Polaris RZR XP 1000 2014 Service manual

Table of Contents

• 7. Table of Contents
• 8. VEHICLE IDENTIFICATION
• 9. VEHICLE IDENTIFICATION NUMBER
• 10. VEHICLE AND ENGINE SERIAL NUMBER LOCATIO...
• 11. REFERENCE INFORMATION
• 12. SPECIAL TOOLS
• 16. GENERAL SPECIFICATIONS
• 17. 2014-2016 RZR XP 1000 CLUTCH CHART
• 21. 2015-2016 RZR XP 1000 HIGH LIFTER CLUTCH...
• 25. 2015 RZR XP 1000 DESERT EDITION CLUTCH C...
• 27. 2015 RZR XP 1000 FOX CLUTCH CHART
• 28. MISC. SPECIFICATIONS AND CHARTS
• 30. CONVERSION TABLE
• 31. STANDARD BOLT TORQUE SPECIFICATION
• 32. SAE TAP / DRILL SIZES
• 33. DECIMAL EQUIVALENTS
• 37. PERIODIC MAINTENANCE CHART
• 38. MAINTENANCE INTERVALS
• 40. MAINTENANCE QUICK REFERENCE
• 42. GREASE LUBRICATION POINTS
• 43. LUBRICANTS / SERVICE PRODUCTS
• 44. ENGINE
• 45. ENGINE OIL AND FILTER CHANGE
• 46. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
• 47. ENGINE CYLINDER LEAKDOWN TEST
• 50. COOLING SYSTEM
• 51. COOLING SYSTEM PRESSURE TEST
• 52. RADIATOR INSPECTION / CLEANING
• 53. FUEL SYSTEM AND AIR INTAKE
• 54. FUEL PUMP / FUEL FILTERS
• 55. THROTTLE PEDAL INSPECTION
• 56. AIR FILTER SERVICE
• 57. PVT / FINAL DRIVE / WHEEL AND TIRE
• 58. DRIVE SHAFT BOOT INSPECTION
• 59. WHEEL INSTALLATION
• 60. BEADLOCK RIMS (DESERT EDITION)
• 61. TRANSMISSION AND FRONT GEARCASE
• 62. FRONT GEARCASE LUBRICATION
• 63. SHIFT CABLE INSPECTION / ADJUSTMENT
• 64. STEERING
• 65. TIE ROD END / WHEEL HUB INSPECTION
• 66. WHEEL TOE ADJUSTMENT
• 67. SUSPENSION
• 68. SHOCK COMPRESSION ADJUSTMENT (WALKER EVA...
• 69. SPRING ADJUSTMENT (FOX®)
• 70. SHOCK COMPRESSION ADJUSTMENT (FOX®)
• 72. BRAKE SYSTEM
• 73. BRAKE HOSE AND FITTING INSPECTION
• 74. ELECTRICAL AND IGNITION SYSTEM
• 75. BATTERY INSTALLATION
• 76. SPARK PLUG SERVICE
• 81. GENERAL INFORMATION
• 82. OIL PRESSURE TEST
• 83. ENGINE OIL FLOW CHART
• 84. ENGINE SPECIFICATIONS (1000)
• 86. MAIN ENGINE COMPONENTS - TORQUE SPECIFIC...
• 87. BALANCE SHAFT / CONNECTING RODS / CRANKC...
• 88. CYLINDER / OIL COOLER / OIL FILTER / OIL...
• 89. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / I...
• 90. SPARK PLUGS / STARTER / THERMOSTAT HOUSI...
• 91. INTAKE / EXHAUST SYSTEM
• 92. EXHAUST SYSTEM ASSEMBLY VIEW
• 93. ENGINE COOLING SYSTEM
• 94. COOLING SYSTEM PRESSURE CAP TEST
• 95. THERMOSTAT REPLACEMENT
• 97. COOLING SYSTEM ASSEMBLY VIEW
• 98. COOLING SYSTEM BLEEDING PROCEDURE
• 99. WATER PUMP REMOVAL
• 101. WATER PUMP SERVICE
• 104. ENGINE SERVICE
• 108. ENGINE INSTALLATION
• 112. ENGINE MOUNTING AND TORQUE VALUES
• 113. ENGINE BREAK-IN PERIOD
• 114. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
• 116. CAMSHAFT SPROCKET INSPECTION
• 118. CYLINDER HEAD REMOVAL
• 119. CYLINDER HEAD DISASSEMBLY
• 120. VALVE INSPECTION
• 121. COMBUSTION CHAMBER CLEANING
• 122. VALVE SEAT RECONDITIONING (1000)
• 125. ENGINE DISASSEMBLY / INSPECTION - BOTTOM...
