Polaris RANGER 1000 2020 Service Manual Download Page 459

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9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc.

10.1

CHAPTER 10

BRAKE SYSTEM

GENERAL INFORMATION - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2

SERVICE NOTES - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2

BRAKE SYSTEM SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3

BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4

BRAKE SYSTEM ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4

BRAKE LINE ROUTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5

BRAKE LINE CLOCKING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7

BRAKE FLUID REPLACEMENT / BRAKE BLEEDING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

MASTER CYLINDER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

MASTER CYLINDER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

BRAKE PEDAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

FRONT BRAKE PAD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

FRONT BRAKE PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

FRONT BRAKE PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

FRONT BRAKE PAD INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

FRONT CALIPER ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

FRONT CALIPER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18

FRONT CALIPER DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19

FRONT CALIPER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20

FRONT CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20

FRONT CALIPER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21

REAR BRAKE PAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

REAR BRAKE PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

REAR BRAKE PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23

REAR BRAKE PAD INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23

REAR CALIPER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

REAR CALIPER ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

REAR CALIPER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25

REAR CALIPER DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

REAR CALIPER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

REAR CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

REAR CALIPER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

BRAKE DISK INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

DISC RUNOUT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

BRAKE DISC REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

Summary of Contents for RANGER 1000 2020

Page 1: ...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 thi...

Page 2: ...n which if not avoided WILL result in death or serious injury WARNING SAFETY ALERT WARNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION SAFETY A...

Page 3: ...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 FO...

Page 4: ...REVISION INDEX REV DATE CHANGES R01 11 06 2020 Initial release...

Page 5: ...r to provide Polaris with an overall satisfaction rating for this service manual provide comments on your experience or upload pictures video This feedback form is viewable on a mobile device by scann...

Page 6: ......

Page 7: ...CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING EXHAUST CHAPTER 4 ENGINE ELECTRICAL CHAPTER 5 FUEL SYSTEM CHAPTER 6 PVT SYSTEM CHAPTER 7 TRANSMISSION CHAPTER 8 FINAL DRIVE CHAPTER 9 STEERING SUSPENSIO...

Page 8: ......

Page 9: ...STIC 1 27 GUIDED SYMPTOM REFERENCES 1 28 ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES 1 29 ENGINE CRANKS BUT DOES NOT START 1 32 NO CRANK NO START OR SLOW CRANK 1 34 OVER HEATING 1 35 WARNING LIGHTS 1...

Page 10: ...ER OVERHEATS BRAKES DRAG 1 68 POOR BRAKE PERFORMANCE 1 68 BRAKES LOCK 1 68 STEERING SUSPENSION DIAGNOSTICS 1 69 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON 1 69 EPS TROUBLESHOOTING P...

Page 11: ...If a torquing sequence is indicated for nuts bolts or screws of a certain component start all fasteners and hand tighten Following the method and sequence indicated tighten evenly to the specified to...

Page 12: ...oice R20TAU99AM AS AZ R20TAU99BM BS BZ 2020 RANGER 1000 CREW R20T6A99A1 R20T6A99B1 R20T6E99A9 AM AS R20T6E99B9 BM BS 2020 RANGER 1000 CREW Factory Choice R20T6U99AM AS R20T6U99BM BS 2021 RANGER 1000 R...

Page 13: ...eries 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 i e In this example the first two digits are 31 which would use key blank...

Page 14: ...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 s...

Page 15: ...Engine Stand 2 Bore PU 50624 Engine Stand Adapter Mounts To The Engine PU 50562 TOOL DESCRIPTION PART NUMBER IMAGE Engine Stand Sleeve Adapter Use With 2 Bore Stand PU 50625 Engine Stand Sleeve Adapt...

Page 16: ...Fuel Pressure Gauge Kit PU 43506 A Fuel Pressure Gauge Adapter PA 48838 Fuel Pressure Gauge Adapter PS 48762 Fuel Pump Service Tool PU 50326 PVT SYSTEM TOOL DESCRIPTION PART NUMBER IMAGE Drive Clutch...

Page 17: ...ot Clamp Pliers 8700226 BRAKE SYSTEM TOOL DESCRIPTION PART NUMBER IMAGE Mityvac Pressure Test Tool 2870975 BODY FRAME TOOL DESCRIPTION PART NUMBER IMAGE Multi Function Pliers 2876389 ELECTRICAL TOOL D...

Page 18: ...UMBER IMAGE Wireless Vehicle Link WVL PU 51435 Fluke 77 Digital Multimeter PV 43568 Static Timing Light Harness 2871745 Hall Effect Sensor Probe Harness 2460761 Battery Conductance Analyzer MDX 610P P...

Page 19: ...EXHAUST PART DESCRIPTION TORQUE SPECIFICATION Air Duct Clamps 35 in lbs 4 Nm Airbox Mount Fastener 44 in lbs 5 Nm Cam Chain Tensioner 15 ft lbs 20 Nm Camshaft Carrier Fastener 7 ft lb 10 Nm Camshaft S...

Page 20: ...er 10 ft lbs 14 Nm Oil Filter Adapter 21 ft lbs 28 Nm Oil Cooler Retaining Fastener 7 lb ft 10 Nm Oil Pump Mounting Fastener 7 ft lbs 10 Nm Oil Pump Pick Up Retaining Fastener 7 ft lbs 10 Nm Oil Pump...

Page 21: ...Fastener 5 ft lbs 7 Nm Fuel Tank Bracket Fastener 10 ft lbs 14 Nm PVT SYSTEM PART DESCRIPTION TORQUE SPECIFICATION Drive Clutch Cover Fastener 44 in lbs 5 Nm Drive Clutch Retaining Fastener Moveable...

Page 22: ...4 Nm Shift Cable Bracket Fasteners 20 ft lbs 27 Nm Shift Cable Fastening Nut 13 ft lbs 18 Nm Shift Cable Locknut 13 ft lbs 18 Nm Snorkel Locking Fastener 9 ft lbs 12 Nm Solenoid 25 ft lbs 34 Nm Speed...

Page 23: ...ar Link Nut 40 ft lbs 54 Nm Stabilizer Bar Mount Fastener 31 ft lbs 42 Nm Steering Adjustment Shock Assembly Nut 7 ft lbs 10 Nm Steering Rack Mounting Nuts 40 ft lbs 54 Nm Steering Wheel Nut 65 ft lbs...

Page 24: ...m Heater Box Distributor Manifold 18 in lbs 2 Nm Heater Box Panel Fasteners 6 ft lbs 8 Nm Inner Cargo Box Fastener 8 in lbs 1 Nm Instrument Cluster Fastener 12 in lbs 1 Nm PART DESCRIPTION TORQUE SPEC...

Page 25: ...ry Terminal Fastener 40 in lbs 5 Nm Chassis Ground 8 ft lbs 11 Nm ECU Retaining Fastener 24 in lbs 2 7 Nm Headlight Fastener 5 ft lbs 7 Nm Ride Command Monitor Mounting Bracket Fasteners 12 in lbs 1 3...

Page 26: ...CATION NUMBER VIN DESIGNATION Example 4XAKA09A0E3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR MFG LOCATION...

Page 27: ...SPECIFICATIONS MODEL SPECIFICATIONS 3 SEAT MODEL MODEL NUMBERS MODEL IMAGE RANGER 1000 R20TAA99A1 A7 R20TAA99B1 B7 R20TAE99A1 A7 A9 AM AS AZ R20TAE99B1 B7 B9 BM BS BZ R21TAA99A1 A7 R21TAA99B1 B7 R21T...

Page 28: ...s 499 kg CA Models Includes riders cargo and accessories Hitch Towing Capacity 2500 lbs 1134 kg Hitch Tongue Capacity 150 lbs 68 kg ENGINE RANGER 1000 Platform 4 Stroke SOHC Twin Cylinder Engine Displ...

Page 29: ...E D 28W Brake Lights 10 L E D 3 1W Ignition System Digital CDI Spark Plug Gap 0 03 in 0 85 mm Battery Amp Hr CCA Polaris Maintenance Free 32 AH 575 CCA DC Outlet Standard 12 Volt DRIVETRAIN RANGER 100...

Page 30: ...pring Adjustment Threaded Spanner Wrench WHEELS BRAKES RANGER 1000 Front Wheel Type Size Aluminum 12 x 6 Rear Wheel Type Size Aluminum 12 x 8 Front Tire Size Model BASE 25 x 10 12 NHS 489 LE 26 x 9 12...

Page 31: ...Manual Copyright Polaris Inc 1 23 MODEL SPECIFICATIONS CREW MODEL MODEL NUMBERS MODEL IMAGE RANGER 1000 CREW R20T6A99A1 R20T6A99B1 R20T6E99A9 AM AS R20T6E99B9 BM BS R21T6A99A1 R21T6A99B1 R21T6E99A9 AG...

Page 32: ...bs 612 kg CA Models Includes riders cargo and accessories Hitch Towing Capacity 2500 lbs 1134 kg Hitch Tongue Capacity 150 lbs 68 kg ENGINE RANGER 1000 CREW Platform 4 Stroke SOHC Twin Cylinder Engine...

Page 33: ...10 L E D 28W Brake Lights 10 L E D 3 1W Ignition System Digital CDI Spark Plug Gap 0 03 in 0 85 mm Battery Amp Hr Polaris Maintenance Free 32 AH 575 CCA DC Outlet Standard 12 Volt DRIVETRAIN RANGER 10...

Page 34: ...l A Arm Rear Travel 10 0 in 25 4 cm Spring Adjustment Threaded Spanner Wrench WHEELS BRAKES RANGER 1000 CREW Front Wheel Type Size Aluminum 12 x 6 Rear Wheel Type Size Aluminum 12 x 8 Front Tire Size...

Page 35: ...mpared to a like vehicle No If the concern has not been able to be duplicated gather more information about the concern After the concern has been duplicated please compare to a like vehicle Is the co...

Page 36: ...n selected Refer to the Transmission or Final Drive Chapters for further diagnostic information No Is the concern related to a Noise Yes Refer to necessary service information for pin pointing noise l...

Page 37: ...h Guided diagnosis Certain failures may not display a CEL MIL on the instrument cluster In this instance record CEL s from the instrument cluster and refer to the necessary section in the Service Manu...

Page 38: ...test battery If battery fails the load test charge replace battery as needed Retest for concern before proceeding Check Ignition Switch and connections Concern may be caused by faulty Ignition Switch...

Page 39: ...moving concern may be within transmission Refer to the necessary section in the applicable service manual u Test drive vehicle for concern If the concern is related to the PVTsystem Transmission or F...

Page 40: ...that the fuel being used meets the correct octane rating specific to the vehicle If filled with fuel vehicle starts and gauge still is not reading test the fuel sending unit 6 Check fuses or fuel sys...

Page 41: ...rn Check ECU for power and grounds to make sure that computer is turning on 12 If all previous checks pass concern may be caused by internal engine issue Refer to Cylinder Leakdown Test Previous testi...

Page 42: ...itive terminals at starter and solenoid for available voltage using DMM Readings should be 12 6 V With battery disconnected check cables for high resistance Reading should be less than 1 Ohm If resist...

Page 43: ...ed of changing may cause increase in engine temperature Too high of oil level may cause engine temperatures may cause increase in engine temperature Check level and correct as necessary Check maintena...

Page 44: ...ct hoses and radiator for coolant leaks Repair as necessary Pressurize cooling system and look for pressure losses This indicates a leak in the cooling system Inspect for external leaks if none are fo...

Page 45: ...ctor Fuel pump inoperative restricted Tank vent plugged or pinched Engine flooded Injector control circuit failure Low compression high cylinder leakage No spark Spark plug fouled ignition component f...

Page 46: ...Worn valve guides or seals Restricted breather Air filter dirty or contaminated LOW COMPRESSION Cylinder head gasket leak No valve clearance cam wear Valve not seating properly bent or carbon accumul...

Page 47: ...in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump Fuel pump output weak Cooling fan inoperative or turning too slowly perform current draw test Faulty hot light circu...

Page 48: ...fer to the Digital Wrench System Help To access the Digital Wrench System Help do one of the following Expand the Digital Wrench Help drop down on the left side of the main screen and click System Hel...

Page 49: ...down select Digital Wrench and then click Digital Wrench Updates 3 Select the Digital Wrench X X Updates link 4 Select the update you want to install on your PC IMPORTANT You must have the latest Base...

Page 50: ...ss the diagnostic connector lift up the passenger seat and remove the storage tray Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble th...

Page 51: ...format This is the most viewed screen Add and or update vehicle and customer information Also view ECU Identification View information from the main ECU sensors Access the Vehicle Home Page Set up da...

Page 52: ...programming is in progress Understand the Process Review the Digital Wrench System Help before you attempt to reprogram See Digital Wrench Software Overview for information on how to access the System...

Page 53: ...rating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred NOTICE The PMDW app will not work on Microsoft Windows 8 or Apple IOS products Dual core processor 2 GB internal memory ex...

Page 54: ...ngine If the CHECK ENGINE lamp or the EPAS lamp illuminates retrieve the active error codes from the display 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to...

Page 55: ...Or Period P0501 9 Abnormal Update Rate P160A 10 Abnormal Rate Of Change C1068 C1705 12 Bad Intelligent Device Or Component P3503 19 Received Vehicle Speed Has Error P106B C1069 P306B 91 Accelerator P...

Page 56: ...mal Or Shorted To Low Source P2228 10 Abnormal Rate Of Change P2230 110 Engine Temperature Sensor 0 Engine Overheat Shutdown P1217 2 Data Erratic Intermittent Or Incorrect P0116 3 Voltage Too High P01...

Page 57: ...tation P121D 523 Gear Sensor Signal 2 Data Erratic Intermittent Or Incorrect P0914 3 Voltage Above Normal Or Shorted To High Source P0917 4 Voltage Too Low P0916 9 Abnormal Update Rate P1914 11 Root C...

Page 58: ...bove Normal Or Shorted To High Source P0647 4 Voltage Below Normal Or Shorted To Low Source P0646 5 Current Below Normal Or Open Circuit P0645 905 Wheel Speed Sensor Front Left 2 Data Erratic Intermit...

Page 59: ...rratic Intermittent Or Incorrect P0236 3 Voltage Above Normal P0238 4 Voltage Below Normal P0237 31 Condition Exists P1234 1268 Ignition Coil Primary Driver 1 MAG 3 Voltage Above Normal P1353 4 Voltag...

Page 60: ...tage Above Normal Or Shorted To High Source P0132 4 Voltage Below Normal Or Shorted To Low Source P0131 C1049 12 Bad Intelligent Device Or Component P113A 17 Data Valid But Below Normal Operating Rang...

Page 61: ...le Release Signal 2 Data Erratic Intermittent Or Incorrect P1553 3 Voltage Above Normal Or Shorted To High Source P1555 4 Voltage Below Normal Or Shorted To Low Source P1554 7 Mechanical System Not Re...

Page 62: ...Failure 31 Condition Exists C1053 520225 EPS Inverter Temperature 0 Data Valid But Above Normal Operational Range Most Severe Level C1055 12 Bad Intelligent Device Or Component C102F 16 Data Valid Bu...

Page 63: ...t Below Normal Or Open Circuit P125A 520275 Accelerator Position Brake Position Interaction 31 Condition Exists P150A U1007 520276 Throttle Position Sensor 1 or 2 Indeterminable 2 Data Erratic Intermi...

Page 64: ...on Exists C1681 520496 Intercooler Pump Driver Circuit 3 Voltage Above Normal Or Shorted To High Source P107D 4 Voltage Below Normal Or Shorted To Low Source P107C 5 Current Below Normal Or Open Circu...

Page 65: ...ng Range Least Severe Level P150F 524076 Engine Oil Pressure Sensor Switch 17 Data Valid But Below Normal Operating Range Least Severe Level P151F 524085 EPS Fault Lamp Driver Circuit 12 Bad Intellige...

