Polaris 2014 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 2013 (PN 9924874 R02)
2014 RZR XP / XP 4 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 PRODUCT(S) 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
4
ELECTRONIC FUEL INJECTION
5
BODY / STEERING / SUSPENSION
6
CLUTCHING
7
FINAL DRIVE
8
TRANSMISSION
9
BRAKES
10
ELECTRICAL

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION.............................................................................. 1.2
MODEL NUMBER DESIGNATION.................................................................. 1.2
ENGINE DESIGNATION NUMBER .................................................................1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ........................................1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATION ............................................. 1.3
VEHICLE INFORMATION ................................................................................ 1.3
PUBLICATION NUMBERS .........................................................................1.3
REPLACEMENT KEYS.............................................................................1.4
SPECIALTOOLS .........................................................................................1.5
GENERAL SPECIFICATIONS............................................................................1.6
MODEL: 2014 RZR XP 1000 / EPS / INT’L ..........................................................1.6
2014 RZR XP 1000 / EPS / INT’L ...................................................................1.7
MODEL: 2014 RZR XP 4 1000......................................................................1.8
2014 RZR XP 4 1000 ...............................................................................1.9
2014 RZR XP / XP 4 1000 CLUTCH CHARTS......................................................1.10
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
MASTER TORQUE TABLE ........................................................................1.11
CONVERSION TABLE ............................................................................1.14
STANDARD BOLT TORQUE SPECIFICATION.....................................................1.15
METRIC BOLT TORQUE SPECIFICATION ........................................................1.15
SAE TAP / DRILL SIZES ..........................................................................1.16
METRIC TAP / DRILL SIZES ......................................................................1.16
DECIMAL EQUIVALENTS .........................................................................1.17

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
VEHICLE IDENTIFICATION
Model Number Designation
Example: R14ST1EAL
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
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 - -
5 = 550
6 = 570
7 = 760
8 = 850
9 = 875
E = EPS
D = Diesel
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.
Engine Designation Number
RZRXP 999-14 High Output 4-Stroke DOHC Twin
Cylinder, Liquid Cooled, Electric Start
Vehicle Identification Number (VIN) Designation
Example: 4XAST1EAXE3000000
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 567891011 12 13 14 15 16 17
4 X A S T 1 E A X E 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014
GENERAL INFORMATION

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 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, 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.
VEHICLE INFORMATION
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
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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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
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
GENERAL INFORMATION

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
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, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/
GENERAL INFORMATION
1