Polaris 2014 RZR XP 1000 Service Manual

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2014 RZR XP / XP 4 1000

Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent

version of this Service Manual is available in electronic format at www.polarisdealers.com.

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

technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from

the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the

service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper

tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service

Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful.

Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask

Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,

2100 Hwy 55, Medina, MN 55340.

Publication Printed August 2013 (PN 9924874 R02)

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Polaris 2014 RZR XP 1000

Page 1 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.
Page 2 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.
Page 3 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.
Page 4: Table Of Contents
GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
Page 6 ............1.6 MODEL: 2014 RZR XP 1000 / EPS / INT’L .
Page 7: Vehicle Identification
World Mfg. ID Individual Serial No. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 8: Vehicle And Engine Serial Number Location
GENERAL INFORMATION 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.
Page 9: Replacement Keys
SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 10: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/...
Page 11: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2014 RZR XP 1000 / EPS / INT’L CATEGORY DIMENSION / CAPACITY Length 119″ / 302.2 cm Width 64″ / 162.5 cm Height 73.75″ / 187.3 cm Wheel Base 90″ / 228.6 cm Ground Clearance 13.5″...
Page 12: 2014 Rzr Xp 1000 / Eps / Int'l
GENERAL INFORMATION 2014 RZR XP 1000 / EPS / INT’L DRIVETRAIN Transmission Type Polaris Automatic PVT ENGINE Shift Type In Line Shift - P/ H / L / N / R Domestic Twin Cyl., 4–Stroke, Platform Transmission Gear Ratios: DOHC High 10.73:1...
Page 13: Model: 2014 Rzr Xp 4 1000
Do not use this vehicle for towing. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 14 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS (if appl.) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 15: 2014 Rzr Xp 4 1000
GENERAL INFORMATION 2014 RZR XP / XP 4 1000 CLUTCH CHARTS CLUTCH CHART (2014 RZR XP 1000 / EPS / INT’L) SHIFT DRIVE DRIVEN ALTITUDE WEIGHT SPRING SPRING White / 0-1500 26-61 Orange (0-5000) (1323098) (3234452) (7043924) Meters (Feet) White /...
Page 16: Misc. Specifications And Charts
8 ft-lb (11 Nm) Door Fasteners Hub Castle Nut (front and 110 ft-lbs (149 Nm) rear) Drive Clutch Retaining Bolt 96 ft-lb (130 Nm) 1.11 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 17 5 ft-lb (7 Nm) Fasteners Stabilizer Bar Mounting 17 ft-lb (23 Nm) Water Pump Impeller 7 ft-lb (10 Nm) Bracket Bolts (rear) 1.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 18 7 ft-lb (10 Nm) Water Pump Cover Bolts (Apply Loctite® 204™ to bolt threads) Wheel Lug Nuts 120 ft-lbs (163 Nm) 1.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 20: Standard Bolt Torque Specification
177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 21: Sae Tap / Drill Sizes
2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 1.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 22: Decimal Equivalents
14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 1.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 24: Maintenance
......2.9 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS GENERAL VEHICLE INSPECTION AND MAINTENANCE ..........2.10 .
Page 26: Periodic Maintenance Chart
▶ = 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.
Page 27: Pre-Ride - 50 Hour Maintenance Interval
▶ 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. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 28: 50 - 500 Hour Maintenance Interval
▶ 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. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 29: Maintenance Quick Reference
- Under Front Hood / Access Panel Coolant bottle (Item 4). * More often under severe use, such as operation in water or under severe loads. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 30: Maintenance Quick Reference, Continued
Polaris AGL the fill hole threads (Item 3) * More often under severe use, such as operation in water or under severe loads. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 31: Grease Lubrication Points
Polaris All Season Grease Bushings each side of the vehicle (Item *There is no grease point on the upper control arm rear mount. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 32: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products PART PART DESCRIPTION DESCRIPTION Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) Loctite® Threadlock 242 2876244 PS-4 Synthetic 4-Cycle Engine Oil (Quart) 2871950 (6 ml.) (12 count)
Page 33: General Vehicle Inspection And Maintenance
4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK. 2.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 34: Fuel System And Air Intake
(Item 2) and an internal fine filter (Item 3) located before the pump regulator. 2.11 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 35: Fuel Lines
Replace line(s) if necessary. The throttle pedal should move freely and always return back to its idle position when released. Check throttle pedal periodically. 2.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 36: Engine Intake Pre-Filter Service
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. 2.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 37: Intake Duct Drain Inspection
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. 2.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 38: Air Box / Air Filter Assembly View
2. Drain Cap 7. Vent Hose 3. Airbox 8. Intake Tubes 4. Air Filter 9. Engine Intake Housing 5. Airbox Cover 2.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 39: Engine
4. Reinstall the dipstick and push it into place. Do not lock the dipstick The 2014 RZR XP 1000 engine has a wet-sump design, meaning the engine oil is contained in the bottom of the NOTE: Make certain the dipstick is inserted all crankcase.
Page 40: Engine Oil And Filter Change
5. Remove the seats and engine service panel to access the oil filter. Engine Oil Drain Plug: 12 ft-lbs (16 Nm) 2.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 41: Engine Crankcase Breather Hose Inspection
20. Reinstall the cargo box access panel, engine service panel and seats. 21. Dispose of used oil and filter properly. 2.18 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 42: Valve Clearance Inspection
5. Remove the spark plug wires to gain access to valve cover as shown below. NOTE: Remove spark plugs to aid engine rotation. 2.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 43 11. Repeat steps 18-20 until all eight valves have been and install the seat. inspected. 20. Start the engine to ensure proper operation. 21. Install the engine access panel. 2.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 44: Transmission And Front Gearcase
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. 2.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 45: Front Gearcase Lubrication
Maintain fluid level even with the bottom of the fill plug hole. 1. Position vehicle on a level surface. 2.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 46: Cooling System
11. Reinstall the fill plug and torque to specification. Overheating of engine could occur if air is not fully purged from system. Polaris Premium 60/40 Antifreeze is premixed and ready to use. Do not dilute with water. Front Gearcase Fill / Drain Plug Torque:...
Page 47: Coolant Level Inspection
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. 2.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 48: Cooling System Pressure Test
3. Check tightness and condition of all hose spring clamps. Replace if necessary. ITEM DESCRIPTION Recovery Bottle Engine Hoses Radiator Hoses To Thermostat Housing To Waterpump To Radiator 2.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 49: Radiator Inspection / Cleaning
8. Refer to Cooling System Bleeding Procedure, page 3.18. Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2871534) (Quart) (PN 2871323) (Gallon) 2.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 50: Pvt / Final Drive / Wheel And Tire
PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 2.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 51: Drive Shaft Boot Inspection
4. Elevate the appropriate side of the vehicle by placing affect vehicle handling. a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 2.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 52: Tire Pressure
10-30% of full potential. Charge battery according to “Charging Procedure”, page 10.36. Do not use the vehicle’s stator/alternator to charge a new battery. 2.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 53: Battery Charging / Off Season Storage
When reinstalling the battery, install the black (negative) cable last. 4. Remove the battery hold-down bracket (Item 2). 5. Lift the battery out of the vehicle. 2.30 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 54: Engine / Chassis Electrical Ground
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. 2.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 55: Steering
Due to the critical nature of the procedures outlined in 7. Clean with electrical contact cleaner or a glass bead this chapter, Polaris recommends steering component spark plug cleaner only. CAUTION: A wire brush or repair and adjustment be performed by an authorized coated abrasive should not be used.
