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2014 RZR XP 1000
Polaris 2014 RZR XP 1000 Service Manual
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5.12
9924874
R02
-
2014
RZR
XP
/
XP
4
1000
Service
Manual
©
Copyright
2013
Polaris
Industries
Inc.
Chassis
/
Main
Frame
XP
4
BODY
/
STEERING
/
SUSPENSION
208
210
Table of Contents
Table of Contents
4
Chapter 1
7
Engine Designation Number
7
General Information
7
Model Number Designation
7
Vehicle Identification
7
Vehicle Identification Number (Vin) Designation
7
Vehicle and Engine Serial Number Location
8
Vehicle Information
8
Publication Numbers
8
Replacement Keys
9
Special Tools
10
General Specifications
11
Model: 2014 Rzr Xp 1000 / Eps / Int'l
11
2014 Rzr Xp 1000 / Eps / Int'l
12
Model: 2014 Rzr Xp 4 1000
13
2014 Rzr Xp 4 1000
15
2014 Rzr Xp / Xp 4 1000 Clutch Charts
15
Misc. Specifications and Charts
16
Master Torque Table
16
Conversion Table
19
Standard Bolt Torque Specification
20
Metric Bolt Torque Specification
20
Sae Tap / Drill Sizes
21
Metric Tap / Drill Sizes
21
Decimal Equivalents
22
Maintenance Chapter 2 Maintenance
24
Maintenance
24
Periodic Maintenance Chart
26
Break-In Period
26
Chapter 2
26
Maintenance Chart Key
26
Periodic Maintenance Overview
26
Pre-Ride - 50 Hour Maintenance Interval
27
50 - 500 Hour Maintenance Interval
28
Maintenance Quick Reference
29
Maintenance Quick Reference, Continued
30
Grease Lubrication Points
31
Lubricants / Service Products
32
Polaris Lubricants, Maintenance and Service Products
32
General Vehicle Inspection and Maintenance
33
Pre-Ride / Daily Inspection
33
Shift Cable Inspection / Adjustment
33
Fuel System and Air Intake
34
Fuel System
34
Fuel Tank Vent Line
34
Fuel Pump / Fuel Filters
34
Fuel Lines
35
Throttle Pedal Inspection
35
Engine Intake Pre-Filter Service
36
Air Filter Service
36
Intake Duct Drain Inspection
37
Air Box / Air Filter Assembly View
38
Engine
39
Engine Oil Level
39
Engine Oil and Filter Change
40
Engine Crankcase Breather Hose Inspection
41
Engine Cylinder Leakdown Test
41
Valve Clearance Inspection
42
Transmission and Front Gearcase
44
Specification Chart
44
Transmission Lubrication
44
Front Gearcase Lubrication
45
Cooling System
46
Cooling System Overview
46
Coolant Strength
46
Coolant Level Inspection
47
Cooling System Pressure Test
48
Cooling System Hoses
48
Radiator Inspection / Cleaning
49
Coolant Drain / Fill
49
Pvt / Final Drive / Wheel and Tire
50
Drive Clutch / Driven Clutch / Belt Service
50
Pvt Intake Pre-Filter Service
50
Pvt Drying
50
Drive Shaft Boot Inspection
51
Wheel and Hub Torque Table
51
Wheel Removal
51
Wheel Installation
51
Tire Inspection
51
Tire Pressure
52
Electrical and Ignition System
52
Battery Maintenance
52
Battery Charging / off Season Storage
53
Battery Removal
53
Battery Installation
53
Engine / Chassis Electrical Ground
54
Spark Plug Service
54
Steering
55
Steering Inspection
55
Steering Wheel Freeplay
55
Tie Rod End / Wheel Hub Inspection
56
Wheel Toe Alignment Inspection
56
Wheel Toe Adjustment
57
Suspension (Walker Evans™)
58
Spring Adjustment
58
Shock Compression Adjustment
59
Brake System
60
Brake Fluid Inspection
60
Brake Pad / Disc Inspection
60
Brake Hose and Fitting Inspection
60
Engine Chapter 3 Engine
62
Chapter 3
64
Engine Lubrication Specifications
64
General Information
64
Special Tools
64
Oil Pressure Test
65
Engine Oil Flow Chart
66
Engine Service Specifications
67
Engine Specifications
67
Engine Detail - Torque Values / Sequences / Assembly Notes
69
Main Engine Components - Torque Specification and Sequence
69
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
70
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
71
