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Polaris RANGER CREW 900 2014, Manual

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9

9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual
© Copyright Polaris Sales Inc.

9.1

BRAKES

CHAPTER 9

BRAKES

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

BRAKE SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

FOOT BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13

PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13

PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14

PAD ASSEMBLY / INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15

FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16

CALIPER EXPLODED VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16

CALIPER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16

CALIPER DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17

CALIPER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18

CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19

CALIPER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19

FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21

DISC RUNOUT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21

DISC INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21

DISC REMOVAL / REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23

PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23

PAD INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23

PAD INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24

REAR CALIPER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25

CALIPER EXPLODED VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25

CALIPER EXPLODED VIEW RANGER CREW 900

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.26

CALIPER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27

CALIPER DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27

Summary of Contents for RANGER CREW 900 2014

Page 1: ...aler for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authori...

Page 2: ...arifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUA...

Page 3: ...Manual Chapter Summary CHAPTER 1 GENERAL INFORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM GENERAL CHAPTER 5 BODY STEERING SUSPENSION CHAPTER 6 CLUTCHING CHAPTER 7 FINAL DRIVE C...

Page 4: ...HICLE INFORMATION 1 4 PUBLICATION NUMBERS 1 4 REPLACEMENT KEYS 1 4 SPECIAL TOOLS 1 5 GENERAL SPECIFICATIONS 1 6 GENERAL SPECIFICATIONS 2013 2014 RANGER XP 900 EPS 1 6 DETAILED SPECIFICATIONS 2013 2014...

Page 5: ...it VIN and are used in digits 4 8 respectively 9th digit will be used on color featured versions of models not including the base First 3 digits and 9th digit are used in model number only They are no...

Page 6: ...vehicle identification number VIN and the engine model number and serial number VEHICLE IDENTIFICATION NUMBER VIN The VIN can be found stamped on a portion of the upper left frame rail above the airbo...

Page 7: ...24546 9924547 2014 RANGER CREW 900 R14WH88AA AAC AR ARC 9924548 9924549 2014 RANGER CREW 900 EPS R14WH9EAC ACC AM AMC AS ASC 9924548 9924549 CA California 50 State Models NOTE When ordering service pa...

Page 8: ...the tools listed or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product...

Page 9: ...Length 116 in 295 cm Width cargo box 60 in 152 4 cm Width tires 58 in 147 3 cm Height 76 in 193 cm Wheel Base 81 in 205 7 cm Ground Clearance 12 in 30 5 cm Turning Radius 161 in 409 cm Dry Weight 1360...

Page 10: ...Pump EPS OPT Rear Diff Solenoid Circuit Breaker Fan Motor 20 Amp Fuses Not in Fuse Relay Box Brake Lights 10 Amp Drive 10 Amp Fuel Pump 10 Amp Accessory 20 Amp ECM 20 Amp Lights 20 Amp EPS OPT 30 Amp...

Page 11: ...res 58 in 147 3 cm Height 76 in 193 cm Wheel Base 113 in 287 cm Ground Clearance 12 in 30 5 cm Turning Radius 214 in 543 5cm Dry Weight 1570 lbs 712 kg Cargo Box Capacity 49 State 1000 lbs 454 kg 50 S...

Page 12: ...ump EPS OPT Rear Diff Solenoid Circuit Breaker Fan Motor 20 Amp Fuses Not in Fuse Relay Box Brake Lights 10 Amp Drive 10 Amp Fuel Pump 10 Amp Accessory 20 Amp ECM 20 Amp Lights 20 Amp EPS OPT 30 Amp D...

Page 13: ...2754 Wht Org 7043924 Blk Red Wht 3235317 2014 All Models Except R14UH9EAB w EBS and CREW Models 0 1500 Meters 0 5000 Feet 27 89 5138015 Wht Blu 7044111 7044021 1500 3700 Meters 5000 12000 Feet 27 83 5...

Page 14: ...x 0 03937 inch inch x 2 54 cm mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 oun...

Page 15: ...40 50 69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 METRIC BOLT TORQUE SPECIFICATION BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LB NM DRY THREADS M3 0...

Page 16: ...1 11 32 12 24 17 1 1 2 12 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2...

Page 17: ...0 375 25 64 0 3906 10 mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14...

Page 18: ...NUTS BOLTS AND FASTENERS 2 12 SHIFT CABLE INSPECTION ADJUSTMENT 2 12 FUEL SYSTEM AND AIR INTAKE 2 14 FUEL SYSTEM WARNING 2 14 FUEL PUMP FUEL FILTERS 2 14 FUEL LINES 2 14 VENT LINE 2 15 ENGINE INTAKE P...

Page 19: ...SURE 2 32 ELECTRICAL AND IGNITION SYSTEM 2 33 BATTERY MAINTENANCE 2 33 BATTERY CHARGING OFF SEASON STORAGE 2 33 BATTERY REMOVAL 2 33 BATTERY INSTALLATION 2 33 CHASSIS ENGINE ELECTRICAL GROUND 2 34 SPA...

Page 20: ...kcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer BREAK IN PERIOD The break in p...

Page 21: ...ights Daily Check operation Brake Pad Wear 10 H Monthly 100 160 Inspect periodically E Air Filter 25 H Monthly 200 320 Inspect replace as needed Battery 25 H Monthly 200 320 Check terminals clean test...

Page 22: ...Demand Drive Fluid 100 H 12 M 1000 1600 Change lubricant Transmission Lubricant AGL Gearcase Lubricant 100 H 12 M 1000 1600 Change lubricant E Fuel System 100 H 12 M 1000 1600 Check for leaks at fill...

Page 23: ...subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services MAINTENANCE QUICK REFERENCE III Item Lube Rec Method Frequency 1 Engine O...

Page 24: ...3 Brake Fluid Polaris DOT 4 Brake Fluid Maintain fluid level between MAX and MIN lines on the master cylinder reservoir Check level during pre ride inspection change fluid every two years 4 Front Gea...

Page 25: ...tabilizer bar bushing and on the propshaft yoke Apply grease until all traces of water have been purged out at each of these areas Item Method Recommended Lube Frequency A A arm Pivot Bushings Grease...

Page 26: ...2 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 2 9 2013 2014 RANGER XP 900 Lubrication Points MAINTENANCE...

Page 27: ...2 10 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 2014 RANGER CREW 900 Lubrication Points MAINTENANCE...

Page 28: ...rive Fluid Quart 2877923 Demand Drive Fluid 2 5 Gallon 2870465 Oil Pump for 1 Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 Count...

Page 29: ...ose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Drive Shaft Boots Inspect inner and outer boots for tea...

Page 30: ...E This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount Tighten the lower jam nut E...

Page 31: ...ge clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness ordeath in a short time Never drain the fuel when the en...

Page 32: ...red NOTE Be sure vent line is not kinked or pinched Throttle Pedal Inspection Inspect the throttle pedal E for free movement Be sure the throttle pedal returns normally when released Refer to Chapter...

Page 33: ...bottom cover D to access the air filter element 3 Remove the air filter element E NOTE Leave the front portion of the lower airbox cover in the hinges It is not necessary to remove the lower cover whe...

Page 34: ...2 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 2 17 ENGINE AIR INTAKE EXPLODED VIEW MAINTENANCE...

Page 35: ...d all the way into the dipstick tube to keep the depth of the dipstick consistent 7 Remove the dipstick and check the oil level 8 Add the recommended oil as necessary to bring the oil level within the...

Page 36: ...bricate the O ring on the new oil filter with a film of fresh engine oil Check to make sure the O ring is in good condition Install it to specification TORQUE Oil Filter Turn by hand until filter O ri...

Page 37: ...BREATHER HOSE INSPECTION The engine crankcase is equipped with a breather hose Inspect the breather hose for possible kinks or wear The hose is form fitted for proper fit Follow the breather hose A fr...

Page 38: ...e valve cover G Note the location and use of the grounding washer H for assembly NOTE Replace rubber isolators F upon assembly 6 The engine will need to be rotated 4 times to inspect all 8 valve clear...

Page 39: ...led incorrectly The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder 16 Install the outer clutch cover and 8 retaining screws see Chapter 6 Belt Insta...

Page 40: ...4880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 2 23 5 Reinstall the arrestor and torque the retaining screw to specification MAINTE...

Page 41: ...ssion Lubricant Level Check The fill plug is located on the rear portion of the transmission gearcase Access the fill plug at the rear of the vehicle Maintain lubricant level even with the bottom of t...

Page 42: ...vehicle is positioned on a level surface when checking or changing the fluid Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located...

Page 43: ...ring and torque to specification 11 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole FLUID CAPACITY Recommended Fro...

Page 44: ...using an antifreeze hydrometer A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight...

Page 45: ...the recommended pre mix coolant You may use a 50 50 or 60 40 mixture of antifreeze and distilled water as required for freeze protection in your area FLUID CAPACITY Recommended Anti Freeze Coolant Pol...

Page 46: ...eam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 3 Slowly remove the pressure cap to relieve any cooli...

Page 47: ...y it out before operating The PVT drain plug C is located at the bottom of the outer clutch cover Access the drain plug through the left rear wheel well 1 Using a flat blade screwdriver remove the PVT...

Page 48: ...required remove the wheel cap G cotter pin H and loosen the hub nut J slightly NOTE Limited Edition models with aluminum wheels require a thin wall socket to loosen or tighten the wheel nuts without...

Page 49: ...of nut goes into taper on wheel TIRE INSPECTION Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard siz...

Page 50: ...hen charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Batteries must be fully charged before use or battery life will be reduced...

Page 51: ...ched to the upper starter mounting bolt The other end of the engine ground cable is attached to the chassis ground terminal A 4 Inspect the engine ground terminals Be sure they are clean and tight SPA...