Page 66: ...he throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur The ch...

Page 67: ...at this time clean and continue to monitor It is possible that the fluid is residual from manufacturing or previous repairs 2 Thoroughly clean the area using an appropriate cleaner Brake cleaner Thro...

Page 68: ...injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts air box cover Faulty oxygen sensor RICH MIXTURE SYMPTOMS CAUSES Hard star...

Page 69: ...rm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector TMAP damaged check with Digi...

Page 70: ...operating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift weigh...

Page 71: ...Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Find leak and repair as necessary Operator error Instruct operator on guidelines for operation in wet terrain as outlined in...

Page 72: ...overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cau...

Page 73: ...ransmission components TRANSMISSION ISOLATION To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the transmission should be isolated using...

Page 74: ...coil magnetized Rule out armature plate by putting it close to something metal to see if it tries to stick Drivetrain wedged Often caused by torsion spring coming out of place AWD Does not engage Rol...

Page 75: ...Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake Adjust pad stop Set to proper level Clean co...

Page 76: ...e throttle and brakes at the same time Excessive use of the brakes POOR BRAKE PERFORMANCE POOR BRAKE PERFORMANCE Air in system Water in system brake fluid contaminated Caliper or disc misaligned Calip...

Page 77: ...dure s available in Digital Wrench Power Steering Non Functional MIL is ON Cycle the ignition switch Is MIL on No There is no issue MIL on due to 5 minute timeout Verify code using Digital Wrench No I...

Page 78: ...l MIL is OFF Is Battery Voltage 11 and 16VDC No Determine cause of incorrect battery voltage and repair Yes Is EPS Fuse OK No Replace EPS Fuse Yes 12 VDC and GND across 2 Pin EPS Connector with Key On...

Page 79: ...EPROM Failure These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit TABLE 2 EPS Inverter Temperature Test 1 Verify that the Powe...

Page 80: ...es the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body i...

Page 81: ...ll only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge S...

Page 82: ...side down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the te...

Page 83: ...ound B so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There are ma...

Page 84: ...Testing Continuity Resistance page 1 75 4 Ensure you have checked for a short to ground Testing For A Short To Ground page 1 75 5 Ensure that neither end of the circuit is connected 6 Set your DMM to...

Page 85: ...tion damage Improper routing especially when it leads to chaffing or heat damage especially near exhaust You may need to use different techniques to duplicate these concerns These include but are not...

Page 86: ...ut electronic components will take time to fully go to sleep after switched power is removed 8 Maximum allowable is 10 milliamps If your meter is ranged to the 10 Amp scale this will appear as 0 010 A...

Page 87: ...ht Polaris Inc 1 79 If you do have a difference in pressure this means there is something adding resistance to the circuit such as corrosion For a video demonstration scan the QR code below or right c...

Page 88: ...1 80 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc NOTES GENERAL INFORMATION...

Page 89: ...NANCE 2 36 LIQUID COOLING SYSTEM OVERVIEW 2 36 COOLANT STRENGTH TYPE 2 36 COOLANT LEVEL INSPECTION 2 37 COOLING SYSTEM HOSE INSPECTION 2 38 RADIATOR INSPECTION 2 38 COOLANT REPLACEMENT 2 38 AIR INTAKE...

Page 90: ...USPENSION MAINTENANCE 2 57 SUSPENSION INSPECTION 2 57 SPRING PRE LOAD ADJUSTMENT 2 57 BRAKE SYSTEM MAINTENANCE 2 58 BRAKE FLUID LEVEL INSPECTION 2 58 BRAKE FLUID REPLACEMENT BRAKE BLEEDING 2 58 BRAKE...

Page 91: ...hese operations NOTICE Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames...

Page 92: ...pressure using the tire pressure gauge included in the vehicle s tool kit CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle MODEL FRONT REAR RANGER...

Page 93: ...9 AGL Gearcase Lubricant 2 5 Gal 2 count 2878070 Demand Drive Fluid Qt 2877922 Demand Drive Fluid 2 5 Gal 2877923 GREASE SPECIALIZED LUBRICANTS DESCRIPTION PART NUMBER Premium All Season Grease 3 oz 2...

Page 94: ...n Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil le...

Page 95: ...re Verify there is adequate tread depth Wheels Lug Nuts Ensure rim is not cracked bent Verify proper lug nut torque Headlights Taillights Ensure all lights are operational Adjust headlight aim as requ...

Page 96: ...ake Pads INT L Inspect pad wear Fuel System Turn key on to pressurize fuel pump check lines fittings for leaks and abrasion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first...

Page 97: ...ubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Throt...

Page 98: ...ck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termin...

Page 99: ...Belt Inspect replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearca...

Page 100: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 101: ...lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Thr...

Page 102: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 103: ...as needed XU D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU E Engine Oil Filter Change Change oil and filter inspec...

Page 104: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 105: ...lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Thr...

Page 106: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 107: ...ling System Inspect coolant strength seasonally pressure test system yearly D Drive Belt Inspect replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU E Engine Oil Fi...

Page 108: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 109: ...lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Thr...

Page 110: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 111: ...ded XU D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU E Engine Oil Filter Change Change oil and filter inspect used...

Page 112: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 113: ...lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Thr...

Page 114: ...eck lines fittings for leaks and abrasion Replace as needed XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check termi...

Page 115: ...fittings XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D E Spark Pl...

Page 116: ...Extreme Duty Full Synthetic Add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month Perform oil and filter change at 100 hours 1000 miles 12 months whichev...

Page 117: ...luid every two years Front Gearcase Polaris Demand Drive Fluid Add lubricant until it is visible at the fill hole threads w 8 5 oz 250 mL Initial level check at 25 hours or 1 month Change lubricant at...

Page 118: ...shing and on the front propshaft yokes Apply grease until all traces of water have been purged out at each of these areas ITEM LUBE REC METHOD FREQUENCY Propshaft Yoke Premium U Joint Lubricant Grease...

Page 119: ...and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTICE Make certain the dipstick is inserted all the way into the dipstick tube to keep the...

Page 120: ...low the oil to drain completely 5 Remove all cargo from the cargo box CAUTION Always remove all cargo from the cargo box before lifting the box to access the engine 6 Pull up on the cargo box release...

Page 121: ...ded oil as necessary to bring the oil level within the SAFE range on dipstick Do not overfill 20 When finished reinstall the oil fill cap oil dipstick and lock the lever 21 Dispose of used oil and fil...

Page 122: ...k plugs Refer to Spark Plug Service page 4 20 3 Install the outer clutch cover Refer to PVT Clutch Cover Service page 6 7 4 Connect the black negative battery cable to the battery TORQUE Battery Termi...

Page 123: ...e plunger and spring are not installed when installing the tensioner 6 Install the two mounting bolts Torque fasteners to specification TORQUE Tensioner Mounting Bolts 7 ft lbs 10 Nm 7 Install the plu...

Page 124: ...al as the system is purging itself of trapped air Observe coolant levels often during the break in period CAUTION Overheating of engine could occur if air is not fully purged from system Polaris Premi...

Page 125: ...ng steam can cause severe burns The engine must be cool before removing the pressure cap ADJUSTMENT 1 Remove the pressure cap Using a funnel add coolant to the top of the radiator filler neck CAUTION...

Page 126: ...ressure washer could damage the radiator fins and impair the radiators effectiveness Use of a high pressure washer is not recommended COOLANT REPLACEMENT 1 Allow the vehicle to cool down if recently o...

Page 127: ...tches q and push up on the alignment tabs to remove the airbox cover 2 Use a twisting and rocking motion to remove the air filter INSTALLATION 1 Clean the airbox and ensure the airbox seal is fully se...

Page 128: ...and are free from dirt and debris when assembling the lid to the box ENGINE CRANKCASE BREATHER HOSE INSPECTION The engine crankcase is equipped with a breather hose Inspect the breather hose for possi...

Page 129: ...area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousnessor death in a very short time Periodically clean spark arrestor to remove accumulated carbon 1 Remove the retai...

Page 130: ...t Exhaust Heat Shields and make sure they are in good condition and are secured properly ITEM DESCRIPTION NOTE q Closeoff Shield w Lower Headpipe Shield Overlaps under the Upper Shield e Inner Silence...

Page 131: ...or signs of wear deterioration damage or leakage Replace line if necessary 3 Ensure fuel lines are properly routed and retained Refer to Fuel Line Routing page 5 5 CAUTION Ensure lines are not kinked...

Page 132: ...old properly once removed 1 Check the fuel tank vent line q for signs of wear deterioration damage or leakage Inspect the quick connector fitting for signs of deterioration Ensure the latch is engaged...

Page 133: ...hould be inspected immediately Use the following instructions to dry the clutches before operating The PVT drain plug is located at the bottom of the outer clutch cover Access the drain plug through t...

Page 134: ...cant Transmission Fluid 4 Reinstall the fill plug and torque to specification TORQUE Transmission Fill Drain Plug 12 ft lbs 16 Nm TRANSMISSION FLUID REPLACEMENT The drain plug is located on the bottom...

Page 135: ...justment proceed with Shift Cable Adjustment STOP If the shifter does not contact the dash in park or high the shift cable requires no further adjustment reinstall the rubber bezel Shift cable adjustm...

Page 136: ...tween shifter and bottom side of the dash opening NOTICE For optimal shift cable adjustment the gap measurements in High and Park should be equal This will ensure the shifter will not contact the dash...

Page 137: ...orque to specification IMPORTANT When setting torque using a crows foot the socket must be at a 90 angle to the torque wrench as shown TORQUE Lower Jam Nut 13 ft lbs 18 N m 9 After adjustment verify t...

Page 138: ...torque to specification TORQUE Front Gearcase Fill Drain Plug 10 ft lbs 14 Nm FRONT GEARCASE FLUID REPLACEMENT The drain plug is located on the bottom of the front gearcase Access the drain plug thro...

Page 139: ...1000 Service Manual Copyright Polaris Inc 2 51 7 Reinstall fill plug with a new O ring and torque to specification TORQUE Front Gearcase Fill Drain Plug 10 ft lbs 14 Nm 8 Check for leaks Dispose of u...

Page 140: ...the appropriate side of the vehicle by placing a suitable stand under the frame CAUTION Ensure the vehicle is properly supported and does not tip or fall 5 Remove the wheel nuts q and remove the wheel...

Page 141: ...ing with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the usable tread depth has wor...

Page 142: ...g to be sure the steering mechanism is not restricted or limited NOTICE Check front end alignment whenever steering components are replaced WARNING Due to the critical nature of the procedures outline...

Page 143: ...rear Try to move the wheel and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub...

Page 144: ...he distance between vehicle center and each wheel This will indicate which tie rod needs adjusting IMPORTANT Ensure the steering wheel is straight before determining which tie rod needs adjustment Mea...

Page 145: ...eakage SPRING PRE LOAD ADJUSTMENT The front and rear shock absorber springs are adjustable Rotate the adjuster cam q either direction to increase or decrease spring tension Always adjust both left and...

Page 146: ...If the fluid level is lower than the MIN level line add brake fluid until it reaches just below the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds a...

Page 147: ...rake pedal before bleeder screw is tight or air may be drawn into master cylinder 10 Release brake pedal pressure Check level of fluid in reservoir and add if necessary 11 Repeat Steps 9 11 until brak...

Page 148: ...y inspect disc for scoring scratches or gouges Replace disc if any are evident 2 Use a 0 1 micrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn bey...

Page 149: ...battery is in service Only add distilled water to the battery if necessary Store the battery in the vehicle with the cables disconnected or store the battery in a cool dry location Batteries will sel...

Page 150: ...AMP charger and inspect the battery every 60 days BATTERY SERVICE REMOVAL 1 Lift the passenger seat and remove 2 Remove the storage bin under the seat 3 Disconnect the black negative cable first then...

Page 151: ...wn clamp 3 Install the fastener q to secure the battery hold down clamp and torque to specification TORQUE Battery Hold Down Clamp 6 ft lbs 8 Nm 4 Connect the red positive cable first then connect the...

Page 152: ...t The other end of the engine ground cable is attached to the chassis ground terminal 3 Inspect the front vehicle ground w located under the hood 4 Remove and clean all ground terminals as necessary 5...

Page 153: ...ICE 3 18 EXHAUST SERVICE 3 19 EXHAUST SYSTEM ASSEMBLY VIEW 3 19 MUFFLER SERVICE 3 20 HEADPIPE SERVICE 3 22 ENGINE SERVICE 3 24 ACCESSIBLE ENGINE COMPONENTS 3 24 ENGINE MOUNT ISOLATOR SERVICE 3 24 CRAN...

Page 154: ...LYWHEEL SERVICE 3 72 STARTER ONE WAY CLUTCH SERVICE 3 73 STARTER ONE WAY CLUTCH INSPECTION 3 75 COOLING SYSTEM SERVICE 3 76 COOLING SYSTEM SPECIFICATIONS 3 76 COOLING SYSTEM ASSEMBLY VIEW 3 77 COOLANT...

Page 155: ...mm Cylinder Taper Limit 0 001 0 025 mm Cylinder to Piston Clearance 0 0014 0 0026 0 035 0 065 mm Cylinder Head Cylinder Head Surface Warp Limit 0 0039 0 1 mm Cylinder Head Standard Height 4 5783 116 2...

Page 156: ...1 7321 1 7323 43 996 44 003 mm 3 Marking Conn Rod Big End Bore I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D 1 6140 1 6143 40 996 41 004 mm 1 6129 40 970 mm G Marking Main...

Page 157: ...CASE UPPER Start with 12 M10 Bolts Step 1 9 ft lb 12 Nm Step 2 21 ft lb 28 Nm Step 3 Tighten additional 90 M8 Bolts 26 ft lbs 35 Nm M8 Bolts 26 ft lbs 35 Nm M6 Bolts 7 ft lbs 10 Nm M6 Bolts 9 ft lbs 1...

Page 158: ...D M8 26 ft lbs 35 Nm M11 Cylinder Head Bolts Torque in sequence Step 1 13 ft lbs 18 Nm Step 2 26 ft lb 35 Nm Step 3 Tighten additional 360 M6 9 ft lbs 12 Nm M6 Cylinder Head Bolts Step 4 7 ft lb 10 Nm...

Page 159: ...d Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3 digit tappet number by 100...

Page 160: ...RS q Connecting Rod Bearing Identification Number one number w Crankcase Bearing Identification Number six numbers Some engines may only have 4 digits The extra two digits will refer to the balance sh...

Page 161: ...haft Rod Code B G Y 1 Blue Blue Green 2 Blue Green Yellow 3 Green Yellow Yellow CRANKSHAFT MAIN BEARING SELECTION In order to select the proper main bearings for the crankshaft you must reference the...

Page 162: ...CRIPTION TORQUE q Fresh Air Intake Hose To Airbox NA w Airbox Fastener M6 x 1 0 x 25 44 in lbs 5 Nm e Intake Hose Airbox to Throttle Body NA r Intake Duct Clamp 35 in lbs 4 Nm t Engine Breather Hose C...

Page 163: ...rom the airbox 3 Remove the push rivet w securing the airbox to the chassis 4 Remove the two fasteners e securing the airbox to the chassis 5 Lower the airbox and remove through the wheel arch INSTALL...

Page 164: ...T SERVICE AIRBOX TO THROTTLE BODY 1 Disconnect the purge line from the intake manifold retainers q 2 Loosen the intake duct clamps w and carefully pull the intake duct off the airbox and throttle body...

Page 165: ...el 4 Carefully remove the duct from the lower closeoff panel CAUTION Use care not to tear the intake duct when removing from the panel AIRBOX TO SIDE BEZEL INSTALLATION 1 Install the duct in the close...