Page 56: Tie Rod End / Wheel Hub Inspection
• Refer to Chapter 7 “Final Drive” for front hub service procedures. 2.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 57: Wheel Toe Adjustment
• Hold tie rod end to keep it from rotating. • Loosen jam nuts at both end of the tie rod. 2.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 58: Suspension (Walker Evans™)
The increased suspension height will negatively impact vehicle stability when operating without a load. 2.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 59: Shock Compression Adjustment
The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counter- clockwise will decrease damping. 2.36 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 60: Brake System
Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 2.37 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 64: General Information
Flywheel Puller PA-49316 (0° F to 120° F) Mity Vac™ Pressure Test Tool 2870975 Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature) Oil Filter Wrench PU-50105 10 PSI @ 1200 RPM Oil Pressure Gauge PV-43531 40 PSI @ 7000 RPM...
Page 65: Oil Pressure Test
Oil Pressure Gauge (PV-43531). 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.
Page 67: Engine Service Specifications
0.0590 ± 0.0039" (1.5 ± 0.10 mm) 0.0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 68 Crankshaft Runout Limit (PTO and MAG) (0.025 mm) Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm) Shaft 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 69: Engine Detail - Torque Values / Sequences / Assembly Notes
ENGINE ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES Main Engine Components - Torque Specification and Sequence 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 70: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
ENGINE Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 71: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
ENGINE Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump 3.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 72: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
ENGINE Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover 3.11 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 73: Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
ENGINE Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover 3.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 74: Engine Cooling System
WARNING flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Never remove pressure cap when engine is warm or Coolant is recommended for use in all cooling systems hot.
Page 75: Radiator Removal / Installation
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. 3.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 76: Thermostat Replacement
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. 3.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 77 Thermostat Cover Bolts: 7 ft-lb (10 Nm) 11. Be sure to properly fill and bleed cooling system as outlined in this chapter. 3.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 78: Cooling System Assembly View
13. Bypass Hose 4. Lower Radiator Hose 9. Upper Radiator Hose 14. Water Pump Outlet Hose 5. Fan Assembly 10. Recovery Bottle 3.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 79: Cooling System Bleeding Procedure
2. Remove the hood. 10. Remove the pressure cap. Add the necessary 3. Remove the recovery bottle cap (Item 1) and fill the amount of Polaris Premium Antifreeze to the radiator bottle to the MAX line. filler neck. 11. Open the bleed screw to allow any trapped air to escape.
Page 80: Water Pump Removal
14. Plug the water pump drive access hole in the engine block with a clean shop towel. 3.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 81 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) 3.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 82: Water Pump Service
6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 3.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 83 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. 3.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 84 10. Loctite 204 14. Drive Tab 18. Impeller 11. Mechanical Seal 15. Water Pump Shaft 19. Washer 12. O-Rings 16. Water Pump Housing 3.23 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 85: Engine Service
9. Remove lower mounting bolt (Item 1) from the left rear shock and discard the nut. Install a new nut upon assembly. 3.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 86 18. Remove the breather hose (Item 7) from the crankcase. NOTE: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 3.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 87 (Item 13) to the rear cross member. NOTE: It is not necessary to remove the bolts that retain bracket (Item transmission. 3.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 88 • Sleeve adapter for a 2″ bore engine stand: • (PU-50625) • Sleeve adapter for a 2.375″ bore engine stand: • (PW-47054) 3.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 89: Engine Installation
6. Align transmission joint mounting holes with the transmission front mounting holes. Starter Motor Bolts: 7 ft-lb (10 Nm) Trans Joint Bracket Bolts: 44 ft-lb (60 Nm) 3.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 90 13. Remove the clutch center distance tool. 9. Align the front transmission mounting holes with transmission joint bracket mounting holes on engine. 3.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 91 22. Install the breather hose to the crankcase. “Maintenance”). 23. Install the spark plug wires to the appropriate 37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 cylinder by referencing the MAG and PTO spark plug or PS-4 Extreme Duty Synthetic Engine Oil to the wire decals.
Page 92: Engine Mounting And Torque Values
39. Install the seats. returning vehicle to customer. 40. Start engine and check for any oil or coolant leaks. Engine Mounting and Torque Values 3.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 93: Engine Break-In Period
Oil Capacity * Approx. 2.5 Quarts (2.4 L) CAUTION Oil Filter Wrench Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic PU-50105 or 2.5” (64 mm) 4-Cycle Engine Oil. Never substitute or mix oil brands. Serious engine Oil Filter damage and voiding of warranty can result.
Page 94: Engine Disassembly / Inspection - Top End
4. Remove the remaining two bolts that retain the front should line up. camshaft carrier (Item 5) and carefully lift the carrier off the camshafts. 3.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 95: Camshaft Sprocket Inspection
10. Mark the intake (Item 11) and exhaust (Item 12) camshafts to ensure proper assembly. 11. Carefully remove camshafts from the cylinder head. 3.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 96 Replace cylinder head if worn. 3. Visually inspect each camshaft journal for scoring, wear or damage. Camshaft Carrier Bolts: 89 in-lbs (10 Nm) 3.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 97: Cylinder Head Removal
Refer to Cylinder / Piston Removal, page 3.54. Calculated Camshaft Oil Clearance: 0.0000 - 0.0026" (0.001 - 0.067 mm) 0.0039" (0.1 mm) 3.36 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 98: Cylinder Head Warp Inspection
0.0039″ (0.1 mm) Cylinder Head Disassembly WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs. 3.37 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 99: Valve Inspection
8. Clean the combustion chamber and head gasket surface. 9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring. 3.38 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 100: Combustion Chamber Cleaning
Valve Sealing Test 1. Clean and dry the combustion chamber area (Item Valve Guide I.D.: 0.2165 - 0.2171" (5.500 - 5.515 mm) 3.39 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 101: Valve Seat Reconditioning
If seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves. 3.40 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 102 Intake: 0.0393 ± 0.0039" (1.0 ± 0.10 mm) Service Limit: 0.0551" (1.4 mm) Exhaust: 0.0590 ± 0.0039" (1.5 ± 0.10 mm) Service Limit: 0.0748" (1.9 mm) 3.41 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 104: Engine Disassembly / Inspection - Lower End
3. Inspect the condition of the stator windings (Item 1) and output wires (Item 2). If replacement is required, refer to Chapter 10. 3.43 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 105: Water Pump Housing Removal
Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 3.44 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 106: Starter One-Way Clutch Disassembly
It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise (Item 5). The gear should immediately lock in position and not slip. 3.45 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 107: Crankcase Disassembly / Inspection
If any starter one-way clutch component is worn or damaged, replace the clutch and starter gear as an assembly. 3. Remove the oil filter. 3.46 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 108 6. Remove the thirteen M6 (Item 5) and three M8 bolts (Item 6) retaining the sump cover (Item 4) to the crankcase. 3.47 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 109 14. Remove the eleven M6 (Item 14) and two M8 (Item pump. 15) upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 3.48 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 110: Balance Shaft Removal / Inspection
4. Inspect the balance shaft gear teeth for damage. Balance Shaft Removal / Inspection 1. Perform Crankcase Disassembly / Inspection, page 3.46 procedure. 3.49 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 111: Crankshaft Removal / Inspection
