Name: Polaris RZR XP 1000 Service Manual
Brand: Polaris
Rating: 5 (1 reviews)

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5. Table of Contents
8. VEHICLE IDENTIFICATION
9. VEHICLE IDENTIFICATION NUMBER
10. VEHICLE AND ENGINE SERIAL NUMBER LOCATIO...
11. VEHICLE INFORMATION
12. SPECIAL TOOLS
16. GENERAL SPECIFICATIONS
17. RZR XP 1000 CLUTCH CHART
19. RZR XP 4 1000
20. RZR 1000 XP4
22. RZR XP 1000 EPS HIGH LIFTER
24. 2015 RZR XP 1000 HIGH LIFTER
26. 2015 RZR XP 1000 DESERT EDITION CLUTCH C...
27. MISC. SPECIFICATIONS AND CHARTS
29. CONVERSION TABLE
30. STANDARD BOLT TORQUE SPECIFICATION
31. SAE TAP / DRILL SIZES
32. DECIMAL EQUIVALENTS
35. PERIODIC MAINTENANCE CHART
36. PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL
37. 50 - 500 Hour Maintenance Interval
38. MAINTENANCE QUICK REFERENCE
39. MAINTENANCE QUICK REFERENCE, CONTINUED
40. GREASE LUBRICATION POINTS
41. LUBRICANTS / SERVICE PRODUCTS
42. GENERAL VEHICLE INSPECTION AND MAINTENAN...
44. FUEL SYSTEM AND AIR INTAKE
45. FUEL PUMP / FUEL FILTERS
46. THROTTLE PEDAL INSPECTION
47. AIR FILTER SERVICE
48. AIR BOX / AIR FILTER ASSEMBLY VIEW
49. ENGINE
50. ENGINE OIL AND FILTER CHANGE
51. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
52. ENGINE CYLINDER LEAKDOWN TEST
55. TRANSMISSION AND FRONT GEARCASE
56. FRONT GEARCASE LUBRICATION
58. COOLING SYSTEM
59. COOLING SYSTEM PRESSURE TEST
60. RADIATOR INSPECTION / CLEANING
61. COOLANT DRAIN / FILL
62. PVT / FINAL DRIVE / WHEEL AND TIRE
63. DRIVE SHAFT BOOT INSPECTION
64. WHEEL INSTALLATION
65. BEADLOCK RIMS (DESERT EDITION)
66. ELECTRICAL AND IGNITION SYSTEM
67. BATTERY INSTALLATION
68. SPARK PLUG SERVICE
69. STEERING
70. TIE ROD END / WHEEL HUB INSPECTION
71. WHEEL TOE ADJUSTMENT
72. SUSPENSION (WALKER EVANS™)
73. SHOCK COMPRESSION ADJUSTMENT
74. BRAKE SYSTEM
75. BRAKE HOSE AND FITTING INSPECTION
79. GENERAL INFORMATION
80. OIL PRESSURE TEST
81. ENGINE OIL FLOW CHART
82. ENGINE SERVICE SPECIFICATIONS
84. ENGINE DETAIL - TORQUE VALUES / SEQUENCE...
85. BALANCE SHAFT / CONNECTING RODS / CRANKC...
86. CYLINDER / OIL COOLER / OIL FILTER / OIL...
87. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / I...
