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RZR XP 1000 2017
Polaris RZR XP 1000 2017 Service Manual
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9.8
9928492
R04
-
2017-2018
RZR
XP
1000
/
XP4
1000
Service
Manual
©
Copyright
Polaris
Industries
Inc.
REAR
BRAKE
LINES
-
JUNCTION
BLOCK
TO
CALIPERS
NOTE
Brake
lines
route
inside
the
stabilizer
bar
and
shock
mounts
as
shown.
q
Brake
Line
Retaining
Clip
r
T
railing
Arm
Brake
Line
Retainer
BRAKE
SYSTEM
405
407
Table of Contents
Table of Contents
7
Vehicle Identification
8
Model Number Designation (2015 +)
8
Vehicle Identification Number (Vin) Designation (2015+)
8
Vehicle and Engine Serial Number Location
8
Reference Information
9
Replacement Keys
9
Publication Numbers
9
Special Tools
10
Master Torque Table
14
General Specifications
17
Rzr Xp 1000 Clutch Chart
18
Rzr Xp 4 1000 Clutch Chart
20
Rzr Xp 1000 High Lifter Clutch Chart
22
Rzr Xp 1000 High Lifter Clutch Chart
24
2017 Rzr Xp 1000 Le Matte Gold Metallic
25
Rzr Xp 1000 Clutch Chart
26
2017 Rzr Xp 1000 Le (Ride Command)
27
Rzr Xp 1000 Clutch Chart
28
Rzr Xp 1000 Clutch Chart
30
Rzr Xp 4 1000 Clutch Chart
32
Rzr Xp 1000 High Lifter Clutch Chart
34
Rzr Xp 1000 High Lifter Clutch Chart
36
Rzr Xp 1000 Clutch Chart
38
Rzr Xp 1000 Clutch Chart
40
Rzr Xp 4 1000 Clutch Chart
42
Misc. Specifications and Charts
43
Conversion Table
43
Sae Tap / Drill Sizes
44
Metric Tap / Drill Sizes
44
Decimal Equivalents
45
Maintenance
49
Periodic Maintenance Chart
49
Pre-Ride Inspection
49
Periodic Maintenance Overview
50
Break-In Period
50
Maintenance Intervals
51
Maintenance Quick Reference
71
Grease Lubrication Points
73
Lubricants / Service Products
74
Lubrication Specifications
74
Engine
75
Engine Oil Level
75
Engine Oil and Filter Change
76
Engine Crankcase Breather Hose Inspection
77
Engine Cylinder Leakdown Test
78
Valve Clearance Inspection
78
Cam Chain Tensioner Inspection
80
Heat Shield Inspection
81
Cooling System
82
Cooling System Overview
82
Coolant Strength
82
Coolant Level Inspection
82
Cooling System Pressure Test
83
Cooling System Hoses
83
Radiator Inspection / Cleaning
84
Coolant Drain / Fill
85
Fuel System and Air Intake
86
Fuel System Warning
86
Fuel Tank Vent Line
86
Vent Line Termination Fitting
86
Fuel Pump / Fuel Filters
86
Fuel Lines
87
Throttle Pedal Inspection
88
Engine Intake Pre-Filter Service
88
Air Filter Service
88
Intake Duct Drain Inspection
89
Pvt / Final Drive / Wheel and Tire
90
Belt Inspection
90
Pvt Intake Pre-Filter Service
90
Pvt Drying
90
Drive Shaft Boot Inspection
91
Wheel and Hub Torque Table
91
Maintenance
91
Wheel Removal
91
Wheel Installation
91
Tire Inspection
92
Tire Pressure
92
Beadlock Rims (if Equipped)
92
Transmission and Front Gearcase
94
Specification Chart
94
Transmission Lubrication
94
Front Gearcase Lubrication
95
Shift Cable Inspection / Adjustment
96
Transmission Vent Line Routing
97
Front Gearcase Vent Line Routing
97
Steering
98
Steering Inspection
98
Steering Wheel Free-Play
98
Tie Rod End / Wheel Hub Inspection
99
Wheel Toe Alignment Inspection
99
Wheel Toe Adjustment
100
Suspension
101
Spring Adjustment (Walker Evans)
101
Shock Compression Adjustment (Walker Evans™)
101
Brake System
103
Brake Hose and Fitting Inspection
103
Brake Fluid Inspection
103
Brake Pad / Disc Inspection
103
Electrical and Ignition System
104
Battery Maintenance
104
Battery Charging / off Season Storage
104
Battery Removal
104
Battery Installation
105
Engine / Chassis Electrical Ground
105
Spark Plug Service
106
General Information
109
Special Tools
109
Engine Lubrication Specifications
109
Oil Pressure Test
110
Engine Oil Flow Chart
111
Engine Specifications (1000)
112
Intake / Exhaust System
114
Air Box / Air Filter Assembly View