(Item 1). Remove the end caps from the crankshaft. 8. If the crankshaft gear or sprocket is damaged, the crankshaft assembly must be replaced. 3.50 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 112 Replace crankshaft if any Bearing) journal is scratched or pitted. 12. Refer to the six letters stamped onto the PTO end of the crankshaft. 3.51 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 113: Crankcase Inspection
“Crankshaft Main Bearing Selection” and “Connecting Rod Bearing Selection” procedures. 3.52 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 114: Cylinder Inspection
NOTE: Always replace plain bearings when the crankcase connecting rods have been disassembled. Refer to Bearing Selection Identification Letters and Numbers, page 3.60. 3.53 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 115: Cylinder / Piston Removal
4. Carefully lift the cylinder and pistons from the upper 0.001″ (0.025 mm) crankcase. Standard Bore Size: 3.6614 ± 0.0003" (93 mm ± 0.008 mm) 3.54 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 116: Piston Disassembly / Inspection
(12:00 position) or bottom (6:00 position). Piston Pin Bore I.D.: 0.7877 - 0.7881" (20.009 - 20.018 mm) Service Limit:0.7893" (20.05 mm) 3.55 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 118: Piston Ring To Groove Clearance Inspection
(wear). The cylinder should be measured for taper and out of round. Piston O.D. (Standard): 3.6597 ± 0.0003" (92.959 ± 0.008 mm) 3.57 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 119: Connecting Rod Inspection
7. Using a dial bore gauge, measure big end I.D. in two directions shown. Record measurements compare to specifications. 3.58 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 120 10. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided in the Connecting Rod Bearing Selection, page 3.61 procedure. 3.59 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 121: Engine Assembly - Lower End
Bearing Selection Identification Letters and Numbers 1. Connecting Rod Bearing 2. Crankcase Bearing Identification 3. Crankshaft Bearing Identification Identification Number (1–number) Number (6–numbers) Letters (6–Letters) 3.60 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 122: Connecting Rod Bearing Selection
Inspect the surfaces closely for nicks, burrs or damage. 2. Clean bolt hole threads to remove any oil or crankcase sealant. 3.61 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 123: Piston Ring Installation
NOTE: Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 3.62 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 124: Piston / Connecting Rod Assembly
CAUTION DO NOT apply heat to piston rings or a loss of radial tension could result. 3.63 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 125: Cylinder / Piston Installation
(Item 1). 5. Rotate the engine so the crankcase to cylinder mounting surface is facing up. 3.64 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 126: Crankshaft Installation
Press bearing insert firmly into place. Repeat for the other connecting rod. 3.65 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 127 Guide connecting rods onto the rod journals of crankshaft as necessary. 6. Apply Polaris PS-4 engine oil to each rod bearing journal (Item 4) and main bearing journal (Item 5) of 10. Adjust the PTO crankshaft seal so it rests properly in crankshaft.
Page 128: Balance Shaft Installation
ENGINE 13. Install new bolts (Item 11) and tighten evenly until 4. Apply Polaris PS-4 engine oil to both balance shaft snug. journals (Item 2). 5. Install the balance shaft, placing the tooth with the 14. Torque connecting rod bolts to specification.
Page 129: Crankcase Assembly
6. Carefully place lower crankcase on upper case, making sure the oil pump drive chain is fed through the lower crankcase. 3. Apply Polaris PS-4 engine oil to the new bearings installed in the lower crankcase half. 4. Clean crankcase mating surfaces to remove any oil.
Page 130 M8 Bolts: 26 ft-lb (35 Nm) M6 Bolts: 9 ft-lb (12 Nm) 11. Rotate the engine so the cylinder is facing up. 3.69 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 132 23. Install the thirteen M6 (Item 16) and three M8 bolts 12 ft-lbs (16 Nm) that retain the oil sump cover (Item 17) to the crankcase. 3.71 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 133: Starter One-Way Clutch Assembly
6. After assembly, be sure the starter gear rotates in the clockwise direction only. 2. Clean screw threads in flywheel to remove all oil or grease. 3.72 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 134: Flywheel Installation
Flywheel Retaining Bolt: 9 ft-lb (12 Nm) 133 ft-lbs (180 Nm) 6. Install the starter torque limit gear as an assembly. 3.73 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 135: Engine Assembly - Top End
9. Install split keepers (Item 5) with gap even on both sides. 10. Repeat this procedure for remaining valves. 3.74 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 136: Cylinder Head Installation
DO NOT rotate the engine without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). 3.75 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 137: Camshaft Installation / Timing
Intake Camshaft - PN 1204784 Exhaust Camshaft - PN 1204786 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3.76 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual...
Page 138 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 3.77 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 139 (Item 7). Do not torque the bolts markings should line up as shown. at this time. NOTE: Use new sprocket retaining bolts upon assembly. 3.78 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 140 Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 21. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. Use a new tensioner sealing washer (Item 12). 22. Install the hydraulic cam chain tensioner (Item 11) into the cylinder and torque to specification.
Page 141: Camshaft Timing - Quick Reference
4. Align marks with surface 2. Exhaust Cam 5. CPS Mounting Hole 3. Align marks with surface 6. Align Flywheel Mark in Mounting Hole 3.80 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 142: Valve Clearance Adjustment
Intake Camshaft - PN 1204784 Exhaust Camshaft - PN 1204786 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes (Item 3) should face out as shown.
Page 144: Intake Valve Lash - Tappet Selection Matrix
0.951-0.975 522 525 528 530 532 535 538 540 542 545 0.976-1.000 525 528 530 532 535 538 540 542 545 3.83 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 145: Exhaust Valve Lash - Tappet Selection Matrix
0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 3.84 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 146: Valve Cover Installation
(Item 4) using a T40 driver. 6. Torque valve cover bolts to specification. Spark Plugs: 7 ft-lbs (10 Nm) Valve Cover Bolts: 7 ft-lbs (10 Nm) 3.85 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 147: Troubleshooting
Engine Idles But Will Not Accelerate • Air filter dirty or contaminated • Spark plug fouled/weak spark Low Compression • Broken throttle cable 3.86 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 148: Cooling System
• Water pump failure/ Loose impeller • Thermistor failure • Cooling fan inoperative or turning too slowly (perform current draw test) • Low oil level 3.87 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 152: General Information
Bosch Automotive Service Bosch Automotive Service Solutions: 1-800-345-2233 Solutions (PU-50621) or DSA at: www.diagsys.com or http://polaris.service-solutions.com/ Fuel Pressure Gauge Kit - PU-43506-A 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 153 SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier Bosch at http://polaris. service- solutions.com or (1-800-345-2233).
Page 154: Efi Service Notes
• Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 155: Efi System Assembly View
4. Dual Throttle Body Assembly 10. Fuel Supply Line 5. Fuel Injectors 11. T-MAP Sensor 6. Fuel Rail / Regulator 12. Electronic Throttle Control 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 156: Efi System Component Locations
Located on the PTO side of the throttle body assembly. Located on the left side of the thermostat housing. The sensor can be accessed with the air box assembly removed. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 158: Fuel Tank
2. Fuel Sender Float Arm 6. Fuel Tank Vent 3. PFA Gasket (replace if removed) 7. Fuel Tank Assembly 4. Fuel Pump / Regulator 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 159: Fuel Line Removal / Installation
3. Pull on the fuel line for removal. 4. To install the line, verify the connections are clean and free of debris. 4.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 161: Fuel Tank Installation
3. Install the vent line. 4. Reinstall block-off panel. Secure with plastic rivets and torque screws to specification. Block-off Panel Screws 8 ft-lbs (11 Nm) 4.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 162 Verify connections are secure. 12. Reinstall the battery and battery bracket. Torque fastener to specification. Battery Bracket: 8 ft-lbs (11 Nm) 4.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 163: Fuel Tank Removal Rzr Xp 4 1000
Once removed, place the mechanism in the rear cargo box to keep it out of the way. 4.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 164: Fuel Tank Installation Rzr Xp 4 1000
12. Remove the fuel tank vent line (Item 11) from the tank 5. Reinstall the seat base frame and torque fasteners to fitting. specification. 4.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 165: Electronic Fuel Injection
When the intake valve opens, the fuel/air Check the fuel line fittings for leaks. mixture is drawn into the combustion chamber, ignited and burned. 4.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 166: Initial Priming / Starting Procedure