88. SPARK PLUGS / STARTER / THERMOSTAT HOUSI...
89. COOLING SYSTEM PRESSURE TEST
90. COOLING SYSTEM PRESSURE CAP TEST
91. THERMOSTAT REPLACEMENT
93. COOLING SYSTEM ASSEMBLY VIEW
94. COOLING SYSTEM BLEEDING PROCEDURE
95. WATER PUMP REMOVAL
97. WATER PUMP SERVICE
100. ENGINE SERVICE
104. ENGINE INSTALLATION
107. ENGINE MOUNTING AND TORQUE VALUES
108. ENGINE BREAK-IN PERIOD
109. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
111. CAMSHAFT SPROCKET INSPECTION
113. CYLINDER HEAD REMOVAL
114. CYLINDER HEAD DISASSEMBLY
115. VALVE INSPECTION
116. COMBUSTION CHAMBER CLEANING
117. VALVE SEAT RECONDITIONING
120. ENGINE DISASSEMBLY / INSPECTION - LOWER ...
121. WATER PUMP HOUSING REMOVAL
122. FLYWHEEL REMOVAL
123. STARTER ONE-WAY CLUTCH DISASSEMBLY
124. CRANKCASE DISASSEMBLY / INSPECTION
126. BALANCE SHAFT REMOVAL / INSPECTION
127. CRANKSHAFT REMOVAL / INSPECTION
130. CRANKCASE INSPECTION
131. CYLINDER INSPECTION
132. CYLINDER / PISTON REMOVAL
133. PISTON DISASSEMBLY / INSPECTION
134. PISTON RING REMOVAL
135. PISTON RING INSTALLED GAP
136. CONNECTING ROD INSPECTION
138. ENGINE ASSEMBLY - LOWER END
139. CONNECTING ROD BEARING SELECTION
140. UPPER CRANKCASE PREPARATION
142. PISTON / CONNECTING ROD ASSEMBLY
143. CYLINDER / PISTON INSTALLATION
144. CRANKSHAFT INSTALLATION
146. BALANCE SHAFT INSTALLATION
147. CRANKCASE ASSEMBLY
151. STARTER ONE-WAY CLUTCH ASSEMBLY
152. FLYWHEEL INSTALLATION
153. ENGINE ASSEMBLY - TOP END
154. CYLINDER HEAD INSTALLATION
155. CAMSHAFT INSTALLATION / TIMING
159. CAMSHAFT TIMING - QUICK REFERENCE
160. VALVE CLEARANCE ADJUSTMENT
162. INTAKE VALVE LASH - TAPPET SELECTION MAT...
163. EXHAUST VALVE LASH - TAPPET SELECTION MA...
164. VALVE COVER INSTALLATION
165. TROUBLESHOOTING
169. GENERAL INFORMATION
171. EFI SERVICE NOTES
172. EFI SYSTEM ASSEMBLY VIEW
173. EFI SYSTEM COMPONENT LOCATIONS
175. FUEL TANK
176. FUEL LINE REMOVAL / INSTALLATION
179. FUEL TANK INSTALLATION
180. FUEL TANK REMOVAL RZR XP 4 1000
182. FUEL TANK INSTALLATION RZR XP 4 1000
183. ELECTRONIC FUEL INJECTION
184. ELECTRONIC CONTROL UNIT (ECU)
186. FUEL INJECTORS
187. FUEL INJECTOR TEST
191. FUEL PUMP
192. FUEL PUMP TEST
193. FUEL PUMP REPLACEMENT
197. TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE...
198. CRANKSHAFT POSITION SENSOR (CPS)
199. CPS REPLACEMENT
200. THROTTLE BODY ASSEMBLY
202. ELECTRONIC THROTTLE CONTROL (ETC)
203. PEDAL POSITION SENSOR (PPS)
205. OXYGEN SENSOR (MY15 ONLY)
206. EFI DIAGNOSTICS
211. EFI TROUBLESHOOTING
212. DIGITAL WRENCH® OPERATION
213. DIGITAL WRENCH SOFTWARE VERSION AND UPDA...
214. DIGITAL WRENCH® COMMUNICATION ERRORS
215. GUIDED DIAGNOSTICS
216. DIGITAL WRENCH® FEATURE MAP
217. ECU REPLACEMENT
222. GENERAL INFORMATION
223. RZR XP 1000 CLUTCH CHART
224. PVT SYSTEM OVERVIEW
225. DRIVEN CLUTCH OPERATION
226. MAINTENANCE / INSPECTION
227. OVERHEATING / DIAGNOSIS
228. PVT SYSTEM SERVICE
230. PVT COVERS AND DUCTING COMPONENTS (HIGH ...
231. PVT DISASSEMBLY
233. PVT ASSEMBLY
235. DRIVE BELT
236. BELT INSPECTION
237. DRIVE CLUTCH SERVICE
238. DRIVE CLUTCH DISASSEMBLY / INSPECTION
