Polaris RZR XP 1000, RZR XP4 1000 Service Manual

2014-2015 RZR XP 1000 / RZR XP4 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 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 2014 (PN 9925724 R01)

technicians in a properly

© Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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 PRODUCTS 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 / COOLING SYSTEM

FUEL SYSTEM

PVT SYSTEM

TRANSMISSION

FINAL DRIVE

STEERING / SUSPENSION

BRAKE SYSTEM

BODY / FRAME

ELECTRICAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

VEHICLE IDENTIFICATION NUMBER.. . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+). .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . 1.5

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . 1.5

PUBLICATION NUMBERS . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . 1.6

GENERAL SPECIFICATIONS. . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .1.10

2014-2015 RZR XP 1000 / EPS. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

RZR XP 1000 CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . 1.11

2014-2015 RZR XP 4 1000 . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . .1.13

2014-2015 RZR 1000 XP4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . .1.14

2015 RZR XP 1000 EPS HIGH LIFTER . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . .1.16

2015 RZR XP 1000 HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .1.18

2015 RZR XP 1000 DESERT EDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .1.18

2015 RZR XP 1000 DESERT EDITION CLUTCH CHART .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . .. . . . . . . . .1.21

MASTER TORQUE TABLE... . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .1.21

CONVERSION TABLE . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . .1.23

STANDARD BOLT TORQUE SPECIFICATION.... . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24

METRIC BOLT TORQUE SPECIFICATION . . . . .. . . . .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .1.25

METRIC TAP / DRILL SIZES . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.25

DECIMAL EQUIVALENTS.... . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .1.26

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Number Designation

Example: Z14ST1EAL

GROUP

1st digit

Z = RZR

* = 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.

MODEL

YEAR

2/3rd

digit

11 12 13 14 15

CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION

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

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)

- - OR - 6 = 570

7 = 760 9 = 875

E = EPS F = D + E

A = ORV

E = EU On-road

F = INT’L

M = Military

S =

Scandinavian

V = EU On-road

C = Calif.

Model Number Designation

Example: A15SEA57AD

GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**

A 1

S E A

A D

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

Vehicle Identification Number

Example: 4XAKA09A0F3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

GENERAL INFORMATION

WORLD MFG. ID

CHASSIS

DRIVELINE

1 2 3 4

4 X A K A 0 9 A 0 F 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015

5 6 7 8 9 10 11 12 13 14 15 16 17

ENGINE SIZE

ENGINE

MODIFIER

Vehicle Identification Number (VIN) Designation (2015+)

Example: 4XARH57A0F3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

WORLD MFG. ID

CHASSIS

DRIVELINE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R H 5 7 A 0 F 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015

ENGINE SIZE

ENGINE MODIFIER

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.

1.4

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

VEHICLE INFORMATION

GENERAL INFORMATION

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

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

4010321

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

2015 RZR XP 1000 EPS 9925838 9925754

2015 RZR XP 1000 INT’L 9925838 9925858

2015 RZR XP4 1000 9925838 9925795

2015 RZR XP 1000 EPS High Lifter

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.

9925836 9925754

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1.5

GENERAL INFORMATION

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:

1-800-345-2233 or http://polaris.service-solutions.com/

1.6

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

2200421

Gas Shock Recharging Kit

2870910-A

Roller Pin Tool

2460761

Hall Sensor Probe Harness

2870975

Mity-Vac Pressure Test Tool

2870341-A

Drive Clutch Spider Remover/Installer

2871056

Driven Clutch Puller

2870386

Piston Pin Puller

2871226

Clutch Bushing Replacement Tool Kit

2870630

Timing Light

2871282

Transmission Seal Driver (50 MM)

2871351

IFP Depth Tool

2872608

Roll Pin Removal Tool (27″)

2871358-B

Drive Clutch Holding Fixture

2876389

Combination Pliers

2871702

Shaft Drive Transmission and Front Gearcase Tool Kit

2877408

Spanner Wrench / Clutch Spreader

2871745

Static Timing Light Harness

8700226

CV Boot Clamp Pliers (ear)

2872085

Drive Clutch Puller

9314177-A

Drive Clutch Holding Tool

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1.7

GENERAL INFORMATION

PA-49316

Water Pump Drive & Rotor Removal Tool

PU-47471

Smartlink Module Kit

PA-50231

Snorkel Driver

PU-48951

CV Boot Clamp Pliers (Stepless)

PS-45908

T-Handle Tool

PU-49466

Relay Bypass

PU-43506-A

Fuel Pressure Gauge Kit

PU-50105

Oil Filter Wrench

PU-45281–A

Shock Body Holding Tool

PU-50296

Battery Tester

PU-50338

Hydrometer

PU-50565

Oil Pressure Gauge Adapter (1/2 NPT)

PU-50518

Clutch Compressor

PU-50566

Transmission Nut Socket

PU-50562

Engine Stand Adapter

PU-50578

Clutch Spider Nut Socket

PU-50563

Cylinder Holding & Camshaft Timing Plate

PU-50624

Rolling Engine Stand

PU-50564

Water Pump Seal Installer

PU-50625

Engine Stand Adapter Sleeve (2″)

1.8

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

PU-50658

Clutch Center Distance Tool

PV-1253

Valve Spring Compressor

PU-50931

Shock Rod Holding Tool (3/4″)

PV-43513-A

Valve Spring Compressor Adapter

PU-50939

Shock Seal Protector Sleeve (5/8″)

PV-43526

Connector Test Kit

PU-51024

Shock Rod Holding Tool

PV-43531

Oil Presure gauge

PU-51039

Gas Shock Fill Tool

PV-43568

Fluke Multimeter

PV-43570

Piston Ring Compressor Pliers

PV-48656

Fuel Pressure Gauge Adapter

PW-47053

Bench Mount Engine Stand

PW-47054

Engine Stand Adapter Sleeve (2 3/8″)

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

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GENERAL INFORMATION

GENERAL SPECIFICATIONS

2014-2015 RZR XP 1000 / EPS

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.5 cm

Height

Wheel Base 90″ / 228.6 cm

Ground Clearance 13.5″ / 34.3 cm

Dry Weight 1379 lbs. / 625.5 kg

Gross Vehicle Weight 2200 lbs. / 998 kg

Cargo Box Capacity 300 lbs. / 136 kg

119″ / 302.2 cm

73.75″ / 187.3 cm

Maximum Weight Capacity (Payload)

Hitch Towing Capacity

Hitch Tongue Capacity

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

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.

1.10

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke 93 x 73.5 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

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

Lubrication

Oil Requirements

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5.44 qt (5.1 L)

Domestic Twin Cyl., 4–Stroke, DOHC

999cc

11:1

1200 +/- 100 RPM

8800 RPM

Instrument Cluster Indicator

Wet Sump

PS4

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,

Circuit Breaker 20A Cooling Fan

Fuses 20A EFI

EPS (if appl.)

