follow the breather hose (Item 1) from the crankcase to the engine intake duct.

NOTE: Make sure hoses are not kinked or pinched.

Engine Cylinder Leakdown Test

A cylinder leak-down test is the best indication of engine condition. Follow tester manufacturer’s instructions to perform a cylinder leak-down test. Never use high pressure leakage testers as crankshaft seals may dislodge and leak.

Cylinder Leakage Service Limit: 20%

If leakage exceeds service limit, inspect the engine

for the cause.

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Valve Clearance Inspection

NOTE: Valve clearance inspection should be performed on a cold engine, at room temperature.

1. Remove the driver’s seat. Disconnect the negative

(-) battery cable.

2. Remove the engine access panel.

3. Remove eight screws retaining the outer clutch

cover.

4. Maneuver the outer clutch cover to allow access to

the drive clutch, in order to rotate the engine.

NOTE: Removal of left rear wheel or left rear shock is NOT necessary to perform this procedure.

5. Remove the spark plug wires to gain access to valve

cover as shown below.

6. Remove the four T40 bolts retaining the valve cover.

7. The engine will need to be rotated four times to inspect all eight valve clearances (Item 13). Two valves can be measured at each camshaft lobe position.

NOTE: Remove spark plugs to aid engine rotation.

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8. Rotate the drive clutch counter-clockwise until the cam lobes (Item 14) above the valves you are inspecting are facing up.

9. Measure the valve clearance using a feeler gauge.

10. If the valve clearance is out of specification, proceed to “Valve Clearance Adjustment” (see Chapter 3).

Intake Valve Clearance (cold):

.006 ± .002″ (0.15 ± 0.05 mm)

Exhaust Valve Clearance (cold):

.008 ± .002″ (0.20 ± 0.05 mm)

11. Repeat steps 18-20 until all eight valves have been inspected.

12. If previously removed, apply anti-seize compound to the spark plug threads and reinstall the spark plugs. Torque spark plugs to specification.

Spark Plug Torque:

7 ft-lbs (10 Nm)

13. Inspect the valve cover seal and replace if necessary.

14. Install NEW isolators on the valve cover bolts. Install the valve cover and the four T40 bolts. Torque bolts to specification.

Valve Cover Bolts:

7 ft-lbs (10 Nm)

15. Install the spark plug wires back into their correct location.

16. Install the push rivet that retains the heat shield to the frame cross member.

17. Install the spark plug wires. Ensure wires are installed on their proper cylinder spark plug and pushed down all the way so they engage onto the spark plugs.

NOTE: The engine will misfire if the spark plug wires are installed incorrectly. The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder.

18. Install outer clutch cover and eight retaining screws. Torque screws to specification.

Outer Clutch Cover Screws:

50 in-lbs (5 Nm)

19. Connect the negative (-) battery cable to the battery and install the seat.

20. Start the engine to ensure proper operation.

21. Install the engine access panel.

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TRANSMISSION AND FRONT GEARCASE

Specification Chart

GEARCASE LUBRICANT CAPACITY

FILL / DRAIN PLUG TORQUE

Transmission AGL

44 oz. (1300 ml) 14 ft-lbs (19 Nm)

Front Gearcase Demand Drive

8.5oz. (250 ml) 10 ft-lbs (14 Nm)

Transmission Lubrication

NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart. Regular lubricant level inspections should be performed as well.

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the lubricant.

• Check vent hose to be sure it is routed properly and unobstructed.

Transmission Lubricant Level Check

The fill plug is located on the rear portion of the transmission gearcase. Access the fill plug at the rear of the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug (Item 1) and check the lubricant level (Item 2).

3. If lubricant level is not even with bottom threads, add recommended lubricant as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

Transmission Fill / Drain Plug Torque:

14 ft-lbs (19 Nm)

Transmission Lubricant Change

The drain plug is located on the bottom of the transmission gearcase. Access the drain plug through the drain hole in the skid plate.

5. Remove the fill plug (refer to “Transmission Lubricant Level Check”).

6. Place a drain pan under the transmission drain plug.

7. Remove drain plug (Item 3) and allow lubricant to drain completely.

8. Clean the drain plug magnetic surface.

9. Reinstall the drain plug and torque to specification.

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10. Add the recommended amount of lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

Recommended Transmission Lubricant:

AGL (PN 2878068) (Quart)

Capacity: 44 oz. (1300 ml)

Capacity (INT’L): 41 oz. (1200 ml)

11. Reinstall the fill plug and torque to specification.

Transmission Fill / Drain Plug Torque:

14 ft-lbs (19 Nm)

12. Check for leaks. Dispose of used lubricant properly.

Front Gearcase Lubrication

NOTE: It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well.

The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface

when checking or changing the fluid.

• Check vent hose to be sure it is routed properly

and unobstructed.

Front Gearcase Fluid Level Check

The fill plug is located on the bottom right side of the front gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug (Item 1) and check the fluid level.

3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

Front Gearcase Fill / Drain Plug Torque:

10 ft-lbs (14 Nm)

Front Gearcase Fluid Change:

The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase.

5. Remove the fill plug (refer to “Front Gearcase Fluid Level Check”).

6. Place a drain pan under the front gearcase drain plug.

7. Remove the drain plug (Item 2) and allow fluid to drain completely.

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8. Clean the drain plug magnetic surface.

9. Reinstall the drain plug and torque to specification.

10. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.

Recommended Front Gearcase Fluid:

Polaris Demand Drive

(PN 2877922) (Quart)

Capacity:  8.5 oz. (250 mL)

11. Reinstall the fill plug and torque to specification.

Front Gearcase Fill / Drain Plug Torque:

10 ft-lbs (14 Nm)

12. Check for leaks. Dispose of used fluid properly.

COOLING SYSTEM

Cooling System Overview

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during break-in period.

Overheating of engine could occur if air is not fully purged from system.

Polaris Premium 60/40 Antifreeze is premixed and ready to use. Do not dilute with water.

Coolant Strength

Test the strength of the coolant using an antifreeze hydrometer.

• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze or straight water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

Recommended Coolant:

Polaris Premium Pre-Mixed Antifreeze

(PN 2871534) (Quart)

(PN 2871323) (Gallon)

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Coolant Level Inspection

The pressure cap (Item 1) and recovery bottle (Item 2) are located under the front hood of the vehicle. The coolant level must be maintained between the minimum and maximum levels indicated on the recovery bottle.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle. If not, perform the following procedure:

1. Position the vehicle on a level surface.

2. Remove the front hood.

3. View the coolant level in the recovery bottle.

4. If the coolant level is below the MIN line, inspect the coolant level in the radiator.

NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.

WARNING

Never remove the pressure cap when the engine is

warm or hot. Escaping steam can cause severe burns.

The engine must be cool before removing the pressure

cap.

5. Remove the pressure cap. Using a funnel, add coolant to the top of the filler neck.

6. Reinstall the pressure cap.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.

7. Remove recovery bottle cap and add coolant using a funnel.

8. Fill recovery bottle to MAX level with recommended coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

Recommended Coolant:

Polaris Premium Pre-Mixed Antifreeze

PN 2871534 (Quart)

PN 2871323 (Gallon)

9. Reinstall the recovery bottle cap.

10. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating.

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Cooling System Pressure Test

Refer to ENGINE COOLING SYSTEM, page 3.13.

Cooling System Hoses

1. Inspect all vehicle hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

ITEM

DESCRIPTION

1 Recovery Bottle

2 Engine Hoses

3 Radiator Hoses

4 To Thermostat Housing

To Waterpump

6 To Radiator

2. Inspect all engine hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

ITEM

DESCRIPTION

7 Bypass Hose

Waterpump Outlet Hose

Oil Cooler Inlet Hose

Oil Cooler Outlet Hose

3. Check tightness and condition of all hose spring clamps. Replace if necessary.

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Radiator Inspection / Cleaning

1. Check radiator air passages for restrictions or damage.

ITEM

DESCRIPTION

1 Radiator

Shroud

3 Fan

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with low pressure compressed air or low pressure water.

