IX
IX.3
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
Crankcase Disassembly / Inspection.................... 3.48
Crankshaft Installation ........................................ 3.68
Crankshaft Main Bearing Selection ...................... 3.63
Crankshaft Removal / Inspection ......................... 3.51
Cylinder / Piston Installation ................................ 3.67
Cylinder / Piston Removal ................................... 3.56
Cylinder Head Assembly..................................... 3.77
Cylinder Head Disassmebly ................................ 3.38
Cylinder Head Installation ................................... 3.78
Cylinder Head Removal ...................................... 3.37
Cylinder Head Warp ........................................... 3.37
Cylinder Inspection............................................. 3.55
Exhaust Valve Lash - Tappet Selection Matrix....... 3.87
Flywheel Installation ........................................... 3.76
Flywheel Removal.............................................. 3.46
Installation ......................................................... 3.28
Intake Valve Lash - Tappet Selection Matrix.......... 3.86
Lower End Assembly.......................................... 3.62
Lower End Disassembly / Inspection.................... 3.44
Mounting ........................................................... 3.31
Oil and Filter Change.......................................... 2.18
Oil Flow Chart ......................................................3.5
Oil Level ............................................................ 2.17
Piston / Connecting Rod Assembly ...................... 3.66
Piston Disassembly / Inspection .......................... 3.57
Piston Ring Installation ....................................... 3.64
Piston Ring Installed Gap.................................... 3.59
Piston Ring Removal / Inspection ........................ 3.58
Removal............................................................ 3.24
Service.............................................................. 3.24
Service Specifications .......................................... 3.6
Special Tools .......................................................3.3
Specifications ......................................................3.6
Starter Drive Installation...................................... 3.76
Stator Cover Installation...................................... 3.76
Top End Assembly.............................................. 3.77
Top End Disassembly / Inspection ....................... 3.33
Troubleshooting ................................................. 3.89
Valve Cover Removal ......................................... 3.33
Valve Inspection................................................. 3.39
Valve Sealing Test .............................................. 3.40
Valve Seat Reconditioning .................................. 3.41
Engine Coolant Temp. Sensor (ECT)..................... 11.25
Engine Serial Number Location ................................ 1.4
Engine Service Panel........................................... 10.19
Engine, Camshaft Timing - Quick Reference............ 3.83
Engine, Valve Cover Installation.............................. 3.88
EPS
Breakout Diagram ............................................ 11.42
Operation ........................................................ 11.41
Troubleshooting ............................................... 11.43
ETC...................................................................... 4.36
Exhaust Valve Lash - Tappet Matrix......................... 3.87
F
Fan Control Circuit Bypass Test ............................ 11.25
Fan Control Circuit Operation ............................... 11.25
Final Drive
Torque Specifications ...........................................7.2
Floor................................................................... 10.15
Removal................................................ 10.23–10.24
Floor / Rocker Panels XP 4................................... 10.16
Flywheel
Installation ......................................................... 3.76
Removal............................................................ 3.46
Front A-arm
Replacement ..................................................... 8.16
Front Body
Removal.......................................................... 10.20
Front Bumper
Removal.......................................................... 10.19
Front Caliper, Piston Bore I.D. ................................ 9.25
Front Gearcase
Assembly........................................................... 7.37
Disassembly / Inspection .................................... 7.34
Installation ......................................................... 7.39
Lubrication......................................................... 2.24
Removal............................................................ 7.33
Front Gearcase, Centralized Hilliard........................ 7.30
Front Propshaft
Installation ......................................................... 7.24
Removal............................................................ 7.23
Fuel Filter.............................................................. 2.13
Fuel Injector .......................................................... 4.20
Troubleshooting ................................................. 4.20
Fuel Line............................................................... 2.13
Fuel Lines
Removal / Installation ......................................... 4.10
Fuel Pump ............................................................ 4.25
Replacement ..................................................... 4.27
Fuel Sender
Test................................................................... 4.25
Fuel System .......................................................... 2.12
Fuel Tank Vent Line and Filter ............................. 2.12
Priming / Starting Procedure ............................... 4.17
Principal Components ........................................ 4.17
Troubleshooting ................................................. 4.45
Fuel Tank
Assembly View .................................................... 4.9
Installation .................................................4.13, 4.16
Removal....................................................4.10, 4.14
Fuse Box ............................................................ 11.27
Fuse Box Detail ................................................... 11.28
G
Ground
Engine / Chassis ................................................ 2.35
H
Headlight Switch.................................................. 11.13
High Altitude Clutch Chart ................................ 1.11, 5.3
Hood
Removal.......................................................... 10.20
Hood / Front Body................................................ 10.10
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