114
Exhaust System Assembly View
115
Engine Cooling System
116
Engine Cooling System Specifications
116
Cooling System Pressure Test
116
Cooling System Pressure Cap Test
117
Radiator Removal / Installation
117
Thermostat Replacement
118
Cooling System Assembly View
120
Cooling System Bleeding Procedure
121
Water Pump Removal
122
Water Pump Installation
122
Water Pump Service
124
Engine Service
127
Accessible Engine Components
127
Top-End Service (Engine in Chassis)
127
Crankshaft Pto Seal Replacement
128
Engine Removal
130
Engine Installation
133
Engine Mounting and Torque Values
136
Engine Break-In Period
136
Engine Lubrication Specifications
137
Engine Disassembly / Inspection - Top End
138
Valve Cover Removal
138
Camshaft Removal
138
Camshaft Sprocket Inspection
140
Camshaft / Camshaft Bore Inspection (1000)
141
Cylinder Head Removal
142
Cylinder Head Warp Inspection
143
Cylinder Head Disassembly
143
Valve Inspection
144
Combustion Chamber Cleaning
145
Valve Sealing Test
146
Valve Seat Reconditioning (1000)
146
Engine Disassembly / Inspection - Bottom End
149
Stator Cover Removal / Inspection
149
Water Pump Housing Removal
150
Flywheel Removal
151
Starter One-Way Clutch Disassembly
152
Crankcase Disassembly / Inspection
153
Balance Shaft Removal / Inspection
155
Crankshaft Removal / Inspection
156
Crankcase Inspection
158
Cylinder Inspection
159
Cylinder / Piston Removal
160
Piston Disassembly / Inspection (1000)
161
Piston Ring Removal
162
Piston Ring to Groove Clearance Inspection
162
Piston Ring Installed Gap (1000)
163
Piston-To-Cylinder Clearance
163
Connecting Rod Inspection
163
Engine Assembly - Bottom End
165
Bearing Selection Identification Letters and Numbers
165
Connecting Rod Bearing Selection
166
Crankshaft Main Bearing Selection
166
Upper Crankcase Preparation
167
Piston Ring Installation
167
Piston / Connecting Rod Assembly
169
Cylinder / Piston Installation
170
Crankshaft Installation
171
Balance Shaft Installation
173
Lower Crankcase Preparation
173
Crankcase Assembly
174
Starter One-Way Clutch Assembly
178
Flywheel Installation
178
Stator Cover Installation
179
Engine Assembly - Top End
180
Cylinder Head Assembly
180
Cylinder Head Installation
181
Camshaft Installation / Timing
182
Camshaft Timing - Quick Reference
186
Valve Clearance Adjustment
187
Valve Lash - Tappet Selection
189
Valve Cover Installation
190
Troubleshooting
191
Engine Cooling System
192
General Information
195
Special Tools
195
Efi Overview
196
Efi Service Notes
196
Efi System Assembly View
197
Efi System Component Locations
198
Principal Components
199
Efi Operation Overview
199
Initial Priming / Starting Procedure
200
Evap System
201
Evap System Overview
201
Evap Conditions and Symptoms
202
Electronic Control Unit (Ecu)
203
Operation Overview
203
Ecu Service
203
Ecu Replacement
203
Etc Learn Procedure
204
Fuel Injectors
205
Operation Overview
205
Fuel Injector O-Rings
205
Fuel Injector Troubleshooting
206
Fuel Injector Test
206
Fuel Injector Replacement
207
Fuel Lines / Tank
210
Assembly View
210
Fuel Vent Line Routing (Non Highlifter)
211
Fuel Vent Line Routing (High Lifter)
213
Vent Line Termination Fitting
214
Fuel Line Quick Connect Removal
214
Fuel Line Removal / Installation
216
Fuel Tank Removal
217
Fuel Tank Installation
219
Fuel Tank Removal Rzr Xp 4 1000
220
Fuel Tank Installation Rzr Xp 4 1000
221
Fuel Pump
223
Operation Overview
223
Fuel Sender Test
223
Fuel Pump Test
224
Fuel Pump Replacement
224
Temperature and Manifold Absolute Pressure Sensor (T-Map)
228
Operation Overview
228
T-Map Test / Replacement
228
Crankshaft Position Sensor (Cps)
229
Operation Overview
229
Cps Test
229
Cps Replacement
230
Electronic Throttle Control (Etc) / Throttle Body