Page 52: ...gauge Adjust gap if necessary by carefully bending the side electrode 9 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used Rec...

Page 53: ...RNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician T...

Page 54: ...alignment The recommended vehicle toe tolerance is 1 8 to 3 16 3 2 to 4 8 mm toe out This means the front of the tire A is 1 8 to 3 16 3 2 to 4 8 mm wider than the measurement at the rear B MEASUREMEN...

Page 55: ...1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc After alignment is complete torque jam nuts to specification TORQUE Tie Rod Jam Nut 14 ft lbs...

Page 56: ...will only affect ride height as the weight transfer will not be changed Vehicle loads effect suspension spring pre load requirements Use Spanner Wrench PN 2871095 to adjust pre load as necessary to av...

Page 57: ...l should be between the MAX and MIN level lines 4 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 app...

Page 58: ...NG TRANS JOINT VALVE COVER 3 14 ENGINE EXHAUST SYSTEM 3 15 EXHAUST REMOVAL INSTALLATION 3 15 ENGINE COOLING SYSTEM 3 16 COOLING SYSTEM PRESSURE TEST 3 16 RADIATOR CAP PRESSURE TEST 3 16 RADIATOR FAN R...

Page 59: ...PISTON RING INSTALLED GAP 3 60 PISTON TO CYLINDER CLEARANCE 3 61 CONNECTING ROD INSPECTION 3 61 ENGINE ASSEMBLY LOWER END 3 63 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 63 CONNECTING ROD...

Page 60: ...3 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 3 3 ENGINE COOLING SYSTEM 3 89 ENGINE...

Page 61: ...haft Timing Plate PU 50563 Engine Stand 2 Bore PU 50624 Engine Stand Adapter Mounts To The Engine PU 50562 Engine Stand Sleeve Adapter Use With 2 Bore Stand PU 50625 Engine Stand Sleeve Adapter Use Wi...

Page 62: ...PN 2878920 Quart Oil PressureMinimum Specification using Polaris engine oil at operating temperature 10 PSI 1200 RPM 40 PSI 7000 RPM Additional oil may be required after complete engine disassembly Ch...

Page 63: ...ation NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 or PS 4 Extreme Duty at operating temperature and may vary considerably if any other oil is used or if engine is...

Page 64: ...3 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 3 7 ENGINE OIL FLOW CHART ENGINE...

Page 65: ...8 0 05 mm Valve Seat Valve Seat Contacting Width Intake Standard 0 0393 0 0039 1 0 0 10 mm Valve Seat Contacting Width Intake Service Limit 0 0551 1 4 mm Valve Seat Contacting Width Exhaust Standard 0...

Page 66: ...e Limit 0 0047 0 12 mm Connecting Rod Connecting Rod Small End I D Standard 0 7879 0 7884 20 015 20 025 mm Connecting Rod Small End I D Service Limit 0 7897 20 06 mm 1 Marking Connecting Rod Big End B...

Page 67: ...10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc ENGINE DETAIL TORQUE VALUES SEQUENCES ASSEMBLY NOTES MAIN ENGINE COMPONENTS TORQUE SPECIFICATION...

Page 68: ...3 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 3 11 BALANCE SHAFT CONNECTING RODS CRANKCASE CRANKSHAFT PISTONS ENGINE...

Page 69: ...3 12 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc CYLINDER OIL COOLER OIL FILTER OIL PUMP OIL SUMP WATER PUMP ENGINE...

Page 70: ...3 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 3 13 CAMSHAFTS CYLINDER HEAD FLYWHEEL IDLER GEARS STATOR COVER ENGINE...

Page 71: ...3 14 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc SPARK PLUGS STARTER THERMOSTAT HOUSING TRANS JOINT VALVE COVER ENGINE...

Page 72: ...o headpipe 3 Pull the two rear isolator mounts B toward the right side of the vehicle to disengage from frame mounting posts 4 Pull silencer toward the rear of the vehicle to disengage silencer mounti...

Page 73: ...the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze Coolant is recom...

Page 74: ...ed 9 Reverse this procedure for installation Upon installation be sure the lower radiator mounts are placed properly in the frame support RADIATOR REMOVAL COOLANT DRAIN 1 Allow the vehicle to cool dow...

Page 75: ...rly in the frame support 15 After installation and reassembly remove the pressure cap and fill the radiator and recovery bottle with coolant 16 Refer to the Cooling System Bleeding Procedure provided...

Page 76: ...stat opens 8 Clean thermostat mating surfaces on the engine and thermostat cover 9 Install a new thermostat and seal into the cover and install the cover onto engine 10 Install the thermostat cover bo...

Page 77: ...3 20 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc COOLING SYSTEM EXPLODED VIEW ENGINE...

Page 78: ...e coolant bleed screw 7 Open the bleed screw C to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 8 Tighten the bleed screw to specification t...

Page 79: ...Remove the 3 bolts retaining water pump to engine block Note different bolt lengths for installation 11 Remove water pump from engine by gently twisting and rocking the water pump housing while pulli...

Page 80: ...noting location of shorter bolt and torque to specification TORQUE Water Pump Mounting Bolts 89 in lbs 10 Nm 11 Install the 3 coolant hoses that attach to the water pump Be sure orientation and routin...

Page 81: ...er pump housing assembly if necessary 9 Clean and inspect water pump shaft for excessive wear or damage Replace water pump housing assembly if necessary as shaft can not be purchased separately 10 Tho...

Page 82: ...nstall the water pump cover and 3 retaining bolts Torque bolts in sequence to specification TORQUE Water Pump Cover Bolts 89 in lbs 10 Nm Apply Loctite 204to bolt threads 21 Install 2 new water pump O...

Page 83: ...3 26 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc WATER PUMP EXPLODED VIEW ENGINE...

Page 84: ...lp guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components WARNING Always wear safety glasses and proper shop clothing when pe...

Page 85: ...gine removal 11 Remove the spark plug wires from the engine NOTE The spark plug wires are marked with MAG and PTO Note during installation procedure 12 Disconnect the stator harness in front of the en...

Page 86: ...able drain pan under the vehicle Remove the coolant hoses from the thermostat cover R and water pump inlet S Dispose of used engine coolant properly 21 With the help of an assistant and the engine hoi...

Page 87: ...engine with suitable lifting straps to an overhead or portable engine hoist 2 Remove the engine stand adapter plate and install the starter motor back onto engine Torque starter motor bolts to specif...

Page 88: ...n joint bracket mounting holes with the front transmission mounting holes 7 Install the Clutch Center Distance Tool PU 50658 onto the crankshaft and transmission input shaft to properly position the c...

Page 89: ...clutch center distance tool 13 Torque the 4 front engine mount fasteners A to specification TORQUE Front Engine Mount Fasteners 40 ft lbs 54 Nm 14 Remove the lifting straps and overhead or portable en...

Page 90: ...fuel rail assembly NOTE Take care not to damage the O rings upon installation 22 Install the 2 bolts that retain the fuel rail assembly to the intake plenum and torque bolts to specification TORQUE F...

Page 91: ...light harness upon installation 32 Connect the negative battery cable 33 Remove the radiator pressure cap and fill the cooling system with properly mixed anti freeze coolant 34 Install a new oil filt...

Page 92: ...of 87 R M 2 2 Refer to Chapter 2 Engine Oil Level Check oil level indicated on dipstick Add oil if necessary 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary thrott...

Page 93: ...tors upon assembly 2 Remove valve cover and valve cover seal Replace isolators and valve cover seal e if oil leaks are evident 3 Remove the spark plugs r Stuff spark plug holes with clean shop towels...

Page 94: ...m the engine 4 Remove the remaining two bolts that retain the front camshaft carrier t and carefully lift the carrier off the camshafts 5 Hold camshafts with an open end wrench y and remove the top bo...

Page 95: ...SHAFT BORE INSPECTION Inspect all main journals and cam lobes as described below and compare to specifications Replace camshaft s or cylinder head if worn beyond service limit or if any surface is pit...

Page 96: ...ly install the camshaft carriers to measure the camshaft bore Torque bolts in sequence to specification Replace cylinder head if worn TORQUE Camshaft Carrier Bolts 89 in lbs 10 Nm NOTE Replace cylinde...

Page 97: ...r head is removed nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 Refer to Cylinder Piston Removal page 3 56 CYLIN...

Page 98: ...n the bottom side of the tappet w 2 Compress the valve spring by hand using valve spring compressor adapter PV 43513 A 3 Push down on spring and remove split keepers e 4 Slowly release valve spring pr...

Page 99: ...d if necessary 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...

Page 100: ...any of the above conditions exist the valve seat must be reconditioned If the valve seat is cracked the cylinder head must be replaced Valve seat width and point of contact on the valve face is very...

Page 101: ...slightly above and must be the proper width If the indicated seat contact is at the top edge of the valve face and contacts the margin area e it is too high on the valve face Use the 30 cutter to low...

Page 102: ...icate valve guides with clean engine oil and apply oil or water based lapping compound to the face of the valve NOTE Lapping is not required if an interference angle reconditioning method is used 10 I...

Page 103: ...stator cover CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal i...

Page 104: ...ylinder inlet and oil cooler Leave them all attached to the water pump housing 2 Remove the three gold colored bolts q retaining the water pump housing to the engine Note the location of the shorter b...

Page 105: ...NOTE The starter one way clutch can be serviced with the engine installed in the chassis 7 Remove the stator cover and flywheel see Chapter 3 Flywheel Removal page 3 47 8 Place flywheel on a work ben...

Page 106: ...eplace the clutch and starter gear as an assembly STARTER ONE WAY CLUTCH ASSEMBLY 1 Install one way clutch in clutch hub with flange of clutch q engaged in recess 2 Clean screw threads in flywheel to...