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

DRIVETRAIN

Transmission Type

Shift Type

Transmission Gear Ratios: High Low Reverse

Front Gearcase Lubricant Requirement

Transmission Lubricant Requirement

Drive Belt 3211148

Polaris Automatic PVT

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

10.73:1

22.79:1

20.41:1 Demand Drive

8.5 oz. (250 ml)

Full Synthetic AGL 44 oz. (1300 ml)

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

Front Travel 16″ (40.6 cm)

Rear Suspension Independent Trailing Arm

Rear Travel 18″ (45.7 cm)

Spring Adjustment Threaded Spanner Wrench

Walker Evans™ 2.0″

Walker Evans™ 2.5″

Adjustment

WHEELS / BRAKES

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

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Brake System Front & Rear

Brake Fluid DOT 4

Maxxis Bighorn 29 x 9 R14

Maxxis Bighorn 29 x 11 R14

Front 16 psi (110 kPa)

Rear 16 psi (110 kPa)

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

RZR XP 1000 CLUTCH CHART

MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING

2014 XP 1000

Meters (Feet)

0-1800 (0-6000)

26-61 (1323098)

White / Orange (7043924)

Red (3234452)

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING

2015 XP 1000

Meters (Feet)

1800-3700 (6000 - 12000)

0-1800 (0-6000)

1800-3700 (6000-12000)

26-55 (1322982)

26-63 (1323176)

26-59 (1322981)

White / Orange (7043924)

Orange / Black (1323176)

Orange / Black (7044338)

Red (3234452)

1.12

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

2014-2015 RZR XP 4 1000

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.5 cm

Height

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

146″ / 370.8 cm

73.75″ / 187.3 cm

GENERAL INFORMATION

Maximum Weight Capacity (Payload)

Hitch Towing Capacity This vehicle is not equipped with

Hitch Tongue Capacity

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

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

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.13

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke 93 x 73.5 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

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

Lubrication

Oil Requirements

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 6.08 qt (5.75 L)

Domestic Twin Cyl., 4–Stroke, DOHC

999cc

11:1

1200 +/- 100 RPM

8800 RPM

Instrument Cluster Indicator

Wet Sump

PS4

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,

Circuit Breaker 20A Cooling Fan

Fuses 20A EFI

EPS (if appl.)

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

DRIVETRAIN

Transmission Type

Shift Type

Transmission Gear Ratios: High Low Reverse

Front Gearcase Lubricant Requirement

Transmission Lubricant Requirement

Drive Belt 3211148

Polaris Automatic PVT

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

12.05:1

25.59:1

22.92:1 Demand Drive

8.5 oz. (250 ml)

Full Synthetic AGL 44 oz. (1300 ml)

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

Front Travel 16″ (40.6 cm)

Rear Suspension Independent Trailing Arm

Rear Travel 18″ (45.7 cm)

Spring Adjustment Threaded Spanner Wrench

Walker Evans™ 2.0″

Walker Evans™ 2.5″

Adjustment

WHEELS / BRAKES

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

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Brake System Front & Rear

Brake Fluid DOT 4

Maxxis Bighorn 29 x 9 R14

Maxxis Bighorn 29 x 11 R14

Front 19 psi (131 kPa)

Rear 21 psi (145 kPa)

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

2014-2015 RZR 1000 XP4

MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING

2014 XP4 1000

Meters (Feet)

0-1800 (0-6000)

26-67 (1323177)

White / Orange (7043924)

Red (3234452)

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING

2015 XP4 1000

Meters (Feet)

1800-3700 (6000 - 12000)

0-1800 (0-6000)

1800-3700 (6000 - 12000)

26-61 (1323098)

26-65 (1323260

26-59 (1322981)

White / Orange (7043924)

Red (3234452)

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.15

GENERAL INFORMATION

2015 RZR XP 1000 EPS High Lifter

CATEGORY DIMENSION / CAPACITY

Length

Width 66″ / 167.6 cm

Height

Wheel Base 90″ / 228.6 cm

Ground Clearance 14.25″ / 36.2 cm

Dry Weight 1545 lbs. / 701 kg

Gross Vehicle Weight 2470 lbs. / 1120 kg

Cargo Box Capacity 300 lbs. / 136 kg

122″ / 310 cm

74.5″ / 189.2 cm

Maximum Weight Capacity (Payload)

Hitch Towing Capacity The tow loop on the rear of the

Hitch Tongue Capacity

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

vehicle is provided for recovery use ONLY. Tow a vehicle ONLY of equal or lesser size and weight. When towing a disabled RZR vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

1.16

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke 93 x 73.5 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

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

Lubrication

Oil Requirements

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5.44 qt (5.1 L)

Domestic Twin Cyl., 4–Stroke, DOHC

999cc

11:1

1200 +/- 100 RPM

8800 RPM

Instrument Cluster Indicator

Wet Sump

PS-4 5W-50 4-Cycle Oil and PS-4 Extreme Duty 10W-50 4Cycle Oil

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,

Circuit Breaker 20A Cooling Fan

Fuses 10A EFI

EPS (if appl.)

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

DRIVETRAIN

Transmission Type

Shift Type

Transmission Gear Ratios: High Low Reverse

Front Gearcase Lubricant Requirement

Transmission Lubricant Requirement

Drive Belt 3211148

Polaris Automatic PVT

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

12.05:1

25.59:1

22.92:1 Demand Drive

8.5 oz. (250 ml)

Full Synthetic AGL 44 oz. (1300 ml)

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

Front Travel 16″ (40.6 cm)

Rear Suspension Independent Trailing Arm

Rear Travel 18″ (45.7 cm)

Spring Adjustment Threaded Spanner Wrench

Walker Evans™ 2.0″

Walker Evans™ 2.5″

Adjustment

WHEELS / BRAKES

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

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Brake System Front & Rear

Brake Fluid DOT 4

High Lifter Outlaw

29.5 x 9.5 R14 High Lifter Outlaw

29.5 x 9.5 R14

Front 18 psi (124 kPa)

Rear 18 psi (124 kPa)

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.17

GENERAL INFORMATION

2015 RZR XP 1000 High Lifter

MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING

High Lifter Edition

Meters (Feet)

0-1800 (0-6000)

2015 RZR XP 1000 Desert Edition

26-61 (1323260)

White / Orange (7043924)

Red (3234452)

1.18

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

CATEGORY DIMENSION / CAPACITY

Length

Width 64″ / 162.5 cm

Height

Wheel Base 90″ / 228.6 cm

Ground Clearance 13.5″ / 34.3 cm

Dry Weight 1379 lbs. / 625.5 kg

Gross Vehicle Weight 2200 lbs. / 998 kg

Cargo Box Capacity 300 lbs. / 136 kg

119″ / 302.2 cm

73.75″ / 187.3 cm

GENERAL INFORMATION

Maximum Weight Capacity (Payload)

Hitch Towing Capacity This vehicle is not equipped with

Hitch Tongue Capacity

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

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

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.19

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke 93 x 73.5 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

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

Lubrication

Oil Requirements

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5.44 qt (5.1 L)

Domestic Twin Cyl., 4–Stroke, DOHC

999cc

11:1

1200 +/- 100 RPM

8800 RPM

Instrument Cluster Indicator

Wet Sump

PS4

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,

Circuit Breaker 20A Cooling Fan

Fuses 20A EFI

EPS (if appl.)