239. NEEDLE BEARING INSPECTION
240. SHIFT WEIGHT INSPECTION
241. SPIDER REMOVAL
242. CLUTCH INSPECTION
243. MOVEABLE SHEAVE BUSHING INSPECTION
245. DRIVE CLUTCH ASSEMBLY
248. DRIVEN CLUTCH SERVICE
251. BUSHING SERVICE
252. CLUTCH ASSEMBLY
256. ASSEMBLY VIEW
257. TROUBLESHOOTING
260. SPECIFICATIONS
261. TRANSMISSION MOUNTING AND TORQUE VALUES
262. SHIFT LEVER
263. SHIFT CABLE
264. TRANSMISSION SERVICE
267. TRANSMISSION INSTALLATION
270. TRANSMISSION DISASSEMBLY
274. DIFFERENTIAL OPERATION (TURF MODE MODELS...
276. PLANETARY DIFFERENTIAL DISASSEMBLY (TURF...
277. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
279. PLANETARY DIFFERENTIAL ASSEMBLY (TURF MO...
280. GEAR / SHAFT / BEARING INSPECTION
281. TRANSMISSION ASSEMBLY / SNORKEL GEAR BAC...
287. TRANSMISSION ASSEMBLY VIEW
289. TRANSMISSION SERVICE (INT
290. TRANSMISSION DISASSEMBLY
296. PLANETARY DIFFERENTIAL DISASSEMBLY (TURF...
297. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
299. PLANETARY DIFFERENTIAL ASSEMBLY (TURF MO...
300. GEAR / SHAFT / BEARING INSPECTION
301. SNORKEL GEAR BACKLASH PROCEDURE
309. TRANSMISSION ASSEMBLY VIEW (TURF MODE MO...
311. TROUBLESHOOTING
314. GENERAL INFORMATION
315. BEARING CARRIER
316. FRONT BEARING REPLACEMENT
317. FRONT BEARING CARRIER INSTALLATION
318. REAR BEARING CARRIER INSPECTION / REMOVA...
320. REAR BEARING REPLACEMENT
321. REAR BEARING CARRIER INSTALLATION
323. DRIVE SHAFT
324. FRONT DRIVE SHAFT INSTALLATION
325. REAR DRIVE SHAFT REMOVAL
326. REAR DRIVE SHAFT INSTALLATION
328. DRIVE SHAFT / CV JOINT HANDLING TIPS
329. OUTER CV JOINT / BOOT REPLACEMENT
331. INNER PLUNGING JOINT / BOOT REPLACEMENT
334. DRIVE SHAFT ASSEMBLY VIEW
335. FRONT PROPSHAFT SERVICE
336. FRONT PROP SHAFT INSTALLATION
337. REAR PROP SHAFT INSTALLATION
338. Rear Prop Shaft Removal XP 4
339. REAR PROP SHAFT INSTALLATION
340. SUPPORT BEARING REPLACEMENT
341. PROP SHAFT U-JOINT SERVICE
343. ALL WHEEL DRIVE OPERATION
344. AWD DIAGNOSIS
345. FRONT GEARCASE REMOVAL
346. FRONT GEARCASE DISASSEMBLY / INSPECTION
349. FRONT GEARCASE ASSEMBLY
351. FRONT GEARCASE INSTALLATION
353. WHEEL HUBS
354. BEADLOCK RIMS (DESERT EDITION)
357. GENERAL INFORMATION
359. STEERING ASSEMBLY
360. STEERING WHEEL REMOVAL (NON-EPS MODELS)
361. STEERING SHAFT BEARING REPLACEMENT
363. ELECTRONIC POWER STEERING ASSEMBLY
365. STEERING WHEEL REMOVAL (EPS MODELS)
367. LOWER STEERING SHAFT REMOVAL (EPS MODELS...
368. POWER STEERING UNIT INSTALLATION
369. UPPER STEERING SHAFT INSTALLATION (EPS M...
370. FRONT A-ARMS
373. BALL JOINT SERVICE
374. BALL JOINT INSTALLATION
375. REAR RADIUS RODS
376. REAR TRAILING ARM
378. TRAILING ARM SPHERICAL BEARING REPLACEME...
379. REAR SUSPENSION ASSEMBLY VIEW
380. REAR STABILIZER BAR
381. SHOCKS / SPRINGS / FASTENERS
382. SHOCK REMOVAL / INSTALLATION
383. WALKER EVANS™SHOCK ASSEMBLY VIEWS
384. WALKER EVANS™ 2.5" REAR SHOCK
385. WALKER EVANS™ SHOCK SERVICE
387. REAR SHOCK SERVICE INFORMATION
390. SPECIAL TOOLS
393. WALKER EVANS™ SHOCK ASSEMBLY
401. GENERAL INFORMATION
402. TORQUE SPECIFICATIONS
403. BRAKE NOISE TROUBLESHOOTING
