Polaris RANGER XP 1000 2018-2019 Service Manual Download Page 421

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9929399 R01 - 2018-2019

RANGER

XP/ CREW 900/1000 Service Manual

9.1

BRAKE SYSTEM

CHAPTER 9

BRAKE SYSTEM

GENERAL INFORMATION - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SERVICE NOTES - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SPECIAL TOOLS - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SERVICE SPECIFICATIONS - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

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

BRAKE SYSTEM ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

BRAKE LINE ROUTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

BRAKE BLEEDING / FLUID CHANGE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

MASTER CYLINDER REMOVAL

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

MASTER CYLINDER INSTALLATION

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

FOOT BRAKE PEDAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

BRAKE PEDAL REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

FRONT BRAKE PAD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12

PAD REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12

PAD INSPECTION

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

PAD ASSEMBLY / INSTALLATION

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

BRAKE BURNISHING PROCEDURE

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

FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15

CALIPER ASSEMBLY VIEW

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

CALIPER REMOVAL

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

CALIPER DISASSEMBLY

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

CALIPER INSPECTION

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

CALIPER ASSEMBLY

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

CALIPER INSTALLATION

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

FRONT BRAKE DISC SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20

DISC RUNOUT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20

DISC INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20

DISC REPLACEMENT

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

REAR BRAKE PAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

PAD REMOVAL

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

PAD INSPECTION

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

PAD INSTALLATION

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

BRAKE BURNISHING PROCEDURE

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

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

CALIPER ASSEMBLY VIEW

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

CALIPER REMOVAL

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

CALIPER DISASSEMBLY

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

CALIPER INSPECTION

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

CALIPER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.28

Summary of Contents for RANGER XP 1000 2018-2019

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

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

Page 3: ...rademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be...

Page 4: ...TER 1 GENERAL INFORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING HVAC SYSTEM CHAPTER 4 FUEL SYSTEM CHAPTER 5 PVT SYSTEM CHAPTER 6 TRANSMISSION CHAPTER 7 FINAL DRIVE CHAPTER 8 STEERING SUSPENSI...

Page 5: ...BER LOCATIONS 1 20 VEHICLE SPECIFICATIONS 1 21 2018 19 RANGER XP 900 EPS OVERVIEW 1 21 2018 19 RANGER XP 900 EPS SPECIFICATIONS 1 22 2018 19 RANGER CREW XP 900 EPS OVERVIEW 1 23 2018 19 RANGER CREW XP...

Page 6: ...jury or death If a torquing sequence is indicated for nuts bolts or screws of a certain component start all fasteners and hand tighten Following the method and sequence indicated tighten evenly to the...

Page 7: ...A4 AE AH AZ B1 B4 BE BH BZ 9928851 2019 RANGER CREW XP 900 EPS R19RVA87A1 B1 R19RVE87A9 B9 AH BH NOTICE When ordering service parts be sure to use the correct parts manual Polaris factory publications...

Page 8: ...ls 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 Dealers...

Page 9: ...U 50105 Shock Spanner Wrench 2871095 CHAPTER 3 ENGINE COOLING SYSTEM Drive Clutch Puller 2872085 Engine Stand Adapter Mounts To The Engine PU 50562 Engine Stand Sleeve Adapter Use With 2 Bore Stand PU...

Page 10: ...R XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc CHAPTER 3 ENGINE COOLING SYSTEM Oil Pressure Gauge Adapter PU 52492 Oil Pressure Gauge PV 43531 Cylinder Holding Camshaft Timing Plat...

Page 11: ...ustries Inc 1 7 CHAPTER 3 ENGINE COOLING SYSTEM Valve Spring Compressor Adapter PV 43513 A Flywheel Puller PA 49316 Piston Ring Compressor Pliers PV 43570 1 Spring Puller PU 45485 Mityvac Pressure Tes...

Page 12: ...echarge Service Kit for PU 51021 PU 51021 1 HVAC Belt Tool PU 52087 Crankshaft Pulley Holder PU 52254 CHAPTER 4 FUEL SYSTEM Fuel Pressure Gauge Kit PU 43506 A Fuel Pressure Gauge Adapter PS 48762 Fuel...

Page 13: ...PTER 4 FUEL SYSTEM Digital Wrench USB Serial Adapter Cable PU 50621 Digital Wrench SmartLink Module Kit PU 47471 Digital Wrench PC Interface Cable PU 47470 Digital Wrench Vehicle Interface Cable PU 47...

Page 14: ...utch Bushing Replacement Tool Kit 2871226 Clutch Holding Fixture 2871358 A Drive Clutch Holding Tool 9314177 A Drive Clutch Puller PA 48595 Drive Clutch Puller 2872085 Drive Clutch Spider Removal and...

Page 15: ...N Drive Clutch Puller PA 48595 Drive Clutch Puller 2872085 Clutch Center Distance Tool PU 50658 A Snorkel Tool PA 50231 Rear Output Seal Driver 2871698 Rear Driveshaft Seal Guide 2871699 CHAPTER 7 FIN...

Page 16: ...ght Polaris Industries Inc CHAPTER 8 STEERING SUSPENSION Ball Joint Tool PU 50506 Spring Compressor Tool 2870623 Shock Spanner Wrench 2871095 CHAPTER 9 BRAKE SYSTEM Mityvac Pressure Test Tool 2870975...

Page 17: ...c 1 13 CHAPTER 11 ELECTRICAL PV 43568 Fluke 77 Digital Multimeter PF 51237 Static Timing Light Harness 2871745 Hall Effect Sensor Probe Harness 2460761 Battery Conductance Analyzer MDX 610P PU 50296 C...

Page 18: ...s Step 1 2 64 lb ft 87 Nm Engine Transmission Mounting Bolts Step 3 5 lb ft 7 Nm Engine Transmission Mounting Bolts Step 4 7 44 lb ft 60 Nm Front Engine Mount Fasteners 40 lb ft 54 Nm CHAPTER 3 ENGINE...

Page 19: ...in 5 4 Nm Compressor Low Pressure Hose 25 lb ft 34 Nm Compressor High Pressure Hose 18 lb ft 24 Nm Compressor Mounting Fasteners 37 lb ft 50 Nm CHAPTER 3 HVAC ITEM TORQUE VALUE Compressor Oil Drain Pl...

Page 20: ...b ft 54 Nm Isolator Mount Bolts 22 lb ft 30 Nm Intake Plenum Hose Clamps 17 lb in 2 Nm Lower Intake Plenum Fastener 22 lb ft 30 Nm CHAPTER 6 TRANSMISSION PART DESCRIPTION TORQUE SPECIFICATION Differen...

Page 21: ...ft 31 Nm Brake Pedal Mount Bracket Nuts 18 lb ft 24 Nm Front Caliper Mounting Bolts 30 lb ft 41 Nm Wheel Nuts Steel Wheels 60 lb ft 81 Nm Wheel Nuts Cast Aluminum Wheels 120 lb ft 163 Nm CHAPTER 9 BRA...

Page 22: ...Service Manual Copyright Polaris Industries Inc CHAPTER 11 ELECTRICAL PART DESCRIPTION TORQUE SPECIFICATION Terminal Block Nuts 20 25 lb in 2 3 2 8 Nm Starter Motor Fasteners 7 lb ft 10 Nm Thermostat...

Page 23: ...d versions of models not including the base First 3 digits and 10th digit are used in model number only They are not used with the 17 digit VIN Digits 1 through 8 determine Digital Wrench calibration...

Page 24: ...ity vehicle be sure to refer to the vehicle identification number VIN and the engine model number and serial number The engine model and serial number can be found on a decal applied to the MAG side o...

Page 25: ...6 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 lb 617 kg Cargo Box Capacity 49 State 1000 lb 454 kg 50 State 600 lb 272 kg Cargo Box...

Page 26: ...l Pump EPS OPT Rear Diff Solenoid Circuit Breaker 20 Amp Fan Motor Fuses Not in Fuse Relay Box 10 Amp Brake Lights Drive Fuel Pump 20 Amp Accessory ECM Lights 30 Amp EPS OPT DRIVETRAIN Transmission Ty...

Page 27: ...eel Base 113 in 287 cm Ground Clearance 12 in 30 5 cm Turning Radius 214 in 543 5 cm Dry Weight 1570 lb 712 kg Cargo Box Capacity 49 State 1000 lb 454 kg 50 State 600 lb 272 kg Cargo Box Dimensions in...

Page 28: ...Box Chassis EFI Fan Fuel Pump EPS OPT Rear Diff Solenoid Circuit Breaker 20 Amp Fan Motor Fuses Not in Fuse Relay Box 10 Amp Brake Lights Drive Fuel Pump 20 Amp Accessory ECM Lights 30 Amp EPS OPT DR...

Page 29: ...6 cm Wheel Base 83 in 210 8 cm Ground Clearance 13 in 33 cm Turning Radius 178 in 452 cm Dry Weight 1562 lb 709 kg Cargo Box Capacity 49 State 1000 lb 454 kg 50 State 600 lb 272 kg Cargo Box Dimension...

Page 30: ...12 Volt Relays Not in Fuse Relay Box Chassis EFI Fan Fuel Pump EPS OPT Rear Diff Solenoid Circuit Breaker 20 Amp Fan Motor Fuses Not in Fuse Relay Box 10 Amp Brake Lights Drive Fuel Pump 20 Amp Acces...

Page 31: ...el Base 113 in 287 cm Ground Clearance 12 in 30 5 cm Turning Radius 214 in 543 5 cm Dry Weight 1570 lb 712 kg Cargo Box Capacity 49 State 1000 lb 454 kg 50 State 600 lb 272 kg Cargo Box Dimensions ins...