This process repeats it self in rapid succession, limiting operation to the preset maximum. RPM Limit: 8800 4.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 167: Ecu Service
Service Department for specific handling instructions. Do not replace the ECU without factory authorization. For the purpose of troubleshooting, a known-good ECU from another Polaris RZR XP 1000 of the same model may be used without system or engine component damage.
Page 168: Fuel Injectors
Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 169: Fuel Injector Test
Fuel Injector Replacement 1. Remove the cargo box assembly (see chapter 5). 2. Be sure the engine has cooled enough to work on. 4.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 170 14. Lightly lubricate the injector O-rings and reinstall the fuel rail / injector assembly into the throttle body. 4.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 172: Fuel Pump
• If the key switch is not promptly turned to the "start" position. • If the engine fails to start. 4.23 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 173: Fuel Sender Test
Normal Fuel Pressure: 58 ± 2 psi (400 ± 14 kPa). NOTE: If the fuel pressure is out of specification, replace the fuel pump assembly. 4.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 174: Fuel Pump Replacement
ECU operation by plugging in a known-good ECU of the same model. NOTE: If the pump still does not operate, replace the fuel pump assembly. 4.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 175 6. Disconnect the fuel pump electrical harness (Item 3). NOTE: Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 4.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 177 21. Install the fuel tank vent line onto the tank fitting. 22. Connect the fuel pump electrical harness. 4.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 178: Temperature / Manifold Absolute Pressure (T-Map) Sensor
If the sensor fails or becomes disconnected for any reason, the engine will stop running. 4.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 179: Cps Test
Follow the CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage. 4. If the resistance is incorrect, follow the “CPS Replacement” procedure. 4.30 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 180: Throttle Body Assembly
2. Be sure the engine has cooled enough to work on. and the TMAP (Item 5) located on the ends of the throttle body assembly. 4.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 181: Electronic Throttle Control (Etc)
44 in-lb (5 Nm) pre-set. No internal servicing or adjustments may be performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization.
Page 182: Etc Replacement
Throttle Position will vary depending on what gear you have selected. • High/Neutral/Park/Invalid ≈ 70%. • Low ≈ 60% • Reverse ≈ 32% 4.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 183: Pps Replacement
8. Connect the negative (-) battery cable and install the drivers seat. 2. Remove the drivers seat and disconnect the negative (-) battery cable. 4.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 184: Efi Diagnostics
Vehicle Speed Signal Received Vehicle Speed Has Error C1069 Voltage Too High P0228 Accelerator Position 1 Voltage Too Low P0227 Not Plausible P0225 4.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 185 Driver Circuit Short to B+ P0232 Driver Circuit Grounded P0231 Voltage Too High P16A2 ECU Output Supply Voltage 1 3597 Voltage Too Low P16A1 4.36 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 186 Throttle Body Control - Return Condition Exists 520278 P151C Spring Check Failed Throttle Body Control - Condition Exists 520279 P151D Adaptation Aborted 4.37 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 187 P1533 Difference Exceeds Limit ECU Fault - ICO Condition Exists 520309 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption 4.38 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 188: Efi Troubleshooting
• Throttle cable incorrectly adjusted • Air Leaks, dirty injector • MAQS damaged (check with Digital Wrench®) • Tight valves (low compression or high leakdown) 4.39 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 189: Digital Wrench® Operation
NOTE: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
Page 190: Diagnostic Software Version
Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 4.41 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 191: Digital Wrench® Version And Update
2. Locate the “Service and Warranty” drop-down menu. 3. Click on “Digital Wrench Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 4. The Digital Wrench® portal website should appear in a new web browser.
Page 192 Select "save" and download them to your PC before running the install. NOTE: Versions and updates are subject to change. 4.43 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 194: Ecu Replacement
ECU, an Authorization Key must be obtained by entering a Request Code in the box provided on the Reflash • Proceed to http://polaris. diagsys. com for specific Authorization site. The Request Code is automatically information and FAQs on how to troubleshoot generated by Digital Wrench®...
Page 195 7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 4.46 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 196 ‘Continue’ button and follow instructions provided screen complete reprogramming procedure. 10. Enter or paste (CTRL+V) the Request Code into the box. 4.47 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 197 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 4.48 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 200: General Information
Multi-Function Pliers Walker Evans™: See Walker Evans™ Shock Service later in this chapter, page 5.52 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 201: Torque Specifications
Front to Rear Frame Bolts Tilt Steering Shock 7 ft-lb (10 Nm) Fasteners Steering Pivot Tube 8 ft-lb (11 Nm) Mounting Fasteners 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 202: Body Assembly Views
Torque fasteners to 40 ft-lb (54 Nm). 5. Install deflector on front ROPS with M10 x 1.25 x 20 bolts. Torque bolts to 8 ft-lb (11 Nm) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 203: Cab Frame Assembly Xp 4
7. Install ROPS front to ROPS mains with M10 x 1.5 x 20 screws (item 7). Torque to 40 ft-lb (54 Nm) 8. Install visor panel on front ROPS with M10 x 1.25 x 20 bolts. Torque to 8 ft-lb (11 Nm) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 204: Doors Xp
BODY / STEERING / SUSPENSION Doors XP 4. Hinge Pin 1. Door Panel 2. Door Frame 5. Latch Release 3. Latch Striker 6. Latch 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 205: Doors Xp 4
1. Door Panel 2. Door Frame 5. Latch Release 3. Latch Striker 6. Latch 7. Door Panel (Rear) 8. Door Frame (Rear) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 206: Dash Instruments / Controls
Dash Instruments / Controls 4. Headlight Switch 1. Instrument Cluster 2. Key Switch 5. AWD Switch 3. 12V Accessory Port 6. Bezel 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 207: Hood / Front Body Work
3. Right Front Fender Flair 8. Front Bumper Cover 4. Left Front Fender 9. Radiator Shroud 5. Left Front Fender Flair 5.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 210: Seat Assembly Front
8. Screw 4 ft-lb (5 Nm) 19. Seat Slider Lever 9. Shoulder Bolt 20. Seat Bottom 10. Spring Lock Washer 21. Seat Back 11. Flat Washer 5.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 211: Seat Assembly Rear
3. Seat Base Assembly 9. Bolt 4. Seat Latch Lever 10. Seat Bottom 5. Spring Seat Latch 11. Seat Back 6. Plate Seat Latch 5.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 212: Floor / Rocker Panels
3. LH Rocker 9. Console Cover 4. U-Type Nuts 10. Seat Belt Boot 5. Block Off Flap 11. Shifter Boot 6. Lower Floor 5.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 213: Floor / Rocker Panels
6. Main Floor Lower 14. Lower Rear Close-off Panel 15. Upper Rear Close-off Panel 7. Rocker RH 8. B-Pillar Cover RH 16. Floor Rear 5.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 216: Body Component Removal
3. Remove the seven (two lower and five upper) T-27 Torx screws retaining rear bumper to the cargo box. 4. Remove rear bumper from vehicle. 5.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 217: Hood And Front Body Work
7. Remove the two T-40 Torx screws retaining the dash and the one T-40 retaining the back of the dash to the bracket.. 13. Remove the front fender. 5.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 218: Rear Fender / Fender Flare Removal
NOTE: Do NOT let the reservoir hang by the hose. Use a wire or string to restrain the 2. Remove the fender flare from the vehicle. reservoir. 5.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 219: Rocker Panels, Console And Floor
4. Remove shift handle knob and remove the console. 8. Remove the 17 Torx screws in the bed of the cargo box. 5.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 220: Rocker Panels, Rear Console And Floor Xp
2. Remove rear fender. (See “Rear Fender Removal”). 3. Remove the four Torx T40 rear door mounting fasteners (Item 1) and remove door. 5.23 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 221 10. Remove two fasteners retaining the voltage regulator to the back of the lower rear close off panel. 5.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 222 Remove two M8x1.25x20 bolts (Item 12) and two M10x1.25x55 bolts (Item 13) from the front seat base. Remove front seat base assembly. 5.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 223: Decal Replacement
2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 5.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 224: Steering Assembly
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Assembly View (Non-EPS Models) 5.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 225: Steering Wheel Removal (Non-Eps Models)