Page 107: ...case 2 Remove the crankcase drain plug w to drain any oil remaining in the engine 3 Remove the oil filter 4 Install the Cylinder Holding Camshaft Timing Plate e PU 50563 onto the cylinder The cylinder...

Page 108: ...move the pump drive sprocket NOTE If unable to extract the dowel pins from the oil pump the oil pump sprocket must be removed Access the sprocket bolt by removing the case plug 11 Lift the oil pump dr...

Page 109: ...se bolts Discard the eight M10 bolts 17 Tap on the lower crankcase in reinforced areas with a soft faced hammer to loosen Carefully lift up and remove the lower crankcase half BALANCE SHAFT REMOVAL IN...

Page 110: ...imit 1 4921 37 900 mm CRANKSHAFT REMOVAL INSPECTION 1 Perform Crankcase Disassembly Inspection procedure 2 Perform Balance Shaft Removal Inspection procedure 3 For ease of assembly mark each connectin...

Page 111: ...or on centers in a crankshaft stand or lathe Measure crankshaft runout where indicated and replace if runout exceeds maximum listed below MEASUREMENT Crankshaft Maximum Runout 001 0 025 mm 12 Visually...

Page 112: ...mm Connecting Rod Bearing Standard 1 6118 1 6122 40 942 40 950 mm Service Limit 1 6104 40 906 mm G Main Bearing Standard 1 6137 1 6140 40 988 40 995 mm Service Limit 1 6126 40 960 mm Connecting Rod B...

Page 113: ...ds r Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case Refer to bearing selection procedures upon assembly NOTE Always replace plain bearings wh...

Page 114: ...ed mark the pistons so they are reassembled in the same cylinder bore and direction from which they were removed MAG PTO CYLINDER INSPECTION 1 Lay a straight edge across the top surface of the cylinde...

Page 115: ...eplaced MEASUREMENT Cylinder Taper Service Limit 0 001 025 mm Cylinder Out of Round Service Limit 0 001 025 mm MEASUREMENT Standard Bore Size 3 6614 0003 93 mm 008 mm PISTON DISASSEMBLY INSPECTION NOT...

Page 116: ...0 7874 19 995 20 000 mm Service Limit 0 7866 19 98 mm PISTON RING REMOVAL 1 Carefully remove top compression ring q by hand or using a ring removal pliers CAUTION DO NOTexpand the ring more than nece...

Page 117: ...piston ring q inside the cylinder w Use the piston to push the ring squarely into cylinder as shown below 2 Measure installed gap with a feeler gauge e at both the top and bottom of the cylinder NOTE...

Page 118: ...mm CONNECTING ROD INSPECTION 1 Inspect the small end and big end of connecting rod and matching rod cap for damage galling of surface or pitting 2 Measure small end I D in two directions as shown Reco...

Page 119: ...nted onto the side of the connecting rod between the small and large bore ends This number represents the bore diameter 7 The table below lists the big end bore diameter specifications Connecting Rod...

Page 120: ...Manual Copyright Polaris Sales Inc 3 63 ENGINE ASSEMBLY LOWER END BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS q Connecting Rod Bearing Identification Number 1 digit w Crankcase Bearing Identi...

Page 121: ...t you would use Green bearing for each connecting rod Bearing Selection Chart Rod Bearings CRANKSHAFT Rod Code B G Y 1 Blue Blue Green 2 Blue Green Yellow 3 Green Yellow Yellow CRANKSHAFT MAIN BEARING...

Page 122: ...beginning of this chapter and trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dry with compresse...

Page 123: ...ary to prevent loss of radial tension Severe engine damage may result if circlips are re used or deformed during installation 2 Install a new circlip q on one side of piston with gap at the top 12 00...

Page 124: ...tom tapered portion of each cylinder sleeve 2 Verify that all ring end gaps e are correctly located on each piston see Chapter 3 Piston Ring Installation page 3 65 3 Note the piston orientation mark a...

Page 125: ...lean the bearing bore surfaces of upper crankcase main bearings connecting rods and connecting rod caps 3 Align tab of new main bearing q with the slot in main bearing bore of crankcase Press bearing...

Page 126: ...necting rod using markings made upon disassembly 13 Install new bolts and tighten evenly until snug 14 Torque connecting rod bolts to specification o TORQUE Connecting Rod Bolts Step 1 9 ft lb 12 Nm S...

Page 127: ...pins are in place where used 5 Refer to Oil Flow Chart at the beginning of this chapter and trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm s...

Page 128: ...tigate the cause of any gaps 9 Install the eight M10 t one M6 yand two M8 u lower crankcase bolts Tighten all bolts lightly by hand NOTE Install new M10 lower crankcase bolts 10 Torque lower crankcase...

Page 129: ...Lift the oil pump drive chain and install the oil pump 17 Install dowel pins a into oil pump mounting holes 18 Install the three bolts f that retain oil pump d to the crankcase Torque mounting bolts t...

Page 130: ...l sump cover h onto the crankcase 23 Install the thirteen M6 j and three M8 bolts that retain the oil sump cover k to the crankcase 24 Torque the oil sump cover bolts in sequence to specification Repe...

Page 131: ...wheel key 2 Clean taper of crankshaft to remove all oil or grease 3 Clean flywheel taper to remove all oil or grease 4 Align flywheel key way with key and install the flywheel seating it fully on tape...

Page 132: ...bly 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 cover...

Page 133: ...seated in retaining groove and square with the guide NOTE Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring e and retainer r in clean...

Page 134: ...LINDER HEAD INSTALLATION 1 If necessary rotate the engine so the cylinder is facing up 2 If installed remove the Cylinder Holding Camshaft Timing Plate q from the cylinder NOTE Once the cylinder head...

Page 135: ...procedure prior to Camshaft Installation Timing 1 Rotate the engine until the flywheel Top Dead Center TDC mark q is aligned or centered in the Crankshaft Position Sensor CPS mounting hole w This pla...

Page 136: ...the flywheel is still properly aligned see Step 1 9 Pull cam chain upward making sure it is engaged with the drive sprocket on the crankshaft 10 While lifting the cam chain up engage the cam sprocket...

Page 137: ...ts to lock cams in correct position 14 If timing marks are not aligned remove sprockets and correct alignment 15 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 from the end of the camshaft...

Page 138: ...her 23 HYDRAULIC TENSIONER ONLY Install the cam chain tensioner f into the cylinder and torque to specification TORQUE Hydraulic Cam Chain Tensioner 29 ft lb 40 Nm 24 MECHANICAL TENSIONER ONLY Retract...

Page 139: ...ANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc CAMSHAFT TIMING QUICK REFERENCE q Intake Cam r Align Exhaust Marks With Surface w Exhaust Cam t CPS Mounting Hole e Align Intake Marks...

Page 140: ...if camshafts were not marked you can reference the part number stamped on the end of the shafts Intake Camshaft q PN 1204583 Exhaust Camshaft w PN 1204584 2 Lubricate the camshaft bearing journal surf...

Page 141: ...measurements are within specification remove the camshaft carriers and proceed to Camshaft Installation Timing page 3 78 10 Remove the valve tappet from a valve that was out of specification NOTE Kee...

Page 142: ...s have been adjusted 16 Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 89 in lbs 10 Nm 17 Measure and confirm that valve clea...

Page 143: ...0 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 376 0 400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 54...

Page 144: ...0 401 0 425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0 450 462 465 468 470 472 475 478 480 482...

Page 145: ...and torque to specification TORQUE Spark Plugs 7 ft lbs 10 Nm 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Inspect the valve cover seal e and replace if necess...

Page 146: ...Tank vent plugged or pinched Engine flooded Low compression high cylinder leakage No spark Spark plug fouled ignition component failure Engine Does Not Turn Over Dead battery Starter motor does not t...

Page 147: ...eating properly bent or carbon accumulated on sealing surface Rocker arm sticking Backfiring Fouled spark plug or incorrect plug or plug gap Intake system air leaks Exhaust system air leaks Valve stic...

Page 148: ...XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 3 91 Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak...

Page 149: ...3 92 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc NOTES ENGINE...

Page 150: ...4 13 FUEL TANK INSTALLATION 4 14 FUEL PUMP 4 15 OPERATION OVERVIEW 4 15 FUEL SENDER TEST 4 15 FUEL PUMP TEST 4 16 FUEL PUMP REPLACEMENT 4 17 ELECTRONIC CONTROL UNIT ECU 4 21 OPERATION OVERVIEW 4 21 E...

Page 151: ...COIL TESTS 4 34 EFI DIAGNOSTICS 4 36 INSTRUMENT CLUSTER TROUBLE CODE DISPLAY 4 36 EFI TROUBLESHOOTING 4 41 DIGITAL WRENCH OPERATION 4 42 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 42 SPECIAL TOOLS...

Page 152: ...t recent version of software w serial number standard interface cable USB Serial Adapter cable and SmartLink Module Kit PU 47471 Digital Wrench SmartLink Module Kit PU 47470 PU 47469 PU 47468 PU 47470...

Page 153: ...or based Polaris EFI systems This kit is available to Polaris dealers through our tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Digital Wrench D...

Page 154: ...joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent...

Page 155: ...4 6 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc EFI SYSTEM EXPLODED VIEW FUEL SYSTEM GENERAL...

Page 156: ...passenger seat Rear passenger seat on CREW 900 2 Electronic Throttle Control ETC Located between the intake boot and intake plenum 3 Crankshaft Position Sensor CPS Located on top of the stator cover 4...

Page 157: ...ed on the side of the throttle pedal assembly cover removed 7 Fuel Injectors Located on the top of the intake plenum in the intake track retained on top by the fuel rail 8 Fuel Rail Assembly Located o...

Page 158: ...NGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 4 9 10 Fuel Pump Regulator Fuel Level Sender Assembly Located under the driver s seat 11 Ignition Coil High Tension Leads Located next t...