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

DRIVETRAIN

Transmission Type

Shift Type

Transmission Gear Ratios: High Low Reverse

Front Gearcase Lubricant Requirement

Transmission Lubricant Requirement

Drive Belt 3211148

Polaris Automatic PVT

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

10.73:1

22.79:1

20.41:1 Demand Drive

8.5 oz. (250 ml)

Full Synthetic AGL 44 oz. (1300 ml)

STEERING / SUSPENSION

Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)

Front Suspension Independent Dual A-arm

Front Travel 16″ (40.6 cm)

Rear Suspension Independent Trailing Arm

Rear Travel 18″ (45.7 cm)

Spring Adjustment Threaded Spanner Wrench

Walker Evans™ 2.0″

Walker Evans™ 2.5″

Adjustment

WHEELS / BRAKES

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

Size Rear Tire Make / Model /

Size

Tire Air Pressure

Brake System Front & Rear

Brake Fluid DOT 4

Maxxis Bighorn 29 x 9 R14

Maxxis Bighorn 29 x 11 R14

Front 16 psi (110 kPa)

Rear 16 psi (110 kPa)

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

2015 RZR XP 1000 Desert Edition Clutch Chart

DRIVEN SPRING

Red (323445-

MODEL

Desert Edition

ALTITUDE

Meters (Feet)

0-1800 (0-6000)

SHIFT WEIGHT

26-61 (13231-

76)

DRIVE SPRING

White / Orange (70439-

24)

1.20

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

MISC. SPECIFICATIONS AND CHARTS

GENERAL INFORMATION

Master Torque Table

ITEM

A-Arm Bolt

(front)

Ball Joint Fasteners

Battery Mount Bracket

Fasteners

Battery Terminal Fasteners 60 in-lbs (7 Nm)

Beadlock Screws

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

Brake Bleed Screws

Brake Caliper Mounting

Bolts

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

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

Brake Pedal Mount Bracket

Bolts

Brake Switch

Cab Frame Bolts

Cam Chain Tensioner

Camshaft Carrier Bolts

Camshaft Sprocket Bolts 14 ft-lb (19 Nm)

Clutch Cover (outer)

Screws

Connecting Rod Bolts

Step 3: Tighten add’n 105°

Coolant Bleed Screw

Coolant Temperature

Sensor

CPS Retaining Bolt 9 ft-lb (12 Nm)

Crankcase Bolts M10

Step 3: Tighten add’n 90°

Crankcase Bolts M8

Crankcase Bolts M6

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

Cylinder Head Bolts

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

Differential Cover Screws

(INTL)

Door Fasteners

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

Drive Clutch Cover Plate

Screw

TORQUE

42 ft-lb (57 Nm)

42 ft-lbs (57 Nm)

8 ft-lbs (11 Nm)

Step 1: 24 in-lbs (3 Nm)

Step 2: 7 ft-lbs (10 Nm)

48 in-lb (5 Nm)

40 ft-lbs (54 Nm)

16 ft-lbs (22 Nm)

15 ft-lbs (20 Nm)

40 ft-lb (54 Nm)

29 ft-lb (40 Nm)

7 ft-lb (10 Nm)

50 in-lbs (5 Nm)

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

89 in-lb (10 Nm)

17 ft-lb (23 Nm)

Step 1: 9 ft-lb (12 Nm)

Step 2: 21 ft-lb (28 Nm)

26 ft-lb (35 Nm)

9 ft-lb (12 Nm)

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

Nm)

22 ft-lb (30 Nm)

8 ft-lb (11 Nm)

9 ft-lb (12 Nm)

ITEM

Drive Clutch Shift Weight

Fasteners

Drive Clutch Spider

Drive Clutch Spider Jamb

Nut

Driven Clutch Retaining

Bolt

Driven Clutch Helix

Retaining Screws

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

ETC Mounting Bolts 7 ft-lb (10 Nm)

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

Floor Screws

Flywheel Bolt 133 ft-lbs (180 Nm)

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

Front Bumper / Fender

Screws

Front Gearcase Cover

Plate Screws

Front Gearcase Drain/Fill

Plugs

Front Gearcase Mounting

Bolts

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

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

Fuel Tank Block-off Panel

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)

Intake Plenum Mount

Screw

Master Cylinder Mount

Bolts

Oil Cooler Bolts

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)

(Apply 0.4 mL Loctite® 7088

Primer and 0.4 mL Loctite®

(Apply 0.1 mL Loctite® 7088

Primer and 0.1 mL Loctite®

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

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

*see procedure for illustration

TORQUE

20 in-lb (2 Nm)

290 ft-lb (393 Nm)

620™)

250 ft-lb (339 Nm)

620™)

55 ft-lb (75 Nm)

48 in-lb (5 Nm)

Step 3: 5 ft-lb (7 Nm)

8 ft-lb (11 Nm)

8 ft-ln (11 Nm)

11 ft-lbs (15 Nm)

10 ft-lbs (14 Nm)

30 ft-lbs (41 Nm)

8 ft-lbs (11 Nm)

110 ft-lbs (149 Nm)

22 ft-lb (30 Nm)

23 ft-lbs (31 Nm)

7 ft-lb (10 Nm)

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.21

GENERAL INFORMATION

ITEM

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

Oxygen Sensor 13 ft-lb (18 Nm)

Parking Brake Caliper

Assembly Bolts

Parking Brake Disc

Mounting Bolts (INTL)

Parking Brake Lever

Mounting Bolts

Power Steering Cover

Screws

Power Steering Bracket to

Frame Nuts

Power Steering Unit to

Mount Bracket

Prop Shaft Support Bearing

Fasteners

PVT Inner Cover Bolts

PVT Outer Cover Screws

Radius Rod Fasteners

Seat Base to Seat Frame

Fasteners

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

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

Seat Belt Mounting

Fasteners

Seat Slider Plate Screws

Shift Cable Bracket Bolts

Shock Guard Screws

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

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

Shock Reservoir Mounting

Clamps (rear)

Skid Plate Fasteners

Spark Plug 7 ft-lbs (10 Nm)

Speed Sensor Screw 12 ft-lb (16 Nm)

Stabilizer Bar Linkage

(rear)

Stabilizer Bar Mounting

Bracket Bolts (rear)

Stabilizer Bar Locating

Clamp Bolts

Starter Mounting Bolts 7 ft-lb (10 Nm)

Starter One-Way Clutch

Screws

Stator Cover Screws

Steering Tilt Shock

Fastener

Steering Pivot Tube

Fasteners

Steering Rack Mounting

Bolts

TORQUE

37 ft-lb (50 Nm)

14 ft-lb (20 Nm)

16 ft-lb (22 Nm)

8 ft-lb (11 Nm)

16 ft-lb (22 Nm)

30 ft-lb (41 Nm)

35 ft-lb (47 Nm)

12 ft-lb (16 Nm)

48 in-lb (5 Nm)

40 ft-lb (54 Nm)

8 ft-lbs (11 Nm)

40 ft-lbs (54 Nm)

4 ft-lb (5 Nm)

17 ft-lb (23 Nm)

14 in-lbs (2 Nm)

35 in-lb (4 Nm)

8 ft-lbs (11 Nm)

40 ft-lbs (54 Nm)

17 ft-lb (23 Nm)

10 ft-lb (14 Nm)

9 ft-lb (12 Nm)

7 ft-lb (10 Nm)

8 ft-lb (11 Nm)

16 ft-lbs (22 Nm)

ITEM

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

Steering Shaft to Steering

Thermostat Cover Bolts

Throttle Pedal Mounting

Tie Rod End to Knuckle

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

Trailing Arm to Bearing

Transmission Bell Crank

Transmission Case Screws

Transmission Drain / Fill

Transmission Isolator Bolt

Transmission Rear Mount

Transmission Joint Bracket

Transmission Park Flange

Transmission Sector Gear

Transmission Shift Fork

Transmission Snorkel Tube

Visor Mounting Screws 8 ft-lb (11 Nm)

Water Pump Impeller

Water Pump Cover Bolts

Rack

Steering Wheel Nut 65 ft-lbs (88 Nm)

Fasteners

Tie Rod Jamb Nuts

Carrier Fasteners

Nut

Plugs

(rear)

Bracket Fasteners

Bolts

Screws

Cover

Screws

Locking Screw

Valve Cover Bolts

Voltage Regulator

Fasteners

(Apply Loctite® 204™ to bolt

Wheel Lug Nuts 120 ft-lbs (163 Nm)

TORQUE

42 ft-lb (57 Nm)

7 ft-lb (10 Nm)

18 ft-lb (24 Nm)