Be sure the lower washers and spacers are still 5. Refer to steps 11-13 of the “Steering Shaft Bearing on the steering shaft. Replacement” procedure for installation. 5.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 227: Electronic Power Steering Assembly
10. Tie Rod End Bolt (Do not reuse) 3. EPS Module 7. EPS Mount Bracket 11. Nut, Nylok (Do not reuse) 4. Lower Steering Shaft 8. EPS Cover 5.30 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 228: Upper Steering Shaft Removal (Eps Models)
(Item 5) that retain the pivot tube. 3. Loosen the nut and back it half way off the steering shaft. 4. Place the assembly in a vise. 5.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 229: Power Steering Unit Removal
2. Disconnect the two electrical harnesses from the 5. Carefully remove the power steering unit and mount power steering unit. bracket from the vehicle as an assembly. 5.32 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 230: Lower Steering Shaft Removal (Eps Models)
3. Install the power steering unit and reassemble the vehicle (see “Power Steering Unit Installation” procedure). 3. Remove the power steering unit (see “Power Steering Unit Removal” procedure). 5.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 231: Power Steering Unit Installation
Torque to specification. Lower Steering Shaft to EPS Unit Pinch Bolt: 15 ft-lbs (20 Nm) 5.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 232 Torque the nut to specification and reinstall the plastic wheel cover. Steering Wheel Nut: 65 ft-lbs (88 Nm) 5.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 233: Front A-Arms
A-arm. Completely remove the ball joint end from the bearing carrier. 5. Remove the front bumper to allow A-arm bolt removal. 5.36 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 236: Ball Joint Service
3. Carefully press the ball joint out of the A-arm and Wheel Nuts (Alum): discard the ball joint. 120 ft-lbs (163 Nm) 5.39 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 237: Rear Radius Rods
5. Remove bolts (Item 3 & 4) attaching radius rods to the vehicle frame. Discard the nuts. 6. Remove radius rods from vehicle. 5.40 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 238: Rear Trailing Arm
4. Remove the lower radius rod mounting bolt (Item 4), nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 5.41 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 239 Rear Brake Caliper Mounting Bolts: 40 ft-lbs (54 Nm) Rear Wheel Hub Castle Nut: 110 ft-lbs (149 Nm) Wheel Nuts: 120 ft-lbs (163 Nm) 5.42 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 240: Trailing Arm Spherical Bearing Replacement
7. Press in new bearing until fully seated into trailing arm casting. 8. Install new snap ring, O-rings (not required) and bushings. 5.43 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 241: Rear Suspension Assembly View
2. Trailing Arm 3. Spherical Bearing 4. Bushing 5. Shock 6. Spring 7. Bearing Carrier 8. Stabilizer Bar 9. Stabilizer Bar Link 5.44 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 242: Rear Stabilizer Bar
0.10” (2.5mm) gap between the bushing face and the locating clamps. Torque locating clamps fasteners to specification. 4. Torque all fasteners to specification (see below). 5.45 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 243: Shocks / Springs / Fasteners
BODY / STEERING / SUSPENSION SHOCKS / SPRINGS / FASTENERS Front Shock Assembly View Rear Shock Assembly View 5.46 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 244: Shock Removal / Installation
Step 1 (see Chapter 2 for factory settings). 6. Reinstall the shock onto the vehicle and torque new fasteners to specification. 5.47 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 245: Walker Evans™Shock Assembly Views
Piston Wear Band (1.750" OD) 36. Shaft, Chrome Clicker Bolt Bump Stop Clicker Knob 2-Piece Piston Asm. Clicker Stud Screw (10/32") Shaft Loop 5.48 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 246: Walker Evans™ 2.5" Rear Shock
Wear Band Ball (.250") O-Ring O-Ring Retention Nut Screw Screw 9/16 Heim Shaftloop O-Ring Snap Ring Shock Body Needle O-Ring Hose 5.49 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 247: Walker Evans™ Shock Service
Extended Length 25.10″ (63.75 mm) 3.375″ (85.7 mm) IFP Location Nitrogen Pressure 125 psi +/- 5% 2874124 (qt.) Gas Shock Oil 5.50 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 248: Rear Shock Service Information
0.80 x 0.01 0.75 x 0.065 1.30 x 0.012 (top-out) 1.20 x 0.012 1.50 x 0.125 (top-out) Piston Bleed Orifice: 0.100″ 5.51 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 249: Walker Evans™ Shock Rebuild Information
Shock Body Holding Tool - Front PU-50979 Shock Body Holding Tool - Rear PU-50938 Shock Rod Holding Tool - Front 2872429 5.52 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 250: Walker Evans™ Shock Disassembly
Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 5.53 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 252: Walker Evans™ Shock Assembly
6. Place the compression valve stack on the rod in the service. reverse order of disassembly. Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 5.55 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 254 • Be sure to bottom out piston in the reservoir body. • Allow time for the bubbles to dissipate. • Repeat the process until all air has been removed. 5.57 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 256 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 5.59 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 257 NOTE: After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 5.60 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 259: General Information
Drive Clutch Puller 2871056 Driven Clutch Puller 2014 RZR XP / XP 4 1000 CLUTCH CHARTS Clutch Holding Wrench 9314177 CLUTCH CHART (2014 RZR XP 1000 / EPS / INT’L) Clutch Holding Fixture 2871358-A SHIFT DRIVE DRIVEN Spider Jam Nut Socket...
Page 260: Pvt System Overview
During the development of system is similar to a power governor. Rather than vary the Polaris vehicle, the PVT system is matched first to the throttle position, as a conventional governor does, the engine power curve; then to average riding conditions PVT system changes engine load requirements by either vehicle’s...
Page 261: Maintenance / Inspection
PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 262: Overheating / Diagnosis
PVT system. full position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD Clutch malfunction. certified technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or Poor engine performance.
Page 263: Pvt System Service
7. DRAIN PLUG, COVER 17. HOSE, AIR OUTLET 8. SEAL, COVER 18. INTAKE BOOT 9. SCREW 19. SEAL, COVER 10. COVER ASSEMBLY 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 264: Pvt Disassembly
Drive Clutch Puller 2872085 NOTE: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 265: Pvt Assembly
(Item 1). 13. Loosen hose clamps (Item 3) that attach clutch outlet duct to inner clutch cover. Disengage hose from the cover. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 266 11. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 12. Install the drive clutch onto the engine. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 267: Drive Belt
NOT necessary for belt replacement. 3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 6.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 268: Belt Inspection
PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 6.11 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 270: Drive Clutch Disassembly / Inspection
Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. Drive Clutch Spring Inspection 6.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 271: Needle Bearing Inspection
1. Rotate the clutch bearing in both clockwise and counter-clockwise directions. non-braking needle bearing should rotate in both directions on the shaft with only a slight amount of drag. 6.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 272: Button To Tower Clearance Inspection
NOTE: Rollers, pins, thrust washers and buttons are not serviceable at the time of this publication. Clutch Spider Nut Socket: PU-50578 Clutch Holding Fixture: PN 2871358-A 6.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 273: Clutch Inspection
Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bush- ing replacement in this chapter. 6.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 274: Bushing Service
Tool Drive Clutch Cover 5020629 Bushing Removal /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 6.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 275 9. Turn sheave counterclockwise on puller rod until it comes free. Lift sheave off puller. 10. Remove nut from puller rod and set aside. 6.18 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 276: Drive Clutch Assembly
34. Turn clutch cover counterclockwise on puller rod until bushing is seated. 35. Remove nut from puller rod. Take installation tool and clutch cover off rod. 6.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 277 Loctite® 7088™ Primer in 90° apart to the threads of the spider jamb nut. Install spider jamb nut onto stationary shaft threads. 6.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 278 12. Install cover bolts and torque in a cross pattern evenly to specification. Drive Clutch Cover Bolts: 9 ft-lb (12 Nm) 6.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 279: Driven Clutch Service
X’s on the components for reference. This will aid in assembly and maintains clutch balance. 6.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 280 9. Remove the clutch assembly from the holding tool. 10. Press out the spring pins (I) in the inner sheave. 6.23 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 281: Bushing Service