CAUTION

Washing the vehicle with a high-pressure washer could

damage the radiator fins and impair the radiators

effectiveness. Use of a high-pressure washer is not

recommended.

Coolant Drain / Fill

1. Remove the front hood.

WARNING

Never drain the coolant when the engine and radiator

are warm or hot. Hot coolant can cause severe burns.

Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling system pressure.

3. Place a suitable drain pan underneath the radiator fitting on the front right side of the vehicle.

4. Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown (Item

1).

5. Allow coolant to drain completely. Properly dispose of the used coolant.

6. Reinstall coolant hose and reposition the spring clamp.

7. Remove the pressure cap. Using a funnel, add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level.

8. Refer to Cooling System Bleeding Procedure, page

3.18.

Recommended Coolant:

Polaris Premium Pre-Mixed Antifreeze

(PN 2871534) (Quart)

(PN 2871323) (Gallon)

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PVT / FINAL DRIVE / WHEEL AND TIRE

Drive Clutch / Driven Clutch / Belt Service

Refer to PVT SYSTEM SERVICE, page 6.6 for service and removal procedures.

PVT Intake Pre-Filter Service

It is recommended that the PVT intake pre-filter be inspected daily. The filter should be inspected using the following procedure:

1. The PVT intake pre-filter is located just above the left rear wheel fender.

2. Loosen the knob on top of the assembly and lift up to disengage the tab from the cargo box.

3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air.

PVT Drying

NOTE: After operating in water, the vehicle’s PVT system should be checked immediately. Use the following instructions to dry it out before operating.

The PVT drain plug is located at the bottom of the outer clutch cover. Access the drain plug through the left rear wheel well.

1. Using a flat blade screwdriver, remove the PVT drain plug (Item 1) and O-ring from the outer clutch cover.

2. Allow the water to drain out completely.

3. Reinstall the drain plug and O-ring.

4. Place the transmission in PARK, apply the brake and start the engine.

5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.

NOTE: Do not hold the throttle pedal wide open for more than 5 seconds.

6. Allow the engine RPM to return to idle, then shift the transmission into low gear.

7. Test the PVT system for belt slippage. If the belt slips, repeat the process or remove the outer clutch cover to inspect the PVT system (see PVT SYSTEM SERVICE, page 6.6 for service and removal procedures).

NOTE: If the vehicle has ingested a large amount of water into the PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage.

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Drive Shaft Boot Inspection

Inspect the front and rear drive shaft boots (Item 1) for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Check to see the boot clamps (Item 2) are properly positioned. Refer to DRIVE SHAFT CV JOINT / BOOT REPLACEMENT , page 7.33for drive shaft boot replacement.

Wheel and Hub Torque Table

ITEM SPECIFICATION

Wheel Nuts (Cast Aluminum Wheels)

120 ft-lbs (163 Nm)

Hub Retaining Nuts (Front and Rear)

110 ft-lbs (149 Nm)

NOTE: Do not lubricate the stud or the lug nut.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK and stop the engine.

3. Loosen the wheel nuts slightly. If wheel hub removal is required, remove the wheel cap, cotter pin and loosen the hub nut slightly.

4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and remove the wheel.

Wheel Installation

1. Verify the transmission is still in PARK.

2. Place the wheel in the correct position on the wheel hub (Item 5). Be sure the valve stem (Item 2) is toward the outside and rotation arrows on the tire point toward forward rotation.

3. Attach the wheel nuts (Item 1) and finger tighten them.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts and/or hub nut (Item 3) to the proper torque specification (see Wheel and Hub Torque Table, page 2.28).

6. If hub nut was removed, install a new cotter pin (Item

4) after the hub nut has been tightened. If the holes do not line up, turn the hub nut counter-clockwise until the cotter pin can be installed.

CAUTION

If wheels are improperly installed it could affect vehicle

handling and tire wear. On vehicles with tapered wheel

nuts, make sure tapered end of nut goes into taper on

wheel.

Tire Inspection

• Improper tire inflation may affect vehicle

maneuverability.

• When replacing a tire always use original

equipment size and type.

• The use of non-standard size or type tires may

affect vehicle handling.

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WARNING

Operating with worn tires will increase the possibility of

the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the usable tread depth has

worn out.

Tire Pressure

Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle’s tool kit.

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

TIRE PRESSURE INSPECTION (COLD)

Front Rear

16 psi (110 kPa) 16 psi (110 kPa)

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related

accessories contain lead and lead compounds, and

other chemicals known to the State of California to

cause cancer and birth defects or other reproductive

harm.

WASH HANDS AFTER HANDLING.

WARNING

Battery electrolyte is poisonous. It contains sulfuric

acid. Serious burns can result from contact with skin,

eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow

with milk of magnesia, beaten egg, or vegetable oil. Call

physician immediately.

Eyes: Flush with water for 15 minutes and get prompt

medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc. away. Ventilate

when charging or using in an enclosed space. Always

shield eyes when

working near batteries.

KEEP OUT OF REACH OF CHILDREN.

NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery according to “Charging Procedure”, page 10.36. Do not use the vehicle’s stator/alternator to charge a new battery.

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Battery Charging / Off Season Storage

Refer to Charging Procedure , page 10.36and Battery Off Season Storage, page 10.35.

Battery Removal

1. Remove the driver’s seat to access the battery (Item

1).

NOTE: Battery is located under left rear seat on RZR XP 4 1000

2. Disconnect the black (negative) battery cable(s).

3. Disconnect the red (positive) battery cable(s).

CAUTION

To reduce the chance of sparks: Whenever removing

the battery, disconnect the black (negative) cable first.

When reinstalling the battery, install the black (negative)

cable last.

4. Remove the battery hold-down bracket (Item 2).

5. Lift the battery out of the vehicle.

Battery Installation

NOTE: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Refer to Charging Procedure , page 10.36before installing the battery.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with hold-down strap.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Connect and tighten the red (positive) cable(s) first.

5. Connect and tighten the black (negative) cable (s) last.

6. Verify that cables are properly routed and reinstall the driver’s seat.

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Engine / Chassis Electrical Ground

Inspect the ground cable connections. Remove ground terminals and clean if necessary.

1. The chassis ground connection (Item 1), located below the start solenoid (Item 2), can be accessed through the left rear wheel area.

2. Inspect the chassis ground terminals. Be sure the grounds are clean and tight.

Spark Plug Service

Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart.

1. Remove the cargo box access panel (Item 1).

WARNING

A hot engine can cause serious burns. Allow engine to

cool or wear protective gloves when removing the spark

plugs.

2. Remove both spark plug caps (Item 2).

NOTE: Note MAG and PTO reference decals on spark plug wires for reassembly.

3. Clean out plug wells with compressed air to remove any loose dirt or debris.

4. Rinse plug wells with water and dry with compressed air.

NOTE: Spark plug wells have drain holes built into the cylinder head to allow water to drain out.

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5. Remove spark plugs using a 5/8” spark plug socket with an extension.

6. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

7. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode.

9. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

Recommended Spark Plug:

Champion RG4YCX

10. Apply anti-seize compound to the spark plug threads.

11. Install spark plugs and torque to specification.

Spark Plug Torque:

7 ft-lbs (10 Nm)

12. Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals. Ensure wires are pushed down all the way so they engage onto the spark plugs.

13. Reinstall the cargo box access panel.

STEERING

Steering Inspection

The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must be replaced.

Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: Check front end alignment whenever steering components are replaced.

WARNING

Due to the critical nature of the procedures outlined in

this chapter, Polaris recommends steering component

repair and adjustment be performed by an authorized

Polaris MSD certified technician.