• 126. WATER PUMP HOUSING REMOVAL
• 127. FLYWHEEL REMOVAL
• 128. STARTER ONE-WAY CLUTCH DISASSEMBLY
• 129. CRANKCASE DISASSEMBLY / INSPECTION
• 131. BALANCE SHAFT REMOVAL / INSPECTION
• 132. CRANKSHAFT REMOVAL / INSPECTION
• 134. CRANKCASE INSPECTION
• 135. CYLINDER INSPECTION
• 136. CYLINDER / PISTON REMOVAL
• 137. PISTON DISASSEMBLY / INSPECTION (1000)
• 138. PISTON RING REMOVAL
• 139. PISTON RING INSTALLED GAP (1000)
• 141. ENGINE ASSEMBLY - BOTTOM END
• 142. CONNECTING ROD BEARING SELECTION
• 143. UPPER CRANKCASE PREPARATION
• 145. PISTON / CONNECTING ROD ASSEMBLY
• 146. CYLINDER / PISTON INSTALLATION
• 147. CRANKSHAFT INSTALLATION
• 149. BALANCE SHAFT INSTALLATION
• 150. CRANKCASE ASSEMBLY
• 154. STARTER ONE-WAY CLUTCH ASSEMBLY
• 155. STATOR COVER INSTALLATION
• 156. ENGINE ASSEMBLY - TOP END
• 157. CYLINDER HEAD INSTALLATION
• 158. CAMSHAFT INSTALLATION / TIMING
• 162. CAMSHAFT TIMING - QUICK REFERENCE
• 163. VALVE CLEARANCE ADJUSTMENT
• 165. INTAKE VALVE LASH - TAPPET SELECTION MAT...
• 166. EXHAUST VALVE LASH - TAPPET SELECTION MA...
• 167. VALVE COVER INSTALLATION
• 168. TROUBLESHOOTING
• 173. GENERAL INFORMATION
• 174. TORQUE SPECIFICATIONS
• 175. EFI OVERVIEW
• 176. EFI SYSTEM ASSEMBLY VIEW
• 177. EFI SYSTEM COMPONENT LOCATIONS
• 178. PRINCIPAL COMPONENTS
• 179. INITIAL PRIMING / STARTING PROCEDURE
• 180. ELECTRONIC CONTROL UNIT (ECU)
• 181. ETC LEARN PROCEDURE
• 182. FUEL INJECTORS
• 183. FUEL INJECTOR TEST
• 186. FUEL TANK
• 187. FUEL LINE REMOVAL / INSTALLATION
• 190. FUEL TANK INSTALLATION
• 191. FUEL TANK REMOVAL RZR XP 4 1000
• 193. FUEL TANK INSTALLATION RZR XP 4 1000
• 194. FUEL PUMP
• 195. FUEL PUMP TEST
• 196. FUEL PUMP REPLACEMENT
• 200. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSU...
• 201. CRANKSHAFT POSITION SENSOR (CPS)
• 202. CPS REPLACEMENT
• 203. ELECTRONIC THROTTLE CONTROL (ETC) / THRO...
• 204. THROTTLE BODY REMOVAL
• 205. ETC TEST
• 206. PEDAL POSITION SENSOR (PPS)
• 208. OXYGEN SENSOR (MY15-16)
• 209. EFI DIAGNOSTICS
• 217. EFI TROUBLESHOOTING
• 218. POLARIS DIGITAL WRENCH
• 219. DIGITAL WRENCH SOFTWARE VERSION AND UPDA...
• 220. DIGITAL WRENCH® COMMUNICATION ERRORS
• 221. GUIDED DIAGNOSTICS
• 223. ECU REPLACEMENT
• 226. POLARIS MOBILE DIGITAL WRENCH (PMDW)
• 229. GENERAL INFORMATION
• 231. PVT SYSTEM OVERVIEW
• 232. DRIVEN CLUTCH OPERATION
• 233. PVT OVERHEATING / DIAGNOSIS
• 234. PVT SYSTEM SERVICE
• 236. PVT COVERS AND DUCTING COMPONENTS (HIGH ...
• 237. PVT DISASSEMBLY (2014-2015)
• 238. PVT ASSEMBLY (2016)
• 243. DRIVE BELT
• 244. BELT INSPECTION
• 245. DRIVE CLUTCH SERVICE
• 246. DRIVE CLUTCH DISASSEMBLY / INSPECTION
• 247. NEEDLE BEARING INSPECTION
• 248. SHIFT WEIGHT INSPECTION
• 249. SPIDER REMOVAL
• 250. CLUTCH INSPECTION
• 251. MOVEABLE SHEAVE BUSHING INSPECTION
• 253. DRIVE CLUTCH ASSEMBLY
• 256. DRIVEN CLUTCH SERVICE (2014-2015)
• 258. DRIVEN CLUTCH BUSHING SERVICE
• 259. CLUTCH BUSHING REMOVAL
• 260. CLUTCH BUSHING INSTALLATION
• 263. DRIVEN CLUTCH ASSEMBLY VIEW
• 264. DRIVEN CLUTCH SERVICE (2016)
• 266. DRIVEN CLUTCH ASSEMBLY
• 268. ASSEMBLY VIEW
• 269. TROUBLESHOOTING
• 272. GENERAL INFORMATION
• 273. TRANSMISSION MOUNTING AND TORQUE VALUES
• 274. SHIFT LEVER / CABLE
• 276. TRANSMISSION SERVICE
• 279. TRANSMISSION INSTALLATION
• 282. TRANSMISSION DISASSEMBLY
• 286. DIFFERENTIAL OPERATION (TURF MODE MODELS...
