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9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
© Copyright Polaris Industries Inc.
10. Install the two bolts
y
retaining the transmission
joint bracket to the engine on the right side. Hand
tighten the bolts so they remain loose at this time.
NOTE
DO NOT torque fasteners at this time.
11. Install the two longer bolts into left side mounting
holes. Torque left side mounting bolts to specification
using the numbered sequence shown.
12. Torque right side mounting bolts to specification
using the numbered sequence shown.
TORQUE
Engine / Transmission Mounting Bolts:
Step 1-2: 64 ft-lb (87 Nm) Step 3: 5 ft-lb (7 Nm) Step
4-7: 44 ft-lb (60 Nm)
13. Remove the clutch center distance tool.
14. Torque the four front engine mount fasteners to
specification.
TORQUE
Front Engine Mount Fasteners:
40 ft-lbs (54 Nm)
15. Remove the lifting straps and overhead or portable
engine hoist.
16. Install the two coolant hoses onto the engine.
17. Install front support bracket
u
and rear support
i
onto the vehicle frame. Torque fasteners to
specification.
18. Install push rivet through heat shield
o
into rear
cross member.
19. Install the exhaust heat shield and push rivets.
20. Replace exhaust gaskets (seals). Install exhaust
head pipe. Install the six fasteners that attach the
exhaust head pipe to the engine and torque to
specification.
TORQUE
Exhaust Head Pipe Bolts:
18 ft-lb (24 Nm)
21. Install the two exhaust springs that attach the head
pipe to the muffler.
22. Install the breather hose to the crankcase.
23. Install the spark plug wires to the appropriate
cylinder by referencing the MAG and PTO spark plug
wire decals.
NOTE
Ensure plug wires caps are pushed down all the way so
they engage onto the spark plugs.
24. Install the throttle body assembly and connect fuel
lines. Install throttle cable retaining clip.
25. Secure wire harness in the routing clip on the rear
cross member.
26. Install (+) positive cable to the starter motor.
27. Install (-) negative cable to the starter motor
mounting bolt.
ENGINE / COOLING SYSTEM
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