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
72
Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
73
Engine Cooling System
74
Cooling System Pressure Test
74
Pressure Cap Test
74
Radiator Removal / Installation
75
Thermostat Replacement
76
Cooling System Assembly View
78
Cooling System Bleeding Procedure
79
Water Pump Removal
80
Water Pump Installation
80
Water Pump Service
82
Engine Service
85
Accessible Engine Components
85
Top-End Service (Engine in Chassis)
85
Engine Removal
85
Engine Installation
89
Engine Mounting and Torque Values
92
Engine Break-In Period
93
Engine Lubrication Specifications
93
Engine Disassembly / Inspection - Top End
94
Valve Cover Removal
94
Camshaft Removal
94
Camshaft Sprocket Inspection
95
Camshaft / Camshaft Bore Inspection
95
Cylinder Head Removal
97
Cylinder Head Warp Inspection
98
Cylinder Head Disassembly
98
Valve Inspection
99
Combustion Chamber Cleaning
100
Valve Sealing Test
100
Valve Seat Reconditioning
101
Engine Disassembly / Inspection - Lower End
104
Stator Cover Removal / Inspection
104
Water Pump Housing Removal
105
Flywheel Removal
105
Starter One-Way Clutch Disassembly
106
Crankcase Disassembly / Inspection
107
Balance Shaft Removal / Inspection
110
Crankshaft Removal / Inspection
111
Crankcase Inspection
113
Cylinder Inspection
114
Cylinder / Piston Removal
115
Piston Disassembly / Inspection
116
Piston Ring Removal
117
Piston Ring to Groove Clearance Inspection
118
Piston Ring Installed Gap
118
Piston-To-Cylinder Clearance
118
Connecting Rod Inspection
119
Engine Assembly - Lower End
121
Bearing Selection Identification Letters and Numbers
121
Connecting Rod Bearing Selection
122
Crankshaft Main Bearing Selection
122
Upper Crankcase Preparation
122
Piston Ring Installation
123
Piston / Connecting Rod Assembly
124
Cylinder / Piston Installation
125
Crankshaft Installation
126
Balance Shaft Installation
128
Lower Crankcase Preparation
128
Crankcase Assembly
129
Starter One-Way Clutch Assembly
133
Flywheel Installation
134
Stator Cover Installation
134
Engine Assembly - Top End
135
Cylinder Head Assembly
135
Cylinder Head Installation
136
Camshaft Installation / Timing
137
Camshaft Timing - Quick Reference
141
Valve Clearance Adjustment
142
Intake Valve Lash - Tappet Selection Matrix
144
Exhaust Valve Lash - Tappet Selection Matrix
145
Valve Cover Installation
146
Troubleshooting
147
Engine
147
Cooling System
148
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
150
Chapter 4
152
General Information
152
Special Tools
152
Efi Service Notes
154
Efi System Assembly View
155
Efi System Component Locations
156
Fuel Tank
158
Assembly View
158
Fuel Line Removal / Installation
159
Fuel Tank Removal
159
Fuel Tank Installation
161
Fuel Tank Removal Rzr Xp 4 1000
163
Fuel Tank Installation Rzr Xp 4 1000
164
Electronic Fuel Injection
165
Principal Components
165
Efi Operation Overview
165
Initial Priming / Starting Procedure
166
Electronic Control Unit (Ecu)
166
Operation Overview
166
Ecu Service
167
Ecu Replacement
167
Fuel Injectors
168
Operation Overview
168
Fuel Injector Troubleshooting
168
Fuel Injector Test
169
Fuel Injector Replacement
169
Fuel Pump
172
Operation Overview
172
Fuel Sender Test
173
Fuel Pump Test
173
Fuel Pump Replacement
174
Crankshaft Position Sensor (Cps)
178
Cps Test
179
Cps Replacement
179
Temperature / Manifold Absolute Pressure (T-Map) Sensor
178
Operation Overview
178
T-Map Test / Replacement
178
Throttle Body Assembly
180
Operation Overview
180
Throttle Body Service
180
Throttle Body Removal
180
Electronic Throttle Control (Etc)
181
Operation Overview
181
Etc Test
181
Etc Replacement
182
Pedal Position Sensor (Pps)
182
Operation Overview
