Polaris RZR XP 1000 2015 Service Manual

1.22
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
© Copyright Polaris Industries Inc.
MISC. SPECIFICATIONS AND CHARTS
MASTER TORQUE TABLE
ITEM
TORQUE
A-Arm Bolt
(front)
42 ft-lb (57 Nm)
Ball Joint Fasteners
42 ft-lbs (57 Nm)
Battery Mount Bracket
Fasteners
8 ft-lbs (11 Nm)
Battery Terminal Fasteners 60 in-lbs (7 Nm)
Beadlock Screws
Step 1: 24 in-lbs (3 Nm)
Step 2: 7 ft-lbs (10 Nm)
Brake Disc Mounting Bolts 30 ft-lb (41 Nm)
Brake Bleed Screws
48 in-lb (5 Nm)
Brake Caliper Mounting
Bolts (front)
30 ft-lb (41 Nm)
Brake Caliper Mounting
Bolts (rear)
46 ft-lbs (62 Nm)
Brake Line Banjo Bolts 15 ft-lbs (20 Nm)
Brake Line Flare Fittings 15 ft-lbs (20 Nm)
Brake Pedal Mount Bracket
Bolts
16 ft-lbs (22 Nm)
Brake Switch
15 ft-lbs (20 Nm)
Cab Frame Bolts
40 ft-lb (54 Nm)
Cam Chain Tensioner
29 ft-lb (40 Nm)
Camshaft Carrier Bolts
7 ft-lb (10 Nm)
Camshaft Sprocket Bolts 14 ft-lb (19 Nm)
Clutch Cover (outer)
Screws
50 in-lbs (5 Nm)
Connecting Rod Bolts
Step 1: 9 ft-lbs (12 Nm)
Step 2: 13 ft-lb (18 Nm)
Step 3: Tighten add’n 105°
Coolant Bleed Screw
89 in-lb (10 Nm)
Coolant Temperature
Sensor
17 ft-lb (23 Nm)
CPS Retaining Bolt 9 ft-lb (12 Nm)
Crankcase Bolts M10
Step 1: 9 ft-lb (12 Nm)
Step 2: 21 ft-lb (28 Nm)
Step 3: Tighten add’n 90°
Crankcase Bolts M8
26 ft-lb (35 Nm)
Crankcase Bolts M6
9 ft-lb (12 Nm)
Crankcase Oil Gallery Plug 11 ft-lbs (15 Nm)
Cylinder Head Bolts
Torque in sequence
Step 1: 9 ft-lbs (12 Nm)
Step 2: 26 ft-lb (35 Nm)
Step 3: Additional 180°
Step 4: M6 bolts: 7 ft-lb (10
Nm)
Differential Cover Screws
(INTL)
22 ft-lb (30 Nm)
Door Fasteners
8 ft-lb (11 Nm)
Drive Clutch Retaining Bolt 96 ft-lb (130 Nm)
Drive Clutch Cover Plate
Screw
9 ft-lb (12 Nm)
ITEM
TORQUE
Drive Clutch Shift Weight
Fasteners
20 in-lb (2 Nm)
Drive Clutch Spider
290 ft-lb (393 Nm)
(Apply 0.4 mL Loctite® 7088
Primer and 0.4 mL Loctite®
620™)
Drive Clutch Spider Jamb
Nut
250 ft-lb (339 Nm)
(Apply 0.1 mL Loctite® 7088
Primer and 0.1 mL Loctite®
620™)
Driven Clutch Retaining
Bolt
55 ft-lb (75 Nm)
Driven Clutch Helix
Retaining Screws
48 in-lb (5 Nm)
ECU Mounting Screws 24 in-lb (3 Nm)
Engine Mount (front) 40 ft-lbs (54 Nm)
Engine Oil Plug 12 ft-lbs (16 Nm)
Engine/Transmission
Mounting Bolts
Step 1-2: 64 ft-lb (87 Nm)
Step 3: 5 ft-lb (7 Nm)
Step 4-7: 44 ft-lb (60 Nm)
*see procedure for illustration
ETC Mounting Bolts 7 ft-lb (10 Nm)
Exhaust Head Pipe Bolts 18 ft-lb (24 Nm)
Exhaust Pipe to Muffler
Fasteners
21 ft-lb (28 Nm)
Floor Screws
8 ft-lb (11 Nm)
Flywheel Bolt 133 ft-lbs (180 Nm)
FOX Shock Body Cap 100 ft-lb (135 Nm)
FOX Shock Bearing
Assembly
35 ft-lb (47 Nm)
FOX Shock Bleed Screw
14 in-lb (2 Nm)
FOX Shock Eyelet 50 ft-lb (68 Nm)
FOX Shock Shaft Nut
22 ft-lb (30 Nm)
Frame Bolts (front to rear) 40 ft-lb (54 Nm)
Front Bumper / Fender
Screws
8 ft-ln (11 Nm)
Front Gearcase Cover
Plate Screws
11 ft-lbs (15 Nm)
Front Gearcase Drain/Fill
Plugs
10 ft-lbs (14 Nm)
Front Gearcase Mounting
Bolts
30 ft-lbs (41 Nm)
Fuel Pump PFA Nut 70 ft-lbs (95 Nm)
Fuel Rail Mounting Screws 44 in-lb (5 Nm)
Fuel Tank Block-off Panel
8 ft-lbs (11 Nm)
Fuel Tank Strap Screw 8 ft-lbs (11 Nm)
Hip Bolster Bolts 14 ft-lb (19 Nm)
Hose Clamp 35 in-lb (4 Nm)
Hub Castle Nut (front and
rear)
180 ft-lbs (244 Nm)
GENERAL INFORMATION

Polaris RZR XP 1000 2015 Specifications

General

Brand	Polaris
Model	RZR XP 1000 2015
Category	Offroad Vehicle
Language	English