15 ft-lbs (20 Nm) + 90°

14 ft-lbs (19 Nm)

42 ft-lb (54 Nm)

18 ft-lb (24 Nm)

20 ft-lbs (27 Nm)

14 ft-lbs (19 Nm)

40 ft-lb (54 Nm)

17 ft-lb (23 Nm)

44 ft-lb (60 Nm)

10 ft-lb (14 Nm)

12 ft-lb (16 Nm)

10 ft-lb (14 Nm)

7 ft-lbs (10 Nm)

5 ft-lb (7 Nm)

7 ft-lb (10 Nm)

threads)

7 ft-lb (10 Nm)

threads)

1.22

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

Conversion Table

GENERAL INFORMATION

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs

in-lbs x 0.0833

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

inch x 2.54

mile (mi) x 1.6 = km

km x 0.6214 = mile

ounces (oz)

fluid ounces (fl oz)

x 12 = in-lbs

= ft-lbs

= mm

x 0.03937 = inch

= cm

x 28.35

x 29.57

= grams (g)

= cubic centimeters (cc)

cubic centimeters (cc) x .03381 = fluid ounces

grams (g)

pounds (lb)

kilogram (kg) x 2.2046 = lbs

cubic inches (cu in)

cubic centimeters (cc)

US quarts x 0.946 = liters (L)

liters (L)

US gallons

liters (L) x 0.264 = US gallons

PSI

kilopascals (kPa) x 0.145 PSI

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x 0.035

x 0.454 = kg

x 16.387

x 0.061 = cubic inches

x 1.057

x 3.785

x 6.895

= ounces

= cc

= US quarts

= liters (L)

= kilopascals (kPa)

= cylinder volume

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.23

GENERAL INFORMATION

Standard Bolt Torque Specification

BOLT SIZE

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

GRADE 2

FT. LBS. (NM)

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

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

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

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

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

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

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

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

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

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

Metric Bolt Torque Specification

BOLT

SIZE

4.6 4.8 8.8 / 8.9 10.9 12.9

GRADE 5

FT. LBS. (NM)

GRADE

FT.— LBS. (NM) DRY THREADS

GRADE 8

FT. LBS. (NM)

M10

M12

M14

M16

M18

0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)

0.8 (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)

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

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

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

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

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

1.24

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

GENERAL INFORMATION

SAE Tap / Drill Sizes

THREAD SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

#1–72

#2–56

#2–64 50 5/8–11 17/32

#3–48 5/64 5/8–18 37/64

#3–56

#4–40 43 3/4–16 11/16

#4–48

#5–40

#5–44

#6–32

#6–40 33 1 1/8–7 63/64

#8–32 29 1 1/8–12 1 3/64

37 1–8

36 1–12

THREAD SIZE DRILL SIZE

1/2–20 29/64

9/16–12 31/64

9/16–18 33/64

3/4–10 21/32

7/8–9 49/64

7/8–14 13/16

7/8

59/64

Metric Tap / Drill Sizes

NEAREST

TAP SIZE DRILL SIZE DECIMAL

3 x .50

3 x .60

4 x .70

4 x .75

5 x .80

5 x .90 #20 0.161 5/32

6 x 1.00 #9 0.196 13/64

7 x 1.00

8 x 1.00 J 0.277

8 x 1.25

9 x 1.00

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

#39

3/32

#30

1/8

#19

16/64

17/64

5/16

0.0995

0.0937

0.1285

0.125

0.166

0.234

0.265

0.3125

FRACTION

3/32

1/8

11/64

15/64

9/32

17/64

5/16

11/32

#8–36 29 1 1/4–7 1 7/64

#10–24

#10–32

#12–24

#12–28

1/4–20

1/4–28 3 2–4 1/2 1 25/32

5/16–18

5/16–24

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

7/16–20 25/64

4.6 mm

F 2–12 1 59/64

U 3–4 2 3/4

1 1/4–12 1 11/64

1 1/2–6 1 11/32

1 1/2–12 1 27/64

1 3/4–5 1 9/16

1 3/4–12 1 43/64

2 1/4–4 1/2 2 1/32

11 x 1.50

12 x 1.50

12 x 1.75

3/8

13/32

0.375

0.406

3/8

13/32

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

1.25

GENERAL INFORMATION

Decimal Equivalents

FRACTION DECIMAL MM TO INCHES

1/64

1/32 0.0312″ 1 mm = 0.0394″

3/64

1/16

5/64

3/32 0.0938″

7/64

1/8

9/64 0.1406″

5/32

11/64

3/16 0.1875″ 5 mm = 0.1969″

13/64

7/32

15/64

1/4 0.25″

17/64

9/32

19/64 0.2969″

5/16

21/64

11/32 0.3438″ 9 mm = 0.3543″

23/64

3/8

25/64 0.3906″ 10 mm = 0.3937″

13/32 0.4063″

27/64

7/16

29/64 0.4531″

15/32

31/64

1/2 0.500″ 13 mm = 0.5118″

33/64

17/32

35/64

9/16 0.5625″

37/64

19/32

39/64 0.6094″

5/8 0.625″ 16 mm = 0.6299″

0.0156″

0.0469″

0.0625″

0.0781″ 2 mm = 0.0787″

0.1094″ 3 mm = 0.1181″

0.1250″

0.1563″ 4 mm = 0.1575″

0.1719″

0.2031″

0.2188″

0.2344″ 6 mm = 0.2362″

0.2656″ 7 mm = 0.2756″

0.2813″

0.3125″ 8 mm = 0.3150″

0.3281″

0.3594″

0.375″

0.4219″ 11 mm = 0.4331″

0.4375″

0.4688″ 12 mm = 0.4724″

0.4844″

0.5156″

0.5313″

0.5469″ 14 mm = 0.5512″

0.5781″ 15 mm = 0.5906″

0.5938″

FRACTION DECIMAL MM TO INCHES

41/64

21/32 0.6563″ 17 mm = 0.6693″

43/64

11/16

45/64

23/32 0.7188″

47/64

3/4

49/64 0.7656″

25/32

51/64

13/16 0.8125″ 21 mm = 0.8268″

53/64 0.8281″

27/32

55/64

7/8 0.875″

57/64

29/32

59/64 0.9219″

15/16

61/64

31/32 0.9688″ 25 mm = 0.9843″

63/64

1 1.000″

0.6406″

0.6719″

0.6875″

0.7031″ 18 mm = 0.7087″

0.7344″ 19 mm = 0.7480″

0.750″

0.7813″ 20 mm = 0.7874″

0.7969″

0.8438″

0.8594″ 22 mm = 0.8661″

0.8906″ 23 mm = 0.9055″

0.9063″

0.9375″ 24 mm = 0.9449″

0.9531″

0.9844″

1.26

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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 . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. .2.12

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . 2.12

FUEL TANK VENT LINE . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .2.12

FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . 2.13

FUEL LINES . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . .2.13

THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .2.14

ENGINE INTAKE PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .2.14

AIR FILTER SERVICE. . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .2.15

INTAKE DUCT DRAIN INSPECTION . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .2.15

AIR BOX / AIR FILTER ASSEMBLY VIEW . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.16

ENGINE . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . .2.17

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . .2.17

ENGINE OIL AND FILTER CHANGE . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .2.18

ENGINE CRANKCASE BREATHER HOSE INSPECTION . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

ENGINE CYLINDER LEAKDOWN TEST.. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . .2.20

VALVE CLEARANCE INSPECTION . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

TRANSMISSION AND FRONT GEARCASE . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .2.23

TRANSMISSION LUBRICATION . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.23

FRONT GEARCASE LUBRICATION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . 2.24

