Polaris RZR XP 1000
POLARIS RZR XP 1000 & XP4 1000 (2019) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS
POLARIS RZR XP 1000 & XP4 1000 (2019) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS - English Workshop Manual and Wiring Schematics, for UTV Polaris RZR XP 1000 & XP4 1000 (2019). INDEX: CHAPTER 1: GENERAL INFORMATION Vehicle Identification - Model Number Designation (2015 +) - Vehicle Identification Number (VIN) Designation (2015+) - Vehicle and Engine Serial Number Location Reference Information - Replacement Keys - Publication Numbers - Special Tools - Master Torque Table General Specifications - 2019 RZR XP 1000 - 2019 RZR XP 1000 Clutch Chart - 2019 RZR XP 4 1000 - 2019 RZR XP 4 1000 Clutch Chart - 2019 RZR XP 1000 High Lifter - 2019 RZR XP 1000 High Lifter Clutch Chart - 2019 RZR XP 4 1000 High Lifter - 2019 RZR XP 4 1000 High Lifter Clutch Chart - 2019 RZR XP 1000 Gold Metallic LE - 2019 RZR XP 1000 Clutch Chart - 2019 RZR XP 1000 Ride Command - 2019 RZR XP 1000 Clutch Chart - 2019 RZR XP 4 1000 Ride Command - 2019 RZR XP 4 1000 Clutch Chart Misc. Specifications and Charts - Conversion Table - SAE Tap / Drill Sizes - Metric Tap / Drill Sizes - Decimal Equivalents CHAPTER 2: MAINTENANCE PERIODIC MAINTENANCE CHART - Pre-Ride Inspection - Periodic Maintenance Overview - Break-In Period - Maintenance Intervals - Maintenance Quick Reference - Grease Lubrication Points LUBRICANTS / SERVICE PRODUCTS - Lubrication Specifications ENGINE - Engine Oil Level - Engine Oil and Filter Change - Engine Crankcase Breather Hose Inspection - Engine Cylinder Leakdown Test - Valve Clearance Inspection - Cam Chain Tensioner Inspection - Heat Shield Inspection COOLING SYSTEM - Cooling System Overview - Coolant Strength - Coolant Level Inspection - Cooling System Pressure Test - Cooling System Hoses - Radiator Inspection / Cleaning - Coolant Drain / Fill FUEL SYSTEM AND AIR INTAKE - Fuel System Warning - Fuel Tank Vent Line - Vent Line Termination Fitting - Fuel Pump / Fuel Filters - Fuel Lines - Throttle Pedal Inspection - Engine Intake Pre-Filter Service - Air Filter Service - Intake Duct Drain Inspection PVT / FINAL DRIVE / WHEEL AND TIRE - Belt Inspection - PVT Intake Pre-Filter Service - PVT Drying - Drive Shaft Boot Inspection - Wheel and Hub Torque Table - Wheel Removal - Wheel Installation - Tire Inspection - Tire Pressure - Beadlock Rims (if equipped) TRANSMISSION AND FRONT GEARCASE - Specification Chart - Transmission Lubrication - Front Gearcase Lubrication - Shift Cable Inspection / Adjustment - Transmission Vent Line Routing - Front Gearcase Vent Line Routing STEERING - Steering Inspection - Steering Wheel Free-play - Tie Rod End / Wheel Hub Inspection - Wheel Toe Alignment Inspection - Wheel Toe Adjustment SUSPENSION - Spring Adjustment (Walker Evans) - Shock Compression Adjustment (WALKER EVANS™) BRAKE SYSTEM - Brake Hose and Fitting Inspection - Brake Fluid Inspection - Brake Pad / Disc Inspection ELECTRICAL AND IGNITION SYSTEM - Battery Maintenance - Battery Charging / Off Season Storage - Battery Removal - Battery Installation - Engine / Chassis Electrical Ground - Spark Plug Service CHAPTER 3: ENGINE / COOLING SYSTEM General Information - Special Tools - Engine Lubrication Specifications - Oil Pressure Test - Engine Oil Flow Chart - Engine Specifications (1000) Intake / Exhaust System - Air Box / Air Filter Assembly View - Exhaust System Assembly View Engine Cooling System - Engine Cooling System Specifications - Cooling System Pressure Test - Cooling System 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) - Crankshaft PTO Seal Replacement - 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 (1000) - Cylinder Head Removal - Cylinder Head Warp Inspection - Cylinder Head Disassembly - Valve Inspection - Combustion Chamber Cleaning - Valve Sealing Test - Valve Seat Reconditioning (1000) Engine Disassembly / Inspection - Bottom 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 (1000) - Piston Ring