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Polaris RZR XP 1000 2017

Polaris RZR XP 1000 2017
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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.
2017-2018 RZR XP 1000 / XP4 1000
Service Manual

Table of Contents

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Polaris RZR XP 1000 2017 Specifications

General IconGeneral
BrandPolaris
ModelRZR XP 1000 2017
CategoryAutomobile
LanguageEnglish

Summary

Chapter 1 General Information

Special Tools

Lists specialized tools required for general information procedures, including part numbers.

Master Torque Table

Provides a comprehensive table of torque specifications for various components and fasteners.

General Specifications

Details key dimensions and capacities for the RZR XP 1000 model.

Chapter 2 Maintenance

Periodic Maintenance Chart

Outlines routine inspection and maintenance items required for the vehicle.

Maintenance Intervals

Details required maintenance and inspection based on vehicle hours or miles.

Lubricants Service Products

Lists recommended lubricants, service products, and their part numbers.

Engine Oil and Filter Change

Provides step-by-step instructions for changing the engine oil and filter.

Cooling System

Covers the overview, specifications, pressure testing, and hose inspection of the cooling system.

Fuel System and Air Intake

Details inspection and service procedures for the fuel system and air intake components.

PVT Final Drive Wheel and Tire

Covers inspection and service for the PVT system, final drive, wheels, and tires.

Transmission and Front Gearcase

Provides specifications and procedures for transmission and front gearcase lubrication.

Steering

Covers inspection and adjustment procedures for the steering system components.

Suspension

Details spring and shock adjustment procedures for Walker Evans™ suspension.

Brake System

Covers inspection, bleeding, and component service for the brake system.

Electrical and Ignition System

Details battery maintenance, installation, testing, and ignition system service.

Chapter 3 Engine Cooling System

Special Tools

Lists essential special tools required for engine and cooling system service.

Engine Lubrication Specifications

Provides fluid capacities, oil types, filter wrench, and oil pressure specifications.

Engine Specifications (1000)

Details standard and service limit measurements for camshaft, cylinder head, cylinder, and valve components.

Intake Exhaust System

Provides assembly views for the air box, air filter, and exhaust system components.

Engine Cooling System

Covers system specifications, pressure testing, hose inspection, and coolant procedures.

Engine Service

Lists accessible engine components and those requiring engine removal for service.

Crankshaft PTO Seal Replacement

Detailed procedure for replacing the crankshaft PTO seal using special tools.

Engine Removal

Step-by-step instructions for removing the engine assembly from the vehicle.

Engine Installation

Provides instructions for installing the engine assembly into the vehicle frame.

Engine Mounting and Torque Values

Details torque specifications for engine mounting hardware.

Engine Disassembly Inspection - Top End

Instructions for removing and inspecting valve cover, camshafts, and related components.

Cylinder Head Removal

Procedure for removing the cylinder head assembly from the engine.

Valve Inspection

Details inspection procedures for valves, valve springs, and related components.

Combustion Chamber Cleaning

Instructions for cleaning carbon deposits from combustion chambers and valve seat areas.

Valve Sealing Test

Procedure to test valve seats for proper sealing using a solvent.

Engine Disassembly Inspection - Bottom End

Instructions for removing and inspecting the stator cover and water pump housing.

Crankcase Disassembly Inspection

Procedures for removing and inspecting crankcase components, including oil pump and sump cover.

Cylinder Inspection

Details inspection for cylinder warp, wear, and taper using measurement tools.

Piston Connecting Rod Assembly

Instructions for lubricating and assembling pistons to connecting rods with circlips.

Crankshaft Installation

Procedure for installing the crankshaft with main and connecting rod bearings.

Chapter 4 Fuel System

Special Tools

Lists specialized tools for EFI system testing, including Digital Wrench and gauges.

EFI Overview

Provides an overview of the Electronic Fuel Injection system and important service notes.

Initial Priming Starting Procedure

Step-by-step guide to prime the injection system before initial engine startup.

EVAP System

Overview of the evaporative emission control system and its components.

Electronic Control Unit (ECU)

Details ECU operation, service, replacement, and reprogramming procedures.

ETC Learn Procedure

Procedure required after ECU or throttle body replacement/reflash.

Fuel Injectors

Covers injector operation, O-rings, troubleshooting, testing, and replacement.