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

COOLING SYSTEM OVERVIEW . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

COOLANT STRENGTH . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . 2.26

COOLANT LEVEL INSPECTION . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.26

COOLING SYSTEM PRESSURE TEST . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.27

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . .2.27

RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . ..2.28

COOLANT DRAIN / FILL . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .2.29

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MAINTENANCE

PVT / FINAL DRIVE / WHEEL AND TIRE... . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .2.30

DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .2.30

PVT INTAKE PRE-FILTER SERVICE . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .2.30

PVT DRYING . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. .2.31

WHEEL AND HUB TORQUE TABLE.. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . .2.31

WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . .2.31

WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .2.32

TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .2.32

BEADLOCK RIMS (DESERT EDITION).. . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

ELECTRICAL AND IGNITION SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. .2.34

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .2.34

BATTERY CHARGING / OFF SEASON STORAGE . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

BATTERY REMOVAL . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

BATTERY INSTALLATION . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

ENGINE / CHASSIS ELECTRICAL GROUND.. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . .2.35

SPARK PLUG SERVICE . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .2.36

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37

STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .2.37

STEERING WHEEL FREEPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .2.37

TIE ROD END / WHEEL HUB INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . .2.38

WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . .2.39

SUSPENSION (WALKER EVANS™) . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

SPRING ADJUSTMENT.... . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . .2.40

SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .2.42

BRAKE PAD / DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. .2.42

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . .2.43

2.2

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

MAINTENANCE

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.

2.3

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

MAINTENANCE

Pre-Ride - 50 Hour Maintenance Interval

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

ITEM

Steering Front / Rear Suspension

Tires Brake Fluid Level Brake Pedal Travel Brake System

Wheels / Fasteners Frame Fasteners Engine Oil Level

Engine Intake Pre-Filter

PVT Intake Pre-Filter

▶

Intake Baffle Box Drain

Coolant Level Suspension Bushings

Spark Arrestor

Head Lights / Tail Lights Power Steering (if

▶

equipped) Brake Pad Wear / Inspect

▶

Parking Brake Pads (INT’L)

■

Fuel System

Parking Brake Cable

▶

Adjustment (INT’L)

■

▶

Air Filter 25 H

Engine Breather Filter (if

▶-

equipped)

Battery

Engine Oil & Filter Change

▶

(Break-In Period)

Front Gearcase Lubricant

▶

(Demand Drive) Transmission Lubricant

▶

(AGL)

▶

General Lubrication 50 H 3 M

■

Throttle Cable / Throttle

Pedal Throttle Body Intake Ducts/

Flange Shift Cable / Linkage Steering

■ Front / Rear Suspension

▶

HOURS CALENDAR

- -

10 H

25 H

25 H 1 M

50 H 6 M

50 H 6 M 50 H 6 M 50 H 6 M

Pre-Ride

Daily Daily

Daily

Daily Daily

Daily

Monthly 100 (160) Inspect periodically

Monthly

Monthly 250 (400) Inspect; replace as needed

Monthly 150 (250) Inspect; replace if necessary

Monthly 250 (400)

MILES

(KM)

- -

250 (400)

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

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

500 (800) Inspect; adjust; replace if necessary

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

500 (800) Inspect; adjust as needed 500 (800) Lubricate (if applicable) 500 (800) Lubricate (if applicable)

REMARKS

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

Inspect and clean often

Inspect drain at the bottom of the air intake baffle box

for obstructions

Check level daily

Lubricate daily or after each use in mud or water

Clean daily when driving in mud and water; replace a

cracked or damaged arrestor before operating

Check operation

Inspect daily; clean often

Inspect; cycle key to pressurize fuel pump; check

lines and fittings for leaks and abrasion

Inspect; adjust tension after first 25 hours

Check terminals; clean; test Perform a break-in oil and filter change at 25 hours or

one month; perform every 50 hours or 6 months thereafter

▶ 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.

2.4

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

50 - 500 Hour Maintenance Interval

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

ITEM

Cooling System

■

Engine Oil/Filter Change

▶

Engine Oil Lines/Fasteners

▶

Parking Brake Cable

▶

Adjustment (INT’L)

■

Front Gearcase Lubricant

▶

(Demand Drive)

Transmission Lubricant

▶

(AGL)

■ Fuel System

■ Spark Plug Inspection

▶

Radiator 100 H 12 M

Cooling Hoses

▶

Engine Mounts

▶

Exhaust Silencer / Pipe

Wiring

▶

Clutches (Drive and Driven)

■

Drive Belt 100 H 12 M

Front Wheel Bearings

■

▶

Shocks 100 H

▶

Shocks

■

Brake Fluid 200 H 24 M

Spark Arrestor

■ Valve Clearance 200 H

■ Spark Plug Replacement

▶

Coolant

Toe Adjustment

■

Headlight Aim

HOURS CALENDAR

50 H 6 M

100 H 6 M

100 H 12 M

200 H 24 M

500 H 36 M

1000 (1600)

1000 (1600) Inspect for leaks and loose fittings

1000 (1600) Inspect; adjust tension as needed

1000 (1600) Change lubricant

1000 (1600)

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

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect for leaks; pressure test system

1000 (1600) Inspect, torque to specification

1000 (1600) Inspect

1000 (1600)

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

- -

12 M

60 M

1500 (2400) Change shock oil and inspect seals

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

2000 (3200)

2000 (3200) Inspect; adjust as needed

5000 (8000) Replace; torque to specification

MILES

(KM)

500 (800)

MAINTENANCE

REMARKS

Inspect coolant strength seasonally; pressure test system yearly

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

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

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

Visually inspect shock seals

Clean daily when driving in mud and water; replace a cracked or damaged arrestor before operating

Replace coolant

Inspect periodically; adjust when parts are replaced

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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MAINTENANCE

Maintenance Quick Reference

ITEM LUBE REC. METHOD

Oil Fill Cap

- Under Cargo Box Access Panel

Oil Filter

- Behind Engine Access Panel

Engine Coolant

- Under Front Hood / Access Panel

/ Dipstick3:

Polaris PS-4 or Polaris PS-4 Extreme Duty

Polaris 60/40 Coolant

Add oil to proper level on dipstick

Maintain coolant level in coolant reservoir bottle

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

FREQUENCY*

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

Check level daily; change coolant every two years

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Maintenance Quick Reference, Continued...

MAINTENANCE

ITEM LUBE REC. METHOD

Brake Fluid

Front Gearcase

Transmission Polaris AGL

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

Polaris DOT 4 Brake Fluid

Polaris Demand Drive

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

Add lubricant until it is visible at the fill hole threads oz. (250 ml))

Add lubricant until it is visible at the fill hole threads

( 8.5

FREQUENCY*

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

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

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MAINTENANCE

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

Front A-arm Pivot Bushings

Propshaft Yokes

Front Stabilizer Bar Bushings (INT’L)

Rear Torsion Bar Bushings

Grease 3 fittings on each side of the vehicle

Grease middle and rear fittings

Grease the fitting on each side of the vehicle

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

Polaris All Season Grease

Polaris Premium U-Joint Grease

Polaris All Season Grease

FREQUENCY

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

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

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LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

MAINTENANCE

PART NO.

Engine Lubricant

2870791

2876244

2876245

2878920

2878919

2540086

2879723

2879324

Gearcase / Transmission Lubricants

2878068

2878069

2878070

2877922

2877923

2870465

Grease / Specialized Lubricants

DESCRIPTION

Fogging Oil (12 oz. Aerosol)

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

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

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

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

Engine Oil Filter

Engine Oil Change Kit (PS-4)

Engine Oil Change Kit (PS-4 Extreme Duty)

AGL (1 Qt.) (12 Count)

AGL (1 Gal.) (4 Count)

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

Demand Drive (Quart)

Demand Drive (2.5 Gallon)

Oil Pump for 1 Gallon Jug

PART NO.

