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RZR XP4 1000 2016
Polaris RZR XP4 1000 2016 User Manual
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10.6
9926816
R07
-
2014-2016
RZR
XP
1000
/
XP4
1000
Service
Manual
©
Copyright
Polaris
Industries
Inc.
DOORS
(XP4)
q
Door
Panel
t
Latch
Release
w
Door
Frame
y
Latch
e
Latch
Striker
u
Door
panel
(Rear)
r
Hinge
Pin
i
Door
Frame
(Rear)
BODY
/
FRAME
451
453
Table of Contents
Chapter 1 1 General Information
7
Table of Contents
7
Model Number Designation (2014 and Older)
8
Model Number Designation (2015 +)
8
Vehicle Identification
8
Vehicle Identification Number
9
Vehicle Identification Number (Vin) Designation (2015+)
9
Vehicle and Engine Serial Number Location
10
Reference Information
11
Replacement Keys
11
Publication Numbers
11
Special Tools
12
General Specifications
16
2014-2016 Rzr Xp 1000 Clutch Chart
17
2015-2016 Rzr Xp 1000 High Lifter Clutch Chart
21
2015 Rzr Xp 1000 Desert Edition Clutch Chart
25
2015 Rzr Xp 1000 Fox Clutch Chart
27
Misc. Specifications and Charts
28
Master Torque Table
28
Conversion Table
30
Standard Bolt Torque Specification
31
Metric Bolt Torque Specification
31
Sae Tap / Drill Sizes
32
Metric Tap / Drill Sizes
32
Decimal Equivalents
33
Chapter 2 Maintenance
35
Break-In Period
37
Maintenance Chart Key
37
Periodic Maintenance Chart
37
Periodic Maintenance Overview
37
Pre-Ride / Daily Inspection
37
Maintenance Intervals
38
Maintenance Quick Reference
40
Grease Lubrication Points
42
Lubricants / Service Products
43
Lubrication Specifications
43
Engine
44
Engine Oil Level
44
Engine Oil and Filter Change
45
Engine Crankcase Breather Hose Inspection
46
Engine Cylinder Leakdown Test
47
Valve Clearance Inspection
47
Cooling System
50
Cooling System Overview
50
Coolant Strength
50
Coolant Level Inspection
50
Cooling System Pressure Test
51
Cooling System Hoses
51
Radiator Inspection / Cleaning
52
Coolant Drain / Fill
52
Fuel System and Air Intake
53
Fuel System Warning
53
Fuel Tank Vent Line
53
Fuel Pump / Fuel Filters
54
Fuel Lines
54
Throttle Pedal Inspection
55
Engine Intake Pre-Filter Service
55
Air Filter Service
56
Intake Duct Drain Inspection
56
Pvt / Final Drive / Wheel and Tire
57
Drive Clutch / Driven Clutch / Belt Service
57
Pvt Intake Pre-Filter Service
57
Pvt Drying
57
Drive Shaft Boot Inspection
58
Wheel and Hub Torque Table
58
Wheel Removal
58
Wheel Installation
59
Tire Inspection
59
Maintenance
59
Tire Pressure
59
Beadlock Rims (Desert Edition)
60
Transmission and Front Gearcase
61
Specification Chart
61
Transmission Lubrication
61
Front Gearcase Lubrication
62
Shift Cable Inspection / Adjustment
63
Steering
64
Steering Inspection
64
Steering Wheel Free-Play
64
Tie Rod End / Wheel Hub Inspection
65
Wheel Toe Alignment Inspection
65
Wheel Toe Adjustment
66
Suspension
67
Spring Adjustment (Walker Evans)
67
Shock Compression Adjustment (Walker Evans™)
68
Spring Adjustment (Fox®)
69
Shock Compression Adjustment (Fox®)
70
Brake System
72
Brake Fluid Inspection
72
Brake Pad / Disc Inspection
72
Brake Hose and Fitting Inspection
73
Electrical and Ignition System
74
Battery Maintenance
74
Battery Charging / off Season Storage
74
Battery Removal
74
Battery Installation
75
Engine / Chassis Electrical Ground
75
Spark Plug Service
76
Chapter 3 Engine / Cooling System
79
Engine Lubrication Specifications
81
General Information
81
Special Tools
81
Oil Pressure Test
82
Engine Oil Flow Chart
83
Engine Specifications (1000)
84
Main Engine Components - Torque Specification and Sequence
86
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
87
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
88
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
89
Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
90
Intake / Exhaust System
91
Air Box / Air Filter Assembly View
91
Exhaust System Assembly View
92
Engine Cooling System
93
Engine Cooling System Specifications
93
Cooling System Pressure Test
93
Cooling System Pressure Cap Test
94
Radiator Removal / Installation
94
Thermostat Replacement
95
Cooling System Assembly View
97
Cooling System Bleeding Procedure
98
Water Pump Removal
99
Water Pump Installation
99
Water Pump Service
101
Engine Service
104
Accessible Engine Components
104
Top-End Service (Engine in Chassis)
104
Engine Removal
104
Engine Installation
108
Engine Mounting and Torque Values
112
Engine Break-In Period
113
Engine Lubrication Specifications
113
Engine Disassembly / Inspection - Top End
114
Valve Cover Removal
114
Camshaft Removal
114
Camshaft Sprocket Inspection
116
Cylinder Head Removal
118
Cylinder Head Warp Inspection
118
Cylinder Head Disassembly
119
Valve Inspection
120
Combustion Chamber Cleaning
121
Valve Sealing Test
121
Valve Seat Reconditioning (1000)
122
Engine Disassembly / Inspection - Bottom End
125
Stator Cover Removal / Inspection
125
Water Pump Housing Removal
126
Flywheel Removal
127
Starter One-Way Clutch Disassembly
128
Crankcase Disassembly / Inspection
129
Balance Shaft Removal / Inspection
131
Crankshaft Removal / Inspection
132
Crankcase Inspection
134
Cylinder Inspection
135
Cylinder / Piston Removal
136
Piston Disassembly / Inspection (1000)
137
Piston Ring Removal
138
Piston Ring to Groove Clearance Inspection
138
Piston Ring Installed Gap (1000)
139
Piston-To-Cylinder Clearance
139
Connecting Rod Inspection
139
Engine Assembly - Bottom End
141
Bearing Selection Identification Letters and Numbers
141
Connecting Rod Bearing Selection
142
Crankshaft Main Bearing Selection
142
Upper Crankcase Preparation
143
Piston Ring Installation
143
Piston / Connecting Rod Assembly
145
Cylinder / Piston Installation
146
Crankshaft Installation
147
Balance Shaft Installation
149
Lower Crankcase Preparation
149
Crankcase Assembly
150
Starter One-Way Clutch Assembly
154
Flywheel Installation
154
Stator Cover Installation
155
Engine Assembly - Top End
156
Cylinder Head Assembly
156
Cylinder Head Installation
157
Camshaft Installation / Timing
158
Camshaft Timing - Quick Reference
162
Valve Clearance Adjustment
163
Intake Valve Lash - Tappet Selection Matrix
165
Exhaust Valve Lash - Tappet Selection Matrix
166
Valve Cover Installation
167
Troubleshooting
168
Engine Cooling System
168
Chapter 4 Fuel System
171
General Information
173
Special Tools
173
Torque Specifications
174
Efi Overview
175
Efi Service Notes
175
Efi System Assembly View
176
Efi System Component Locations
177
Principal Components
178
Efi Operation Overview
178
Initial Priming / Starting Procedure
179
Electronic Control Unit (Ecu)
180
Operation Overview
180
Ecu Service
180
Ecu Replacement
180
Etc Learn Procedure
181
Fuel Injectors
182
Operation Overview
182
Fuel Injector Troubleshooting
182
Fuel Injector Test
183
Fuel Injector Replacement
183
Fuel Tank
186
Assembly View
186
Fuel Line Removal / Installation
187
Fuel Tank Removal
187
Fuel Tank Installation
190
Fuel Tank Removal Rzr Xp 4 1000
191
Fuel Tank Installation Rzr Xp 4 1000
193
Fuel Pump
194
Operation Overview
194
Fuel Sender Test
194
Fuel Pump Test
195
Fuel Pump Replacement
196
Temperature and Manifold Absolute Pressure Sensor (T-Map)
200
Operation Overview
200
T-Map Test / Replacement
200
Crankshaft Position Sensor (Cps)
201
Operation Overview
201
Cps Test
201
Cps Replacement
202
Electronic Throttle Control (Etc) / Throttle Body
203
Operation Overview
203
Throttle Body Service
203
Throttle Body Removal
204
Etc Test
205
Etc Replacement
205