404. BRAKE SYSTEM ASSEMBLY VIEW
405. MASTER CYLINDER
406. MASTER CYLINDER INSTALLATION
408. BRAKE PEDAL LEVER
409. PARKING BRAKE (INT'L MODEL)
410. PARKING BRAKE INSPECTION
411. PARKING BRAKE CALIPER
414. PARKING BRAKE DISC
417. FRONT BRAKE PADS
418. PAD INSPECTION
419. BRAKE BURNISHING PROCEDURE
420. FRONT CALIPER SERVICE
421. CALIPER REMOVAL
422. CALIPER DISASSEMBLY
423. CALIPER INSPECTION
424. CALIPER INSTALLATION
425. FRONT BRAKE DISC
426. DISC REPLACEMENT
427. REAR BRAKE PADS
428. PAD INSPECTION
429. PAD ASSEMBLY / INSTALLATION
430. BRAKE BURNISHING PROCEDURE
431. REAR CALIPER SERVICE
432. CALIPER REMOVAL
433. CALIPER DISASSEMBLY
434. CALIPER ASSEMBLY
436. REAR BRAKE DISC
438. TROUBLESHOOTING
440. GENERAL INFORMATION
441. BODY ASSEMBLY VIEWS
442. Cab Frame Assembly XP 4
443. DOORS
444. DOORS
445. DOORS HIGH LIFTER
446. DASH INSTRUMENTS / CONTROLS
447. DASH INSTRUMENTS / CONTROLS HIGH LIFTER
448. HOOD / FRONT BODY WORK
449. CHASSIS / MAIN FRAME XP / HIGH LIFTER
450. Chassis / Main Frame XP 4
451. SEAT ASSEMBLY FRONT
452. SEAT ASSEMBLY REAR
453. FLOOR / ROCKER PANELS XP / HIGH LIFTER
454. Floor / Rocker Panels XP 4
455. REAR CARGO BOX / FENDERS
456. REAR BUMPER
457. BODY COMPONENT REMOVAL
458. REAR BUMPER
459. REAR FENDER / FENDER FLARE REMOVAL XP / ...
460. REAR FENDER FLARE / REAR FENDER REMOVAL ...
462. ROCKER PANELS, REAR CONSOLE AND FLOOR XP
465. DECAL REPLACEMENT
469. GENERAL INFORMATION
470. INSTRUMENT CLUSTER
472. RIDER INFORMATION DISPLAY
473. INFORMATION DISPLAY AREA
476. DIAGNOSTIC MODE
478. INSTRUMENT CLUSTER REMOVAL
479. SWITCHES
480. IGNITION (KEY) SWITCH
481. TRANSMISSION (GEAR POSITION) SWITCH
482. SEAT BELT SWITCH
483. ALL WHEEL DRIVE COIL
484. VEHICLE SPEED SENSOR
485. IGNITION COIL
486. IGNITION COIL TESTS
487. LIGHTING SYSTEM
488. HEADLAMP REPLACEMENT
489. HEADLAMP INSTALLATION
490. DASH LIGHT
491. COOLING SYSTEM
492. ECT SENSOR TEST
493. FUSE / RELAY BOX
494. FUSE BOX DETAIL
495. RELAY OPERATION
497. CHARGING SYSTEM
498. CHARGING SYSTEM STATOR (ALTERNATOR) TEST...
499. STATOR (ALTERNATOR) REPLACEMENT
500. CHARGING SYSTEM TESTING FLOW CHART
501. BATTERY
502. BATTERY REMOVAL / INSTALLATION
503. LOAD TEST
504. STARTING SYSTEM
505. STARTER MOTOR REMOVAL
506. STARTER SOLENOID BENCH TEST
507. ELECTRONIC POWER STEERING (EPS)
508. EPS SYSTEM BREAKOUT
509. EPS TROUBLESHOOTING (POWER STEERING NON-...
510. EPS TROUBLESHOOTING (POWER STEERING NON-...
511. EPS TROUBLESHOOTING (USING DIGITAL WRENC...
512. ELECTRICAL SYSTEM BREAKOUT DIAGRAMS
513. VEHICLE SPEED SENSOR
514. COOLING SYSTEM
515. UNSWITCHED CHASSIS POWER
516. KEY-ON BATTERY POWER
517. LIGHTS
518. CHARGING SYSTEM

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5. Table of Contents
8. VEHICLE IDENTIFICATION
9. VEHICLE IDENTIFICATION NUMBER
10. VEHICLE AND ENGINE SERIAL NUMBER LOCATIO...
11. VEHICLE INFORMATION
12. SPECIAL TOOLS
16. GENERAL SPECIFICATIONS
17. RZR XP 1000 CLUTCH CHART
19. RZR XP 4 1000
20. RZR 1000 XP4
22. RZR XP 1000 EPS HIGH LIFTER
24. 2015 RZR XP 1000 HIGH LIFTER
26. 2015 RZR XP 1000 DESERT EDITION CLUTCH C...