Steering Wheel Freeplay

Check steering wheel for specified freeplay and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8-1.0″ (20-25 mm) of freeplay.

4. If there is excessive freeplay or the steering feels rough, inspect the following components.

• Tie Rod Ends (Item 1)

• Steering Shaft U-Joints (Item 2)

• Steering Gearbox (Item 3)

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Tie Rod End / Wheel Hub Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Replace any worn steering components. Steering should move freely through entire range of travel without binding.

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front wheel/hub assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).

• Refer to Chapter 7 “Final Drive” for front hub service procedures.

Wheel Toe Alignment Inspection

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible (1).

NOTE: It is important the height of both marks be equally positioned to get an accurate measurement.

3. Measure the distance between the marks and record the measurement. Call this measurement “2”.

4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

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5. Again measure the distance between the marks and record. Call this measurement “3”. Subtract measurement “3” from measurement “2”. The difference between measurements “2” and “3” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8 to 3/16″ (3.2 to 4.8 mm) toe out. This means the measurement at the front of the tire (2) is 1/8 to 3/16″ (3.2 to 4.8 mm) wider than the measurement at the rear (3).

Wheel Toe-Out:

(A) - (B) = 1/8" to 3/16″ (3.2 to 4.8 mm)

Wheel Toe Adjustment

If toe alignment is incorrect, repeat steps 3-5 of “Wheel Toe Alignment Inspection”, but instead measure the distance between each wheel and the vehicle center. This will tell you which tie rod needs adjusting.

NOTE: Be sure steering wheel is straight ahead before determining which tie rod needs adjustment.

CAUTION

During tie rod adjustment, it is very important that the

following precautions be taken when tightening tie rod

end jam nuts.

If the rod end is positioned incorrectly it will not pivot,

and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”.

• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

• After alignment is complete, torque jam nuts to specification.

Tie Rod Jamb Nut:

14 ft-lbs (19 Nm)

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SUSPENSION (WALKER EVANS™)

Spring Adjustment

The front and rear shocks have a ride height adjustment. Suspension springs may be adjusted to suit different riding conditions or vehicle payloads.

WARNING

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and serious

injury or death. Always adjust both the left and right

spring equally.

Spring Adjustment - Factory Setting

FRONT REAR

RZR XP 1000: 18.618″ (47.289 cm)

RZR XP 1000: 22.930″ (58.242 cm)

RZR XP 4 1000: 17.593″ (44.686 cm)

RZR XP 4 1000: 22.418″ (56.941 cm)

NOTE: Refer to the shock illustrations within this procedure for spring measurement location.

The factory setting is appropriate for nearly all riding conditions. Since this vehicle is equipped with full skid plates, adjustment is not necessary.

If desired, the spring setting may be adjusted to maintain vehicle clearance height when carrying loads.

1. Raise and safely support front or rear of the vehicle off the ground to allow the suspension to fully extend.

2. Using the shock spanner/spreader tool (PN

2878925) included in the vehicle’s tool kit, turn the adjustment collar (Item 1) to increase or decrease ride height.

Shock Spanner / Clutch Spreader Tool:

PN 2878925

NOTE: DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting.

NOTE: Always return the spring preload to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load.

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Shock Compression Adjustment

The compression damping adjustment is located on the shock ‘Piggyback’ reservoir of each shock. Damping adjustments can be made without using any tools.

NOTE: When the adjuster knob is turned counterclockwise until it stops, the damping is in the fully open position (softest).

Turn the adjuster knob clockwise to increase compression damping. Turn the adjuster knob counterclockwise to decrease compression damping.

NOTE: The recommended factory setting for the front and rear shocks are provided in the following compression adjustment tables.

Walker Evans™ 2.0" Front Shock:

Compression Adjustment Table

SETTING COMPRESSION DAMPING

Softest

Full counter-clockwise position

Factory

6 clicks from softest position

Firmest

Full clockwise position

Walker Evans™ 2.5" Rear Shock:

Compression Adjustment Table

SETTING COMPRESSION DAMPING

Softest

Full counter-clockwise position

Factory

7 clicks from softest position

Firmest

Full clockwise position

The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counterclockwise will decrease damping.

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BRAKE SYSTEM

Brake Fluid Inspection

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. View the brake fluid level in the reservoir (Item 1). The level should be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches the MAX level line.

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material (Item 1) is worn to 0.040″ (1 mm).

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

6. The disc (s) should be replaced if thickness is less than 0.170″ (4.32 mm).

Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

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NOTES

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ENGINE

CHAPTER 3

ENGINE

GENERAL INFORMATION . .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. . 3.3

SPECIAL TOOLS . . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . . 3.3

ENGINE LUBRICATION SPECIFICATIONS. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. . 3.3

OIL PRESSURE TEST .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . 3.4

ENGINE OIL FLOW CHART. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . 3.5

ENGINE SERVICE SPECIFICATIONS. . . . .. .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. 3.6

ENGINE SPECIFICATIONS . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . . 3.6

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . . . .. .. . . . .. .. .. . . . .. .. . . 3.8

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE. . .. .. . . . . . .. .. . . . . . . 3.8

BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS .. . . . . . .. .. . . 3.9

CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP . .. . . . . . .. .. . . . ..3.10

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER. . . . . .. .. . . . .. .. 3.11

SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER . . . . .3.12

ENGINE COOLING SYSTEM . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . 3.13

COOLING SYSTEM PRESSURE TEST.. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .3.13

PRESSURE CAP TEST . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . .3.13

RADIATOR REMOVAL / INSTALLATION. . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . .3.14

THERMOSTAT REPLACEMENT . . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .3.15

COOLING SYSTEM ASSEMBLY VIEW . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. ..3.17

COOLING SYSTEM BLEEDING PROCEDURE . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. ..3.18

WATER PUMP REMOVAL. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . .3.19

WATER PUMP INSTALLATION. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .3.19

WATER PUMP SERVICE.. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . .3.21

ENGINE SERVICE .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .3.24

ACCESSIBLE ENGINE COMPONENTS . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . .3.24

TOP-END SERVICE (ENGINE IN CHASSIS) . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . .3.24

ENGINE REMOVAL . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .3.24

ENGINE INSTALLATION . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .3.28

ENGINE MOUNTING AND TORQUE VALUES. . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . .3.31

ENGINE BREAK-IN PERIOD . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .3.32

ENGINE LUBRICATION SPECIFICATIONS. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . ..3.32

ENGINE DISASSEMBLY / INSPECTION - TOP END . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .3.33

VALVE COVER REMOVAL . .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . 3.33

CAMSHAFT REMOVAL . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..3.33

CAMSHAFT SPROCKET INSPECTION .. . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. ..3.34

CAMSHAFT / CAMSHAFT BORE INSPECTION . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . .3.34

CYLINDER HEAD REMOVAL . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . .3.36

CYLINDER HEAD WARP INSPECTION . . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .3.37

CYLINDER HEAD DISASSEMBLY . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . ..3.37

VALVE INSPECTION. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. ..3.38

COMBUSTION CHAMBER CLEANING. . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . .3.39

VALVE SEALING TEST . . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .3.39

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

VALVE SEAT RECONDITIONING . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .3.40

ENGINE DISASSEMBLY / INSPECTION - LOWER END . .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . .3.43

STATOR COVER REMOVAL / INSPECTION .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .3.43

WATER PUMP HOUSING REMOVAL.. . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. ..3.44

FLYWHEEL REMOVAL. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .3.44

STARTER ONE-WAY CLUTCH DISASSEMBLY. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . .3.45

CRANKCASE DISASSEMBLY / INSPECTION . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. ..3.46

BALANCE SHAFT REMOVAL / INSPECTION . .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .3.49

CRANKSHAFT REMOVAL / INSPECTION . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .3.50

