Polaris RZR XP 1000 (2014) - Workshop Manual / Repair Manual

POLARIS RZR XP 1000 (2014) - REPAIR, SERVICE, WORKSHOP MANUAL

- English ServicevManual to Polaris RZR XP 1000 (2014).



INDEX:


VEHICLE IDENTIFICATION
- Model Number Designation
- Engine Designation Number
- Vehicle Identification Number (Vin) Designation
- Vehicle And Engine Serial Number Location
VEHICLE INFORMATION
- Publication Numbers
- Replacement Keys
SPECIAL TOOLS
GENERAL SPECIFICATIONS
- Model: 2014 Rzr Xp 1000 / Eps / Int’l
- 2014 Rzr Xp 1000 / Eps / Int’l
- Model: 2014 Rzr Xp 4 1000
- 2014 Rzr Xp 4 1000
- 2014 Rzr Xp / Xp 4 1000 Clutch Charts
MISC. SPECIFICATIONS AND CHARTS
- Master Torque Table
- Conversion Table
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- Sae Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
PERIODIC MAINTENANCE CHART
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 50 Hour Maintenance Interval
- 50 - 500 Hour Maintenance Interval
- Maintenance Quick Reference
- Maintenance Quick Reference, Continued...
- Grease Lubrication Points
LUBRICANTS / SERVICE PRODUCTS
- Polaris Lubricants, Maintenance And Service Products
GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Pre-Ride / Daily Inspection
- Shift Cable Inspection / Adjustment
FUEL SYSTEM AND AIR INTAKE
- Fuel System
- Fuel Tank Vent Line
- Fuel Pump / Fuel Filters
- Fuel Lines
- Throttle Pedal Inspection
- Engine Intake Pre-Filter Service

- Air Filter Service
- Intake Duct Drain Inspection
- Air Box / Air Filter Assembly View
ENGINE
- Engine Oil Level
- Engine Oil And Filter Change
- Engine Crankcase Breather Hose Inspection
- Engine Cylinder Leakdown Test
- Valve Clearance Inspection
TRANSMISSION AND FRONT GEARCASE
- Specification Chart
- Transmission Lubrication
- Front Gearcase Lubrication
COOLING SYSTEM
- Cooling System Overview
- Coolant Strength
- Coolant Level Inspection
- Cooling System Pressure Test
- Cooling System Hoses
- Radiator Inspection / Cleaning
- Coolant Drain / Fill
PVT / FINAL DRIVE / WHEEL AND TIRE
- Drive Clutch / Driven Clutch / Belt Service
- Pvt Intake Pre-Filter Service
- Pvt Drying
- Drive Shaft Boot Inspection
- Wheel And Hub Torque Table
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
ELECTRICAL AND IGNITION SYSTEM
- Battery Maintenance
- Battery Charging / Off Season Storage
- Battery Removal
- Battery Installation
- Engine / Chassis Electrical Ground
- Spark Plug Service
STEERING
- Steering Inspection
- Steering Wheel Freeplay
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
SUSPENSION (WALKER EVANS™)
- Spring Adjustment
- Shock Compression Adjustment
BRAKE SYSTEM
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose And Fitting Inspection
GENERAL INFORMATION
- Special Tools
- Engine Lubrication Specifications
- Oil Pressure Test
- Engine Oil Flow Chart
ENGINE SERVICE SPECIFICATIONS
- Engine Specifications
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES
- Main Engine Components - Torque Specification And Sequence
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
- Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
ENGINE COOLING SYSTEM
- Cooling System Pressure Test
- Pressure Cap Test
- Radiator Removal / Installation
- Thermostat Replacement
- Cooling System Assembly View
- Cooling System Bleeding Procedure
- Water Pump Removal
- Water Pump Installation
- Water Pump Service
ENGINE SERVICE
- Accessible Engine Components
- Top-End Service (Engine In Chassis)
- Engine Removal
- Engine Installation
- Engine Mounting And Torque Values
- Engine Break-In Period
- Engine Lubrication Specifications
ENGINE DISASSEMBLY / INSPECTION - TOP END
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Warp Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Sealing Test
- Valve Seat Reconditioning
ENGINE DISASSEMBLY / INSPECTION - LOWER END
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-Way Clutch Disassembly
- Crankcase Disassembly / Inspection
