Polaris RZR XP 1000 2018

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

Polaris RZR XP 1000 2018 Specifications

General

Brand	Polaris
Model	RZR XP 1000 2018
Category	Automobile
Language	English

Summary

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Details on identifying vehicle models, VIN, and serial numbers.

MASTER TORQUE TABLE

Provides torque specifications for various fasteners across the vehicle.

GENERAL SPECIFICATIONS

Lists key dimensions, weights, and capacities for the vehicle models.

MAINTENANCE

PERIODIC MAINTENANCE CHART

Outlines scheduled maintenance tasks based on time or mileage.

PRE-RIDE INSPECTION

Lists items to inspect before riding the vehicle.

MAINTENANCE INTERVALS

ENGINE

Maintenance procedures related to the engine system.

COOLING SYSTEM

Maintenance procedures for the engine cooling system.

FUEL SYSTEM AND AIR INTAKE

PVT FINAL DRIVE WHEEL AND TIRE

TRANSMISSION AND FRONT GEARCASE

STEERING

SUSPENSION

BRAKE SYSTEM

Maintenance and inspection procedures for the brake system.

ELECTRICAL AND IGNITION SYSTEM

ENGINE COOLING SYSTEM

ENGINE LUBRICATION SPECIFICATIONS

OIL PRESSURE TEST

Procedure for testing engine oil pressure.

ENGINE SPECIFICATIONS (1000)

ENGINE COOLING SYSTEM

Overview of the engine cooling system and its components.

ENGINE SERVICE

Procedures for servicing accessible and non-accessible engine components.

ENGINE DISASSEMBLY INSPECTION - TOP END

Procedures for disassembling and inspecting the engine's top-end components.

ENGINE DISASSEMBLY INSPECTION - BOTTOM END

Procedures for disassembling and inspecting the engine's bottom-end components.

VALVE COVER REMOVAL

CAMSHAFT REMOVAL

CYLINDER HEAD REMOVAL

Procedure for removing the cylinder head from the engine.

FUEL SYSTEM

EFI OVERVIEW

ELECTRONIC CONTROL UNIT (ECU)

ETC LEARN PROCEDURE

FUEL INJECTORS

FUEL PUMP

EFI DIAGNOSTICS

Procedures for displaying and interpreting diagnostic trouble codes.

PVT SYSTEM

SPECIAL TOOLS AND SUPPLIES

PVT SYSTEM OVERVIEW

PVT SYSTEM SERVICE

Procedures for servicing PVT covers and ducting components.

DRIVE BELT

DRIVE CLUTCH SERVICE

Procedures for servicing the drive clutch assembly.

DRIVEN CLUTCH SERVICE

Procedures for servicing the driven clutch assembly.

TRANSMISSION

TRANSMISSION SERVICE

General procedures for transmission service.

TRANSMISSION REMOVAL

Step-by-step instructions for removing the transmission from the vehicle.

TRANSMISSION INSTALLATION

Step-by-step instructions for installing the transmission into the vehicle.

TRANSMISSION DISASSEMBLY

Procedures for disassembling the transmission.

GEAR SHAFT BEARING INSPECTION

TRANSMISSION ASSEMBLY SNORKEL GEAR BACKLASH PROCEDURE

FINAL DRIVE

BEARING CARRIER

DRIVE SHAFT

STEERING SUSPENSION

STEERING SYSTEM

Overview and service procedures for the steering system.

FRONT SUSPENSION

Removal, installation, and service procedures for front suspension components.

REAR SUSPENSION

Removal, installation, and service procedures for rear suspension components.

SHOCKS SPRINGS

Procedures for shock assembly, removal, installation, and service.

WALKER EVANS SHOCK SERVICE

Detailed service information for Walker Evans™ shocks.

BRAKE SYSTEM

BRAKE SYSTEM SERVICE NOTES

BRAKE NOISE TROUBLESHOOTING

Common causes and remedies for brake noise issues.

MASTER CYLINDER

Procedures for master cylinder removal, installation, and bleeding.

FRONT BRAKES

Procedures for front brake pad and caliper service.

REAR BRAKES

Procedures for rear brake pad and caliper service.

TROUBLESHOOTING

Common brake system troubleshooting guides.

BODY FRAME

CAB FRAME ASSEMBLY XP

CAB FRAME ASSEMBLY XP 4

DASH INSTRUMENTS CONTROLS

HOOD FRONT BODY WORK

CHASSIS MAIN FRAME XP HIGH LIFTER

CHASSIS MAIN FRAME XP 4

BODY COMPONENT REMOVAL

DOORS

ELECTRICAL

SPECIAL TOOLS

Lists specialized tools for electrical system diagnostics and testing.

ELECTRICAL SERVICE NOTES

INSTRUMENT CLUSTER

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

RIDE COMMAND SYSTEM

DIAGNOSTICS

Procedures for accessing and interpreting diagnostic trouble codes.

FUSES RELAYS