CRANKCASE INSPECTION. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..3.52

CYLINDER INSPECTION . . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. ..3.53

CYLINDER / PISTON REMOVAL . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . .3.54

PISTON DISASSEMBLY / INSPECTION . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .3.55

PISTON RING REMOVAL . .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..3.56

PISTON RING TO GROOVE CLEARANCE INSPECTION . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .3.57

PISTON RING INSTALLED GAP . .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. ..3.57

PISTON-TO-CYLINDER CLEARANCE . . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . .3.57

CONNECTING ROD INSPECTION . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . .3.58

ENGINE ASSEMBLY - LOWER END . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .3.60

BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .3.60

CONNECTING ROD BEARING SELECTION .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . ..3.61

CRANKSHAFT MAIN BEARING SELECTION.. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . .3.61

UPPER CRANKCASE PREPARATION . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. ..3.61

PISTON RING INSTALLATION . .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . .3.62

PISTON / CONNECTING ROD ASSEMBLY. . .. .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . .3.63

CYLINDER / PISTON INSTALLATION . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..3.64

CRANKSHAFT INSTALLATION . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . .3.65

BALANCE SHAFT INSTALLATION . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . .3.67

LOWER CRANKCASE PREPARATION . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .3.67

CRANKCASE ASSEMBLY . . . . .. .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .3.68

STARTER ONE-WAY CLUTCH ASSEMBLY . . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. ..3.72

FLYWHEEL INSTALLATION. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . .3.73

STATOR COVER INSTALLATION . .. .. . . . . . .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .3.73

ENGINE ASSEMBLY - TOP END.. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . .3.74

CYLINDER HEAD ASSEMBLY .. . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . ..3.74

CYLINDER HEAD INSTALLATION. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. . . . . . .. .. . 3.75

CAMSHAFT INSTALLATION / TIMING. .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . .3.76

CAMSHAFT TIMING - QUICK REFERENCE . .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . ..3.80

VALVE CLEARANCE ADJUSTMENT .. . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..3.81

INTAKE VALVE LASH - TAPPET SELECTION MATRIX . .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . .3.83

EXHAUST VALVE LASH - TAPPET SELECTION MATRIX. .. .. . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .3.84

VALVE COVER INSTALLATION . .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. .3.85

TROUBLESHOOTING . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . .. .. .. . . . .. .3.86

ENGINE . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . .3.86

COOLING SYSTEM . . . . . .. .. . . . .. .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. .. . . . . . .. .. . . . . . .. .. . . . . . .. .. . . . .. ..3.87

ENGINE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

GENERAL INFORMATION

Special Tools

TOOL DESCRIPTION PART NUMBER

Bench Mount Engine Stand Adapter

PW-47053

Clutch Center Distance Tool PU-50658

Cylinder Holding & Camshaft Timing Plate

PU-50563

Engine Stand (2″ Bore)

PU-50624

Engine Stand Adapter (Mounts To The Engine)

PU-50562

Engine Stand Sleeve Adapter (Use With 2” Bore Stand)

PU-50625

Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)

PW-47054

Flywheel Puller

PA-49316

Mity Vac™ Pressure Test Tool

2870975

Oil Filter Wrench PU-50105

Oil Pressure Gauge

PV-43531

Oil Pressure Gauge Adapter

PU-50565

Piston Ring Compressor Pliers

PV-43570-1

Valve Spring Compressor

PV-1253 or PV-4019 (Quick Release)

Valve Spring Compressor Adapter

PV-43513-A

Water Pump Mechanical Seal Installer

PU-50564

Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/

Engine Lubrication Specifications

Oil Capacity *

Approx. 2.5 Quarts (2.4 L)

Oil Filter Wrench

PU-50105 or 2.5″ (64 mm)

Oil Filter

PN 2540086

Oil Type

PS-4 PSynthetic Engine oil

(PN 2876244) (Quart)

(-35° F to 100° F)

PS-4 Extreme Duty

Synthetic Engine Oil

(PN 2878920) (Quart)

(0° F to 120° F)

Oil Pressure Minimum Specification

(using Polaris engine oil at operating temperature)

10 PSI @ 1200 RPM 40 PSI @ 7000 RPM

*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

ENGINE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Oil Pressure Test

1. Attach the Oil Pressure Gauge Adapter (PU-50565) to the Oil Pressure Gauge (PV-43531).

Oil Pressure Gauge Adapter: PU-50565

Oil Pressure Gauge: PV-43531

2. Remove the seats, engine service panel, and divider panel heat shield.

3. Clean the area around the main oil gallery plug (A), located in the upper crankcase on the MAG side of the engine.

4. Remove the crankcase gallery plug (Item 1) and insert the oil pressure adapter.

5. Start engine and allow it to reach operating temperature, monitoring gauge indication.

NOTE: Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.

Oil Pressure Specification (Engine Hot):

Minimum @ 1200 RPM: 10 PSI Minimum @ 7000 RPM: 40 PSI

6. Upon assembly, torque the crankcase gallery plug to specification.

Crankcase Oil Gallery Plug:

11 ft-lbs (15 Nm)

ENGINE

3.5

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Engine Oil Flow Chart

ENGINE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

ENGINE SERVICE SPECIFICATIONS

Engine Specifications

CAMSHAFT / CYLINDER HEAD / CYLINDER

ITEM

STANDARD SERVICE LIMIT

Camshaft

Cam Lobe Height - Intake 1.5390 - 1.5429" (39.09 - 39.19 mm) 1.5370" (39.04 mm)

Cam Lobe Height - Exhaust 1.5142 - 1.5181" (38.46 - 38.56 mm) 1.5122" (38.41 mm)

Camshaft Journal O.D. - All

0.9036 - 0.9055" (22.954 - 22.999 mm) 0.9033" (22.944 mm)

Camshaft Carrier Bore I.D. - All

0.9055 - 0.9063" (23.000 - 23.021 mm) 0.9072" (23.044 mm)

Camshaft Oil Clearance

0.0000 - 0.0026" (0.001 - 0.067 mm) 0.0039" (0.1 mm)

Camshaft End Play 0.0040 - 0.0100" (0.101 - 0.254 mm) 0.0157" (0.4 mm)

Cylinder

Cylinder - Surface Warp Limit (cylinder head surface)

0.002″ (0.05 mm)

Cylinder Bore - Standard 3.6614 ± 0.0003" (93 mm ± 0.008 mm)

Cylinder Out of Round Limit

0.001″ (0.025 mm)

Cylinder Taper Limit

0.001″ (0.025 mm)

Cylinder to Piston Clearance 0.0009 - 0.0019" (0.025 - 0.050 mm)

Cylinder Head

Cylinder Head - Surface Warp Limit

0.0039″ (0.1 mm)

Cylinder Head - Standard Height 4.717 ± 0.0019" (119.82 ± 0.05 mm)

Valve

Valve Lash (Cold) - Intake 0.006 ± 0.002" (0.15 ± 0.5 mm)

Valve Lash (Cold) - Exhaust 0.008 ± 0.002" (0.20 ± 0.5 mm)

Valve Stem Diameter - Intake

0.2155 - 0.2161" (5.475 - 5.490 mm)

Valve Stem Diameter - Exhaust

0.2147 - 0.2153" (5.455 - 5.470 mm)

Valve Stem Oil Clearance - Intake

0.0003 - 0.0015" (0.010 - 0.040 mm)

Valve Stem Oil Clearance - Exhaust

0.0011 - 0.0023" (0.030 - 0.060 mm)

Valve Stem Overall Length - Intake 3.7704" (95.77 mm)

Valve Stem Overall Length - Exhaust 3.8023" (96.58 mm)

Valve Guide

Valve Guide Inner Diameter

0.2165 - 0.2171" (5.500 - 5.515 mm)

Valve Seat

Valve Seat - Contacting Width - Intake 0.0393 ± 0.0039" (1.0 ± 0.10 mm) 0.0551" (1.4 mm)

Valve Seat - Contacting Width - Exhaust 0.0590 ± 0.0039" (1.5 ± 0.10 mm) 0.0748" (1.9 mm)

Valve Seat Angles

30.0° ± 1.5°

45.0° ± 0.5°

60.0° ± 1.5°

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT

ITEM

STANDARD SERVICE LIMIT

Piston

Standard O.D. - Measured 90° to pin, 0.39 in. (10 mm) up from piston skirt

3.6597 ± 0.0003" (92.959 ± 0.008 mm)

Piston Pin Bore I.D. (Standard) 0.7877 - 0.7881" (20.009 - 20.018 mm) 0.7893" (20.05 mm)

Piston Pin O.D.

