5.16
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
© Copyright Polaris Industries Inc.
5. Install and properly align the inner clutch cover. Be
sure the fuel line, vent line and battery cables are
properly routed through the guard plate as shown
w
.
6. Install the protective cover and the four push rivets
that secure the cover to the top of the inner PVT
cover.
7. Install the three inner clutch cover bolts and washers
that retain the cover to the engine and the four inner
clutch cover bolts and washers that retain the cover
to the transmission. Torque bolts to specification.
TORQUE
Inner Clutch Cover Bolts:
12 ft-lb (16 Nm)
8. Clean the splines inside the driven clutch and on the
transmission input shaft.
9. Apply a light film of grease to the splines on the shaft.
10.Install the driven clutch, washer and retaining bolt.
Torque to specification.
TORQUE
Driven Clutch Retaining Bolt:
55 ft-lb (75 Nm)
11. Clean the end of the taper on the crankshaft and the
tapered bore inside the drive clutch.
12.Install the drive clutch onto the engine.
13.Install the Drive Clutch Holding Tool (9314177-A) and
torque the retaining bolt to specification.
TORQUE
Drive Clutch Retaining Bolt:
96 ft-lb (130 Nm)
14.Install the drive belt noting direction of belt rotation
(see Chapter 5 – Belt Installation, page 5.18). If a new
belt is installed, install so numbers can be easily read.
15.Install a new outer clutch cover seal with the colored
stripe facing the inner clutch cover.
16.Reinstall outer clutch cover and secure with screws.
Torque screws to specification.
TORQUE
Outer Clutch Cover Retaining Screws:
48 in-lb (5 Nm)
17.Install inlet and outlet ducts and tighten hose clamps.
18.Install the left rear shock lower mounting bolt and the
left rear wheel. Torque fasteners to specification.
TORQUE
Rear Shock Mounting Bolt:
70 ft-lbs (95 Nm)
TORQUE
Wheel Nuts:
120 ft-lbs (163 Nm)
PVT SYSTEM
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