Page 32: ...lets 2 Standard 12 Volt Relays Not in Fuse Relay Box Chassis EFI Fan Fuel Pump EPS OPT Rear Diff Solenoid Circuit Breaker 20 Amp Fan Motor Fuses Not in Fuse Relay Box 10 Amp Brake Lights Drive Fuel Pu...

Page 33: ...15 Wht Blu 7044111 7044015 1800 3700 Meters 6000 12000 Feet 27 83 5632754 Wht Blu 7044111 7044015 2018 19 HUNTER PKG EDITION w EBS 0 1800 Meters 0 6000 Feet 27 81 5140011 Wht Blu 7044111 3234452 1800...

Page 34: ...nch 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 ounces pounds l...

Page 35: ...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 3 0 5 0 5 0 7...

Page 36: ...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 3 4 4 2 1 2...

Page 37: ...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 mm 0 5512 9 1...

Page 38: ...1 34 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc NOTES GENERAL INFORMATION...

Page 39: ...CTS 2 13 GENERAL VEHICLE INSPECTION AND MAINTENANCE 2 14 PRE RIDE DAILY INSPECTION 2 14 FRAME NUTS BOLTS AND FASTENERS 2 14 SHIFT CABLE INSPECTION ADJUSTMENT 2 14 ENGINE MAINTENANCE 2 15 ENGINE OIL LE...

Page 40: ...LLATION 2 32 TIRE INSPECTION 2 33 TIRE PRESSURE 2 33 STEERING MAINTENANCE 2 34 STEERING INSPECTION 2 34 TIE ROD END WHEEL HUB INSPECTION 2 34 WHEEL TOE ALIGNMENT INSPECTION 2 35 WHEEL TOE ADJUSTMENT 2...

Page 41: ...your Polaris dealer Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart IMPORTANT Service and adjustments are critical If you re not familiar...

Page 42: ...ssure Minimum 10 PSI 1200 RPM Minimum 40 PSI 7000 RPM Minimum Spark Plug Type Gap NGK MR7F 0 030 in 0 75 mm Tire Pressure Base CREW Front 10 psi 69 kPa 14 psi 97 kPa Rear 12 psi 83 kPa 16 psi 110 kPa...

Page 43: ...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 period consist...

Page 44: ...nspect for tire damage nails in tire Verify there is adequate tread depth Wheels Lug Nuts Ensure rim is not cracked bent Verify proper lug nut torque Headlights Taillights Ensure all lights are operat...

Page 45: ...7 ITEM INSPECTION CHECK Engine Intake Pre Filter Screen LH side Inspect clean often PVT Intake Pre Filter Screen RH side Inspect clean often Power Steering Unit Inspect clean often Spark Arrester Clea...

Page 46: ...hange fluid every 25 hours if ADC is subjected to extreme use Front Gearcase Lubricant Demand Drive Fluid 25 H 1 M Initial fluid level inspection add lubricant if needed Transmission Lubricant AGL Gea...

Page 47: ...pressurize fuel pump check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years Cooling Hoses 100 H 12 M 1000 1600 Inspect for leaks Engine Mounts 100 H 12 M 1000 1600 In...

Page 48: ...reme Duty Remove cargo box panel and add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereafter Engine Coolant Reservoirr Radia...

Page 49: ...vel during pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant until it is visible at the fill hole threads w 7 5 oz 222 mL Initial level check at 25 hou...

Page 50: ...il all traces of water have been purged out at each of these areas ITEM METHOD RECOMMENDED LUBE FREQUENCY q A arm Pivot Bushings Grease all fittings on each side of the vehicle Polaris All Season Grea...

Page 51: ...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 2871423 Premium All Season Grease 14 o...

Page 52: ...ear drive shafts Check all suspension components for wear or damage FRAME NUTS BOLTS AND FASTENERS Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check th...

Page 53: ...Do not lock the dipstick NOTICE Make certain the dipstick is inserted 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 A...

Page 54: ...t Oil Filter Wrench PU 50105 2 5 64 mm 9 Using a clean dry cloth clean the filter sealing surface on the engine crankcase 10 Lubricate the O ring on the new oil filter with a film of fresh engine oil...

Page 55: ...ded oil as necessary to bring the oil level within the SAFE range on dipstick Do not overfill 21 When finished reinstall the oil fill cap oil dipstick and lock the lever 22 Dispose of used oil and fil...

Page 56: ...Belt Removal page 5 12 procedure 4 Remove the spark plug wires q from the engine 5 Remove the four T 40 bolts w and rubber isolators e retaining the valve cover r Note the location and use of the gro...

Page 57: ...ark plug wire s Ensure wires are pushed down all the way so they engage onto the spark plug s NOTICE The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are...

Page 58: ...to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousnessor dea...

Page 59: ...not fully purged from system Polaris Premium 50 50 Extended Life coolant is already premixed and ready to use Do not dilute with water COOLANT STRENGTH TYPE Test the strength of the coolant using an...

Page 60: ...dard pressure cap will not allow the recovery system to function properly 7 Remove the recovery bottle cap and add coolant using a funnel 8 Fill the recovery bottle to the MAX mark with the recommende...

Page 61: ...steam 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 co...

Page 62: ...if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and waterand change clothing Never start the engine or let i...

Page 63: ...ly NOTICE Make sure lines are not kinked or pinched VENT LINE NOTICE If the vent line fitting is removed from the fuel tank it must be replaced The fitting will not hold properly once it is removed 1...

Page 64: ...eriodic Maintenance Chart In extremely dusty conditions air filter replacement will be required more often 1 Tilt the rear cargo box to access the airbox 2 Release the 5 airbox cover latches and lower...

Page 65: ...D VIEW REF DESCRIPTION REF DESCRIPTION q LID AIRBOX o CLAMP HOSE w BASE AIRBOX a CLAMP SPRINGBAND e CLIP AIRBOX s FILTER MAIN AIRBOX r BRACKET AIRBOX MOUNT d PLUG DRAIN t HOSE ENGINE INTAKE f HOSE INT...

Page 66: ...ual Copyright Polaris Industries Inc EXHAUST HEAT SHIELD INSPECTION IMPORTANT Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly ITEM DESCRIPTION q Close of...

Page 67: ...not even with bottom threads add recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification TORQUE Transmission Fill Drain Plug 10 14 lb ft 14 19 Nm Transmi...

Page 68: ...If fluid level is not even with the bottom threads add the recommended fluid as needed Do not overfill 5 Reinstall the fill plug and torque to specification TORQUE Front Gearcase Fill Drain Plug 8 10...

Page 69: ...rain plug 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 drain plug q and O ring from the out...

Page 70: ...on is still in PARK 2 Install the wheel on the wheel hub with the valve stem toward the outside Be sure rotation arrow on the tire if applicable point toward forward rotation 3 Attach the wheel nuts q...

Page 71: ...RNING Operating with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the usable tread d...

Page 72: ...steering components are replaced WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized...

Page 73: ...ance between the marks and record Call this measurement B Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe...

Page 74: ...the proper toe setting as specified in Wheel Toe Alignment Inspection IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wea...

Page 75: ...affect ride height as the weight transfer will not be changed Vehicle loads effect suspension spring pre load requirements Use Spanner Wrench to adjust pre load as necessary to avoid bottoming of the...

Page 76: ...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 apply the brake pedal forcefully for a few seconds...

Page 77: ...or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTICE Batteries must be fully charged before use or battery life will be reduced by 10 30 o...

Page 78: ...round terminals Be sure they are clean and tight SPARK PLUG SERVICE Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart 1 Tilt the rear cargo box to access...

Page 79: ...incorrect spark plug is used Recommended Spark Plugs NGK MR7F 10 Apply anti seize compound to the spark plug threads 11 Install spark plugs and torque to specification TORQUE Spark Plug 7 lb ft 10 Nm...

Page 80: ...2 42 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc NOTES MAINTENANCE...

Page 81: ...LER GEARS STATOR COVER 3 18 SPARK PLUGS STARTER THERMOSTAT HOUSING THROTTLE BODY VALVE COVER 3 19 ENGINE SERVICE 900 1000 3 20 ACCESSIBLE ENGINE COMPONENTS 3 20 ENGINE REMOVAL 3 20 ENGINE INSTALLATION...

Page 82: ...ARING SELECTION 3 65 CRANKSHAFT MAIN BEARING SELECTION 3 65 UPPER CRANKCASE PREPARATION 3 66 PISTON RING INSTALLATION 3 66 PISTON CONNECTING ROD ASSEMBLY 3 68 CYLINDER PISTON INSTALLATION 3 69 CRANKSH...

Page 83: ...TEM OVERVIEW 3 118 AIR CONDITIONING DESCRIPTION 3 118 HVAC ASSEMBLY VIEW 3 119 A C SYSTEM DIAGRAM 3 120 SAFETY EQUIPMENT 3 121 HVAC SYSTEM COMPONENTS 3 121 HVAC MAINTENANCE 3 124 COMPRESSOR DRIVE BELT...

Page 84: ...ERATURE POTENTIOMETER TESTING 3 141 HVAC BREAKOUT DIAGRAM 3 142 TROUBLESHOOTING HVAC 3 143 BLOWER MOTOR DOES NOT OPERATE 3 143 BLOWER MOTOR OPERATES NORMALLY BUT AIR FLOW IS INSUFFICIENT 3 143 INSUFFI...

Page 85: ...Oil Pump Sprocket or Chain Piston Rings SPECIAL TOOLS ENGINE COOLING SYSTEM 900 1000 TOOL DESCRIPTION PART NUMBER Drive Clutch Puller 2872085 Engine Stand Adapter Mounts To The Engine PU 50562 Engine...

Page 86: ...al 105 Lower Crankcase Bolts Step 1 M10 9 lb ft 12 Nm Lower Crankcase Bolts Step 2 M10 21 lb ft 28 Nm Lower Crankcase Bolts Step 3 M10 Additional 90 Lower Crankcase Bolts M8 26 lb ft 35 Nm PART DESCRI...