0.7873 - 0.7875" (20.000 - 20.005 mm) 0.7866" (19.98 mm)

Piston Ring

Installed Gap

Top Ring 0.010 - 0.014" (0.25 - 0.35 mm) 0.0196" (0.5 mm)

Second Ring 0.015 - 0.025" (0.37 - 0.63 mm) 0.028" (0.70 mm)

Oil Control Rails

0.008 - 0.028" (0.20 - 0.70 mm) 0.0354" (0.9 mm)

Ring to Groove Clearance

Top Ring

0.0007 - 0.0023" (0.020 - 0.060 mm) 0.0047" (0.12 mm)

Second Ring

Connecting Rod

Connecting Rod Small End I.D. 0.7879 - 0.7885" (20.015 - 20.030 mm) 0.7897" (20.06 mm)

1 - Marking Conn. Rod Big End Bore I.D. 1.7318 - 1.7321" (43.989 - 43.996 mm)

2 - Marking Conn. Rod Big End Bore I.D. 1.7321 - 1.7323" (43.996 - 44.003 mm)

3 - Marking Conn. Rod Big End Bore I.D. 1.7323 - 1.7326" (44.003 - 44.010 mm)

Crankshaft

B - Marking

Main Journal O.D.

1.6140 - 1.6143" (40.996 - 41.004 mm) 1.6129" (40.970 mm)

G Marking

Main Journal O.D.

1.6137 - 1.6140" (40.988 - 40.995 mm) 1.6129" (40.970 mm)

Y - Marking

Main Journal O.D.

1.6134 - 1.6137" (40.980 - 40.987 mm) 1.6129" (40.970 mm)

B - Marking

Rod Journal O.D.

1.6118 - 1.6122" (40.942 - 40.950 mm) 1.6104" (40.906 mm)

G Marking

Rod Journal O.D.

1.6115 - 1.6118" (40.934 - 40.941 mm) 1.6104" (40.906 mm)

Y - Marking

Rod Journal O.D.

1.6112 - 1.6115" (40.926 - 40.933 mm) 1.6104" (40.906 mm)

Crankshaft Runout Limit (PTO and MAG)

Less than 0.001″

(0.025 mm)

Balance Shaft

Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm)

ENGINE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES

Main Engine Components - Torque Specification and Sequence

ENGINE

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

ENGINE

3.10

9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual

Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

ENGINE

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Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

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Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover

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ENGINE COOLING SYSTEM

Cooling System Specifications

CONDITION

COOLANT TEMP °F (°C)

Room Temperature 68° F (20° C)

Thermostat Open 180° F (82° C)

Fan Off

192° F (89° C)

Fan On

198° F (92° C)

Thermostat Full Open 203° F (95° C)

Engine Temperature Overheat Indicator

233° F (112° C)

Engine Protection Ignition Misfire

236° F (113° C)

Engine Protection Shutdown

257° F (125° C)

ITEM SPECIFICATION

Cooling System Capacity 4.9 qts. (4.6 L)

Pressure Cap Relief

13 PSI

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.

CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

Cooling System Pressure Test

1. Remove the hood from the front cab.

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and serious

burns may result.

Allow the engine to cool before servicing.

2. Remove pressure cap and pressure test the cooling

system using a commercially available pressure tester.

3. The system must maintain 10 psi for five minutes or

longer. If pressure loss is evident within five minutes, check the filler neck, radiator, hoses, clamps and water pump weep hole for leakage.

Pressure Cap Test

1. Remove the hood from the front cab.

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and serious

burns may result. Allow the engine to cool before

servicing.

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2. Remove pressure cap (Item 1) and test using a pressure cap tester (commercially available).

3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

Radiator Removal / Installation

1. Remove the hood and front bumper (See Hood and Front Body Work, page 5.20and Front Bumper, page 5.19).

2. Remove the four fasteners that secure the front bumper support to the main frame.

3. Drain radiator by removing lower radiator hose (Item

1). Be sure to catch and dispose of coolant properly.

WARNING

The cooling system is under pressure and serious

burns may result.

Allow the engine to cool before servicing.

4. Disconnect cooling fan electrical connector.

5. Remove the upper radiator hose from the radiator.

6. Remove the four upper radiator support fasteners (Item 2) and disconnect the small radiator bypass hose (Item 3).

7. Lift radiator up to disengage it from its lower mounting points. Tilt top of radiator outward and remove the radiator from the vehicle.

8. Separate the fan motor assembly from the radiator. Inspect fan blades for damage.

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9. Reverse this procedure for installation. Be sure to properly fill and bleed cooling system as outlined in this chapter.

3. Upper Radiator Hose 6. To Radiator Fitting

4. Lower Radiator Hose 7. Fan Motor Assembly

5. Recovery Bottle 8. Radiator

Thermostat Replacement

1. Remove the hood from the front cab.

WARNING

The cooling system is under pressure and serious

burns may result.

Allow the engine to cool before servicing.

2. Remove the pressure cap to relieve any system pressure (see “Pressure Cap Test”).

3. Drain coolant to a level below the thermostat housing.

4. Remove upper coolant hose from thermostat housing (Item 1).

5. Remove the rear bolt (Item 2) retaining the thermostat cover.

6. Remove the cargo box access panel.

7. Using an 8 mm swivel socket and long extension, remove the front bolt (Item 3) retaining the thermostat cover.

8. Lift the cover from the housing and remove the thermostat.

NOTE: Thermostat has a pop-off relief to allow the bypass system to operate until thermostat opens.

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9. Install a new thermostat with the bleed hole (Item 4) positioned closest to the engine.

NOTE: Image shown above is with engine removed for clarity.

10. Reverse this procedure for installation. Torque thermostat cover bolts to specification.

Thermostat Cover Bolts:

7 ft-lb (10 Nm)

11. Be sure to properly fill and bleed cooling system as outlined in this chapter.

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Cooling System Assembly View

1. Thermostat housing 6. Filler Neck

11. Oil Cooler Inlet Hose

2. Water Pump 7. Radiator

12. Oil Cooler Outlet Hose

3. Engine Hoses 8. Pressure Cap 13. Bypass Hose

4. Lower Radiator Hose 9. Upper Radiator Hose

14. Water Pump Outlet Hose

5. Fan Assembly 10. Recovery Bottle

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Cooling System Bleeding Procedure

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this manual. Failing

to do so may lead to possible injury or death.

CAUTION

Use caution when performing these procedures.

Coolant may be hot and may cause

severe injury or burns.

NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

1. Allow engine and cooling system to cool down.

CAUTION

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be hot and could cause severe

injury or burns.

2. Remove the hood.

3. Remove the recovery bottle cap (Item 1) and fill the bottle to the MAX line.

4. Remove the pressure cap (Item 2) and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

5. Remove the seats, engine service panel and divider panel heat shield to access the coolant bleed screw.

6. Open the bleed screw (Item 3) to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

7. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

Coolant Bleed Screw:

89 in-lb (10 Nm)

8. Start the engine and allow it to idle until the coolant fan has cycled two times.

9. Allow engine and cooling system to completely cool down (see CAUTION).

10. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

12. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

Coolant Bleed Screw:

89 in-lb (10 Nm)

13. Fill the recovery bottle to the MAX line.

14. Reinstall the hood.

15. Reinstall the seats and engine service panel.

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Water Pump Removal

1. Allow engine and cooling system to cool down.

CAUTION

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be hot and could cause severe

injury or burns.