Page 166: ...ice Manual Copyright Polaris Inc 3 Instal the duct on the airbox and tighten the clamp to specification TORQUE Intake Duct Clamp 35 in lbs 4 Nm 4 Install the side bezel cover Refer to Side Bezel Cover...

Page 167: ...tle body to the engine and remove the throttle body INSTALLATION 1 Inspect the throttle body gasket and replace as needed 2 Install the throttle body gasket and four throttle body fasteners and torque...

Page 168: ...ase the harness retention clips from the intake manifold 4 Loosen the intake manifold clamps 5 Remove the lower manifold fastener on the transmission bracket and carefully lift the manifold out of the...

Page 169: ...he lower intake manifold fastener TORQUE Lower Intake Manifold Fastener 18 ft lbs 24 Nm 5 Install the harness retention clips on the intake manifold NOTICE Replace cable ties if previously cut 6 Conne...

Page 170: ...2 Remove the four fasteners q securing the intake manifold adapters w to the engine and remove the adapters INSTALLATION 1 Inspect the gasket surface on the adapters and replace the adapter as needed...

Page 171: ...olator NA t Oxygen Sensor NA y Gasket NA u Spring NA i Exhaust Spring Bolt 21 ft lbs 28 Nm o Spark Arrestor 7 ft lbs 10 Nm a Muffler Assembly NA s Exhaust Spring NA d Muffler Hanger Isolator NA f Heat...

Page 172: ...onnect the exhaust muffler springs w from the chassis 3 Pull the muffler isolators e from the chassis and remove the muffler assembly INSTALLATION 1 Install the muffler assembly and push the muffler i...

Page 173: ...45 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 3 21 4 Install the exhaust spring bolts q and torque to specification TORQUE Exhaust Spring Fasteners 21 ft lbs 28 Nm ENGINE COOLING E...

Page 174: ...steners q securing the upper heat shield w to the headpipe and remove the heat shield 4 Remove the two fasteners e securing the lower heat shield r to the headpipe and remove the heat shield 5 Remove...

Page 175: ...the lower heat shield r and secure to the headpipe using heat shield fasteners e Torque to specification TORQUE Heat Shield Fasteners 6 ft lbs 8 Nm 5 Install the upper heat shield w and secure to the...

Page 176: ...aft PTO Seal The following components require engine removal for service Camshaft Timing Chain Connecting Rod s Counterbalance Shaft Bearings Crankcase Crankshaft Main Bearings Cylinder Oil Pump Oil P...

Page 177: ...NOTICE Continue to support the weight of the engine when installing the isolator 2 Install the isolator fastener r and nut e Torque to specification TORQUE Engine Isolator Fastener 40 ft lbs 54 Nm 3 I...

Page 178: ...11 2 Using a commercially available seal puller tool remove crankcase seal from crankcase IMPORTANT Use care not to scratch the crankcase while removing seal 3 Inspect the crankcase and crankshaft sur...

Page 179: ...efer to Battery Service page 2 62 2 Remove the intake manifold Refer to Intake Manifold Service page 3 16 3 Remove the inner clutch cover Refer to Inner PVT Cover Service page 6 11 4 Remove the exhaus...

Page 180: ...MAG side of the engine 11 Remove the nuts e and fasteners r securing the engine to the front engine mount 12 Carefully lift the engine straight up and out of the vehicle INSTALLATION 1 With the aid o...

Page 181: ...rs and washers q on the PTO side of the engine IMPORTANT Do NOT torque at this time 6 Install clutch center distance tool PU 50658 onto the crankshaft and transmission input shaft using hole pattern 4...

Page 182: ...the rear engine mount bracket in the sequence shown below TORQUE Rear Engine Mount Fasteners 45 ft lbs 61 Nm 11 Torque the front engine mount nuts e and fasteners r TORQUE Rear Engine Mount Fasteners...

Page 183: ...olaris Inc 3 31 16 Connect the fuel supply line to the fuel rail Refer to Fuel Supply Line Service page 5 8 17 Install the intake manifold Refer to Intake Manifold Service page 3 16 18 Connect the bat...

Page 184: ...rvice page 3 35 3 Rotate the engine until the alignment mark is visible through the CPS hole 4 Verify offset alignment marks are located parallel to the cylinder head as shown below Incorrect Timing N...

Page 185: ...teners q securing the camshaft sprocket to the camshaft and slide the sprocket off the camshaft NOTICE Fasteners are one time use Discard after removing 4 When rotating the camshaft in the next step u...

Page 186: ...e rotating camshaft 6 Slide the sprocket on the camshaft Install NEW sprocket fasteners q and torque to specification TORQUE Camshaft Sprocket Fasteners 14 ft lbs 19 Nm 7 Install the chain tensioner R...

Page 187: ...r 2 Remove the five fasteners q and isolators w securing the valve cover e to the engine Remove the valve cover 3 Remove the valve cover gasket r and discard INSTALLATION 1 Install a new valve cover g...

Page 188: ...ust be performed before valve clearance adjustment Refer to Valve Clearance Inspection page 2 33 1 Remove the camshaft Refer to Camshaft Service page 3 39 2 Remove the valve tappet s q from the out of...

Page 189: ...ce Inspection page 2 33 Repeat valve clearance adjustment as needed 8 Finish engine assembly Refer to Camshaft Service page 3 39 CAM CHAIN TENSIONER SERVICE 1 Locate the cam chain tensioner on the MAG...

Page 190: ...ue fastener to specification TORQUE Plunger Bolt 15 ft lbs 20 Nm 8 Turn the engine over by hand to ensure proper chain tension is applied CAMSHAFT SPROCKET SERVICE REMOVAL 1 Remove the valve cover Ref...

Page 191: ...w securing the camshaft bearing caps e to the cylinder head and remove the bearing caps 3 Lift the camshaft straight up to remove from the cylinder head INSTALLATION 1 Reinstall the camshaft into the...

Page 192: ...Lobe Height 2 0257 2 0294 51 45 51 55 mm Service Limit 2 0237 51 40 mm Exhaust Camshaft Lobe Height 2 0257 2 0294 51 45 51 55 mm Service Limit 2 0237 51 40 mm CAMSHAFT JOURNAL 1 Visually inspect each...

Page 193: ...EASUREMENT Calculated Camshaft Oil Clearance 0 0018 0 0035 0 046 0 088 mm Service Limit 0047 0 119 mm CYLINDER HEAD REMOVAL AND INSTALLATION REMOVAL 1 Remove the Intake Manifold Refer to Intake Manifo...

Page 194: ...t using the Cylinder Holding Camshaft Timing Plate PU 50563 IMPORTANT Fasteners are one time use Discard after removing 10 Refer to Cylinder Head Inspection page 3 49 before reassembly INSTALLATION 1...

Page 195: ...he Camshaft Sprocket Refer to Camshaft Sprocket Service page 3 38 6 Connect the engine outlet hose w and oil cooler outlet hose e TORQUE Coolant Hose Clamp 35 in lbs 4 Nm 7 Connect the Coolant Tempera...

Page 196: ...ring using valve spring compressor PU 52917 to expose the valve keepers 4 Remove the two valve keepers q 5 Remove the valve spring cap w valve spring e and valve stem seal r Discard the valve stem sea...

Page 197: ...pring e and valve spring cap w 3 Compress the valve spring using valve spring compressor PU 52917 to expose the valve keepers 4 Install the two valve keepers q 5 Install the cylinder head Refer to Cyl...

Page 198: ...cessary They must be replaced if extensively worn burnt bent or damaged 5 Measure diameter of valve stem with a micrometer in three places then rotate 90 and measure again take six measurements total...

Page 199: ...at transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3...

Page 200: ...nuous contact point on the black marker all the way around the valve face MEASUREMENT Valve Seat Width Intake 0 0591 0 0039 1 5 0 10 mm Service Limit 0 0748 1 9 mm Exhaust 0 0787 0 0039 2 0 0 10 mm Se...

Page 201: ...warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head MEASUREMENT Cylinder Head Warp Limit 0 0039 0 1 mm...

Page 202: ...ee fasteners securing the oil filter adapter to the engine and remove the oil filter adapter assembly INSTALLATION 1 Replace the oil filter adapter gasket q upon reassembly 2 Install the three oil fas...

Page 203: ...e oil sump to the engine 4 Remove the thirteen M6 fasteners w securing the oil sump to the engine 5 Remove the oil sump from the engine INSTALLATION 1 Clean the gasket surface on the engine 2 Clean th...

Page 204: ...l Sump Fasteners M6 26 ft lbs 35 Nm 5 Fill the engine oil Refer to Engine Oil Level Inspection 6 Install the skid plate Refer to Skid Plate Service page 11 35 OIL PUMP SERVICE REMOVAL 1 Remove the oil...

Page 205: ...il pump straight up to remove IMPORTANT Ensure the oil pump pickup is clean and free of debris INSTALLATION 1 Lift the oil pump drive chain and install the oil pump IMPORTANT Ensure the oil pump shaft...

Page 206: ...emoval Installation page 3 27 2 Remove the oil filter adapter Refer to Oil Filter Adapter Service page 3 50 3 Remove the oil pump and oil cooler Refer to Oil Pump Service page 3 52 and Engine Oil Cool...

Page 207: ...gine 2 Clean the gasket surface on the upper crankcase and apply a thin film of crankcase sealant PN 2881416 3 Install the upper crankcase on the engine and align with the mounting holes 4 Install eig...

Page 208: ...ecure the rear engine mount bracket w to the engine and torque to specification TORQUE Rear Engine Mount Bracket 45 ft lbs 61 Nm 9 Install the starter motor Refer to Starter Motor Service page 4 14 10...

Page 209: ...shaft w and remove it from the crankcase 4 Inspect the balance shaft gear teeth for damage 5 Measure each bearing journal in two locations 90 degrees apart Replace balance shaft if either journal is...

Page 210: ...e oil pump drive chain t and PTO main seal r from the crankshaft INSPECTION 1 Inspect the crankshaft gear u and auxiliary sprocket y for broken or worn teeth 2 If the crankshaft gear or sprocket is d...

Page 211: ...nkshaft assembly CRANKSHAFT BEARING JOURNAL DIAMETERS B Main Bearing Standard 1 6140 1 6143 40 996 41 004 mm Service Limit 1 6129 40 970 mm Conn Rod Bearing Standard 1 6118 1 6122 40 942 40 950 mm Ser...

Page 212: ...em and connecting rod end cap Press bearing insert firmly into place Repeat for the other connecting rod 5 Install oil drain diverter e into the upper crankcase 6 Apply Polaris PS 4 engine oil to each...

Page 213: ...ap on connecting rod with 3 digit serial number stampings aligned w e 13 Install new bolts s and tighten evenly until snug 14 Torque connecting rod bolts to specification TORQUE Connecting Rod Bolts S...

Page 214: ...bore and direction from which they were removed MAG PTO INSTALLATION CAUTION Pistons must be installed into the cylinders with the connecting rods attached DO NOTattempt to service the cylinder or pis...

Page 215: ...ankcase to cylinder mounting surface is facing up 6 Clean base gasket sealing surface on cylinder and crankcase to remove all oil and grease IMPORTANT Base gasket and surfaces must be DRY and oil free...

Page 216: ...re used 4 Be sure oil passages are clean and free of any cleaning solvent 5 Remove and discard the plain bearings located in the upper crankcase w lower crankcase e and connecting rods r Replace the c...

Page 217: ...one the cylinders or attempt to repair a damaged cylinder by honing 3 Inspect taper and out of round with a dial bore gauge 4 Inspect cylinder for taper and out of round with a telescoping gauge or a...

Page 218: ...ith a heat gun if pin cannot be removed by hand Discard circlips CAUTION DO NOTapply heat to piston rings or a loss of radial tension could result 3 Measure piston pin bore I D in two directions 90 ap...

Page 219: ...econd compression ring w 3 The oil control ring e is a three piece design consisting of a top and bottom steel rail and a center expander section Remove top rail first then bottom rail then the expand...

Page 220: ...0 025 0 37 0 63 mm Service Limit 0 031 0 8 mm Second Ring 0 010 0 014 0 25 0 35 mm Service Limit 0 0197 0 5 mm Oil Control Rails 0 010 0 040 0 25 1 02 mm Service Limit 0 0433 1 1 mm NOTICE Always chec...

Page 221: ...ng of surface or pitting 4 Measure small end I D in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service limit specification MEASUR...

Page 222: ...her using new connecting rods or re installing the original ones refer to the bearing selection chart provided in the Connecting Rod Bearing Selection page 3 9 procedure in this chapter STATOR COVER S...

Page 223: ...ssembly 2 Install a new stator cover gasket over alignment pins CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between co...

Page 224: ...hten the center bolt to remove the flywheel INSTALLATION 1 If previously removed reinstall the flywheel key 2 Inspect and clean crankshaft and flywheel taper with isopropyl alcohol or similar cleaning...

Page 225: ...bs 175 Nm Step 2 Back out bolt 180 Step 3 Torque to 129 ft lbs 175 Nm 7 Wipe off excess Loctite and let stand for 1 hour before starting engine NOTICE Loctite cures with time the longer the unit is ab...

Page 226: ...the starter gear y and the bushing u for wear damage or uneven surfaces NOTICE If any starter one way clutch component is worn or damaged replace the clutch and starter gear as an assembly INSTALLATIO...

Page 227: ...se direction only STARTER ONE WAY CLUTCH INSPECTION 1 Remove the flywheel Refer to Flywheel Service page 3 72 2 Place flywheel on a work bench with the one way clutch facing up Grasp clutch gear and r...

Page 228: ...CIFICATION Cooling System Capacity 5 0 Qt 4 75 L Pressure Cap Relief 13 PSI 50 50 Extended Life Antifreeze Quart 2880514 Gallon 2880513 Recommended Coolant Use only high quality antifreeze coolant mix...

Page 229: ...1 0 24 in lbs 3 Nm e Radiator Overflow Hose NA r Cooling Fan Fastener 35 in lbs 4 Nm t Hose Clamp NA y Radiator Assembly NA u Cooling Fan Assembly NA i Lower Radiator Hose Assembly NA o Coolant Hose...

Page 230: ...leed Fastener M6 x 1 0 x 13 6 ft lbs 8 Nm e Fastener M6 x 1 0 x 20 7 ft lbs 10 Nm r Oil Cooler NA t Oil Cooler Outlet Hose NA y Water Pump NA u Coolant Hose Clamp 35 in lbs 4 Nm i Water Pump Fastener...

Page 231: ...r Cooling Fan Fastener M6 x 1 0 x 15 35 in lbs 4 Nm t Upper Cooling Hose NA y Heater Return Hose NA u Heater Feed Hose NA i Retainer Screw 22 in lbs 4 5 Nm o Retainer Bolt M6 x 1 0 x 40 44 in lbs 5 0...

Page 232: ...clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is wa...

Page 233: ...the pressure cap TORQUE Coolant Bleed Screw 6 ft lbs 8 Nm 13 Fill the recovery bottle to the MAX line 14 Reinstall the upper exhaust heat shield 15 Reinstall the hood COOLING SYSTEM PRESSURE TEST 1 R...

Page 234: ...ef pressure is 13 psi Replace cap if it does not meet this specification RADIATOR SERVICE REMOVAL 1 Remove the hood 2 Remove four upper radiator support fasteners q w Remove the two radiator support b...

Page 235: ...from the radiator 8 Lift the radiator up to remove from the vehicle 9 Inspect fan blades for damage INSTALLATION 1 Install the radiator in the vehicle CAUTION Use care not to damage the radiator fins...

Page 236: ...age 3 80 7 Install the radiator access flap up 8 Install the radiator support brackets e and four support fasteners q w Torque to specification TORQUE Radiator Support Fasteners 42 in lbs 5 Nm 9 Insta...

