Polaris RZR XP4 1000 2017

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9928492 R04 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual

9.7

REAR BRAKE LINE - MASTER CYLINDER TO JUNCTION BLOCK

Brake Line Retaining Clip

Zip Tie

BRAKE SYSTEM

Main Page

Table of Contents7
Vehicle Identification8
Model Number Designation (2015 +)8
Vehicle Identification Number (Vin) Designation (2015+)8
Vehicle and Engine Serial Number Location8
Reference Information9
Replacement Keys9
Publication Numbers9
Special Tools10
Master Torque Table14
General Specifications17
Rzr Xp 1000 Clutch Chart18
Rzr Xp 4 1000 Clutch Chart20
Rzr Xp 1000 High Lifter Clutch Chart22
Rzr Xp 1000 High Lifter Clutch Chart24
2017 Rzr Xp 1000 Le Matte Gold Metallic25
Rzr Xp 1000 Clutch Chart26
2017 Rzr Xp 1000 Le (Ride Command)27
Rzr Xp 1000 Clutch Chart28
Rzr Xp 1000 Clutch Chart30
Rzr Xp 4 1000 Clutch Chart32
Rzr Xp 1000 High Lifter Clutch Chart34
Rzr Xp 1000 High Lifter Clutch Chart36
Rzr Xp 1000 Clutch Chart38
Rzr Xp 1000 Clutch Chart40
Rzr Xp 4 1000 Clutch Chart42
Misc. Specifications and Charts43
Conversion Table43
Sae Tap / Drill Sizes44
Metric Tap / Drill Sizes44
Decimal Equivalents45
Maintenance49
Periodic Maintenance Chart49
Pre-Ride Inspection49
Periodic Maintenance Overview50
Break-In Period50
Maintenance Intervals51
Maintenance Quick Reference71
Grease Lubrication Points73
Lubricants / Service Products74
Lubrication Specifications74
Engine75
Engine Oil Level75
Engine Oil and Filter Change76
Engine Crankcase Breather Hose Inspection77
Engine Cylinder Leakdown Test78
Valve Clearance Inspection78
Cam Chain Tensioner Inspection80
Heat Shield Inspection81
Cooling System82
Cooling System Overview82
Coolant Strength82
Coolant Level Inspection82
Cooling System Pressure Test83
Cooling System Hoses83
Radiator Inspection / Cleaning84
Coolant Drain / Fill85
Fuel System and Air Intake86
Fuel System Warning86
Fuel Tank Vent Line86
Vent Line Termination Fitting86
Fuel Pump / Fuel Filters86
Fuel Lines87
Throttle Pedal Inspection88
Engine Intake Pre-Filter Service88
Air Filter Service88
Intake Duct Drain Inspection89
Pvt / Final Drive / Wheel and Tire90
Belt Inspection90
Pvt Intake Pre-Filter Service90
Pvt Drying90
Drive Shaft Boot Inspection91
Wheel and Hub Torque Table91
Maintenance91
Wheel Removal91
Wheel Installation91
Tire Inspection92
Tire Pressure92
Beadlock Rims (if Equipped)92
Transmission and Front Gearcase94
Specification Chart94
Transmission Lubrication94
Front Gearcase Lubrication95
Shift Cable Inspection / Adjustment96
Transmission Vent Line Routing97
Front Gearcase Vent Line Routing97
Steering98
Steering Inspection98
Steering Wheel Free-Play98
Tie Rod End / Wheel Hub Inspection99
Wheel Toe Alignment Inspection99
Wheel Toe Adjustment100
Suspension101
Spring Adjustment (Walker Evans)101
Shock Compression Adjustment (Walker Evans™)101
Brake System103
Brake Hose and Fitting Inspection103
Brake Fluid Inspection103
Brake Pad / Disc Inspection103
Electrical and Ignition System104
Battery Maintenance104
Battery Charging / off Season Storage104
Battery Removal104
Battery Installation105
Engine / Chassis Electrical Ground105
Spark Plug Service106
General Information109
Special Tools109
Engine Lubrication Specifications109
Oil Pressure Test110
Engine Oil Flow Chart111
Engine Specifications (1000)112
Intake / Exhaust System114
Air Box / Air Filter Assembly View114
Exhaust System Assembly View115
Engine Cooling System116
Engine Cooling System Specifications116
Cooling System Pressure Test116
Cooling System Pressure Cap Test117
