Polaris RZR XP 1000 2017 Service Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Automobile
  5. RZR XP 1000 2017
  6. Service manual

Polaris RZR XP 1000 2017 Service Manual

Hide thumbs
1
2
3
4
5
6
Table Of Contents
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
Table of Contents

Advertisement

Quick Links

Download this manual
2017-2018 RZR XP 1000 / XP4 1000
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
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 February 2018 (PN 9928492 R04)
© Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Advertisement

Table of Contents
loading

Related Manuals for Polaris RZR XP 1000 2017

Summary of Contents for Polaris RZR XP 1000 2017

  • Page 1 Publication Printed February 2018 (PN 9928492 R04) © Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 SAFETY WARNINGS 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. REVISION INDEX DATE...
  • Page 5 2017-2018 RZR XP 1000 / XP4 1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM...

  • Page 7: Table Of Contents

    ................1.39 DECIMAL EQUIVALENTS 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 8: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018 VEHICLE AND ENGINE SERIAL NUMBER LOCATION Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

  • Page 9: Reference Information

    NOTE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright 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.
  • Page 11 8700226 9314177-A Roll Pin Removal Tool Combination Pliers Spanner Wrench / CV Boot Clamp Pliers Drive Clutch Holding (27″) Clutch Spreader (ear) Tool 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 12 PU-50624 Water Pump Seal Oil Pressure Gauge Clutch Spider Nut Rolling Engine Stand Oil Pressure Gauge Installer Adapter (1/2 NPT) Socket Adapter (M20) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Tool PU-51838 PV-1253 PV-43513-A PV-43526 PV-43531 Shock Body Holding Valve Spring Valve Spring Connector Test Kit Oil Presure gauge Tool Compressor Compressor Adapter 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 14: Master Torque Table

    7 ft-lb (10 Nm) Camshaft Carrier Bolts 180° Camshaft Sprocket Bolts 14 ft-lb (19 Nm) Step 4: M6 bolts: 7 ft-lb (10 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 14 ft-lb (19 Nm) Starter Mounting Bolts 7 ft-lb (10 Nm) Hose Clamp 35 in-lb (4 Nm) Starter One-Way Clutch Screws 9 ft-lb (12 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 16 7 ft-lb (10 Nm) (Apply Loctite® Water Pump Cover Bolts 204™ to bolt threads) Wheel Lug Nuts 120 ft-lbs (163 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.10 © Copyright Polaris Industries Inc.

  • Page 17: General Specifications

    Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.11 © Copyright Polaris Industries Inc.

  • Page 18: Rzr Xp 1000 Clutch Chart

    XP 1000 (7044263) (7044708) 1800-3700 29-68,PM 10A Key (6000-12000) (5139618 ) 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 20: Rzr Xp 4 1000 Clutch Chart

    XP4 1000 (7044708) 1800-3700 29-68,PM (7044504) 10A Key (6000-12000) (5139618 ) 15A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: Rzr Xp 1000 High Lifter Clutch Chart

    10A Key lettering High Lifter (7044709) 1800-3700 29-66,PM (7044465) 10A Term (6000-12000) (5633496 ) 25A EPS 10A Lights 10A Drive 10A Accessory 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.16 © Copyright Polaris Industries Inc.
  • Page 23 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.17 © Copyright Polaris Industries Inc.

  • Page 24: Rzr Xp 1000 High Lifter Clutch Chart

    10A Key lettering High Lifter (7044709) 1800-3700 29-66,PM (7044465) 10A Term (6000-12000) (5633496 ) 25A EPS 10A Lights 10A Drive 15A Accessory 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 25: 2017 Rzr Xp 1000 Le Matte Gold Metallic

    Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.19 © Copyright Polaris Industries Inc.

  • Page 26: Rzr Xp 1000 Clutch Chart

    10A Key XP 1000 (7044263) (7044708) 1800-3700 29-68,PM 10A Term (6000-12000) (5139618 ) 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.20 © Copyright Polaris Industries Inc.

  • Page 27: 2017 Rzr Xp 1000 Le (Ride Command)

    Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 28: Rzr Xp 1000 Clutch Chart

    10A Key XP 1000 (7044263) (7044708) 1800-3700 29-68,PM 10A Term (6000-12000) (5139618 ) 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.22 © Copyright Polaris Industries Inc.
  • Page 29 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 30: Rzr Xp 1000 Clutch Chart

    XP 1000 (7044263) (7044708) 1800-3700 29-68,PM 10A Key (6000-12000) (5139618 ) 10A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.24 © Copyright Polaris Industries Inc.
  • Page 31 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.25 © Copyright Polaris Industries Inc.

  • Page 32: Rzr Xp 4 1000 Clutch Chart

    XP4 1000 (7044708) 1800-3700 29-68,PM (7044504) 10A Key (6000-12000) (5139618 ) 15A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.26 © Copyright Polaris Industries Inc.
  • Page 33 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.27 © Copyright Polaris Industries Inc.

  • Page 34: Rzr Xp 1000 High Lifter Clutch Chart

    10A Key lettering High Lifter (7044709) 1800-3700 29-66,PM (7044465) 10A Term (6000-12000) (5633496 ) 25A EPS 10A Lights 10A Drive 10A Accessory 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.28 © Copyright Polaris Industries Inc.
  • Page 35 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.29 © Copyright Polaris Industries Inc.

  • Page 36: Rzr Xp 1000 High Lifter Clutch Chart

    10A Key lettering High Lifter (7044709) 1800-3700 29-66,PM (7044465) 10A Term (6000-12000) (5633496 ) 25A EPS 10A Lights 10A Drive 15A Accessory 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.30 © Copyright Polaris Industries Inc.
  • Page 37 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 38: Rzr Xp 1000 Clutch Chart

    10A Key XP 1000 (7044263) (7044708) 1800-3700 29-68,PM 10A Term (6000-12000) (5139618 ) 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.32 © Copyright Polaris Industries Inc.
  • Page 39 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.33 © Copyright Polaris Industries Inc.

  • Page 40: Rzr Xp 1000 Clutch Chart

    10A Key XP 1000 (7044263) (7044708) 1800-3700 29-68,PM 10A Term (6000-12000) (5139618 ) 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.34 © Copyright Polaris Industries Inc.
  • Page 41 Do not use this vehicle for Hitch Tongue Capacity towing. Do not modify the vehicle by adding a hitch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.35 © Copyright Polaris Industries Inc.

  • Page 42: Rzr Xp 4 1000 Clutch Chart

    XP4 1000 (7044708) 1800-3700 29-68,PM (7044504) 10A Key (6000-12000) (5139618 ) 15A Term 25A EPS 10A Lights 10A Drive 10A Accessory 10A Instrument 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.36 © Copyright Polaris Industries Inc.

  • Page 43: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.37 © Copyright Polaris Industries Inc.

  • Page 44: Sae Tap / Drill Sizes

    5/16–24 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 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.38 © Copyright Polaris Industries Inc.

  • Page 45: Decimal Equivalents

    15/32 0.4688″ 12 mm = 0.4724″ 31/32 0.9688″ 25 mm = 0.9843″ 31/64 0.4844″ 63/64 0.9844″ 0.500″ 13 mm = 0.5118″ 1.000″ 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.39 © Copyright Polaris Industries Inc.
  • Page 46 GENERAL INFORMATION NOTES 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 1.40 © Copyright Polaris Industries Inc.
  • Page 47 ..............2.45 WHEEL AND HUB TORQUE TABLE 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 48 ................. . .2.60 SPARK PLUG SERVICE 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 49: Maintenance

    • Verify coolant level is filled to the FULL COLD mark on Coolant Level coolant reservoir (if engine is cold) • Inspect hoses and radiator for leaks 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 50: Periodic Maintenance Overview

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

  • Page 51: Maintenance Intervals

    Initial fluid level inspection; add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual...
  • Page 52 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual...
  • Page 53 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual...
  • Page 54 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual...
  • Page 55 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual...
  • Page 56 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.10...
  • Page 57 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.11...
  • Page 58 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.12...
  • Page 59 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.13...
  • Page 60 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.14...
  • Page 61 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.15...
  • Page 62 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.16...
  • Page 63 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.17...
  • Page 64 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.18...
  • Page 65 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.19...
  • Page 66 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.20...
  • Page 67 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.21...
  • Page 68 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.22...
  • Page 69 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.23...
  • Page 70 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or other qualified person perform these services. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.

  • Page 71: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant bottle * More often under severe use, such as operation in water or under severe loads. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.25 © Copyright Polaris Industries Inc.
  • Page 72 Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 73: Grease Lubrication Points

    Grease middle and rear Prop Shaft Yokes Polaris Premium U-Joint Grease fittings 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 74: Lubricants / Service Products

    Premium U-Joint Lube 2871551 14 oz cartridge (10 count) NOTE Each item can be purchased separately at your local Polaris dealer. PART NO. DESCRIPTION Additives / Sealants / Thread Locking Agents / Misc. Loctite® Threadlock 242 (6 ml.) (12 count)

  • Page 75: Engine

    Access the oil dipstick through the opening in front of the passenger rear tire. Access the oil fill cap through the cargo box access panel. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. FLUID CAPACITY Recommended Engine Oil: Capacity: 2.5 qt (2.4 L)

  • Page 76: Engine Oil And Filter Change

    TORQUE 5. Remove the seats and engine service panel to Engine Oil Drain Plug: access the oil filter. 12 ft-lbs (16 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 77: 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 78: Engine Cylinder Leakdown Test

    Removal of left rear wheel or left rear shock is NOT necessary to perform this procedure. 5. Remove the spark plug wires to gain access to valve cover as shown below. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.32 © Copyright Polaris Industries Inc.
  • Page 79 15. Install the spark plug wires back into their correct location. 16. Install the push rivet that retains the heat shield to the frame cross member. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 80: Cam Chain Tensioner Inspection

    7 ft-lb (10 Nm) 7. Install plunger bolt. Torque fastener specification. 3. Remove the two tensioner mounting bolts TORQUE Plunger Bolt: 15 ft-lb (20 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 81: Heat Shield Inspection

    Inspect all heat shields to make sure they are not damaged or missing. Replace any damaged or missing heat shields. Front Box Shield Rear Box Shield Access Panel Shield Silencer Shield Side Box Foil Shield Head Pipe Shield 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 82: Cooling System

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Antifreeze is premixed and ready to use. Do not dilute with water. With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle.

  • Page 83: Cooling System Pressure Test

    Replace if necessary. your area. Recommended Coolant: Polaris 50/50 Extended Life Anti-freeze 2880514 (quart) 2880513 (gallon) 9. Reinstall the recovery bottle cap. 10. If coolant was required, start engine and check for leaks.