2. Remove driver’s seat.

3. Disconnect the (-) negative battery cable.

4. Remove all debris and thoroughly clean water pump area and RH side of engine block.

5. Remove the hood.

6. Remove the pressure cap from the filler neck.

7. Drain cooling system as outlined in this chapter.

8. Elevate the rear of the vehicle off the ground using a suitable ATV lift and remove the right rear wheel.

9. Remove the right rear shock lower mounting bolt. Discard the nut. Swing and support right rear shock rearward to gain access to water pump area.

10. Remove the five coolant hoses that are attached to the water pump. Note location and routing for installation. Be sure to catch and dispose of coolant properly.

11. Remove the three bolts (Item 1 & 2) retaining water pump to engine block. Note different bolt lengths for installation.

12. Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward.

13. Maneuver water pump downward and remove it through the access hole in the skid plate.

14. Plug the water pump drive access hole in the engine block with a clean shop towel.

Water Pump Installation

1. Replace the two sealing O-rings on the water pump housing.

NOTE: Do not reuse the water pump O-rings. Always use NEW O-rings each time the water pump is removed.

2. Lubricate new O-rings (Item 1) with fresh engine oil.

3. Remove the shop towel from the water pump drive access hole in the engine block.

4. Clean the O-ring sealing surface (Item 2) in the engine block using a clean shop towel.

5. Use a shop light to illuminate the water pump drive access hole in engine crankcase and note orientation of the water pump drive slot (Item 3).

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6. Rotate water pump drive tab (Item 4) so it matches the angle of the drive slot in the engine.

CAUTION

The water pump drive tab and slot must be aligned

properly during installation. Severe engine or water

pump damage will occur if the tab and slot are not in

alignment during water pump installation.

7. Maneuver water pump up through the access hole in the skid plate on the RH side of the vehicle.

8. Slide water pump into engine crankcase.

9. Be sure water pump is fully seated and the drive tab and slot are properly engaged.

10. Install the three water pump mounting bolts (Item 5 &

6) and torque to specification.

NOTE: Install different bolt lengths as shown.

Water Pump Mounting Bolts:

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt threads)

11. Install the four coolant hoses (Item 7–10) that attach to the water pump. Be sure orientation and routing are correct.

12. Install the right rear lower shock bolt and new nut. Torque mounting bolt to specification.

Rear Shock Mounting Bolt:

70 ft-lbs (95 Nm)

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13. Install the right rear wheel. Torque wheel nuts to specification.

Wheel Nuts:

120 ft-lbs (163 Nm)

14. Connect the (-) negative battery cable.

15. Fill and bleed cooling system as outlined in this chapter.

16. Install the hood, engine service panel and seats.

Water Pump Service

NOTE: The water pump cover gasket can be replaced while the water pump housing is still installed in the engine.

1. Remove water pump assembly as outlined in this chapter.

2. Remove the three bolts retaining water pump cover (Item 1) to water pump housing (Item 2). Discard cover gasket (Item 3).

3. Place the water pump drive tab (Item 4) vertically into a soft jaw vice.

4. Remove the bolt and washer retaining the water pump impeller to the shaft. Inspect the impeller veins and water pump housing for damage. Replace if needed.

NOTE: The water pump impeller bolt (Item 5) is left hand thread (reverse thread).

5. Remove impeller from water pump shaft.

6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side.

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7. Extract the mechanical seal and the oil seal from the water pump housing.

NOTE: A 5/32" (4 mm) diameter punch (Item 6) will fit in the lubrication slot to aid in the removal of the oil seal. Be sure not to damage the water pump shaft bearing surface.

8. Inspect the water pump shaft bore for excessive wear or damage. Replace water pump housing assembly if necessary.

9. Clean and inspect water pump shaft for excessive wear or damage. Replace water pump housing assembly if necessary, as shaft can not be purchased separately.

10. Thoroughly clean mechanical seal and oil seal bores.

11. Install a NEW oil seal into the water pump housing until fully seated.

12. Fully install the water pump shaft and two washers into the housing.

13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure.

14. Install a NEW mechanical seal into the water pump housing using special tool PU-50564. Press the new mechanical seal in until it is flush with the water pump housing.

15. Rotate water pump shaft after seal installation to verify free movement.

16. Place impeller onto the water pump shaft.

17. Apply Loctite

204™to the threads of the impeller bolt. Install washer and impeller bolt and torque to specification.

Water Pump Impeller Bolt:

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt threads)

18. Clean cover (Item 1) and housing gasket surfaces (Item 2).

19. Install a new water pump cover gasket (Item 3).

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20. Install the water pump cover and three retaining bolts (Item 8). Torque bolts in sequence to specification.

Water Pump Cover Bolts:

7 ft-lb (10 Nm)

(Apply Loctite® 204™ to bolt threads)

21. Install two new water pump (O-rings) and lubricate them with fresh engine oil.

22. Install water pump assembly into engine as shown in the “Water Pump Installation” procedure.

9. Bolt 13. Washers

17. Oil Seal

10. Loctite 204 14. Drive Tab 18. Impeller

11. Mechanical Seal 15. Water Pump Shaft

19. Washer

12. O-Rings 16. Water Pump Housing

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ENGINE SERVICE

Accessible Engine Components

The following components can be serviced or removed with the engine installed:

• Camshaft(s)

• Camshaft Sprocket(s)

• Cylinder Head

• Flywheel

• Oil Cooler

• Starter Motor / Idler Gear Asm

• Stator (Alternator)

• Thermostat

• Valve Cover

• Water Pump

The following components require engine removal for service:

• Camshaft Timing Chain

• Connecting Rod(s)

• Counterbalance Shaft / Bearings

• Crankcase

• Crankshaft / Main Bearings

• Crankshaft Seal (PTO)

• Cylinder

• Oil Pump / Oil Pump Sprocket or Chain

• Piston / Rings

Top-End Service (Engine in Chassis)

Some top-end engine components can be serviced while the engine is mounted in the chassis.

To service the top-end of the engine refer to Valve Clearance Inspection, page 2.19, which provides detailed steps to access the valve cover.

Engine Removal

NOTE: Some engine repair procedures can be performed without removing the engine assembly from the vehicle. Refer to Accessible Engine Components, page 3.24 for further information.

The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine.

Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this Service

Manual. Failing to do so may lead to possible injury.

1. If vehicle was recently operated, allow it to cool down before attempting to perform any work.

2. Thoroughly clean the engine and chassis.

3. Drain the engine oil and coolant prior to engine removal (See Coolant Drain / Fill, page 2.26).

4. Remove the seats.

5. Disconnect the (-) negative battery cable from the battery.

6. Remove the rear bumper and cargo box (see Chapter 5).

7. Remove the air box assembly.

8. Elevate the rear of the vehicle off the ground using a suitable lift and remove the left rear wheel.

WARNING

Use care when supporting vehicle so that it does not tip

or fall.

Serious injury may occur if vehicle tips or falls.

9. Remove lower mounting bolt (Item 1) from the left rear shock and discard the nut. Install a new nut upon assembly.

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10. Remove the outer clutch cover screws (Item 2) and remove the cover from the vehicle.

11. Remove drive belt, drive clutch, driven clutch, inner clutch cover and clutch outlet duct (see Chapter 6).

CAUTION

Correct Drive Clutch Puller P/N 2872085

NOTE: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft.