ITEM QTY. PART # TOOL DESCRIPTION P-90 Drive/Driven 5020628 Clutch Bushing Install Tool Drive Clutch Cover 5020629 Bushing Removal/ Installation Tool 6.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 282 4. Flip sheave over so bushing faces downward and install onto puller. 13. Apply Loctite® 648 evenly to bushing bore inside moveable sheave. 6.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 283: Clutch Assembly
2. Install the shaft and bearing assembly into the outer sheave. NOTE: Press only on the outer race of the bearing during installation to prevent damaging the bearing. 6.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 284 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 6.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 285 Once the spider passes the retaining ring notch on the shaft, install the retaining ring. 11. Place the driven clutch into the Universal Clutch Compressor PU-50518. 6.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 286 (helix) side down. Press down on the moveable sheave belt face with both hands and the helix will release. Helix Retaining Screws: 48 in-lb (5 Nm) 6.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 288: Troubleshooting
Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 6.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 289 Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 6.32 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 291: General Information
30 ft-lbs (41 Nm) Mounting Bolts Bearing Carrier to 42 ft-lb (54 Nm) Trailing Arm Bolts Radius Rod 40 ft-lb (54 Nm) Fasteners 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 293: Bearing Replacement
Use an arbor and press only on the outer race, Ball Joint Pinch Bolts: otherwise bearing damage may occur. 42 ft-lbs (57 Nm) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 294 NOTE: Refer to the photos below to ensure proper placement of the tie rod end. Wheel Nuts: 120 ft-lbs (163 Nm) 11. Rotate wheel and check for smooth operation. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 295: Front Drive Shaft
5. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 6. Remove the front wheel hub assembly. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 296: Drive Shaft Installation
3. Install drive shaft into the front bearing carrier. 4. Install the upper and lower ball joint ends into the front bearing carrier. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 297: Front Propshaft Service
NOTE: Right front wheel can be removed to gain better access to the propshaft roll pin. Wheel Nuts: 120 ft-lbs (163 Nm) 11. Rotate wheel and check for smooth operation. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 298: Front Prop Shaft Installation
6. Reposition the front gearcase and install the four bolts that secure the front gearcase to the frame. Torque bolts to specification. Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 299: Rear Prop Shaft Removal
5. Lubricate the support bushing with light oil to ease installation and install the bushing on the rear prop shaft bearing. 7.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 300 Reference these marks during installation if still visible. 7. Torque support bearing fasteners specification. Support Bearing Fasteners: 35 ft-lb (47 Nm) 7.11 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 301: Rear Prop Shaft Removal Xp
4. Align the front and rear prop shafts and slide them drivers side to slide the rear prop shaft yoke (Item 6) together. off the transmission output shaft. 7.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 302: Support Bearing Replacement
NOTE: Do not attempt to separate the bearing from the rubber isolated support assembly upon installation. 7.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 303 8. Install the rear prop shaft into the vehicle (see “Rear Prop Shaft Installation” procedure). 7.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 304: Prop Shaft U-Joint Service
The prop shafts on this unit are not serviceable. If a cross or yoke is worn, the prop shaft assembly needs to be replaced. 7.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 305: Front Gearcase / Centralized Hilliard
Cover Screws, M6 (T30 Torx) Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic 7.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 306: All Wheel Drive Operation
Torsion Spring Operation: The torsion spring acts as a return mechanism to help disengage the coupling of the 7.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 307: Front Gearcase Removal
6. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 7.18 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 308: Front Gearcase Disassembly / Inspection
3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. NOTE: Nylon spacer is non-serviceable and should not be removed. 7.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 309 5. Remove the torsion spring retainer and torsion 7. Remove the RH output hub assembly from the spring from the top of the ring gear. gearcase housing. 7.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 310 13. Inspect clutch housing / ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 7.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 311: Front Gearcase Assembly
NOTE: If bearing replacement was required, press new bearing onto the pinion shaft and install a new external snap ring. 7.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 312 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 7.23 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 313 NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 7.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 314: Front Gearcase Installation
8.5 oz. (250 ml) 5. Install the vent line (Item 2). (fill on a level surface to bottom of threads on the fill hole) 7.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 315: Rear Bearing Carrier
5. Remove the lower radius rod outer mounting bolt (Item 4), nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 7.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 316: Bearing Replacement
Use an arbor and press only on the outer race, otherwise bearing damage may occur. 1. Remove the outer snap ring (Item 1). 7.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 317: Bearing Carrier Installation
4. Install rear wheel hub assembly (Item 2), cone washers (Item 3), and hand tighten the castle nut. Install washers with domed side out. 7.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 318 8. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 7.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 319: Rear Drive Shaft
6. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 7.30 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 320: Drive Shaft Installation
3. Swing the rear trailing arm assembly outward and upward until the rear axle can be inserted into the bearing carrier. Support the trailing arm from underneath. 7.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 321 10. Install wheel and (4) wheel nuts. Torque wheel nuts to specification. Rear Hub Castle Nut: 110 ft-lbs (149 Nm) Wheel Nuts: 120 ft-lbs (163 Nm) 7.32 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 322: Drive Shaft Cv Joint / Boot Replacement
Outer CV Joint / Boot Replacement 1. Use a side cutters to cut and discard the boot clamps. NOTE: Tap on inner race only! 7.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 323 7. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 7.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 324: Inner Plunging Joint / Boot Replacement
Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft. 7.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 326 17. Remove excess grease from the plunging joint’s Axle Boot Clamp Tool: PU-48951 external surfaces and place the excess grease in the boot. CV Boot Clamp Pliers: 8700226 7.37 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 331: Specifications
Capacity (INT’L): 41 oz. (1200 ml) Mounting Bolt (INT’L) Park Flange Screws 10 ft-lb (14 Nm) Rear Transmission 40 ft-lb (54 Nm) Isolator Bolt 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 332: Transmission Mounting And Torque Values
(Item 4). 2. Remove the screws retaining the center console using a T27 and T30 Torx driver. Remove the console from the vehicle. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 333: Installation
(Item 2). Replace if worn or 1. Perform the removal steps in reverse order to install damaged. the gear shift lever (lever, cable, console, shift knob). 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 334: Transmission Removal
(see Chapter 6). NOTE: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 335 Reinstall the lower shock bolts (Item 3) to hold the with new upon assembly. trailing arms up during the rest of the removal procedure. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 336 (Item 8) from the transmission. 21. Remove the two rear exhaust springs securing the muffler to the rear transmission mounting bracket. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 337: Transmission Installation
M8 bolts and nuts. Torque nuts to specification. Rear Transmission Mount Bracket Fasteners (Item 1): 17 ft-lb (23 Nm) 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 338 Step 3: 5 ft-lb (7 Nm) NOTE: DO NOT torque fasteners at this time. Step 4-7: 44 ft-lb (60 Nm) 12. Remove the clutch center distance tool. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 339 18. Lubricate the transmission splines and mid propshaft crankshaft position sensor connector (Item 7), shift joint splines with Polaris All Purpose Grease. Install bracket and shift bracket bolts (Item 8), shift cable the propshaft onto the transmission output shaft (see clevis pin and washer (Item 9) onto the transmission.