Page 87: ...7 lb ft 10 Nm Engine Intake Duct Clamps 17 lb in 2 Nm Air Box Fasteners 8 lb ft 11 Nm Exhaust Headpipe Mounting Bolts 18 lb ft 24 Nm Thermostat Cover Bolts 7 1 lb ft 10 1 Nm Coolant Bleed Screw 7 1 l...

Page 88: ...eat 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 0590 0 0039 1 5...

Page 89: ...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 Bore I D 1 7318 1 7321 4...

Page 90: ...t 001 0 025 mm Cylinder Taper Limit 001 0 025 mm Cylinder to Piston Clearance 0009 0019 0 025 0 050 mm Cylinder Head Cylinder Head Surface Warp Limit 0039 0 1 mm Cylinder Head Standard Height 4 717 00...

Page 91: ...d Bore I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D 1 6140 1 6143 40 996 41 004 mm 1 6129 40 970 mm G Marking Main Journal O D 1 6137 1 6140 40 988 40 995 mm 1 6129 40 970...

Page 92: ...ANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc ENGINE DETAIL TORQUE VALUES SEQUENCES ASSEMBLY NOTES 900 1000 MAIN ENGINE COMPONENTS TORQUE SPECIFICATION AND SEQUENCE Cam Carrie...

Page 93: ...3 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 3 13 Crankcase Split Line Bottom Crankcase Split Line Top ENGINE COOLING HVAC SYSTEM...

Page 94: ...3 14 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc Cylinder Head Sump Cover ENGINE COOLING HVAC SYSTEM...

Page 95: ...3 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 3 15 Stator Cover ENGINE COOLING HVAC SYSTEM...

Page 96: ...3 16 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc BALANCE SHAFT CONNECTING RODS CRANKCASE CRANKSHAFT PISTONS ENGINE COOLING HVAC SYSTEM...

Page 97: ...3 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 3 17 CYLINDER OIL COOLER OIL FILTER OIL PUMP OIL SUMP WATER PUMP ENGINE COOLING HVAC SYSTEM...

Page 98: ...3 18 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc CAMSHAFTS CYLINDER HEAD FLYWHEEL IDLER GEARS STATOR COVER ENGINE COOLING HVAC SYSTEM...

Page 99: ...3 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 3 19 SPARK PLUGS STARTER THERMOSTAT HOUSING THROTTLE BODY VALVE COVER ENGINE COOLING HVAC SYSTEM...

Page 100: ...t 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 whe...

Page 101: ...lastic tie straps J retaining the harness to the transmission 10 Using an 8mm socket remove the two bolts retaining the fuel rail and fuel injectors Remove the fuel rail assembly from the intake and p...

Page 102: ...tronic throttle control as an assembly 15 Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current position 16 Using a 15mm socket remove the four bolts from...

Page 103: ...the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 22 Remove the starter motor bolts and starter motor from the engine 23 Remov...

Page 104: ...Bolts 44 lb ft 60 Nm 4 Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame NOTICE Have an assistant help guide the engine in and out of the...

Page 105: ...the bolts so they remain loose at this time NOTICE DO NOT torque fasteners at this time 10 Install NEW two longer bolts into left side mounting holes Torque left side mounting bolts to specification...

Page 106: ...dapters before tightening the hose clamps 19 Loosely install the fastener securing the bottom of the intake plenum to the rear transmission mount Do NOT torque fastener yet 20 Tighten the hose clamps...

Page 107: ...ll the rear cargo box assembly Refer to Cargo Box Assembly page 10 27 procedure NOTICE Be sure to connect the tail light harness upon installation 33 Connect the negative battery cable 34 Remove the r...

Page 108: ...not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unl...

Page 109: ...ug and thread in the oil pressure adapter Torque the adapter to specification TORQUE PU 52492 22 ft lbs 30 Nm 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOT...

Page 110: ...3 30 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc ENGINE OIL FLOW CHART ENGINE COOLING HVAC SYSTEM...

Page 111: ...over seal e if oil leaks are evident 3 Remove the spark plugs r Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber CAMSHAFT REMOVAL NOTICE The camshaf...

Page 112: ...tensioner from the cylinder Use a new tensioner gasket upon assembly 7 Remove the remaining bolts r from each camshaft sprocket 8 Lift the chain and sprockets off the camshafts to allow each sprocket...

Page 113: ...ead if worn beyond service limit or if any surface is pitted or damaged 1 Visually inspect each cam lobe for wear or damage 2 Measure the height of each cam lobe from the base circle to highest point...

Page 114: ...carriers to measure the camshaft bore Torque bolts in sequence to specification Replace cylinder head if worn TORQUE Camshaft Carrier Bolts 7 lb ft 10 Nm NOTICE Replace cylinder head if camshaft jour...

Page 115: ...if any part is worn past the service limit MEASUREMENT Camshaft Lobe Height Intake 1 5390 1 5429 39 09 39 19 mm Service Limit 1 5370 39 04 mm Exhaust 1 5142 1 5181 38 46 38 56 mm Service Limit 1 5122...

Page 116: ...cylinder head can be serviced with the engine installed in the chassis 1 Disconnect coolant hose from thermostat housing if connected 2 Remove the two outer M6 bolts A that retain the cylinder head B...

Page 117: ...points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head MEASUREMENT Cylinder Head Warp L...

Page 118: ...alve L out keeping it in order for reassembly in the same valve guide 7 Repeat the previous steps to remove the remaining valves 8 Clean the combustion chamber and head gasket surface 9 Measure the fr...

Page 119: ...and end of the guide using a small hole gauge and a micrometer Measure in two directions MEASUREMENT Valve Guide I D 0 2165 0 2171 5 500 5 515 mm 7 Be sure to measure each guide and valve combination...

Page 120: ...ace shield during cylinder head disassembly and reassembly Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions...

Page 121: ...erence angle 46 apply black permanent marker to the entire valve face A 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Blue indicate...

Page 122: ...performed by a technician proficient in cylinder head reconditioning techniques Reconditioning techniques vary so follow the instructions provided by the valve reconditioning equipment manufacturer D...

Page 123: ...rence angle 46 apply black permanent marker to the entire valve face q 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Blue indicates...

Page 124: ...with clean engine oil and apply oil or water based lapping compound to the face of the valve NOTICE Lapping is not required if an interference angle reconditioning method is used 10 Insert the valve...

Page 125: ...tor 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 insta...

Page 126: ...oil cooler Leave them all attached to the water pump housing 2 Remove the three gold colored bolts retaining the water pump housing to the engine Note the location of the shorter bolt 3 Remove the wa...

Page 127: ...e engine installed in the chassis 7 Remove the stator cover and flywheel Refer to Stator Cover Removal Inspection page 3 45 and Flywheel Removal page 3 46 procedures 8 Place flywheel on a work bench w...

Page 128: ...Inspect drive surface of starter gear D and bushing E for wear damage or uneven surface If any starter one way clutch component is worn or damaged replace the clutch and starter gear as an assembly C...

Page 129: ...taining the sump cover D to the crankcase 8 Remove the sump cover D from the crankcase 9 Remove and clean oil pump pick up E 10 Remove the three bolts F that retain the oil pump G to the crankcase 11...

Page 130: ...assembly must be replaced Replace the oil pump seal J during crankcase assembly NOTICE Oil pump assembly is non serviceable 14 Rotate the engine so the cylinder is facing up 15 Remove the eleven M6 an...

Page 131: ...pon assembly 3 Carefully rotate the balance shaft L and remove it from the crankcase 4 Inspect the balance shaft gear teeth for damage 5 Measure each bearing journal in two locations 90 degrees apart...

Page 132: ...each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts M Remove the end caps from the crankshaft 5 Carefully lift the crankshaft N out of the crankcase 6 Remove the...

Page 133: ...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 in 0 025 mm 11 Visu...

Page 134: ...rd 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 Bearing Standard 1 6115 1 6118 40...

Page 135: ...ted in the case Refer to bearing selection procedures upon assembly NOTICE Always replace plain bearings when the crankcase or connecting rods have been disassembled Refer to the bearing selection cha...

Page 136: ...he same cylinder bore and direction from which they were removed MAG PTO CYLINDER INSPECTION 1 Lay a straight edge E across the top surface of the cylinder at several different points and measure warp...

Page 137: ...der 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 900 NOTICE New pistons are d...

Page 138: ...n if out of specification MEASUREMENT Piston Pin O D 0 7872 0 7874 19 995 20 000 mm Service Limit 0 7866 19 98 mm PISTON DISASSEMBLY INSPECTION 1000 NOTICE New pistons are directional intake vs exhaus...

Page 139: ...Limit 7866 19 98 mm PISTON RING REMOVAL 1 Carefully remove top compression ring B by hand or using a ring removal pliers PV 43570 1 CAUTION DO NOTexpand the ring more than necessary to remove it from...

Page 140: ...ts MEASUREMENT Piston Ring to Groove Clearance Top Ring 0 0012 0 0037 0 030 0 095 mm Second Ring 0 0012 0 0030 0 030 0 076 mm Service Limit 0 0047 0 12 mm PISTON RING TO GROOVE CLEARANCE INSPECTION 1...

Page 141: ...1 02 mm Service Limit 0 059 1 50 mm NOTICE Always check piston ring installed gap when installing new rings and or a new cylinder PISTON RING INSTALLED GAP 1000 1 Place each piston ring q inside the...

Page 142: ...ge 3 56 procedure MEASUREMENT Piston O D Standard 3 6592 0003 92 950 008 mm MEASUREMENT Piston to Cylinder Clearance 0014 0026 035 065 mm PISTON TO CYLINDER CLEARANCE 1000 Measure piston outside diame...

