Polaris RZR XP 1000 User 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 August 2014 (PN 9925724 R01)
© Copyright 2014 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.
2014-2015 RZR XP 1000 / RZR 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 of Textron
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.

1
GENERAL INFORMATION
2
MAINTENANCE
3
ENGINE / COOLING SYSTEM
4
FUEL SYSTEM
5
PVT SYSTEM
6
TRANSMISSION
7
FINAL DRIVE
8
STEERING / SUSPENSION
9
BRAKE SYSTEM
10
BODY / FRAME
11
ELECTRICAL

1
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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION..............................................................................1.2
MODEL NUMBER DESIGNATION..................................................................1.2
MODEL NUMBER DESIGNATION..................................................................1.2
VEHICLE IDENTIFICATION NUMBER..............................................................1.3
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)................................1.3
VEHICLE AND ENGINE SERIAL NUMBER LOCATION .............................................1.4
VEHICLE INFORMATION ................................................................................1.5
REPLACEMENT KEYS ............................................................................1.5
PUBLICATION NUMBERS .........................................................................1.5
SPECIAL TOOLS ..................................................................................1.6
GENERAL SPECIFICATIONS...........................................................................1.10
2014-2015 RZR XP 1000 / EPS....................................................................1.10
RZR XP 1000 CLUTCH CHART ...................................................................1.11
2014-2015 RZR XP 4 1000 ........................................................................1.13
2014-2015 RZR 1000 XP4.........................................................................1.14
2015 RZR XP 1000 EPS HIGH LIFTER ............................................................1.16
2015 RZR XP 1000 HIGH LIFTER .................................................................1.18
2015 RZR XP 1000 DESERT EDITION ............................................................1.18
2015 RZR XP 1000 DESERT EDITION CLUTCH CHART ..........................................1.20
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
MASTER TORQUE TABLE ........................................................................1.21
CONVERSION TABLE ............................................................................1.23
STANDARD BOLT TORQUE SPECIFICATION.....................................................1.24
METRIC BOLT TORQUE SPECIFICATION ........................................................1.24
SAE TAP / DRILL SIZES ..........................................................................1.25
METRIC TAP / DRILL SIZES ......................................................................1.25
DECIMAL EQUIVALENTS.........................................................................1.26

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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VEHICLE IDENTIFICATION
Model Number Designation
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
Example: A15SEA57AD
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
A 1 5S E A 57A D
* = 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

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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.
12345 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: 4XARH57A0F3000000
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 R H 5 7 A 0 F 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015
GENERAL INFORMATION
1

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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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, behind the lower shock mounting location. Refer to
Figure 1-1.
The engine serial number can be found on a decal applied to the front of the engine crankcase (A) or stamped into the
crankcase on the PTO side of the engine (B). Refer to Figure 1-2.
GENERAL INFORMATION

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VEHICLE INFORMATION
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
SERIES# PART NUMBER
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
Publication Numbers
MODEL OWNER’S MANUAL PARTS MANUAL
2014 RZR XP 1000 9924687 9924688
2014 RZR XP 1000 EPS 9924687 9924688
2014 RZR XP 1000 INT’L 9924687 9924688
2014 RZR XP 4 1000 9924687 9924688
2015 RZR XP 1000 EPS 9925838 9925754
2015 RZR XP 1000 INT’L 9925838 9925858
2015 RZR XP4 1000 9925838 9925795
2015 RZR XP 1000 EPS High Lifter 9925836 9925754
NOTE: When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.
GENERAL INFORMATION
1

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SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier.
Bosch Automotive Service Solutions:
1-800-345-2233 or http://polaris.service-solutions.com/
GENERAL INFORMATION

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2200421
Gas Shock
Recharging Kit
2460761
Hall Sensor Probe
Harness
2870341-A
Drive Clutch Spider
Remover/Installer
2870386
Piston Pin Puller
2870630
Timing Light
2870910-A
Roller Pin Tool
2870975
Mity-Vac Pressure
Test Tool
2871056
Driven Clutch Puller
2871226
Clutch Bushing
Replacement Tool Kit
2871282
Transmission Seal
Driver (50 MM)
2871351
IFP Depth Tool
2871358-B
Drive Clutch Holding
Fixture
2871702
Shaft Drive
Transmission and
Front Gearcase Tool
Kit
2871745
Static Timing Light
Harness
2872085
Drive Clutch Puller
2872608
Roll Pin Removal Tool
(27″)
2876389
Combination Pliers
2877408
Spanner Wrench /
Clutch Spreader
8700226
CV Boot Clamp Pliers
(ear)
9314177-A
Drive Clutch Holding
Tool
GENERAL INFORMATION
1

