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ENGINE / COOLING SYSTEM
CHAPTER 3
ENGINE / COOLING SYSTEM
GENERAL INFORMATION............................................................................... 3.3
SPECIAL TOOLS ...................................................................................... 3.3
ENGINE LUBRICATION SPECIFICATIONS ............................................................ 3.3 3
OIL PRESSURE TEST................................................................................. 3.4
ENGINE OIL FLOW CHART ........................................................................... 3.5
ENGINE SPECIFICATIONS (1000)..................................................................... 3.6
INTAKE / EXHAUST SYSTEM ........................................................................... 3.8
AIR BOX / AIR FILTER ASSEMBLY VIEW .............................................................. 3.8
EXHAUST SYSTEM ASSEMBLY VIEW ................................................................ 3.9
ENGINE COOLING SYSTEM...........................................................................3.10
ENGINE COOLING SYSTEM SPECIFICATIONS ......................................................3.10
COOLING SYSTEM PRESSURE TEST ...............................................................3.10
COOLING SYSTEM PRESSURE CAP TEST..........................................................3.11
RADIATOR REMOVAL / INSTALLATION ..............................................................3.11
THERMOSTAT REPLACEMENT......................................................................3.12
COOLING SYSTEM ASSEMBLY VIEW ...............................................................3.14
COOLING SYSTEM BLEEDING PROCEDURE .......................................................3.15
WATER PUMP REMOVAL ............................................................................3.16
WATER PUMP INSTALLATION .......................................................................3.16
WATER PUMP SERVICE .............................................................................3.18
ENGINE SERVICE ......................................................................................3.21
ACCESSIBLE ENGINE COMPONENTS ..............................................................3.21
TOP-END SERVICE (ENGINE IN CHASSIS) ..........................................................3.21
CRANKSHAFT PTO SEAL REPLACEMENT ..........................................................3.22
ENGINE REMOVAL ..................................................................................3.24
ENGINE INSTALLATION..............................................................................3.27
ENGINE MOUNTING AND TORQUE VALUES ........................................................3.30
ENGINE BREAK-IN PERIOD .........................................................................3.31
ENGINE LUBRICATION SPECIFICATIONS ...........................................................3.31
ENGINE DISASSEMBLY / INSPECTION - TOP END .................................................3.32
VALVE COVER REMOVAL............................................................................3.32
CAMSHAFT REMOVAL...............................................................................3.32
CAMSHAFT SPROCKET INSPECTION...............................................................3.34
CAMSHAFT / CAMSHAFT BORE INSPECTION (1000)................................................3.35
CYLINDER HEAD REMOVAL.........................................................................3.36
CYLINDER HEAD WARP INSPECTION...............................................................3.37
CYLINDER HEAD DISASSEMBLY ....................................................................3.37
VALVE INSPECTION .................................................................................3.38
COMBUSTION CHAMBER CLEANING ...............................................................3.39
VALVE SEALING TEST ...............................................................................3.40
VALVE SEAT RECONDITIONING (1000)..............................................................3.40
9928492 R06 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 3.1
© Copyright Polaris Industries Inc.