182
Location
182
Pps Test
182
Pps Replacement
183
Efi Diagnostics
184
Instrument Cluster Trouble Code Display
184
Diagnostic Trouble Code Table
184
Efi Troubleshooting
188
Digital Wrench® Operation
189
Digital Wrench® Diagnostic Software Overview
189
Special Tools (also Refer to the Beginning of this Chapter)
189
Diagnostic Software Version
190
Guided Diagnostic Available
190
Digital Wrench® Communication Errors
190
Digital Wrench® - Diagnostic Connector
190
Digital Wrench® Serial Number Location
190
Digital Wrench® Version and Update
191
Digital Wrench® Updates
191
Digital Wrench® Feature Map
193
Ecu Replacement
194
Engine Controller Reprogramming (Reflash)
194
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
198
Body / Steering / Suspension
198
General Information
200
Chapter 5
200
Multi-Function Pliers
200
Special Tools
200
Torque Specifications
201
Body Assembly Views
202
Cab Frame Assembly Xp
202
Cab Frame Assembly Xp 4
203
Doors Xp
204
Doors XP 4
205
Dash Instruments / Controls
206
Hood / Front Body Work
207
Chassis / Main Frame Xp
208
Chassis / Main Frame
209
Seat Assembly Front
210
Seat Assembly Rear
211
Floor / Rocker Panels
212
Floor / Rocker Panels
213
Rear Cargo Box / Fenders
214
Rear Bumper
215
Body Component Removal
216
Seats
216
Engine Service Panel
216
Front Bumper
216
Rear Bumper
216
Hood and Front Body Work
217
Rear Fender / Fender Flare Removal
218
Rear Fender Flare / Rear Fender Removal Xp
218
Cargo Box Assembly Removal
218
Rocker Panels, Console and Floor
219
Rocker Panels, Rear Console and Floor Xp
220
Decal Replacement
223
Steering Assembly
224
Assembly View (Non-Eps Models)
224
Steering Wheel Removal (Non-Eps Models)
225
Steering Shaft Removal (Non-Eps Models)
225
Steering Shaft Bearing Replacement
225
Electronic Power Steering Assembly
227
Assembly View (Eps Models)
227
Upper Steering Shaft Removal (Eps Models)
228
Steering Wheel Removal (Eps Models)
228
Power Steering Unit Removal
229
Lower Steering Shaft Removal (Eps Models)
230
Lower Steering Shaft Installation (Eps Models)
230
Power Steering Unit Installation
231
Upper Steering Shaft Installation (Eps Models)
231
Front A-Arms
233
Removal / Replacement
233
Ball Joint Service
236
Service Preparation
236
Ball Joint Removal
236
Ball Joint Installation
236
Rear Radius Rods
237
Removal / Installation
237
Rear Trailing Arm
238
Trailing Arm Removal / Installation
238
Trailing Arm Spherical Bearing Replacement
240
Rear Suspension Assembly View
241
Rear Stabilizer Bar
242
Stabilizer Bar Removal
242
Stabilizer Bar Installation
242
Shocks / Springs / Fasteners
243
Front Shock Assembly View
243
Rear Shock Assembly View
243
Shock Removal / Installation
244
Shock Replacement
244
Walker Evans™Shock Assembly Views
245
Walker Evans™ 2.0" Front Shock
245
Walker Evans™ 2.5" Rear Shock
246
Walker Evans™ Shock Service
247
General Service Information
247
Front Shock Service Information
247
Rear Shock Service Information
248
Walker Evans™ Shock Rebuild Information
249
Special Tools
249
Valve Shim Arrangement
249
Piston Orientation
249
Walker Evans™ Shock Disassembly
250
Walker Evans™ Shock Assembly
252
Clutching Chapter 6 Clutching
258
Clutching
258
General Information
259
Chapter 6
259
Pvt System Torque Specifications
259
Special Tools and Supplies
259
Pvt System Overview
260
General Operation
260
Drive Clutch Operation
260
Driven Clutch Operation
260
Pvt Break-In (Drive Belt / Clutches)
260
Maintenance / Inspection
261
Overheating / Diagnosis
262
Pvt System Service
263
Pvt Covers and Duct Components
263
Pvt Disassembly
264
Pvt Assembly
265
Drive Belt
267
Belt Removal
267
Belt Inspection
268
Belt Installation
268
Pvt Break-In (Drive Belt / Clutches)