27. MISC. SPECIFICATIONS AND CHARTS
29. CONVERSION TABLE
30. STANDARD BOLT TORQUE SPECIFICATION
31. SAE TAP / DRILL SIZES
32. DECIMAL EQUIVALENTS
35. PERIODIC MAINTENANCE CHART
36. PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL
37. 50 - 500 Hour Maintenance Interval
38. MAINTENANCE QUICK REFERENCE
39. MAINTENANCE QUICK REFERENCE, CONTINUED
40. GREASE LUBRICATION POINTS
41. LUBRICANTS / SERVICE PRODUCTS
42. GENERAL VEHICLE INSPECTION AND MAINTENAN...
44. FUEL SYSTEM AND AIR INTAKE
45. FUEL PUMP / FUEL FILTERS
46. THROTTLE PEDAL INSPECTION
47. AIR FILTER SERVICE
48. AIR BOX / AIR FILTER ASSEMBLY VIEW
49. ENGINE
50. ENGINE OIL AND FILTER CHANGE
51. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
52. ENGINE CYLINDER LEAKDOWN TEST
55. TRANSMISSION AND FRONT GEARCASE
56. FRONT GEARCASE LUBRICATION
58. COOLING SYSTEM
59. COOLING SYSTEM PRESSURE TEST
60. RADIATOR INSPECTION / CLEANING
61. COOLANT DRAIN / FILL
62. PVT / FINAL DRIVE / WHEEL AND TIRE
63. DRIVE SHAFT BOOT INSPECTION
64. WHEEL INSTALLATION
65. BEADLOCK RIMS (DESERT EDITION)
66. ELECTRICAL AND IGNITION SYSTEM
67. BATTERY INSTALLATION
68. SPARK PLUG SERVICE
69. STEERING
70. TIE ROD END / WHEEL HUB INSPECTION
71. WHEEL TOE ADJUSTMENT
72. SUSPENSION (WALKER EVANS™)
73. SHOCK COMPRESSION ADJUSTMENT
74. BRAKE SYSTEM
75. BRAKE HOSE AND FITTING INSPECTION
79. GENERAL INFORMATION
80. OIL PRESSURE TEST
81. ENGINE OIL FLOW CHART
82. ENGINE SERVICE SPECIFICATIONS
84. ENGINE DETAIL - TORQUE VALUES / SEQUENCE...
85. BALANCE SHAFT / CONNECTING RODS / CRANKC...
86. CYLINDER / OIL COOLER / OIL FILTER / OIL...
87. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / I...