  • Page 84: Radiator Inspection / Cleaning

    Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.38 © Copyright Polaris Industries Inc.

  • Page 85: Coolant Drain / Fill

    MAX level. 8. Refer to Cooling System Bleeding Procedure, page 3.15. Recommended Coolant: Polaris 50/50 Extended Life Anti-freeze 2880514 (quart) 2880513 (gallon) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.39...

  • Page 86: Fuel System And Air Intake

    This engine uses a serviceable, high-volume, high- pressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 87: Fuel Lines

    EFI System. 3. Be sure fuel lines are routed and retained properly. NOTE Make sure lines are not kinked or pinched. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 88: Throttle Pedal Inspection

    3. Pull cover rearward far enough to remove air filter 3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 89: 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 90: 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.44 © Copyright Polaris Industries Inc.

  • Page 91: Drive Shaft Boot Inspection

    4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.45 © Copyright Polaris Industries Inc.

  • Page 92: Tire Inspection

    TIRE PRESSURE INSPECTION (COLD) Model Front Rear 16 psi (110 kPa) 16 psi (110 kPa) 19 psi (131 kPa) 20 psi (138 kPa) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.46 © Copyright Polaris Industries Inc.
  • Page 93 Step 1: 24 in-lbs (3 Nm)Step 2: 7 ft-lbs (10 Nm) NOTE Beadlock bolts should be checked and torqued every 300 miles (450 km). 7. Seat bead and inflate to 16 psi. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.47 © Copyright Polaris Industries Inc.

  • Page 94: Transmission And Front Gearcase

    2. Remove the fill plug and check the lubricant level. 8. Clean the drain plug magnetic surface. 9. Reinstall the drain plug and torque to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.48 © Copyright Polaris Industries Inc.

  • Page 95: Front Gearcase Lubrication

    5. Remove the fill plug (see Chapter 2 – Front Gearcase Lubrication, page 2.49). 6. Place a drain pan under the front gearcase drain plug. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.49 © Copyright Polaris Industries Inc.

  • Page 96: Shift Cable Inspection / Adjustment

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.50 © Copyright Polaris Industries Inc.

  • Page 97: Transmission Vent Line Routing

    The line terminates to open air (does not terminate to a fitting or hole in the frame). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.51 © Copyright Polaris Industries Inc.

  • Page 98: Steering

    WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.52...

  • Page 99: Tie Rod End / Wheel Hub Inspection

    MEASUREMENT Wheel Toe-Out: 1/8" to 3/16″ (3.2 to 4.8 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.53 © Copyright Polaris Industries Inc.

  • Page 100: Wheel Toe Adjustment

    When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.54 © Copyright Polaris Industries Inc.

  • Page 101: Suspension

    Suspension springs may be adjusted to suit different riding conditions or vehicle payloads. NOTE Polaris does not recommend increasing the spring WARNING adjustment by more than one inch (25.4 mm) over the Uneven adjustment may cause poor handling of the...
  • Page 102 Firmest The rear shock adjuster can be found on the remote reservoir. Clockwise will increase damping and counter- clockwise will decrease damping. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.56 © Copyright Polaris Industries Inc.

  • Page 103: Brake System

    MEASUREMENT Brake Disc Thickness Service Limit: .170″ (4.32 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.57 © Copyright Polaris Industries Inc.

  • Page 104: Electrical And Ignition System

    “Charging Procedure”, page 11.48. Do not use the vehicle’s stator/alternator to charge a new battery. 5. Lift the battery out of the vehicle. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.58 © Copyright Polaris Industries Inc.

  • Page 105: Battery Installation

    TORQUE Battery Terminal Fasteners: 60 in-lbs (7 Nm) 6. Verify that cables are properly routed and reinstall the driver’s seat. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.59 © Copyright Polaris Industries Inc.

  • Page 106: Spark Plug Service

    Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 5. Remove spark plugs using a 5/8” spark plug socket with an extension. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 2.60 © Copyright Polaris Industries Inc.
  • Page 107 ............. .3.40 VALVE SEAT RECONDITIONING (1000) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 108 ..................3.86 COOLING SYSTEM 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 109: General Information

    (Use With 2.375” Bore Stand) Oil Filter Flywheel Puller PA-49316 PN 2540086 Mity Vac™ Pressure Test Tool 2870975 Oil Pressure Minimum Specification (using Polaris Oil Filter Wrench PU-50105 engine oil at operating temperature) 10 PSI @ 1200 RPM Oil Pressure Gauge PV-43531...

  • Page 110: Oil Pressure Test

    2. Remove the seats, engine service panel, and divider Test results are based on the use of the recommended panel heat shield. engine oil (Polaris PS-4 or PS-4 Extreme Duty) at 3. Clean the area around the main oil gallery plug operating temperature, and may vary considerably if...

  • Page 111: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM TORQUE 16 ft-lbs (22 Nm) Crankcase Oil Gallery Plug (1/2 NPT): ENGINE OIL FLOW CHART 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 112: Engine Specifications (1000)

    .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 113 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 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 114: Intake / Exhaust System

    AIR BOX / AIR FILTER ASSEMBLY VIEW Intake Airbox Hose Airbox Clip (4) Drain Cap Vent Hose Airbox Intake Tubes Air Filter Engine Intake Housing Airbox Cover 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 115: Exhaust System Assembly View

    Exhaust Pipe Head Pipe Gasket Muffler / Silencer Head Pipe Bolts Muffler Isolator Mounts 18 ft-lb (24 Nm) Oxygen Sensor13 ft-lb (18 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 116: Engine Cooling System

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

  • Page 117: Cooling System Pressure Cap Test

    Allow the engine to cool before servicing. 4. Disconnect cooling fan electrical connector. 5. Remove the upper radiator hose from the radiator. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 118: Thermostat Replacement

    Upper Radiator Hose To Radiator Fitting Lower Radiator Hose Fan Motor Assembly Recovery Bottle Radiator 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.12 © Copyright Polaris Industries Inc.
  • Page 119 Thermostat Cover Bolts: 7 ft-lb (10 Nm) 11. Be sure to properly fill and bleed cooling system as outlined in this chapter. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 120: Cooling System Assembly View

    Oil Cooler Outlet Hose Engine Hoses Pressure Cap Bypass Hose Lower Radiator Hose Upper Radiator Hose Water Pump Outlet Hose Fan Assembly Recovery Bottle 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 121: Cooling System Bleeding Procedure

    10. Remove the pressure cap. Add the necessary to the MAX line. amount of Polaris Premium Antifreeze to the radiator filler neck. 11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

  • Page 122: Water Pump Removal

    14. Plug the water pump drive access hole in the engine block with a clean shop towel. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.16 © Copyright Polaris Industries Inc.
  • Page 123 16. Install the hood, engine service panel and seats. NOTE Install different bolt lengths as shown. TORQUE Water Pump Mounting Bolts: 7 ft-lb (10 Nm)(Apply Loctite® 204™ to bolt threads) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 124: Water Pump Service

    13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 5. Remove impeller from water pump shaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.18 © Copyright Polaris Industries Inc.
  • Page 125 7 ft-lb (10 Nm)(Apply Loctite® 204™ to bolt threads) 18. Clean cover and housing gasket surfaces 19. Install a new water pump cover gasket 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.19 © Copyright Polaris Industries Inc.
  • Page 126 Water Pump Assembly View Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.20 © Copyright Polaris Industries Inc.

  • Page 127: Engine Service

    • Crankshaft / Main Bearings • Crankshaft Seal (PTO) • Cylinder • Oil Pump / Oil Pump Sprocket or Chain • Piston / Rings 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.21 © Copyright Polaris Industries Inc.

  • Page 128: Crankshaft Pto Seal Replacement

    3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 129 5. Field test the vehicle before putting back into service. the flat side of the seal facing out as shown. Inspect for any leaks. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.23 © Copyright Polaris Industries Inc.

  • Page 130: Engine Removal

    2872085) to prevent damage to crankshaft. 9. Remove lower mounting bolt from the left rear shock and discard the nut. Install a new nut upon assembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 131 21. Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose the water pump coolant hose from the engine. Dispose of engine coolant properly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 132 Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.26 © Copyright Polaris Industries Inc.

  • Page 133: Engine Installation

    2014-15 RZR XP 1000 personal injury or damage to vehicle components. 2013 RANGER 900 2014-16 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.27 © Copyright Polaris Industries Inc.
  • Page 134 15. Remove the lifting straps and overhead or portable engine hoist. NOTE 16. Install the two coolant hoses onto the engine. DO NOT torque fasteners at this time. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 135 (see Chapter 2 – Engine Oil NOTE and Filter Change, page 2.30). 37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 Ensure plug wires caps are pushed down all the way so or PS-4 Extreme Duty Synthetic Engine Oil to the they engage onto the spark plugs.

  • Page 136: Engine Mounting And Torque Values

    CAUTION Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil.Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

  • Page 137: Engine Lubrication Specifications

    Oil Filter Wrench PU-50105 or 2.5″ (64 mm) Oil Filter PN 2540086 Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature) 10 PSI @ 1200 RPM 40 PSI @ 7000 RPM *Additional oil may be required after complete engine disassembly.

  • Page 138: Engine Disassembly / Inspection - Top End

    3. Remove the spark plugs . Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 139 NOTE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 140: Camshaft Sprocket Inspection

    Replace timing chain and sprockets if worn or damaged. 10. Mark the intake and exhaust camshafts to ensure proper assembly. 11. Carefully remove camshafts from the cylinder head. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.34 © Copyright Polaris Industries Inc.

  • Page 141: Camshaft / Camshaft Bore Inspection (1000)

    1.5122" (38.41 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 142: Cylinder Head Removal

    Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal, Service Limit: page 3.54. .0039" (0.1 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 143: Cylinder Head Warp Inspection

    Note the tappet size engraved on the underside of the bucket. MEASUREMENT Cylinder Head Warp Limit: .0039″ (0.1 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 144: 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.38 © Copyright Polaris Industries Inc.

  • Page 145: Combustion Chamber Cleaning

    .2165 - .2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 146: Valve Sealing Test

    1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.40 © Copyright Polaris Industries Inc.
  • Page 147 6. Insert valve into guide and tap valve lightly into place a few times. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.41 © Copyright Polaris Industries Inc.
  • Page 148 12. Thoroughly clean cylinder head and valves. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 149: Engine Disassembly / Inspection - Bottom End

    . If replacement is required, refer to the Electrical chapter. 4. Inspect the ball bearing that supports the starter motor shaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.43 © Copyright Polaris Industries Inc.