268
Drive Clutch Service
269
Drive Clutch Assembly View
269
Drive Clutch Disassembly / Inspection
270
Needle Bearing Inspection
271
Shift Weight Inspection
271
Button to Tower Clearance Inspection
272
Spider Removal
272
Roller, Pin, and Thrust Washer Inspection
272
Clutch Inspection
273
Moveable Sheave Bushing Inspection
273
Bushing Service
274
Drive Clutch Assembly
276
Driven Clutch Service
279
Clutch Disassembly
279
Bushing Service
281
Clutch Assembly
283
Assembly View
287
Troubleshooting
288
Final Drive Chapter 7 Final Drive
290
Final Drive
290
General Information
291
Chapter 7
291
Final Drive Torque Specifications
291
Special Tools
291
Front Bearing Carrier
292
Bearing Carrier Inspection / Removal
292
Bearing Replacement
293
Bearing Carrier Installation
293
Front Drive Shaft
295
Drive Shaft Removal
295
Drive Shaft Installation
296
Front Propshaft Service
297
Front Propshaft Removal
297
Front Prop Shaft Installation
298
Rear Prop Shaft Removal
299
Rear Prop Shaft Installation
299
Transmission
299
Rear Prop Shaft Removal Xp
301
Rear Prop Shaft Installation Xp
301
Support Bearing Replacement
302
Prop Shaft U-Joint Service
304
Front Gearcase / Centralized Hilliard
305
Centralized Hilliard Assembly View
305
All Wheel Drive Operation
306
Awd Diagnosis
306
Front Gearcase Removal
307
Front Gearcase Disassembly / Inspection
308
Front Gearcase Assembly
311
Front Gearcase Installation
314
Rear Bearing Carrier
315
Bearing Carrier Inspection / Removal
315
Brakes
315
Bearing Replacement
316
Bearing Carrier Installation
317
Rear Drive Shaft
319
Drive Shaft Removal
319
Drive Shaft Installation
320
Drive Shaft CV Joint / Boot Replacement
322
Drive Shaft / CV Joint Handling Tips
322
Outer CV Joint / Boot Replacement
322
Inner Plunging Joint / Boot Replacement
324
Drive Shaft Assembly View
327
Wheel Hubs
328
Front Hub Assembly View
328
Rear Hub Assembly View
328
Transmission Chapter 8 Transmission
330
Chapter 8
331
Lubrication
331
Special Tools
331
Specifications
331
Torque Specifications
331
Shift Lever
332
Removal
332
Installation
333
Transmission Mounting and Torque Values
332
Shift Cable
333
Inspection
333
Adjustment
333
Transmission Removal
334
Transmission Installation
337
Transmission Service
341
Transmission Disassembly
341
Gear / Shaft / Bearing Inspection
346
Snorkel Gear Backlash Procedure
347
Electrical
354
Transmission Disassembly
355
Planetary Differential Disassembly
360
Planetary Differential Bushing Replacement
361
Planetary Differential Assembly
364
Gear / Shaft / Bearing Inspection
365
Snorkel Gear Backlash Procedure
366
Troubleshooting
374
Troubleshooting Checklist
374
Transmission Assembly View
375
Transmission Assembly View (Int
377
Transmission Service (Int
354
Differential Operation
354
Brakes Chapter 9 Brakes
380
Brake System Service Notes
382
Chapter 9
382
General Information
382
General Specifications
382
Special Tools
382
Torque Specifications
382
Brake Noise Troubleshooting
383
Hydraulic Brake System Operation
383
Brake System
386
Assembly View
386
Master Cylinder
387
Removal
387
Installation
387
Brake Bleeding / Fluid Change
388
Brake Pedal Lever
388
Pedal Removal
388
Pedal Installation
388
Parking Brake (Int'l Model)
390
Assembly View
390
Parking Brake Inspection
391
Parking Brake Cable Adjustment
391
Parking Brake Caliper Service (Int'l Model)
392
Caliper Assembly View
392
Caliper Removal
393
Caliper Disassembly / Inspection
393
New Brake Pad Installation
394
Caliper Installation
395
Parking Brake Disc (Int'lmodel)
395
Disc Inspection
395
Disc Replacement
396
Front Brake Pads
396
Pad Removal
396
Pad Inspection
397
Pad Assembly / Installation
398
Brake Burnishing Procedure
398