231
Operation Overview
231
Throttle Body Service
231
Throttle Body Removal
232
Etc Test
233
Etc Replacement
233
Etc Learn Procedure
233
Pedal Position Sensor (Pps)
234
Operation Overview
234
Location
234
Pps Test
234
Pps Replacement
234
Oxygen Sensor
236
Oxygen Sensor Information
236
Oxygen Sensor Replacement
236
Efi Diagnostics
238
Trouble Code Display (Dtc)
238
Cylinder Misfire Detection
245
Efi Troubleshooting
246
Polaris Digital Wrench
247
Digital Wrench® Diagnostic Software Overview
247
Special Tools (Digital Wrench)
247
Digital Wrench Software Version and Update
248
Digital Wrench® Updates
248
Digital Wrench® Communication Errors
249
Digital Wrench® - Diagnostic Connector
250
Guided Diagnostics
251
Digital Wrench® Serial Number Location
251
Digital Wrench® Feature Map
252
Ecu Replacement
253
Etc Learn Procedure
253
Ecu Reprogramming (Reflash)
253
Polaris Mobile Digital Wrench (Pmdw)
256
General Information
259
Special Tools and Supplies
259
Rzr Xp 1000 Clutch Chart
259
Rzr Xp 4 1000 Clutch Chart
259
Rzr Xp 1000 High Lifter Clutch Chart
259
Rzr Xp 4 1000 High Lifter Clutch Chart
259
Rzr Xp 1000 Le Gold Metallic Clutch Chart
259
Pvt System Overview
260
General Operation
260
Drive Clutch Operation
260
Driven Clutch Operation
261
Pvt Break-In (Drive Belt / Clutches)
261
Maintenance / Inspection
261
Pvt Overheating / Diagnosis
262
Pvt System Service
263
Pvt Covers and Ducting Components (High Lifter)
264
Pvt Disassembly
265
Pvt Assembly
267
Drive Belt
269
Belt Removal
269
Belt Inspection
270
Belt Installation
270
Pvt Break-In (Drive Belt / Clutches)
270
Drive Clutch Service
271
Drive Clutch Assembly View
271
Drive Clutch Disassembly / Inspection
272
Needle Bearing Inspection
273
Shift Weight Inspection
274
Button to Tower Clearance Inspection
274
Spider Removal
275
Roller, Pin, and Thrust Washer Inspection
275
Clutch Inspection
276
Moveable Sheave Bushing Inspection
277
Bushing Service
277
Drive Clutch Assembly
279
Driven Clutch Service
282
Driven Clutch Slider Inspection
282
Driven Clutch Disassembly
282
Driven Clutch Assembly
284
Driven Clutch Assembly View
286
General Information
290
Special Tools
290
Lubrication
290
Shift Lever / Cable
291
Shift Lever Removal
291
Shift Lever Installation
291
Shift Lever Removal (Gold Metallic Le)
291
Spherical Bearing Removal
292
Shift Lever Installation (Gold Metallic Le)
292
Gated Shifter Adjustment (Gold Metallic Le)
293
Shift Cable Inspection
294
Shift Cable Adjustment
294
Transmission Service
296
Transmission Removal
296
Transmission Installation
299
Transmission Vent Line Routing
302
Transmission Disassembly
302
Differential Operation
307
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 Inspection
314
Transmission Assembly / Snorkel Gear Backlash Procedure
315
Troubleshooting
321
Shifting Difficulty
321
General Information
324
Special Tools
324
Bearing Carrier
325
Front Bearing Carrier Inspection / Removal
325
Front Bearing Replacement
326
Front Bearing Carrier Installation
327
Rear Bearing Carrier Inspection / Removal
328
Rear Bearing Replacement
330
Rear Bearing Carrier Installation
331
Drive Shaft
333
Front Drive Shaft Removal
333
Front Drive Shaft Installation
334
Rear Drive Shaft Removal
335
Rear Drive Shaft Installation
336
Drive Shaft / CV Joint Handling Tips
338
CV Joint Service
338
Outer CV Boot Replacement
338
Inner Plunging Joint / Boot Replacement
340
Prop Shaft Service
342
Front Propshaft Removal
342
Rear Prop Shaft Removal
343
Rear Prop Shaft Removal Xp 4
344
Support Bearing Replacement
345
U-Joint Disassembly
346
U-Joint Assembly
346
Front Prop Shaft Installation
347
Rear Prop Shaft Installation
347
Rear Prop Shaft Installation Xp 4
348
Front Gearcase / Centralized Hilliard
349
Front Gearcase Assembly View