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652

2872189

2871557

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

DESCRIPTION

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

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

Fuel Stabilizer (16 oz.) (12 count)

DOT 4 Brake Fluid (12 count)

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

2871312 Grease Gun Kit

2871322

2871423

2871460

2871515

2871551

2871329

Coolant

2871323

2871534

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

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

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

Starter Drive Grease (12 Count)

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

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

Dielectric Grease (Nyogel™)

60/40 Coolant (Gallon) (6 Count)

60/40 Coolant (Quart) (12 Count)

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2.9

MAINTENANCE

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 (see Chapter 2 – Engine Oil Level, page 2.17)

• 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 case in the right rear wheel well area.

2. Inspect shift cable, clevis pin, pivot bushings dust boot

. Replace if worn or damaged.

3. If adjustment is required, loosen the lower jam nut and pull the cable out of the mount2to move the upper jam nut

attached to the transmission

, and

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.

MAINTENANCE

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.

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2.11

MAINTENANCE

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.

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MAINTENANCE

Fuel Pump / Fuel Filters

The fuel pump assembly1is 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 before the pump regulator.

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

and an internal fine filter3located

Fuel Lines

1. Check the quick-connect fuel line1at the fuel tank

for signs of wear, deterioration, damage or leakage. Replace line(s) if necessary.

2. Locate the fuel supply fitting2through 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.

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

NOTE: Make sure lines are not kinked or pinched.

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MAINTENANCE

Throttle Pedal Inspection

This vehicle is equipped with Pedal Position Sensor used to detect when the throttle pedal2is pushed or released.

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

Check throttle pedal periodically.

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.

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MAINTENANCE

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

2. Disengage the four cover latches2.

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.

Intake Duct Drain Inspection

It is recommended that the intake drain be inspected daily.

1. Access the intake baffle box drain

rear wheel well.

through the left

3. Pull cover rearward far enough to remove air filter3.

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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MAINTENANCE

Air Box / Air Filter Assembly View

Intake Airbox Hose

Drain Cap

Airbox

Air Filter

Airbox Cover

Airbox Clip (4)

Vent Hose

Intake Tubes

Engine Intake Housing

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ENGINE

MAINTENANCE

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 wipe it dry with a clean cloth.

. Remove the dipstick and

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 top of the valve cover, under the cargo box access panel.

located on

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

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MAINTENANCE

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 completely.

. Allow the oil to drain

6. Using the Oil Filter Wrench (PU-50105), turn the oil filter

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.

counter-clockwise to remove it.

Oil Filter Wrench:

PU-50105: 2.5″ (64 mm)

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.

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

Engine Oil Drain Plug:

12 ft-lbs (16 Nm)

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MAINTENANCE

11. Remove oil fill cap (see Chapter 2 – Engine Oil

Level, page 2.17). 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 Chapter 2 – Engine Oil Level, page 2.17).

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

lock the dipstick

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 engine intake duct.

NOTE: Make sure hoses are not kinked or pinched.

from the crankcase to the

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.

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MAINTENANCE

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.

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.

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MAINTENANCE

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 be measured at each camshaft lobe position.

. Two valves can

9. Measure the valve clearance using a feeler gauge.

10. If the valve clearance is out of specification, see Chapter 3 – Valve Clearance Adjustment, page

3.84.

Intake Valve Clearance (cold):

.006 ± .002″ (0.15 ± 0.05 mm)

Exhaust Valve Clearance (cold):

.008 ± .002″ (0.20 ± 0.05 mm)

NOTE: Remove spark plugs to aid engine rotation.

8. Rotate the drive clutch counter-clockwise until the cam lobes are facing up.

above the valves you are inspecting

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)

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MAINTENANCE

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

MAINTENANCE

GEARCASE LUBRICANT CAPACITY

without turf mode:

44 oz. (1300 ml)

Transmission AGL

Front Gearcase Demand Drive

with turf mode:

40.5 oz. (1200 mL)

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 .

and check the lubricant level

FILL / DRAIN PLUG TORQUE

14 ft-lbs (19 Nm)

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 (see Chapter 2 – Transmission Lubrication, page 2.23).

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

7. Remove drain plug completely.

and allow lubricant to drain

8. Clean the drain plug magnetic surface.

9. Reinstall the drain plug and torque to specification.

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

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MAINTENANCE

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

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 (see Chapter 2 – Front Gearcase Lubrication, page 2.24).

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6. Place a drain pan under the front gearcase drain

plug.

7. Remove the drain plug completely.

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.

and allow fluid to drain

MAINTENANCE

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.

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MAINTENANCE

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 50/50 Antifreeze is premixed and ready to use. Do not dilute with water.

Coolant Strength

Test the strength of the coolant using an antifreeze hydrometer.

Coolant Level Inspection

The pressure cap1and recovery bottle2are 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.

• A 50/50 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 2880514) (Quart)

(PN 2880513) (Gallon)

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.

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MAINTENANCE

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.

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

Recovery Bottle

Engine Hoses

Radiator Hoses

To Thermostat Housing

To Waterpump

To Radiator

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MAINTENANCE

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

ITEM

DESCRIPTION

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.

Radiator Inspection / Cleaning

1. Check radiator air passages for restrictions or damage.

ITEM

2. Carefully straighten any bent radiator fins.

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

DESCRIPTION

Radiator

Shroud

Fan

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.

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Coolant Drain / Fill

1. Remove the front hood.

WARNING

MAINTENANCE

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

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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MAINTENANCE

PVT / FINAL DRIVE / WHEEL AND TIRE

Drive Clutch / Driven Clutch / Belt Service

Refer to PVT SYSTEM SERVICE, page 5.8 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.

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

and O-ring from the outer clutch cover.

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

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 Chapter 4 – PVT SYSTEM SERVICE, page 5.8 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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MAINTENANCE

Drive Shaft Boot Inspection

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

are properly positioned.

for

Wheel and Hub Torque Table

ITEM SPECIFICATION

Wheel Nuts (Cast Aluminum Wheels)

Hub Retaining Nuts (Front and Rear)

Beadlock Screws

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

120 ft-lbs (163 Nm)

110 ft-lbs (149 Nm)

Step 1: 24 in-lbs (3 Nm) Step 2: 7 ft-lbs (10 Nm)

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.

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MAINTENANCE

Wheel Installation

1. Verify the transmission is still in PARK.

2. Place the wheel in the correct position on the wheel hub outside and rotation arrows on the tire point toward forward rotation.

3. Attach the wheel nuts

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts and/or hub nut proper torque specification (see Chapter 2 – Wheel and Hub Torque Table, page 2.31).

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

. Be sure the valve stem

and finger tighten them.

is toward the

to the

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.

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

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.

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

TIRE PRESSURE INSPECTION (COLD)

Model Front Rear

XP4

High Lifter 18 psi (124 kPa) 18 psi (124 kPa)

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

19 psi (131 kPa) 21 psi (145 kPa)

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Beadlock Rims (Desert Edition)

The RZR XP Desert Edition model comes with Walker Evans™ beadlock rims. The beadlock does not come set up from factory, but may be changed to use the beadlock feature.

To make the beadlock rim functional:

1. Deflate the tire.

2. Remove the beadlock screws and beadlock ring.

MAINTENANCE

Beadlock Screws:

Step 1: 24 in-lbs (3 Nm)

Step 2: 7 ft-lbs (10 Nm)

3. Dismount the tire on the side with the beadlock holes.

4. Place the beadlock ring so the tire is sandwiched between the rim and the ring making sure the valve stem is aligned with the slot in the ring.