Page 340 30. Install the engine service panel, console cover and seats. 31. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris AGL (see Chapter 2 “Transmission Lubrication”). Recommended Transmission Lubricant: 24. Install the stabilizer bar link mounting bolts and new AGL (PN 2878068) (Quart) nuts (Item 13).
Page 341: Transmission Service
6. Remove the compression spring (H). CAUTION Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 8.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 342 16. Place the gear cluster assembly on a clean surface for inspection. If disassembly is required, refer to “Gear Cluster Disassembly”. 8.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 343 Remove the retaining ring and slide the washers, 53T gear and needle bearing off the reverse shaft (see Figure 8-1). 8.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 344 25. Extract the seal from the snorkel shaft to access the snorkel tube for removal. 28. Remove the snap ring (Y) and shim (Z) from the snorkel shaft. 8.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 347: Snorkel Gear Backlash Procedure
8. Apply Loctite ® ™ to the threads of the bearing cover retaining screws. 8.18 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 348 Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 8.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 349 17. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 8.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 351 (.070" or 1.8 mm from outer face of bore). 25. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to left-hand transmission mating surface. 8.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 354: Transmission Service (Int
This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 8.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 355: Transmission Disassembly
(Item 4), flat washer (Item 4) and gear switch (Item outward for reassembly. 5). Remove the switch. 8. Remove the spacer (J). 8.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 356 CAUTION Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 8.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 357 If disassembly is required, refer to “Gear Cluster Disassembly”. Gear Cluster Disassembly 18. Slide engagement dog (X) off of shift fork guides. 8.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 358 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. Snorkel Shaft Removal / Disassembly 8.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 359 29. Using the Snorkel Tool (PA-50231), fully loosen the snorkel tube. 32. Use an arbor press to remove the snorkel tube from the snorkel shaft. 8.30 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 360: Planetary Differential Disassembly
“Gearcase Disassembly and Inspection” procedure. 1. Use a scribe to mark the differential cover and ring gear prior to disassembly. 8.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 361: Planetary Differential Bushing Replacement
1. Press the old bushing out of the ring gear. 2. Thoroughly clean the bore of the ring gear and check for any unwanted burs. 8.32 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 362 5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 8.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 364: Planetary Differential Assembly
2. Assemble the side gears and place them onto the ring gear along with the (6) planet gears. Differential Cover Screws: 22 ft-lb (30 Nm) 8.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 366: Snorkel Gear Backlash Procedure
8. Apply Loctite® 242™ to the threads of the bearing cover retaining screws. 8.37 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 367 Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 8.38 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 368 18. Install shift fork (S) and torsion spring into transmission housing as an assembly. Load spring as shown in image below 8.39 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 369 23. Install the rear output shaft assembly (C). Rotate output shaft assembly to align slots with engagement dog. Ensure bearing is fully seated upon assembly. 8.40 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 370 Sealant (PN 2871557) to the left hand transmission mating surface. NOTE: Shift fork pins should be offset towards the input shaft as shown above. 8.41 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 371 Seals should be installed just past the case lead-in chamfer (.070" or 1.8 mm from outer face of bore). Transmission Case Screws: 20 ft-lbs (27 Nm) 8.42 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 372 35. Install the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 8.43 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 373 40. Install the sector cover and align the transmission case dowel with the alignment hole. Install and torque the bolts to specification. Sector Cover Bolts: 12 ft-lb (16 Nm) 8.44 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 374: Troubleshooting
(rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 8.45 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 376 Sensor, Speed Bearing, Ball Cover, Sector Gears Spring, Wave Case, RH Case, LH Bracket, Wire Harness Drum, Shift Collar Sleeve, Input Shaft 8.47 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 378 Bearing, Plain 108. Bearing, Ball Gear, 44T Collar Sleeve, Input Shaft 109. Bearing, Ball Fork, Shift Bearing, Needle Cage Sprocket, 48T, 6-Face 8.49 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 382: General Information
• Make sure caliper moves freely on guide pins (where applicable). • Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 383: Brake Noise Troubleshooting
Inspect and repair as necessary HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.
Page 384 This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 387: Master Cylinder
Master Cylinder Mounting Fasteners 23 ft-lbs (31 Nm) 2. After installing the foot brake check pedal free-play. Pedal free-play should not exceed .090″ (2.286 mm). 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 388: Brake Pedal Lever
Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 389 10. Add brake fluid to MAX level inside reservoir. Master Cylinder Fluid Level Between MIN and MAX lines on reservoir. 11. Install master cylinder reservoir cover. 9.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 391: Parking Brake Inspection
4. Adjust the parking brake cable where it attaches to the caliper mount / shift cable bracket. The mount bracket is located on the right-hand side of the transmission. 9.12 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 392: Parking Brake Caliper Service (Int'l Model)
BRAKES PARKING BRAKE CALIPER SERVICE (INT’L MODEL) Caliper Assembly View 9.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 393: Caliper Removal
3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. 9.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 394: New Brake Pad Installation
3. Once you have determined the correct amount of shims to use, reassemble the caliper and apply an Anti-Seize Lubricant to the thrust washer and shims. 9.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 395: Caliper Installation
Parking Brake Caliper - Mount Bracket Bolts: 37 ft-lb (50 Nm) 3. Install the cable, pin and clip pin. Test the park brake for proper function. 9.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 396: Disc Replacement
14 ft-lb (20 Nm) NOTE: When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 397: Pad Inspection
0.297 ± 0.007" (7.5 ± .178 mm) Service Limit: 0.180" (4.6 mm) 7. Remove the inner pad from the bracket and caliper. 9.18 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 398: Pad Assembly / Installation
Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). Front Caliper Mount Bolt: 40 ft-lbs (54 Nm) 9.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 399: Front Caliper Service
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 3. Clean caliper area before removal. 9.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 400: Caliper Disassembly
NOTE: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 401: Caliper Inspection
NOTE: Be sure to clean seal grooves in caliper body. Front Caliper Piston O.D.: Std: 1.370” (34.80 mm) Service Limit: 1.368” (34.75 mm) 9.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 402: Caliper Assembly
NOTE: If disc scraper (Item 1) was removed, residue or brakes may drag upon assembly. reinstall it upon caliper installation. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 403: Front Brake Disc
If the brake drags, re-check assembly and Service Limit: 0.010″ (0.254 mm) installation. NOTE: If new pads are installed, refer to Brake Burnishing Procedure, page 9.19. 9.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 404: Disc Inspection
Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9.25 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 406: Pad Inspection
8. Remove the inner brake pad. Rear Brake Pad Thickness: 0.298 ± 0.007″ (7.57 mm ± .178 mm) Service Limit: 0.180″ (4.6 mm) 9.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 407: Pad Assembly / Installation
8. Install wheel and torque wheel nuts to specification. Wheel Nuts: 120 ft-lbs (163 Nm) Rear Caliper Mount Bolt (Item 1): 40 ft-lbs (54 Nm) 9.28 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 408: Brake Burnishing Procedure
Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 409: Rear Caliper Service
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 2. Remove the four wheel nuts and rear wheel. Clean caliper area before removal. 9.30 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 410: Caliper Disassembly
5. Clean the caliper body, piston, and retaining bracket (Item 10) with brake cleaner or alcohol. NOTE: Be sure to clean caliper body seal grooves. 9.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 411: Caliper Inspection