Page 237: ...coolant hoses from the oil cooler CAUTION Catch and properly dispose of any escaping coolant 4 Remove the four fasteners r securing the oil cooler t to the engine Remove the oil cooler CAUTION Catch...

Page 238: ...adpipe assembly Refer to Headpipe Service page 3 22 6 Top off engine oil as needed Refer to Engine Oil Level Inspection THERMOSTAT REPLACEMENT 1 Remove the hood from the front cab WARNING The cooling...

Page 239: ...n this chapter WATER PUMP SERVICE WARNING Ensure the engine has cooled down and no pressure is present in the cooling system Escaping coolant can cause severe injury or burns REMOVAL 1 Disconnect the...

Page 240: ...mpeller side 6 Extract the mechanical seal and the oil seal from the water pump housing CAUTION A 5 32 4 mm diameter punch y will fit in the lubrication slot to aid in the removal of the oil seal Be s...

Page 241: ...octite 204 to the threads of the impeller bolt Install washer and impeller bolt and torque to specification TORQUE Water Pump Impeller Bolt 7 ft lbs 10 Nm Apply Loctite 204 to bolt threads 17 Clean co...

Page 242: ...1000 Service Manual Copyright Polaris Inc WATER PUMP ASSEMBLY VIEW o Bolt f Washers k Oil Seal a Loctite 204 g Drive Tab l Impeller s Mechanical Seal h Water Pump Shaft 1 Washer d O Rings j Water Pum...

Page 243: ...e the water pump drive access hole in engine crankcase and note orientation of the water pump drive slot e 5 Rotate water pump drive tab r so it matches the angle of the drive slot in the engine CAUTI...

Page 244: ...ight rear wheel Refer to Wheel Service page 2 52 11 Connect the battery Refer to Battery Service page 2 62 HEATER VALVE SERVICE 1 Drain the cooling system Refer to Coolant Service page 3 80 2 Remove t...

Page 245: ...head gasket A cylinder leakdown test is the most accurate test to examine engine condition NOTICE Leakdown testing is preferred over compression testing for the following Piston rings take time to se...

Page 246: ...culate the leak Some testers may not use a calculation and the gauge may give you a percent of leak or capacity NOTICE If the same cylinder is tested multiple times without running the engine can caus...

Page 247: ...STARTER SOLENOID OPERATION 4 13 STARTER SOLENOID BENCH TEST 4 14 STARTER MOTOR SERVICE 4 14 STARTING SYSTEM TESTING FLOW CHART 4 16 VOLTAGE DROP TEST 4 17 TROUBLESHOOTING 4 17 IGNITION SYSTEM SERVICE...

Page 248: ...4 30 DRIVE MODE SWITCH DESCRIPTION AND OPERATION 4 30 DRIVE MODE SWITCH REPLACEMENT 4 30 ACCELERATOR POSITION SENSOR APS 4 31 APS OPERATION OVERVIEW 4 31 APS REPLACEMENT 4 31 APS TEST 4 31 COOLING SY...

Page 249: ...NESS ENGINE HARNESS ROUTING INTAKE MANIFOLD HARNESS REF DESCRIPTION q Box Harness Connector w Throttle Body Connector e Oxygen Sensor Connector r T MAP Sensor t Box Lift Actuator Connector y Zip Tie O...

Page 250: ...ice Manual Copyright Polaris Inc INJECTOR HARNESS REF DESCRIPTION q PTO Fuel Injector Connector w MAG Fuel Injector Connector e Tree Clip Into Intake Manifold r Coolant Temperature Sensor Connector t...

Page 251: ...00 Service Manual Copyright Polaris Inc 4 5 IGNITION HARNESS REF DESCRIPTION q MAG Ignition Coil Wire w PTO Ignition Coil Wire e Tree Clip Into PVT Duct r Tree Clip Into Intake Manifold t Tree Clip In...

Page 252: ...on Clip Wrap around both wiring bundles and attach to chassis e Purge Solenoid Connector CA Models ONLY r Throttle Body Connector t Zip Tie Around both wiring bundles y Trunk Harness Connector u Tree...

Page 253: ...S REF DESCRIPTION q Tree Clip Into Intake Manifold w CPS In line Connector e Retention Clip Into Coolant Hose Bracket r Crankshaft Position Sensor t Retention Clip Into Transmission y Gear Position Se...

Page 254: ...es the fault code in its fault memory Depending on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technic...

Page 255: ...to the Digital Wrench diagnostic connector Go to the Special Tests menu and select ECU Replacement Carefully follow the ECU replacement instructions 3 Tilt the cargo box to access the ECU 4 Remove the...

Page 256: ...ace during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop...

Page 257: ...move CPS retaining fastener w and remove the sensor from the stator cover 5 Install new sensor using a light coating of oil on the O ring to aid installation 6 Torque CPS retaining fastener to specifi...

Page 258: ...contact the Polaris Service Department for specific handling instructions Do not replace the ETC without factory authorization Use Digital Wrench to perform all troubleshooting of this component Use a...

Page 259: ...must occur The brake must be applied to close the brake pressure switch and provide 12V power to the key switch and ECU The key switch must be turned to the start position to provide 12V power to the...

Page 260: ...ification replace the starter solenoid STARTER MOTOR SERVICE REMOVAL 1 Disconnect the battery Refer to Battery Service page 2 62 2 Remove the Intake Manifold Refer to Intake Manifold Service page 3 16...

Page 261: ...s when installing 3 Install the starter mounting fasteners and torque to specification TORQUE Starter Mounting Fasteners 7 lb ft 10 Nm 4 Install the starter cables and secure with starter cable nuts T...

Page 262: ...4 16 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc STARTING SYSTEM TESTING FLOW CHART ENGINE ELECTRICAL...

Page 263: ...connection TROUBLESHOOTING Starter Motor Does Not Run Battery discharged Loose or faulty battery cables or corroded connections Refer to Voltage Drop Test page 4 17 Related wiring loose disconnected...

Page 264: ...creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between...

Page 265: ...bly Torque the fastener to specification TORQUE Ignition Coil Bracket Fastener 7 ft lbs 9 Nm INSTALLATION 1 Mounting the ignition coil r on the chassis and install the two fasteners e Torque to specif...

Page 266: ...NOTICE Cracks can be difficult to see Any cracking on the insulation can lead to a drivability concern Inspect the ground electrode w for signs of wear or irregular engine conditions Verify the electr...

Page 267: ...is dropped 4 If reusing spark plugs refer to Spark Plug Inspection page 4 20 to ensure they are fit for service INSTALLATION 1 Install the spark plugs e and torque to specification CAUTION Use care wh...

Page 268: ...nition coil can be tested by using an ohm meter Use the following illustration and specification table to test the ignition coil resistance IGNITION COIL RESISTANCE READINGS TEST PIN CONNECTION RESIST...

Page 269: ...n The T MAP sensor provides the ECU with engine load data T MAP SENSOR REPLACEMENT 1 Lift the rear cargo box to the raised position 2 Disconnect the vehicle harness q from the T MAP sensor 3 Remove th...

Page 270: ...o allow the coolant to cool and fuel pressure to drop 1 Lift the rear cargo box to the raised position 2 Drain the coolant so the level is below the sensor Refer to Coolant Replacement page 2 38 3 Rem...

Page 271: ...13 k 40 490 k 50 136 k 22 30 26 114 k 23 580 k 28 647 k 4 20 15 462 k 14 096 k 16 827 k 14 10 9 397 k 8 642 k 10 152 k 32 0 5 896 k 5 466 k 6 326 k 50 10 3 792 k 3 542 k 4 043 k 68 20 2 500 k 2 351 k...

Page 272: ...ure sensor or circuit malfunctions the radiator fan will default to ON while the engine is running Refer to COOLANT TEMPERATURE SENSOR for additional ECTsensor information Polaris dealers can test the...

Page 273: ...delay The delay time ensures the oxygen sensor heater has run long enough to provide accurate data OXYGEN SENSOR SERVICE REMOVAL 1 Cut the zip ties q securing the oxygen sensor harness to the vehicle...

Page 274: ...lse width 0 45V STOICHIOMETRIC 14 7 1 MAINTAIN 0 45V RICH ECU Leans injector pulse width 1 0V 1 64V OPEN LOOP ECU Ignores O2 sensor Readings INTERPRETING DIGITAL WRENCH READINGS The Air Fuel Ratio rea...

Page 275: ...9 O2 SENSOR HEATER TESTING 1 Measure the resistance between pins B and D CONNECTOR PIN WIRE COLOR PIN AND WIRE CONNECTION A Gray Sensor Ground B Black Sensor Output C White Heater Power D White Heater...

Page 276: ...the ECU to monitor voltage drop indicating the selected mode The modes are PERF Performance mode Aggressive pedal feel Resistor in the switch for this mode is 4 K Ohms STND Standard mode Balanced peda...

Page 277: ...PS is calibrated to the throttle pedal If the APS is faulty the throttle pedal assembly must be replaced 1 Disconnect the APS harness q 2 Remove the three fasteners w retaining the throttle pedal brac...

Page 278: ...4 32 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc COOLING SYSTEM TESTING COOLING SYSTEM BREAK OUT DIAGRAM ENGINE ELECTRICAL...

Page 279: ...feature Digital Wrench The fan can also be commanded on and off from this feature This is another test that can be used prior to the circuit bypass test 1 Disconnect harness from coolant temperature s...

Page 280: ...4 34 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc NOTES ENGINE ELECTRICAL...

Page 281: ...5 5 FUEL LINE ROUTING 5 5 FUEL LINE QUICK CONNECT REMOVAL 5 6 FUEL SUPPLY LINE SERVICE 5 8 VENT LINE TERMINATION FITTING 5 9 FUEL VENT LINE ROUTING 5 10 FUEL VENT LINE ROUTING EVAP MODELS 5 11 FUEL TA...

Page 282: ...r attempt to service any fuel system component while engine is running or ignition switch is on Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system...

Page 283: ...computer chip and the ECU adjusts the fuel delivery and ignition timing based on these values During operation the ECU has the ability to re adjust temporarily providing compensation for changes in o...

Page 284: ...num in the intake track retained on top by the fuel rail 2 Fuel Rail Assembly Located on the intake plenum on top of the fuel injectors 3 Fuel Supply Line Connected to the left end of the fuel rail an...

Page 285: ...aris Inc 5 5 FUEL LINES FUEL LINE ROUTING The fuel line is routed from the fuel tank to the fuel rail on the engine It is secured to the engine breather hose inner clutch cover and clutch duct with re...

Page 286: ...l straight blade screwdriver Screwdriver Method 1 Insert a 1 flat blade screw driver into the pry slot on the top of the retaining clip IMPORTANT To prevent damage to the retaining clip be sure to use...

Page 287: ...of a hard line end The retaining clip is designed to lock only when a hard line end has been fully inserted 2 Retaining tabs are deformed and no longer lock into the body of the quick connect 3 Broke...

Page 288: ...MOVAL 1 Place a shop towel around the fuel line to catch any dripping fuel 2 To remove the fuel line from the tank q or the fuel rail w pull open tabs while moving the connector out to release the lin...

Page 289: ...t the fuel tank q and fuel rail w and slide the connector locking mechanism back into place Verify the connector tabs snap back into place by pulling out lightly on connector VENT LINE TERMINATION FIT...

Page 290: ...ROUTING The fuel tank is vented through a vent line The vent line is routed from the fuel tank underneath the driver seat and secured into a vertical section of the frame with a vent line termination...

Page 291: ...nnect fitting The purge jumper line y routes from the purge valve to the air intake manifold This line assembly is secured to the purge port on the manifold and to the purge valve using a quick connec...

Page 292: ...ight Polaris Inc FUEL TANK FUEL TANK ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION q Fuel Tank Asm y Tank Vent Rollover Valve w Fuel Inlet u Fuel Pump Regulator e Fuel Cap i Fuel Level Float Arm r Gas...

Page 293: ...uring the carbon canister bracket to the chassis and remove the bracket 5 While holding a shop towel around the fuel line connectors disconnect the fuel line q from the fuel pump Refer to Fuel Line Qu...

Page 294: ...ide out of the frame 11 Rotate and slide the fuel tank and remove the tank from vehicle INSTALLATION 1 Install the fuel tank in the vehicle 2 Secure the seat base fastener y and torque to specificatio...

Page 295: ...ightly pull back to ensure it is fully seated 6 Connect the fuel pump electrical harness w 7 Connect the fuel tank vent line quick connect fitting e to the tank fitting 8 EVAP MODELS ONLY Install the...

Page 296: ...lluminate but turn off after 4 cranking revolutions if the system functions properly Once the engine is running the fuel pump remains on to maintain fuel pressure FUEL SENDER TEST 1 Remove the fuel pu...

Page 297: ...mp outlet 5 Install the Fuel Pressure Gauge Adapter in line between the fuel pump outlet and fuel supply line Fuel Pressure Gauge Adapter PA 48838 6 Connect the hose from the Fuel Pressure Gauge Kit t...

Page 298: ...fuel pump assembly 10 If voltage at the plug was within the specified range and there was continuity across the pump terminals reconnect the plug to the fuel pump making sure you have a clean connect...

Page 299: ...may lead to debris entering the fuel tank during service Excessive debris in fuel tank may cause premature wear of fuel pump and or clogging of internal fuel filters 4 Ensure that static has been disc...

Page 300: ...equire flashlight and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly CAUTION It is recommended to remove the f...

Page 301: ...ks are still aligned between fuel pump and fuel tank 18 Torque nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench TORQUE Fuel Pump Nut 70 ft lbs 95 Nm 19 Ver...

Page 302: ...purge line w and fresh air line e 3 Push the retaining tab in and lift the canister straight up to remove from the bracket INSTALLATION 1 Install the canister in the vehicle and align with the bracke...

Page 303: ...connector q 3 Disconnect both purge valve quick connectors Refer to Fuel Line Quick Connect Removal page 5 6 4 Slide the purge valve grommet off of the bracket IMPORTANT When reinstalling ensure the...

Page 304: ...operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect th...

Page 305: ...AG wire colors are Red Blue and Black the PTO wire colors are Red Blue and White FUEL INJECTOR SERVICE CAUTION Allow the vehicle to sit for one hour after key off to allow fuel pressure to drop WARNIN...

Page 306: ...arefully pull the injector s off of the fuel rail as needed INSTALLATION 1 Lightly lubricate the injector O rings prior to installation 2 Install the fuel injectors onto the fuel rail until the O ring...

Page 307: ...1000 Service Manual Copyright Polaris Inc 5 27 4 Connect the fuel supply line and ensure the latch is pushed down Gently pull back to ensure it is fully seated 5 Connect the battery Refer to Battery...

Page 308: ...5 28 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc NOTES FUEL SYSTEM...

Page 309: ...4 DRIVEN CLUTCH ALIGNMENT 6 5 PVT SYSTEM SERVICE 6 6 PVT COVERS AND DUCTING ASSEMBLY VIEW 6 6 PVT CLUTCH COVER SERVICE 6 7 DRIVE CLUTCH REMOVAL INSTALLATION 6 9 DRIVEN CLUTCH REMOVAL INSTALLATION 6 10...

Page 310: ...ton to Tower Clearance 000 010 0 020 0 508 mm Drive Clutch Shaft Diameter 1 57 in 39 98 mm Vespel Thrust Washer Thickness 0 030 0 040 0 762 0 962 mm 0 029 0 742 mm Driven Clutch Spring Free Length 4 5...

Page 311: ...and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly matched PVTsystem should hold engine RPM at the peak of the power curve This RPM should be mai...

Page 312: ...direction of travel before removing 3 Remove the belt off the bottom of the driven clutch and slowly turn the driven clutch counter clockwise to aid in removal INSTALLATION 1 Install the belt over dr...