5. Install bolts and thread them to 24 in-lbs (3 Nm).

6. Tighten in a criss-cross pattern to 7 ft-lbs (10 Nm).

NOTE: Beadlock bolts should be checked and retorqued every 300 miles (450 km).

7. Seat bead and inflate to 16 psi.

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MAINTENANCE

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 Charging / Off Season Storage

Refer to Charging Procedure , page 11.37and Battery Off Season Storage, page 11.36.

Battery Removal

1. Remove the driver’s seat to access the battery1.

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

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 11.37. Do not use the vehicle’s stator/alternator to charge a new battery.

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

5. Lift the battery out of the vehicle.

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MAINTENANCE

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 11.37before 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.

Engine / Chassis Electrical Ground

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

1. The chassis ground connection start solenoid rear wheel area.

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

, can be accessed through the left

, located below the

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

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MAINTENANCE

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

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

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.

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.

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.

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MAINTENANCE

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

• Steering Shaft U-Joints

• Steering Gearbox

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MAINTENANCE

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.

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”.

• 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.

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

MAINTENANCE

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:

(2) - (3) = 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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2.39

MAINTENANCE

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: 16.625″ (42.228 cm)

RZR XP 4 1000: 15.600″ (39.625 cm)

RZR XP High Lifter:

14.444″ (36.689 cm)

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

RZR XP 1000: 22.430″ (56.972 cm)

RZR XP 4 1000: 21.918″ (55.671 cm)

RZR XP High Lifter:

21.547″ (54.73 cm)

2. Using the shock spanner/spreader tool (PN

2878925) included in the vehicle’s tool kit, turn the adjustment collar height.

Shock Spanner / Clutch Spreader Tool:

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

to increase or decrease ride

PN 2878925

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.

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

MAINTENANCE

Softest

Factory

Firmest

Full counter-clockwise position

6 clicks from softest position

Full clockwise position

Walker Evans™ 2.5" Rear Shock:

Compression Adjustment Table

SETTING COMPRESSION DAMPING

Softest

Factory

Firmest

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

Full counter-clockwise position

7 clicks from softest position

Full clockwise position

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2.41

MAINTENANCE

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 level should be between the MAX and MIN level lines.

. The

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 is worn to 0.040″ (1 mm).

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 Thickness

Service Limit: 0.040” (1 mm)

4. Check surface condition of the brake discs.

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

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MAINTENANCE

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

Brake Disc Thickness

Service Limit: 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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2.43

MAINTENANCE

NOTES

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ENGINE / COOLING SYSTEM

CHAPTER 3

ENGINE / COOLING SYSTEM

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

COOLING SYSTEM PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .3.35

CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .3.35

CYLINDER HEAD REMOVAL . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

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

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .3.38

VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .3.39

COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . 3.40

VALVE SEALING TEST . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.40

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ENGINE / COOLING SYSTEM

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

ENGINE DISASSEMBLY / INSPECTION - LOWER END . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44

STATOR COVER REMOVAL / INSPECTION . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .3.44

WATER PUMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45

FLYWHEEL REMOVAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .3.46

STARTER ONE-WAY CLUTCH DISASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .3.47

CRANKCASE DISASSEMBLY / INSPECTION . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .3.48

BALANCE SHAFT REMOVAL / INSPECTION. .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .3.50

CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .3.51

CRANKCASE INSPECTION.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .3.54

CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55

CYLINDER / PISTON REMOVAL . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.56

PISTON DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . .3.57

PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58

PISTON RING TO GROOVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . .3.58

PISTON RING INSTALLED GAP . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .3.59

CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. .3.60

ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .3.62

BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . .3.62

CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .3.63

CRANKSHAFT MAIN BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.63

UPPER CRANKCASE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . .3.64

PISTON RING INSTALLATION . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64

PISTON / CONNECTING ROD ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .3.66

CYLINDER / PISTON INSTALLATION . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.67

CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. .3.68

BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . .3.70

LOWER CRANKCASE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . .3.70

CRANKCASE ASSEMBLY . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71

STARTER ONE-WAY CLUTCH ASSEMBLY . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75

FLYWHEEL INSTALLATION . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76

STATOR COVER INSTALLATION . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .3.76

ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .3.77

CYLINDER HEAD ASSEMBLY . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77

CYLINDER HEAD INSTALLATION . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .3.78

CAMSHAFT INSTALLATION / TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . .3.79

CAMSHAFT TIMING - QUICK REFERENCE.. . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . .3.83

VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . .3.84

INTAKE VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86

EXHAUST VALVE LASH - TAPPET SELECTION MATRIX. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . .3.87

VALVE COVER INSTALLATION . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .3.88

TROUBLESHOOTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .3.89

ENGINE . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . .3.89

COOLING SYSTEM . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.90

3.2

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ENGINE / COOLING SYSTEM

GENERAL INFORMATION

Special Tools

TOOL DESCRIPTION PART NUMBER

Bench Mount Engine Stand Adapter

Clutch Center Distance Tool PU-50658

Cylinder Holding & Camshaft Timing Plate

Engine Stand (2″ Bore)

Engine Stand Adapter (Mounts To The Engine)

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

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

Flywheel Puller

Mity Vac™ Pressure Test Tool

Oil Filter Wrench PU-50105

Oil Pressure Gauge

Oil Pressure Gauge Adapter

Piston Ring Compressor Pliers

Valve Spring Compressor

PW-47053

PU-50563

PU-50624

PU-50562

PU-50625

PW-47054

PA-49316

2870975

PV-43531

PU-50565

PV-43570-1

PV-1253 or PV-4019 (Quick Release)

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.

Valve Spring Compressor Adapter

Water Pump Mechanical Seal Installer

Bosch Automotive Service Solutions: 1-800-3452233 or http://polaris.service-solutions.com/

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

PV-43513-A

PU-50564

3.3

ENGINE / COOLING SYSTEM

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 , located in the upper crankcase on the MAG side of the engine.

4. Remove the crankcase gallery plug oil pressure adapter.

and insert the

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)

3.4

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Engine Oil Flow Chart

ENGINE / COOLING SYSTEM

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3.5

ENGINE / COOLING SYSTEM

ENGINE SERVICE SPECIFICATIONS

Engine Specifications

CAMSHAFT / CYLINDER HEAD / CYLINDER

ITEM

Camshaft

Cylinder

Cylinder Head

STANDARD SERVICE LIMIT

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

Camshaft Carrier Bore I.D. - All

Camshaft Oil Clearance

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

Cylinder - Surface Warp Limit (cylinder head surface)

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

Cylinder Out of Round Limit

Cylinder Taper Limit

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

Cylinder Head - Surface Warp Limit

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

Valve Lash (Cold) - Intake 0.006 ± 0.002" (0.15 ± 0.05 mm)

Valve Lash (Cold) - Exhaust 0.008 ± 0.002" (0.20 ± 0.05 mm)

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

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

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

0.002″ (0.05 mm)

0.001″ (0.025 mm)

0.0039″ (0.1 mm)

Valve

Valve Guide

Valve Seat

Valve Stem Diameter - Intake

Valve Stem Diameter - Exhaust

Valve Stem Oil Clearance - Intake

Valve Stem Oil Clearance - Exhaust

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

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

Valve Guide Inner Diameter

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

0.2155 - 0.2161" (5.475 - 5.490 mm)

0.2147 - 0.2153" (5.455 - 5.470 mm)

0.0003 - 0.0015" (0.010 - 0.040 mm)

0.0011 - 0.0023" (0.030 - 0.060 mm)

0.2165 - 0.2171" (5.500 - 5.515 mm)

30.0° ± 1.5°

45.0° ± 0.5°

60.0° ± 1.5°

3.6

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ENGINE / COOLING SYSTEM

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT

ITEM

Piston

Piston Ring

Connecting Rod

STANDARD SERVICE LIMIT

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

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

Piston Pin O.D.