Etc Learn Procedure
205
Pedal Position Sensor (Pps)
206
Operation Overview
206
Location
206
Pps Test
206
Pps Replacement
206
Oxygen Sensor (My15-16)
208
Oxygen Sensor Information
208
Oxygen Sensor Replacement
208
Efi Diagnostics
209
Cylinder Misfire Detection
209
Trouble Code Display (Etc)
209
Efi Troubleshooting
217
Polaris Digital Wrench
218
Digital Wrench® Diagnostic Software Overview
218
Special Tools (Digital Wrench)
218
Digital Wrench Software Version and Update
219
Digital Wrench® Updates
219
Digital Wrench® Communication Errors
220
Digital Wrench® - Diagnostic Connector
220
Guided Diagnostics
221
Digital Wrench® Serial Number Location
221
Digital Wrench® Feature Map
222
Ecu Replacement
223
Etc Learn Procedure
223
Ecu Reprogramming (Reflash)
223
Polaris Mobile Digital Wrench (Pmdw)
226
Chapter 5 Pvt System
227
General Information
229
Pvt System Torque Specifications
229
Special Tools and Supplies
229
Pvt System Overview
231
General Operation
231
Drive Clutch Operation
231
Driven Clutch Operation
232
Pvt Break-In (Drive Belt / Clutches)
232
Maintenance / Inspection
232
Pvt Overheating / Diagnosis
233
Pvt System Service
234
Pvt Covers and Duct Components
234
Pvt Covers and Ducting Components (High Lifter)
236
Pvt Disassembly (2014-2015)
237
Pvt Disassembly (2016)
237
Pvt Assembly (2016)
238
Drive Belt
243
Belt Removal
243
Belt Inspection
244
Belt Installation
244
Pvt Break-In (Drive Belt / Clutches)
244
Drive Clutch Service
245
Drive Clutch Assembly View
245
Drive Clutch Disassembly / Inspection
246
Needle Bearing Inspection
247
Shift Weight Inspection
248
Button to Tower Clearance Inspection
248
Spider Removal
249
Roller, Pin, and Thrust Washer Inspection
249
Clutch Inspection
250
Moveable Sheave Bushing Inspection
251
Bushing Service
251
Drive Clutch Assembly
253
Driven Clutch Service (2014-2015)
256
Driven Clutch Disassembly
256
Driven Clutch Bushing Service
258
Clutch Bushing Removal
259
Clutch Bushing Installation
260
Driven Clutch Assembly
260
Driven Clutch Assembly View
263
Driven Clutch Service (2016)
264
Driven Clutch Slider Inspection
264
Driven Clutch Disassembly
264
Driven Clutch Assembly
266
Assembly View
268
Troubleshooting
269
Chapter 6 Transmission
271
General Information
272
Lubrication
272
Special Tools
272
Torque Specifications
272
Transmission Mounting and Torque Values
273
Shift Lever / Cable
274
Shift Lever Removal
274
Shift Lever Installation
274
Shift Cable Inspection
274
Shift Cable Adjustment
274
Transmission Service
276
Transmission Removal
276
Transmission Installation
279
Transmission Disassembly
282
Differential Operation (Turf Mode Models Only)
286
Planetary Differential Disassembly (Turf Mode Models Only)
288
Planetary Differential Bushing Replacement (Turf Mode Models Only)
289
Planetary Differential Assembly (Turf Mode Models Only)
292
Gear / Shaft / Bearing Inspection
293
Transmission Assembly / Snorkel Gear Backlash Procedure
294
Transmission Assembly View
300
Transmission Assembly View (Turf Mode Models)
302
Troubleshooting
304
Shifting Difficulty
304
Chapter 7 Final Drive
305
Final Drive Torque Specifications
307
General Information
307
Special Tools
307
Bearing Carrier
308
Front Bearing Carrier Inspection / Removal
308
Front Bearing Replacement
309
Front Bearing Carrier Installation
310
Rear Bearing Carrier Inspection / Removal
311
Rear Bearing Replacement
313
Rear Bearing Carrier Installation
314
Drive Shaft
316
Front Drive Shaft Removal
316
Front Drive Shaft Installation
317
Rear Drive Shaft Removal
318
Rear Drive Shaft Installation
319
Drive Shaft / CV Joint Handling Tips
321
Outer CV Joint / Boot Replacement
321
Inner Plunging Joint / Boot Replacement
324
Outer CV Boot Replacement
326