Radiator Removal / Installation117
Thermostat Replacement118
Cooling System Assembly View120
Cooling System Bleeding Procedure121
Water Pump Removal122
Water Pump Installation122
Water Pump Service124
Engine Service127
Accessible Engine Components127
Top-End Service (Engine in Chassis)127
Crankshaft Pto Seal Replacement128
Engine Removal130
Engine Installation133
Engine Mounting and Torque Values136
Engine Break-In Period136
Engine Lubrication Specifications137
Engine Disassembly / Inspection - Top End138
Valve Cover Removal138
Camshaft Removal138
Camshaft Sprocket Inspection140
Camshaft / Camshaft Bore Inspection (1000)141
Cylinder Head Removal142
Cylinder Head Warp Inspection143
Cylinder Head Disassembly143
Valve Inspection144
Combustion Chamber Cleaning145
Valve Sealing Test146
Valve Seat Reconditioning (1000)146
Engine Disassembly / Inspection - Bottom End149
Stator Cover Removal / Inspection149
Water Pump Housing Removal150
Flywheel Removal151
Starter One-Way Clutch Disassembly152
Crankcase Disassembly / Inspection153
Balance Shaft Removal / Inspection155
Crankshaft Removal / Inspection156
Crankcase Inspection158
Cylinder Inspection159
Cylinder / Piston Removal160
Piston Disassembly / Inspection (1000)161
Piston Ring Removal162
Piston Ring to Groove Clearance Inspection162
Piston Ring Installed Gap (1000)163
Piston-To-Cylinder Clearance163
Connecting Rod Inspection163
Engine Assembly - Bottom End165
Bearing Selection Identification Letters and Numbers165
Connecting Rod Bearing Selection166
Crankshaft Main Bearing Selection166
Upper Crankcase Preparation167
Piston Ring Installation167
Piston / Connecting Rod Assembly169
Cylinder / Piston Installation170
Crankshaft Installation171
Balance Shaft Installation173
Lower Crankcase Preparation173
Crankcase Assembly174
Starter One-Way Clutch Assembly178
Flywheel Installation178
Stator Cover Installation179
Engine Assembly - Top End180
Cylinder Head Assembly180
Cylinder Head Installation181
Camshaft Installation / Timing182
Camshaft Timing - Quick Reference186
Valve Clearance Adjustment187
Valve Lash - Tappet Selection189
Valve Cover Installation190
Troubleshooting191
Engine Cooling System192
General Information195
Special Tools195
Efi Overview196
Efi Service Notes196
Efi System Assembly View197
Efi System Component Locations198
Principal Components199
Efi Operation Overview199
Initial Priming / Starting Procedure200
Evap System201
Evap System Overview201
Evap Conditions and Symptoms202
Electronic Control Unit (Ecu)203
Operation Overview203
Ecu Service203
Ecu Replacement203
Etc Learn Procedure204
Fuel Injectors205
Operation Overview205
Fuel Injector O-Rings205
Fuel Injector Troubleshooting206
Fuel Injector Test206
Fuel Injector Replacement207
Fuel Lines / Tank210
Assembly View210
Fuel Vent Line Routing (Non Highlifter)211
Fuel Vent Line Routing (High Lifter)213
Vent Line Termination Fitting214
Fuel Line Quick Connect Removal214
Fuel Line Removal / Installation216
Fuel Tank Removal217
Fuel Tank Installation219
Fuel Tank Removal Rzr Xp 4 1000220
Fuel Tank Installation Rzr Xp 4 1000221
Fuel Pump223
Operation Overview223
Fuel Sender Test223
Fuel Pump Test224
Fuel Pump Replacement224
Temperature and Manifold Absolute Pressure Sensor (T-Map)228
Operation Overview228
T-Map Test / Replacement228
Crankshaft Position Sensor (Cps)229
Operation Overview229
Cps Test229
Cps Replacement230
Electronic Throttle Control (Etc) / Throttle Body231
Operation Overview231
Throttle Body Service231
Throttle Body Removal232
Etc Test233
Etc Replacement233
Etc Learn Procedure233
Pedal Position Sensor (Pps)234
Operation Overview234
Location234
Pps Test234
Pps Replacement234
Oxygen Sensor236
Oxygen Sensor Information236
Oxygen Sensor Replacement236
Efi Diagnostics238
Trouble Code Display (Dtc)238
Cylinder Misfire Detection245
Efi Troubleshooting246
Polaris Digital Wrench247
Digital Wrench® Diagnostic Software Overview247
Special Tools (Digital Wrench)247
Digital Wrench Software Version and Update248
Digital Wrench® Updates248
Digital Wrench® Communication Errors249
Digital Wrench® - Diagnostic Connector250
Guided Diagnostics251
Digital Wrench® Serial Number Location251
Digital Wrench® Feature Map252
Ecu Replacement253
Etc Learn Procedure253
Ecu Reprogramming (Reflash)253
Polaris Mobile Digital Wrench (Pmdw)256
General Information259
Special Tools and Supplies259
Rzr Xp 1000 Clutch Chart259
Rzr Xp 4 1000 Clutch Chart259
Rzr Xp 1000 High Lifter Clutch Chart259
Rzr Xp 4 1000 High Lifter Clutch Chart259
Rzr Xp 1000 Le Gold Metallic Clutch Chart259
Pvt System Overview260
General Operation260
Drive Clutch Operation260
Driven Clutch Operation261
Pvt Break-In (Drive Belt / Clutches)261
Maintenance / Inspection261
Pvt Overheating / Diagnosis262
Pvt System Service263
Pvt Covers and Ducting Components (High Lifter)264
Pvt Disassembly265
Pvt Assembly267
Drive Belt269
Belt Removal269
Belt Inspection270
Belt Installation270
Pvt Break-In (Drive Belt / Clutches)270
Drive Clutch Service271
Drive Clutch Assembly View271
Drive Clutch Disassembly / Inspection272
Needle Bearing Inspection273
Shift Weight Inspection274
Button to Tower Clearance Inspection274
Spider Removal275
Roller, Pin, and Thrust Washer Inspection275
Clutch Inspection276
Moveable Sheave Bushing Inspection277
Bushing Service277
Drive Clutch Assembly279
Driven Clutch Service282
Driven Clutch Slider Inspection282
Driven Clutch Disassembly282
Driven Clutch Assembly284
Driven Clutch Assembly View286
General Information290
Special Tools290
Lubrication290
Shift Lever / Cable291
Shift Lever Removal291
Shift Lever Installation291
Shift Lever Removal (Gold Metallic Le)291
Spherical Bearing Removal292
Shift Lever Installation (Gold Metallic Le)292
Gated Shifter Adjustment (Gold Metallic Le)293
Shift Cable Inspection294
Shift Cable Adjustment294
Transmission Service296
Transmission Removal296
Transmission Installation299
Transmission Vent Line Routing302
Transmission Disassembly302
Differential Operation307
Planetary Differential Disassembly (Turf Mode Models Only)310
Planetary Differential Bushing Replacement (Turf Mode Models Only)311
Planetary Differential Assembly (Turf Mode Models Only)313
Gear / Shaft / Bearing Inspection314
Transmission Assembly / Snorkel Gear Backlash Procedure315
Troubleshooting321
Shifting Difficulty321
General Information324
Special Tools324
Bearing Carrier325
Front Bearing Carrier Inspection / Removal325
Front Bearing Replacement326
Front Bearing Carrier Installation327
Rear Bearing Carrier Inspection / Removal328
Rear Bearing Replacement330
Rear Bearing Carrier Installation331
Drive Shaft333
Front Drive Shaft Removal333
Front Drive Shaft Installation334
Rear Drive Shaft Removal335
Rear Drive Shaft Installation336
Drive Shaft / CV Joint Handling Tips338
CV Joint Service338
Outer CV Boot Replacement338
Inner Plunging Joint / Boot Replacement340
Prop Shaft Service342
Front Propshaft Removal342
Rear Prop Shaft Removal343
Rear Prop Shaft Removal Xp 4344
Support Bearing Replacement345
U-Joint Disassembly346
U-Joint Assembly346
Front Prop Shaft Installation347
Rear Prop Shaft Installation347
Rear Prop Shaft Installation Xp 4348
Front Gearcase / Centralized Hilliard349
Front Gearcase Assembly View349
All Wheel Drive Operation350
Awd Diagnosis350
Front Gearcase Removal352
Front Gearcase Disassembly / Inspection352
Front Gearcase Assembly355
Front Gearcase Installation358
Front Gearcase Vent Line Routing358
Wheel Hubs359
Front Hub Assembly View359
Rear Hub Assembly View359
Beadlock Rims (if Equipped)360
General Information363
Special Tools363
Multi-Function Pliers363
Steering System364
Steering System Assembly View364
Upper Steering Shaft Removal365
Steering Wheel Removal366
Power Steering Unit Removal366
Lower Steering Shaft Removal368
Lower Steering Shaft Installation368
Power Steering Unit Installation369
Upper Steering Shaft Installation370
Steering Shaft Bearing Replacement371
Front Suspension372
Front A-Arm Removal / Replacement372
Front Stabilizer Bar Removal373
Front Stabilizer Bar Installation374
Ball Joint Service Preparation375
Ball Joint Removal375
Ball Joint Installation375
Rear Suspension376
Radius Rod Removal / Installation376
Trailing Arm Removal / Installation376
Trailing Arm Spherical Bearing Replacement379
Rear Suspension Assembly View380
Rear Stabilizer Bar Removal381
Stabilizer Bar Installation381
Shocks / Springs382
Shock Assembly View382
Shock Removal / Installation382
Shock / Spring Replacement382
Shock Service383
Walker Evans Shock Service383
Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock383
General Service Information384
Front Shock Service Information384
Rear Shock Service Information386
Spring Adjustment (Walker Evans)388
Walker Evans™ Shock Rebuild Information389
Special Tools389
Valve Shim Arrangement389
General Information401
Special Tools401
General Specifications401
Brake System Service Notes401
Brake Noise Troubleshooting402
Hydraulic Brake System Operation402
Brake System Overview403
Brake System Assembly View403
Brake Line Routing / Retention404
Front Brake Lines to Master Cylinder404
Rear Brake Line - Master Cylinder to Junction Block405
Rear Brake Lines - Junction Block to Calipers406
Master Cylinder407
Master Cylinder Removal407
Master Cylinder Installation407
Brake Bleeding / Fluid Change409
Brake Pedal Lever411
Brake Pedal Removal411
Brake Pedal Installation411
Front Brakes412
Pad Removal412
Pad Inspection412
Pad Assembly / Installation413
Brake Burnishing Procedure413
Front Caliper Assembly View414
Caliper Removal415
Caliper Disassembly416
Caliper Inspection417
Caliper Assembly417
Caliper Installation418
Disc Runout419
Disc Inspection419
Disc Replacement420
Rear Brakes421
Pad Removal421
Pad Inspection422
Pad Assembly / Installation423
Brake Burnishing Procedure423
Rear Caliper Assembly View424
Caliper Removal425
Caliper Disassembly426
Caliper Inspection426
Caliper Assembly427
Caliper Installation427
Disc Inspection428
Disc Replacement429
Troubleshooting430
Poor Brake Performance430
Pedal Vibration430
Caliper Overheats (Brakes Drag)430
Brakes Lock430
General Information432
Special Tools432
Decal Replacement432
Body Assembly Views433
Cab Frame Assembly433
Cab Frame Assembly Xp433
Doors436
Doors (Xp4)437
Doors High Lifter438
Dash Instruments / Controls439
Dash Instruments / Controls High Lifter440
Hood / Front Body Work441
Chassis / Main Frame Xp / High Lifter442
Chassis / Main Frame Xp 4443
Seat Assembly Front444
Seat Assembly Rear445
Floor / Rocker Panels Xp / High Lifter446
Floor / Rocker Panels Xp 4 / Xp 4 High Lifter447
Rear Cargo Box / Fenders448
Rear Bumper449
Body Component Removal450
Seats450
Engine Service Panel450
Front Bumper Xp450
Rear Bumper451
Hood and Front Body Work451
Rear Fender / Fender Flair Removal Xp452
Rear Fender Flare / Rear Fender Removal Xp 4453
Cargo Box Assembly Removal453
Rocker Panels, Console and Floor Xp454
Rocker Panels, Rear Console and Floor Xp454
Doors458
Door Panel / Latch Replacement458
Door Adjustment458
General Information464
Special Tools464
Under-Dash Components464
Electrical Service Notes466
Electrical Diagnostics466
Digital Multi-Meter (DMM) Notes466
Static and Dynamic Testing466
Static Testing466
Dynamic Testing466
Connector Probing Guidelines467
Front Probing467
Back Probing467
Break out467
Testing Continuity/Resistance468
Testing for a Short to Ground468
Testing for a Short to Voltage469
Testing for Intermittent Conditions469
Testing Current Flow (Amperage)470
Testing Parasitic Draw471
Testing Voltage Drop471
Instrument Cluster472
Overview472
Information Display Area474
Diagnostic Mode477
Instrument Cluster Pinouts478
Instrument Cluster Removal478
Instrument Cluster Installation478
Ride Command System479
Ride Command Display479
Touchscreen Buttons / Icons480
Gauge Screen480
Audio481
Map481
Device Manager484
Apps Screen487
General Settings488
Time488
Audio488
Vehicle488
Diagnostics489
Lock Touchscreen489
Satellite Status489
Ride Status489
Gopro489
Engine Overheat Indicators490
Usb Hardware Recommendations490
Update Software / Maps491
Update Software491
Update Maps491
Ride Command Troubleshooting492
Switches494
Brake Light Switch494
Headlamp Switch494
Ignition / Key Switch495
Awd / 2Wd Switch (no Turf Mode)495
Transmission / Gear Position Switch496
Seat Belt Switch496
Hazard Switch (Int'l / Tractor)497
Turn/Lights/Horn Switch (Int'l/Tractor)497
Horn498
Turn Lights498
Flasher Module (Int'l/Tractor)498
Brake Alarm (Int'l/Tractor)499
Differential Solenoid Overview499
Differential Solenoid Circuit Operation499
All Wheel Drive Coil500
Operation Overview500
Diagnosing System Failures500
Vehicle Speed Sensor501
Speed Sensor Location501
Speed Sensor Testing501
Ignition Coil502
Operation Overview502
Ignition Coil / Ht Lead Replacement502
Ignition Coil Tests502
Charging System503
Current Draw - Key off503
Charging System "Break Even" Test503
Charging System Stator (Alternator) Tests503
Stator (Alternator) Replacement504
Voltage Regulator505
Regulator Replacement505
Battery506
Battery Specifications506
General Battery Information506
Battery Removal / Installation507
Battery off Season Storage507
Battery Testing507
Ocv - Open Circuit Voltage Test507
Load Test507
Battery Conductance Analyzer507
Charging Procedure508
Lighting System509
Headlight Adjustment509
Headlamp Replacement509
Headlamp Installation510
Taillight Replacement510
Dash Light510
Cooling System511
Fan Control Circuit Operation / Testing511
Fan Control Circuit Bypass Test511
Engine Coolant Temperature Sensor (Ect) Overview511
Ect Sensor Test511
Ect Sensor Replacement512
Starting System513
Troubleshooting513
Voltage Drop Test513
Starter Motor Removal513
Starter Motor Installation514
Starter Solenoid Bench Test514
Starter Solenoid Operation514
Electronic Power Steering515
Eps Operation515
Proper Eps System Diagnosing515
Eps Troubleshooting (Power Steering Non-Functional with Mil On)516
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)517
Eps Troubleshooting (Using Digital Wrench®)518
Fuses / Relays519
Fuse Box519
Rzr Xp 1000 (Non-High Lifter)519
Rzr Xp 1000 (High Lifter)521
Relay / Fuse / Circuit Breaker Details523
Wiring Harness525
Main Harness Retention Locations525
Main Harness Routing526
Break-Out Diagram Viewing527
Can System528
Can System Overview528
Can System Testing528

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