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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PA-49316
Water Pump Drive &
Rotor Removal Tool
PA-50231
Snorkel Driver
PS-45908
T-Handle Tool
PU-43506-A
Fuel Pressure Gauge
Kit
PU-45281–A
Shock Body Holding
Tool
PU-47471
Smartlink Module Kit
PU-48951
CV Boot Clamp Pliers
(Stepless)
PU-49466
Relay Bypass
PU-50105
Oil Filter Wrench
PU-50296
Battery Tester
PU-50338
Hydrometer
PU-50518
Clutch Compressor
PU-50562
Engine Stand Adapter
PU-50563
Cylinder Holding &
Camshaft Timing
Plate
PU-50564
Water Pump Seal
Installer
PU-50565
Oil Pressure Gauge
Adapter (1/2 NPT)
PU-50566
Transmission Nut
Socket
PU-50578
Clutch Spider Nut
Socket
PU-50624
Rolling Engine Stand
PU-50625
Engine Stand Adapter
Sleeve (2″)
GENERAL INFORMATION

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
PU-50658
Clutch Center
Distance Tool
PU-50931
Shock Rod Holding
Tool (3/4″)
PU-50939
Shock Seal Protector
Sleeve (5/8″)
PU-51024
Shock Rod Holding
Tool
PU-51039
Gas Shock Fill Tool
PV-1253
Valve Spring
Compressor
PV-43513-A
Valve Spring
Compressor Adapter
PV-43526
Connector Test Kit
PV-43531
Oil Presure gauge
PV-43568
Fluke Multimeter
PV-43570
Piston Ring
Compressor Pliers
PV-48656
Fuel Pressure Gauge
Adapter
PW-47053
Bench Mount Engine
Stand
PW-47054
Engine Stand Adapter
Sleeve (2 3/8″)
GENERAL INFORMATION
1

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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GENERAL SPECIFICATIONS
2014-2015 RZR XP 1000 / EPS
CATEGORY DIMENSION / CAPACITY
Length 119″ / 302.2 cm
Width 64″ / 162.5 cm
Height 73.75″ / 187.3 cm
Wheel Base 90″ / 228.6 cm
Ground Clearance 13.5″ / 34.3 cm
Dry Weight 1379 lbs. / 625.5 kg
Gross Vehicle Weight 2200 lbs. / 998 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity (Payload)
740 lbs. / 335.6 kg
(Includes riders, cargo and
accessories)
Hitch Towing Capacity This vehicle is not equipped with
a hitch for towing loads. Do not
use this vehicle for towing. Do not
modify the vehicle by adding a
hitch.
Hitch Tongue Capacity
GENERAL INFORMATION

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ENGINE
Platform Domestic Twin Cyl., 4–Stroke,
DOHC
Engine Displacement 999cc
Number of Cylinders 2
Bore & Stroke 93 x 73.5 mm
Compression Ratio 11:1
Engine Idle Speed 1200 +/- 100 RPM
Engine Max Speed 8800 RPM
Valve Clearance (Intake) 0.005-0.007″ (0.125-0.175 mm)
Valve Clearance (Exhaust) 0.009-0.011″ (0.229-0.275 mm)
Engine Hot Light Instrument Cluster Indicator
Lubrication Wet Sump
Oil Requirements PS4
Oil Capacity 2.5 qts. (2.4 L)
Coolant Capacity 5.44 qt (5.1 L)
FUEL SYSTEM
Type Bosch ME17 EFI
Fuel Delivery Electronic Fuel Pump (in-tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Fuel Capacity /
Requirement
9.5 gal. (36 L)
87 Octane (minimum)
ELECTRICAL
Alternator Max Output 560 Watts @ 3000 RPM
Lights: Main Headlights Dual Beam LED cluster
Taillights 0.2 Watt LED cluster
Brake Lights 2.9 Watt LED cluster
Ignition System ME17 ECU
Spark Plug / Gap XG4YCX / 0.7–0.8 mm
Battery / Amp Hr 12v Flooded, 575 CCA
DC Outlet Standard 12 Volt
Relays Fan, EFI, Fuel Pump, Chassis,
EPS (if appl.)
Circuit Breaker 20A Cooling Fan
Fuses 20A EFI
10A Fuel Pump
5A Brake Light
20A Accessory
10A Drive
10A Lights
20A EPS (if appl.)
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Type In Line Shift - P/ H / L / N / R
Transmission Gear Ratios:
High
Low
Reverse
10.73:1
22.79:1
20.41:1
Front Gearcase Lubricant
Requirement
Demand Drive
8.5 oz. (250 ml)
Transmission Lubricant
Requirement
Full Synthetic AGL
44 oz. (1300 ml)
Drive Belt 3211148
STEERING / SUSPENSION
Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)
Front Suspension Independent Dual A-arm
Walker Evans™ 2.0″
Front Travel 16″ (40.6 cm)
Rear Suspension Independent Trailing Arm
Walker Evans™ 2.5″
Rear Travel 18″ (45.7 cm)
Spring Adjustment Threaded Spanner Wrench
Adjustment
WHEELS / BRAKES
Front Rim / Size Aluminum 14 x 6
Rear Rim / Size Aluminum 14 x 8
Front Tire Make / Model /
Size
Maxxis Bighorn
29 x 9 R14
Rear Tire Make / Model /
Size
Maxxis Bighorn
29 x 11 R14
Tire Air Pressure Front 16 psi (110 kPa)
Rear 16 psi (110 kPa)
Brake System
Front & Rear
Foot Actuated 4 Wheel
Hydraulic – Dual Bore Caliper
Brake Fluid DOT 4
RZR XP 1000 CLUTCH CHART
MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING
2014 XP 1000 Meters
(Feet)
0-1800
(0-6000)
26-61
(1323098)
White / Orange
(7043924)
Red
(3234452)
GENERAL INFORMATION
1