Fuel Lines Tank

Provides assembly views and procedures for fuel lines, fuel tank removal and installation.

Fuel Pump

Details fuel pump operation, testing, and replacement procedures.

Temperature and Manifold Absolute Pressure Sensor (T-MAP)

Explains the T-MAP sensor's operation, testing, and replacement.

Crankshaft Position Sensor (CPS)

Covers CPS operation, testing, and replacement procedures.

Electronic Throttle Control (ETC) Throttle Body

Details ETC/throttle body operation, service, and removal procedures.

Pedal Position Sensor (PPS)

Covers PPS operation, testing, and replacement procedures.

Oxygen Sensor

Provides information on oxygen sensor operation, testing, and replacement.

EFI Diagnostics

Explains trouble code display and provides a diagnostic trouble code table.

Polaris Digital Wrench

Information on diagnostic software, updates, and troubleshooting communication errors.

Chapter 5 PVT System

Special Tools and Supplies

Lists specialized tools and supplies required for PVT system service.

RZR XP 1000 Clutch Chart

Provides clutch specifications for RZR XP 1000 models.

PVT System Overview

Explains the general operation of the Polaris Variable Transmission (PVT) system.

PVT Break-in (Drive Belt Clutches)

Details the recommended break-in procedure for clutches and drive belt.

Maintenance Inspection

Lists items that should be inspected and maintained for optimal PVT system performance.

PVT Overheating Diagnosis

Provides diagnostic steps for PVT system overheating issues.

PVT System Service

Details service procedures for PVT covers and ducting components.

Drive Belt

Covers drive belt removal, inspection, and installation procedures.

Drive Clutch Service

Provides assembly views and disassembly/inspection procedures for the drive clutch.

Driven Clutch Service

Details inspection, disassembly, and assembly procedures for the driven clutch.

Chapter 6 Transmission

Special Tools

Lists specialized tools required for transmission service.

Lubrication

Details recommended transmission lubricant and fluid capacity.

Shift Lever Cable

Covers shift lever and cable removal, installation, and adjustment procedures.

Transmission Service

Provides step-by-step instructions for transmission removal and installation.

Transmission Disassembly

Detailed instructions for disassembling the transmission components.

Differential Operation

Explains the operation of the differential modes (Turf Mode).

Planetary Differential Disassembly (Turf Mode Models Only)

Procedure for disassembling the planetary differential in turf mode vehicles.

Gear Shaft Bearing Inspection

Instructions for inspecting all gear sets, shafts, and bearings for wear or damage.

Transmission Assembly Snorkel Gear Backlash Procedure

Procedure for assembling the snorkel tube and checking gear backlash.

Troubleshooting

Provides troubleshooting guidance for shifting difficulties encountered with the transmission.

Chapter 7 Final Drive

Special Tools

Lists specialized tools required for final drive service.

Bearing Carrier

Covers inspection, removal, and replacement of front and rear bearing carriers.

Drive Shaft

Details removal and installation procedures for front and rear drive shafts.

Prop Shaft Service

Covers front and rear propshaft removal and installation procedures.

Front Gearcase Centralized Hilliard

Provides assembly views and disassembly/inspection for the front gearcase.

All Wheel Drive Operation

Explains the operation of the AWD system and its engagement criteria.

AWD Diagnosis

Troubleshooting guide for AWD system engagement issues.

Front Gearcase Removal

Step-by-step instructions for removing the front gearcase assembly.

Front Gearcase Disassembly Inspection

Procedures for draining, removing cover, and inspecting front gearcase components.

Front Gearcase Assembly

Instructions for assembling the front gearcase, including installing seals and hubs.

Wheel Hubs

Provides assembly views for front and rear wheel hubs.

Chapter 8 Steering Suspension

Special Tools

Lists specialized tools required for steering and suspension service.

Steering System

Covers steering system assembly, shaft removal, installation, and power steering unit service.

Front Suspension

Details removal and installation procedures for A-arms, stabilizer bars, and ball joints.

Rear Suspension

Covers radius rod and trailing arm removal, installation, and bearing replacement.

Shocks Springs

Provides shock assembly views, removal/installation, and service procedures.

Walker Evans Shock Service

Detailed service information for Walker Evans™ shocks, including disassembly and assembly.

Spring Adjustment (Walker Evans)

Instructions for adjusting spring preload and ride height on Walker Evans™ shocks.