349
All Wheel Drive Operation
350
Awd Diagnosis
350
Front Gearcase Removal
352
Front Gearcase Disassembly / Inspection
352
Front Gearcase Assembly
355
Front Gearcase Installation
358
Front Gearcase Vent Line Routing
358
Wheel Hubs
359
Front Hub Assembly View
359
Rear Hub Assembly View
359
Beadlock Rims (if Equipped)
360
General Information
363
Special Tools
363
Multi-Function Pliers
363
Steering System
364
Steering System Assembly View
364
Upper Steering Shaft Removal
365
Steering Wheel Removal
366
Power Steering Unit Removal
366
Lower Steering Shaft Removal
368
Lower Steering Shaft Installation
368
Power Steering Unit Installation
369
Upper Steering Shaft Installation
370
Steering Shaft Bearing Replacement
371
Front Suspension
372
Front A-Arm Removal / Replacement
372
Front Stabilizer Bar Removal
373
Front Stabilizer Bar Installation
374
Ball Joint Service Preparation
375
Ball Joint Removal
375
Ball Joint Installation
375
Rear Suspension
376
Radius Rod Removal / Installation
376
Trailing Arm Removal / Installation
376
Trailing Arm Spherical Bearing Replacement
379
Rear Suspension Assembly View
380
Rear Stabilizer Bar Removal
381
Stabilizer Bar Installation
381
Shocks / Springs
382
Shock Assembly View
382
Shock Removal / Installation
382
Shock / Spring Replacement
382
Shock Service
383
Walker Evans Shock Service
383
Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock
383
General Service Information
384
Front Shock Service Information
384
Rear Shock Service Information
386
Spring Adjustment (Walker Evans)
388
Walker Evans™ Shock Rebuild Information
389
Special Tools
389
Valve Shim Arrangement
389
General Information
401
Special Tools
401
General Specifications
401
Brake System Service Notes
401
Brake Noise Troubleshooting
402
Hydraulic Brake System Operation
402
Brake System Overview
403
Brake System Assembly View
403
Brake Line Routing / Retention
404
Front Brake Lines to Master Cylinder
404
Rear Brake Line - Master Cylinder to Junction Block
405
Rear Brake Lines - Junction Block to Calipers
406
Master Cylinder
407
Master Cylinder Removal
407
Master Cylinder Installation
407
Brake Bleeding / Fluid Change
409
Brake Pedal Lever
411
Brake Pedal Removal
411
Brake Pedal Installation
411
Front Brakes
412
Pad Removal
412
Pad Inspection
412
Pad Assembly / Installation
413
Brake Burnishing Procedure
413
Front Caliper Assembly View
414
Caliper Removal
415
Caliper Disassembly
416
Caliper Inspection
417
Caliper Assembly
417
Caliper Installation
418
Disc Runout
419
Disc Inspection
419
Disc Replacement
420
Rear Brakes
421
Pad Removal
421
Pad Inspection
422
Pad Assembly / Installation
423
Brake Burnishing Procedure
423
Rear Caliper Assembly View
424
Caliper Removal
425
Caliper Disassembly
426
Caliper Inspection
426
Caliper Assembly
427
Caliper Installation
427
Disc Inspection
428
Disc Replacement
429
Troubleshooting
430
Poor Brake Performance
430
Pedal Vibration
430
Caliper Overheats (Brakes Drag)
430
Brakes Lock
430
General Information
432
Special Tools
432
Decal Replacement
432
Body Assembly Views
433
Cab Frame Assembly
433
Cab Frame Assembly Xp
433
Doors
436
Doors (Xp4)
437
Doors High Lifter
438
Dash Instruments / Controls
439
Dash Instruments / Controls High Lifter
440
Hood / Front Body Work
441
Chassis / Main Frame Xp / High Lifter
442
Chassis / Main Frame Xp 4
443
Seat Assembly Front
444
Seat Assembly Rear
445
Floor / Rocker Panels Xp / High Lifter
446
Floor / Rocker Panels Xp 4 / Xp 4 High Lifter
447
Rear Cargo Box / Fenders
448
Rear Bumper
449
Body Component Removal
450
Seats
450
Engine Service Panel
450
Front Bumper Xp
450
Rear Bumper
451
Hood and Front Body Work
451
Rear Fender / Fender Flair Removal Xp
452
Rear Fender Flare / Rear Fender Removal Xp 4