Page 313: ...t closer to the inner sheave of the drive clutch or remove shims to move the belt closer to the outer sheave of the drive clutch IMPORTANT Ensure the driven clutch splines and transmission splines and...

Page 314: ...Hose Ducting Fastener 14 x 3 4 18 in lbs 2 Nm e Clutch Intake Duct NA r Clutch Outlet Duct NA t Hose Clamp 35 in lbs 4 Nm y Outlet Duct Fastener 7 in lbs 1 Nm u Outer Clutch Cover NA i Outer Clutch C...

Page 315: ...aris Inc 6 7 PVT CLUTCH COVER SERVICE REMOVAL 1 Remove the eight fasteners q securing the clutch cover to the vehicle 2 Lift the cover over the a arm assembly 3 Rotate the cover towards the engine 4 R...

Page 316: ...Replace if necessary 3 Install the cover in the vehicle and rotate counter clockwise 4 Lift the rear of the cover up to the a arm while simultaneously rotating away from the engine 5 Lift the cover o...

Page 317: ...tationary post If you are unable to remove the movable sheave by hand remove the six cover bolts drive spring outer post and washers Use a three jaw puller to remove the spider The Drive Clutch puller...

Page 318: ...twards towards Outer Post w and Outer Post q TORQUE Drive Clutch Retaining Bolt Moveable sheave only removed 96 ft lbs 130 Nm Drive Clutch Retaining Bolt Stationary sheave completely removed Step 1 11...

Page 319: ...h is not flush with the Input Shaft 3 Wedge a six inch extension between the driven clutch movable sheave and the A arm 4 Install all driven clutch washers w belleville washer q and the bolt Torque to...

Page 320: ...place if necessary 2 Install the inner clutch cover and the seven cover fasteners t Torque to specification TORQUE Inner Clutch Cover Fasteners 5 ft lbs 7 Nm 3 Install the retention clips r on the top...

Page 321: ...mp w Torque to specification TORQUE PVT Air Duct Clamp 35 in lbs 4 Nm 6 Install the drive clutch Refer to Drive Clutch Removal Installation page 6 9 7 Install the driven clutch Refer to Driven Clutch...

Page 322: ...96 ft lbs 130 Nm Stationary Sheave removed Step 1 110 ft lbs 149 Nm Step 2 Loosen Fastener Step 3 96 ft lbs 130 Nm w Drive Clutch Cover Fasteners M6 x 1 0 x 50 44 in lbs 5 Nm e Drive Clutch Cover NA r...

Page 323: ...ave been in alignment before disassembly 2 Remove cover bolts q evenly in a cross pattern and remove cover plate w 3 Remove the clutch spring r belleville washer t and washer y 4 Remove the spider ass...

Page 324: ...h spider assembly 2 Install the washer y belleville washer t and clutch spring r IMPORTANT Belleville washer must be installed with dome facing the outer post 3 Using a clutch spring compressor instal...

Page 325: ...ton to Tower Clearance 000 010 SHIFT WEIGHT Remove shift weight fasteners q and weights w Inspect the contact surface of the weight w The surface should be smooth and free of dents or gall marks Inspe...

Page 326: ...ing or flat spots replace all the rollers CLUTCH BEARING Verify there are no binding or rough spots If problems are noted replace the bearing and thrust washers MOVEABLE SHEAVE Inspect the moveable cl...

Page 327: ...than Teflon is visible on the bushing s Refer to Bushing Service ROLLER REPLACEMENT IMPORTANT When replacing rollers install new roller pins and thrust washers 1 Remove the roller buttons Inspect and...

Page 328: ...ng until tiny smoke tailings appear 8 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 9 Remove nut from puller rod and set aside 10 Pull bushing removal tool and...

Page 329: ...and cover comes free 6 Remove nut from puller rod and set aside 7 Remove bushing and bushing removal tool from puller Discard bushing COVER BUSHING INSTALLATION 1 Apply Loctite 620 evenly to bushing b...

Page 330: ...EF DESCRIPTION TORQUE NOTE q Driven Clutch Bolt 20 ft lbs 27 Nm w Washer NA e Shim 0 8 r Stationary Sheave NA t Helix NA y Bushing NA u Spring NA i Spring Cup NA o Bushing NA a Moveable Sheave NA s He...

Page 331: ...Separate the sheaves and place the driven clutch helix side up into the Universal Clutch Compressor Universal Clutch Compressor PU 50518 A 3 Spin the compressor down until it just starts to contact t...

Page 332: ...clip t Roller y and Washer u from sheave Replace as necessary NOTICE Roller pin is not serviceable 6 Inspect the sheaves for excessive wear or damage Replace if necessary REASSEMBLY 1 Re install washe...

Page 333: ...6 Once back together verify the alignment marks made during disassembly are properly aligned HELIX AND MOVABLE SHEAVE BUSHING INSPECTION 1 Inspect the Teflon coating q on the moveable sheave bushing I...

Page 334: ...move the bushing and bushing removal tool from the puller Discard the bushing HELIX BUSHING INSTALLATION 1 Apply Loctite 620R evenly to bushing bore in cover 2 From the bottom of the Helix insert the...

Page 335: ...hift linkage cable issue Proceed to diagnose shift cable issues Follow the proper direction q for hard shifting creeping w for unconfirmed customer complaint of hard shifting creeping q Perform clutch...

Page 336: ...ng to Belt Removal Apply load on each roller firmly with your finger while rotating Do all three rotate freely No Service Spider Rollers Refer to PVT Inner Cover Disassem bly Yes Yes Yes Yes Replace i...

Page 337: ...3 SHIFT CABLE INSPECTION 7 3 SHIFT CABLE ADJUSTMENT 7 4 SHIFT CABLE ROUTING 7 7 SHIFT CABLE SERVICE 7 9 TRANSMISSION SERVICE 7 14 TRANSMISSION ASSEMBLY VIEW 7 14 TRANSMISSION VENT LINE ROUTING 7 15 T...

Page 338: ...ear differential makes maneuvering easier and minimizes damage to terrain SPECIAL TOOLS TRANSMISSION PART NUMBER TOOL DESCRIPTION PU 52547 Snorkel Tube Tool 2871699 Rear Driveshaft Seal Guide 2871698...

Page 339: ...end from the lever 5 Remove the retaining ring o and slide the shift lever r off the mounting bracket and out from the frame 6 Remove both bushings a from the shift lever and service as needed 7 Perfo...

Page 340: ...e gear lash noise Gear selector moving out of desired range Inspect shift cable clevis pins and pivot bushings and replace if worn or damaged SHIFT CABLE ADJUSTMENT Shift cable adjustment may be neces...

Page 341: ...t and pull the cable out of the mount bracket to move the upper jam nut y 6 With the cable removed from the bracket turn the upper jam nut y to adjust the cable Moving the upper jam nut y closer to t...

Page 342: ...t be at a 90 angle to the torque wrench as shown TORQUE Lower Jam Nut 13 ft lbs 18 N m 9 After adjustment verify there is no contact with the dash in both Park High If the shifter is still contacting...

Page 343: ...7 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 7 7 SHIFT CABLE ROUTING NOTICE Ensure the retention points q and the jam nuts w are secure TOP VIEW TRANSMISSION...

Page 344: ...7 8 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc SIDE VIEW TRANSMISSION...

Page 345: ...per retaining tabs Remove from the vehicle 4 Remove the 10mm fastener w two push rivets e and T40 Torx fastener r securing the left dash bracket 5 Rotate the left dash bracket t to the left as shown a...

Page 346: ...Remove the shift cable from the retainer a near the vehicle battery 12 Remove the 10mm fastener s securing the shift cable to the transmission 13 Loosen the fasteners d securing the shift cable bracke...

Page 347: ...ft Cable Routing page 7 7 for proper routing 3 Install fasteners d securing the shift cable brackets f to the transmission and torque to specification TORQUE Shift Cable Brackets 37 ft lbs 50 Nm 4 Ins...

Page 348: ...nto the dash retainer and torque the locknut i to specification TORQUE Shift Cable Locknut 13 ft lbs 18 Nm 9 Install the shift cable u into the shift lever assembly and secure with a new fastening nut...

Page 349: ...cket Fastener 6 ft lbs 8 Nm TORQUE T40 Dash Bracket Fastener 42 in lbs 5 Nm 12 Install the center dash panel and connect all electrical connectors IMPORTANT Ensure the top retaining tabs are engaged i...

Page 350: ...ork Retainer Fastener 9 ft lbs 12 Nm t Transmission Case Fastener QTY 14 20 ft lbs 27 Nm y Speed Sensor Fastener 10 ft lbs 14 Nm u Rear Mount Bracket Fastener QTY 2 20 ft lbs 27 Nm i Bearing Cover Fas...

Page 351: ...SSION VENT LINE ROUTING The transmission vent line runs along the rear passenger side frame It is secured along the front frame by one retention clip as shown The vent line ends its routing secured in...

Page 352: ...ble Service page 7 9 NOTICE The shift cable only needs to be disconnected from the transmission and does not need to be removed from the vehicle 5 Remove the transmission vent line Refer to Transmissi...

Page 353: ...r fastener and nut TORQUE Transmission Rear Isolator Fastener 40 ft lbs 54 Nm 3 Loosen the two fasteners securing the transmission mount bracket to the engine 4 Loosely install NEW engine to transmiss...

Page 354: ...stance 7 Torque the upper transmission to engine mount fastener first then torque the lower fastener TORQUE Mounting Fasteners 45 ft lbs 61 Nm 8 Torque the two fasteners securing the transmission moun...

Page 355: ...plywood under the engine 13 Connect all connectors at the transmission Refer to Transmission Harness in Engine Harness Routing page 4 3 14 Install the transmission vent line Refer to Transmission Vent...

Page 356: ...sector cover bolts t and remove the cover 5 Remove detent spring detent pawl and detent star Note the master spline on the detent star and the shift shaft 6 Remove the two sector gears NOTICE Note the...

Page 357: ...dler shaft assembly k 13 Remove the four screws retaining the pinion shaft plate l NOTICE One screw is longer 1 and than the others and must be put back in the correct location 14 Remove the pinion sh...

Page 358: ...Remove the Reverse High shift dog 3 Remove the snap ring washer needle bearing and reverse gear from the reverse shaft 4 If necessary disassemble the other end of the reverse shaft Remove the bearing...

Page 359: ...pped with Turf Mode have three traction operational modes Differential Lock in 2WD 4WD and Differential Unlock in Turf mode Differential lock is beneficial in low traction and rough terrain conditions...

Page 360: ...4WD power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift fork back into place and mates the engagement dog to the side gear that is par...

Page 361: ...Gear Assembly w Male Side Gear Assembly e Planet Gear Assembly r Female Gear Assembly t Differential Cover Assembly y Planetary Differential Assembly Fasteners u Engagement Dog i Bearing o Shift Fork...

Page 362: ...differential carrier and ring gear q prior to disassembly 2 Remove eight fasteners w retaining the ring gear 3 Remove ring gear e thrust washer r and output gear t 4 Remove dowel pin from the differen...

Page 363: ...3 Place the pinion gears e into the carrier and slide the differential pin r into the carrier NOTICE Align the hole of the differential pin with the dowel pin hole in the carrier 4 Insert the dowel p...

Page 364: ...7 28 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 6 Install eight fasteners i securing ring gear TORQUE Ring Gear Fasteners 28 ft lbs 38 Nm TRANSMISSION...

Page 365: ...al Copyright Polaris Inc 7 29 GEAR SHAFT BEARING INSPECTION Inspect all of the gears shafts and bearings shown for excessive wear or damage IMPORTANT If gear replacement is required also replace the c...

Page 366: ...h to the shoulder install the washer and new retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly NO...

Page 367: ...ew k out at this point NOTICE DO NOT install the longer screw k Installing the longer screw will lock the snorkel tube and not allow for backlash setting adjustment 10 Torque the bearing cover retaini...

Page 368: ...crew 9 ft lbs 12 Nm TRANSMISSION ASSEMBLY NOTICE The snorkel shaft and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after assembling the transmis...

Page 369: ...q Bearing w Engagement Dog e Retaining Ring r Washer t Low Gear 67T y Needle Bearing u Reverse Shaft i Gear 48T o Engagement Dog a Gear 49T s Bearing d Washer f Bearing g Chain h Input Shaft j Bearin...

Page 370: ...ngagement dogs Install the assembly into the transmission housing all at the same time NOTICE Shift fork pins should be offset towards the input shaft as shown above 7 Inspect the shift drum for any d...

Page 371: ...ack into it s free state If the torsion spring is left out or installed incorrectly the shift into PARK may not engage completely ITEM DESCRIPTION o Retaining Clip a Washer s Torsion Spring d Cam f Dr...

Page 372: ...er face of bore 14 Thoroughly clean the shift shaft housing IMPORTANT Make sure the transmission is in HIGH gear prior to reassembly 15 Install the sector gear 16T onto the shift drum shaft Install th...

Page 373: ...ble onto the cover and transmission case mating surface 21 Install the sector cover and align the transmission case dowel 2 with the alignment hole Install and torque the bolts to specification TORQUE...

Page 374: ......

Page 375: ...LS 8 19 FRONT GEARCASE ASSEMBLY VIEW 8 19 FRONT GEARCASE REMOVAL 8 20 FRONT GEARCASE DISASSEMBLY INSPECTION 8 21 FRONT GEARCASE ASSEMBLY 8 24 FRONT GEARCASE INSTALLATION 8 26 FRONT GEARCASE SERVICE 20...

Page 376: ...2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc DRIVE SHAFT SERVICE 8 53 DRIVE SHAFT CV JOINT HANDLING TIPS 8 53 OUTER CV JOINT BOOT REPLACEMENT 8 53 INNER PLUNGING JOINT BOOT REPLACEMENT 8...

Page 377: ...heels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest FINAL DRIVE SPECIFICATIONS 2020 PART DESCRIPTION SERVICE SPE...

Page 378: ...installation procedures IMPORTANT Both hubs use Belleville style washers All Belleville washers must be installed with the dome side facing out ALUMINUM HUB PN 5137431 IRON HUB PN 5142964 Casting ind...

Page 379: ...movement The tire should rotate smoothly without binding or rough spots NOTICE Side to side play could also indicate tie rod end wear and top to bottom play could also indicate upper or lower ball jo...

Page 380: ...retaining the tie rod end to the bearing carrier 9 Remove the upper ball joint pinch bolt 10 Remove the lower ball joint fastener 11 Using a soft faced hammer lightly tap the bearing carrier while rem...

Page 381: ...ing on outer edges so bearing can be removed 5 Inspect bearing carrier housing for scratches wear or damage Replace front bearing carrier if damaged INSTALLATION 1 Thoroughly clean the front bearing c...

Page 382: ...g carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install the lower ball joint fastener Torque to specification TORQUE Lower Ball Joint fastener 42 lb ft 57 Nm 4...

Page 383: ...OTICE If cone washers are used ensure that the washer is installed with the domed side facing out 9 Install the castle nut Torque to specification TORQUE Front Hub Castle Nut 80 lb ft 108 Nm 10 Instal...

Page 384: ...TORQUE Front Caliper Mounting Bolts 28 ft lbs 38 Nm 12 Install wheel and four wheel nuts Torque wheel nuts to specification TORQUE Wheel Nuts Steel 60 lb ft 81 Nm Wheel Nuts Cast Alum 120 lb ft 163 Nm...

Page 385: ...ront of the vehicle NOTICE If there is insufficient clearance to remove the propshaft loosen the steering rack nuts and allow the steering rack to shift for more clearance Refer to Steering Rack Remov...

Page 386: ...ice page 11 31 FRONT PROP SHAFT SERVICE CREW REMOVAL 1 Raise the vehicle off the ground WARNING Use care when lifting the vehicle Serious injury or death may occur if the vehicle tips or falls 2 Remov...