Page 143: ...l the bolts 4 Tighten bolts by hand then torque to 9 ft lbs 12 Nm prior to taking any measurements 5 Using a dial bore gauge measure big end I D in two directions shown Record measurements and compare...

Page 144: ...TIFICATION LETTERS AND NUMBERS q Connecting Rod Bearing Identification Number one number w Crankcase Bearing Identification Number six numbers Some engines may only have 4 digits The extra two digits...

Page 145: ...Rod Crankshaft Rod Code B G Y 1 Blue Blue Green 2 Blue Green Yellow 3 Green Yellow Yellow CRANKSHAFT MAIN BEARING SELECTION In order to select the proper main bearings for the crankshaft you must refe...

Page 146: ...to Engine Oil Flow Chart page 3 30 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 soapy water Rinse wit...

Page 147: ...second ring with marking facing top of piston Rotate ring to position the end gap toward intake side of piston as shown below 5 Install top ring with mark facing top of piston Rotate ring to position...

Page 148: ...cting rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is recommended th...

Page 149: ...Piston Ring Installation page 3 66 procedure 3 Note the piston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side NOTICE Orientation arrow is also located o...

Page 150: ...down 2 Clean the bearing bore surfaces of upper crankcase main bearings connecting rods and connecting rod caps 3 Align tab of new main bearing A with the slot in main bearing bore of crankcase Press...

Page 151: ...l 90 CRANKSHAFT INSTALLATION 1000 IMPORTANT Whether installing a new crankshaft or re installing the original refer to the bearing selection charts in the Crankshaft Main Bearing Selection page 3 65 a...

Page 152: ...aft 9 Carefully lower the crankshaft into upper crankcase Guide connecting rods onto the rod journals of crankshaft as necessary 10 Adjust the PTO crankshaft seal so it rests properly in the upper cra...

Page 153: ...bearings A with the slot in each bearing bore of crankcase Press bearing insert firmly into place 3 Rotate the crankshaft until the alignment dot B on the crankshaft MAG end gear is visible 4 Apply P...

Page 154: ...ssages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before assembling the crankcase CRANKCASE ASSEMBLY 1 Check to...

Page 155: ...0 Bolts Step 1 9 lb ft 12 Nm Step 2 21 lb ft 28 Nm Step 3 Additional 90 M8 Bolts 26 lb ft 35 Nm M6 Bolts 9 lb ft 12 Nm 11 Rotate the engine so the cylinder is facing up 12 Install the eleven M6 and tw...

Page 156: ...ously removed Torque mounting screws to specification TORQUE Oil Pump Pick Up Retaining Screws 7 lb ft 10 Nm 20 Clean the gasket sealing surfaces on oil sump cover and crankcase to remove old gasket m...

Page 157: ...sump cover bolts in sequence to specification Repeat the sequence to verify final torque TORQUE Oil Sump Cover Bolts M6 Bolts 9 lb ft 12 Nm M8 Bolts 26 lb ft 35 Nm 25 Reinstall the crankcase drain pl...

Page 158: ...cess 2 Clean screw threads in flywheel to remove all oil or grease 3 Place one way clutch on flywheel and install three NEW screws Torque screws to specification IMPORTANT One Way Clutch Retaining Scr...

Page 159: ...unavailable using an applicator to internal taper surface on flywheel Apply bead 5 6 mm from the center of the taper offset to the larger diameter of the taper on the flywheel By hand lightly press th...

Page 160: ...or 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 and crankcase at any tim...

Page 161: ...ated in retaining groove and square with the guide CAUTION Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring C and retainer D in clean...

Page 162: ...ance Adjustment page 3 93 for proper shim selection If any valve train components were replaced refer to Valve Clearance Adjustment page 3 93 procedure prior to Camshaft Installation Timing page 3 84...

Page 163: ...shaft Timing Plate PU 50563 3 Prepare cylinder head gasket sealing surfaces by cleaning thoroughly to remove all residue The head gasket must be installed clean and dry free from oil or grease NOTICE...

Page 164: ...to this procedure 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 places the PTO cylinder at TDC for...

Page 165: ...te PU 50563 into the end of camshafts as shown Use a 13 16 open end wrench to rotate camshafts slightly if needed 8 Verify TDC mark on the flywheel is still properly aligned see Step 1 9 Pull cam chai...

Page 166: ...aining bolts t upon assembly Install the top bolt in each camshaft sprocket Do not torque the bolts at this time IMPORTANT Use NEW sprocket retaining bolts upon assembly 13 Verify cam timing is correc...

Page 167: ...ification TORQUE Tensioner Mounting Bolts 7 ft lb 10 Nm 20 Install the plunger bolt Torque fastener to specification TORQUE Plunger Bolt 15 ft lb 20 Nm 21 Rotate the engine using the flywheel and inst...

Page 168: ...9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 26 Rotate crankshaft through two revolutions and verify camshaft timing is correct ENGINE COOLING HVAC SY...

Page 169: ...s made during disassembly If installing new camshafts or if camshafts were not marked you can reference the part number stamped on the end of the shafts and compare to the electronic parts catalog 3 L...

Page 170: ...face Refer to Camshaft Timing Quick Referencepage 3 92 topic NOTICE Intake cam sprocket should have I marks aligned with gasket surface and the exhaust cam sprocket should have E marks aligned with ga...

Page 171: ...the flywheel and torque the remaining sprocket bolts to specification 18 Install the front camshaft carrier o and two outer retaining bolts 19 Install the fixed cam chain guide a and two retaining bo...

Page 172: ...3 92 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc CAMSHAFT TIMING QUICK REFERENCE ENGINE COOLING HVAC SYSTEM...

Page 173: ...ll the camshafts into the cylinder head The PTO camshaft lobes e should face out as shown 4 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when...

Page 174: ...a valve adjustment shim from falling into the cylinder or crankcase 11 Record the 3 digit number on the bottom of the tappet i 12 Reference the valve clearance measurement recorded for that valve alo...

Page 175: ...cation TORQUE Spark Plugs 7 lb ft 10 Nm 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Inspect the valve cover seal B and replace if necessary 5 Replace the isol...

Page 176: ...sh Specification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the...

Page 177: ...ntaminants from entering the engine 3 Remove the clamp holding the engine crankcase breather hose 4 Remove the fasteners holding the air box assembly to the frame of the vehicle 5 Remove the clamp hol...

Page 178: ...el Install the clamp holding the air box intake hose to the intake duct Torque the clamp to specification TORQUE Intake Duct Clamps 17 lb in 2 Nm 3 Place the air box assembly with engine intake hose i...

Page 179: ...kcase breather hose to the air box assembly 6 Remove clean cloth in the throttle body inlet preventing anything from entering engine Install the clamp holding the engine intake hose to the throttle bo...

Page 180: ...the throttle body Place clean cloth inside throttle body inlet to prevent any contaminants from entering the engine 5 Carefully remove electrical harness from fuel injectors q TMAP sensor w and Throt...

Page 181: ...Industries Inc 3 101 9 Loosen intake boot Hose Clamps o at cylinder head IMPORTANT Make note of Hose Clamps orientation for installation 10 Loosen Intake Manifold Mounting Bolt a located at the trans...

Page 182: ...p 17 lb in 2 Nm 5 Torque Intake Manifold Mounting Bolt to specification TORQUE Intake Manifold Mounting Bolt 22 lb ft 30 Nm 6 Install electrical harness to engine and plug in Fuel Injectors q TMAP sen...

Page 183: ...all engine intake hose to throttle body Torque clamp to specification TORQUE Intake Hose Clamp 17 lb in 2 Nm 12 Perform ETC Learn Procedurepage 4 24 connecting battery as needed 13 Inspect engine whil...

Page 184: ...tor 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 mounting post from front isolator mount C...

Page 185: ...3 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 3 105 COOLING SYSTEM SERVICE 900 1000 COOLING SYSTEM EXPLODED VIEW ENGINE COOLING HVAC SYSTEM...

Page 186: ...3 106 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc WATER PUMP EXPLODED VIEW ENGINE COOLING HVAC SYSTEM...

Page 187: ...ssible engine damage Polaris Premium 50 50 Extended Life Antifreeze is recommended for use in all cooling systems and comes pre mixed ready to use COOLING SYSTEM PRESSURE TEST 1 Remove the hood from t...

Page 188: ...re placed properly in the frame support RADIATOR REMOVAL COOLANT DRAIN 1 Allow the vehicle to cool down if recently operated 2 Remove the hood from the front cab WARNING Escaping steam can cause burns...

Page 189: ...e page 3 110 THERMOSTAT REPLACEMENT 1 Remove the hood from the front cab WARNING Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to...

Page 190: ...the hood from the front cab 3 Remove the recovery bottle cap q and fill the bottle to the MAX line 4 Remove the pressure cap w and add the necessary amount of Polaris Premium Antifreeze to the radiato...

Page 191: ...the three coolant hoses that are attached to the water pump Note location and routing for installation Be sure to catch and dispose of coolant properly 10 Remove the three bolts retaining water pump t...

Page 192: ...ne crankcase 9 Be sure water pump is fully seated and the drive tab and slot are properly engaged 10 Install the three water pump mounting bolts noting location of shorter bolt and torque to specifica...

Page 193: ...arbor press properly support the water pump housing and press out the water pump shaft from the impeller side 7 Extract the mechanical seal and the oil seal from the water pump housing NOTICE A 5 32 4...

Page 194: ...e impeller bolt Install washer and impeller bolt and torque to specification TORQUE Water Pump Impeller Bolt 7 lb ft 10 Nm Apply Loctite 204 to bolt threads 18 Clean water pump cover and housing gaske...

Page 195: ...ical failure Engine Runs But Will Not Idle Restricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable...