• 288. PLANETARY DIFFERENTIAL DISASSEMBLY (TURF...
• 289. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
• 292. PLANETARY DIFFERENTIAL ASSEMBLY (TURF MO...
• 293. GEAR / SHAFT / BEARING INSPECTION
• 294. TRANSMISSION ASSEMBLY / SNORKEL GEAR BAC...
• 300. TRANSMISSION ASSEMBLY VIEW
• 302. TRANSMISSION ASSEMBLY VIEW (TURF MODE MO...
• 304. TROUBLESHOOTING
• 307. GENERAL INFORMATION
• 308. BEARING CARRIER
• 309. FRONT BEARING REPLACEMENT
• 310. FRONT BEARING CARRIER INSTALLATION
• 311. REAR BEARING CARRIER INSPECTION / REMOVA...
• 313. REAR BEARING REPLACEMENT
• 314. REAR BEARING CARRIER INSTALLATION
• 316. DRIVE SHAFT
• 317. FRONT DRIVE SHAFT INSTALLATION
• 318. REAR DRIVE SHAFT REMOVAL
• 319. REAR DRIVE SHAFT INSTALLATION
• 321. DRIVE SHAFT / CV JOINT HANDLING TIPS
• 324. INNER PLUNGING JOINT / BOOT REPLACEMENT
• 326. OUTER CV BOOT REPLACEMENT
• 328. INNER PLUNGING JOINT / BOOT REPLACEMENT
• 330. DRIVE SHAFT ASSEMBLY VIEW
• 331. PROP SHAFT SERVICE
• 332. FRONT PROP SHAFT INSTALLATION
• 333. REAR PROP SHAFT INSTALLATION
• 334. REAR PROP SHAFT REMOVAL XP 4
• 335. REAR PROP SHAFT INSTALLATION
• 336. SUPPORT BEARING REPLACEMENT
• 337. FRONT GEARCASE / CENTRALIZED HILLIARD
• 338. ALL WHEEL DRIVE OPERATION
• 339. AWD DIAGNOSIS
• 340. FRONT GEARCASE REMOVAL
• 341. FRONT GEARCASE DISASSEMBLY / INSPECTION
• 344. FRONT GEARCASE ASSEMBLY
• 346. FRONT GEARCASE INSTALLATION
• 348. WHEEL HUBS
• 353. GENERAL INFORMATION
• 354. STEERING SYSTEM
• 355. UPPER STEERING SHAFT REMOVAL
• 356. STEERING WHEEL REMOVAL
• 358. LOWER STEERING SHAFT REMOVAL
• 359. POWER STEERING UNIT INSTALLATION
• 360. UPPER STEERING SHAFT INSTALLATION
• 361. STEERING SHAFT BEARING REPLACEMENT
• 363. FRONT SUSPENSION
• 364. FRONT STABILIZER BAR REMOVAL
• 365. FRONT STABILIZER BAR INSTALLATION
• 366. BALL JOINT REMOVAL
• 367. REAR SUSPENSION
• 370. TRAILING ARM SPHERICAL BEARING REPLACEME...