Page 159: ...requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When the intake valve opens the fuel air mixture is drawn into the combustio...

Page 160: ...4 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 4 11 FUEL TANK FUEL TANK EXPLODED VIEW FUEL SYSTEM GENERAL...

Page 161: ...he fuel line pull open tabs while moving the connector out to release the line 3 Pull the fuel line outward to remove 4 To reinstall the line verify the connections are clean and free of debris 5 Plac...

Page 162: ...e before attempting to remove it from the vehicle 4 While holding a shop towel over the fuel line connectors disconnect the fuel line A from the fuel pump see Fuel Line Removal Installation NOTE A sma...

Page 163: ...the fuel tank 3 Install fuel tank brackets and 2 fasteners retaining fuel tank to chassis Torque fasteners to specification TORQUE Fuel Tank Bracket Fasteners 8 ft lbs 11 Nm 4 Reconnect the fuel pump...

Page 164: ...the case of an accident In these situations the check engine light will illuminate but turn off after 4 cranking revolutions if the system functions properly Once the engine is running the fuel pump...

Page 165: ...y spark around fuel or fuel vapors 1 Couple Fuel Pressure Gauge Adapter PS 48762 to the Fuel Pressure Gauge Kit PU 43506 A 2 Lift the rear cargo box to the raised position 3 Locate the fuel pressure v...

Page 166: ...the key switch and listen for the pump to activate NOTE If the pump starts repeat steps 3 4 and 5 to verify correct pressure 9 If the pump still does not operate check for correct ECU operation by plu...

Page 167: ...ne before servicing the fuel pump This allows the exhaust to cool and fuel pressure to drop NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitab...

Page 168: ...ank should be flushed and cleaned out prior to installation of new fuel pump assembly NOTE It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel Do...

Page 169: ...nut ensuring threads are properly aligned Verify orientation marks are still aligned between fuel pump and fuel tank 19 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a...

Page 170: ...Trouble Code Table or by using Digital Wrench The ECU requires a minimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected To prevent engine over...

Page 171: ...rotate it up until the connector is free from the ECU NOTE Upon removing the ECU connector you should hear a click when the connector is fully open 5 Remove the ECU from the vehicle 6 To reinstall re...

Page 172: ...or adjustments may be performed If a problem is encountered and you determine the ETC to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ETC wit...

Page 173: ...zation of the CPS and crankshaft position takes place 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 become...

Page 174: ...CPS harness connector A 3 Remove CPS wire lead from wire clip B 4 Remove CPS retaining bolt and remove the sensor from the stator cover 5 Install new sensor using a light coating of oil on the O ring...

Page 175: ...tion requirements during operation The T MAP sensor provides the ECU with engine load data T MAP SENSOR TEST The T MAP sensor is a non serviceable item If it is faulty it must be replaced NOTE This se...

Page 176: ...on the instrument cluster This indicates all other components are working properly Refer to Chapter 10 for additional ECT sensor information Polaris dealers can test the sensor by using Digital Wrenc...

Page 177: ...4 28 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc FUEL SYSTEM GENERAL...

Page 178: ...an be tested utilizing Digital Wrench by verifying that throttle position readout varies as the pedal is pressed Reference the Data Display section and be sure Throttle Position is displayed With the...

Page 179: ...al assembly to the bracket 6 Install new pedal assembly and torque the 2 retaining nuts to specification 7 Install the throttle and brake pedal bracket onto the chassis aligning the brake pedal and ma...

Page 180: ...idle feel for 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 stethoscop...

Page 181: ...rm this procedure 3 Used compressed air to remove any debris from around fuel injectors CAUTION Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failin...

Page 182: ...fuel injector ports on the intake plenum 14 Lightly lubricate the injector O rings and reinstall the fuel rail injector assembly into the intake plenum 15 Install the fuel rail mounting screws and to...

Page 183: ...HT LEAD REPLACEMENT NOTE The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG from the factory and should be installed to the cor...

Page 184: ...4 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 4 35 Secondary Test FUEL SYSTEM GENERAL...

Page 185: ...l illuminate and blink in place of the check engine MIL 1 If the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area 2 Press and hold t...

Page 186: ...Low 4 P0107 Intake Air Temperature T MAP Voltage Too High 105 3 P0113 Voltage Too Low 4 P0112 Engine Temperature Sensor ECT Voltage Too High 110 3 P0118 Voltage Too Low 4 P0117 Temperature Too High 1...

Page 187: ...ge Too High 3599 3 P17AA Voltage Too Low 4 P17AB ETC Accelerator Position Sensor Outputs 1 2 Correlation Correlation Fault 65613 2 P1135 Throttle Position Sensor 2 Voltage Too High 520198 3 P0223 Volt...

Page 188: ...ndition Exists 520280 31 P151E Throttle Body Control Mechanical Stop Adaptation Failure Condition Exists 520281 31 P152A Throttle Body Control Repeated Adaptation Failed Condition Exists 520282 31 P15...

Page 189: ...t Polaris Sales Inc COMPONENT CONDITION SPN FMI DIGITAL WRENCH P CODE Accelerator Sensor Synchronicity Fault Sensor Difference Exceeds Limit Condition Exists 520308 31 P1533 ECU Fault ICO Condition Ex...

Page 190: ...ine loads up backfire Air intake restricted inspect intake boots Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug Injector failure Poor Idle Symptom Idle Too High if 1400 RPM when...

Page 191: ...ilable refer to diagnostic software user manual or HELP section for minimum requirements DIAGNOSTIC SOFTWARE VERSION Always use the most current version of the Digital Wrench software to ensure you ha...

Page 192: ...h a center console the center console must be removed Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble the SmartLink Module and attach...

Page 193: ...Digital Wrench see Digital Wrench Updates NOTE Always operate with the latest update DIGITAL WRENCH UPDATES Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Dig...

Page 194: ...e 7 Click on the link shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or open the file from where they are Select save and downlo...

Page 195: ...ev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc DIGITAL WRENCH FEATURE MAP ENGINE CONTROLLER REPROGRAMMING REFLASH Process Overview FUEL S...

Page 196: ...am DEDICATED LAPTOP Best results are obtained using a laptop computer that is dedicated to Digital Wrench A laptop that is used by a variety of people and in several applications around the dealership...

Page 197: ...formation 1 Verify the most current update has been downloaded and loaded into Digital Wrench See Digital Wrench Version and Update ID page 4 44 2 Connect SmartLink Module cables to PC and vehicle See...

Page 198: ...click on ReFlash Authorization from the Service and Warranty drop down menu 10 Enter or paste CTRL V the Request Code into the box 11 Select the same file type from the list that you selected previous...

Page 199: ...l Copyright Polaris Sales Inc 14 At this point the reflash process will begin Do not touch the vehicle or PC during the process 15 Once the ECU reprogramming procedure is complete click the Finish but...

Page 200: ...SEAT BELTS 5 16 BUCKET SEATS 5 18 REAR CARGO BOX 5 20 TAILGATE CARGO BOX PANELS 5 20 CARGO BOX SUPPORT 5 21 BOX REMOVAL 5 22 BOX INSTALLATION 5 22 BODY COMPONENT REMOVAL 5 23 LOWER SEAT BASE 5 23 HOOD...

Page 201: ...ICE 5 39 SERVICE PREPARATION 5 39 BALL JOINT REMOVAL 5 39 BALL JOINT INSTALLATION 5 40 REAR A ARMS 5 42 EXPLODED VIEW 5 42 REAR UPPER A ARM REMOVAL 5 43 REAR UPPER A ARM INSTALLATION 5 43 REAR LOWER A...

Page 202: ...olt EPS 40 ft lbs 54 Nm Pivot Tube Mounting Bolts 18 ft lbs 24 Nm Rear Cab Support Bolts 30 ft lbs 41 Nm Rocker Support Bolts 8 ft lbs 11 Nm Seat Belt Mounting Bolts 40ft lbs 54 Nm Shock Mounting Bolt...

Page 203: ...Manual Copyright Polaris Sales Inc SPECIAL TOOLS TOOL DESCRIPTION PART NUMBER Shock Spanner Wrench 2871095 Shock Spring Compressor Tool 2870623 Multi Function Pliers 2876389 Bosch Automotive Service...

Page 204: ...4 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 5 MULTI FUNCTION PLIERS Included in the tool kit this multi function pliers is designed to remove plastic push rivets and install...

Page 205: ...ER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc CAB FRAME ASSEMBLY CAB FRAME HEADRESTS SIDE NETS Vehicles with bucket seats and doors do not include Side Nets Hip Bols...

Page 206: ...NGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 7 Cab Frame Headrests Side Nets CREW 900 Vehicles with bucket seats and doors do not include Side Nets Hip Bolster...

Page 207: ...5 8 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc DOORS LE ONLY BODY STEERING SUSPENSION...

Page 208: ...CH DOOR 5 BRACKET HINGE SUPPORT MATTE BLACK 6 ROD DOOR LATCH 7 GROMMET SEATFILLER TRUNK 8 BUMPER RUBBER 9 PANEL DOOR 10 COVER LATCH INNER 11 ACTUATOR SPRING 12 SCREW 13 SCREW 14 PANEL DOOR OUTER 15 RI...

Page 209: ...5 10 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc CHASSIS MAIN FRAME FRAME SUPPORTS FRONT BUMPER BODY STEERING SUSPENSION...

Page 210: ...5 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 11 RANGER CREW 900 BODY STEERING SUSPENSION...

Page 211: ...5 12 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc BODY COMPONENTS DASH PANELS GLOVE BOX BODY STEERING SUSPENSION...

Page 212: ...5 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 13 HOOD FRONT FENDERS FRONT FASCIA BODY STEERING SUSPENSION...