  • Page 150: Water Pump Housing Removal

    Water Pump Service, page 3.18. 2. Remove the three long gold colored bolts retaining the water pump housing to the engine. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.44 © Copyright Polaris Industries Inc.

  • Page 151: Flywheel Removal

    5. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel (left hand thread - turn flywheel puller counterclockwise to install). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 152: Starter One-Way Clutch Disassembly

    3. Remove the one-way clutch and inspect both sides of drive rollers . Inspect the roller contact surface inside the hub for wear, damage or uneven surface. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 153: Crankcase Disassembly / Inspection

    The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 5. Rotate engine to access the crankcase sump cover. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.47 © Copyright Polaris Industries Inc.
  • Page 154 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 155: Balance Shaft Removal / Inspection

    3. Carefully rotate the balance shaft and remove it from the crankcase. 4. Inspect the balance shaft gear teeth for damage. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 156: Crankshaft Removal / Inspection

    5. Carefully lift the crankshaft out of the crankcase. 6. Remove the cam chain , oil pump drive chain and PTO main seal from the crankshaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.50 © Copyright Polaris Industries Inc.
  • Page 157 If worn past the service limit, replace the crankshaft assembly. CRANKSHAFT BEARING JOURNAL DIAMETERS 1.6140 - 1.6143" Main (40.996 - 41.004 Standard Bearing 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.51 © Copyright Polaris Industries Inc.

  • Page 158: Crankcase Inspection

    Crankshaft Main Bearing Selection, page 3.60 and Connecting Rod Bearing Selection, page 3.60 procedures. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 159: Cylinder Inspection

    Inspect cylinder for wear, scratches, or damage. NOTE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 160: Cylinder / Piston Removal

    (MAG / PTO). 4. Carefully lift the cylinder and pistons from the upper crankcase. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 161: Piston Disassembly / Inspection (1000)

    DO NOT apply heat to piston rings or a loss of radial tension could result. Piston Pin O.D.: .7873 - .7875" (20.000 - 20.005 mm) Service Limit: .7866" (19.98 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 162: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 163: Piston Ring Installed Gap (1000)

    Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.57 © Copyright Polaris Industries Inc.
  • Page 164 5. Install matching rod cap on connecting rod (without bearings) and install the bolts. 6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 165: Engine Assembly - Bottom End

    *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 166: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 167: Upper Crankcase Preparation

    Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.61 © Copyright Polaris Industries Inc.
  • Page 168 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 169: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 170: Cylinder / Piston Installation

    NOTE Orientation arrow is also located on the bottom side of piston as an additional reference. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 171: Crankshaft Installation

    Press bearing insert firmly into place. is rotated. Repeat for the other connecting rod. 5. Install oil drain diverter into the upper crankcase. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.65 © Copyright Polaris Industries Inc.
  • Page 172 ENGINE / COOLING SYSTEM 6. Apply Polaris PS-4 engine oil to each rod bearing 11. Clean bolt hole threads in connecting rod to remove journal and main bearing journal of crankshaft. all oil. 12. Install matching rod cap on connecting rod with 3 digit serial number stampings aligned &...

  • Page 173: Balance Shaft Installation

    5. Refer to Engine Oil Flow Chart, page 3.5 at the beginning of this chapter and trace the oil paths through the crankcase and cylinder. 3. Apply Polaris PS-4 engine oil to both balance shaft 6. Flush all oil passages with solvent and then warm journals soapy water.

  • Page 174: Crankcase Assembly

    8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 3. Apply Polaris PS-4 engine oil to the new bearings installed in the lower crankcase half. 9. Install the eight M10 , two M8 and one M6 lower crankcase bolts.
  • Page 175 11. Rotate the engine so the cylinder is facing up. 12. Install the eleven M6 and two M8 upper crankcase bolts. Tighten all bolts lightly by hand. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.69 © Copyright Polaris Industries Inc.
  • Page 176 NOTE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.70 © Copyright Polaris Industries Inc.
  • Page 177 TORQUE Oil Cooler bolts: 7 ft-lbs (10 Nm) 27. Proceed to Flywheel Installation, page 3.72 and then Cylinder Head Installation, page 3.75. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 178: Starter One-Way Clutch Assembly

    Loctite cures with time, the longer the unit is let stand clockwise direction only. before engine starting the better the joint will be. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 179: Stator Cover Installation

    3. Install stator cover and thirteen screws. Torque screws in sequence to specification. TORQUE Stator Cover Screws: 9 ft-lb (12 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 180: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.74 © Copyright Polaris Industries Inc.

  • Page 181: Cylinder Head Installation

    5. Carefully set the cylinder head in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder head bolts evenly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 182: Camshaft Installation / Timing

    3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head.
  • Page 183 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 184 18. Install the front camshaft carrier and two outer retaining bolts. 19. Install the fixed cam chain guide and two retaining bolts. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.78 © Copyright Polaris Industries Inc.
  • Page 185 • Install the two mounting bolts. Torque fasteners to Camshaft Carrier Bolts: specification. 7 ft-lb (10 Nm) TORQUE 21. Apply Polaris PS-4 engine oil to the cam chain Tensioner Mounting Bolts: tensioner bore prior to assembly. Use a new 7 ft-lb (10 Nm) tensioner sealing washer 22.

  • Page 186: Camshaft Timing - Quick Reference

    DO NOT use the “V” mark located on the flywheel opposite of the “I” mark. Only the “I” mark should be used as a TDC reference 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 187: Valve Clearance Adjustment

    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 should face out as shown.
  • Page 188 NOTE Lubricate the outer portion of the valve tappet upon installation. 15. Repeat steps 10-14 until all necessary valves have been adjusted. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 189: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i. e. 459 should be rounded to 460 since there is a 460 tappet). Available Tappets 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 190: Valve Cover Installation

    T40 driver. 6. Torque valve cover bolts to specification. TORQUE Spark Plugs: 7 ft-lbs (10 Nm) Valve Cover Bolts: 7 ft-lbs (10 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.84 © Copyright Polaris Industries Inc.

  • Page 191: Troubleshooting

    • Cylinder, piston, ring, or valve wear or damage (check compression) • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.85 © Copyright Polaris Industries Inc.

  • Page 192: Engine Cooling System

    Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.86 © Copyright Polaris Industries Inc.
  • Page 193 ................4.36 OPERATION OVERVIEW 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 194 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........

  • Page 195: General Information

    This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench® diagnostic software. This module kit is used on all 8 pin connector-based Polaris EFI systems. NOTE The EFI fuel system remains under high pressure, even when the engine is not running.

  • Page 196: Efi Overview

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 197: Efi System Assembly View

    Engine Coolant Temperature Sensor (ECT) Fuel Filter Dual Throttle Body Assembly Fuel Supply Line Fuel Injectors T-MAP Sensor Fuel Rail / Regulator Electronic Throttle Control 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 198: Efi System Component Locations

    Located between the air box assembly and rubber cylinder head adapters. • Crankshaft Position Sensor (CPS) Located on top of the stator cover. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 199: Principal Components

    Fuel pressure regulators located in the tank and on the end of the fuel 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 200: Initial Priming / Starting Procedure

    Digital Wrench® Diagnostic Software warm up, acceleration, etc., a richer air / fuel ratio is (dealer only). automatically calculated by the ECU. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 201: Evap System

    Fuel Cap: On EVAP equipped vehicles, the fuel cap will have a ratcheting style fuel cap with a tether. It is important to note that Polaris does not use an enhanced EVAP control system. This means the system does not detect a gross leak, or restrictions in the EVAP system such as a missing or loose fuel cap.

  • Page 202: Evap Conditions And Symptoms

    Excessive carbon monoxide emissions may be caused by any of the following: • Rich air/fuel mixture • Dirty air filter • Leaking fuel injectors • Fuel pressure too high/bad regulator 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 203: Electronic Control Unit (Ecu)

    Polaris RZR of the same model may be requirements for the immediate operating conditions. used without system or engine component damage. The ECU then sends output signals to set injector duration and ignition timing.

  • Page 204: Etc Learn Procedure

    5. To install, reverse the procedure and tighten the mounting screws to specification. NOTE Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 205: Fuel Injectors

    IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 206: Fuel Injector Troubleshooting

    Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.14 © Copyright Polaris Industries Inc.

  • Page 207: Fuel Injector Replacement

    5 mm Allen wrench. 5. Remove the driver’s seat and disconnect the negative battery cable. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.15 © Copyright Polaris Industries Inc.
  • Page 208 20. Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.16 © Copyright Polaris Industries Inc.
  • Page 209 25. Reinstall the cargo box access panel. • Be sure the air box boots fully seat onto the dual throttle body before tightening the hose clamps 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.17 © Copyright Polaris Industries Inc.

  • Page 210: Fuel Lines / Tank

    Preliminary Filter PFA Nut Fuel Sender Float Arm Fuel Tank Vent PFA Gasket (replace if removed) Fuel Tank Assembly Fuel Pump / Regulator 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.18 © Copyright Polaris Industries Inc.

  • Page 211: Fuel Vent Line Routing (Non Highlifter)

    2. Retain the fuel vent line to the frame with a hinge clip a Panduit strap and Panduit strap 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.19 © Copyright Polaris Industries Inc.
  • Page 212 5. Route the fuel vent line through the shock mount and secure vent line to the frame with two hinge clips attach the vent line to the fitting in the frame 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.20 © Copyright Polaris Industries Inc.

  • Page 213: Fuel Vent Line Routing (High Lifter)

    2. Retain the fuel vent line to the frame with a hinge clip a Panduit strap and Panduit strap 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.21 © Copyright Polaris Industries Inc.

  • Page 214: Vent Line Termination Fitting

    There are two methods of disconnecting Fuel line quick connects, the preferred method is by using a small straight blade screwdriver. Screwdriver Method: 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.22 © Copyright Polaris Industries Inc.
  • Page 215 5. Push retaining clip upward into the open position. 3. Remove quick connect from the fuel fitting. 6. Remove quick connect from the fuel fitting. Hand Method: Replacement Needs: 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.23 © Copyright Polaris Industries Inc.

  • Page 216: 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 217: Fuel Tank Removal

    Remove the bolt retaining the battery bracket and remove the battery from the vehicle. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.25 © Copyright Polaris Industries Inc.
  • Page 218 T40 Torx driver. 8. Remove the shift linkage from the shifter. Remove the panel from the vehicle. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.26 © Copyright Polaris Industries Inc.

  • Page 219: Fuel Tank Installation

    Check the fuel line fittings for leaks. inner tank bracket with the fuel tank to ensure the bracket is inserted properly into the lower fuel tank mount. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.27 © Copyright Polaris Industries Inc.