Inner Plunging Joint / Boot Replacement
328
Drive Shaft Assembly View
330
Prop Shaft Service
331
Front Propshaft Removal
331
Front Prop Shaft Installation
332
Rear Prop Shaft Removal
332
Rear Prop Shaft Installation
333
Rear Prop Shaft Removal Xp 4
334
Rear Prop Shaft Installation
335
Support Bearing Replacement
336
Front Gearcase / Centralized Hilliard
337
Centralized Hilliard Assembly View
337
All Wheel Drive Operation
338
Awd Diagnosis
339
Front Gearcase Removal
340
Front Gearcase Disassembly / Inspection
341
Front Gearcase Assembly
344
Front Gearcase Installation
346
Wheel Hubs
348
Front Hub Assembly View
348
Rear Hub Assembly View
348
Chapter 8 Steering / Suspension
351
General Information
353
Multi-Function Pliers
353
Special Tools
353
Torque Specifications
353
Steering System
354
Assembly View
354
Upper Steering Shaft Removal
355
Steering Wheel Removal
356
Power Steering Unit Removal
356
Lower Steering Shaft Removal
358
Lower Steering Shaft Installation
358
Power Steering Unit Installation
359
Upper Steering Shaft Installation
360
Steering Shaft Bearing Replacement
361
Front Suspension
363
Front A-Arm Removal / Replacement
363
Front Stabilizer Bar Removal
364
Front Stabilizer Bar Installation
365
Ball Joint Service Preparation
365
Ball Joint Removal
366
Ball Joint Installation
366
Rear Suspension
367
Radius Rod Removal / Installation
367
Trailing Arm Removal / Installation
367
Trailing Arm Spherical Bearing Replacement
370
Rear Suspension Assembly View
371
Stabilizer Bar Removal
372
Stabilizer Bar Installation
372
Shocks / Springs
373
Shock Assembly View
373
Shock Removal / Installation
373
Shock / Spring Replacement
373
Shock Service
374
Walker Evans™Shock Assembly Views
374
Walker Evans™ 2.0" Front Shock
374
Walker Evans™ 2.5" Rear Shock
375
Walker Evans Shock Service
376
General Service Information
376
Front Shock Service Information
376
Rear Shock Service Information
378
Spring Adjustment (Walker Evans)
380
Walker Evans™ Shock Rebuild Information
381
Special Tools
381
Valve Shim Arrangement
381
Shock Piston Orientation
381
Walker Evans™ Shock Disassembly
382
Walker Evans™ Shock Assembly
385
Fox 2.5" O.e. Podium Bypass
390
Fox Shock Assembly Views
390
Fox 3.0" O.e. Podium Bypass
391
Fox 2.5" Front Shock Information
392
Fox Shock Service
392
Fox 3.0" Rear Shock Information
393
Spring Adjustment (Fox®)
394
Offset Torque Formula
395
Fox Shock Disassembly
396
Fox Shock Assembly
403
Chapter 9 Brake System
409
General Information
411
Special Tools
411
Torque Specifications
411
Brake System Service Notes
412
General Specifications
412
Brake Noise Troubleshooting
413
Hydraulic Brake System Operation
413
Brake System Assembly View
414
Master Cylinder
415
Master Cylinder Removal
415
Master Cylinder Installation
416
Brake Bleeding / Fluid Change
416
Brake Pedal Lever
418
Brake Pedal Removal
418
Brake Pedal Installation
418
Parking Brake (Int'l Model)
419
Parking Brake Assembly View
419
Parking Brake Inspection
420
Parking Brake Cable Adjustment
420
Parking Brake Caliper
421
Parking Brake Disc
424
Front Brake Pads
425
Pad Removal
425
Pad Inspection
426
Pad Assembly / Installation
426
Brake Burnishing Procedure
427
Front Caliper Service
428
Caliper Assembly View
428
Caliper Removal
429
Caliper Disassembly
430
Caliper Inspection
431
Caliper Assembly
431
Caliper Installation
432
Front Brake Disc
433
Disc Runout
433
Disc Inspection
433
Disc Replacement
434
Rear Brake Pads
435
Pad Removal
435
Pad Inspection
436
Pad Assembly / Installation
437
Brake System
437
Brake Burnishing Procedure
437
Rear Caliper Service
438
Caliper Assembly View
438
Caliper Removal
439
Caliper Disassembly
440
Caliper Inspection
440
Caliper Assembly
441
Caliper Installation
441
