Polaris RANGER XP 1000 2018-2019, Service Manual

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3.20
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
ENGINE SERVICE (900 / 1000)
ACCESSIBLE ENGINE COMPONENTS
The following components can be serviced or removed
with the engine installed:
• Camshaft(s)
• Camshaft Sprocket(s)
• Cylinder Head
• Flywheel
• Oil Cooler
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
• Water Pump
The following components require engine removal for
service:
• Camshaft Timing Chain
• Connecting Rod(s)
• Counterbalance Shaft / Bearings
• Crankcase
• Crankshaft / Main Bearings
• Crankshaft Seal (PTO)
• Cylinder
• Oil Pump / Oil Pump Sprocket or Chain
• Piston / Rings
ENGINE REMOVAL
NOTICE
Some engine repair procedures can be performed
without removing the engine assembly from the vehicle.
Refer to “Accessible Engine Components”page 3.20
for further information.
The use of an overhead or portable engine hoist is the
only recommended method for removing and installing
the engine.
Have an assistant help 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 performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
1. If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Drain the engine oil and coolant prior to engine
removal.
Refer to Engine Oil and Filter
Changepage 2.15 and “Radiator Removal /
Coolant Drain”page 3.108 procedures.
4. Remove rear cargo box from vehicle. Refer to
“Cargo Box Removal”page 10.27 procedure.
5. Lift up the passenger seat and disconnect the (-)
negative battery cable from the battery.
6. Remove the PVT outer cover, drive and driven
clutch,
and inner cover. Refer to PVT
Disassemblypage 5.9 procedure.
Correct Drive Clutch Puller P/N 2872085
CAUTION
Be sure to use the correct Drive Clutch Puller (PN
2872085 ) to prevent damage to crankshaft.
7. Remove the exhaust system from the vehicle. Refer
“Exhaust Removal / Installation”page 3.104
procedure.
ENGINE / COOLING / HVAC SYSTEM