Page 196: ...ROUBLESHOOTING Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to...

Page 197: ...ulley Fastener 44 lb ft 60 Nm 180 Upper Condenser Hose 18 ft lb 24 Nm Lower Condenser Receiver Drier Hose 12 ft lb 16 Nm Condenser Upper Mounting Bolt 14 ft lb 19 Nm Condenser Lower Mounting Bolts 8 f...

Page 198: ...so serves as the storage tank for the liquid refrigerant The liquid refrigerant still under high pressure flows to the expansion valve The expansion valve meters the amount of refrigerant into the eva...

Page 199: ...Condenser 3 Receiver Drier 4 Pressure Relief Valve 5 Expansion Valve 6 Heater Evaporator Unit 7 Cabin Air Filter 8 Electronic De icing Thermostat EDT 9 A C Charge Port 10 Heater Valve 11 High Pressur...

Page 200: ...3 120 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc A C SYSTEM DIAGRAM ENGINE COOLING HVAC SYSTEM...

Page 201: ...us frostbite if it contacts the skin Gaseous R 134a becomes lethal phosgene gas when it contacts open flame or very hot substances NEVER smoke when there is the possibility of even small amounts of R...

Page 202: ...ols and dehumidifies the air before it enters the cab Thermostat The thermostat o and probe a controls the temperature of the evaporator coil Heater Evaporator Blower The blower s is used to pull air...

Page 203: ...he heater valve h is used to control the amount of engine coolant that flows to the heater coil Pressure Switch The high pressure switch j will disengage the compressor clutch at high pressure reading...

Page 204: ...ge wear separation or oil Check for debris or buildup in the drive belt splines If any of these conditions exist replace the belt NOTICE ALWAYS use the specified drive belt Using a non specified belt...

Page 205: ...e dash 2 Remove the hood and the cabin air filter 3 Clean the filter with low air pressure Check for damage replace if damaged REFRIGERANT This system uses R 134a refrigerant Running or mixing any oth...

Page 206: ...lethal phosgene gas when it contacts open flame or very hot substances NEVER smoke when there is the possibility of even small amounts of R 134a in the air Any servicing work that involves release or...

Page 207: ...euse a drive belt that has been removed Always replace with a NEW belt 1 Position the vehicle on a level surface place the transmission in PARK and stop the engine 2 Tilt the rear cargo box to the upr...

Page 208: ...of the pulley holes 10 Route the belt over the wedge of the tool and then turn the tool counter clockwise using 3 8 in drive ratchet until the belt is fully seated on the pulley 11 Verify the belt is...

Page 209: ...rigerant using an A C recovery system 2 Remove the compressor drive belt Refer to Compressor Drive Belt Replacement page 3 127 procedure 3 Disconnect the compressor clutch wire 4 Remove the low pressu...

Page 210: ...ded to the system because the compressor comes factory filled with oil IMPORTANT Only PAG 100 oil should be used Never mix R 12 and R 134a Oils COMPRESSOR OIL INSPECTION The compressor oil should be c...

Page 211: ...sor oil through the suction side connector r Add 150 170 cc s of PAG 100 oil NOTICE The suction port on the compressor is marked with an S and is the larger ALTERNATOR INSPECTION 1 Disconnect the nega...

Page 212: ...the compressor drive belt Refer to Compressor Drive Belt Replacement page 3 127 procedure 3 Disconnect the wire harness connector and power cable from the alternator 4 Remove the alternator mounting...

Page 213: ...sing Crankshaft Pulley Holder PU 52254 to assist 5 Remove the fasteners holding the HVAC cover mount to the engine 6 If necessary remove the fasteners holding the timing wheel and adapter hub to the e...

Page 214: ...e inlet tube w from the condenser 5 Cap and plug the tube and the condenser fittings with the proper A C caps and plugs 6 Remove the two bolts e and move the drier out of the way 7 Remove the two bolt...

Page 215: ...stem the receiver drier q must be changed 3 Remove the tube line w from receiver drier IMPORTANT Never leave hose fittings compressor fittings or components uncapped while working on the A C system 4...

Page 216: ...coming off the receiver drier HPCO SWITCH REPLACEMENT NOTICE Replacement of the high pressure cut out switch does NOT require discharging recharging the R 134a refrigerant 1 Disconnect the pressure sw...

Page 217: ...se removal procedure Torque heater evaporator unit mounting fasteners to specification TORQUE Heater Evaporator Unit Mounting Fasteners 10 lb ft 14 Nm 10 Recharge the A C system EXPANSION VALVE EVAPOR...

Page 218: ...g the hoses and the expansion valve fittings with the proper A C caps and plugs 6 If removing the evaporator coil remove the fasteners holding the evaporator coil to the heater coil 7 To Install rever...

Page 219: ...es a toxic gas 2 Remove the heater evaporator unit from the vehicle Refer to Heater Evaporator Unit Replacement procedure 3 Remove the heater coil from the heater evaporator unit Refer to Heater Coil...

Page 220: ...EATER VALVE REPLACEMENT 1 Remove the passenger seat and storage bin 2 Disconnect the wiring harness from the heater valve 3 Remove the hose clamps and coolant hoses from the heater valve NOTICE Plug t...

Page 221: ...ter is interpreted by the water valve to control the flow of warm water through the heater core to warm the air The HVAC control panel is a single unit If any of the individual switches are found to n...

Page 222: ...3 142 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc HVAC BREAKOUT DIAGRAM ENGINE COOLING HVAC SYSTEM...

Page 223: ...tinuity to ground when powered on Fan should also turn on If the fan does not turn on verify proper continuity to the HVAC control head Repair replace harness as necessary Pin 46 should have continuit...

Page 224: ...ace the relay Repair replace the harness if necessary 5 Check the High pressure cutoff switch for power at Pin A If power is present replace the HP switch If there is no Power at the HP switch measure...

Page 225: ...ary SYMPTOM POSSIBLE CAUSE SOLUTION 1 Loose drive belt The belt is vibrating or oscillating Adjust tension 2 Internal compressor malfunction The compressor is locked up and the belt slips Replace comp...

Page 226: ...xpansion valve A Negative low pressure reading may be shown Flush system or replace hose 4 Thermostat malfunction The evaporator is frozen Adjust themostat s temperature setting or probe placement or...

Page 227: ...71 19 140 229 40 75 78 75 145 245 80 80 86 80 150 263 00 85 95 40 155 281 10 90 104 40 160 300 10 91 106 30 165 320 10 92 108 20 170 340 80 Evaporator Pressures represent gas temperatures inside the c...

Page 228: ...position Turn the temperature control e to the High A C position 2 Start the utility vehicle and run at high idle for ten minutes 3 Check the heater hose r for temperature If the hose is hot the heate...

Page 229: ...VENT LINE ROUTING 4 12 FUEL TANK SERVICE 4 13 FUEL TANK EXPLODED VIEW 4 13 FUEL LINE REMOVAL INSTALLATION 4 14 FUEL TANK REMOVAL 4 14 FUEL TANK INSTALLATION 4 15 FUEL PUMP SERVICE 4 16 OPERATION OVERV...

Page 230: ...GEN SENSOR REPLACEMENT 4 34 FUEL SYSTEM DIAGNOSIS 4 35 INSTRUMENT CLUSTER TROUBLE CODE DISPLAY 4 35 CYLINDER MISFIRE DETECTION 4 40 FUEL SYSTEM TROUBLESHOOTING 4 41 DIGITAL WRENCH OPERATION 4 42 DIGIT...

Page 231: ...ning issues a known good ECU from another RANGER of the same model and year may be used without damaging system or engine components Never attempt to service any fuel system component while engine is...

Page 232: ...re Gauge Kit PU 43506 A NOTICE The EFI fuel system remains under high pressure even when the engine is not running Before attempting to service any part of the fuel system pressure should be relieved...

Page 233: ...Solutions 1 800 345 2233 or http polaris service solutions com Digital Wrench Diagnostic Connector The diagnostic connector is located under the passenger seat connected to a sealed plug To access the...

Page 234: ...el being injected and the ignition timing by monitoring the primary sensor signals for intake air temperature manifold absolute pressure load engine temperature engine speed RPM and throttle pedal pos...

Page 235: ...Engine Coolant Temperature Sensor ECT Electronic Throttle Control ETC Fuel Injectors Fuel Pressure Regulator Fuel Pump Fuel Rail Supply Line Ignition Coil Intake Plenum Pedal Position Sensor PPS Temp...

Page 236: ...ted on the cylinder head below the intake manifold 6 Pedal Position Sensor PPS Located on the side of the throttle pedal assembly cover removed 7 Fuel Injectors Located on the top of the intake plenum...

Page 237: ...1000 Service Manual Copyright Polaris Industries Inc 4 9 10 Fuel Pump Regulator Fuel Level Sender Assembly q q Located under the driver s seat 11 Ignition Coil High Tension Leads Located next to the a...

Page 238: ...to the fuel rail on the engine The fuel line is routed from the fuel tank underneath the driver seat and is secured to the electrical harnessq The fuel line then continues under the clutch outlet duc...

Page 239: ...elease the line 3 Disconnect the fuel line connector e securing the fuel line to the electrical harness 4 Pull the fuel line outward to remove 5 To reinstall the line verify the connections are clean...

Page 240: ...The fuel tank is vented through a vent line The vent line is routed from the fuel tank underneath the driver seat and tucked into a horizontal section of the frame w as shown The vent line is secured...

Page 241: ...ustries Inc 4 13 FUEL TANK SERVICE FUEL TANK EXPLODED VIEW REF DESCRIPTION REF DESCRIPTION q Fuel Tank Asm y Tank Vent Rollover Valve w Fuel Fill Hose u Fuel Sender Nut e Fuel Inlet i Fuel Pump Regula...