12. Disconnect the TMAP sensor (Item 3), fuel injector harness leads (Item 4), CPS (Item 5), ECT sensor (Item 6), and ignition coil harness lead. Remove wire ties retaining harness to the fuel rail and rear cross member.

13. Disconnect the stator harness.

14. Remove (+) positive cable from the starter motor.

15. Remove (-) negative cable from the starter mounting bolt.

16. Disconnect fuel lines and remove throttle body assembly (See Fuel Line Removal / Installation, page 4.10 Fuel Line Removal / Installation, page

4.10 Throttle Body Removal, page 4.31). Make note of line routing for installation.

17. Remove spark plug wires from the engine.

NOTE: The spark plug wires are marked with MAG and PTO. Note during installation procedure.

18. Remove the breather hose (Item 7) from the crankcase.

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19. Remove the six fasteners that attach the exhaust head pipe to the engine. Remove the two exhaust springs (Item 8) that attach the head pipe (Item 9) to the muffler. Remove exhaust head pipe towards the front of the vehicle. Discard exhaust gaskets (Item

10).

20. Remove the four fasteners retaining the box support (Item 11) and the two fasteners retaining the box support bracket (Item 12). Remove the push rivet that attaches the heat shield (Item 13) to the rear cross member.

21. Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose (Item

14) and the water pump coolant hose (Item 15) from the engine. Dispose of engine coolant properly.

22. Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current position.

23. Remove the four rear mounting bolts (Item 16) that attach the rear of the engine to the transmission.

NOTE: It is not necessary to remove the bolts that retain the bracket (Item 17) to the transmission.

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24. Remove the four front engine mounting bolts (Item

18) and nuts (Item 19).

25. With the help of an assistant and the engine hoist, raise the engine vertically out of the vehicle frame.

NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

26. Remove the starter motor bolts (Item 20) and starter motor from the engine.

27. Remove the six transmission joint bracket bolts (Item

21) and transmission joint bracket (Item 22) from the engine.

28. Install the engine stand adapter (PU-50562) onto the engine where the starter motor was located.

29. Select the proper engine stand sleeve adapter and install it onto the engine stand adapter.

• Sleeve adapter for a 2″ bore engine stand:

• (PU-50625)

• Sleeve adapter for a 2.375″ bore engine stand:

• (PW-47054)

30. Place engine onto the engine stand (PU- 50624) for service.

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Engine Installation

Use the following procedure to reinstall the engine assembly.

1. Attach engine with suitable lifting straps to an overhead or portable engine hoist.

2. Remove the engine stand adapter plate and install the starter motor back onto engine. Torque starter motor bolts to specification.

3. Install transmission joint bracket onto engine and torque fasteners to specification in sequence.

Starter Motor Bolts:

7 ft-lb (10 Nm)

Trans Joint Bracket Bolts:

44 ft-lb (60 Nm)

4. Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame.

NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

5. Align both the front and rear engine mounting locations. Install and hand tighten the four front engine mounting nuts (Item 1) and bolts (Item 2).

NOTE: DO NOT torque fasteners at this time.

6. Align transmission joint mounting holes with the transmission front mounting holes.

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7. Install the Clutch Center Distance Tool (PU-50658) onto the crankshaft (Item 3) and transmission input shaft to properly position the clutch center distance. The pictures below show the tool (PU-50658) properly installed (Item 4).

8. Loosen the two bolts (Item 5) retaining transmission joint bracket to the transmission on the right side.

9. Align the front transmission mounting holes with transmission joint bracket mounting holes on engine.

10. Install the two bolts (Item 6) retaining the transmission joint bracket to the engine on the right side. Hand tighten the bolts so they remain loose at this time.

NOTE: DO NOT torque fasteners at this time.

11. Install the two longer bolts into left side mounting holes. Torque left side mounting bolts to specification using the numbered sequence shown.

12. Torque right side mounting bolts to specification using the numbered sequence shown.

Engine / Transmission Mounting Bolts:

Step 1-2: 64 ft-lb (87 Nm)

Step 3: 5 ft-lb (7 Nm)

Step 4-7: 44 ft-lb (60 Nm)

13. Remove the clutch center distance tool.

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14. Torque the four front engine mount fasteners to specification.

Front Engine Mount Fasteners:

40 ft-lbs (54 Nm)

15. Remove the lifting straps and overhead or portable engine hoist.

16. Install the two coolant hoses onto the engine.

17. Install front support bracket (Item 7) and rear support (Item 8) onto the vehicle frame. Torque fasteners to specification.

18. Install push rivet through heat shield (Item 9) into rear cross member.

19. Install the exhaust heat shield and push rivets.

20. Replace exhaust gaskets (seals). Install exhaust head pipe. Install the six fasteners that attach the exhaust head pipe to the engine and torque to specification.

Exhaust Head Pipe Bolts:

18 ft-lb (24 Nm)

21. Install the two exhaust springs that attach the head pipe to the muffler.

22. Install the breather hose to the crankcase.

23. Install the spark plug wires to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals.

NOTE: Ensure plug wires caps are pushed down all the way so they engage onto the spark plugs.

24. Install the throttle body assembly and connect fuel lines. Install throttle cable retaining clip.

25. Secure wire harness in the routing clip on the rear cross member.

26. Install (+) positive cable to the starter motor.

27. Install (-) negative cable to the starter motor mounting bolt.

28. Properly route and connect the harness leads for the stator, CPS, TMAP sensor, ECT sensor, fuel injectors and ignition coil.

29. Install the air box assembly as outlined in the EFI Chapter (See ETC Replacement, page 4.33).

30. Install the inner clutch cover, drive clutch, driven clutch, drive belt, outer clutch cover and clutch outlet duct (see Chapter 6).

31. Install the left rear shock lower mounting bolt and new nut. Torque to specification.

Rear Shock Mounting Bolt:

70 ft-lbs (95 Nm)

32. Install the left rear wheel and torque wheel nuts to specification.

Wheel Nuts:

120 ft-lbs (163 Nm)

33. Install the rear bumper and cargo box as an assembly.

NOTE: Be sure to connect the engine intake hose and clutch air intake hose to the rear cargo box asm upon installation.

34. Connect the (-) negative battery cable.

35. Remove the pressure cap and fill the cooling system through the filler neck with properly mixed anti-freeze / coolant.

36. Install a new oil filter. Lubricate the seal with engine oil prior to installation (see Chapter 2 “Maintenance”).

37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 or PS-4 Extreme Duty Synthetic Engine Oil to the engine. Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

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38. Follow the Cooling System Bleeding Procedure, page 3.18 as outlined in this chapter.

39. Install the seats.

40. Start engine and check for any oil or coolant leaks.

41. Check the engine oil level.

42. Refer customer to “Engine Break-In Period” upon returning vehicle to customer.

Engine Mounting and Torque Values

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Engine Break-In Period

The break-in period consists of the first 25 hours of operation, or the time it takes to use 15 gallons (57 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION

Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic

4-Cycle Engine Oil.

Never substitute or mix oil brands. Serious engine

damage and voiding of warranty can result.

Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

1. Fill fuel tank with unleaded fuel which has a minimum pump octane number of 87 = (R + M)/2.

2. Refer to Engine Oil Level, page 2.16. Check oil level indicated on dipstick. Add oil if necessary.

3. Drive slowly at first to gradually bring engine up to operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important bolt torques.

6. Change oil and oil filter after 25 hour break-in period.

Engine Lubrication Specifications

Oil Capacity *

Approx. 2.5 Quarts (2.4 L)

Oil Filter Wrench

PU-50105 or 2.5” (64 mm)

Oil Filter

PN 2540086

Oil Type

Ambient Temp Range:

-35° F to 100° F

PS-4 Synthetic Engine oil

(PN 2876244) (Quart)

Ambient Temp Range:

0° F to 120° F

PS-4 Extreme Duty

Synthetic Engine Oil

(PN 2878920) (Quart)

Oil Pressure

Minimum Specification

(using Polaris engine oil at operating temperature)

10 PSI @ 1200 RPM 40 PSI @ 7000 RPM

* Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

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ENGINE DISASSEMBLY / INSPECTION - TOP END

Valve Cover Removal

NOTE: The valve cover can be removed with the engine installed in the chassis.