Page 387: ...fferential 7 Slide the propshaft off the rear splines and carefully guide the prop shaft out from the right front of the vehicle INSTALLATION 1 Carefully guide the prop shaft through the right front o...

Page 388: ...id plate Refer to Skid Plate Service page 11 35 6 Install the front bumper Refer to Front Bumper Service page 11 31 REAR PROP SHAFT SERVICE CREW REMOVAL 1 Remove the front prop shaft Refer to Front Pr...

Page 389: ...e Manual Copyright Polaris Inc 8 15 2 Install the two carrier fasteners q and torque to specification TORQUE Center Bearing Fasteners 40 ft lbs 54 Nm 3 Install the front prop shaft Refer to Front Prop...

Page 390: ...remove the retaining rings q from both sides of the yoke 2 Using a commercially available Ball Joint U Joint Press Set place a receiving cup adapter w with a larger ID than the U joint cap OD on one e...

Page 391: ...ves are clean before installing new U joint 3 Place U joint ends w without caps into yoke bores 4 Place caps e into yoke bores and align with U joint ends by hand 5 Place clamp and installer adapters...

Page 392: ...away from U joint into exposed groove 10 Place larger adapter u with ID larger than yoke bore on side with retaining ring 11 Tighten clamp until other cap is below retaining ring groove 12 Install sec...

Page 393: ...t Hose Fitting 2 Spring Wireform t Ball Bearing 2 H Clip Spring y Ball Bearing Double Row 2 Connector Assembly u Bushing 2 Nylon Spacer i Bushing 2 Torsion Spring Retainer o Oil Seal 2 Backlash Spacer...

Page 394: ...ning this service procedure 2 Remove the prop shaft pin at the front differential using special tool PN 2872608 3 Slide the propshaft off the front gearcase input shaft splines 4 Disconnect the AWD wi...

Page 395: ...l particles from the drain plug magnet 2 Remove the seven cover fastener q and remove the cover plate w assembly 3 Remove the LH output hub assembly e from the clutch housing or outer cover plate asse...

Page 396: ...inspect the ring gear roll pin and ensure that it is seated correctly 7 Remove the RH output hub assembly i from the gearcase housing 8 Remove pinion seal o internal retaining ring a and pinion gear...

Page 397: ...st slide up and down and in and out freely within the roll cage j sliding surfaces and H springs NOTICE Refer to the Electronic Parts Catalog for individual part availability Most parts are to be repl...

Page 398: ...nion shaft seal q into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub w into...

Page 399: ...ure plate u Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTICE Verify armature plate tabs are in...

Page 400: ...Install the seven cover plate screws s and torque to specification TORQUE Front Gearcase Cover Plate Screws 9 ft lbs 12 N m FRONT GEARCASE INSTALLATION 1 Install the gearcase between the left hand upp...

Page 401: ...t gearcase and drive a new prop shaft pin into the propshaft 6 Connect the AWD harness and tie the harness to the brake lines with a plastic tie strap 7 Add the proper lubricant to the front gearcase...

Page 402: ...Nm e Cover h Torsion Spring 2 Oil Seal r O Ring j Stud Dowel Pin 2 Isolation Bushing t Coil k Ring Gear 2 Gearcase Vent Hose Fitting y Backlash Spacer l Spacer 3 Bushing u Bearing 1 Bushing Outer 3 P...

Page 403: ...ure before beginning this service procedure 2 Remove the front bumper 3 Remove both front wheels 4 Remove both front brake caliper assemblies 5 Remove both tie rod ends from the bearing carriers 6 Rem...

Page 404: ...etach the front gearcase vent hose 11 Disconnect the AWD wire harness 12 Remove the upper front gearcase nut and bolt 13 Remove the lower front gearcase nut and bolt 14 Slide the propshaft off the spl...

Page 405: ...or damage replace if necessary NOTICE Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assembly or as a kit 1 Drain and properly dispose of ge...

Page 406: ...the top of the ring gear 6 Remove the ring gear and roll cage assembly from the gearcase housing With the ring gear removed inspect the ring gear dowel pin and ensure that it is seated correctly 7 Rem...

Page 407: ...nual Copyright Polaris Inc 8 33 10 Remove the internal retaining ring snap ring 11 Remove the pinion gear assembly from the gearcase housing 12 Inspect and clean the gearcase housing and replace any o...

Page 408: ...or chipped broken or missing teeth 2 Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting AWD COIL INSPECTION 1 Inspect the AWD coil q located in the outer cover...

Page 409: ...ken or missing teeth 4 Inspect the roll cage assembly t sliding surfaces and H springs y The sliding surfaces must be clean and free of nicks burrs or scratches If damaged replace the roll cage assemb...

Page 410: ...E Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assembly or as a kit 1 Replace all O rings seals and worn components 2 Install pinion shaft...

Page 411: ...rollers to prevent them from falling out of the roller cage NOTICE Install roll cage so that the ring gear grooves line up with the roll cage windows 9 Install the torsion spring r by wrapping each le...

Page 412: ...ly into the gearcase housing 14 Install a new O ring on the cover plate assembly NOTICE Be sure the square O ring is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 1...

Page 413: ...T GEARCASE INSTALLATION 1 Install the front gearcase through the opening in the front of the chassis Line up the propshaft with the splines on the front gearcase during installation 2 Loosely install...

Page 414: ...This will allow the lower control arms to be lowered creating clearance to remove the axles from the front gearcase 10 Install both front upper ball joint fasteners Torque to specification TORQUE Fro...

Page 415: ...ting Fastener 28 ft lbs 38 Nm 13 Install the front bumper 14 Install both front wheels Torque to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm 15 Add the proper lubricant to the front gearcase...

Page 416: ...TING The front gearcase vent line runs along the front passenger side frame It is secured along the front frame by four retention clips two horizontal and two vertical as shown The vent line ends its...

Page 417: ...is engaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 volt DC input which...

Page 418: ...1 volts DC should be present 3 If electrical tests are within specification remove gearcase see FRONT GEARCASE REMOVAL and inspect components 4 Inspect armature plate e for a consistent wear pattern T...

Page 419: ...inside of the ring gear for gouging rough spots 7 Inspect the roll cage o assembly for cracks or excessive wear If damaged replace the roll cage assembly 8 Inspect the rollersa for nicks and scratches...

Page 420: ...f the tire firmly and checking for movement 3 If movement is detected inspect wheel hub castle nut torque bearing condition and upper and lower ball joint wear REAR BEARING CARRIER REMOVAL 1 Place the...

Page 421: ...he bearing for smoothness and side to side movement replace as needed REAR BEARING CARRIER BEARING REPLACEMENT 1 Remove the retaining ring from the bearing carrier 2 From the back side using a press p...

Page 422: ...the bearing carrier housing NOTICE Use care to not allow any of the Loctite compound to get in the bearing 8 Wipe the housing clean of any excess compound and install the snap ring REAR BEARING CARRIE...

Page 423: ...180 ft lbs 245 N m 8 Install the cotter pin 9 Install the rear brake caliper and torque the mounting bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 10 Install the wheel washe...

Page 424: ...e cotter pin 5 Remove the castle nut 6 Remove the washer s NOTICE Image for reference only Each hub requires a different number of washers Refer to Rear Hub Identification page 8 4 to make sure that t...

Page 425: ...astener 10 Tilt the carrier down while removing the end of the driveshaft 11 With a short sharp jerk remove drive shaft from the transmission REAR DRIVE SHAFT INSTALLATION 1 Install a new spring ring...

Page 426: ...llet to tap on the outboard end of the drive shaft if necessary 3 Perform push pull test on the axle ensure the retaining ring is locked into the rear gearcase 4 Rotate the bearing carrier onto the dr...

Page 427: ...damage Make sure surface ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components T...

Page 428: ...expose each ball Severe pitting galling play between the ball and its cage window any cracking or damage to the cage pitting or galling or chips in raceways call for joint replacement NOTICE Shiny ar...

Page 429: ...g and shaft Make sure the boot is not dimpled or collapsed 18 Install and tighten the large clamp e using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 19 Wh...

Page 430: ...nging joint and slide the boot down the shaft 3 Clean the grease from the face of the joint and place the drive shaft in a soft jawed vise 4 Using a soft faced hammer or brass drift strike the inner r...

Page 431: ...d in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the...

Page 432: ...a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot 21 Position the boot lip in its groo...

Page 433: ...NG UNIT INSTALLATION 9 10 STEERING INSPECTION 9 11 TIE ROD END WHEEL HUB INSPECTION 9 12 WHEEL TOE MEASUREMENT 9 12 WHEEL TOE ADJUSTMENT 9 13 FRONT A ARM SERVICE 9 14 FRONT LOWER A ARM REMOVAL INSTALL...

Page 434: ...s destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation IMPORTANT New ball joint bolts have a pre applied locking agent which...

Page 435: ...r NA j Steering Adjustment Shock Assembly Bolt NA t Steering Gear Box Asm NA k Steering Adjustment Shock Assembly Nut 7 ft lbs 10 Nm y Tilt Steering Asm NA l Steering Rack Mount Nuts 40 ft lbs 54 Nm u...

Page 436: ...1 25 44 ft lbs 60 N m r A Arm Assembly NA t Shaft Pivot NA y Bushing NA u O Ring NA i Pivot Cap NA o Washer NA a A Arm Fastener M10 x 1 25 x 95 44 ft lbs 60 N m s Rivet NA d Lower Ball Joint Snap Rin...

Page 437: ...DESCRIPTION TORQUE l Upper Ball Joint Snap Ring NA 1 Upper Ball Joint 2 Lower Shock Mounting Fastener M10 x 1 25 x 60 40 ft lbs 54 Nm 2 Lower Shock Mounting Nut M10 x 1 25 40 ft lbs 54 Nm 2 Shock Asse...

Page 438: ...y Washer NA u Pivot Cap NA i A Arm Fastening Nut M10 x 1 25 NA o Upper A Arm Mounting Fastener M10 x 1 25 x 115 44 ft lbs 60 N m a Lower A Arm Fastener M12 x 1 5 x 170 30 ft lbs 40 N m 180 s Lower A A...

Page 439: ...the upper steering shaft w to the power steering unit 3 Remove the steering tilt assembly fasteners 4 Remove the fastener retaining the upper steering shaft to the power steering unit 5 Remove the st...

Page 440: ...e steering rack to the frame 4 Remove Steering Rack from vehicle STEERING RACK INSTALLATION 1 Lay the old and new steering racks next to each other on a clean surface Measure the old steering rack len...

Page 441: ...the Steering Rack Removal page 9 8 procedure 2 Remove the steering wheel cap and retaining nut 3 Press steering shaft out of the steering wheel and pivot tube 4 Note the order and location of the spac...

Page 442: ...to specification TORQUE Steering Wheel Nut 65 ft lbs 88 Nm 13 Wipe the pivot tube clean of any excess Loctite 14 Install steering wheel cap and field test steering operation POWER STEERING UNIT INSTA...

Page 443: ...sure to reconnect the instrument cluster both 12V outlets and all the switches 12 Turn the key switch on and test EPS operation STEERING INSPECTION Steering system components should be checked period...

Page 444: ...rear Try to move the wheel and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub...

Page 445: ...distance between vehicle center and each wheel This will indicate which tie rod needs adjusting IMPORTANT Ensure the steering wheel is straight before determining which tie rod needs adjustment Measur...

Page 446: ...Examine A arm bushings and pivot tube Replace if worn Discard hardware 6 If not replacing the A arm thoroughly clean the A arm and pivot tube 7 Install new ball joint into A arm Refer to Ball Joint S...

Page 447: ...Arm while using the punch and hammer 2 Install new Pivot Cap q Bushings w and Pivot Shaft e into new A arm A light press force may be needed FRONT UPPER A ARM REMOVAL INSTALLATION 1 Elevate and safely...

Page 448: ...8 If not replacing the A arm thoroughly clean the A arm and pivot tube 9 Install new ball joint into A arm Refer to Ball Joint Service section 10 Insert new A arm bushings and pivot tube into new A ar...

Page 449: ...ce the upper ball joint 3 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc Refer to FRONT BRAKE CALIPER REMOVAL procedure 4 Remove and discard t...

Page 450: ...NEW ball joint into the A arm 2 Position the Installation Adapter w over the face of the ball joint NOTICE Image for reference only 3 Position the Spacer q over the shaft of the ball joint so it is ag...

Page 451: ...new pinch bolts and nuts Torque to specification 9 If needed install new brake caliper mounting bolts and torque to specification IMPORTANT New bolts have a pre applied locking agent which is destroy...

Page 452: ...ut q from the lower portion of the stabilizer bar link 4 Remove the four wheel nuts and remove the wheel 5 Remove the fastener w retaining the lower portion of the rear shock to the lower A arm 6 Remo...

Page 453: ...lbs 110 N m 2 Attach the upper A arm to the bearing carrier Torque new fastener to specification TORQUE Rear Upper A Arm to Bearing Carrier Fastener 44 ft lbs 60 N m 3 Attach the lower portion of the...

Page 454: ...arm A light press force may be needed REAR LOWER A ARM REMOVAL 1 Properly lift and support the vehicle by the frame 2 Remove the four nuts retaining the rear stabilizer bar to the frame 3 Remove the n...

Page 455: ...er Bar Fasteners 17 lb ft 23 Nm 6 Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm WARNING Upon A arm installation completion test vehicle at low speeds bef...

Page 456: ...il lubricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and sh...

Page 457: ...k mounting point is NOT PERMITTED 3 Seat Models Front Shock Inboard Mount Rear Shock Inboard Mount Crew Models Front Shock Inboard Mount Rear Shock Outboard Mount REMOVAL 1 Elevate the vehicle and rel...

Page 458: ...shock and note the spring preload cam setting 2 Using spring compressor compress the shock spring far enough to remove spring retainer Spring Compressor 2870623 3 Remove the spring and adjusting cam f...

Page 459: ...PAD INSPECTION 10 14 FRONT BRAKE PAD INSTALLATION 10 15 BRAKE BURNISHING PROCEDURE 10 16 FRONT CALIPER SERVICE 10 17 FRONT CALIPER ASSEMBLY VIEW 10 17 FRONT CALIPER REMOVAL 10 18 FRONT CALIPER DISASSE...

Page 460: ...loses a small opening compensating port within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake caliper...

Page 461: ...nt Brake Disc Runout 0 010 0 254 mm Front Caliper Piston Bore I D 1 373 34 87 mm 1 375 34 93 mm Front Caliper Piston O D 1 370 34 80 mm 1 368 34 75 mm REAR BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Rea...

Page 462: ...SYSTEM ASSEMBLY VIEW REF DESCRIPTION q CALIPER BRAKE FRONT RH w LINE BRAKE FRONT RH e LINE BRAKE REAR MIDDLE r LINE BRAKE REAR RH t CALIPER BRAKE REAR RH y CALIPER BRAKE REAR LH u LINE BRAKE REAR LH i...

Page 463: ...10 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 10 5 BRAKE LINE ROUTING FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER BRAKE SYSTEM...

Page 464: ...10 6 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS BRAKE SYSTEM...

Page 465: ...0 2021 RANGER 1000 Service Manual Copyright Polaris Inc 10 7 BRAKE LINE CLOCKING MASTER CYLINDER ITEM DESCRIPTION ANGLE q To Tee Block 30 2 5 w To Right Front Caliper 25 2 5 e To Left Front Caliper 15...

Page 466: ...10 8 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc FRONT BRAKE CALIPER MEASUREMENT MY19 Front Brake Line Clocking 42 5 2 5 BRAKE SYSTEM...

Page 467: ...10 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 10 9 REAR BRAKE CALIPER MEASUREMENT Rear Brake Line Clocking 20 0 2 5 BRAKE SYSTEM...