88. SPARK PLUGS / STARTER / THERMOSTAT HOUSI...
89. COOLING SYSTEM PRESSURE TEST
90. COOLING SYSTEM PRESSURE CAP TEST
91. THERMOSTAT REPLACEMENT
93. COOLING SYSTEM ASSEMBLY VIEW
94. COOLING SYSTEM BLEEDING PROCEDURE
95. WATER PUMP REMOVAL
97. WATER PUMP SERVICE
100. ENGINE SERVICE
104. ENGINE INSTALLATION
107. ENGINE MOUNTING AND TORQUE VALUES
108. ENGINE BREAK-IN PERIOD
109. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
111. CAMSHAFT SPROCKET INSPECTION
113. CYLINDER HEAD REMOVAL
114. CYLINDER HEAD DISASSEMBLY
115. VALVE INSPECTION
116. COMBUSTION CHAMBER CLEANING
117. VALVE SEAT RECONDITIONING
120. ENGINE DISASSEMBLY / INSPECTION - LOWER ...
121. WATER PUMP HOUSING REMOVAL
122. FLYWHEEL REMOVAL
123. STARTER ONE-WAY CLUTCH DISASSEMBLY
124. CRANKCASE DISASSEMBLY / INSPECTION
126. BALANCE SHAFT REMOVAL / INSPECTION
127. CRANKSHAFT REMOVAL / INSPECTION
130. CRANKCASE INSPECTION
131. CYLINDER INSPECTION
132. CYLINDER / PISTON REMOVAL
133. PISTON DISASSEMBLY / INSPECTION
134. PISTON RING REMOVAL
135. PISTON RING INSTALLED GAP
136. CONNECTING ROD INSPECTION
138. ENGINE ASSEMBLY - LOWER END
139. CONNECTING ROD BEARING SELECTION
140. UPPER CRANKCASE PREPARATION
142. PISTON / CONNECTING ROD ASSEMBLY
143. CYLINDER / PISTON INSTALLATION
144. CRANKSHAFT INSTALLATION
146. BALANCE SHAFT INSTALLATION
147. CRANKCASE ASSEMBLY
151. STARTER ONE-WAY CLUTCH ASSEMBLY
152. FLYWHEEL INSTALLATION
153. ENGINE ASSEMBLY - TOP END
154. CYLINDER HEAD INSTALLATION
155. CAMSHAFT INSTALLATION / TIMING
159. CAMSHAFT TIMING - QUICK REFERENCE
160. VALVE CLEARANCE ADJUSTMENT
162. INTAKE VALVE LASH - TAPPET SELECTION MAT...
163. EXHAUST VALVE LASH - TAPPET SELECTION MA...
164. VALVE COVER INSTALLATION
165. TROUBLESHOOTING
169. GENERAL INFORMATION
171. EFI SERVICE NOTES
172. EFI SYSTEM ASSEMBLY VIEW
173. EFI SYSTEM COMPONENT LOCATIONS
175. FUEL TANK
176. FUEL LINE REMOVAL / INSTALLATION
179. FUEL TANK INSTALLATION
180. FUEL TANK REMOVAL RZR XP 4 1000
182. FUEL TANK INSTALLATION RZR XP 4 1000
183. ELECTRONIC FUEL INJECTION
184. ELECTRONIC CONTROL UNIT (ECU)
186. FUEL INJECTORS
187. FUEL INJECTOR TEST
191. FUEL PUMP
192. FUEL PUMP TEST
193. FUEL PUMP REPLACEMENT
197. TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE...
198. CRANKSHAFT POSITION SENSOR (CPS)
199. CPS REPLACEMENT
200. THROTTLE BODY ASSEMBLY
202. ELECTRONIC THROTTLE CONTROL (ETC)
203. PEDAL POSITION SENSOR (PPS)
205. OXYGEN SENSOR (MY15 ONLY)
206. EFI DIAGNOSTICS
211. EFI TROUBLESHOOTING
212. DIGITAL WRENCH® OPERATION
213. DIGITAL WRENCH SOFTWARE VERSION AND UPDA...
214. DIGITAL WRENCH® COMMUNICATION ERRORS
215. GUIDED DIAGNOSTICS
216. DIGITAL WRENCH® FEATURE MAP
217. ECU REPLACEMENT
222. GENERAL INFORMATION
223. RZR XP 1000 CLUTCH CHART
224. PVT SYSTEM OVERVIEW
225. DRIVEN CLUTCH OPERATION
226. MAINTENANCE / INSPECTION
227. OVERHEATING / DIAGNOSIS
228. PVT SYSTEM SERVICE
230. PVT COVERS AND DUCTING COMPONENTS (HIGH ...
231. PVT DISASSEMBLY
233. PVT ASSEMBLY
235. DRIVE BELT
236. BELT INSPECTION
237. DRIVE CLUTCH SERVICE
238. DRIVE CLUTCH DISASSEMBLY / INSPECTION
239. NEEDLE BEARING INSPECTION
240. SHIFT WEIGHT INSPECTION
241. SPIDER REMOVAL
242. CLUTCH INSPECTION
243. MOVEABLE SHEAVE BUSHING INSPECTION
245. DRIVE CLUTCH ASSEMBLY
248. DRIVEN CLUTCH SERVICE
251. BUSHING SERVICE
252. CLUTCH ASSEMBLY
256. ASSEMBLY VIEW
257. TROUBLESHOOTING
260. SPECIFICATIONS