- Balance Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Inspection
- Cylinder Inspection
- Cylinder / Piston Removal
- Piston Disassembly / Inspection
- Piston Ring Removal
- Piston Ring To Groove Clearance Inspection
- Piston Ring Installed Gap
- Piston-To-Cylinder Clearance
- Connecting Rod Inspection
ENGINE ASSEMBLY - LOWER END
- Bearing Selection Identification Letters And Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- Upper Crankcase Preparation
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Cylinder / Piston Installation
- Crankshaft Installation
- Balance Shaft Installation
- Lower Crankcase Preparation
- Crankcase Assembly
- Starter One-Way Clutch Assembly
- Flywheel Installation
- Stator Cover Installation
ENGINE ASSEMBLY - TOP END
- Cylinder Head Assembly
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Clearance Adjustment
- Intake Valve Lash - Tappet Selection Matrix
- Exhaust Valve Lash - Tappet Selection Matrix
- Valve Cover Installation
TROUBLESHOOTING
- Engine
- Cooling System
GENERAL INFORMATION
- Special Tools
- Efi Service Notes
- Efi System Assembly View
- Efi System Component Locations
FUEL TANK
- Assembly View
- Fuel Line Removal / Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank Removal Rzr Xp 4 1000
- Fuel Tank Installation Rzr Xp 4 1000
ELECTRONIC FUEL INJECTION
- Principal Components
- Efi Operation Overview
- Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
- Operation Overview
- Ecu Service
- Ecu Replacement
FUEL INJECTORS
- Operation Overview
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement
FUEL PUMP
- Operation Overview
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump Replacement
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP) SENSOR
- Operation Overview
- T-Map Test / Replacement
CRANKSHAFT POSITION SENSOR (CPS)
- Operation Overview
- Cps Test
- Cps Replacement
THROTTLE BODY ASSEMBLY
- Operation Overview
- Throttle Body Service
- Throttle Body Removal
ELECTRONIC THROTTLE CONTROL (ETC)
- Operation Overview
- Etc Test
- Etc Replacement
PEDAL POSITION SENSOR (PPS)
- Operation Overview
- Location
- Pps Test
- Pps Replacement
EFI DIAGNOSTICS
- Instrument Cluster Trouble Code Display
- Efi Troubleshooting
DIGITAL WRENCH® OPERATION
- Digital Wrench® Diagnostic Software Overview
- Special Tools (Also Refer To The Beginning Of This Chapter)
- Diagnostic Software Version
- Guided Diagnostic Available
- Digital Wrench® Communication Errors
- Digital Wrench® - Diagnostic Connector
- Digital Wrench® Serial Number Location
- Digital Wrench® Version And Update Id
- Digital Wrench® Updates
- Digital Wrench® Feature Map
- Ecu Replacement
- Engine Controller Reprogramming (Reflash)
GENERAL INFORMATION
- Special Tools
- Multi-Function Pliers
- Torque Specifications
BODY ASSEMBLY VIEWS
- Cab Frame Assembly Xp
- Cab Frame Assembly Xp 4
- Doors Xp
- Doors Xp 4
- Dash Instruments / Controls
- Hood / Front Body Work
- Chassis / Main Frame Xp
- Chassis / Main Frame Xp 4
- Seat Assembly Front
- Seat Assembly Rear
- Floor / Rocker Panels Xp
- Floor / Rocker Panels Xp 4
- Rear Cargo Box / Fenders
- Rear Bumper
BODY COMPONENT REMOVAL
- Seats
- Engine Service Panel
- Front Bumper Xp
- Rear Bumper
- Hood And Front Body Work
- Rear Fender / Fender Flare Removal
- Rear Fender Flare / Rear Fender Removal Xp 4
- Cargo Box Assembly Removal
- Rocker Panels, Console And Floor Xp
- Rocker Panels, Rear Console And Floor Xp 4
- Decal Replacement
STEERING ASSEMBLY
- Assembly View (Non-Eps Models)
- Steering Wheel Removal (Non-Eps Models)
- Steering Shaft Removal (Non-Eps Models)
- Steering Shaft Bearing Replacement
ELECTRONIC POWER STEERING ASSEMBLY
- Assembly View (Eps Models)
- Upper Steering Shaft Removal (Eps Models)
- Steering Wheel Removal (Eps Models)
- Power Steering Unit Removal
- Lower Steering Shaft Removal (Eps Models)
- Lower Steering Shaft Installation (Eps Models)
- Power Steering Unit Installation