  • Page 220: Fuel Tank Removal Rzr Xp 4 1000

    Once removed, place the mechanism in the rear cargo box to keep it out of the way. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.28 © Copyright Polaris Industries Inc.

  • Page 221: Fuel Tank Installation Rzr Xp 4 1000

    13. Lift the rear of the fuel tank up first. Carefully pull the 9. Reinstall seat belt mechanism. Torque bolt to fuel tank out of the vehicle. specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.29 © Copyright Polaris Industries Inc.
  • Page 222 11. Reconnect the fuel line and fuel pump electrical harness. Verify connections are secure. 12. Reinstall the battery and battery bracket. Torque fastener to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.30 © Copyright Polaris Industries Inc.

  • Page 223: Fuel Pump

    Refer to Fuel Pump Replacement procedure. • If the key switch is not promptly turned to the "start" position. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 224: Fuel Pump Test

    7 volts is present. NOTE If the voltage was below 7 VDC, test the battery, ignition switch, relay(s), wiring harness and ECU. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.32 © Copyright Polaris Industries Inc.
  • Page 225 A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.33 © Copyright Polaris Industries Inc.
  • Page 226 15. Gently push down on fuel pump flange ensuring flange is centered. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.34 © Copyright Polaris Industries Inc.
  • Page 227 24. Install the passenger seat / storage box. when starting PFA nut, ensuring threads are properly aligned. Verify orientation marks are still aligned between fuel pump and fuel tank. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.35 © Copyright Polaris Industries Inc.

  • Page 228: Temperature And Manifold Absolute Pressure Sensor (T-Map)

    ECU and compared to its programming for determining the fuel and ignition requirements during engine operation. The T-MAP provides the ECU with engine load data. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.36 © Copyright Polaris Industries Inc.

  • Page 229: Crankshaft Position Sensor (Cps)

    CPS Replacement procedure to inspect CPS and flywheel encoder ring for damage. 5. If the resistance is incorrect, follow the CPS Replacement, page 4.38 procedure. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.37 © Copyright Polaris Industries Inc.

  • Page 230: Cps Replacement

    5. Torque the CPS retaining bolt to specification. and remove the sensor from the stator cover. TORQUE CPS Retaining Bolt: 9 ft-lb (12 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.38 © Copyright Polaris Industries Inc.

  • Page 231: Electronic Throttle Control (Etc) / Throttle Body

    . The ETC is a non-serviceable component and can only be tested using Digital Wrench®. If the ETC is faulty, the entire assembly must be replaced. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.39 © Copyright Polaris Industries Inc.

  • Page 232: Throttle Body Removal

    O-rings to aid installation. Torque the fuel rail mounting screws to specification. TORQUE Fuel Rail Mounting Screws: 44 in-lb (5 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.40 © Copyright Polaris Industries Inc.

  • Page 233: Etc Test

    If a problem is encountered, and you specification. determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do TORQUE not replace the ETC without factory authorization.

  • Page 234: Pedal Position Sensor (Pps)

    1. Remove the drivers seat and disconnect the negative (-) battery cable. 2. Disconnect the PPS harness connection located on the throttle pedal. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.42 © Copyright Polaris Industries Inc.
  • Page 235 8. Manually cycle the throttle pedal to verify the throttle pedal moves freely. 9. Connect the negative (-) battery cable and install the drivers seat. 4. Remove the protective shield 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.43 © Copyright Polaris Industries Inc.

  • Page 236: Oxygen Sensor

    1. Disconnect the harness going to the oxygen sensor. 2. Remove the oxygen sensor from the exhaust pipe. 3. Install new oxygen sensor. Torque sensor to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.44 © Copyright Polaris Industries Inc.
  • Page 237 FUEL SYSTEM 4. Connect the harness going to the oxygen sensor. TORQUE Oxygen Sensor: 13 ft-lb (18 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.45 © Copyright Polaris Industries Inc.

  • Page 238: Efi Diagnostics

    MODE button or turn the ignition key OFF once the codes are recorded. 2. Press and hold the MODE button to enter the diagnostics code menu. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.46 © Copyright Polaris Industries Inc.
  • Page 239 P0112 MAP) Abnormal rate of Change P0114 Valid But Above Normal P0127 (least severe) Engine Temperature Sensor Engine Overheat Shutdown P1217 (ECT) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.47 © Copyright Polaris Industries Inc.
  • Page 240 P1262 Driver Circuit Open P0261 Driver Circuit Short to B+ P0265 Injector 2 (PTO) Driver Circuit Grounded P1265 Driver Circuit Open P0264 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.48 © Copyright Polaris Industries Inc.
  • Page 241 3599 Valid But Above Normal P17AD (least severe) Valid But Below Normal P17AF (least severe) Cylinder Not Identified Misfire Detected 65590 P0314 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.49 © Copyright Polaris Industries Inc.
  • Page 242 EPS Power Save Condition 520231 C1071 Power Save/Timeout Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520268 P1519 M17; IAC Stepper Pin 3 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.50 © Copyright Polaris Industries Inc.
  • Page 243 Repeated Adaptation Failed Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.51 © Copyright Polaris Industries Inc.
  • Page 244 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.52 © Copyright Polaris Industries Inc.

  • Page 245: Cylinder Misfire Detection

    • If the cylinder with the misfire cannot be detected (code P0314), the ECU will limit available power by limiting how far the throttle plate opens. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.53 © Copyright Polaris Industries Inc.

  • Page 246: Efi Troubleshooting

    • Poor fuel quality (old fuel) • Spark plug wires loose or worn • Fouled spark plug • Faulty electrical connection • Injector failure Poor Idle 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.54 © Copyright Polaris Industries Inc.

  • Page 247: Polaris Digital Wrench

    Refer to Section 2, 3 and 4 in the Instruction Manual • Perform output state control tests (some models) 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...

  • Page 248: Digital Wrench Software Version And Update

    4. The Digital Wrench® portal website should appear in a new web browser. 5. Click on “Digital Wrench Version Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. NOTE You must already have the current version installed before adding an update.

  • Page 249: Digital Wrench® Communication Errors

    Digital Wrench® start-up screen should match the update you just downloaded. NOTE Versions and updates are subject to change. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.57 © Copyright Polaris Industries Inc.

  • Page 250: Digital Wrench® - Diagnostic Connector

    ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.58 © Copyright Polaris Industries Inc.

  • Page 251: Guided Diagnostics

    Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.59 © Copyright Polaris Industries Inc.

  • Page 252: Digital Wrench® Feature Map

    Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.60 © Copyright Polaris Industries Inc.

  • Page 253: Ecu Replacement

    ECU. The Digital Wrench® Engine Controller Reprogramming • Proceed to http://polaris.diagsys.com for specific (or “Reflash”) feature allows reprogramming of the ECU information and FAQs on how to troubleshoot fuel and ignition map. To successfully reprogram the communication problems.
  • Page 254 EXACTLY as they appear on the screen. 9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop- down menu. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.62 © Copyright Polaris Industries Inc.
  • Page 255 12. An “Authorization Key” will appear in the upper left corner of the screen. Copy this key exactly as it appears. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 4.63 © Copyright Polaris Industries Inc.

  • Page 256: Polaris Mobile Digital Wrench (Pmdw)

    Locate the Service (PMDW) and Warranty drop-down menu. Select: “Mobile Digital Polaris Mobile Digital Wrench (PMDW) is a diagnostic Wrench App Download”. Tap on the link to download the software application (app) designed specifically for app.
  • Page 257 ..............5.30 DRIVEN CLUTCH ASSEMBLY VIEW 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 258 ..................5.31 TROUBLESHOOTING 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 259: General Information

    WEIGHT SPRING SPRING 0-1800 29-75,PM 2017 LE (0-6000) (5633720) Black / Red Black Matte (7044263) (7044708) Gold 1800-3700 29-68,PM Metallic (6000-12000) (5139618 ) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 260: Pvt System Overview

    The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage.

  • Page 261: Driven Clutch Operation

    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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 262: Pvt Overheating / Diagnosis

    PVT system. 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 certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty Poor engine performance.

  • Page 263: Pvt System Service

    48 in-lb (5 Nm) Outlet Duct Clutch Cover Drain Screw Inner Cover Screws Outer Clutch Cover 12 ft-lb (16 Nm) Inner Clutch Cover 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 264: Pvt Covers And Ducting Components (High Lifter)

    Inner Clutch Cover Screw (7) Lower Exhaust Hose Outer Cover Seal Outlet Duct Outer Clutch Cover Inlet Duct Outer Clutch Cover Screw (8) Boot PVT Drain Screw 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 265: Pvt Disassembly

    9. Mark the drive belt direction of rotation and remove drive belt (see Chapter 5 – Belt Removal, page 5.13). 10. Remove the driven clutch retaining bolt and driven clutch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 266 PVT cover. Make note of the routing of the fuel lines, vent line, battery cable and wire harness for proper assembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 267: Pvt Assembly

    12. Apply a light film of grease to the splines on the shaft. 13. Install the driven clutch, washer and retaining bolt. Torque to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.11 © Copyright Polaris Industries Inc.
  • Page 268 Torque fasteners to specification. TORQUE Rear Shock Mounting Bolt: 70 ft-lbs (95 Nm) TORQUE Wheel Nuts: 120 ft-lbs (163 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 269: Drive Belt

    3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 270: Belt Inspection

    5. Install the outer clutch cover and eight screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws: 48 in-lb (5 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 271: Drive Clutch Service

    Spider Jam Nut 250 ft-lb (339 Nm) Shift Weight (Apply 0.1 mL Loctite® 7088 Primer and 0.1 mL Loctite® 620™) Spacer Moveable Sheave 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 272: Drive Clutch Disassembly / Inspection

    Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and Drive Clutch Spring Inspection remove cover plate. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 273: Needle Bearing Inspection

    Check to see that spring coils are parallel to one another using a straight-edge. Distortion of the spring indicates stress fatigue, requiring replacement. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 274: Shift Weight Inspection

    A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Drive Clutch Roller Pin and Button Service”. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 275: Spider Removal

    Rollers, pins, thrust washers and buttons are not using Clutch Spider Removal / Installation Tool serviceable at the time of this publication. Spider Removal / Installation Tool: 2870341-A 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 276: Clutch Inspection

    3. Lift bearing and thrust washers off the shaft. Replace as an assembly if worn, damaged, or if operational problems were noted prior disassembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 277: Moveable Sheave Bushing Inspection

    /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.21 © Copyright Polaris Industries Inc.
  • Page 278 3. Remove nut from puller rod and set aside. Moveable Sheave - Bushing Installation 12. Place main adapter on puller. 4. Install puller adapter from kit PN 2871226. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 279: Drive Clutch Assembly

    29. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 30. Apply Loctite® 648 evenly to bushing bore in the cover. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.23 © Copyright Polaris Industries Inc.
  • Page 280 8. Tighten the spider jam nut using Clutch Spider Nut Socket . Torque jam nut to specification. Clutch Spider Nut Socket: PU-50578 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.24 © Copyright Polaris Industries Inc.
  • Page 281 10. Install the limiter spacer and the clutch spring CAUTION DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.25 © Copyright Polaris Industries Inc.