261. TRANSMISSION MOUNTING AND TORQUE VALUES
262. SHIFT LEVER
263. SHIFT CABLE
264. TRANSMISSION SERVICE
267. TRANSMISSION INSTALLATION
270. TRANSMISSION DISASSEMBLY
274. DIFFERENTIAL OPERATION (TURF MODE MODELS...
276. PLANETARY DIFFERENTIAL DISASSEMBLY (TURF...
277. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
279. PLANETARY DIFFERENTIAL ASSEMBLY (TURF MO...
280. GEAR / SHAFT / BEARING INSPECTION
281. TRANSMISSION ASSEMBLY / SNORKEL GEAR BAC...
287. TRANSMISSION ASSEMBLY VIEW
289. TRANSMISSION SERVICE (INT
290. TRANSMISSION DISASSEMBLY
296. PLANETARY DIFFERENTIAL DISASSEMBLY (TURF...
297. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
299. PLANETARY DIFFERENTIAL ASSEMBLY (TURF MO...
300. GEAR / SHAFT / BEARING INSPECTION
301. SNORKEL GEAR BACKLASH PROCEDURE
309. TRANSMISSION ASSEMBLY VIEW (TURF MODE MO...
311. TROUBLESHOOTING
314. GENERAL INFORMATION
315. BEARING CARRIER
316. FRONT BEARING REPLACEMENT
317. FRONT BEARING CARRIER INSTALLATION
318. REAR BEARING CARRIER INSPECTION / REMOVA...
320. REAR BEARING REPLACEMENT
321. REAR BEARING CARRIER INSTALLATION
323. DRIVE SHAFT
324. FRONT DRIVE SHAFT INSTALLATION
325. REAR DRIVE SHAFT REMOVAL
326. REAR DRIVE SHAFT INSTALLATION
328. DRIVE SHAFT / CV JOINT HANDLING TIPS
329. OUTER CV JOINT / BOOT REPLACEMENT
331. INNER PLUNGING JOINT / BOOT REPLACEMENT
334. DRIVE SHAFT ASSEMBLY VIEW
335. FRONT PROPSHAFT SERVICE
336. FRONT PROP SHAFT INSTALLATION
337. REAR PROP SHAFT INSTALLATION
338. Rear Prop Shaft Removal XP 4
339. REAR PROP SHAFT INSTALLATION
340. SUPPORT BEARING REPLACEMENT
341. PROP SHAFT U-JOINT SERVICE
343. ALL WHEEL DRIVE OPERATION
344. AWD DIAGNOSIS
345. FRONT GEARCASE REMOVAL
346. FRONT GEARCASE DISASSEMBLY / INSPECTION
349. FRONT GEARCASE ASSEMBLY
351. FRONT GEARCASE INSTALLATION
353. WHEEL HUBS
354. BEADLOCK RIMS (DESERT EDITION)
357. GENERAL INFORMATION
359. STEERING ASSEMBLY
360. STEERING WHEEL REMOVAL (NON-EPS MODELS)
361. STEERING SHAFT BEARING REPLACEMENT
363. ELECTRONIC POWER STEERING ASSEMBLY
365. STEERING WHEEL REMOVAL (EPS MODELS)
367. LOWER STEERING SHAFT REMOVAL (EPS MODELS...
368. POWER STEERING UNIT INSTALLATION
369. UPPER STEERING SHAFT INSTALLATION (EPS M...
370. FRONT A-ARMS
373. BALL JOINT SERVICE
374. BALL JOINT INSTALLATION
375. REAR RADIUS RODS
376. REAR TRAILING ARM
378. TRAILING ARM SPHERICAL BEARING REPLACEME...
379. REAR SUSPENSION ASSEMBLY VIEW
380. REAR STABILIZER BAR
381. SHOCKS / SPRINGS / FASTENERS
382. SHOCK REMOVAL / INSTALLATION
383. WALKER EVANS™SHOCK ASSEMBLY VIEWS
384. WALKER EVANS™ 2.5" REAR SHOCK
385. WALKER EVANS™ SHOCK SERVICE
387. REAR SHOCK SERVICE INFORMATION
390. SPECIAL TOOLS
393. WALKER EVANS™ SHOCK ASSEMBLY
401. GENERAL INFORMATION
402. TORQUE SPECIFICATIONS
403. BRAKE NOISE TROUBLESHOOTING
404. BRAKE SYSTEM ASSEMBLY VIEW
405. MASTER CYLINDER
406. MASTER CYLINDER INSTALLATION
408. BRAKE PEDAL LEVER
409. PARKING BRAKE (INT'L MODEL)
410. PARKING BRAKE INSPECTION
411. PARKING BRAKE CALIPER
414. PARKING BRAKE DISC
417. FRONT BRAKE PADS
418. PAD INSPECTION
419. BRAKE BURNISHING PROCEDURE
420. FRONT CALIPER SERVICE
421. CALIPER REMOVAL
422. CALIPER DISASSEMBLY
423. CALIPER INSPECTION
424. CALIPER INSTALLATION
425. FRONT BRAKE DISC
426. DISC REPLACEMENT
427. REAR BRAKE PADS
428. PAD INSPECTION
429. PAD ASSEMBLY / INSTALLATION
430. BRAKE BURNISHING PROCEDURE
431. REAR CALIPER SERVICE
432. CALIPER REMOVAL