- Upper Steering Shaft Installation (Eps Models)
FRONT A-ARMS
- Removal / Replacement
BALL JOINT SERVICE
- Service Preparation
- Ball Joint Removal
- Ball Joint Installation
REAR RADIUS RODS
- Removal / Installation
REAR TRAILING ARM
- Trailing Arm Removal / Installation
- Trailing Arm Spherical Bearing Replacement
- Rear Suspension Assembly View
REAR STABILIZER BAR
- Stabilizer Bar Removal
- Stabilizer Bar Installation
SHOCKS / SPRINGS / FASTENERS
- Front Shock Assembly View
- Rear Shock Assembly View
- Shock Removal / Installation
- Shock Replacement
WALKER EVANS™SHOCK ASSEMBLY VIEWS
- Walker Evans™ 2.0" Front Shock
- Walker Evans™ 2.5" Rear Shock
WALKER EVANS™ SHOCK SERVICE
- General Service Information
- Front Shock Service Information
- Rear Shock Service Information
- Walker Evans™ Shock Rebuild Information
- Special Tools
- Valve Shim Arrangement
- Piston Orientation
- Walker Evans™ Shock Disassembly
- Walker Evans™ Shock Assembly
GENERAL INFORMATION
- Special Tools And Supplies
- Pvt System Torque Specifications
- 2014 Rzr Xp / Xp 4 1000 Clutch Charts
PVT SYSTEM OVERVIEW
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- Pvt Break-In (Drive Belt / Clutches)
- Maintenance / Inspection
- Overheating / Diagnosis
PVT SYSTEM SERVICE
- Pvt Covers And Duct Components
- Pvt Disassembly
- Pvt Assembly
DRIVE BELT
- Belt Removal
- Belt Inspection
- Belt Installation
- Pvt Break-In (Drive Belt / Clutches)
DRIVE CLUTCH SERVICE
- Drive Clutch Assembly View
- Drive Clutch Disassembly / Inspection
- Needle Bearing Inspection
- Shift Weight Inspection
- Button To Tower Clearance Inspection
- Spider Removal
- Roller, Pin, And Thrust Washer Inspection
- Clutch Inspection
- Moveable Sheave Bushing Inspection
- Bushing Service
- Drive Clutch Assembly
DRIVEN CLUTCH SERVICE
- Clutch Disassembly
- Bushing Service
- Clutch Assembly
- Assembly View
TROUBLESHOOTING
GENERAL INFORMATION
- Special tools
- Final drive torque specifications
FRONT BEARING CARRIER
- Bearing carrier inspection / removal
- Bearing replacement
- Bearing carrier installation
FRONT DRIVE SHAFT
- Drive shaft removal
- Drive shaft installation
FRONT PROPSHAFT SERVICE
- Front propshaft removal
- Front prop shaft installation
- Rear prop shaft removal
- Rear prop shaft installation
- Rear prop shaft removal xp 4
- Rear prop shaft installation xp 4
- Support bearing replacement
- Prop shaft u-joint service
FRONT GEARCASE / CENTRALIZED HILLIARD
- Centralized hilliard assembly view
- All wheel drive operation
- Awd diagnosis
- Front gearcase removal
- Front gearcase disassembly / inspection
- Front gearcase assembly
- Front gearcase installation
REAR BEARING CARRIER
- Bearing carrier inspection / removal
- Bearing replacement
- Bearing carrier installation
REAR DRIVE SHAFT
- Drive shaft removal
- Drive shaft installation
DRIVE SHAFT CV JOINT / BOOT REPLACEMENT
- Drive shaft / cv joint handling tips
- Outer cv joint / boot replacement
- Inner plunging joint / boot replacement
- Drive shaft assembly view
WHEEL HUBS
- Front hub assembly view
- Rear hub assembly view
SPECIFICATIONS
- Special tools
- Torque specifications
- Lubrication
- Transmission mounting and torque values
SHIFT LEVER
- Removal
- Installation
SHIFT CABLE
- Inspection
- Adjustment
TRANSMISSION REMOVAL
TRANSMISSION INSTALLATION
TRANSMISSION SERVICE
- Transmission disassembly
- Gear / shaft / bearing inspection

- Snorkel gear backlash procedure
TRANSMISSION SERVICE (INT’L)
- Differential operation
- Transmission disassembly
- Planetary differential disassembly
- Planetary differential bushing replacement
- Planetary differential assembly
- Gear / shaft / bearing inspection
- Snorkel gear backlash procedure
TROUBLESHOOTING
- Troubleshooting checklist
TRANSMISSION ASSEMBLY VIEW
TRANSMISSION ASSEMBLY VIEW (INT’L)
GENERAL INFORMATION
- Special tools
- General specifications
- Torque specifications
- Brake system service notes
- Brake noise troubleshooting
- Hydraulic brake system operation