Removal - Piston Ring to Groove Clearance Inspection - Piston Ring Installed Gap (1000) - Piston-to-Cylinder Clearance - Connecting Rod Inspection Engine Assembly - Bottom 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 - Valve Lash - Tappet Selection - Valve Cover Installation Troubleshooting - Engine - Cooling System CHAPTER 4: FUEL SYSTEM General Information - Special Tools EFI Overview - EFI Service Notes - EFI System Assembly View - EFI System Component Locations - Principal Components - EFI Operation Overview - Initial Priming / Starting Procedure EVAP SYSTEM - EVAP System Overview - EVAP Conditions and Symptoms Electronic Control Unit (ECU) - Operation Overview - ECU Service - ECU Replacement - ETC Learn Procedure Fuel Injectors - Operation Overview - Fuel Injector O-rings - Fuel Injector Troubleshooting - Fuel Injector Test - Fuel Injector Replacement Fuel Lines / Tank - Assembly View - Fuel Vent Line Routing (non HighLifter) - Fuel Vent Line Routing (High Lifter) - Fuel Vent Line Routing (EVAP Models) - Vent Line Termination Fitting - Fuel Line Quick Connect Removal - Fuel Line Removal / Installation - Fuel Tank Removal - Fuel Tank Installation - Fuel Tank Removal RZR XP 4 1000 - Fuel Tank Installation RZR XP 4 1000 Fuel Pump - Operation Overview - Fuel Sender Test - Fuel Pump Test - Fuel Pump Replacement Temperature and Manifold Absolute Pressure Sensor (T-MAP) - Operation Overview - T-MAP Test / Replacement Crankshaft Position Sensor (CPS) - Operation Overview - CPS Test - CPS Replacement Electronic Throttle Control (ETC) / Throttle Body - Operation Overview - Throttle Body Service - Throttle Body Removal - ETC Test - ETC Replacement - ETC Learn Procedure Pedal Position Sensor (PPS) - Operation Overview - Location - PPS Test - PPS Replacement Oxygen Sensor - Oxygen Sensor Information - Oxygen Sensor Replacement EFI Diagnostics - Trouble Code Display (DTC) - Cylinder Misfire Detection - EFI Troubleshooting Polaris Digital Wrench - Digital Wrench® Diagnostic Software Overview - Special Tools (Digital Wrench) - Digital Wrench Software Version and Update ID - Digital Wrench® Updates - Digital Wrench® Communication Errors - Digital Wrench® - Diagnostic Connector - Guided Diagnostics - Digital Wrench® Serial Number Location - Digital Wrench® Feature Map - ECU Replacement - ETC Learn Procedure - ECU Reprogramming (Reflash) Polaris Mobile Digital Wrench (PMDW) - Polaris Mobile Digital Wrench (PMDW) CHAPTER 5: PVT SYSTEM General Information - SPECIAL TOOLS AND SUPPLIES - RZR XP 1000 Clutch Chart - RZR XP 4 1000 Clutch Chart - RZR XP 1000 High Lifter Clutch Chart - RZR XP 4 1000 High Lifter Clutch Chart - RZR XP 1000 LE Gold Metallic Clutch Chart PVT System Overview - General Operation - Drive Clutch Operation - Driven Clutch Operation - PVT Break-In (Drive Belt / Clutches) - Maintenance / Inspection - PVT Overheating / Diagnosis PVT System Service - XP / XP4 PVT Covers and Ducting Components - PVT Covers and Ducting Components (High Lifter) - 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 - Driven Clutch Slider Inspection - Driven Clutch Disassembly - Driven Clutch Assembly - Driven Clutch Assembly View Troubleshooting - TROUBLESHOOTING CHAPTER 6: TRANSMISSION General Information - Special Tools - Lubrication Shift Lever / Cable - Shift Lever Removal - Shift Lever Installation - Shift Lever Removal (Gold Metallic LE) - Shift Lever Installation (Gold Metallic LE) - Gated Shifter Adjustment (Gold Metallic LE) - Shift Cable Inspection - Shift Cable Adjustment Transmission Service - Transmission Removal - Transmission Installation - Transmission Vent Line Routing - Transmission Disassembly - Differential Operation - Planetary Differential Disassembly (Turf Mode Models Only) - Planetary Differential Bushing Replacement (Turf Mode Models Only) - Planetary Differential Assembly (Turf Mode Models Only) - Gear / Shaft / Bearing Inspection - Transmission Assembly / Snorkel Gear Backlash Procedure Troubleshooting - Shifting