  • Page 282: Driven Clutch Service

    Universal Clutch Compressor. Slider to Sheave Clearance Service Limit: 0.175″ (4.5 mm) Slider Width Service Limit: 0.975″ (24.8 mm) Universal Clutch Compressor: PU-50518-A 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.26 © Copyright Polaris Industries Inc.
  • Page 283 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTE Spring is compression only and has no torsional wind. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.27 © Copyright Polaris Industries Inc.

  • Page 284: Driven Clutch Assembly

    5. Install the spring so the arm rests into the notch in the moveable sheave. 2. Install the square sliders and slider pins 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.28 © Copyright Polaris Industries Inc.
  • Page 285 9. Once back together, verify the grease / tape marks made during disassembly are properly aligned. 10. Install the drive clutch on the vehicle. See PVT Assembly, page 5.11 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.29 © Copyright Polaris Industries Inc.

  • Page 286: Driven Clutch Assembly View

    Bearing Spider Spring Pin Roller Slider Washer E-clip Slider Pin Stationary Sheave Helix (Cam) Helix Screws Moveable Sheave 48 in-lb (5 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.30 © Copyright Polaris Industries Inc.
  • Page 287 Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.31 © Copyright Polaris Industries Inc.
  • Page 288 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 5.32 © Copyright Polaris Industries Inc.
  • Page 289 ................6.33 SHIFTING DIFFICULTY 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 290: General Information

    Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ LUBRICATION FLUID CAPACITY Recommended Transmission Lubricant: Capacity (Standard): 44 oz (1300 mL) Capacity (INT’L): 40.5 oz (1200 mL) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 291: Shift Lever / Cable

    5. Remove both bushings from the shift lever and service as needed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 292: Spherical Bearing Removal

    2. Remove the spherical bearing from the shift lever. 5. Install the shift cable to the shift lever. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 293: Gated Shifter Adjustment (Gold Metallic Le)

    3. Remove the shifter boot from the center console. TORQUE Gated Shifter Bracket Fasteners: 14 ft-lb (19 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 294: Shift Cable Inspection

    5. If the gaps are not equal, loosen the four bracket bolts . Move the bracket until the gaps are equal and tighten the fasteners to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 295 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 296: Transmission Service

    (see Chapter 5 – PVT Disassembly (2014–2015), page NOTE Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 297 Reinstall the lower shock bolts to hold the trailing arms up during the rest of the removal procedure. 19. Remove wire ties retaining harness transmission and mounts. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 298 Remove the fasteners that attach the rear mount to the transmission. Remove the mount assembly from the vehicle. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 299: Transmission Installation

    Rear Transmission Isolator Fasteners 40 ft-lb (54 Nm) 5. Install the two rear exhaust springs securing the muffler to the rear transmission mounting bracket. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.11 © Copyright Polaris Industries Inc.
  • Page 300 12. Remove the clutch center distance tool. NOTE 13. Remove the spacer or support between the vehicle DO NOT torque fasteners at this time. frame and engine. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.12 © Copyright Polaris Industries Inc.
  • Page 301 17. Install and properly route the vent hose. 18. Lubricate the transmission splines and mid prop shaft joint splines with Polaris All Purpose Grease. Install the prop shaft onto the transmission output shaft (see Chapter 7 – Rear Prop Shaft Installation, page 7.25).

  • Page 302: Transmission Vent Line Routing

    27. If transmission lubricant was drained, fill the bracket. The line terminates to open air (does not transmission with the specified amount of Polaris terminate to a fitting or hole in the frame). AGL (see Chapter 2 – Transmission Lubrication, page 2.48).
  • Page 303 Note the timing marks on the shift gears for reassembly purposes. 10. Remove the O-rings from each shaft and discard. Use new O-rings upon assembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.15 © Copyright Polaris Industries Inc.
  • Page 304 16. Place the gear cluster assembly on a clean surface for inspection. If disassembly is required, refer to “Gear Cluster Disassembly”. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 305 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 306 Snorkel Tool: PA-50231 31. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 307: Differential Operation

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 308 This locks the rear differential as a solid rear axle, increasing traction. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 309 Differential Cover Assembly Planetary Differential Assembly Fasteners Engagement Dog Bearing Shift Fork Retainer Fastener Torsion Spring Retainer Shift Fork Solenoid Spring Solenoid 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 310: Planetary Differential Disassembly (Turf Mode Models Only)

    Planetary Differential Bushing Replacement (Turf Mode Models Only), page 6.23. 2. Remove the six screws retaining the differential cover and remove the cover. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.22 © Copyright Polaris Industries Inc.

  • Page 311: Planetary Differential Bushing Replacement (Turf Mode Models Only)

    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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.23 © Copyright Polaris Industries Inc.
  • Page 312 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 313: Planetary Differential Assembly (Turf Mode Models Only)

    4. Apply Loctite® 2760™ to cover screws. Differential Cover Screws (8.8 Fastener): 22 ft-lb (30 Nm) TORQUE Differential Cover Screws (10.9 Fastener):28 ft-lbs (38 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.25 © Copyright Polaris Industries Inc.

  • Page 314: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.26 © Copyright Polaris Industries Inc.

  • Page 315: Transmission Assembly / Snorkel Gear Backlash Procedure

    Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.27 © Copyright Polaris Industries Inc.
  • Page 316 8. Apply Loctite ® ™ to the threads of the bearing and may have some tight spots. cover retaining screws. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 317 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.29 © Copyright Polaris Industries Inc.
  • Page 318 Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.30 © Copyright Polaris Industries Inc.
  • Page 319 28. Install the spacer and then 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.31 © Copyright Polaris Industries Inc.
  • Page 320 12 ft-lb (16 Nm) 34. Install the transmission drain plug and torque to specification. TORQUE Fill / Drain Plug: 14 ft-lbs (19 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.32 © Copyright Polaris Industries Inc.

  • Page 321: Troubleshooting

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.33 © Copyright Polaris Industries Inc.
  • Page 322 TRANSMISSION NOTES 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 6.34 © Copyright Polaris Industries Inc.
  • Page 323 ..............7.38 BEADLOCK RIMS (IF EQUIPPED) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 324: General Information

    Roll Pin Removal Tool CV Boot Clamp Pliers 8700226 (earless type) Axle Boot Clamp Tool PU-48951 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 325: Bearing Carrier

    12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 326: Front Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 327: Front Bearing Carrier Installation

    6. Install new brake caliper mounting bolts and torque to specification. TORQUE Front Caliper Mounting Bolts: TORQUE 30 ft-lb (41 Nm) Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 328: Rear Bearing Carrier Inspection / Removal

    5. Remove the lower radius rod outer mounting bolt nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 329 11. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 330: Rear Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 331: Rear Bearing Carrier Installation

    Radius Rod to Bearing Carrier Fasteners: M10: 40 ft-lb (54 Nm) M12 (outer): 50 ft-lb + 90° (68 Nm + 90°) 3. Apply anti-seize to drive shaft splines. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 332 120 ft-lbs (163 Nm) 8. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 333: Drive Shaft

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 334: Front 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.12 © Copyright Polaris Industries Inc.

  • Page 335: Rear Drive Shaft Removal

    2. Remove the four wheel nuts and rear wheel. rear trailing arm assembly outward until it is free from the rear drive shaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.13 © Copyright Polaris Industries Inc.

  • Page 336: Rear Drive Shaft Installation

    Torque fastener to specification. TORQUE Stabilizer Bar Linkage: 40 ft-lbs (54 Nm) 6. Apply Anti-Seize to drive shaft axle splines. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 337 Torque fasteners to specification. TORQUE Radius Rods to Bearing Carrier: M10: 40 ft-lb (54 Nm) M12 (outer): 50 ft-lb + 90° (68 Nm + 90°) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 338: Drive Shaft / Cv Joint Handling Tips

    IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.16 © Copyright Polaris Industries Inc.
  • Page 339 10. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.17 © Copyright Polaris Industries Inc.

  • Page 340: Inner Plunging Joint / Boot Replacement

    9. Visually inspect the joint for damage. Replace if needed. 10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 341 17. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 342: Prop Shaft Service

    Roll Pin Removal Tool: PN 2872608 NOTE Right front wheel can be removed to gain better access to the propshaft roll pin. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.20 © Copyright Polaris Industries Inc.

  • Page 343: Rear Prop Shaft Removal

    3. While moving the prop shaft support bearing assembly, slide the rear prop shaft towards the rear until the front prop shaft yoke disengages from the splines. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.21 © Copyright Polaris Industries Inc.

  • Page 344: Rear Prop Shaft Removal Xp 4

    6. Move the prop shaft support bearing assembly to the drivers side to slide the rear prop shaft yoke off the transmission output shaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.22 © Copyright Polaris Industries Inc.

  • Page 345: Support Bearing Replacement

    Chapter 7 – Rear Prop Shaft Installation, page 7.25). 5. Install the new support bearing assembly onto the end of the prop shaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 346: U-Joint Disassembly

    If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.24 © Copyright Polaris Industries Inc.

  • Page 347: Front Prop Shaft Installation

    Reference these marks during Torque bolts to specification. installation if still visible. TORQUE Front Gearcase Mounting Bolts: 35 ft-lbs (47 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 348: Rear Prop Shaft Installation Xp 4

    Reference these marks during installation if still visible. 5. Torque the support bearing fasteners to specification. TORQUE Support Bearing Fasteners: 35 ft-lb (47 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 349: Front Gearcase / Centralized Hilliard

    Fill / Check Plug Roller Cage 10 ft-lbs (14 Nm) Roller Pinion Gear Spring Retainer Snap Ring Cover Plate Screws O-ring 11 ft-lbs (15 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 350: All Wheel Drive Operation

    3. If electrical tests are within specification, remove gearcase (see Chapter 7 – Front Gearcase Removal, page 7.30) and inspect components. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.28 © Copyright Polaris Industries Inc.
  • Page 351 AWD system. If this is found, replace the cover plate assembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.29 © Copyright Polaris Industries Inc.