Page 242: ...ARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications 1 Remove the driver and passenger seat base and s...

Page 243: ...fuel tank into the chassis taking care not to damage brake lines or the wire harness 2 Install three plastic tie straps to retain the wire harness to the fuel tank 3 Install fuel tank brackets and two...

Page 244: ...e 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 remains on to maintain fuel pressure FUEL SENDE...

Page 245: ...el line 4 Turn on key switch to activate the pump and check the system pressure on the gauge If fuel pressure is within specification the ignition switch ECU fuel pump and pressure regulator are worki...

Page 246: ...fuel pump to ensure no debris will enter the fuel system when the fuel pump is removed CAUTION Failure to clean area around fuel pump may lead to debris entering the fuel tank during service Excessiv...

Page 247: ...sket and nut from packaging Use care not to bend float arm during un packaging Do not lift or carry fuel pump assembly by the float arm 13 Use cleaning wipes provided to clean fuel tank surface and th...

Page 248: ...Line Removal Installation page 4 14 procedure IMPORTANT Be sure to engage the retainers on each fuel line until each snaps into place Pull on fuel lines lightly to confirm connection 22 Connect the f...

Page 249: ...on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technician can determine the cause of the Check Engine...

Page 250: ...nnector Go to the Special Tests menu and select ECU Replacement Carefully follow the ECU replacement instructions 3 Remove the four T 25 Torx head screws retaining ECU to center tray 4 With the igniti...

Page 251: ...vicing 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 E...

Page 252: ...is replaced 1 After the reflash ECU replacement throttle body change leave the key on engine not running for 60 seconds Do NOTcrank the engine during this time 2 Turn the key off and wait 3 minutes Du...

Page 253: ...nkshaft 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 becomes disconnected for any re...

Page 254: ...ness connector A 3 Remove CPS wire lead from wire clip 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 to aid in...

Page 255: ...irements 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 IMPORTANT This sensor...

Page 256: ...ng operation The ECU also uses this signal to determine when to activate the cooling fan during operation ECT SENSOR TEST To quickly rule out other components and wiring related to the ECT disconnect...

Page 257: ...Removal Installation page 4 14 procedure 4 Disconnect the vehicle harness from the ECTsensor 5 Using a wrench loosen and remove ECT sensor from engine 6 Apply thread sealant to the new sensor threads...

Page 258: ...S can 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 SENSOR...

Page 259: ...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 stethoscope Disc...

Page 260: ...ised position 2 Be sure the engine has cooled enough to perform this procedure 3 Used compressed air to remove any debris from around fuel injectors CAUTION Always wear safety glasses and proper shop...

Page 261: ...jector and fuel rail as shown above 13 Thoroughly clean the area around the fuel injector ports on the intake plenum 14 Lightly lubricate the injector O rings and reinstall the fuel rail injector asse...

Page 262: ...verify if there are any stored codes for the oxygen sensor NOTICE The ECU must first run though the O2 sensor time delay before a trouble code will be set This may take several minutes at idle to occ...

Page 263: ...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 the MODE button to enter the diagnostics code menu 3 A set of...

Page 264: ...age Too Low 4 P0117 Temperature Too High 16 P0217 Engine Overheat Shutdown 0 P1217 System Power Battery Potential Power Input Voltage Too High 168 3 P0563 C1063 Voltage Too Low 4 P0562 C1064 Engine Sp...

Page 265: ...P17AA Voltage Too Low 4 P17AB Misfire Detected Cylinder Not Identified 65590 7 P0314 Cylinder 1 65591 7 P0301 Cylinder 2 65592 7 P0302 ETC Accelerator Position Sensor Outputs 1 2 Correlation Correlati...

Page 266: ...ntrol Return Spring Check Failed Condition Exists 520278 31 P151C Throttle Body Control Adaptation Aborted Condition Exists 520279 31 P151D Throttle Body Control Limp Home Position Check Failed Condit...

Page 267: ...ion Exists 520307 31 P1532 Accelerator Sensor Synchronicity Fault Sensor Difference Exceeds Limit Condition Exists 520308 31 P1533 ECU Fault ICO Condition Exists 520309 31 P1534 ECU Fault Hardware Dis...

Page 268: ...iting how far the throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues...

Page 269: ...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 war...

Page 270: ...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 271: ...enter 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 the PC Interface Cable...

Page 272: ...ng Digital Wrench NOTICE Always operate with the latest update DIGITAL WRENCH UPDATES Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website ca...

Page 273: ...ure 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 NOTICE Do not run or open the file from where they are Select save and do...

Page 274: ...4 46 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc DIGITAL WRENCH FEATURE MAP FUEL SYSTEM...

Page 275: ...likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent ca...

Page 276: ...he Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check and obtain a Request Code...

Page 277: ...pleted click the Authorize button once to proceed 12 An Authorization Key will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 13 Enter or paste CTRL V the Aut...

Page 278: ...and functions found in Digital Wrench PMDW Main Page Wireless Vehicle Link WVL Part Number PU 51435 To download the PMDW app navigate your Android device to www polarisdealers com Locate the Service...

Page 279: ...5 8 PVT DISASSEMBLY 5 9 PVT ASSEMBLY 5 10 DRIVE BELT SERVICE 5 12 BELT REMOVAL 5 12 BELT INSPECTION 5 13 BELT INSTALLATION 5 13 DRIVE CLUTCH SERVICE 5 14 DRIVE CLUTCH ASSEMBLY VIEW 5 14 DRIVE CLUTCH...

Page 280: ...upshift and backshift During the development of the Polaris vehicle the PVTsystem is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefor...

Page 281: ...IPTION SERVICE SPECIFICATION SERVICE LIMIT Drive Clutch Spring Part Number 7044111 Drive Clutch Spring Color White Blue Drive Clutch Spring Free Length 3 905 in 9 92 cm Drive Clutch Button to Tower Cl...

Page 282: ...ine RPM At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT...

Page 283: ...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 vehicle overturn...

Page 284: ...5138015 Wht Blu 7044111 7044015 1800 3700 Meters 6000 12000 Feet 27 83 5632754 Wht Blu 7044111 7044015 2018 19 HUNTER PKG EDITION w EBS 0 1800 Meters 0 6000 Feet 27 81 5140011 Wht Blu 7044111 3234452...

Page 285: ...DUCTING COMPONENTS REF DESCRIPTION REF DESCRIPTION q OUTER CLUTCH COVER o HOSE CLUTCH AIR OUTLET w O RING a HOSE CLUTCH INTAKE e PLUG DRAIN s CLAMP WORM DRIVE r SEAL OUTER d BRACKET SCREEN BELT t SEA...

Page 286: ...SCRIPTION PART DESCRIPTION PART DESCRIPTION 1 OUTER CLUTCH COVER 7 CLAMP NARROW 13 CLAMP WORM DRIVE 2 O RING 8 SCREW 14 DUCT CLUTCH INLET 3 PLUG DRAIN 9 SCREW 15 DUCT CLUTCH OUTLET 4 SEAL OUTER 10 INN...

Page 287: ...et hose clamp A and remove the ducting hose from the vehicle 3 Remove the driven clutch retaining bolt B and driven clutch 4 Install the Drive Clutch Holding Tool on the drive clutch Drive Clutch Hold...

Page 288: ...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 289: ...2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 5 11 13 Install the PVT inlet duct hose Torque the hose clamp A to specification TORQUE PVT Duct Hose Clamps 3 lb ft 4...

Page 290: ...mbly up so it sits slightly higher than the PVT cover to ease of clutch cover removal 3 Remove the grease zerk fitting D on the upper rear control arm Remove the eight screws retaining the outer clutc...

Page 291: ...it was removed 1 Install belt over drive clutch and start to install belt over driven clutch While pushing down on the belt turn the driven clutch clockwise Work the belt down in the clutch to give mo...

Page 292: ...e a Pin w Washers s Washer e Needle Bearing non EBS models One Way Clutch EBS models d Button r Spacer f Jam Nut 250 ft lb 339 Nm Apply 0 1 mL Loctite 620 t Bushing g Limiter Spacer y Moveable Sheave...

Page 293: ...alignment the clutch will not be in balance and the assembly MUST be replaced 3 Remove cover bolts evenly in a cross pattern and remove cover plate 4 Inspect cover bushing q The outer cover bushing i...

Page 294: ...rive Clutch Spring Specifications Part Number 7044263 Color White Blue Free Length 3 219 81 76 mm Spring Wire Diameter 0 177 4 50 mm BEARING INSPECTION Needle Bearing Inspection non EBS clutch 1 Rotat...

Page 295: ...new bolts and nuts CAUTION The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTICE A damaged shift weight is usually caused by a damag...

Page 296: ...2 Loosen and remove the spider w counterclockwise using Clutch Spider Removal Installation Tool PN 2870341 Spider Removal Installation Tool 2870341 Clutch Holding Fixture 2871358 A ROLLER PIN AND THR...

Page 297: ...moveable clutch sheave 3 Lift thrust washers t and bearing y off the shaft Replace as an assembly if worn damaged or if operational problems were noted prior to disassembly 4 Inspect surface of shaft...

Page 298: ...d EBS Clutch Bushing Tool Kit 2201379 ITEM QTY PART TOOL DESCRIPTION A B 1 5132027 EBS Puller Tool C 1 5132501 EBS Puller Nut D 1 5132029 EBS Main Adapter E 1 5132028 EBS Bushing Removal Tool Instruct...

Page 299: ...With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave NOTICE Use Bushing Tool PA 47336 8 Install nut C onto...

Page 300: ...arrel to increase tension as needed 26 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 27 Remove nut from puller rod and set aside 28 Remove bushing and...

