Polaris RZR 1000 Head Stud Installation Guide (2014–2026) — CP891

This guide covers installation of the XOTIC PERFORMANCE™ CP891 head stud kit for 2014–2026 Polaris RZR 1000cc models. Prefer a printable copy? Download the PDF manual.

Why the RZR 1000 needs head studs

Factory OEM head bolts are torque-to-yield: you torque them to a specified value, then add a final 90° rotation that stretches the bolt to its maximum point. That works at stock power levels. But RZRs get worked hard — big-bore kits, turbos, aggressive tunes, and long days at sustained load create higher cylinder pressures than the factory clamping setup was designed for. When the clamping force securing the gasket, head, and block is no longer sufficient, the result is a blown head gasket.

Head studs are engineered to resist stretching. XOTIC PERFORMANCE™ head studs are manufactured from our premium XOTIC 7200 steel alloy, superior in tensile strength to any bolt, and backed by a lifetime warranty. The key to getting that strength into your engine is accurate preload — the tensile force generated when a fastener is tightened, creating clamp force in the joint. Everything in this guide is in service of achieving equal, accurate preload on all six studs.

What's in the CP891 kit

• 6 × head studs (XOTIC 7200 alloy) — M11 × 178mm
• 6 × hardened parallel washers
• 6 × nuts
• 2 × outer bolts — M6 × 90mm
• 2 × sockets
• 1 × allen wrench
• 1 × fastener assembly lubricant

Before you start: verify first

Confirm that part number CP891 is compatible with your application (Polaris RZR 1000cc) before installing any components. Inspect all package contents and clean as necessary to ensure accurate installation. Report any obvious defects or shipping damage to us before proceeding.

How to install head studs on a Polaris RZR 1000

1. Clean the block threads. Clean the threads in the block prior to installing the studs to ensure proper fitment and accurate torque readings. A dedicated M11 x 1.25 thread chaser (CS305) makes this fast and protects the threads.
2. Install the studs hand-tight. Thread the head studs into the block by hand until snug. Do not apply torque.
3. Check stud height with a straightedge. Use a straightedge ruler to measure the distance from the mating surface (deck or main cap) to the top of each installed stud. Ensure all studs of the same length group sit level with each other (within 1 mm / 0.040”). Uneven height may indicate debris or incorrect thread engagement. Properly installed studs will bottom out smoothly and show uniform height across all positions. If a stud appears higher or lower than the others, remove it, re-clean the hole, and reinstall by hand. Do not use tools to force studs deeper. Incorrect stud seating can cause off-angle stress, uneven preload, or stud fracture during engine operation.
4. Set the gasket and head. Install the head gasket and cylinder head, ensuring proper alignment.
5. Clean the washer seating areas. Clean the washer seating surfaces on the cylinder head with a fast-evaporating solvent such as non-chlorinated brake cleaner to remove oil, grease, and contaminants. A clean surface is essential for achieving proper fastener preload.
6. Lubricate. Using the supplied fastener assembly lubricant, lubricate the stud threads and the bottom surface of the nuts.
7. Install the nuts. Thread the nuts onto the studs and hand-tighten until they make contact with the washers.
8. Torque in sequence. Follow the torque stages below in the numbered sequence shown in the manual's torque sequence diagram, then finish with the M6 outer bolts.

Polaris RZR 1000 head stud torque specs

M11 studs (three stages)

M6 outer bolts

Torque the two M6 outer bolts to 10 ft-lbs.

Frequently asked questions

What are the torque specs for RZR 1000 head studs?

M11 studs: three stages, in the numbered sequence — 28 ft-lbs, then 57 ft-lbs, then a final pass at 85 ft-lbs. The two M6 outer bolts torque to 10 ft-lbs.

Which models does the CP891 kit fit?

2014–2026 Polaris RZR 1000cc models. Verify compatibility with your specific machine before installing.

What are the M6 outer bolts for?

The kit includes two M6 × 90mm outer bolts that install alongside the six main studs — they torque to 10 ft-lbs after the M11 sequence is complete. See the manual's diagram for their locations.

What size thread chaser do I need?

M11 x 1.25 — the CS305 chaser.

Need help?

For technical support, email support@xotic-performance.com. All XOTIC PERFORMANCE™ fasteners are covered by our limited lifetime warranty. Finished your install? Tag #XOTICPERFORMANCE on Instagram for a chance to be featured.

© 2026 XOTIC PERFORMANCE™. This installation guide is an original copyrighted work of XOTIC PERFORMANCE™. Reproduction, distribution, or use of this content in whole or in part without written permission is prohibited. Doc ref: 2025.11.08 (web edition 2026.08).