  • Page 352: Front Gearcase Removal

    Lift and remove the gearcase from the front LH wheel well area and slide it out of the vehicle above the upper A-arm. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.30 © Copyright Polaris Industries Inc.
  • Page 353 AWD Diagnosis, page 7.28 for detailed inspection process. 6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 354 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.32 © Copyright Polaris Industries Inc.

  • Page 355: Front Gearcase Assembly

    Bearing Roller Surface Spacer Thrust Bearing 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 356 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 357 Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. TORQUE Cover Plate Screws: 9 ft-lbs (12 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.35 © Copyright Polaris Industries Inc.

  • Page 358: Front Gearcase Installation

    The vent line is secured by one retaining clip and is routed through a hole in the frame support behind the radiator. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.36 © Copyright Polaris Industries Inc.

  • Page 359: Wheel Hubs

    120 ft-lbs (163 Nm) Wheel Bearing Valve Stem Wheel Hub Hub Castle Nut Bearing Carrier Brake Disc 180 ft-lbs (244 Nm) REAR HUB ASSEMBLY VIEW 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.37 © Copyright Polaris Industries Inc.

  • Page 360: Beadlock Rims (If Equipped)

    Step 1: 24 in-lbs (3 Nm)Step 2: 7 ft-lbs (10 Nm) NOTE Beadlock bolts should be checked and torqued every 300 miles (450 km). 7. Seat bead and inflate to 16 psi. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 7.38 © Copyright Polaris Industries Inc.
  • Page 361 ..............8.29 VALVE SHIM ARRANGEMENT 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 362 ............. .8.33 WALKER EVANS™ SHOCK ASSEMBLY 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 363: General Information

    MULTI-FUNCTION PLIERS Included in the tool kit, the multi-function pliers is designed to remove the plastic push rivets used to fasten body components. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 364: Steering System

    8 ft-lb (11 Nm) 8 ft-lb (11 Nm) Tie Rod End Jam Nut Tilt Steering Shock EPS Mount Bracket 14 ft-lbs (19 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 365: Upper Steering Shaft Removal

    2. Remove the pinch bolt retaining the upper steering shaft to the power steering unit. 3. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 366: Steering Wheel Removal

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 367 IMPORTANT Electronic Power Steering (EPS) units are programmed to be vehicle specific and are not interchangeable between product lines. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 368: Lower Steering Shaft Removal

    5. Lift up on the shaft and remove it through the floor panel. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 369: Power Steering Unit Installation

    Torque to specification. TORQUE Lower Steering Shaft to EPS Unit Pinch Bolt: 15 ft-lbs (20 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 370: Upper Steering Shaft Installation

    Torque the nut to specification and reinstall the plastic wheel cover. TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 371: Steering Shaft Bearing Replacement

    65 ft-lbs (88 Nm) 15. Wipe the pivot tube clean of any excess Loctite ® 16. Install steering wheel cap and field test steering operation. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 372: Front Suspension

    TORQUE 6. Remove the front bumper to allow A-arm bolt Front Ball Joint Pinch Bolts: removal. 42 ft-lbs (57 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 373: Front Stabilizer Bar Removal

    2. Remove the Fasteners retaining the stabilizer bar mount to the frame. 3. Remove the stabilizer bar out the side of the vehicle. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 374: Front Stabilizer Bar Installation

    4. Install the nut retaining the front stabilizer bar link to the upper control arm on both sides. Torque fasteners to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 375: Ball Joint Service Preparation

    3. Carefully press the ball joint out of the A-arm and discard the ball joint. Wheel Nuts (Alum): 120 ft-lbs (163 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 376: Rear Suspension

    6. Remove radius rods from vehicle. 7. Examine radius rod shafts, boots and spherical bearings. Replace entire radius rod if any excessive wear is evident. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.16 © Copyright Polaris Industries Inc.
  • Page 377 6. Remove the rear wheel hub and brake disk assembly. 7. Remove the five remaining bolts that attach the rear bearing carrier to trailing arm. Discard the nuts. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.17 © Copyright Polaris Industries Inc.
  • Page 378 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) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 379: 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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 380: Rear Suspension Assembly View

    Rear Bearing Carrier 20 ft-lb (27 Nm) Bearing Carrier Bolts Trailing Arm Mounting Bolts 40 ft-lb (54 Nm) 70 ft-lb (95 Nm) Trailing Arm 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 381: Rear Stabilizer Bar Removal

    7. Carefully remove the stabilizer from the LH wheel well area of the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 382: Shocks / Springs

    Step 1 (see Chapter 2 – Spring Adjustment (WALKER EVANS™), page 6. Reinstall the shock onto the vehicle and torque new fasteners to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 383: Shock Service

    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 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 384: General Service Information

    25.10″ (63.75 cm) 2.875″ (73.02 cm) All models Location Nitrogen Pressure 125 psi (862 kPa) +/- 5% 2874124 (qt.) Gas Shock Oil 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.24 © Copyright Polaris Industries Inc.
  • Page 385 0.900 x 0.010 1.300 x 0.008 0.750 x 0.065 1.200 x .012 1.100 x .012 0.750 x 0.065 Piston Bleed Orifice: none 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 386: Rear Shock Service Information

    1.450 x 0.010 0.800 x 0.010 1.100 x 0.012 0.750 x 0.065 1.000 x 0.012 1.500 x 0.125 No Piston Bleed Orifice 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 387 1.000 x 0.095 1.550 x 0.008 1.450 x 0.010 1.300 x 0.012 1.200 x 0.012 1.500 x 0.125 Piston Bleed Orifice: 0.100″ 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.27 © Copyright Polaris Industries Inc.

  • Page 388: Spring Adjustment (Walker Evans)

    Suspension springs may be adjusted to suit different riding conditions or vehicle payloads. NOTE Polaris does not recommend increasing the spring WARNING adjustment by more than one inch (25.4 mm) over the Uneven adjustment may cause poor handling of the...

  • Page 389: Walker Evans™ Shock Rebuild Information

    The rebound and compression valve stacks will always be positioned as shown in the illustration, regardless of how the shock assembly is installed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.29 © Copyright Polaris Industries Inc.
  • Page 390 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.30 © Copyright Polaris Industries Inc.
  • Page 391 Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.31 © Copyright Polaris Industries Inc.
  • Page 392 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.32 © Copyright Polaris Industries Inc.
  • Page 393 NOTE If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.33 © Copyright Polaris Industries Inc.
  • Page 394 15. Screw IFP Tool (PS-45908) onto the floating piston. FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.34 © Copyright Polaris Industries Inc.
  • Page 395 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.35 © Copyright Polaris Industries Inc.
  • Page 396 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.36 © Copyright Polaris Industries Inc.
  • Page 397 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 398 STEERING / SUSPENSION NOTES 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 399 ................9.28 CALIPER DISASSEMBLY 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 400 ................... .9.32 BRAKES LOCK 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 401: General Information

    • Perform a brake burnishing procedure after installing new pads to maximize service life. • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 402: 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 403: Brake System Overview

    Brake Tee-Fitting MC Rear Brake Line Bleed Screw 47 in-lbs (5 Nm) RH Rear Brake Line Banjo Fitting 15 ft-lbs (20 Nm) Brake Switch 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 404: Brake Line Routing / Retention

    BRAKE SYSTEM BRAKE LINE ROUTING / RETENTION FRONT BRAKE LINES TO MASTER CYLINDER Brake Line Retaining Clip Control Arm Brake Line Retainer 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 405: Rear Brake Line - Master Cylinder To Junction Block

    BRAKE SYSTEM REAR BRAKE LINE - MASTER CYLINDER TO JUNCTION BLOCK Brake Line Retaining Clip Zip Tie 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 406: Rear Brake Lines - Junction Block To Calipers

    REAR BRAKE LINES - JUNCTION BLOCK TO CALIPERS NOTE Brake lines route inside the stabilizer bar and shock mounts as shown. Brake Line Retaining Clip Trailing Arm Brake Line Retainer 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 407: Master Cylinder

    IMPORTANT Lubricate seals with a thin film of DOT 4 brake fluid prior to installation. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 408 7. Perform the BRAKE BLEEDING / FLUID CHANGE, page 9.11 procedure. TORQUE Banjo Bolt / Brake Pressure Switch: 15 ft-lbs (20 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 409: Brake Bleeding / Fluid Change

    1. Clean master cylinder reservoir cover thoroughly and remove the cover Polaris DOT 4 Brake Fluid 2872189 4. Bleed the brakes in the following order: right rear, left rear, right front and finally the left front. Install a box end wrench on caliper bleeder screw.
  • Page 410 Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 411: Brake Pedal Lever

    2. Remove the E-clip from the pedal mount and remove the brake pedal lever from the vehicle. Brake Pedal Free-play: 0.090″ (2.28 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 412: Front Brakes

    Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 413: Pad Assembly / Installation

    Maintain at least 1/2" (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 414: Front Caliper Assembly View

    Socket Set Screw Pistons Bleeder Screw 48 in-lb (5 Nm) Caliper Mount Caliper Assembly Brake Pads Brake Scraper Boots Square O-Rings Bolts 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 415: Caliper Removal

    . Remove brake line from caliper. 5. Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 416: Caliper Disassembly

    Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 417: Caliper Inspection

    Replace if damaged or worn beyond may drag upon assembly. service limit. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing MEASUREMENT inward. Piston should slide in and out of bore smoothly, with light resistance.

  • Page 418: Caliper Installation

    NOTE If new pads are installed, refer to Brake Burnishing Procedure, page 9.15. TORQUE Banjo Bolt 15 ft-lbs (20 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 419: Disc Runout

    Service Limit: 0.170″ (4.32 mm) Brake Disc Thickness Variance Service Limit: 0.002″ (.051 mm) Brake Disc Runout: Service Limit: .010″ (0.254 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 420: Disc Replacement

    30 ft-lb (41 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 421: Rear Brakes

    Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.23 © Copyright Polaris Industries Inc.

  • Page 422: Pad Inspection

    8. Remove the inner brake pad. MEASUREMENT Rear Brake Pad Thickness: .298 ± .007″ (7.57 mm ± .178 mm) Service Limit: .180″ (4.6 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 423: Pad Assembly / Installation

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 424: Rear Caliper Assembly View

    REAR CALIPER ASSEMBLY VIEW Socket Set Screw Pistons Bleeder Screw 48 in-lb (5 Nm) Boots Caliper Assembly Caliper Mount Square O-Rings Brake Pad 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 425: Caliper Removal

    Discard nut. 5. Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 426: Caliper Disassembly

    Rear Caliper Piston O.D.: Standard: 1.500″ (38.10 mm) Service Limit: 1.498″ (38.05 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.28 © Copyright Polaris Industries Inc.