Rear Brake Disc
443
Disc Inspection
443
Disc Replacement
443
Troubleshooting
445
Poor Brake Performance
445
Pedal Vibration
445
Caliper Overheats (Brakes Drag)
445
Brakes Lock
445
Chapter 10 Body / Frame
447
General Information
448
Special Tools
448
Torque Specifications
448
Body Assembly Views
449
Cab Frame Assembly
449
Cab Frame Assembly Xp
449
Doors
451
Doors (Xp4)
452
Doors High Lifter
453
Dash Instruments / Controls
454
Dash Instruments / Controls High Lifter
455
Hood / Front Body Work
456
Chassis / Main Frame Xp / High Lifter
457
Chassis / Main Frame Xp 4
458
Seat Assembly Front
459
Seat Assembly Rear
460
Floor / Rocker Panels Xp / High Lifter
461
Floor / Rocker Panels Xp 4 / Xp 4 High Lifter
462
Rear Cargo Box / Fenders
463
Rear Bumper
464
Body Component Removal
465
Seats
465
Engine Service Panel
465
Front Bumper Xp
465
Rear Bumper
466
Hood and Front Body Work
466
Rear Fender / Fender Flair Removal Xp
467
Rear Fender Flare / Rear Fender Removal Xp
468
Cargo Box Assembly Removal
468
Rocker Panels, Console and Floor Xp
469
Rocker Panels, Rear Console and Floor Xp
470
Decal Replacement
473
Chapter 11 Electrical
475
Electrical Service Notes
478
General Information
478
Special Tools
478
Torque Specifications
478
Under-Dash Components
478
Instrument Cluster
479
Overview
479
Information Display Area
481
Diagnostic Mode
484
Switches
486
Brake Light Switch
486
Headlamp Switch
486
Ignition (Key) Switch
487
Awd / 2Wd Switch (Models Without Turf)
487
Transmission (Gear Position) Switch
488
Seat Belt Switch
489
All Wheel Drive Coil
490
Operation Overview
490
Diagnosing System Failures
490
Vehicle Speed Sensor
491
Speed Sensor Location
491
Speed Sensor Testing
491
Ignition Coil
492
Operation Overview
492
Ignition Coil / Ht Lead Replacement
492
Ignition Coil Tests
492
Charging System
493
Current Draw - Key off
493
Charging System "Break Even" Test
493
Charging System Stator (Alternator) Tests
493
Stator (Alternator) Replacement
494
Regulator / Rectifier
495
Charging System Testing Flow Chart
496
Battery
497
Battery Specifications
497
General Battery Information
497
Battery Removal / Installation
498
Battery off Season Storage
498
Battery Testing
498
Ocv - Open Circuit Voltage Test
498
Load Test
498
Battery Conductance Analyzer
498
Charging Procedure
499
Lighting System
500
Headlight Adjustment
500
Headlamp Replacement
500
Headlamp Installation
501
Taillight Replacement
501
Dash Light
501
Cooling System
502
Fan Control Circuit Operation / Testing
502
Fan Control Circuit Bypass Test
502
Engine Coolant Temperature Sensor (Ect) Overview
502
Ect Sensor Test
502
Ect Sensor Replacement
503
Starting System
504
Troubleshooting
504
Voltage Drop Test
504
Starter Motor Removal
504
Starter Motor Installation
505
Starter Solenoid Bench Test
505
Starter Solenoid Operation
505
Starter Fails to Turn over the Engine
506
Electronic Power Steering
507
Eps Operation
507
Eps Torque Offset Procedure
507
Proper Eps System Diagnosing
508
Eps System Breakout
509
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
510
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
511
Eps Troubleshooting (Using Digital Wrench®)
512
Fuses / Relays
513
Overview / Operation
513
Fuse Box Detail (2014)
514
Fuse Box Detail (2015-2016)
515
Relay Operation
515
Can System
517
Can System Overview
517
Can System Testing
517
Break-Out Diagrams
518
Awd
518
Vehicle Speed Sensor
519
Cooling System
520
Unswitched Chassis Power
521
Key-On Battery Power
522
Lights
523
4
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Polaris RZR XP4 1000 2016 Specifications
General
Brand
Polaris
Model
RZR XP4 1000 2016
Category
Offroad Vehicle
Language
English
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