Page 213: ...5 14 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc FLOOR REAR FENDERS SKID PLATE STORAGE BODY STEERING SUSPENSION...

Page 214: ...5 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 15 RANGER CREW 900 BODY STEERING SUSPENSION...

Page 215: ...5 16 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc SEAT MOUNTING SEAT BELTS BODY STEERING SUSPENSION...

Page 216: ...5 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 17 RANGER CREW 900 BODY STEERING SUSPENSION...

Page 217: ...5 18 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc BUCKET SEATS BODY STEERING SUSPENSION...

Page 218: ...BOTTOM 40 INCL 4 QTY 2 OF 5 6 4 BRACKET SEAT HINGE DOUBLE 5 SCREW TORQUE 24 in lbs 2 7 Nm 6 PIN SEAT LATCH 7 KIT SEAT BELT 3 POINT DRIVER 8 KIT SEAT BELT 3 POINT PASSENGER 9 SCREW 10 NUT TORQUE 40 ft...

Page 219: ...5 20 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc REAR CARGO BOX TAILGATE CARGO BOX PANELS BODY STEERING SUSPENSION...

Page 220: ...5 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 21 CARGO BOX SUPPORT BODY STEERING SUSPENSION...

Page 221: ...the 2 hinge fasteners that retain the cargo box to the frame CAUTION Use caution when removing the box It is recommended to have two people carefully remove the box from the frame 6 Lift the cargo bo...

Page 222: ...ood 2 Lift up the hood between the locks and slide hood forward to disengage the front of the hood from the front fascia FRONT BUMPER 1 Remove the 2 fasteners A retaining the bottom of the bumper to t...

Page 223: ...the front fenders on each side 6 Carefully pull the front fascia straight out to remove it from the vehicle FRONT FENDERS 1 Remove the hood see Hood removal 2 Remove the push rivets E retaining the f...

Page 224: ...dash panel and remove the panel 5 Open the glove box and remove the 4 T 25 Torx head screws N 6 Remove the 10 T 40 Torx head screws retaining the bottom of the lower dash 7 Remove the 5 push rivets on...

Page 225: ...900 Service Manual Copyright Polaris Sales Inc 2 Remove the 5 T 40 Torx head screws P 3 Remove the 2 push rivets Q NOTE If removing the LH panel loosen the hose clamp R retaining the fuel fill hose t...

Page 226: ...6 Remove the rocker panel assembly from the vehicle 7 Cover the fuel fill hose to prevent leakage and to prevent debris from entering the fuel tank NOTE WARNING Gasoline is extremely flammable and ex...

Page 227: ...see Main Floor 3 Remove the clip and pin T securing the brake pedal to the master cylinder push rod Using a 13mm socket remove the 4 bolts retaining the throttle and brake pedal mount 4 Disconnect the...

Page 228: ...ocker panels see Rocker Panel Removal 3 Remove the battery 4 Remove 4 T 25 Torx fasteners A Fig 1 securing the fuse box to the center under seat storage box 5 Remove 4 T 25 Torx fasteners B Fig 1 secu...

Page 229: ...014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 10 Remove 14 T 40 Torx fasterners F Fig 3 from the main floor panel 11 Lift the floor panel out of the vehicle 12 Installation is...

Page 230: ...5 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 31 STEERING ASSEMBLY EXPLODED VIEW BODY STEERING SUSPENSION...

Page 231: ...ING SHAFT REMOVAL EPS MODELS 1 Remove upper and lower dash panels see Dash Panel Glove Box Removal CAUTION Striking the steering wheel or steering shaftwhile installed in the vehicle can permanently d...

Page 232: ...LACEMENT NOTE Replacement pivot tube assembly comes with new upper and lower bearings installed Use this procedure if replacing just the bearings only 1 Perform the Steering Shaft Removal procedure 2...

Page 233: ...stall steering wheel cap and field test steering operation POWER STEERING UNIT REMOVAL 1 Remove upper steering shaft and steering wheel see Steering Wheel Removal EPS models 2 Using a 15mm socket remo...

Page 234: ...tall the upper steering shaft pinch bolt and torque to specification TORQUE Upper Power Steering Shaft Pinch Bolt 15 ft lbs 20 Nm 10 Verify that the pivot tube bushings are properly seated into the pi...

Page 235: ...5 36 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc FRONT A ARMS EXPLODED VIEW BODY STEERING SUSPENSION...

Page 236: ...test vehicle at low speeds before putting into service FRONT LOWER A ARM INSTALLATION WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious inj...

Page 237: ...UPPER A ARM INSTALLATION WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during oper...

Page 238: ...iper mounting bolts and remove the caliper from the brake disc see Brakes chapter 5 Remove and discard the upper ball joint pinch bolt 6 If necessary remove the lower front shock fastener from the A a...

Page 239: ...o engage the Installation Adapter and Spacer 5 Tighten the Press Asm screw and fully install the ball joint into the arm 6 After the new ball joint is fully installed into the A arm install a new reta...

Page 240: ...ales Inc 5 41 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification TORQUE Ball Joint Pinch Bolts 42 ft lbs 57 Nm Front Shock Mounting Bolts 40 ft lbs 54 Nm Front Caliper Mounting Bolts...

Page 241: ...5 42 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc REAR A ARMS EXPLODED VIEW BODY STEERING SUSPENSION...

Page 242: ...fasteners retaining the upper A arm to the frame 8 Allow the lower A arm to drop and remove the upper A arm by maneuvering the rear shock and stabilizer link out REAR UPPER A ARM INSTALLATION WARNING...

Page 243: ...tion completion test vehicle at low speeds before putting into service REAR LOWER A ARM REMOVAL 1 Properly lift and support the vehicle by the frame 2 Using a 13mm socket remove the 4 nuts retaining t...

Page 244: ...ier Torque new fastener to specification TORQUE Lower A Arm to Bearing Carrier 40 ft lbs 54 Nm 3 Attach the lower portion of the rear shock to the lower A arm Torque new fastener to specification TORQ...

Page 245: ...5 46 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc REAR STABILIZER BAR LINKAGE EXPLODED VIEW BODY STEERING SUSPENSION...

Page 246: ...ining the stabilizer bar to the frame 3 Using a 15mm socket remove the upper stabilizer bar linkage nut on each side 4 Remove the stabilizer bar from the frame and inspect the stabilizer bar for strai...

Page 247: ...bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame tre...

Page 248: ...ners to specification TORQUE Shock Mounting Bolts 40 ft lbs 54 Nm SHOCK REPLACEMENT 1 Remove the shock and note the spring preload cam setting 2 Using a spring compressor compress the shock spring far...

Page 249: ...5 50 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc NOTES BODY STEERING SUSPENSION...

Page 250: ...G COMPONENTS 6 8 PVT DISASSEMBLY 6 9 PVT ASSEMBLY 6 11 DRIVE BELT 6 13 BELT REMOVAL 6 13 BELT INSPECTION 6 14 BELT INSTALLATION 6 14 PVT BREAK IN DRIVE BELT CLUTCHES 6 14 DRIVE CLUTCH SERVICE 6 15 DRI...

Page 251: ...nual Copyright Polaris Sales Inc CLUTCH DISASSEMBLY INSPECTION 2014 NON EBS 6 29 CLUTCH ASSEMBLY 2014 NON EBS 6 30 2014 DRIVEN CLUTCH SERVICE EBS 6 31 EXPLODED VIEW 2014 EBS 6 31 CLUTCH DISASSEMBLY EB...

Page 252: ...in Puller 2870386 Roller Pin Tool 2870910 Universal Clutch Compressor PU 50518 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com SPECIAL SUPPLIES PART NUMBER Loct...

Page 253: ...2000 Feet 27 83 5632754 Wht Org 7043924 Blk Red Wht 3235317 2014 All Models Except R14UH9EAB w EBS and CREW Models 0 1500 Meters 0 5000 Feet 27 89 5138015 Wht Blu 7044111 7044021 1500 3700 Meters 5000...

Page 254: ...sheave moves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive b...

Page 255: ...oubleshooting checklist at the end of this chapter for more information 1 Belt Inspection 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers...

Page 256: ...uck in mud or snow Shift the transmission to Low carefully use quick firm throttle application and avoid excessive slipping of the PVTsystem WARNING Excessive throttle may cause loss of control and ve...

Page 257: ...6 8 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc PVT SYSTEM SERVICE PVT COVERS AND DUCTING COMPONENTS CLUTCHING...

Page 258: ...er and drive belt see DRIVE BELT Belt Removal 2 Disconnect spark plug wires from the spark plugs Remove spark plug wires from the PVT outlet hose A Loosen the PVT inlet and outlet hose clamps B and re...

Page 259: ...rive Clutch Puller 2872085 Drive Clutch Puller 2872085 NOTE Be sure to use the correct Drive Clutch Puller PN 2872085 to prevent damage to crankshaft 6 Remove the fuel line D and wiring harness E from...

Page 260: ...ean the end of the taper on the crankshaft and the tapered bore inside the drive clutch 7 Clean the splines inside the driven clutch and on the transmission input shaft Apply a light film of grease to...

Page 261: ...yright Polaris Sales Inc 13 Install the PVT inlet and outlet duct hoses Torque the hose clamps F to specification TORQUE PVT Duct Hose Clamps 35 in lbs 4 Nm 14 Connect the spark plug wires to the spar...

Page 262: ...mbly up so it sits slightly higher than the PVT cover to ease of clutch cover removal 3 Using a 10mm wrench remove the grease zerk fitting D on the upper rear control arm Using a 8mm socket remove the...

Page 263: ...ack Note On 2014 Non EBS Models the driven clutch mounting bolt should be loose to allow the clutch sheaves to spread Torque driven clutch mounting bolt to specification TORQUE Driven Clutch Retaining...