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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING
1800-3700
(6000 - 12000)
26-55
(1322982)
White / Orange
(7043924)
Red
(3234452)
2015 XP 1000 Meters
(Feet)
0-1800
(0-6000)
26-63
(1323176)
Orange / Black
(1323176)
Red
(3234452)
1800-3700
(6000-12000)
26-59
(1322981)
Orange / Black
(7044338)
Red
(3234452)
GENERAL INFORMATION

1.13
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
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2014-2015 RZR XP 4 1000
CATEGORY DIMENSION / CAPACITY
Length 146″ / 370.8 cm
Width 64″ / 162.5 cm
Height 73.75″ / 187.3 cm
Wheel Base 117″ / 297.2 cm
Ground Clearance 13.5″ / 34.3 cm
Dry Weight 1596 lbs. / 724 kg
Gross Vehicle Weight 2560 lbs. / 1161 kg
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Capacity (Payload)
900 lbs. / 408 kg
(Includes riders, cargo and
accessories)
Hitch Towing Capacity This vehicle is not equipped with
a hitch for towing loads. Do not
use this vehicle for towing. Do not
modify the vehicle by adding a
hitch.
Hitch Tongue Capacity
GENERAL INFORMATION
1

1.14
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
ENGINE
Platform Domestic Twin Cyl., 4–Stroke,
DOHC
Engine Displacement 999cc
Number of Cylinders 2
Bore & Stroke 93 x 73.5 mm
Compression Ratio 11:1
Engine Idle Speed 1200 +/- 100 RPM
Engine Max Speed 8800 RPM
Valve Clearance (Intake) 0.005-0.007″ (0.125-0.175 mm)
Valve Clearance (Exhaust) 0.009-0.011″ (0.229-0.275 mm)
Engine Hot Light Instrument Cluster Indicator
Lubrication Wet Sump
Oil Requirements PS4
Oil Capacity 2.5 qts. (2.4 L)
Coolant Capacity 6.08 qt (5.75 L)
FUEL SYSTEM
Type Bosch ME17 EFI
Fuel Delivery Electronic Fuel Pump (in-tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Fuel Capacity /
Requirement
9.5 gal. (36 L)
87 Octane (minimum)
ELECTRICAL
Alternator Max Output 560 Watts @ 3000 RPM
Lights: Main Headlights Dual Beam LED cluster
Taillights 0.2 Watt LED cluster
Brake Lights 2.9 Watt LED cluster
Ignition System ME17 ECU
Spark Plug / Gap XG4YCX / 0.7–0.8 mm
Battery / Amp Hr 12v Flooded, 575 CCA
DC Outlet Standard 12 Volt
Relays Fan, EFI, Fuel Pump, Chassis,
EPS (if appl.)
Circuit Breaker 20A Cooling Fan
Fuses 20A EFI
10A Fuel Pump
5A Brake Light
20A Accessory
10A Drive
10A Lights
20A EPS (if appl.)
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Type In Line Shift - P/ H / L / N / R
Transmission Gear Ratios:
High
Low
Reverse
12.05:1
25.59:1
22.92:1
Front Gearcase Lubricant
Requirement
Demand Drive
8.5 oz. (250 ml)
Transmission Lubricant
Requirement
Full Synthetic AGL
44 oz. (1300 ml)
Drive Belt 3211148
STEERING / SUSPENSION
Toe Out 1/8 - 3/16″ (3.2 - 4.8 mm)
Front Suspension Independent Dual A-arm
Walker Evans™ 2.0″
Front Travel 16″ (40.6 cm)
Rear Suspension Independent Trailing Arm
Walker Evans™ 2.5″
Rear Travel 18″ (45.7 cm)
Spring Adjustment Threaded Spanner Wrench
Adjustment
WHEELS / BRAKES
Front Rim / Size Aluminum 14 x 6
Rear Rim / Size Aluminum 14 x 8
Front Tire Make / Model /
Size
Maxxis Bighorn
29 x 9 R14
Rear Tire Make / Model /
Size
Maxxis Bighorn
29 x 11 R14
Tire Air Pressure Front 19 psi (131 kPa)
Rear 21 psi (145 kPa)
Brake System
Front & Rear
Foot Actuated 4 Wheel
Hydraulic – Dual Bore Caliper
Brake Fluid DOT 4
2014-2015 RZR 1000 XP4
MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING
2014 XP4 1000 Meters
(Feet)
0-1800
(0-6000)
26-67
(1323177)
White / Orange
(7043924)
Red
(3234452)
GENERAL INFORMATION