Chapter 9 Brake System

Special Tools

Lists specialized tools required for brake system service.

General Specifications

Provides standard and service limit measurements for brake pads, discs, and runout.

Front Brake System

Details specifications for front brake pads, disc thickness, and runout.

Rear Brake System

Details specifications for rear brake pads, disc thickness, and runout.

Master Cylinder

Covers master cylinder removal, installation, and bleeding procedures.

Brake Pedal Lever

Details brake pedal lever removal and installation procedures.

Front Brakes

Covers pad removal, inspection, assembly, and burnishing procedures.

Rear Brakes

Covers pad removal, inspection, assembly, and burnishing procedures for rear brakes.

Troubleshooting

Provides troubleshooting guidance for common brake system issues.

Chapter 10 Body Frame

Decal Replacement

Procedure for flame treating plastic surfaces for decal adhesion.

Cab Frame Assembly XP

Assembly view and installation steps for the XP cab frame.

Cab Frame Assembly XP 4

Assembly view and installation steps for the XP 4 cab frame.

Dash Instruments Controls

Assembly view of dash instruments and controls.

Hood Front Body Work

Assembly view and removal/installation procedures for hood and front body panels.

Chassis Main Frame XP High Lifter

Assembly view of the chassis and main frame for XP / High Lifter models.

Chassis Main Frame XP 4

Assembly view of the chassis and main frame for XP 4 models.

Floor Rocker Panels XP High Lifter

Assembly view of floor and rocker panel components for XP / High Lifter models.

Floor Rocker Panels XP 4 XP 4 High Lifter

Assembly view of floor and rocker panel components for XP 4 / High Lifter models.

Rear Cargo Box Fenders

Assembly view of rear cargo box and fender components.

Rear Bumper

Assembly view of the rear bumper components.

Body Component Removal

Provides removal procedures for various body components like seats and bumpers.

Seats

Instructions for removing and installing vehicle seats.

Front Bumper XP

Procedure for removing and installing the front bumper assembly.

Rocker Panels, Console and Floor XP

Removal procedures for rocker panels, console, and floor components for XP models.

Rocker Panels, Rear Console and Floor XP 4

Removal procedures for rocker panels, rear console, and floor for XP 4 models.

Doors

Covers door panel and latch replacement.

Door Panel Latch Replacement

Step-by-step instructions for replacing door panels and latches.

Door Adjustment

Procedure for adjusting doors to ensure proper opening and latching.

Chapter 11 Electrical

Special Tools

Lists specialized tools required for electrical system diagnostics and service.

Electrical Service Notes

Important notes and guidelines for diagnosing electrical problems.

Electrical Diagnostics

Covers static and dynamic testing methods for electrical circuits.

Static and Dynamic Testing

Explains methods for static circuit testing (resistance, voltage) and dynamic testing (current flow).

Connector Probing Guidelines

Provides guidelines for safely probing electrical connectors without causing damage.

Instrument Cluster

Overview of the instrument cluster, its display functions, and diagnostic mode.

Ride Command System

Information on the Ride Command display, including gauge screens, audio, map, and device management.

Device Manager

Instructions for connecting smartphones via Bluetooth and managing devices.

General Settings

Allows users to adjust language, speed units, temperature units, and auto brightness.

Diagnostics

Explains how to access and interpret diagnostic trouble codes (DTCs) displayed by the vehicle.

Switches

Covers testing procedures for various vehicle switches like brake, headlamp, and ignition.

Ignition Key Switch

Details the operation and testing procedures for the ignition switch assembly.

AWD 2 WD Switch (No Turf Mode)

Covers the operation and testing of the AWD/2WD switch.

Charging System

Includes tests for current draw, charging system operation, and stator/alternator tests.

Battery

Provides battery specifications, general information, and testing procedures.

Battery Testing

Explains OCV test, load test, and conductance analyzer usage for battery condition.

Lighting System

Covers headlight adjustment, replacement, taillight replacement, and dash light.

Cooling System

Details fan control circuit operation, testing, and the Engine Coolant Temperature Sensor.

Starting System

Provides troubleshooting for starter motor issues and voltage drop testing.

Electronic Power Steering

Covers EPS operation, proper system diagnosing, and troubleshooting procedures.

Fuses Relays

Details fuse box layouts and relay/fuse/circuit breaker information for various models.

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