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

Installed Gap

Ring to Groove Clearance

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)

B - Marking

G Marking

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

Oil Control Rails

Top Ring

Second Ring

Main Journal O.D.

3.6597 ± 0.0003" (92.959 ± 0.008 mm)

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

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

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

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

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

Crankshaft

Balance Shaft

Y - Marking

B - Marking

G Marking

Y - Marking

Crankshaft Runout Limit (PTO and MAG)

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

Main Journal O.D.

Rod Journal O.D.

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

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

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

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

Less than 0.001″

(0.025 mm)

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3.7

ENGINE / COOLING SYSTEM

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES

Main Engine Components - Torque Specification and Sequence

3.8

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ENGINE / COOLING SYSTEM

Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

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3.9

ENGINE / COOLING SYSTEM

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

3.10

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ENGINE / COOLING SYSTEM

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

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3.11

ENGINE / COOLING SYSTEM

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

3.12

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ENGINE COOLING SYSTEM

ENGINE / COOLING SYSTEM

Cooling System Specifications

CONDITION

Room Temperature 68° F (20° C)

Thermostat Open

Fan Off

Fan On

Thermostat Full Open 203° F (95° C)

Engine Temperature Overheat Indicator

Engine Protection Ignition Misfire

Engine Protection Shutdown

ITEM SPECIFICATION

Cooling System Capacity 4.9 qts. (4.6 L)

Pressure Cap Relief

COOLANT TEMP °F (°C)

180° F (82° C)

192° F (89° C)

198° F (92° C)

233° F (112° C)

236° F (113° C)

257° F (125° C)

13 PSI

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.

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.

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.

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3.13

ENGINE / COOLING SYSTEM

Cooling System 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.

2. Remove pressure cap cap tester (commercially available).

and test using a pressure

Radiator Removal / Installation

1. Remove the hood and front bumper (See Chapter 10 – Hood and Front Body Work, page 10.20and Front Bumper, page 10.19).

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

3. Drain radiator by removing lower radiator hose1. Be sure to catch and dispose of coolant properly.

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

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.

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ENGINE / COOLING SYSTEM

6. Remove the four upper radiator support fasteners

and disconnect the small radiator bypass hose3.

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.

9. Reverse this procedure for installation. Be sure to

properly fill and bleed cooling system as outlined in this chapter.

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 Chapter 3 – Cooling System Pressure Cap Test, page 3.14).

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

4. Remove upper coolant hose from thermostat housing

5. Remove the rear bolt

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

retaining the thermostat

cover.

Upper Radiator Hose

Lower Radiator Hose

Recovery Bottle

To Radiator Fitting

Fan Motor Assembly

Radiator

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ENGINE / COOLING SYSTEM

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.

9. Install a new thermostat with the bleed hole 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

ENGINE / COOLING SYSTEM

Thermostat housing

Water Pump

Engine Hoses

Lower Radiator Hose

Fan Assembly

Filler Neck

Radiator

Pressure Cap

Upper Radiator Hose

Recovery Bottle

Oil Cooler Inlet Hose

Oil Cooler Outlet Hose

Bypass Hose

Water Pump Outlet Hose

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ENGINE / COOLING SYSTEM

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.

6. Open the bleed screw 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.

to allow any trapped air to

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 to the MAX line.

4. Remove the pressure cap2and 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.

and fill the bottle

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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1&2

ENGINE / COOLING SYSTEM

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 to engine block. Note different bolt lengths for installation.

retaining water pump

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

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

4. Clean the O-ring sealing surface block using a clean shop towel.

with fresh engine oil.

in the engine

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

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.

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5&6

7–10

ENGINE / COOLING SYSTEM

6. Rotate water pump drive tab

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 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

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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ENGINE / COOLING SYSTEM

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

to water pump housing2. Discard cover gasket

3. Place the water pump drive tab

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

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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ENGINE / COOLING SYSTEM

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

NOTE: A 5/32" (4 mm) diameter punch

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

19. Install a new water pump cover gasket

and housing gasket surfaces2.

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

20. Install the water pump cover and three retaining bolts

. Torque bolts in sequence to specification.

ENGINE / COOLING SYSTEM

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.

Bolt Loctite 204

Mechanical Seal

O-Rings

Washers Drive Tab

Water Pump Shaft

Water Pump Housing

Oil Seal Impeller

Washer

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ENGINE / COOLING SYSTEM

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 2.20, 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 Chapter 2 – Coolant Drain / Fill, page

2.29).

4. Remove the seats.

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

6. Remove the rear bumper and cargo box (see Chapter 10 – Cargo Box Assembly Removal, page

10.22).

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.

3.24

WARNING

Use care when supporting vehicle so that it does not tip

or fall.

Serious injury may occur if vehicle tips or falls.

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

Polaris RZR XP 1000, RZR XP4 1000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

2014-2015 RZR XP 1000 / RZR XP4 1000

TRADEMARKS

VEHICLE IDENTIFICATION

Model Number Designation

Model Number Designation

Vehicle Identification Number

Vehicle Identification Number (VIN) Designation (2015+)

Vehicle and Engine Serial Number Location

VEHICLE INFORMATION

Replacement Keys

Publication Numbers

SPECIAL TOOLS

GENERAL SPECIFICATIONS

2014-2015 RZR XP 1000 / EPS

RZR XP 1000 CLUTCH CHART

2014-2015 RZR XP 4 1000

2014-2015 RZR 1000 XP4

2015 RZR XP 1000 EPS High Lifter

2015 RZR XP 1000 High Lifter

2015 RZR XP 1000 Desert Edition

2015 RZR XP 1000 Desert Edition Clutch Chart

MISC. SPECIFICATIONS AND CHARTS

Master Torque Table

Conversion Table

Standard Bolt Torque Specification

Metric Bolt Torque Specification

SAE Tap / Drill Sizes

Metric Tap / Drill Sizes

Decimal Equivalents

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Break-In Period

Maintenance Chart Key

Pre-Ride - 50 Hour Maintenance Interval

50 - 500 Hour Maintenance Interval

Maintenance Quick Reference

Maintenance Quick Reference, Continued...

Grease Lubrication Points

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Shift Cable Inspection / Adjustment

FUEL SYSTEM AND AIR INTAKE

Fuel System

Fuel Tank Vent Line

Fuel Pump / Fuel Filters

Fuel Lines

Throttle Pedal Inspection

Engine Intake Pre-Filter Service

Air Filter Service

Intake Duct Drain Inspection

Air Box / Air Filter Assembly View

ENGINE

Engine Oil Level

Engine Oil and Filter Change

Engine Crankcase Breather Hose Inspection

Engine Cylinder Leakdown Test

Valve Clearance Inspection

TRANSMISSION AND FRONT GEARCASE

Specification Chart

Transmission Lubrication

Front Gearcase Lubrication

COOLING SYSTEM

Cooling System Overview

Coolant Strength

Coolant Level Inspection

Cooling System Pressure Test

Cooling System Hoses

Radiator Inspection / Cleaning

Coolant Drain / Fill

PVT / FINAL DRIVE / WHEEL AND TIRE

Drive Clutch / Driven Clutch / Belt Service

PVT Intake Pre-Filter Service

PVT Drying

Drive Shaft Boot Inspection