Difficulty CHAPTER 7: FINAL DRIVE General Information - SPECIAL TOOLS Bearing Carrier - Front Bearing Carrier Removal / Inspection - Front Bearing Replacement - Front Bearing Carrier Installation - Rear Bearing Carrier Inspection / Removal - Rear Bearing Replacement - Rear Bearing Carrier Installation Drive Shaft - Front Drive Shaft Removal - Front Drive Shaft Installation - Rear Drive Shaft Removal - Rear Drive Shaft Installation - Drive Shaft / CV Joint Handling Tips - CV Joint Service - Outer CV Boot Replacement - Inner Plunging Joint / Boot Replacement Prop Shaft Service - Front Prop Shaft Removal - Rear Prop Shaft Removal - Rear Prop Shaft Removal XP 4 - Support Bearing Replacement - U-Joint Disassembly - U-Joint Assembly - Front Prop Shaft Installation - Rear Prop Shaft Installation - Rear Prop Shaft Installation XP 4 Front Gearcase / Centralized Hilliard - Front Gearcase Assembly View - All Wheel Drive Operation - AWD Diagnosis - Front Gearcase Removal - Front Gearcase Disassembly / Inspection - Front Gearcase Assembly - Front Gearcase Installation - Front Gearcase Vent Line Routing Wheel Hubs - Front Hub Assembly View - Rear Hub Assembly View - Beadlock Rims (if equipped) CHAPTER 8: STEERING / SUSPENSION General Information - SPECIAL TOOLS - Multi-Function Pliers Steering System - Steering System Assembly View - Upper Steering Shaft Removal - Steering Wheel Removal - Power Steering Unit Removal - Lower Steering Shaft Removal - Lower Steering Shaft Installation - Power Steering Unit Installation - Upper Steering Shaft Installation - Steering Shaft Bearing Replacement Front Suspension - Front A-arm Removal / Replacement - Front Stabilizer Bar Removal - Front Stabilizer Bar Installation - Ball Joint Service Preparation - Ball Joint Removal - Ball Joint Installation Rear Suspension - Radius Rod Removal / Installation - Trailing Arm Removal / Installation - Trailing Arm Spherical Bearing Replacement - Rear Suspension Assembly View - Rear Stabilizer Bar Removal - Stabilizer Bar Installation Shocks / Springs - Shock Assembly View - Shock Removal / Installation - Shock / Spring Replacement Shock Service - WALKER EVANS SHOCK SERVICE - Walker Evans™ 2.0" Front Shock / 2.5" Rear Shock - General Service Information - Front Shock Service Information - Rear Shock Service Information - Spring Adjustment (Walker Evans) - Walker Evans™ Shock Rebuild Information - Special Tools - Valve Shim Arrangement - Shock Piston Orientation - Walker Evans™ Shock Disassembly - Walker Evans™ Shock Assembly DYNAMIX ACTIVE SUSPENSION - Dynamix Shocks Disassembly / Assembly - Dynamix Overview - Demonstration Mode - Suspension Control Module (SCM) - DYNAMIX™ System Features - Vehicle Speed Sensitivity - Cornering Control - Braking - Acceleration - Airborne Detection - Advanced Diagnostics - Processing Capability - Suspension Mode Switch (Dynamix models) - Dynamix Troubleshooting - Shock Valve Power Supply - SCM System Voltage - SCM Shock Valve Diagnostics - SCM Mode Switch - SCM CAN Diagnostics - SCM Steering Angle Adapted Offset Diagnostics - SCM / Inertial Measurement Unit CHAPTER 9: BRAKE SYSTEM General Information - SPECIAL TOOLS - GENERAL SPECIFICATIONS - BRAKE SYSTEM SERVICE NOTES - BRAKE NOISE TROUBLESHOOTING - HYDRAULIC BRAKE SYSTEM OPERATION BRAKE SYSTEM OVERVIEW - Brake System Assembly View - Brake Line Routing / Retention MASTER CYLINDER - Master Cylinder Removal - Master Cylinder Installation - BRAKE BLEEDING / FLUID CHANGE BRAKE PEDAL LEVER - Brake Pedal Removal - Brake Pedal Installation FRONT BRAKES - Front Caliper Assembly View - Brake Caliper / Pad Removal - Pad Inspection - Caliper Disassembly - Caliper Inspection - Caliper Assembly - Pad Assembly / Installation - Brake Burnishing Procedure - Disc Runout - Disc Inspection - Disc Replacement REAR BRAKES - Pad Removal - Pad Inspection - Pad Assembly / Installation - Brake Burnishing Procedure - Rear Caliper Assembly View - Caliper Removal - Caliper Disassembly - Caliper Inspection - Caliper