Page 301: ...sheave onto stationary sheave shaft Be sure the moveable sheave slides freely on the spacer 4 Apply 0 4 mL of Loctite 620 and 0 4 mL of Loctite 7088 Primer in 90 apart in vertical stripes to the shaft...

Page 302: ...olding fixture and inspect the alignment marks made during disassembly NOTICE If the marks illustrated below are not in alignment upon assembly the clutch will not be in balance and the drive clutch a...

Page 303: ...of the clutch sheaves before disassembly or use the X s q on the sheaves for reference This aids in reassembly and maintains clutch balance after reassembly 3 Place the driven clutch into the Universa...

Page 304: ...side the moveable sheave 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...

Page 305: ...maintains clutch balance 3 Place the driven clutch helix side up into the Universal Clutch Compressor Universal Clutch Compressor PU 50518 A 4 Spin the compressor down until it just starts to contact...

Page 306: ...e the stationary sheave from the moveable sheave Note the X s a on the stationary and fixed sheaves for reassembly 11 Inspect the clutch bushings for wear If there is heavy wear on the bushings replac...

Page 307: ...ner clutch rollers for excessive wear or damage Replace components as needed Use new E rings upon assembly 5 Inspect the flanged bearings in the clutch sheaves and cam helix If bearings are damaged or...

Page 308: ...veable and stationary sheaves 2 Install the square sliders w and slider pins e 3 Install the spring pins r to retain the slider pins 4 If removed install the rollers t washers y and E clips u onto the...

Page 309: ...proper compressor may result in personal injury or damage to the clutch 8 Align the marks previously made on the helix cover and moveable sheave Install the helix cover and the four fasteners a Torque...

Page 310: ...ons B Inspect movable sheave for excessive bushing clearance Replace the clutch Engine RPM above specified operating range Incorrect drive clutch spring too high of rate Drive clutch shift weights inc...

Page 311: ...tion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Bel...

Page 312: ...earing or Flange Sleeve sticking Verify flange sleeve is retracting to flush with stationary sheave at idle Shim and align clutches to ensure proper alignment Inspect the one way bearing for drag Insp...

Page 313: ...6 6 SHIFT CABLE INSPECTION 6 6 SHIFT CABLE ADJUSTMENT 6 7 TRANSMISSION SERVICE 6 8 TRANSMISSION REMOVAL 6 8 TRANSMISSION INSTALLATION 6 11 TRANSMISSION MOUNTING TORQUE VALUES 6 14 DIFFERENTIAL OPERATI...

Page 314: ...ifferential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain SPECIAL TOOLS TRANSMISSION TOOL DESCRIPT...

Page 315: ...6 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 6 3 TRANSMISSION ASSEMBLY VIEW TRANSMISSION...

Page 316: ...asher 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 85 O Ring 19 Snap Ring 52...

Page 317: ...6 5 TRANSMISSION VENT LINE ROUTING The transmission vent line runs along the rear passenger side frame It is secured along the front frame by one retention clip as shown The vent line ends its routing...

Page 318: ...D Disconnect cable end from the lever 5 Remove the retaining ring J and slide the shift lever D off the mounting bracket and out from the frame 6 Remove both bushings K from the shift lever and servi...

Page 319: ...ove the upper jam nut F 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain pr...

Page 320: ...d support the vehicle 4 Remove the front propshaft Refer to Front Propshaft Removal Installation page 7 9 procedure 5 Remove both rear drive shafts from the transmission Refer to Rear Drive Shaft Remo...

Page 321: ...at the fuel rail wrap the ends with a clean rag to assure no dirt gets in the fuel system 13 Using a 13mm socket and wrench remove the fastener R securing the bottom of the intake plenum to the rear...

Page 322: ...the rear transmission mount bolt W 18 With the help of an assistant and a hoist raise the transmission vertically out of the vehicle frame NOTICE Have an assistant help guide the transmission in and o...

Page 323: ...the rear mount NOTICE Place a spacer or support between the vehicle frame and engine to hold the engine up in position while installing the transmission to engine mounting bolts 3 Align both the fron...

Page 324: ...b ft 60 Nm 10 Remove the clutch center distance tool 11 Remove the spacer or support between the vehicle frame and engine 12 Torque the rear transmission mount bolt B to specification TORQUE Rear Tran...

Page 325: ...he vehicle harness over the intake plenum and install five new plastic tie straps to retain the harness to the intake plenum 20 Install the transmission shift cable and washer L onto the bellcrank Ins...

Page 326: ...opshaft Removal Installation page 7 9 procedure 28 Safely lower the vehicle 29 Install the rear cargo box assembly Refer to Cargo Box Installation page 10 27 procedure NOTICE Be sure to connect the ta...

Page 327: ...rical 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 that is part...

Page 328: ...ION q Ring Gear Assembly w Male Side Gear Assembly e Planet Gear Assembly r Female Gear Assembly t Differential Cover Assembly y Planetary Differential Assembly Fasteners u Engagement Dog i Bearing o...

Page 329: ...e aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the...

Page 330: ...ly 14 Remove the rear output shaft assembly S by lifting underneath the gear or by tapping the shaft from the opposite side If use of a pry bar is necessary take care not to pry on sealing surfaces of...

Page 331: ...ks the snorkel tube 20 Remove all seals from the gearcase halves and clean the cases in preparation for assembly GEAR CLUSTER DISASSEMBLY 1 Remove the bearing from the reverse shaft using a bearing pu...

Page 332: ...g X from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compressed springs on the shift rail may pop off causing eye or face injury SNORKEL SHAFT RE...

Page 333: ...ring Y and shim Z from the snorkel shaft 5 Use an arbor press to remove the snorkel tube from the snorkel shaft 6 Remove the snap ring A and shim B retaining the bearing in the snorkel tube 7 Lightly...

Page 334: ...r and ring gear prior to disassembly 2 Remove the six screws retaining the differential cover and remove the cover 3 Remove the six planet gears and each side gear assembly from the ring gear 4 Inspec...

Page 335: ...g out of the ring gear 2 Thoroughly clean the bore of the ring gear and check for any unwanted burs 3 Press the new bushing into the ring gear housing 4 Install the bushing to the specified depth as s...

Page 336: ...s 10 Press the new bushing into the differential cover 11 Install the bushing to the specified depth as shown Female Side Gear Bushing Replacement 12 Locate the bushing split Using a small chisel or f...

Page 337: ...viously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification NOTICE The are two possible grades for the differ...

Page 338: ...6 26 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc GEAR SHAFT BEARING INSPECTION TRANSMISSION...

Page 339: ...the washer and new retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly CAUTION Failure to press th...

Page 340: ...ANT DO NOT install the longer screw A Installing the longer screw will lock the snorkel tube and not allow for backlash setting adjustment 10 Torque the bearing cover retaining screws to specification...

Page 341: ...o the 3rd notch from the zero backlash position obtained in step 11 14 Check the pinion shaft gear backlash again by feel If the pinion shaft gear lash appears to be too tight rotate the snorkel shaft...

Page 342: ...e halves thoroughly Inspect case half mating surfaces for damage 2 Install shift fork S and torsion spring into transmission housing as an assembly Load spring as shown in image below 3 Apply Loctite...

Page 343: ...lots with engagement dog Ensure bearing is fully seated upon assembly 8 Assemble shift shaft rail if previously disassembled NOTICE Both shift forks need to be orientated the same way so that the shif...

Page 344: ...d Sealant PN 2871557 to the left hand transmission mating surface 13 Install the transmission case cover and retaining bolts Torque bolts to specification TORQUE Transmission Case Bolts 15 20 lb ft 20...

Page 345: ...shift drum shaft Install the shift shaft assembly and sector gear 11T into the bushing pocket on the left side Align the timing marks on the gears as shown 17 Install the spacer onto the shift drum s...

Page 346: ...7 onto the cover and transmission case mating surface 23 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification TORQUE Sec...

Page 347: ...Shift selector rail travel Worn broken or damaged internal transmission components NOTICE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the trans...

Page 348: ...6 36 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc NOTES TRANSMISSION...

Page 349: ...AFT U JOINT SERVICE 7 11 PROPSHAFT U JOINT DISASSEMBLY 7 11 PROPSHAFT U JOINT ASSEMBLY 7 12 FRONT GEARCASE SERVICE 7 14 FRONT GEARCASE EXPLODED VIEW 7 14 ALL WHEEL DRIVE OPERATION 7 15 AWD DIAGNOSIS 7...

Page 350: ...ER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc DRIVE SHAFT CV JOINT HANDLING TIPS 7 39 OUTER CV JOINT BOOT REPLACEMENT 7 39 INNER PLUNGING JOINT BOOT REPLACEMENT 7 41 DRIVE SHAFT...

Page 351: ...o AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest SPECIAL TOOLS FINAL DRIVE TOOL DESCRIP...

Page 352: ...Manual Copyright Polaris Industries Inc FRONT GEARCASE VENT LINE ROUTING The front gearcase vent line runs along the front passenger side frame It is secured along the front frame by three retention c...

Page 353: ...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 four wheel nuts C Remove the...

Page 354: ...at all oil residue has been removed from each surface 6 Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 7 App...

Page 355: ...tle nut Install washers with domed side out 7 Install the front brake caliper Install the mounting bolts D and torque to specification TORQUE Front Caliper Mounting Bolts 30 lb ft 41 Nm 8 Torque wheel...

Page 356: ...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 page 7 39 procedure i...

Page 357: ...n NOTICE If the propshaft does not fully disengage from the transmission snorkel shaft remove the skid plate to access the front engine mount support Remove the two driver s side engine mount nuts Doi...

Page 358: ...nstallation 1 Install the rear section of the propshaft onto the transmission output shaft 2 Install and torque the two flex bearing mounting fasteners to specification TORQUE Flex Bearing Mounting Fa...

