Polaris RANGER XP 1000 2018-2019, Service Manual

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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
POTENTIAL
PROBLEM DIAGNOSIS
PROCEDURE PROBLEM
DIAGNOSIS REPAIR
PROCEDURE REPAIR
VERIFICATION
Differential
removed
from
vehicle
Hub Plate Hub Plate will be attached
to output hub. Initially look
at plate and see if any
excessive wear is present.
Look and see if plate is
bent or warped. Look to
see if any debris is on
plate or debris is causing
uneven wear. To do further
evaluation plate would
need to be removed from
hub, by removing bearing.
Plate then can be placed
on a flat surface to
determine if plate is flat. Plate should be flat. Plate
should have even wear
on both sides and no
significant gauging
should be present. Replace hub plate or hub
assembly with hub plate.
May need to replace Hub
plate and Armature plate
at the same time. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
ADC Armature Plate Place Plate on flat surface
with tangs up to check for
flatness. Also look for
even wear on surface
towards Hub plate Plate should not have
significant rock when
pushing on one side of
the plate. Plate should
also have even consistent
wear on the surface. Replace Armature plate.
May need to replace both
Armature plate and hub
plate at the same time. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
Roll Cage Check to see if cage is
broken or cracked. Look to
see if any springs are
broken or stuck in place.
Look to see if cage can
index properly in both
directions Roll cage should have no
cracks or breaks. Springs
should have no cracks
and fully intact. Clutch
should be able to
advance down the
engagement ramp
smoothly. Replace roll cage
assembly (cage and
spring). Always replace
both. (do not take springs
off old cage and put onto
new cage). Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
Torsion Spring Make sure Spring is
installed properly. Make
sure Spring is able to
index properly in both
directions Plastic retainer should
index with some force
from spring. Retainer
should also index far
enough to allow clutch to
engage. If torsion spring is not
installed correctly, install
correctly and retest. If
other issue with retainer or
spring, replace one or both
and retest. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
Cover Side Hub Check to see if Hub plate
can slide on hub spline. If Hub plate can not slide
it may not engage coil
correctly. Replace with new hub
assembly and Hub Plate. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
ADC Coil/Coil Pocket
(Output Cover) Check Pole Faces for
debris Pole faces should be
smooth and even wear
should be present. Clean off pole faces if no
significant wear is noticed.
If pole faces are severely
worn and damaged,
replace output cover. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
Check for Coil raised
above pole faces Coil should be well below
the pole faces. If coil is
outside pole faces it
would cause the plates
not to touch the pole
faces. Replace output cover. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
Check Wear on Pole faces Pole faces should be
smooth and even wear
should be present.
Clean off pole faces if no
significant wear is noticed.
If pole faces are severely
worn and damaged,
replace output cover. Drive vehicle with ADC
mode on to determine if
problem has been fixed. If
not, continue onto
additional problems listed.
FINAL DRIVE