  • Page 427: Caliper Assembly

    Torque mounting bolts to specification. may drag upon assembly. TORQUE 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion Rear Caliper Mount Bolt while pushing inward. Piston should slide in and out 40 ft-lbs (54 Nm) of bore smoothly with light resistance.

  • Page 428: Disc Inspection

    NOTE MEASUREMENT If new pads are installed, refer to Brake Burnishing Procedure, page 9.25. Brake Disc Runout: Service Limit: .010″ (0.254 mm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.30 © Copyright Polaris Industries Inc.

  • Page 429: Disc Replacement

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Brake Disc Mounting Bolts: 30 ft-lb (41 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 430: Troubleshooting

    • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.32 © Copyright Polaris Industries Inc.
  • Page 431 ............... . . 10.28 DOOR ADJUSTMENT 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.1 © Copyright Polaris Industries Inc.

  • Page 432: General Information

    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. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 433: Body Assembly Views

    Visor Screws 8 ft-lb (11 Nm) Front ROPS Bracket 40 ft-lb (54 Nm) Cab Frame Extenders Hip Bolster Lower Fasteners 14 ft-lb (19 Nm) Hip Bolster 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.3 © Copyright Polaris Industries Inc.
  • Page 434 17 ft-lb (23 Nm) Hip Bolster Bottom Fasteners ROPS Mid Hoop 14 ft-lb (19 Nm) Visor Fasteners Hip Bolster 8 ft-lb (11 Nm) ROPS Main 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.4 © Copyright Polaris Industries Inc.
  • Page 435 . 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) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 436: Doors

    Latch Striker 8 ft-lb (11 Nm) Door Latch Screws Hinge Pin 8 ft-lb (11 Nm) Striker Screws Latch Release 8 ft-lb (11 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.6 © Copyright Polaris Industries Inc.

  • Page 437: Doors (Xp4)

    BODY / FRAME DOORS (XP4) Door Panel Latch Release Door Frame Latch Door panel (Rear) Latch Striker Hinge Pin Door Frame (Rear) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 438: Doors High Lifter

    Latch Striker Upper Door Frame Latch Striker Screws (8 ft-lbs, 11 Nm) Lower Door Frame Hinge Screws (8 ft-lbs, 11 Nm) Hinge Pin 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.8 © Copyright Polaris Industries Inc.

  • Page 439: Dash Instruments / Controls

    BODY / FRAME DASH INSTRUMENTS / CONTROLS Headlight Switch Instrument Cluster Key Switch AWD Switch 12V Accessory Port Bezel 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.9 © Copyright Polaris Industries Inc.

  • Page 440: Dash Instruments / Controls High Lifter

    BODY / FRAME DASH INSTRUMENTS / CONTROLS HIGH LIFTER Instrument Cluster AWD Switch Key Switch Winch Switch 12V Accessory Port Bezel Headlight Switch 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 441: Hood / Front Body Work

    8 ft-lb (11 Nm) Lower Radiator Mount Screws Passenger Front Fender Flair 8 ft-lb (11 Nm) Fan Shroud Screws Hood 8 ft-lb (11 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.11 © Copyright Polaris Industries Inc.

  • Page 442: Chassis / Main Frame Xp / High Lifter

    M8 Fasteners14 ft-lb (19 Nm) Dash Frame Front Skid Plate T-40 Torx Fasteners8 ft-lbs (11 Rear Frame Cargo Box Brackets Rear Skid Plate 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 443: Chassis / Main Frame Xp 4

    BODY / FRAME CHASSIS / MAIN FRAME XP 4 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.13 © Copyright Polaris Industries Inc.

  • Page 444: Seat Assembly Front

    4 ft-lb (5 Nm) Screw Seat Back 4 ft-lb (5 Nm) Seat Base Seat Base Pad Seat Base Slider Assembly Seat Latch Lever 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 445: Seat Assembly Rear

    4 ft-lb (5 Nm) Seat Bottom Screws Seat Base Assembly 4 ft-lb (5 Nm) Seat Base Fasteners Seat Latch 4 ft-lb (5 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 446: Floor / Rocker Panels Xp / High Lifter

    RH Rocker T27 Screws Push Rivots LH Rocker Console Cover U-Type Nuts Seat Belt Boot Block Off Flap Shifter Boot Lower Floor 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 447: Floor / Rocker Panels Xp 4 / Xp 4 High Lifter

    Block Off Flap Console Rear Main Floor Lower Lower Rear Close-off Panel Upper Rear Close-off Panel Rocker RH B-Pillar Cover RH Floor Rear 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 448: Rear Cargo Box / Fenders

    Rear Fascia Support Brackets Shock Panel Bracket Fasteners Passenger Side Cargo Box Half 8 ft-lb (11 Nm) Driver Side Cargo Box Half Fender Flair 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 449: Rear Bumper

    Rear Fascia Fasteners Exhaust Cover/Bumper 8 ft-lb (11 Nm) Exhaust Cover Bracket (lower) Rear Fascia Fascia Support Brackets Exhaust Cover Bracket (upper) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 450: Body Component Removal

    • Remove the driver and passenger seats 2. Lift the panel upward and towards the front of the vehicle to remove the panel 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 451: Rear Bumper

    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.. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.21 © Copyright Polaris Industries Inc.

  • Page 452: Rear Fender / Fender Flair Removal Xp

    12. Remove the front portion of the cab frame assembly. Refer to appropriate Cab Frame Assembly XP, page 10.3 procedure for assembly torque specifications. 13. Remove the front fender. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 453: Rear Fender Flare / Rear Fender Removal Xp 4

    7. Remove the engine access panel and the panel locking pin 4. Remove the plastic rivets and one T40 Torx fastener retaining the rear fender. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 454: Rocker Panels, Console And Floor Xp

    10 – Floor / Rocker Panels XP / High Lifter, page 10.16). 3. Remove the T27 screws retaining the console to the floor. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.24 © Copyright Polaris Industries Inc.
  • Page 455 1. Remove seats and rocker panels (see Chapter 10 – Floor / Rocker Panels XP 4 / XP 4 High Lifter, page 10.17). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.25 © Copyright Polaris Industries Inc.
  • Page 456 5. Remove the rear console. 6. Remove two M10x1.25x20 bolts from the rear seat frame and two M10x1.50x55 bolts from the rear seat frame assembly. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.26 © Copyright Polaris Industries Inc.
  • Page 457 15. Remove the Torx screws retaining the main floor and remove the main floor from the vehicle. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.27 © Copyright Polaris Industries Inc.

  • Page 458: Doors

    Door Panel Fasteners: 22 in-lb (2 Nm) 5. Adjust the door so it properly opens and latches. Refer to Door Adjustment, page 10.28. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.28 © Copyright Polaris Industries Inc.
  • Page 459 . Torque to specification. TORQUE Door Hinge Fasteners: 8 ft-lb (11 Nm) 6. Install the door panel onto the door frame. Torque fasteners to specification. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.29 © Copyright Polaris Industries Inc.
  • Page 460 BODY / FRAME NOTES 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 10.30 © Copyright Polaris Industries Inc.
  • Page 461 ................11.29 DIAGNOSTICS 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.1 © Copyright Polaris Industries Inc.
  • Page 462 ..............11.47 BATTERY OFF SEASON STORAGE 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.2 © Copyright Polaris Industries Inc.
  • Page 463 ................. 11.68 CAN SYSTEM TESTING 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 464: General Information

    PU-50296 (MDX-610P) Relay Bypass PU-49466 Digital Wrench® (see Chapter 4 – DIGITAL WRENCH® OPERATION, page Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.4 © Copyright Polaris Industries Inc.
  • Page 465 • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. • Most electrical issues are related to damaged wiring. Fully test wiring before replacing any components. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 466: Electrical Service Notes

    DIGITAL MULTI-METER (DMM) NOTES • All associated circuits have no shorts to ground. Polaris advises to only use a high quality DMM that Testing For A Short To Ground, page 11.8 meets the same standards as the Fluke™ 77 (PV-43568) •...

  • Page 467: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris NOTE machines can be tested using terminal test kit PV–...

  • Page 468: Testing Continuity/Resistance

    Short To Voltage, page 11.9 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 469: Testing For A Short To Voltage

    Here is a list of possible failures that can be associated with an intermittent electrical failure: 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 470: Testing Current Flow (Amperage)

    Failure to do so can lead to Serious injury and/or damage to the machine. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 471: Testing Parasitic Draw

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 472: Instrument Cluster

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.12 © Copyright Polaris Industries Inc.
  • Page 473 Hours Indicator - Illuminates when Hours are being displayed on the Information Display Mode Button - Used to move through the menu features. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 474: Information Display Area

    Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. Engine Hours 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.14 © Copyright Polaris Industries Inc.
  • Page 475 2. Press and hold the MODE button while turning the 4. To turn off the service interval function, toggle the key to the ON position. MODE button until “OFF” is displayed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.15 © Copyright Polaris Industries Inc.
  • Page 476 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 477: Diagnostic Mode

    MIL will illuminate and blink in place of the check engine MIL. 2. Press and hold the MODE button to enter the diagnostics code menu. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 478: Instrument Cluster Pinouts

    1. Disconnect the wire harness connector from the instrument cluster. back side of the instrument cluster. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 479: Ride Command System

    ELECTRICAL RIDE COMMAND SYSTEM RIDE COMMAND DISPLAY Gauge Screen Button Audio Button Map Button Device Manager Button App Screen Button 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 480: Touchscreen Buttons / Icons

    5. Press on the coolant icon to cycle to battery voltage, and turbo boost pressure (if applicable), then back to engine temperature. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 481: Audio

    • Option 2) press the Navigation Menu icon shown below to open the rides and way point management menu. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.21 © Copyright Polaris Industries Inc.
  • Page 482 Navigate to waypoint icon. Or simply press the view waypoint icon to view it on your navigation screen. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.22 © Copyright Polaris Industries Inc.
  • Page 483 Simply USB drive, plug the USB drive in to the USB pigtail/ create or join a group with your friends from the Polaris port (to find this location refer to page 31) and press RIDE COMMAND™...

  • Page 484: Device Manager

    “OK” on your phone. Connect Your Phone With The Display The RIDE COMMAND™ Display is compatible with Android and iOS. Check polaris. com/ridecommand for latest operating system compatibility. Click on the Bluetooth icon below the cellphone image to open up the Bluetooth connection window.
  • Page 485 Bluetooth. 8. After a phone is connected, the Device Manager Screen will appear as shown below. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.25 © Copyright Polaris Industries Inc.
  • Page 486 USB music playback is not available on all devices. Connecting Your Bluetooth Headset With The Display The Display can connect with Polaris approved Bluetooth headsets to listen to music, take phone calls, and talk with other riders. Use the following steps to connect your Bluetooth headset to the Display.

