2014-2016 POLARIS RZR XP 1000/ XP4 1000 Service Shop Manual

FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer ® technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed March 2016 (PN 9926816 R06) © Copyright 2016 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2014-2016 RZR XP 1000 / XP4 1000 Service Manual

UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE NOTE provides key information by clarifying instructions. IMPORTANT IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark ofTextron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX REV DATE CHANGES R01 08/14/2015 Initial release R02 10/12/2015 Added XP4 High Lifter information 10/30/2015 Call out engine/trans centering tool as PU-50658-A R03 11/11/2015 Front and Rear Hub Nut torque changed 11/17/2015 Updated shock spring adjustment procedure / table 11/17/2015 Added prop shaft support bearing service R04 12/14/2015 Corrected spark plug information R05 2/29/2016 Corrected wiring diagram for ECU wiring Clarified CAN system testing R06 3/10/2016 Updated CV Joint service 3/20/2016 Added information for MY16 Driven Clutch service

2014-2016 RZR XP 1000 / XP4 1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10: BODY / FRAME CHAPTER 11: ELECTRICAL

1 9926816 R06 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc. 1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ............................................................................. 1.2 MODEL NUMBER DESIGNATION (2014 AND OLDER)................................................. 1.2 MODEL NUMBER DESIGNATION (2015 +) ............................................................ 1.2 VEHICLE IDENTIFICATION NUMBER ................................................................. 1.3 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) ................................... 1.3 VEHICLE AND ENGINE SERIAL NUMBER LOCATION................................................. 1.4 REFERENCE INFORMATION ........................................................................... 1.5 REPLACEMENT KEYS ................................................................................ 1.5 PUBLICATION NUMBERS ............................................................................. 1.5 SPECIAL TOOLS ...................................................................................... 1.6 GENERAL SPECIFICATIONS .......................................................................... 1.10 2014-2016 RZR XP 1000 ............................................................................. 1.10 2014-2016 RZR XP 1000 CLUTCH CHART ........................................................... 1.11 2014-2016 RZR XP 4 1000............................................................................ 1.12 2014-2016 RZR XP4 1000 ............................................................................ 1.13 2015-2016 RZR XP 1000 HIGH LIFTER ............................................................... 1.14 2015–2016 RZR XP 1000 HIGH LIFTER CLUTCH CHART ............................................ 1.15 2016 RZR XP4 1000 HIGH LIFTER ................................................................... 1.16 2016 RZR XP4 1000 HIGH LIFTER CLUTCH CHART ................................................. 1.17 2015 RZR XP 1000 DESERT EDITION ................................................................ 1.18 2015 RZR XP 1000 DESERT EDITION CLUTCH CHART .............................................. 1.19 2015 RZR XP 1000 FOX EDITION .................................................................... 1.20 2015 RZR XP 1000 FOX CLUTCH CHART ............................................................ 1.21 MISC. SPECIFICATIONS AND CHARTS .............................................................. 1.22 MASTER TORQUE TABLE ........................................................................... 1.22 CONVERSION TABLE ................................................................................ 1.24 STANDARD BOLT TORQUE SPECIFICATION ........................................................ 1.25 METRIC BOLT TORQUE SPECIFICATION ............................................................ 1.25 SAE TAP / DRILL SIZES .............................................................................. 1.26 METRIC TAP / DRILL SIZES .......................................................................... 1.26 DECIMAL EQUIVALENTS ............................................................................ 1.27

1.2 9926816 R06 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc. VEHICLE IDENTIFICATION MODEL NUMBER DESIGNATION (2014 AND OLDER) Example: Z14ST1EAL GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit Z = RZR 11 12 13 14 15 J = RZR XP V = RZR X = Multi- pass RZR E = 4x4 Shaft / IRS H = 4x4 Shaft / IRS T = 4x4 Shaft / Trailing Arm Displacement in cc divided by 10 and rounded to two digits (i.e. 50 = 498cc) A = ORV E = EU On-road F = INT’L M = Military S= Scandinavian V = EU On-road C = Calif. - - OR - - 6 = 570 7 = 760 9 = 875 E = EPS F=D+E * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. MODEL NUMBER DESIGNATION (2015 +) Example: R15RUE57AC GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION 1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th** R 1 5 R U E 5 7 A C * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration. GENERAL INFORMATION

9926816 R06 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc. 1.3 VEHICLE IDENTIFICATION NUMBER Example: 4XAKA09A0F3000000 WORLD MFG. ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR * MFG. LOCATION INDIVIDUAL SERIAL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 F 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) Example: 4XARUE573FG000000 WORLD MFG. ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE CHASSIS MODIFIER ENGINE SIZE ENGINE MODIFIER CHECK DIGIT MODEL YEAR * MFG. LOCATION INDIVIDUAL SERIAL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R U E 5 7 3 F G 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016 GENERAL INFORMATION 1

1.4 9926816 R06 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual © Copyright Polaris Industries Inc. VEHICLE AND ENGINE SERIAL NUMBER LOCATION Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the left rear frame upright q, behind the PVT cover. The engine serial number can be found on a decal applied to the front of the engine crankcase w or stamped into the crankcase on the PTO side of the engine e. GENERAL INFORMATION

2014-2016 POLARIS RZR XP 1000/ XP4 1000 Service Shop Manual

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