Assembly - Caliper Installation - Disc Inspection - Disc Replacement TROUBLESHOOTING - Poor Brake Performance - Pedal Vibration - Caliper Overheats (Brakes Drag) - Brakes Lock CHAPTER 10: BODY / FRAME General Information - SPECIAL TOOLS - DECAL REPLACEMENT Body Assembly Views - Cab Frame Assembly XP - Cab Frame Assembly XP 4 - Doors XP - Doors (XP4) - Doors High Lifter - Dash Instruments / Controls - Dash Instruments / Controls (Ride Command) - Hood / Front Body Work - Chassis / Main Frame XP / High Lifter - Chassis / Main Frame XP 4 - Seat Assembly Front - Seat Assembly Rear - Floor / Rocker Panels - Floor / Rocker Panels XP 4 / XP 4 High Lifter - Rear Cargo Box / Fenders - Rear Bumper Body Component Removal - Seats - Engine Service Panel - Front Fascia - Rear Fascia - Hood and Front Body Work - Rear Fender / Fender Flair - Cargo Box - Rocker Panels, Console and Floor XP - Rocker Panels, Rear Console and Floor XP 4 - Doors - Door Panel / Latch Replacement - Door Adjustment CHAPTER 11: ELECTRICAL General Information - Special Tools - Under-Dash Components - Electrical Service Notes Electrical Diagnostics - Electrical Service Notes - Digital Multi-Meter (DMM) Notes - Static and Dynamic Testing - Connector Probing Guidelines - Testing Continuity/Resistance - Testing For A Short To Ground - Testing For A Short To Voltage - Testing for Intermittent Conditions - Testing Current Flow (Amperage) - Testing Parasitic Draw - Testing Voltage Drop INSTRUMENT CLUSTER - Rider Display Overview - Information Display Area - Instrument Cluster Pinouts RIDE COMMAND SYSTEM - Ride Command Display - Touchscreen Buttons / Icons - General Settings - Update Software / Maps - Ride Command Troubleshooting Switches - Brake Light Switch - Headlamp Switch - Ignition / Key Switch - AWD / 2WD Switch (no Turf mode) - Transmission / Gear Position Switch - Seat Belt Switch - Hazard Switch (INT'L / Tractor) - Turn/Lights/Horn Switch (INT'L/Tractor) - Horn - Turn Lights - Flasher Module (INT'L/Tractor) - Brake Alarm (INT'L/Tractor) - 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 Charging System - Current Draw - Key Off - Charging System “Break Even” Test - Charging System Stator (Alternator) Tests - Stator (Alternator) Replacement - Voltage Regulator (Non-Dynamix) - Voltage Regulator (Dynamix) Battery - 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 Lighting System - Headlight Adjustment - Headlamp Replacement - Headlamp Installation - Taillight Replacement - Dash Light Cooling System - Fan Control Circuit Operation / Testing - Fan Control Circuit Bypass Test - Engine Coolant Temperature Sensor (ECT) Overview - ECT Sensor Test - ECT Sensor Replacement Starting System - Troubleshooting - Voltage Drop Test - Starter Motor Removal - Starter Motor Installation - Starter Solenoid Bench Test - Starter Solenoid Operation Electronic Power Steering - EPS Operation - Proper EPS System Diagnosing - EPS Troubleshooting (Power Steering Non-Functional with MIL ON) - EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) - EPS Troubleshooting (Using Digital Wrench®) Fuses / Relays - Fuse Box - Relay / Fuse / Circuit Breaker Details WIRING HARNESS - Main Harness Retention Locations - Main Harness Routing - Break-Out Diagram viewing CAN SYSTEM - CAN System Overview - CAN System Testing WIRING SCHEMATICS RZR XP 1000 w EVAP wiring diagrams RZR XP 1000 Ride Command wiring diagrams - Sheet 1 - Sheet 2 - Sheet 3 - Sheet 4 - Sheet 5 RZR XP 1000 Dynamix Edition wiring diagrams - Sheet 1 - Sheet 2 - Sheet 3 - Sheet 4 - Sheet 5 RZR XP 4 1000 w EVAP wiring diagrams - Sheet 1 - Sheet 2 - Sheet 3 RZR XP 4 1000 Ride Command wiring diagrams - Sheet 1 - Sheet 2 - Sheet 3 - Sheet 4 - Sheet 5 RZR XP 4 1000 Dynamix Edition wiring diagrams - Sheet 1 - Sheet 2 - Sheet 3 - Sheet 4 - Sheet 5
Polaris RZR XP 1000 & XP4 1000 (2019) - Workshop Manual, Repair Manual - Wiring Schematics
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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