Page 264: ...6 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 6 15 DRIVE CLUTCH SERVICE DRIVE CLUTCH EXPLODED VIEW CLUTCHING...

Page 265: ...is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the...

Page 266: ...surfaces Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requiring replacement Drive Clutch Spring Specifications Part Number 7043924...

Page 267: ...rocedure Button to Tower Clearance 000 005 2 Inspect sheave surfaces Replace the entire clutch if worn damaged or cracked SPIDER REMOVAL 1 Install clutch in holding fixture PN 2871358 A and loosen the...

Page 268: ...your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly i...

Page 269: ...damaged MEASUREMENT Shaft Diameter Standard 1 374 34 89 mm Service Limit 1 372 34 86 mm 5 Visually inspect Vespel thrust washers for damage Measure the thickness and compare to specification Replace...

Page 270: ...1 Drive Clutch Cover Bushing Removal Installation Tool all clutches 5020629 5 1 P 90 Driven Clutch Cover Bushing Removal Tool 5020631 ITEM QTY PART DESCRIPTION PART 8 1 Main Puller Adapter 5020632 9 1...

Page 271: ...ift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Drive Clutch Bushing Installation 12 Pla...

Page 272: ...utch cover 32 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 33 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 34...

Page 273: ...ive Clutch Spider 290 ft lbs 393 Nm Apply 263 Loctite 5 After the spider has been torqued remove the clutch assembly from the holding fixture and inspect the shaft and sheave alignment marks made duri...

Page 274: ...pression spring 1 Remove driven clutch from transmission input shaft 2 Mark the position of the clutch sheaves before disassembly or use the X s on the sheaves for reference This aids in reassembly an...

Page 275: ...relieved remove the outer spring retainer B compression spring C spacer D and inner spring retainer E 5 Separate the two clutch sheaves 6 Inspect the helix on the moveable sheave 7 Inspect the inner...

Page 276: ...le on the bearing 10 Inspect driven clutch sheave faces for wear or damage 11 Clean and inspect splines on helix and transmission input shaft 12 Lube splines with a light film of grease Do not lubrica...

Page 277: ...900 Service Manual Copyright Polaris Sales Inc 5 Install the outer retainer on top of the spring 6 Place the driven clutch into the Universal Clutch Compressor PU 50518 7 Apply and hold downward pres...

Page 278: ...hen removing compression spring to prevent serious personal injury 1 Remove driven clutch from transmission input shaft 2 Mark the position of the clutch sheaves before disassembly or use the X s on t...

Page 279: ...the rollers in the stationary sheave for wear If rollers are worn a new driven clutch assembly may be needed 9 Inspect the bearings inside the moveable sheave 10 Inspect driven clutch sheave faces fo...

Page 280: ...6 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 6 31 2014 DRIVEN CLUTCH SERVICE EBS EXPLODED VIEW 2014 EBS CLUTCHING...

Page 281: ...fter reassembly 3 Place the driven clutch into the Universal Clutch Compressor PU 50518 Spin the tool down until it touches the cam helix 4 Using a T25 Torx driver remove the four screws that secure t...

Page 282: ...lutch rollers as shown 9 Lift the stationary sheave off the moveable sheave CLUTCH INSPECTION 1 Clean the sheaves and inspect each of them for damage NOTE If either clutch sheave is damaged the entire...

Page 283: ...h sheaves and cam helix If bearings are damaged or have an excessive amount of wear the entire component must be replaced NOTE The flanged bearings are not serviceable If either clutch sheave bearing...

Page 284: ...5 Install the inner clutch rollers thrust washers and E rings onto the spider if previously disassembled 6 Install the compression spring and spider assembly into the moveable sheave Align the X mark...

Page 285: ...e sure the X mark on the cam helix is aligned with the X mark on the moveable sheave 9 Replace the 4 T25 Torx screws thread locking agent applied or apply Loctite 242 to the existing screws 10 Use a T...

Page 286: ...above specified operating range Incorrect drive clutch spring too high of rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter shea...

Page 287: ...r different terrain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines f...

Page 288: ...JOINT SERVICE 7 10 DISASSEMBLY 7 10 ASSEMBLY 7 11 FRONT GEARCASE CENTRALIZED HILLIARD 7 12 CENTRALIZED HILLIARD EXPLODED VIEW 7 12 ALL WHEEL DRIVE OPERATION 7 13 AWD DIAGNOSIS 7 14 FRONT GEARCASE REMO...

Page 289: ...ervice solutions com TORQUE SPECIFICATIONS ITEM SPECIFICATION Wheel Nuts Steel Wheels 60 ft lbs 81 Nm Wheel Nuts Cast Aluminum Wheels 120 ft lbs 163 Nm Front Wheel Hub Castle Nut 75 ft lbs 102 Nm Rear...

Page 290: ...hicle so the front wheels are on the ground to prevent the wheel from spinning while attempting to loosen the castle nut 4 Lift the vehicle up again safely and remove the 4 wheel nuts C Remove the fro...

Page 291: ...wear or damage Replace front bearing carrier if damaged Bearing Installation 5 Thoroughly clean the front bearing carrier housing and the outer race on the new bearing Be sure that all oil residue ha...

Page 292: ...Install a NEW cotter pin C TORQUE Tie Rod End Fastener 40 ft lbs 54 Nm 5 Apply grease to the drive shaft splines 6 Install front wheel hub assembly cone washers and hand tighten the castle nut Instal...

Page 293: ...Inc 9 Install wheel and 4 wheel nuts G Torque wheel nuts to specification TORQUE Wheel Nuts Steel Wheels 60 ft lbs 81 Nm Aluminum Wheels 120 ft lbs 163 Nm 10 Rotate wheel and check for smooth operati...

Page 294: ...eginningthis service procedure 2 Remove the drive shaft from the front bearing carrier 3 With a short sharp jerk remove drive shaft from the front gearcase 4 Refer to the DRIVE SHAFT SERVICE procedure...

Page 295: ...e transmission snorkel shaft remove the skid plate to access the front engine mount support Remove the 2 driver s side engine mount nuts Doing so will allow you to lift up on the engine to get more cl...

Page 296: ...r section of the propshaft onto the transmission output shaft 2 Install and torque the 2 flex bearing mounting fasteners to 40 ft lbs 54 Nm 3 Install rear floor see Rear Floor CREW in Chapter 5 4 Inst...

Page 297: ...otection NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting and mark inner and outer yoke for correct re positioning during installation 2 Support inn...

Page 298: ...ing cap in one side 3 Continually check for free movement of bearing cross as bearing caps are assembled 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Ins...

Page 299: ...Vent Hose Fitting 1 20 Spring Wireform 2 5 Ball Bearing 2 21 H Clip Spring 20 6 Ball Bearing Double Row 1 22 Connector Assembly 1 7 Bushing 1 23 Nylon Spacer 2 8 Bushing 1 24 Torsion Spring Retainer...

Page 300: ...D switch on If AWD 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 Vd...

Page 301: ...s indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the coil is seated in the U shaped insert that i...

Page 302: ...plines 5 Disconnect the AWD wire harness and remove the plastic zip tie holding the AWD coil pigtail 6 Using a 15mm socket remove the 4 bolts retaining the front gearcase to the skid plate frame 7 Rem...

Page 303: ...e LH output hub assembly from the clutch housing or outer cover plate assembly NOTE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate Refer to AWD Diagn...

Page 304: ...ousing 7 Remove the RH output hub assembly from the gearcase housing 8 Remove pinion seal internal retaining ring and pinion gear assembly from the gearcase housing Inspect and clean the gearcase hous...

Page 305: ...lers A for nicks and scratches The rollers must slide up and down and in and out freely within the roll cage B sliding surfaces and H springs IMPORTANT Refer to the Electronic Parts Catalog for indivi...

Page 306: ...install a new external snap ring 3 Install a new pinion shaft seal into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the ho...

Page 307: ...and retainer are installed properly 9 Be sure the armature plate tabs are fully engaged into the roll cage assembly and are resting on the cut grooves of the ring gear NOTE Verify armature plate tabs...

Page 308: ...over Plate Screws 7 11 ft lbs 10 15 Nm FRONT GEARCASE INSTALLATION 1 Install the gearcase between the left hand upper and lower control arms into the frame 2 Install the vent line on the gearcase and...

Page 309: ...rvice Manual Copyright Polaris Sales Inc 8 Connect the AWD harness and tie the harness to the brake lines with a plastic tie strap 9 Add the proper lubricant to the front gearcase Check drain plug for...

Page 310: ...bearing condition and upper and lower ball joint wear REMOVAL 1 Place the transmission in Park 2 Elevate the rear end of the vehicle and safely support the vehicle under the main frame area 3 Remove...

Page 311: ...e rear bearing carrier if damaged 4 Replace the bearing carrier bushings H if worn or damaged 5 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all...

Page 312: ...eely 4 Torque the upper and lower bearing carrier fasteners to specification TORQUE Bearing Carrier Fasteners 40 ft lbs 54 Nm 5 Install the wheel hub assembly onto the drive shaft 6 Install the washer...

Page 313: ...the DRIVE SHAFT SERVICE section if repairing the drive shaft INSTALLATION 1 Install a new spring ring A on the end of the drive shaft if not replacing the drive shaft assembly Apply an anti seize com...

Page 314: ...d damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension components Never us...

Page 315: ...and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 10 Clean the sp...

Page 316: ...e large clamp using the appropriate clamp tool Axle Boot Clamp Tool PU 48951orCV Boot Clamp Pliers 8700226 20 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pi...

Page 317: ...left in the joint 7 Remove the boot from the shaft CAUTION Complete disassembly of the plunging joint is NOT recommended The internal components are precision fit and develop their own characteristic...

Page 318: ...press the joint and push the drive shaft firmly into the inner race 15 Align the circlip with the lead in chamfer 16 Use a soft faced hammer to tap the joint onto the drive shaft until you reach the e...