1. Remove the four valve cover shoulder bolts (Item 1)

and isolators (Item 2) using a T40 driver.

2. Replace isolators (Item 2) when they are removed

and replace valve cover seal (Item 3) if oil leaks are evident.

3. Remove the spark plugs (Item 4). Stuff spark plug

holes with shop towels to prevent anything from falling into the combustion chamber.

Camshaft Removal

NOTE: The camshafts can be removed with the engine installed in the chassis.

1. Rotate the engine so the PTO cylinder is at Top

Dead Center (TDC) to relieve most of the valve spring pressure. The camshaft lobes should face out (Item 1) and the slots on the end of the camshafts should line up.

2. Remove the hydraulic cam chain tensioner (Item 2) from the cylinder. Replace the sealing washer (Item

3) upon reassembly.

3. Remove the two bolts retaining the fixed cam chain guide (Item 4) and remove the assembly from the engine.

4. Remove the remaining two bolts that retain the front camshaft carrier (Item 5) and carefully lift the carrier off the camshafts.

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5. Hold camshafts (Item 6) with an open-end wrench, and remove the top bolt (Item 7) from the camshaft sprockets (Item 8).

6. Rotate the engine using the flywheel and remove the remaining bolt from each camshaft sprocket.

7. Lift the chain and sprockets off the camshafts to allow each sprocket to be removed.

8. Using a paperclip or other tool, hold cam chain up to keep it from falling down into the crankcase.

NOTE: The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft.

9. Evenly loosen the four bolts retaining each rear camshaft carrier (Item 10) and carefully lift the carriers off the camshafts.

10. Mark the intake (Item 11) and exhaust (Item 12) camshafts to ensure proper assembly.

11. Carefully remove camshafts from the cylinder head.

Camshaft Sprocket Inspection

Inspect cam sprocket teeth (Item 1) for wear or damage. Replace timing chain and sprockets if worn or damaged.

Camshaft / Camshaft Bore Inspection

Inspect all main journals and cam lobes as described below and compare to specifications. Replace camshaft (s) or cylinder head if worn beyond service limit or if any surface is pitted or damaged.

1. Visually inspect each cam lobe for wear or damage.

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2. Measure the height of each cam lobe from the base

circle to highest point on the lobe using a micrometer. Compare to specification.

NOTE: Replace camshafts if damaged or if any part is worn past the service limit.

Camshaft Lobe Height:

Intake: 1.5390 - 1.5429" (39.09 - 39.19 mm)

Service Limit: 1.5370" (39.04 mm)

Exhaust: 1.5142 - 1.5181" (38.46 - 38.56 mm)

Service Limit: 1.5122" (38.41 mm)

3. Visually inspect each camshaft journal for scoring,

wear or damage.

4. Measure the diameter of the camshaft journals using a micrometer. Compare to specification.

NOTE: Replace camshafts if damaged or if any part is worn past the service limit.

Camshaft Journal O.D.:

0.9036 - 0.9055" (22.954 - 22.999 mm)

0.9033" (22.944 mm)

5. Temporarily install the camshaft carriers to measure the camshaft bore. Torque bolts in sequence to specification. Replace cylinder head if worn.

Camshaft Carrier Bolts:

89 in-lbs (10 Nm)

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6. Measure camshaft bore and compare to specifications.

NOTE: Replace cylinder head if camshaft journal bores are damaged or if worn past the service limit.

Camshaft Carrier Bore I.D.:

0.9055 - 0.9063" (23.000 - 23.021 mm)

0.9072" (23.044 mm)

7. Calculate oil clearance by subtracting camshaft journal O. D. s from camshaft carrier bore I. D. s. Compare to specification.

Calculated Camshaft Oil Clearance:

0.0000 - 0.0026" (0.001 - 0.067 mm)

0.0039" (0.1 mm)

Cylinder Head Removal

NOTE: The cylinder head can be serviced with the engine installed in the chassis.

1. Remove the two outer M6 bolts (Item 1) that retain the cylinder head (Item 2) to the cylinder.

2. Loosen the six cylinder head bolts (Item 3) evenly 1/ 8 turn at a time until all are loose.

3. Remove and discard the cylinder head bolts.

4. Tap cylinder head lightly with a soft faced hammer until loose.

5. Tap only in reinforced areas or on thick parts of the cylinder head casting.

6. Remove the cylinder head and head gasket (Item 4).

NOTE: Once the cylinder head is removed, nothing retains the cylinder to the engine. DO NOT rotate the engine without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal, page 3.54.

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Cylinder Head Warp Inspection

Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

CAUTION

Use care not to damage gasket sealing surface. All

gasket surfaces must be clean, dry and free of any oil

or grease upon assembly. Clean sealing surfaces with

rubbing alcohol or electrical contact cleaner. Do not

touch sealing surfaces of the new head gasket.

1. Lay a straight edge (Item 1) across the surface of the cylinder head at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

Cylinder Head Warp Limit:

0.0039″ (0.1 mm)

Cylinder Head Disassembly

WARNING

Wear eye protection during cylinder head disassembly

and reassembly or when working with the valve springs.

NOTE: Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes. It is important to install cylinder head components back in the same location. Mark each component or place them in an organized rack as you remove them.

1. Remove the valve tappet (Item 1) from the cylinder head. Note the tappet size (Item 2) engraved on the underside of the bucket.

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2. Compress the valve spring by hand using valve spring compressor adapter (PV-43513-A).

3. Push down on spring and remove split keepers (Item

3).

4. Slowly release valve spring pressure and remove the compressor adapter.

5. Remove the valve retainer (Item 4), valve spring (Item 5), valve stem seal (Item 6) and valve spring seat (Item 7). Discard the valve seal.

NOTE: Replace valve seals whenever cylinder head is disassembled. Hardened, cracked or worn seals will cause excessive oil consumption.

6. Lift up the cylinder head and push the valve (Item 8) out, keeping it in order for reassembly in the same valve guide.

7. Repeat the previous steps to remove the remaining valves.

8. Clean the combustion chamber and head gasket surface.

9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring.

Valve Inspection

1. Remove all carbon from valves with a soft wire wheel or brush.

2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.

3. Check the end of the valve stem for flaring, pitting, wear or damage.

4. Inspect split keeper groove for wear or flaring in the keeper seat area.

NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged.

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5. Measure diameter of valve stem with a micrometer in three places, then rotate 90° and measure again (take six measurements total). Compare to specifications.

Valve Stem Diameter:

Intake:0.2155 - 0.2161" (5.475 - 5.490 mm)

Exhaust: 0.2147 - 0.2153" (5.455 - 5.470 mm)

6. Measure valve guide inside diameter at the top, middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions.

Valve Guide I.D.:

0.2165 - 0.2171" (5.500 - 5.515 mm)

7. Be sure to measure each guide and valve combination individually.

NOTE: The valve guides cannot be replaced.

Combustion Chamber Cleaning

WARNING

Wear eye protection during combustion chamber

cleaning.

1. Clean all accumulated carbon deposits from combustion chambers and valve seat area (Item 1).

NOTE: Carbon Clean Fuel Treatment (2871326) can be used to help remove carbon deposits.

Do not use a metal scraper, a coarse wire brush or abrasive cleaners to clean the cylinder head. Damage may result.

2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to areas around spark plug and valve seats.

Valve Sealing Test

1. Clean and dry the combustion chamber area (Item

1).

ENGINE

Polaris 2014 RZR XP 1000, 2014 RZR XP 4 1000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual