Polaris RZR XP4 1000 2018 User Manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
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Publication Printed February 2018 (PN 9928492 R04)
© Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2017-2018 RZR XP 1000 / XP4 1000
Service Manual

Polaris RZR XP4 1000 2018 Specifications

General

Brand	Polaris
Model	RZR XP4 1000 2018
Category	Automobile
Language	English

Summary

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION

MASTER TORQUE TABLE

Comprehensive table of torque specifications for various components.

CHAPTER 2 MAINTENANCE

PERIODIC MAINTENANCE CHART

Schedule for regular inspections and maintenance tasks.

ENGINE

COOLING SYSTEM

FUEL SYSTEM AND AIR INTAKE

PVT / FINAL DRIVE / WHEEL AND TIRE

TRANSMISSION AND FRONT GEARCASE

STEERING

SUSPENSION

BRAKE SYSTEM

ELECTRICAL AND IGNITION SYSTEM

CHAPTER 3 ENGINE / COOLING SYSTEM

ENGINE LUBRICATION SPECIFICATIONS

OIL PRESSURE TEST

Procedure for testing engine oil pressure.

ENGINE SPECIFICATIONS (1000)

Detailed specifications for camshaft, cylinder head, and cylinder.

ENGINE COOLING SYSTEM

Specifications, pressure testing, hoses, and radiator inspection.

ENGINE SERVICE

Procedures for accessible engine components and engine removal/installation.

CHAPTER 4 FUEL SYSTEM

EFI OVERVIEW

ELECTRONIC CONTROL UNIT (ECU)

Operation, service, replacement, and reprogramming procedures for the ECU.

FUEL INJECTORS

Operation, o-rings, troubleshooting, testing, and replacement of fuel injectors.

FUEL LINES / TANK

FUEL PUMP

Operation overview, fuel sender test, fuel pump test, and replacement.

TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)

CRANKSHAFT POSITION SENSOR (CPS)

Operation overview and testing procedures for the crankshaft position sensor.

ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE BODY

Operation overview and service procedures for the ETC and throttle body assembly.

PEDAL POSITION SENSOR (PPS)

Operation overview, location, testing, and replacement of the pedal position sensor.

OXYGEN SENSOR

Information, testing, and replacement procedures for the oxygen sensor.

EFI DIAGNOSTICS

Procedures for displaying and interpreting diagnostic trouble codes (DTCs).

POLARIS DIGITAL WRENCH

CHAPTER 5 PVT SYSTEM

PVT SYSTEM OVERVIEW

PVT SYSTEM SERVICE

DRIVE BELT

Procedures for drive belt removal, inspection, and installation.

DRIVE CLUTCH SERVICE

Assembly view and disassembly/inspection of the drive clutch.

DRIVEN CLUTCH SERVICE

Inspection and disassembly procedures for the driven clutch.

CHAPTER 6 TRANSMISSION

SHIFT LEVER / CABLE

Procedures for removing, installing, and adjusting the shift lever and cable.

TRANSMISSION SERVICE

Procedures for transmission removal and installation.

TRANSMISSION DISASSEMBLY

Step-by-step instructions for disassembling the transmission.

PLANETARY DIFFERENTIAL DISASSEMBLY (TURF MODE MODELS ONLY)

PLANETARY DIFFERENTIAL BUSHING REPLACEMENT (TURF MODE MODELS ONLY)

PLANETARY DIFFERENTIAL ASSEMBLY (TURF MODE MODELS ONLY)

GEAR / SHAFT / BEARING INSPECTION

Inspection of transmission gears, shafts, and bearings.

TRANSMISSION ASSEMBLY / SNORKEL GEAR BACKLASH PROCEDURE

Procedure for assembling the snorkel gear and checking backlash.

CHAPTER 7 FINAL DRIVE

BEARING CARRIER

DRIVE SHAFT

PROP SHAFT SERVICE

FRONT GEARCASE / CENTRALIZED HILLIARD

Assembly view, operation, removal, and disassembly of the front gearcase.

CHAPTER 8 STEERING / SUSPENSION

STEERING SYSTEM

Assembly view and removal/installation of steering system components.

FRONT SUSPENSION

Procedures for A-arm, stabilizer bar, ball joint, and shock removal/installation.

REAR SUSPENSION

Procedures for radius rod, trailing arm, and stabilizer bar removal/installation.

SHOCKS / SPRINGS

Shock assembly view, removal/installation, and replacement procedures.

WALKER EVANS SHOCK SERVICE

Service information for Walker Evans™ shocks.

SPRING ADJUSTMENT (WALKER EVANS)

WALKER EVANS™ SHOCK REBUILD INFORMATION

Information and special tools required for shock rebuilds.

CHAPTER 9 BRAKE SYSTEM

GENERAL SPECIFICATIONS

BRAKE NOISE TROUBLESHOOTING

Troubleshooting common causes and remedies for brake noise.

BRAKE SYSTEM OVERVIEW

MASTER CYLINDER

Procedures for master cylinder removal and installation.

BRAKE BLEEDING / FLUID CHANGE

Procedure for bleeding the brake system and changing the fluid.

BRAKE PEDAL LEVER

FRONT BRAKES

Procedures for pad removal, inspection, assembly, burnishing, and caliper service.

REAR BRAKES

TROUBLESHOOTING

Troubleshooting common brake system issues.

CHAPTER 11 ELECTRICAL

ELECTRICAL SERVICE NOTES

ELECTRICAL DIAGNOSTICS

STATIC AND DYNAMIC TESTING

CONNECTOR PROBING GUIDELINES

INSTRUMENT CLUSTER

DIAGNOSTICS

Information on displaying and interpreting diagnostic trouble codes (DTCs).