Page 468: ...l well area Clean reservoir cover thoroughly 2 Remove cover from reservoir NOTICE Inspect the bellows in the cap and reset to fully collapsed if necessary If any holes are found in the bellows replace...

Page 469: ...uid Level Between the MIN and MAX line CAUTION During the procedure maintain at least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 12 Tighten bleeder sc...

Page 470: ...ainer under the master cylinder brake lines CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 4 Loosen the brake line banjo bolt r an...

Page 471: ...g clip 6 Follow the Brake Fluid Replacement Brake Bleeding page 10 10 procedure 7 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes BRAKE PE...

Page 472: ...oving caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads instal...

Page 473: ...bracket and make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use...

Page 474: ...Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of n...

Page 475: ...Inc 10 17 FRONT CALIPER SERVICE FRONT CALIPER ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q Brake Pad Assembly y Brake Piston w Caliper Mount Assembly u Ring e Brake Caliper i Bolt r Pin...

Page 476: ...TION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removi...

Page 477: ...e a commercially available caliper piston pliers to extract the pistons from the caliper CAUTION Do not remove the caliper pistons with a standard pliers The piston sealing surfaces will become damage...

Page 478: ...Service Limit 1 368 34 75 mm 3 Inspect brake disc and pads as outlined in this chapter FRONT CALIPER ASSEMBLY 1 Install new O rings in the caliper body Be sure the grooves are clean and free of resid...

Page 479: ...Brake Line Banjo Bolts 15 ft lbs 20 Nm 3 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Bleed the brake System Refer to Brake Fluid Replacement...

Page 480: ...rew 2 3 turns 3 Clean caliper area before removal 4 Remove caliper mounting bolts and lift caliper off of disc NOTICE When removing caliper be careful not to damage brake line Support caliper so as no...

Page 481: ...not use the pads Use only new clean pads 3 Install caliper and torque bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 4 Install the pad adjustment screw and turn until statio...

Page 482: ...olaris Inc REAR CALIPER SERVICE REAR CALIPER ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q Brake Pad Assembly y Brake Piston w Caliper Mount Assembly u Ring e Brake Caliper i Bolt r Pin Se...

Page 483: ...Clean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removing the brake line Use a wrench to remove the brake line banjo bolt q 5 If necessary loosen brak...

Page 484: ...ecome damaged if a standard pliers is used 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTICE Be sure to clean caliper body seal grooves REAR CALIPER INSPECTION...

Page 485: ...ads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease REAR CALIPER INSTALLATION 1 Install the rear caliper and torque the mounting bolts to specifi...

Page 486: ...is recommended Refer to Brake Burnishing Procedure page 10 23 BRAKE DISC SERVICE BRAKE DISK INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches ar...

Page 487: ...icle and material of the hub Record the number of washers and hub material during removal to make sure that the correct installation procedure is used NOTICE If replacing a rear brake disc refer to Re...

Page 488: ...ing serviced NOTICE If replacing a rear brake disc refer to Rear Hub Identification page 8 4 to make sure that the correct washer and washer quantity is used 6 Reinstall the applicable brake caliper R...

Page 489: ...ME SERVICE 11 19 WINDSHIELD SERVICE 11 19 TIP OUT WINDSHIELD SERVICE 11 20 TIP OUT WINDSHIELD ADJUSTMENT 11 21 ROOF SERVICE 11 22 HEADLINER SERVICE 11 25 HEADLINER SERVICE CREW 11 27 EXTERIOR BODY SER...

Page 490: ...GER 1000 Service Manual Copyright Polaris Inc SEAT BACK SERVICE 11 62 LOWER SEAT BASE REMOVAL 11 63 FLOOR PANEL SERVICE 11 63 ROOF REMOVAL INSTALLATION 11 64 REAR PANEL REMOVAL INSTALLATION 11 65 ACCE...

Page 491: ...ht Polaris Inc 11 3 GENERAL INFORMATION BODY FRAME SERVICE NOTES BODY FRAME WARNING Serious injury may result if machine tips or falls Be sure machine is secure before beginning any procedure that req...

Page 492: ...MBLY VIEWS CHASSIS ASSEMBLY VIEW REF DESCRIPTION TORQUE q Crossbar NA w Seat frame NA e Main Frame NA r Front A arm Bracket NA t Seat Frame Fastener M8 x 1 25 x 20 10 ft lbs 14 Nm y Engine Shield NA u...

Page 493: ...SEMBLY VIEW CREW REF DESCRIPTION TORQUE q Rear Cross Bar NA w Rear Seat Frame NA e Front Cross Bar NA r Front Seat Frame NA t Main Frame NA y Front A arm Bracket NA u Seat Frame Fastener M8 x 1 25 x 2...

Page 494: ...40 ft lbs 54 Nm y Rear Cab Frame Fastener 45 ft lbs 61 N m u Rear Cab Seat Belt Fastener Nut 45 ft lbs 61 N m i Bolster Lower Fastener 6 ft lbs 8 Nm o Passenger Bolster NA a Side Bezel Fastener 6 ft...

Page 495: ...RANGER 1000 Service Manual Copyright Polaris Inc 11 7 REF DESCRIPTION TORQUE l Bolster Handle Nut 6 ft lbs 8 Nm 1 Closeout Panel Fastener 42 in lbs 5 Nm 2 Heat Shield Fastener 42 in lbs 5 Nm 2 Heat Sh...

Page 496: ...M10X1 50X35 HX FL Y D NA y WED CAB FRAME REAR RH NA u NUT HEX M10X1 5 10 ZB3 NYL 36 ft lbs 54 N m i SCR HXFL M10X1 5X45 10 9 RIE NA o WELD CAB FRAME REAR LH NA a WELD CAB FRAME REAR M NA s SCR TXTH M6...

Page 497: ...REF DESCRIPTION TORQUE l WELD CAB FRAME FRT LH NA 1 WELD BOLSTER FRONT RH M NA 2 SCR HXFLSH M12X1 75 M14X9 40 ft lbs 54 Nm 2 WASHER SEATBELT RUBBER NA 2 BOLT M8X1 25X20 HXFLG 10 ft lbs 14 Nm 2 NUT HXF...

Page 498: ...TORQUE q Upper Dash Panel NA w Center Console Trim NA e Push Rivet NA r Dash Bracket NA t Lower Dash Panel Fastener M6 x 1 0 x 20 6 ft lbs 8 Nm y Lower Storage Bin NA u Dash Fastener M6 x 1 0 x 25 42...

Page 499: ...SCRIPTION TORQUE q Left Front Fender NA w Left Front Fender Fare NA e Body Fastener M6 x 1 0 x 25 42 in lbs 5 Nm r Front Grill NA t Front Fascia NA y Hood NA u Push Rivet NA i Right Front Fender NA o...

Page 500: ...REF DESCRIPTION TORQUE q Upper Close Off Panel NA w Side Bezel NA e Seat Frame Panel NA r Bulkhead Fastener M6 x 1 0 x 25 42 in lbs 5 Nm t Push Rivet NA y Floor Screw 14 x 3 4 22 in lbs 2 5 Nm u Prop...

Page 501: ...ner M6 x 1 0 x 25 42 in lbs 5 Nm w Roof Fastener M6 x 1 0 x 40 42 in lbs 5 Nm e Rubber Washer NA r Washer NA t Spacer NA y Front Roof Seal NA u A Pillar Seal NA i Side Roof Seal NA o Rear Roof Seal NA...

Page 502: ...5 Nm w Roof Fastener M6 x 1 0 x 40 42 in lbs 5 Nm e Rubber Washer NA r Washer NA t Spacer NA y Front Roof Panel NA u Front Roof Seal NA i A Pillar Seal NA o Side Roof Seal NA a Roof Fastener 24 in lbs...

Page 503: ...R PANEL GLASS NA w SLEEVE NA e HANDLE REAR WINDSHIELD NA r SHIM NA t WINDSHIELD BASE NA y MOUNT REAR WINDSHIELD NA u SEAL REAR GLASS NA i REAR GLASS FASTENER Torque until lock and ride clamps are full...

Page 504: ...R TAILGATE PANEL NA e TAILGATE SUPPORT BRACKET NA r TAILGATE ROD LEFT AND RIGHT ROD t TAILGATE SUPPORT FASTENER 42 in lbs 5 Nm y TAILGATE LATCH NA u TAILGATE CAP NA i TAILGATE LOWER PANEL FASTENER 42...

Page 505: ...in lbs 1 Nm r INNER CARGO BOX FASTENER 42 in lbs 5 Nm t OUTER CARGO BOX PANEL FASTENER 8 in lbs 1 Nm y CARGO BOX OUTER PANEL NA u LOWER TAILGATE SUPPORT FASTENER M8X1 25 10 ft lbs 14 Nm i TAILGATE SUP...

Page 506: ...in lbs 2 Nm e CARGO BOX LATCH BUSHING FASTENING NUT 13 ft lbs 18 Nm r CARGO BOX LATCH BUSHING NA t LATCH SPRING NA y CARGO BOX LATCH BUSHING FASTENER 13 ft lbs 18 Nm u HITCHPIN CLIP NA i CARGO BOX SHO...

Page 507: ...nectors w and set the trim panel with rear view mirror aside 3 Release the lock and ride connections e securing the windshield to the ROPS 4 With the aid of an assistant remove the windshield and set...

Page 508: ...UE Windshield Wiper Motor Trim Torque until fully seated TIP OUT WINDSHIELD SERVICE REMOVAL 1 Rotate the windshield lever on the dash to release the windshield 2 Remove the four fasteners q securing t...

Page 509: ...windshield adjustment Refer to Tip out Windshield Adjustment page 11 21 TIP OUT WINDSHIELD ADJUSTMENT 1 Rotate the windshield level counter clockwise to release the windshield 2 Loosen the four T40 To...

Page 510: ...specification TORQUE Tip out Windshield Hinge Fasteners 17 ft lbs 23 Nm 6 Rotate the windshield clockwise to secure to the vehicle ROOF SERVICE PRELIMINARY STEPS 1 If equipped remove the headliner Ref...

Page 511: ...disengage the front retainers r from the windshield plate 5 With the aid of an assistant lift the roof straight up to remove INSTALLATION 1 If necessary install the front windshield sealing tape on t...

Page 512: ...ear ROPS 7 Install the two front roof fasteners washers and spacers y Torque to specification TORQUE Roof Fasteners 42 in lbs 5 Nm 8 Install the four rear roof fasteners u and torque to specification...

Page 513: ...2 Remove the five push rivets securing both headliners to the windshield plate 3 Remove the rear headliner NOTICE If equipped removing the dome light may ease removal of the headliner This can also pr...

Page 514: ...behind the ROPS on both sides 2 Install the two T30 fasteners from the front headliner Torque to specification TORQUE 24 in lbs 3 N m 3 Install the rear headliner and tuck behind the ROPS on both side...

Page 515: ...OPS 2 Remove the two T25 fasteners and washers retaining the center of the headliner to the roof 3 Remove the four T40 Torx fasteners securing the rear headliner to the roof 4 Remove the three fastene...

Page 516: ...eadliner This can also prevent damage to the headliner and dome light 8 Remove the two T30 fasteners from the front headliner 9 Lower the front headliner INSTALLATION 1 Install the front headliner and...

Page 517: ...enter ROPS cross bar and center headliner will be under the rear headliner 6 Loosely install the two T25 fasteners and washers retaining the center of the headliner to the roof 7 Install the two rear...

Page 518: ...orque the four T40 Torx fasteners securing the rear headliner to the roof TORQUE T40 Rear Headliner Fasteners 42 in lbs 5 Nm 11 Torque the two T25 fasteners and washers retaining the center of the hea...

Page 519: ...er to the frame 2 Remove the two fasteners w retaining the top of the bumper to the frame 3 Carefully pull the bumper straight out to remove it from the vehicle INSTALLATION 1 Align the bumper mount t...

Page 520: ...s 30 ft lbs 41 Nm FRONT FENDER SERVICE UPPER FENDER REMOVAL 1 Remove the hood by turning each 1 4 turn fastener 90 degrees to unlock the hood Lift the hood straight up and out 2 Remove the three push...

Page 521: ...ips on the back of the fender are properly inserted or damage may occur to upper fender 2 Install the two push rivets q behind the front fascia 3 Install the three push rivets e Install the T 30 torx...

Page 522: ...2 Remove the four push rivets q 3 Remove the five T 40 torx fasteners w 4 Pull the lower fender straight out from vehicle to remove LOWER FENDER INSTALLATION 1 Install the lower fender straight on as...

Page 523: ...Polaris Inc 11 35 3 Install the four push rivets w 4 Reinstall the upper fender SKID PLATE SERVICE Remove the thirteen fasteners and washers q securing the skid plate to the vehicle and remove the sk...

Page 524: ...fastener w Repeat procedure on passenger side 3 Remove the two T 40 torx fasteners e 4 Disconnect the headlight connector Remove the three T 25 torx fasteners r Remove the headlight assembly 5 Pull th...

Page 525: ...nnect the headlight connector 3 Install the two T 40 torx fasteners w Torque to specification TORQUE Body Fasteners 42 in lbs 5 Nm 4 Install the three push rivets e and the T 40 torx fastener r Torque...

Page 526: ...intake cover to the side bezel 2 Carefully pry out the retainers w and remove the cover towards the front of the vehicle INSTALLATION 1 Install the intake cover and ensure the front retention clips e...

Page 527: ...lower bolster fastener 3 Remove the two upper bolster fasteners and remove the bolster 4 Remove the inside push rivet securing the side bezel to the rocker panel 5 Remove the two push rivets securing...

Page 528: ...ivot into the vehicle and align the push rivet holes 2 Carefully pull the intake duct retainers in to secure the intake duct 3 Install the two rear side bezel push rivets 4 Install the inside push riv...

Page 529: ...KER PANEL SERVICE REMOVAL 1 Remove the side bezel Refer to Side Bezel Cover Service page 11 38 2 Remove the push rivet q and seven fasteners w securing the rocker panel to the vehicle 3 Remove the pus...

Page 530: ...s CAUTION DRIVER S SIDE Use care when pivoting over the fuel filler neck to avoid dropping debris into the tank 2 DRIVER S SIDE ONLY Install the fuel cap 3 Install the rear rocker panel push rivet e a...

Page 531: ...ear Close Off Panel t to the ROPS assembly 6 Remove the Lower Rear Close Off Panel from the vehicle INSTALLATION 1 Install the Lower Rear Close Off Panel q Push in on the Rear Close Off Panel to help...

Page 532: ...850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 5 Install the 5 heat shield retaining fasteners t Torque the heat shield fasteners TORQUE Heat Shield Fasteners 42 in lbs 5 Nm BOD...

Page 533: ...de down on a clean flat surface 2 If available use the tab on the decal to remove the liner 3 Peel back the liner at 180 to the decal Use a clean finger lightly placed in the middle of the decal adhes...

Page 534: ...e Use a squeegee to continue to press the decal into place working from the center of the decal outwards CAUTION Squeegees should not be used on urocals and other domed adhesives to prevent damage to...

Page 535: ...same holds true for any oils or chemicals on the surface which may prevent achieving full adhesion If not properly cleaned the following issues may occur Poor adhesion resulting in the decal coming of...

Page 536: ...ss retainer w from the chassis 3 With the aid of an assistant remove the cotter pin e and pin r from the box shockt Remove the box shock from the cargo box CAUTION Cargo box can drop backwards after s...

Page 537: ...box hinges and torque to specification TORQUE Cargo Box Hinge Fasteners 5 ft lbs 7 Nm 3 With the aid of an assistant install the box shock t pin r and cotter pin e CAUTION Ensure the cargo box is pro...