Page 319: ...7 32 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc DRIVE SHAFT CUTAWAY VIEW FINAL DRIVE...

Page 320: ...AL INSTALLATION 8 4 SHIFT CABLE 8 5 INSPECTION 8 5 ADJUSTMENT 8 5 TRANSMISSION REMOVAL 8 6 TRANSMISSION INSTALLATION 8 10 TRANSMISSION SERVICE 8 14 DIFFERENTIAL OPERATION 8 14 TRANSMISSION DISASSEMBLY...

Page 321: ...Screws 7 10 ft lbs 10 14 Nm Snorkel Tube Refer to Snorkel Gear Backlash Procedure Snorkel Tube Locking Screw 8 10 ft lbs 11 14 Nm Differential Solenoid 25 ft lbs 34 Nm Transmission Case Screws 15 20 f...

Page 322: ...8 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 8 3 TRANSMISSION MOUNTING AND TORQUE VALUES TRANSMISSION...

Page 323: ...ove the panel to access the shift lever 3 Remove the rubber grommet E from the dash and shift lever D 4 Remove clip F and washer G retaining the shift cable H to the shift lever D Disconnect cable end...

Page 324: ...dust boot C and the clevis pin and pivot bushings D Replace if worn or damaged 3 If adjustment is required loosen the lower jam nut E and pull the cable out of the mount bracket to move the upper jam...

Page 325: ...rear drive shafts from the transmission see Chapter 7 6 Remove the outer clutch cover drive and driven clutch and inner clutch cover see Chapter 6 NOTE Be sure to use the correct Drive Clutch Puller P...

Page 326: ...e the shift cable assembly from the bracket Q 12 Relieve pressure from the fuel rail Disconnect the fuel line at the fuel rail wrap the ends with a clean rag to assure no dirt gets in the fuel system...

Page 327: ...on by securing a strap T through the rear mount NOTE Place a spacer or support between the vehicle frame and engine to hold the engine up in position while removing the transmission to engine mounting...

Page 328: ...ght Polaris Sales Inc 8 9 18 With the help of an assistant and a hoist raise the transmission vertically out of the vehicle frame NOTE Have an assistant help guide the transmission in and out of the v...

Page 329: ...support the transmission by securing a strap A through the rear mount NOTE Place a spacer or support between the vehicle frame and engine to hold the engine up in position while installing the transmi...

Page 330: ...lts to specification using the numbered sequence shown 9 Torque right side mounting bolts to specification using the numbered sequence shown TORQUE Engine Transmission Mounting Bolts Step 1 2 64 ft lb...

Page 331: ...the intake plenum to the rear transmission mount Torque fastener to specification TORQUE Lower Intake Plenum Fastener 22 ft lbs 30 Nm 17 Wipe any dirt off the fuel line connector and the fuel rail Rec...

Page 332: ...ower jam nut V to secure the shift cable in the bracket 25 Install the PVT inner clutch cover drive clutch driven clutch drive belt and outer clutch cover see Chapter 6 PVT Assembly 26 Install both re...

Page 333: ...ns An electrical solenoid mounted in the rear portion of the gearcase actuates the shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear th...

Page 334: ...ee Chapter 2 3 Remove the bellcrank nut A and bellcrank B 4 Remove E clip C that retains spring washer D flat washer D and gear switch E Remove the switch 5 Remove the sector cover bolts F and remove...

Page 335: ...emove all the transmission case bolts Using suitable pry bars remove the cover using the designated pry points indicated by the black arrows in the illustration below CAUTION Do not pry on case sealin...

Page 336: ...16 Place the idler gear shaft assembly T and gear cluster assembly U on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly 17 Slide engagement dog X off of shi...

Page 337: ...wo shafts towards each other and remove the silent chain from the two shafts 25 If necessary disassemble the other end of the reverse shaft Remove the bearing engagement dog retaining ring washer gear...

Page 338: ...Tool PA 50231 fully loosen the snorkel tube 29 Remove the snorkel tube and shaft assembly from the transmission case 30 Remove the snap ring Y and shim Z from the snorkel shaft 31 Use an arbor press t...

Page 339: ...om the snorkel shaft PLANETARY DIFFERENTIAL DISASSEMBLY NOTE If the gearcase is completely assembled perform the Gearcase Disassembly and Inspection procedure 1 Use a scribe to mark the differential c...

Page 340: ...l necessary differential components If bushing replacement is required proceed to Planetary Differential Bushing Replacement PLANETARY DIFFERENTIAL BUSHING REPLACEMENT NOTE If the differential is comp...

Page 341: ...ar 6 Thoroughly clean the bore of the planet gear and check for any unwanted burs 7 Press the new bushing into the planet gear until it is flush on each end Repeat this procedure for the remaining pla...

Page 342: ...old bushing from the side gear being careful not to damage the side gear 13 Thoroughly clean the bore of the side gear and check for any unwanted burs 14 Press the new bushing into the side gear unti...

Page 343: ...14 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification TORQUE Differential Cover Screws 18 22 ft l...

Page 344: ...the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5...

Page 345: ...klash position you should still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel...

Page 346: ...sembling the transmission 17 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 18 Install shift fork S and torsion spring into transmission housing as an asse...

Page 347: ...bly to align slots with engagement dog Ensure bearing is fully seated upon assembly 24 Assemble shift shaft rail if previously disassembled NOTE Both shift forks need to be orientated the same way so...

Page 348: ...ankcase 3 Bond Sealant PN 2871557 to the left hand transmission mating surface 29 Install the transmission case cover and retaining bolts Torque bolts to specification TORQUE Transmission Case Bolts 1...

Page 349: ...raised edge facing outward and skip tooth aligned 35 Install the detent pawl onto the shift shaft and carefully install the compression spring 36 Install a new O ring on each shift shaft Apply a small...

Page 350: ...utch center distance Transmission lubricant type quality Loose fasteners on sector gear cover Worn rod ends clevis pins or pivot arm bushings Shift selector rail travel Worn broken or damaged internal...

Page 351: ...8 32 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc TRANSMISSION EXPLODED VIEW EXPLODED VIEW TRANSMISSION...

Page 352: ...47 Case LH 81 Spacer 15 Washer 48 Case RH 82 Chain Silent 16 Pin Dowel 49 Drum Shift 83 Solenoid 17 Pin Spring 50 Gear Sector 16T 84 Switch Rotary 2 Pin 18 Retaining Ring External 51 Gear Sector 31T...

Page 353: ...8 34 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc NOTES TRANSMISSION...

Page 354: ...EDING FLUID CHANGE 9 11 FRONT BRAKE PADS 9 13 PAD REMOVAL 9 13 PAD INSPECTION 9 14 PAD ASSEMBLY INSTALLATION 9 14 BRAKE BURNISHING PROCEDURE 9 15 FRONT CALIPER SERVICE 9 16 CALIPER EXPLODED VIEW 9 16...

Page 355: ...Sales Inc CALIPER INSPECTION 9 28 CALIPER ASSEMBLY 9 28 CALIPER INSTALLATION 9 29 REAR BRAKE DISC 9 30 DISC RUNOUT 9 30 DISC INSPECTION 9 30 DISC REMOVAL REPLACEMENT 9 31 TROUBLESHOOTING 9 32 BRAKES S...

Page 356: ...4 78 mm 0 170 4 32 mm Front Brake Disc Runout 0 010 254 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 STA...

Page 357: ...Banjo Bolts All 15 20 Brake Line Flare Fittings 12 15 16 20 Brake Switch 15 20 Caliper Bleed Screws 47 5 Caliper Mounting Bolts Front 30 41 Caliper Mounting Bolts Rear 48 65 Front Brake Scraper Screw...

Page 358: ...e brake pedal returns freely and completely Adjust the caliper stop pin after pad service Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservo...

Page 359: ...n or equivalent non flammable aerosol brake cleaner Remove pads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear because of improper adju...

Page 360: ...outward and becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little...

Page 361: ...9 8 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc BRAKE SYSTEM ASSEMBLY VIEW BRAKES...

Page 362: ...nd brake switch E allowing the fluid to drain 5 Discard seals F and replace upon assembly NOTE Make note of front and rear brake line orientation on the master cylinder 6 Dispose of brake fluid proper...

Page 363: ...etaining clip C and clevis pin D from the master cylinder E to free it from the brake pedal F 3 Slide the brake pedal F and bushings G off the pedal mount bracket B INSTALLATION 1 If the pedal mount b...

Page 364: ...nd wrench on caliper bleeder screw 7 Attach a tight fitting clear hose to the bleeder fitting 8 Place a small amount of fresh brake fluid into a small clear container and place the other end of bleede...

Page 365: ...00 Service Manual Copyright Polaris Sales Inc 16 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve s...

Page 366: ...liper mounting bolts and remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 4 Push caliper piston...

Page 367: ...of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are c...

Page 368: ...voir 7 Install wheel and torque wheel nuts to specification TORQUE Wheel Nuts Steel Wheels 60 ft lbs 81 Nm Aluminum Wheels 120 ft lbs 163 Nm BRAKE BURNISHING PROCEDURE It is required that a burnishing...

Page 369: ...front of the vehicle 2 Remove the 4 wheel nuts and the front wheel CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before removal...

Page 370: ...rom the caliper see FRONT BRAKE PADS Pad Removal 2 Remove the mount bracket assembly and dust boots from caliper Thoroughly clean caliper before disassembly and prepare a clean work area 3 Use a comme...

Page 371: ...seal grooves in caliper body CALIPER INSPECTION 1 Inspect caliper body for nicks scratches pitting or wear Measure bore size and compare to specifications Replace if damaged or worn beyond service lim...

Page 372: ...ght resistance 3 Lubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seal boots are fully seated Inst...