  • Page 487: Apps Screen

    Press the Apps Menu button shown above to display the Apps Menu. From this menu Settings, Diagnostics, Lock Screen, GPS Satellite Status, Ride Stats, and GoPro features can all be accessed. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.27 © Copyright Polaris Industries Inc.

  • Page 488: General Settings

    VEHICLE By pressing the vehicle tab on the left side users can see oil life. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.28 © Copyright Polaris Industries Inc.

  • Page 489: Diagnostics

    For a system diagnostics inspection and/or service, please see your authorized Polaris dealer. RIDE STATUS The Ride Stats icon shows a summary of previous rides.

  • Page 490: Engine Overheat Indicators

    12. Press "Preview" on the display to pull an image NOTE preview and confirm that the camera is operating Polaris recommends the use of a MicroSD card properly. comparable to a SanDisk Extreme Plus for optimal • To record an image or video press the Capture button experience.

  • Page 491: Update Software / Maps

    Do not remove the USB until the display has fully restarted. UPDATE MAPS 1. To update maps on the display go to my.polaris.com and download the map update to a USB flash drive. 2. Insert the USB flash drive into the USB pigtail/port on your vehicle.

  • Page 492: Ride Command Troubleshooting

    2. Fix any shorts in the wiring and reinstall new fuse. Go to Step 8 Go to Step 4 Did you find and repair the condition? 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.32 © Copyright Polaris Industries Inc.
  • Page 493 7. If resistance value is out of spec, check for breaks in yellow/green CAN wiring. 8. If all values are within specification, replace GPS antenna with new unit. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.33 © Copyright Polaris Industries Inc.

  • Page 494: Switches

    4. For switch replacement, refer to Chapter 9 “Brakes”. NOTE Pins 7 and 8 provide power and ground to light the switch lamp. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.34 © Copyright Polaris Industries Inc.

  • Page 495: Ignition / Key Switch

    A, B and D. • Turn the key to START position. There should be continuity between all the pins on the switch. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.35 © Copyright Polaris Industries Inc.

  • Page 496: Transmission / Gear Position Switch

    HIGH 620 Ω Between both 300 Ω ∞ (OL) < 1 Ω pins on switch 160 Ω 75 Ω PARK 24 Ω 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.36 © Copyright Polaris Industries Inc.

  • Page 497: Hazard Switch (Int'l / Tractor)

    • Turn on the Right Turn Signal. There should be continuity between switch pins 1 and 7. • Depress the Horn. There should be continuity between switch pins 3 and 4. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.37 © Copyright Polaris Industries Inc.

  • Page 498: Horn

    The rear turn lights are integrated into the rear taillight. If the taillights are functioning properly but there is no blinker, check the wiring connections and the flasher module. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.38 © Copyright Polaris Industries Inc.

  • Page 499: Brake Alarm (Int'l/Tractor)

    CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.39 © Copyright Polaris Industries Inc.

  • Page 500: All Wheel Drive Coil

    80% of all electrical issues are caused by bad/failed connections and grounds. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.40 © Copyright Polaris Industries Inc.

  • Page 501: Vehicle Speed Sensor

    4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.41 © Copyright Polaris Industries Inc.

  • Page 502: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Mounting Bolt: 8 ft-lb (11 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.42 © Copyright Polaris Industries Inc.

  • Page 503: Charging System

    The battery should be fully charged before performing this test. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.43 © Copyright Polaris Industries Inc.

  • Page 504: Stator (Alternator) Replacement

    7. Refer to the following table for approximate AC Voltage readings according to RPM. Test each leg at the specified RPM in the table. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.44 © Copyright Polaris Industries Inc.

  • Page 505: Voltage Regulator

    8. Install the battery negative terminal. Torque fastener to specification. TORQUE 3. Disconnect both regulator connectors Battery Terminal Fastener: 60 in-lbs (7 Nm) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.45 © Copyright Polaris Industries Inc.

  • Page 506: Battery

    ELECTRICAL BATTERY BATTERY SPECIFICATIONS GENERAL BATTERY INFORMATION Polaris / Johnson Controls 575 WARNING Type Sealed - Maintenance Free CALIFORNIA PROPOSITION 65 WARNING:Batteries, Voltage 12 Vdc battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known...

  • Page 507: Battery Removal / Installation

    NOTE To perform this test, use a load testing device that has an Battery charge can be maintained by using a Polaris adjustable load. Apply a load of three times the ampere- battery tender or by charging once a month to make up hour rating.

  • Page 508: Charging Procedure

    Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.48 © Copyright Polaris Industries Inc.

  • Page 509: Lighting System

    (see Chapter 10 – Front Bumper XP, page 10.20). 3. Carefully lift and remove headlamp assembly from the bumper. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.49 © Copyright Polaris Industries Inc.

  • Page 510: Headlamp Installation

    12 volts and that a ground path is present. 1. Disconnect the wire harness 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.50 © Copyright Polaris Industries Inc.

  • Page 511: Cooling System

    This indicates all other and connector terminals. components are working properly. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.51...

  • Page 512: Ect Sensor Replacement

    7. Reinstall the throttle body. 8. Add the required amount of coolant and bleed the system (see Chapter 3 – Cooling System Bleeding Procedure, page 3.15). 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.52 © Copyright Polaris Industries Inc.

  • Page 513: Starting System

    Refer to the voltage drop tests on the starter system in this chapter. Voltage should not exceed 0.1 DC volts per connection 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.53 © Copyright Polaris Industries Inc.

  • Page 514: Starter Motor Installation

    12V power via the Green / White wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.54 © Copyright Polaris Industries Inc.

  • Page 515: Electronic Power Steering

    EPS system is detected, PROPER EPS SYSTEM DIAGNOSING the system will illuminate a fault indicator and transition READ BEFORE YOU REPLACE THE EPS UNIT! to a normal mechanically coupled steering system. The system is Polaris Digital Wrench® compatible for NOTE simplified diagnostics system troubleshooting through the vehicle’s diagnostic port.

  • Page 516: Eps Troubleshooting (Power Steering Non-Functional With Mil On)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.56 © Copyright Polaris Industries Inc.

  • Page 517: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.57 © Copyright Polaris Industries Inc.

  • Page 518: Eps Troubleshooting (Using Digital Wrench®)

    ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.58 © Copyright Polaris Industries Inc.

  • Page 519: Fuses / Relays

    Power Out Coil Low Coil High Fuel Pump Power In Relay Power Out Coil Low Power In Unsw 10A Fuse Power Out 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.59 © Copyright Polaris Industries Inc.
  • Page 520 Power Out Coil Low Power In Unsw 10A Fuse Power Out Power In Drive 10A Fuse Power Out Chassis Relay Coil High 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.60 © Copyright Polaris Industries Inc.

  • Page 521: Rzr Xp 1000 (High Lifter)

    Power Out Coil Low Power In Key 10A Fuse Power Out Power In Drive 10A Fuse Power Out Chassis Relay Coil High 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.61 © Copyright Polaris Industries Inc.
  • Page 522 Power Out Coil Low Power In Key 10A Fuse Power Out Power In Drive 10A Fuse Power Out Chassis Relay Coil High 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.62 © Copyright Polaris Industries Inc.

  • Page 523: Relay / Fuse / Circuit Breaker Details

    Accy 10A Fuse 12V Receptacle(s) Key 10A Fuse Key Switch Instrument Cluster Diagnostic Plug Instr Fuse Out Splice Insr 10A Fuse LED Light(s) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.63 © Copyright Polaris Industries Inc.
  • Page 524 B+ ACC Fuse Out Splice Term 10A Fuse Winch Remote Accy 10A Fuse (15A for XP 4) 12V Acc Splice 12V Receptacle(s) 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.64 © Copyright Polaris Industries Inc.

  • Page 525: Wiring Harness

    WIRING HARNESS MAIN HARNESS RETENTION LOCATIONS Front The white tape on a harness signifies a retention point. Zip Tie Retention Locations Rear 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.65 © Copyright Polaris Industries Inc.

  • Page 526: Main Harness Routing

    ELECTRICAL MAIN HARNESS ROUTING 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.66 © Copyright Polaris Industries Inc.

  • Page 527: Break-Out Diagram Viewing

    2. If the wiring diagram does not open the Adobe navigation bars, click on the Adobe Icon. 3. Click on the Layers Icon. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.67 © Copyright Polaris Industries Inc.

  • Page 528: Can System

    • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 11.68 © Copyright Polaris Industries Inc.
  • Page 529 Routing ..............9.6 Console Brake Pad Removal............ 10.24–10.25 Inspection.............2.57 Continuity ..............11.8 Installation (Front) ..........9.15 Control Arm Thickness .............9.14 Replacement (front) ..........8.12 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 530 Decal Replacement ...........10.2 Replacement..........4.11, 4.61 Decimal Equivalent Chart..........1.39 Diagnostic Trouble Codes (ETC) ........4.46 Operation Overview ..........4.7 Differential Service Notes ............4.4 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 531 Installation ............ 4.27, 4.29 Removal............4.25, 4.28 Fuel Vent Line Routing ..........4.19 Testing ..............4.41 ETC Learn Procedure ......... 4.12, 4.41, 4.61 Fuse 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 532 Piston to Cylinder Clearance........3.57 Plunging Joint / Boot Leakdown Test ............2.32 Replacement (Inner) ..........7.18 Lower Steering Shaft Polaris Mobile Digital Wrench (PMDW) ......4.64 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 533 RZR XP 4 1000 High Lifter ........1.17 Rocker Panels XP 4 ..........10.17 Transmission and Front Gearcase ......2.48 Walker Evans 2.0 Shocks.........8.24 Speedometer ............11.12 Spring 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 534 VIN Location ............. 1.2 Voltage Drop ............11.11 Toe Adjustment ............2.54 Voltage Drop Test ............ 11.53 Torque Specifications Master ..............1.8 Voltage Regulator............ 11.45 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 535 Wheel Bearing Replacement (front) ..........7.4 Replacement (rear)..........7.8 Wheel Hub Assembly View (front) ..........7.37 Assembly View (rear) ..........7.37 Wheel Toe Adjustment..........2.54 9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual IX.7 © Copyright Polaris Industries Inc.

This manual is also suitable for:

Rzr xp4 1000 2017Rzr xp 1000 2018Rzr xp4 1000 2018

Table of Contents