• 371. REAR SUSPENSION ASSEMBLY VIEW
• 372. STABILIZER BAR REMOVAL
• 373. SHOCKS / SPRINGS
• 374. SHOCK SERVICE
• 375. WALKER EVANS™ 2.5" REAR SHOCK
• 376. WALKER EVANS SHOCK SERVICE
• 378. REAR SHOCK SERVICE INFORMATION
• 380. SPRING ADJUSTMENT (WALKER EVANS)
• 381. WALKER EVANS™ SHOCK REBUILD INFORMATION
• 382. WALKER EVANS™ SHOCK DISASSEMBLY
• 385. WALKER EVANS™ SHOCK ASSEMBLY
• 390. FOX SHOCK ASSEMBLY VIEWS
• 391. FOX 3.0" O.E. PODIUM BYPASS
• 392. FOX SHOCK SERVICE
• 393. FOX 3.0" REAR SHOCK INFORMATION
• 394. SPRING ADJUSTMENT (FOX®)
• 395. OFFSET TORQUE FORMULA
• 396. FOX SHOCK DISASSEMBLY
• 403. FOX SHOCK ASSEMBLY
• 411. GENERAL INFORMATION
• 412. GENERAL SPECIFICATIONS
• 413. BRAKE NOISE TROUBLESHOOTING
• 414. BRAKE SYSTEM ASSEMBLY VIEW
• 415. MASTER CYLINDER
• 416. MASTER CYLINDER INSTALLATION
• 418. BRAKE PEDAL LEVER
• 419. PARKING BRAKE (INT'L MODEL)
• 420. PARKING BRAKE INSPECTION
• 421. PARKING BRAKE CALIPER
• 424. PARKING BRAKE DISC
• 425. FRONT BRAKE PADS
• 426. PAD INSPECTION
• 427. BRAKE BURNISHING PROCEDURE
• 428. FRONT CALIPER SERVICE
• 429. CALIPER REMOVAL
• 430. CALIPER DISASSEMBLY
• 431. CALIPER INSPECTION
• 432. CALIPER INSTALLATION
• 433. FRONT BRAKE DISC
• 434. DISC REPLACEMENT
• 435. REAR BRAKE PADS
• 436. PAD INSPECTION
• 437. PAD ASSEMBLY / INSTALLATION
• 438. REAR CALIPER SERVICE
• 439. CALIPER REMOVAL
• 440. CALIPER DISASSEMBLY
• 441. CALIPER ASSEMBLY
• 443. REAR BRAKE DISC
• 445. TROUBLESHOOTING
• 448. GENERAL INFORMATION
• 449. BODY ASSEMBLY VIEWS
• 451. DOORS
• 452. DOORS (XP4)
• 453. DOORS HIGH LIFTER
• 454. DASH INSTRUMENTS / CONTROLS
• 455. DASH INSTRUMENTS / CONTROLS HIGH LIFTER
• 456. HOOD / FRONT BODY WORK
• 457. CHASSIS / MAIN FRAME XP / HIGH LIFTER
• 458. CHASSIS / MAIN FRAME XP 4
• 459. SEAT ASSEMBLY FRONT
• 460. SEAT ASSEMBLY REAR
• 461. FLOOR / ROCKER PANELS XP / HIGH LIFTER
• 462. FLOOR / ROCKER PANELS XP 4 / XP 4 HIGH L...
• 463. REAR CARGO BOX / FENDERS
• 464. REAR BUMPER
• 465. BODY COMPONENT REMOVAL
• 466. REAR BUMPER
• 467. REAR FENDER / FENDER FLAIR REMOVAL XP
• 468. REAR FENDER FLARE / REAR FENDER REMOVAL ...
• 470. ROCKER PANELS, REAR CONSOLE AND FLOOR XP
• 473. DECAL REPLACEMENT
• 478. GENERAL INFORMATION
• 479. INSTRUMENT CLUSTER
• 481. INFORMATION DISPLAY AREA
• 484. DIAGNOSTIC MODE
• 486. SWITCHES
• 487. IGNITION (KEY) SWITCH
• 488. TRANSMISSION (GEAR POSITION) SWITCH
• 489. SEAT BELT SWITCH
• 490. ALL WHEEL DRIVE COIL
• 491. VEHICLE SPEED SENSOR
• 492. IGNITION COIL
• 493. CHARGING SYSTEM
• 494. STATOR (ALTERNATOR) REPLACEMENT
• 495. REGULATOR / RECTIFIER
• 496. CHARGING SYSTEM TESTING FLOW CHART
• 497. BATTERY
• 498. BATTERY REMOVAL / INSTALLATION
• 499. CHARGING PROCEDURE
• 500. LIGHTING SYSTEM
• 501. HEADLAMP INSTALLATION
• 502. COOLING SYSTEM
• 503. ECT SENSOR REPLACEMENT
• 504. STARTING SYSTEM
• 505. STARTER MOTOR INSTALLATION
• 506. STARTER FAILS TO TURN OVER THE ENGINE
• 507. ELECTRONIC POWER STEERING
• 508. PROPER EPS SYSTEM DIAGNOSING
• 509. EPS SYSTEM BREAKOUT
• 510. EPS TROUBLESHOOTING (POWER STEERING NON-...
• 511. EPS TROUBLESHOOTING (POWER STEERING NON-...
• 512. EPS TROUBLESHOOTING (USING DIGITAL WRENC...
• 513. FUSES / RELAYS
• 514. FUSE BOX DETAIL (2014)
• 515. FUSE BOX DETAIL (2015-2016)
• 517. CAN SYSTEM
• 518. BREAK-OUT DIAGRAMS
• 519. VEHICLE SPEED SENSOR
• 520. COOLING SYSTEM
• 521. UNSWITCHED CHASSIS POWER
• 522. KEY-ON BATTERY POWER
• 523. LIGHTS