Page 538: ...to the door assembly and remove the door handle 2 Remove the u clip securing the crank handle w and remove the crank handle 3 Remove the fastener e securing the door panel trim to the door assembly 4...

Page 539: ...rim panel i straight up and over the door handle to remove from the vehicle INSTALLATION 1 Install the lower trim panel i straight down over the door handle to install in the vehicle 2 Install the upp...

Page 540: ...ll and torque the fastener e to specification TORQUE Door Panel Trim Fastener 42 in lbs 5 Nm 6 Install the crank handle and u clip to secure the crank handle w to the door 7 Install the door handle an...

Page 541: ...d four fasteners q to secure the latch Torque to specification TORQUE Door Latch Fasteners 8 ft lbs 11 Nm 2 Install the door panel WINDOW REGULATOR DOOR GLASS SERVICE REMOVAL 1 Remove the door panels...

Page 542: ...the fasteners securing the glass to the regulator to service the glass or regulator INSTALLATION 1 Install the glass in the window regulator and tighten the fasteners TORQUE Window Glass Fasteners To...

Page 543: ...rs e to secure the bracket Torque the fasteners to specification TORQUE Window Regulator Support Fastener 6 ft lbs 8 Nm 6 Reconnect the speaker and window harness from the regulator support 7 Install...

Page 544: ...21 RANGER 1000 Service Manual Copyright Polaris Inc DOOR REMOVAL INSTALLATION 1 Open the door and lift straight off the hinge 2 Reinstall by gently installing the door over both hinges Ensure proper d...

Page 545: ...ce page 12 23 3 Remove the two push rivets on the upper dash panel below the instrument cluster 4 Open the glovebox and remove the two push rivets inside 5 Remove the two center trim push rivets secur...

Page 546: ...el INSTALLATION 1 Install the dash panel and seven push rivets q 2 WINTER PREP MODELS Install the six upper dash panel ducts and secure to the ducting hoses before securing the dash panel 3 Install th...

Page 547: ...nders Refer to Front Fender Service page 11 32 LOWER DASH PANEL SERVICE REMOVAL 1 Remove the upper dash panel Refer to Upper Dash Panel Service page 11 57 2 Remove the two push rivets securing the cen...

Page 548: ...ound the steering column to remove 7 WINTER PREP MODELS Cut the zip ties securing the two lower dash panel ducts before removing the dash panel INSTALLATION 1 Install the lower dash panel and four low...

Page 549: ...trim panel and torque to specification TORQUE Dash Fasteners 42 in lbs 5 Nm 5 Install the center trim panel and engage the upper retainers Plug in all electrical connectors and rotate to align the low...

Page 550: ...NOTICE Center seat belt will need to be fully extended to gain clearance to remove the seat back INSTALLATION 1 Slide seatback from the drivers side towards the passenger side and line up with mountin...

Page 551: ...vertically lift the seat up to remove the seat tabs from the slots on the frame FLOOR PANEL SERVICE PROPSHAFT TUNNEL Remove the six push rivets to remove the propshaft tunnel FLOOR PANEL 1 Remove the...

Page 552: ...er 42 in lbs 5 Nm ROOF REMOVAL INSTALLATION 1 Remove the clips q and fasteners w holding the headliner to the roof 2 If equipped remove the two fasteners e holding the overhead light to the headliner...

Page 553: ...locked position 2 Rotate the top of the rear window slightly away from the vehicle then lift the windshield up and away from the vehicle NOTICE Store windshield in an upright position in a location wh...

Page 554: ...11 66 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc ACCESSORY SERVICE Refer to accessory kit instructions for accessory removal and installation BODY FRAME...

Page 555: ...RCUIT SERVICE 12 19 AWD 2WD TURF SWITCH 12 19 OPERATION OVERVIEW 12 19 DIAGNOSING SYSTEM FAILURES 12 19 VEHICLE SPEED SENSOR SERVICE 12 20 SPEED SENSOR LOCATION 12 20 SPEED SENSOR TESTING 12 21 REAR D...

Page 556: ...BATTERY 12 37 LEAD ACID LOW MAINTENANCE BATTERY CHARGING AND TESTING 12 37 LEAD ACID LOW MAINTENANCE BATTERY MAINTENANCE 12 37 AGM LOW MAINTENANCE BATTERY 12 38 AGM LOW MAINTENANCE BATTERY CHARGING 12...

Page 557: ...Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical problems Readings obtained with ot...

Page 558: ...e Mode Switch Work 1600 AWD Hub Coil Resistance 24 5 Current Draw Key Off Max 01 DCA 10 mA Stator Output 660 900 Factory Choice Watts 3000 RPM Stator Leg to Leg Resistance Less than 1 Stator Leg to Gr...

Page 559: ...ower In 14 Power Out Spare 30A Fuse 3 Power In 9 Power Out Spare 20A Fuse 4 Power In 10 Power Out BLANK 5 BLANK 11 Heater 20A Fuse 6 Power In 12 Power Out BLANK 19 BLANK 20 Spare 15A Fuse 15 Power In...

Page 560: ...nd Play 10A Fuse 39 Power In 45 Power Out Fuel Pump 15A Fuse 40 Power In 46 Power Out Fuel Pump Relay 41 Coil High 42 Power In 47 Power Out 48 Coil Low BLANK 49 BLANK 50 Drive 15A Fuse 51 Power In 57...

Page 561: ...nd Orange 12 Vdc power input from key switch to enable relay White Provides 12 Vdc power for lights drive and accessory circuits ACCESSORY RELAY provides power to the following systems Accessories 12V...

Page 562: ...e Provides 12 Vdc power for fuel pump operation EPS RELAY OPT provides power to the following system Electronic Power Steering Unit EPS RELAY OPT COLOR FUNCTION Red 30 Amp fuse protected 12 Vdc consta...

Page 563: ...E Engine harness routing is located in the Engine Electrical Chapter Refer to Engine Harness Routing page 4 3 FRONT UPPER VEHICLE ROUTING REF DESCRIPTION q Terminal Block w Terminal Block Connector e...

Page 564: ...REF DESCRIPTION q Tree Clip Into Vehicle Frame w Vehicle Ground e Cooling Fan Connector r AWD Hub Coil Connector t Brake Pressure Switch Connector y Voltage Regulator Connector AC u Voltage Regulator...

Page 565: ...s Inc 12 11 LEFT DASH ROUTING REF DESCRIPTION q Tree Clip Into Dash Brackets w EPS Signal Connector e EPS Power Connector r Retention Clip Into Dash Bracket t Ignition Switch Connector y Headlight Swi...

Page 566: ...N q Tree Clip Into Bulkhead w Pedal Position Sensor Connector e Winch Connector r In Line Rear Accessory Switch Connector t Box Lift Harness Connector y Temperature Control Connector u 12V Receptacle...

Page 567: ...RANGER 1000 Service Manual Copyright Polaris Inc 12 13 FLOOR TUNNEL ROUTING REF DESCRIPTION q Seat Belt Switch Connector w Tree Clip Into Trim Panel e Harness Guide Tunnel r Harness Retention Covers...

Page 568: ...r Tree Clip Zip Tie Into Fuel Tank Flange t Cable Holder Fuel Pump Connector to Fuel Line y Fuel Pump Connector u Retention Cap Tree Into Seat Frame i Diagnostic Connector o Cooling Fan 20A Circuit Br...

Page 569: ...X ROUTING REF DESCRIPTION q Right Tail Light Connector w Left Tail Light Connector e Retention Clip Into Cargo Box Frame r Retention Clip Into Bottom of Cargo Box t Retention Clip Tree Into Vehicle Fr...

Page 570: ...ss Routing CHASSIS HARNESS INSTALLATION 1 Install the harness in the vehicle Refer to Chassis Harness Routing 2 Install the lower steering shaft and unbolt the EPS unit from the frame Refer to Steerin...

Page 571: ...ing on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs OFF ON START If any of the tests fail replace ignition switch assembly Turn the ignition key to ON There should be c...

Page 572: ...terlock switch to prevent the vehicle from exceeding 15 MPH 24 KPH unless the driver seat belt is secured in the seat belt lock The switch is powered by the EFI Relay sending a signal to the ECU NOTIC...

Page 573: ...the circuit repair and recheck operation 6 If the concern is still present it is possible that there may be a concern with the ECU ALL WHEEL DRIVE CIRCUIT SERVICE AWD 2WD TURF SWITCH 1 Disconnect the...

Page 574: ...nectors connector pins and grounds are undamaged clean and connected properly 4 Verify continuity of wire connections with a volt ohm meter NOTICE Verify all wires and wiring connections have been tes...

Page 575: ...th an engagement dog which locks and unlocks the rear differential DIFFERENTIAL SOLENOID CIRCUIT OPERATION The Rear Diff Solenoid Relay is attached to the rear portion of the main frame and can be acc...

Page 576: ...OLENOID REPLACEMENT 1 Disconnect the wire harness from the solenoid 2 Remove the nut q holding the solenoid to the transmission 3 To install reverse the removal procedure Torque the solenoid fastener...

Page 577: ...h 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 INSTRUMENT CLUSTER SERVICE 1 Carefully pry the instrument cluster out of the upper dash panel an...

Page 578: ...work surface to remove the bearing from the housing A blind bearing puller can also be used Replace bearing if removed STATOR SERVICE REMOVAL 1 Disconnect the battery Refer to Battery Service page 2...

Page 579: ...h the mounting holes 2 Attach the harness grommet w to the cover and install the three stator fasteners q Torque to specification TORQUE Stator Fasteners 9 ft lbs 12 Nm 3 Install the stator cover and...

Page 580: ...cing the regulator rectifier remove the two retaining screws and disconnect the wire harness Remove the regulator and heat sink plate from the vehicle 6 Reverse this procedure to install the new regul...

Page 581: ...12 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 12 27 CHASSIS BODY ELECTRICAL...

Page 582: ...the engine With the engine running at idle observe meter readings 4 Increase engine RPM while observing ammeter and tachometer 5 Note RPM at which the battery starts to charge ammeter indication is po...

Page 583: ...alternator current output reading should be approximately 18 VAC at 1300 RPM between each leg NOTICE If one or more of the stator leg output AC voltage varies significantly from the specified value t...

Page 584: ...lush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes and get prom...

Page 585: ...rvicing and upkeep of the battery is very important for maintaining long battery life The types of batteries are Lead Acid Conventional Dry Shipped Absorbed Glass Mat AGM Lead Acid Low Maintenance AGM...

Page 586: ...onventional battery do the following 1 Remove sealing cap from the vent elbow Remove cap plugs WARNING NEVER put the sealing cap back onto the battery The gas pressure can cause the battery to rupture...

Page 587: ...o 60 days If the battery is stored or used in a partially charged condition hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery IMPORTANT NEVER add e...

Page 588: ...ler ports on the battery 6 Press down evenly to break the foil seals and allow electrolyte to flow into the battery NOTICE Air bubbles will begin to rise indicating the flow of electrolytes 7 Leave th...

Page 589: ...Absorbent Glass Mat AGM batteries The charger can be ordered through your normal parts channel BatteryMINDer 2012 AGM 2 AMP battery charger 2830438 Nominal voltage is 12 8 Volts when fully charged If...

Page 590: ...yte or distilled water to the battery once the battery is in service If you do not drive the vehicle for more than TWO weeks maintain the Absorbent Glass Mat AGM battery with the BatteryMINDer 2012 AG...

Page 591: ...lled acid during charging see Battery Removal 2 Charge the battery with a charging output no larger than 10 of the battery s amp hour rating Charge as needed to raise the specific gravity to 1 270 or...

Page 592: ...AGM BATTERY CHARGING LOW CHARGE The nominal voltage for an AGM battery is 12 8 Volts when fully charged The battery will self discharge when disconnected from a vehicle and will discharge at a faster...

Page 593: ...teries to full capacity Listed in the table below are the approximate charging times for deeply discharged batteries Always use the recommended automatic battery charger and wait for the charger to co...

Page 594: ...he battery from the vehicle and store the battery in a cool dry location Continue to maintain the battery with the BatteryMINDer 2012 AGM 2 AMP charger and inspect the battery every 60 days BATTERY TE...

Page 595: ...ERY LOAD TEST NOTICE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indic...

Page 596: ...reading at 40 F BATTERY CHARGING PROCEDURE If battery voltage is 12 6 Vdc or less the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for...

Page 597: ...ate for up to five minutes After the five minutes you will need to cycle the key switch and restart the engine to regain power steering operation NOTICE To conserve battery power the EPS unit will shu...

Page 598: ...between the 3 sets of outputs HIGH LOW OFF If any of the tests fail replace headlamp switch assembly Move the switch to HIGH There should be continuity between switch pins 2 and 4 7 and 8 Move the swi...

Page 599: ...light switch to the LOW position 4 The most intense part of the LOW beam headlight beam should be aimed 7 5 in 19 0 cm q below the mark placed on the wall NOTICE Rider weight must be included in the s...

Page 600: ...12 46 9850045 R01 2020 2021 RANGER 1000 Service Manual Copyright Polaris Inc 7 Tighten Headlight adjustment screws q TORQUE Headlight Fasteners 5 ft lbs 7 Nm CHASSIS BODY ELECTRICAL...

Page 601: ...ht bulb and install the hood HEADLIGHT HOUSING SERVICE REMOVAL 1 Remove the hood from the front cab 2 Remove the front fenders See Front Fender Service page 11 32 3 Disconnect the harness from the bul...

Page 602: ...mp from the rear cargo box and disconnect the tail light brake light wire harness NOTICE Before replacing the LED lamp assembly use a digital multi meter to test the harness to ensure the lamp is rece...

Page 603: ...14 Body Component Service 11 22 Standard Door Panel Service 11 50 Cab Component Service Headliner Service 11 25 Headliner Service CREW 11 27 Tip out Windshield Adjustment 11 21 Tip out Windshield Serv...

Page 604: ...Even Test 12 28 Regulator Rectifier Operation 12 26 Stator Tests 12 28 Testing Flow Chart 12 26 Charging System Service Stator Inspection 12 24 Chassis Harness Routing Below Seat Routing 12 14 Cargo...

Page 605: ...llation 12 16 Chassis Harness Removal 12 16 Electrical Maintenance Chassis Engine Electrical Ground 2 64 Throttle Pedal Inspection 2 64 Electronic Power Steering EPS Operation 12 43 Troubleshooting EP...

Page 606: ...ing Carrier Installation 8 8 Front Bearing Carrier Removal Inspection 8 5 Front Gearcase Assembly 8 24 8 36 Front Gearcase Assembly View 8 19 8 28 Front Gearcase Disassembly 8 31 Front Gearcase Disass...

Page 607: ...Inspection Pre Ride 2 7 Installation Drive Clutch 6 10 Instrument Cluster Pinouts 12 23 Instrument Cluster Service Installation 12 23 Intake Maintenance Air Filter Service 2 39 Intake Service Intake D...

Page 608: ...e Differential Solenoid Service Differential Solenoid Replacement 12 22 Rear Drive Shaft Installation 8 51 Removal 8 50 Rear Panel Assembly View 11 15 Removal Installation 11 65 Rear Prop Shaft Servic...

Page 609: ...lacement 9 26 Suspension Assembly View Front Suspension 9 4 Suspension Assembly Views Rear Suspension 9 6 Suspension Inspection 2 57 Suspension Maintenance Spring Pre Load Adjustment 2 57 Switch AWD 2...

Page 610: ...Lash Tappet Selection 3 7 Valve Clearance Tappet Selection 3 7 Vehicle Harness Service Chassis Harness Routing 12 9 Vehicle Information VIN Number 1 18 Vent Line Termination Fitting 5 9 Vent Line Rout...

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Summary of Contents for RANGER 1000 2020

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Polaris RANGER 1000 2020, Service Manual, Page: 459 / 610

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Summary of Contents for RANGER 1000 2020

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