polaris RZR XP 1000
SERVICE MANUAL & OWNER´S MANUAL
POLARIS RZR XP 1000 (2014) - REPAIR, SERVICE, WORKSHOP MANUAL - English ServicevManual to Polaris RZR XP 1000 (2014). CONTENTS: 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)
Polaris RZR XP 1000 (2014) Service Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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