Polaris RZR XP4 1000 2016

IX
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
© Copyright Polaris Industries Inc.
IX.3
Breather Hose Inspection.........................................2.12
Camshaft Installation / Timing ...................................3.80
Camshaft Removal .................................................3.36
Camshaft Sprocket Inspection...................................3.38
Connecting Rod Bearing Selection .............................3.64
Cooling System Troubleshooting ...............................3.91
Crankcase Assembly ..............................................3.72
Crankcase Disassembly / Inspection ..........................3.51
Crankshaft Installation .............................................3.69
Crankshaft Main Bearing Selection ............................3.64
Crankshaft Removal / Inspection ...............................3.54
Cylinder / Piston Installation......................................3.68
Cylinder / Piston Removal ........................................3.58
Cylinder Head Assembly..........................................3.78
Cylinder Head Disassmebly......................................3.41
Cylinder Head Installation ........................................3.79
Cylinder Head Removal ...........................................3.40
Cylinder Head Warp................................................3.40
Cylinder Inspection .................................................3.57
Exhaust Valve Lash - Tappet Selection Matrix...............3.88
Flywheel Installation ...............................................3.76
Flywheel Removal ..................................................3.49
Installation ............................................................3.30
Intake Valve Lash - Tappet Selection Matrix .................3.87
Limiting / Misfire .....................................................4.39
Mounting ..............................................................3.34
Oil and Filter Change .............................................. 2.11
Oil Flow Chart......................................................... 3.5
Oil Level ...............................................................2.10
Piston / Connecting Rod Assembly.............................3.67
Piston Disassembly / Inspection (1000) .......................3.59
Piston Ring Installation ............................................3.65
Piston Ring Installed Gap (1000) ...............................3.61
Piston Ring Removal / Inspection...............................3.60
Removal...............................................................3.26
Special Tools.......................................................... 3.3
Specifications (RZR 1000)......................................... 3.6
Starter Drive Installation...........................................3.76
Stator Cover Installation...........................................3.77
Troubleshooting .....................................................3.90
Valve Cover Removal..............................................3.36
Valve Inspection.....................................................3.42
Valve Sealing Test ..................................................3.43
Valve Seat Reconditioning (1000) ..............................3.44
Engine Coolant Temp. Sensor (ECT) ........................... 11.28
Engine Serial Number Location ..................................... 1.4
Engine Service Panel ............................................... 10.19
Engine, Camshaft Timing - Quick Reference ...................3.84
Engine, Valve Cover Installation ...................................3.89
EPS
Breakout Diagram ................................................ 11.35
Operation ........................................................... 11.33
Torque Offset Procedure ........................................ 11.33
Troubleshooting ................................................... 11.36
ETC
Testing .................................................................4.35
ETC Learn Procedure ................................. 4.11, 4.35, 4.53
Exhaust
Assembly View ......................................................3.14
Exhaust Valve Lash - Tappet Matrix...............................3.88
F
Fan
Control Circuit Bypass Test..................................... 11.28
Fan Control Circuit Operation..................................... 11.28
Fender Flair
Removal – Rear ................................................... 10.21
Final Drive
Torque Specifications ............................................... 7.3
Floor..................................................................... 10.15
Removal....................................................10.23–10.24
Floor / Rocker Panels XP 4........................................ 10.16
Flywheel
Installation ............................................................3.76
Removal...............................................................3.49
Fox Shock
Specifications (front) ...............................................8.42
Specifications (rear) ................................................8.43
FOX Shock
Assembly .............................................................8.53
Assembly View (front) .............................................8.40
Assembly View (rear) ..............................................8.41
Disassembly .........................................................8.46
Front A-arm
Replacement.........................................................8.13
Front Bearing Carrier
Inspection / Removal................................................ 7.4
Front Body
Removal............................................................. 10.20
Front Bumper
Removal............................................................. 10.19
Front Caliper, Piston Bore I.D. ......................................9.23
Front Gearcase
Assembly .............................................................7.40
Assembly View ......................................................7.33
Disassembly / Inspection .........................................7.37
Installation ............................................................7.42
Lubrication............................................................2.28
Removal...............................................................7.36
Front Propshaft
Installation ............................................................7.28
Removal...............................................................7.27
Fuel Injector .............................................................4.12
Troubleshooting .....................................................4.12
Fuel Lines
Removal / Installation ..............................................4.17
Fuel Pump ...............................................................4.24
Replacement.........................................................4.26
Fuel Sender
Test .....................................................................4.24
Fuel System
Fuel Lines.............................................................2.20
Fuel Tank Vent Line and Filter ...................................2.19
Priming / Starting Procedure ...................................... 4.9
Principal Components .............................................. 4.8
Pump / Filters Maintenance ......................................2.20
Torque Specifications ............................................... 4.4
Troubleshooting .....................................................4.47
Warning ...............................................................2.19
Fuel Tank
Assembly View ......................................................4.16
Installation .................................................... 4.20, 4.23
Removal....................................................... 4.17, 4.21
Fuse Box ............................................................... 11.39
Details (2015–2016) ............................................. 11.41
Fuse Box Detail ...................................................... 11.40