433. CALIPER DISASSEMBLY
434. CALIPER ASSEMBLY
436. REAR BRAKE DISC
438. TROUBLESHOOTING
440. GENERAL INFORMATION
441. BODY ASSEMBLY VIEWS
442. Cab Frame Assembly XP 4
443. DOORS
444. DOORS
445. DOORS HIGH LIFTER
446. DASH INSTRUMENTS / CONTROLS
447. DASH INSTRUMENTS / CONTROLS HIGH LIFTER
448. HOOD / FRONT BODY WORK
449. CHASSIS / MAIN FRAME XP / HIGH LIFTER
450. Chassis / Main Frame XP 4
451. SEAT ASSEMBLY FRONT
452. SEAT ASSEMBLY REAR
453. FLOOR / ROCKER PANELS XP / HIGH LIFTER
454. Floor / Rocker Panels XP 4
455. REAR CARGO BOX / FENDERS
456. REAR BUMPER
457. BODY COMPONENT REMOVAL
458. REAR BUMPER
459. REAR FENDER / FENDER FLARE REMOVAL XP / ...
460. REAR FENDER FLARE / REAR FENDER REMOVAL ...
462. ROCKER PANELS, REAR CONSOLE AND FLOOR XP
465. DECAL REPLACEMENT
469. GENERAL INFORMATION
470. INSTRUMENT CLUSTER
472. RIDER INFORMATION DISPLAY
473. INFORMATION DISPLAY AREA
476. DIAGNOSTIC MODE
478. INSTRUMENT CLUSTER REMOVAL
479. SWITCHES
480. IGNITION (KEY) SWITCH
481. TRANSMISSION (GEAR POSITION) SWITCH
482. SEAT BELT SWITCH
483. ALL WHEEL DRIVE COIL
484. VEHICLE SPEED SENSOR
485. IGNITION COIL
486. IGNITION COIL TESTS
487. LIGHTING SYSTEM
488. HEADLAMP REPLACEMENT
489. HEADLAMP INSTALLATION
490. DASH LIGHT
491. COOLING SYSTEM
492. ECT SENSOR TEST
493. FUSE / RELAY BOX
494. FUSE BOX DETAIL
495. RELAY OPERATION
497. CHARGING SYSTEM
498. CHARGING SYSTEM STATOR (ALTERNATOR) TEST...
499. STATOR (ALTERNATOR) REPLACEMENT
500. CHARGING SYSTEM TESTING FLOW CHART
501. BATTERY
502. BATTERY REMOVAL / INSTALLATION
503. LOAD TEST
504. STARTING SYSTEM
505. STARTER MOTOR REMOVAL
506. STARTER SOLENOID BENCH TEST
507. ELECTRONIC POWER STEERING (EPS)
508. EPS SYSTEM BREAKOUT
509. EPS TROUBLESHOOTING (POWER STEERING NON-...
510. EPS TROUBLESHOOTING (POWER STEERING NON-...
511. EPS TROUBLESHOOTING (USING DIGITAL WRENC...
512. ELECTRICAL SYSTEM BREAKOUT DIAGRAMS
513. VEHICLE SPEED SENSOR
514. COOLING SYSTEM
515. UNSWITCHED CHASSIS POWER
516. KEY-ON BATTERY POWER
517. LIGHTS
518. CHARGING SYSTEM

Description

The Service Manual of the Polaris RZR XP 1000 and RZR XP4 1000 Offroad Vehicle provides detailed instructions for servicing and maintaining your vehicle. This manual contains information for engine identification and serial numbers, safety instructions, operating instructions, and information on how to maintain and service your vehicle. It also includes troubleshooting guides and step-by-step instructions for basic repairs and maintenance. The Service Manual provides information on the engine, transmission, brakes, suspension, electrical systems, and other components of the vehicle. It also provides detailed instructions on how to properly drive and use the vehicle, including tips on how to ride safely and how to properly maintain the vehicle. The Service Manual also covers maintenance and service procedures, such as changing the oil, air filter, and spark plugs, as well as inspecting and replacing the tires, brakes, and other components. Additionally, it includes detailed instructions on how to properly use and care for the vehicle, including information on how to clean and check for wear and tear. With the Service Manual, you can be sure that your Polaris RZR XP 1000 and RZR XP4 1000 Offroad Vehicle is running optimally and safely.

Also for: RZR XP4 1000

File size: 50.37 MB

Created: January 31, 2023

Last updated: March 23, 2023