Page 373: ...this chapter 5 Install wheel and torque wheel nuts to specification TORQUE Wheel Nuts Steel Wheels 60 ft lbs 81 Nm Aluminum Wheels 120 ft lbs 163 Nm 6 Field test unit for proper braking action before...

Page 374: ...specification Brake Disc Runout Service Limit 010 254 mm DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Use a 0 1 microme...

Page 375: ...Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal TORQUE Front Brake Disc Mounting Bolts 18 ft lbs 24 Nm 5 Install wheel hub assembly...

Page 376: ...and lift caliper off of disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper piston into caliper bore slowly with pad...

Page 377: ...p brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in reservoir to prevent air from entering master cylinder BRAKE BURNISHING PROCEDURE It is required that a b...

Page 378: ...9 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 9 25 REAR CALIPER SERVICE CALIPER EXPLODED VIEW BRAKES...

Page 379: ...9 26 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc CALIPER EXPLODED VIEW RANGER CREW 900 BRAKES...

Page 380: ...id when removing the brake line Use a wrench to remove the brake line banjo bolt A 5 After the fluid has drained into the container remove the two caliper mounting bolts B and brake caliper 6 Clean th...

Page 381: ...D Standard 1 505 38 23 mm Service Limit 1 507 38 28 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit MEASUREMENT Rear Calipe...

Page 382: ...ll the brake line and torque the banjo bolt A to specification TORQUE Brake Line Banjo Bolt 15 ft lbs 20 Nm 3 Install the pad adjustment screw C and turn until stationary pad contacts disc then back o...

Page 383: ...disc if runout exceeds specification Brake Disc RunoutService Limit 010 254 mm DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace disc if any are evident 2 Use a 0 1 micr...

Page 384: ...Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal TORQUE Rear Brake Disc Mounting Bolts 28 ft lbs 38 Nm 5 Install wheel hub assembly...

Page 385: ...or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator PEDAL VIBRATION Disc damaged Disc worn runout or thickness variance...

Page 386: ...D SENSOR TESTING 10 7 REAR DIFF SOLENOID 10 8 DIFFERENTIAL SOLENOID OVERVIEW 10 8 DIFFERENTIAL SOLENOID CIRCUIT OPERATION 10 8 INSTRUMENT CLUSTER 10 10 OVERVIEW 10 10 RIDER INFORMATION DISPLAY 10 11 I...

Page 387: ...RY SERVICE 10 33 BATTERY SPECIFICATIONS 10 33 GENERAL BATTERY INFORMATION 10 33 BATTERY TERMINAL BLOCK 10 33 BATTERY REMOVAL INSTALLATION 10 34 BATTERY OFF SEASON STORAGE 10 34 BATTERY TESTING 10 34 O...

Page 388: ...k for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manua...

Page 389: ...er than 0 5 ohms clean the switch contacts and re test Replace switch if necessary 4 Refer to Chapter 9 if replacing the brake switch as the brake bleeding procedure will need to be performed HEADLAMP...

Page 390: ...e ignition key to START There should be continuity between switch pins A and B C and D AWD 2WD TURF SWITCH 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pulling on...

Page 391: ...switch is located on the right side of the transmission The switch can be accessed through the right rear wheel well opening 1 Disconnect the transmission switch harness by lifting the connector lock...

Page 392: ...al Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connec...

Page 393: ...lting the rear cargo box When the switch is pushed to activate TURF a ground signal is provided to the ECU from the AWD switch Depending on engine speed and gear position criteria the ECU energizes th...

Page 394: ...10 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 10 9 ELECTRICAL...

Page 395: ...descriptions NOTE Some features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Cer...

Page 396: ...cators will initially flash to indicate the engine is overheating The indicators will stay lit and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory...

Page 397: ...e odometer records and displays the total distance traveled by the vehicle The odometer can not be reset Trip Meter The trip meter records the miles traveled by the vehicle on each trip To reset the t...

Page 398: ...splays the time in a 12 hour or 24 hour format Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour To set the clock follow these steps 7 Toggle the MODE button until the...

Page 399: ...sible only when the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate...

Page 400: ...ower steering MIL will illuminate and blink in place of the check engine MIL INSTRUMENT CLUSTER PINOUTS FUNCTION PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam I...

Page 401: ...area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily 2 Be sure the rubber mount is fully installed and that the indexing key on the rubber mount...

Page 402: ...rounded to operate DIAGNOSING SYSTEM FAILURES 1 Verify AWD switch is functional and that a minimum of 11 volts is present at the hub coil 2 Verify AWD hub coil is functional Test the AWD hub coil usin...

Page 403: ...re 5 Remove the hood and locate the adjustment screw A on the side of the headlight housing B Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appro...

Page 404: ...using 4 Disconnect the harness from the bulb see Headlight Bulb Replacement 5 Remove the O rings A from each side of the headlight housing 6 Remove the adjustment screw B 7 Carefully push on the face...

Page 405: ...10 20 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 6 Adjust headlights using the Headlight Adjustment procedure ELECTRICAL...

Page 406: ...D lamp assembly 3 Remove the LED lamp from the rear cargo box and disconnect the tail light brake light wire harness NOTE Before replacing the LED lamp assembly use a digital multi meter to test the h...

Page 407: ...Ohm meter measure the resistance of the fuel sender as shown below 3 Allow the sender float to sit in the empty position and compare to specification Fuel Sender Empty 90 4 5 4 Slowly move the sender...

Page 408: ...10 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 10 23 COOLING SYSTEM COOLING SYSTEM BREAK OUT DIAGRAM ELECTRICAL...

Page 409: ...should start running and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly 3 If the fan does not run or runs slowly check the...

Page 410: ...for wiring and components such as the instrument cluster ECU EFI system main harness lights and accessories The relays assist with component operation like the cooling fan fuel pump EFI system and dri...

Page 411: ...10 26 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc FUSE BOX DETAIL ELECTRICAL...

Page 412: ...tery voltage Dark Green Yellow ECU ground input to enable relay Red White 20 Amp fuse protected 12 Vdc constant battery voltage Red Dark Blue Provides 12 Vdc power for EFI system circuits FAN RELAY pr...

Page 413: ...Dark Green 10 Amp fuse protected 12 Vdc battery voltage Dark Green White ECU input to enable relay Brown Relay coil ground Red Relay switched power to operate the Rear Diff Solenoid Blue Ground to en...

Page 414: ...e battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test WARNING Never start the engine with an a...

Page 415: ...ity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 4 Set the selector dial to measure AC Voltage 5 Start the engine and let it id...

Page 416: ...y from the vehicle to access the regulator rectifier A 5 If replacing the regulator rectifier remove the 2 retaining screws B and disconnect the wire harness C Remove the regulator A and heat sink pla...

Page 417: ...REW 900 Service Manual Copyright Polaris Sales Inc CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected proceed with the following system check after verifying that all w...

Page 418: ...ink 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 prompt medical attention Batter...

Page 419: ...attery is stored or used at a low state of charge hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery Use a volt ohm meter to test battery voltage Op...

Page 420: ...eing properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced WARNING An overheated battery could explode causing severe injury or death Alwa...

Page 421: ...p Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage readin...

Page 422: ...olts and Nut 7 ft lbs 10 Nm 6 Torque upper starter mounting bolt to specification 7 Install the negative battery cable to the upper starter mounting bolt stud Torque nut to specification 8 Install the...

Page 423: ...2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc Once the pull in coil is energized the solenoid provides a current path for 12V power to reach the...

Page 424: ...10 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 10 39 STARTING SYSTEM TESTING FLOW CHART ELECTRICAL...

Page 425: ...gain power steering operation NOTE To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction...

Page 426: ...10 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 10 41 EPS SYSTEM BREAKOUT ELECTRICAL...

Page 427: ...10 42 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON ELECTRICAL...

Page 428: ...0 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc 10 43 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF ELECTRICAL...

Page 429: ...10 44 9924880 Rev 2 1 10 2014 2013 2014 RANGER XP 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc EPS TROUBLESHOOTING USING DIGITAL WRENCH ELECTRICAL...

Page 430: ...2013 RANGER XP 900 NON EPS...

Page 431: ...2013 RANGER XP 900 NON EPS...

Page 432: ...2013 RANGER XP 900 EPS...

Page 433: ...2013 RANGER XP 900 EPS...

Page 434: ...2013 RANGER XP 900 CARGO BOX...

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Page 443: ...Inspection 3 38 Installation 3 78 Removal 3 36 Sprocket Inspection 3 38 Timing 3 78 Camshaft Timing Quick Reference 3 82 Cargo Box Removal Installation 5 22 Centralized Hilliard Exploded View 7 12 Cha...

Page 444: ...tion 3 64 Crankshaft Removal Inspection 3 53 Cylinder Piston Installation 3 67 Cylinder Piston Removal 3 56 Cylinder Head Assembly 3 76 Cylinder Head Inspection 3 40 Cylinder Head Installation 3 77 Cy...

Page 445: ...nance Cooling System 2 27 Maintenance Electrical and Ignition 2 33 Maintenance Engine 2 18 Maintenance Final Drive 2 30 Maintenance Fuel System 2 14 Maintenance General Vehicle Inspection 2 12 Mainten...

Page 446: ...acement 5 33 Steering Shaft Removal Non EPS 5 33 Steering Wheel Removal EPS 5 32 Steering Wheel Removal Non EPS 5 32 Steering Exploded View 5 31 Steering Inspection 2 36 Suspension Inspection 2 39 Sus...

Page 447: ...P 900 2014 RANGER XP 900 CREW 900 Service Manual Copyright Polaris Sales Inc IX 5 W Water Pump Housing Removal 3 47 Water Pump Exploded View 3 23 Water Pump Service 3 21 3 23 Wheel Alignment 2 37 Whee...

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