453
Cargo Box Assembly Removal
453
Rocker Panels, Console and Floor Xp
454
Rocker Panels, Rear Console and Floor Xp
454
Doors
458
Door Panel / Latch Replacement
458
Door Adjustment
458
General Information
464
Special Tools
464
Under-Dash Components
464
Electrical Service Notes
466
Electrical Diagnostics
466
Digital Multi-Meter (DMM) Notes
466
Static and Dynamic Testing
466
Static Testing
466
Dynamic Testing
466
Connector Probing Guidelines
467
Front Probing
467
Back Probing
467
Break out
467
Testing Continuity/Resistance
468
Testing for a Short to Ground
468
Testing for a Short to Voltage
469
Testing for Intermittent Conditions
469
Testing Current Flow (Amperage)
470
Testing Parasitic Draw
471
Testing Voltage Drop
471
Instrument Cluster
472
Overview
472
Information Display Area
474
Diagnostic Mode
477
Instrument Cluster Pinouts
478
Instrument Cluster Removal
478
Instrument Cluster Installation
478
Ride Command System
479
Ride Command Display
479
Touchscreen Buttons / Icons
480
Gauge Screen
480
Audio
481
Map
481
Device Manager
484
Apps Screen
487
General Settings
488
Time
488
Audio
488
Vehicle
488
Diagnostics
489
Lock Touchscreen
489
Satellite Status
489
Ride Status
489
Gopro
489
Engine Overheat Indicators
490
Usb Hardware Recommendations
490
Update Software / Maps
491
Update Software
491
Update Maps
491
Ride Command Troubleshooting
492
Switches
494
Brake Light Switch
494
Headlamp Switch
494
Ignition / Key Switch
495
Awd / 2Wd Switch (no Turf Mode)
495
Transmission / Gear Position Switch
496
Seat Belt Switch
496
Hazard Switch (Int'l / Tractor)
497
Turn/Lights/Horn Switch (Int'l/Tractor)
497
Horn
498
Turn Lights
498
Flasher Module (Int'l/Tractor)
498
Brake Alarm (Int'l/Tractor)
499
Differential Solenoid Overview
499
Differential Solenoid Circuit Operation
499
All Wheel Drive Coil
500
Operation Overview
500
Diagnosing System Failures
500
Vehicle Speed Sensor
501
Speed Sensor Location
501
Speed Sensor Testing
501
Ignition Coil
502
Operation Overview
502
Ignition Coil / Ht Lead Replacement
502
Ignition Coil Tests
502
Charging System
503
Current Draw - Key off
503
Charging System "Break Even" Test
503
Charging System Stator (Alternator) Tests
503
Stator (Alternator) Replacement
504
Voltage Regulator
505
Regulator Replacement
505
Battery
506
Battery Specifications
506
General Battery Information
506
Battery Removal / Installation
507
Battery off Season Storage
507
Battery Testing
507
Ocv - Open Circuit Voltage Test
507
Load Test
507
Battery Conductance Analyzer
507
Charging Procedure
508
Lighting System
509
Headlight Adjustment
509
Headlamp Replacement
509
Headlamp Installation
510
Taillight Replacement
510
Dash Light
510
Cooling System
511
Fan Control Circuit Operation / Testing
511
Fan Control Circuit Bypass Test
511
Engine Coolant Temperature Sensor (Ect) Overview
511
Ect Sensor Test
511
Ect Sensor Replacement
512
Starting System
513
Troubleshooting
513
Voltage Drop Test
513
Starter Motor Removal
513
Starter Motor Installation
514
Starter Solenoid Bench Test
514
Starter Solenoid Operation
514
Electronic Power Steering
515
Eps Operation
515
Proper Eps System Diagnosing
515
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 / Relays
519
Fuse Box
519
Rzr Xp 1000 (Non-High Lifter)
519
Rzr Xp 1000 (High Lifter)
521
Relay / Fuse / Circuit Breaker Details
523
Wiring Harness
525
Main Harness Retention Locations
525
Main Harness Routing
526
Break-Out Diagram Viewing
527
Can System
528
Can System Overview
528
Can System Testing
528
4
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Polaris RZR XP 1000 2017 Specifications
General
Brand
Polaris
Model
RZR XP 1000 2017
Category
Automobile
Language
English
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