(Item 2). Be sure groove is clean and free of residue or brakes may drag upon assembly. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (Item 3) with a twisting motion while pushing inward. Piston should slide in Rear Caliper Piston Bore I.D.:...
Page 412: Caliper Installation
6. Install wheel and torque wheel nuts to specification. Wheel Nuts: 120 ft-lbs (163 Nm) NOTE: If new pads are installed, refer to Brake Burnishing Procedure, page 9.29. 9.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 413: Rear Brake Disc
Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. Brake Disc Mounting Bolts: 30 ft-lb (41 Nm) 9.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 414: Troubleshooting
• Operator riding brakes Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.35 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 419: General Information
(i. e. 10A jack for current readings). Refer to the Owner’s Manual included with your meter for more information. 10.4 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 420: Efi Diagnostics
Chapter 4. Refer to Chapter 4 “Electronic Fuel Injection System (EFI)” when diagnosing an EFI system or component. 10.5 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 421: Instrument Cluster
Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 10.6 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 422: Rider Information Display
TURF position (INT’L Model Only). 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 10.7 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 423: Information Display Area
1. Toggle the MODE button to TRIP 1. Engine hours are logged anytime the engine is running. Total hours can not be reset. 10.8 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 424 (Standard 12-hour / Metric-24 hour). To set the clock, follow these steps: 7. Toggle the MODE button until the odometer is displayed. 10.9 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 425 When the park brake is fully engaged, “BRAKE” appears in the rider information display. Engine speed is limited to 1500 RPM in all gears, except 10.10 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 428: Switches / Controls
4. For switch replacement, refer to Chapter 9 “Brakes”. NOTE: Pins 7 and 8 provide power and ground to light the switch lamp. 10.13 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 429: Ignition (Key) Switch
• Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and 10.14 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 430: Awd / 2Wd Switch
• Move the switch to TURF. There should be continuity between switch pins 1 and 2; 4 and 5. 10.15 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 431: Turn Signal Switch (Int'l)
2. Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring. 10.16 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 432: Parking Brake Switch (Int'l Model)
620 Ω Testing The Parking Brake Switch 1. Disconnect the harness connector at the parking brake switch (Orange/Red and Red/Blue wires). 10.17 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 433: Rear Diff Solenoid (Int'l)
• Check the AWD / 2WD / TURF Switch wires for loose connections. • Remove solenoid from rear differential and ensure the solenoid plunger is actuating. 10.18 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 434: All Wheel Drive Coil
80% of all electrical issues are caused by bad/failed connections and grounds. 10.19 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 435: Vehicle Speed Sensor
4. Install the new ignition coil and/or high tension lead (s). Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 10.20 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 436: Ignition Coil Tests
5. Adjust the beam to the desired position by loosening or tightening the (3) T-25 adjustment screws and moving the lamp to the appropriate height. Secondary Test 10.21 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 437: Headlamp Replacement
(see Chapter 5). 3. Carefully lift and remove headlamp assembly from the bumper. 10.22 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 438: Headlamp Installation
6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlight Adjustment” procedure as shown in this chapter. 10.23 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 439: Cooling System
If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 10.24 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 440: Ect Sensor Test
5. Using a wrench, remove and replace the sensor, applying a light coating of thread sealant to aid installation. Refer to Chapter 3 and 10 for additional ECT sensor information. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). TEMPERATURE °F (°C) RESISTANCE 68 °F (20 °C)
Page 441: Fuel Sender
6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly (see Chapter 4). 10.26 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 442: Fuse Box: Fuses / Relays / Circuit Breaker
20-amp circuit breaker protects the fan motor circuit. Two separate relays located under the dash operate the headlights and the “flash to pass” function on INT’L models. 10.27 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 444: Relay Operation
Provides 12 Vdc power for EFI Red / Dark Blue system circuits. FAN RELAY provides power to the following system: • Fan Motor 10.29 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 446: Charging System Stator (Alternator) Tests
7. Refer to the following table for approximate AC Voltage readings according to RPM. Test each leg at the specified RPM in the table. 10.31 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 447: Stator (Alternator) Replacement
The regulator / rectifier (Item 1) is located in the left rear wheel well area in front of the left rear shock. It is mounted under the LH panel divider. 10.32 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 448: Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 10.33 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 449: Battery Service
Refer to OCV table (see “OCV - Open harm. WASH HANDS AFTER HANDLING. Circuit Voltage Test”). 5. Charge the battery as recommended (see “Charging Procedure”). 10.34 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 450: Battery Removal / Installation
For this reason, a battery capacity or load test should be NOTE: Battery charge can be maintained by using a conducted whenever poor battery performance is Polaris battery tender charger or by charging once a encountered. month to make up for normal self-discharge. Battery...
Page 451: Charging Procedure
Refer to the voltage drop tests on the starter system in this chapter. Voltage should not exceed 0.1 DC volts per connection 10.36 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 452: Starter Motor Removal
NOTE: “ELECTRICAL SYSTEM 6. Torque upper starter mounting screw to specification. BREAOUTS: Starter-Interlock” provided in this chapter for starter solenoid operation. 10.37 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 453: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. 10.38 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 454: Electronic Power Steering (Eps)
EPS system is detected, the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system. The WIRE COLOR FUNCTION system is Polaris Digital Wrench® compatible for simplified diagnostics system troubleshooting...
Page 456: Eps Troubleshooting (Power Steering Non-Functional With Mil On)
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL ON) 10.41 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 457: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 10.42 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 458: Eps Troubleshooting (Using Digital Wrench®)
ELECTRICAL EPS Troubleshooting (Using Digital Wrench®) 10.43 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 466 Pressure Cap Test..........3.13 Brake Light Switch ..........10.13 Pressure Test............. 3.13 Brake Pad Specifications ............ 3.13 Installation (Front) ..........9.19 CPS ..............4.29 IX.1 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 467 Cover Bushing ........... 6.17 Crankcase Assembly.......... 3.68 Disassembly ............6.13 Crankcase Disassembly / Inspection....3.46 Moveable Sheave Inspection ......6.16 Crankshaft Installation ........3.65 IX.2 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 468 Fan Control Circuit Operation ....... 10.24 Hood / Front Body..........5.10 Final Drive Torque Specifications ........... 7.2 Floor..............5.15 Removal ............5.22–5.23 IX.3 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 469 Metric Bolt Torque Specification ......1.15 Radiator Removal / Installation ......... 3.14 Valve Clearance Adjustment ....... 3.81 Radiator Inspection / Cleaning ........ 2.26 IX.4 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 470 EFI..............4.3 Headlamp............10.13 Electrical ............10.4 Ignition ............10.14 Engine..............3.3 Parking Brake (INT’L) ........10.17 Final Drive ............7.2 IX.5 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
Page 471 Brake System ............ 9.35 Clutch..............6.31 Fuel Injector............4.19 Transmission ............. 8.45 Turn Signal Switch (INT’L)........10.16 Upper Steering Shaft (EPS) IX.6 9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual © Copyright 2013 Polaris Industries Inc.
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2014 rzr xp 4 1000

Polaris 2014 RZR XP 1000 Service Manual

Table of Contents

Maintenance Chapter 2 Maintenance

Engine Chapter 3 Engine

Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

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Chapters

Troubleshooting

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