Front Caliper Service
399
Caliper Assembly View
399
Caliper Removal
399
Caliper Disassembly
400
Caliper Inspection
401
Caliper Assembly
402
Caliper Installation
402
Front Brake Disc
403
Disc Runout
403
Disc Inspection
404
Disc Replacement
404
Rear Brake Pads
405
Pad Removal
405
Pad Inspection
406
Pad Assembly / Installation
407
Brake Burnishing Procedure
408
Rear Caliper Service
409
Caliper Assembly View
409
Caliper Removal
409
Caliper Disassembly
410
Caliper Inspection
411
Caliper Assembly
411
Caliper Installation
412
Rear Brake Disc
413
Disc Inspection
413
Disc Replacement
413
Troubleshooting
414
Brakes Squeal / Poor Brake Performance
414
Pedal Vibration
414
Caliper Overheats (Brakes Drag)
414
Brakes Lock
414
Electrical Chapter 10 Electrical
416
Chapter 10
419
Electrical Service Notes
419
General Information
419
Special Tools
419
Torque Specifications
419
Under-Dash Components
419
Efi Diagnostics
420
Efi Component Testing
420
Instrument Cluster
421
Overview
421
Rider Information Display
422
Information Display Area
423
Diagnostic Mode
426
Switches / Controls
428
Brake Light Switch
428
Headlamp Switch
428
Ignition (Key) Switch
429
Ignition (Key) Switch (Int'l)
429
Awd / 2Wd Switch
430
Awd / 2Wd / Turf Switch (Int'l)
430
Turn Signal Switch (Int'l)
431
Hazard Switch (Int'l)
431
Transmission (Gear Position) Switch
431
Parking Brake Switch (Int'l Model)
432
Rear Diff Solenoid (Int'l)
433
Differential Solenoid Overview
433
Differential Solenoid Circuit Operation
433
All Wheel Drive Coil
434
Operation Overview
434
Diagnosing System Failures
434
Ignition Coil
435
Operation Overview
435
Ignition Coil / Ht Lead Replacement
435
Ignition Coil Tests
436
Vehicle Speed Sensor
435
Speed Sensor Location
435
Speed Sensor Testing
435
Head Lights
436
Headlight Adjustment
436
Headlamp Replacement
437
Headlamp Installation
438
Tail / Brake Lights
438
Taillight Replacement
438
Cooling System
439
Fan Control Circuit Operation / Testing
439
Fan Control Circuit Bypass Test
439
Engine Coolant Temperature Sensor (Ect) Overview
439
Ect Sensor Test
440
Ect Sensor Replacement
440
Fuel Sender
441
Testing
441
Fuse Box: Fuses / Relays / Circuit Breaker
442
Overview / Operation
442
Fuse Box Detail
443
Relay Operation
444
Charging System
445
Current Draw - Key off
445
Charging System "Break Even" Test
445
Charging System Stator (Alternator) Tests
446
Stator (Alternator) Replacement
447
Regulator / Rectifier
447
Charging System Testing Flow Chart
448
Battery Service
449
Battery Specifications
449
General Battery Information
449
Battery Removal / Installation
450
Battery off Season Storage
450
Battery Testing
450
Ocv - Open Circuit Voltage Test
450
Load Test
450
Battery Conductance Analyzer
450
Charging Procedure
451
Starting System
451
Troubleshooting
451
Voltage Drop Test
451
Starter Motor Removal
452
Starter Motor Installation
452
Starter Solenoid Bench Test
452
Starter Solenoid Operation
452
Starting System Testing Flow Chart
453
Condition: Starter Fails to Turn over the Engine
453
Electronic Power Steering (Eps)
454
Eps Operation
454
Proper Eps System Diagnosing
454
Eps System Breakout
455
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
456
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
457
Eps Troubleshooting (Using Digital Wrench®)
458
Electrical System Breakouts
459
Awd
459
Vehicle Speed Sensor
460
Cooling System
461
Unswitched Chassis Power
462
Key-On Battery Power
463
Lights
464
Charging System
465
4
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Polaris 2014 RZR XP 1000 Specifications
General
Brand
Polaris
Model
2014 RZR XP 1000
Category
Utility Vehicle
Language
English
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