BRAKE SYSTEM
- Assembly view
MASTER CYLINDER
- Removal
- Installation
BRAKE PEDAL LEVER
- Pedal removal
- Pedal installation
BRAKE BLEEDING / FLUID CHANGE
PARKING BRAKE (INT’L MODEL)
- Assembly view
- Parking brake inspection
- Parking brake cable adjustment
PARKING BRAKE CALIPER SERVICE (INT’L MODEL)
- Caliper assembly view
- Caliper removal
- Caliper disassembly / inspection
- New brake pad installation
- Caliper installation
PARKING BRAKE DISC (INT’L MODEL)
- Disc inspection
- Disc replacement
FRONT BRAKE PADS
- Pad removal
- Pad inspection
- Pad assembly / installation
- Brake burnishing procedure
FRONT CALIPER SERVICE
- Caliper assembly view
- Caliper removal
- Caliper disassembly
- Caliper inspection
- Caliper assembly
- Caliper installation
FRONT BRAKE DISC
- Disc runout
- Disc inspection
- Disc replacement
REAR BRAKE PADS
- Pad removal
- Pad inspection
- Pad assembly / installation
- Brake burnishing procedure
REAR CALIPER SERVICE
- Caliper assembly view
- Caliper removal
- Caliper disassembly
- Caliper inspection
- Caliper assembly
- Caliper installation
REAR BRAKE DISC
- Disc inspection
- Disc replacement
TROUBLESHOOTING
- Brakes squeal / poor brake performance
- Pedal vibration
- Caliper overheats (brakes drag)
- Brakes lock
GENERAL INFORMATION
- Special tools
- Torque specifications
- Electrical service notes
- Under-dash components
EFI DIAGNOSTICS
- Efi component testing
INSTRUMENT CLUSTER
- Overview
- Rider information display
- Information display area
- Diagnostic mode
- Instrument cluster pinouts
- Instrument cluster removal
- Instrument cluster installation
SWITCHES / CONTROLS
- Brake light switch
- Headlamp switch
- Ignition (key) switch
- Ignition (key) switch (int’l)
- Awd / 2wd switch
- Awd / 2wd / turf switch (int’l)
- Turn signal switch (int’l)
- Hazard switch (int’l)
- Transmission (gear position) switch
- Parking brake switch (int’l model)
REAR DIFF SOLENOID (INT’L)
- Differential solenoid overview
- Differential solenoid circuit operation
ALL WHEEL DRIVE COIL
- Operation overview
- Diagnosing system failures
VEHICLE SPEED SENSOR
- Speed sensor location
- Speed sensor testing
IGNITION COIL
- Operation overview
- Ignition coil / ht lead replacement
- Ignition coil tests
HEAD LIGHTS
- Headlight adjustment
- Headlamp replacement
- Headlamp installation
TAIL / BRAKE LIGHTS
- Taillight replacement
COOLING SYSTEM
- Fan control circuit operation / testing
- Fan control circuit bypass test
- Engine coolant temperature sensor (ect) overview
- Ect sensor test
- Ect sensor replacement
FUEL SENDER
- Testing
FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER
- Overview / operation
- Fuse box detail
- Relay operation
CHARGING SYSTEM
- Current draw - key off
- Charging system “break even” test
- Charging system stator (alternator) tests
- Stator (alternator) replacement
- Regulator / rectifier
- Charging system testing flow chart
BATTERY SERVICE
- Battery specifications
- General battery information
- Battery removal / installation
- Battery off season storage
- Battery testing
- Ocv - open circuit voltage test
- Load test
- Battery conductance analyzer
- Charging procedure
STARTING SYSTEM
- Troubleshooting
- Voltage drop test
- Starter motor removal
- Starter motor installation
- Starter solenoid bench test
- Starter solenoid operation
STARTING SYSTEM TESTING FLOW CHART
- Condition: starter fails to turn over the engine.
ELECTRONIC POWER STEERING (EPS)
- Eps operation
- Proper eps system diagnosing
- Eps system breakout
- Eps troubleshooting (power steering non-functional with mil on)
- Eps troubleshooting (power steering non-functional with mil off)
- Eps troubleshooting (using digital wrench®)
ELECTRICAL SYSTEM BREAKOUTS
- Awd
- Vehicle speed sensor
- Cooling system
- Unswitched chassis power
- Key-on battery power
- Lights
- Charging System
2014 RZR 1000 WIRING HARNESSES
- 2014 ranger rzr xp 1000 (chassis)
- 2014 ranger rzr xp 1000 (box)