Page 359: ...aft removed and marked for alignment orientation remove the retaining rings q from both sides of the yoke 2 Using a commercially available Ball Joint U Joint Press Set place a receiving cup adapter w...

Page 360: ...installation 2 Ensure yoke bores and ring grooves are clean before installing new U joint 3 Place U joint ends w without caps into yoke bores 4 Place caps e into yoke bores and align with U joint ends...

Page 361: ...edge facing away from U joint into exposed groove 10 Place larger adapter u with ID larger than yoke bore on side with retaining ring 11 Tighten clamp until other cap is below retaining ring groove 12...

Page 362: ...r Vent Hose Fitting 2 Spring Wireform t Ball Bearing 2 H Clip Spring y Ball Bearing Double Row 2 Connector Assembly u Bushing 2 Nylon Spacer i Bushing 2 Torsion Spring Retainer o Oil Seal 2 Backlash S...

Page 363: ...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 Vdc input whic...

Page 364: ...nt or if there is wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5...

Page 365: ...out of the front propshaft yoke at the front gearcase 4 Slide the propshaft off the front gearcase input shaft splines 5 Disconnect the AWD wire harness and remove the plastic zip tie holding the AWD...

Page 366: ...late assembly NOTICE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate r Refer to AWD Diagnosis page 7 16 for detailed inspection process 5 Remove the t...

Page 367: ...detailed inspection process Replace the cover plate seal f and O ring g 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in order to retain a...

Page 368: ...all remaining front gearcase components Check each for excessive wear or damage FRONT GEARCASE ASSEMBLY 1 As mentioned during gearcase disassembly section replace all O rings seals and worn component...

Page 369: ...r grooves line up with the roll cage windows see below Be sure role cage top groove is facing upward 6 Install the torsion spring r by wrapping each leg of the spring around the dowel pin on the ring...

Page 370: ...nstall the ring gear and roll cage assembly i into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTICE Be sure the square O ring is placed flat on the cover surface If the...

Page 371: ...the propshaft onto the front gearcase 5 Install new gearcase mounting bolts A and torque to specification TORQUE Front Gearcase Mounting Bolts 30 lb ft 41 Nm 6 Drive a new roll pin into the front pro...

Page 372: ...ll faster than it is being driven ADC will not slow the vehicle When the vehicle is in 4x4 ADC the AWD coil is turned on and the ADC coil remains off until necessary When descending a hill the EBS slo...

Page 373: ...y 3 Remove the outer cover plate assembly NOTICE Press on the output hub assembly e while lifting up on the outer cover plate r to prevent removing more than the cover plate 4 Remove the output hub as...

Page 374: ...d contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or damaged 12 Thoroughly clean all parts Inspect the bearing surfaces of the output hub Inspect t...

Page 375: ...te indicates a warped plate which may cause intermittent operation NOTICE See Troubleshooting Front Gearcase ADC page 7 31 for more details 16 Drill a hole in the input shaft seal d and remove the sea...

Page 376: ...bearing onto shaft NOTICE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration...

Page 377: ...ousing 10 Align the spring retainer dowel pin with the ring gear dowel pin and install the retainer y on top of the torsion spring 11 Check the action of the torsion spring by rotating in both directi...

Page 378: ...e O ring is placed flat on the cover surface If the O ring is twisted fluid leaks may occur 15 Torque the cover plate bolts w to specification TORQUE AWD Cover Screws 8 ft lbs 11 Nm 16 Fill the gearca...

Page 379: ...blem has been fixed If not continue onto additional problems listed Check to see if front differential is plugged into wire harness Unplugged Plug wire harness into front drive connector Drive vehicle...

Page 380: ...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 li...

Page 381: ...Front Gearcase Coil Resistance B C 4X4 23 4 A D 4X4 ADC 12 49 4 2 Check the minimum battery voltage at the Grey Brown White wires that feed the hub coil wires AWD Coil Applied Battery Voltage 11 80 12...

Page 382: ...s the pole gap If the top of the coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough...

Page 383: ...ng condition and upper and lower ball joint wear REAR BEARING CARRIER REMOVAL 1 Place the transmission in Park 2 Elevate the rear end of the vehicle and safely support the vehicle under the main frame...

Page 384: ...horoughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 6 Support the bottom of the bearing carrier housi...

Page 385: ...arrier Fasteners 40 lb ft 54 Nm 5 Install the wheel hub assembly onto the drive shaft 6 Install the washers D with domed side out and the wheel hub castle nut E Torque the wheel hub castle nut to spec...

Page 386: ...HAFT SERVICE page 7 39 section if repairing the drive shaft REAR DRIVE SHAFT INSTALLATION 1 Install a new spring ring on the end of the drive shaft if not replacing the drive shaft assembly Apply an a...

Page 387: ...ot 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 use a hammer or...

Page 388: ...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 splines on the...

Page 389: ...sing the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 20 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small...

Page 390: ...oint 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 wear patterns...

Page 391: ...int 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 end of the sp...

Page 392: ...7 44 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc DRIVE SHAFT CUTAWAY VIEW FINAL DRIVE...

Page 393: ...PECTION 8 11 WHEEL TOE ALIGNMENT INSPECTION 8 11 WHEEL TOE ADJUSTMENT 8 12 SUSPENSION SERVICE 8 13 SUSPENSION INSPECTION 8 13 SPRING PRE LOAD ADJUSTMENT 8 13 SHOCK POSITION ADJUSTMENT 8 13 FRONT A ARM...

Page 394: ...01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc SHOCK SPRING SERVICE 8 27 SHOCKS ASSEMBLY VIEW 8 27 SHOCK REMOVAL INSTALLATION 8 27 SPRING REPLACEMENT 8 27 STEERIN...

Page 395: ...O NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation IMPORTANT New ball joint bolts have a pre applied locking agent which is destroyed upon removal A...

Page 396: ...SEMBLY VIEW Non EPS Models REF PART DESCRIPTION REF PART DESCRIPTION REF PART DESCRIPTION q ASM TILT STEERING u BOLT f NUT w WHEEL STEERING i BOLT g NUT e SHAFT STEERING UPPER LOWER o SCREW h NUT r AS...

Page 397: ...IPTION REF PART DESCRIPTION q MOUNT EPAS o ASM SHOCK OIL LOCKING k NUT w WHEEL STEERING a BOLT l NUT e SHAFT STEERING LOWER s BOLT 1 NUT r SHAFT STEERING UPPER d BOLT 2 NUT t ASM GEAR BOX STEERING f S...

Page 398: ...ng shaft nut NOTICE If the steering wheel will not pop loose proceed to Steering Shaft Removal Non EPS page 8 6 4 Once the steering wheel pops loose completely remove the nut and lift the steering whe...

Page 399: ...ing the upper steering shaft to the power steering unit 3 Remove the steering tilt assembly fasteners 4 Remove the fastener retaining the upper steering shaft to the power steering unit 5 Remove the s...

Page 400: ...ON q CAP w NUT e STEERING WHEEL r HUB INSERT t BUSHING y SHAFT UPPER u TILT ASSEMBLY 8 Apply Loctite 271 Red to the outer circumference of the new upper bearing race Slide the new upper bearing onto t...

Page 401: ...nto the mount bracket and torque power steering mounting bolts to specification TORQUE EPS Unit Mount Bolts 30 lb ft 41 Nm 2 Align the skip tooth spline on the power steering output shaft with the ope...

Page 402: ...king sure to reconnect the instrument cluster both 12V outlets and all the switches 12 Turn the key switch on and test EPS operation STEERING INSPECTION Steering system components should be checked pe...

Page 403: ...res 1 Place machine on a smooth level surface and set steering wheel in a straight ahead position Secure the steering wheel in this position 2 Place a chalk mark on the center line of the front tires...

Page 404: ...precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold tie rod end to keep it from rotating Loo...

Page 405: ...t ride height as the weight transfer will not be changed Vehicle loads effect suspension spring pre load requirements Use Spanner Wrench to adjust pre load as necessary to avoid bottoming of the shock...

Page 406: ...VIEW REF PART DESCRIPTION REF PART DESCRIPTION q A ARM FRONT UPPER a RING RETAINING INT w A ARM FRONT LOWER s BEARING BALL SEALED e FITTING ZERK d SHIELD CV r JOINT BALL 13 RIVET t RING RETAINER EXT...

Page 407: ...is Industries Inc 8 15 FRONT A ARM ASSEMBLY VIEW HIGH LIFTER REF DESCRIPTION REF DESCRIPTION q A ARM FRONT UPPER i NUT w A ARM FRONT LOWER o PIVOT TUBE e BEARING CARRIER a BUSHING r BEARING s BOLT t R...

Page 408: ...nto service FRONT LOWER A ARM INSTALLATION DANGER 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...

Page 409: ...val DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 1 Install the upper A arm onto the frame Torque the new upper A arm fastener to specificatio...

Page 410: ...wheel To service the upper ball joint 3 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc Refer to Front Brake Caliper Removal page 9 16 procedu...

Page 411: ...he 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 retaining ring...

Page 412: ...Inc 10 Install wheel and four wheel nuts Torque wheel nuts to specification TORQUE Ball Joint Pinch Bolts 42 lb ft 57 Nm Front Shock Mounting Bolts 40 lb ft 54 Nm Front Caliper Mounting Bolts 30 lb ft...

Page 413: ...tries Inc 8 21 REAR A ARM SERVICE REAR A ARM ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION 1 A ARM REAR UPPER 8 BOLT 2 A ARM REAR LOWER 9 WASHER 3 BEARING CARRIER 10 NUT 4 BEARING 11 PIVOT TUBE 5 RETA...

Page 414: ...yright Polaris Industries Inc REAR A ARM ASSEMBLY VIEW HIGH LIFTER REF DESCRIPTION REF DESCRIPTION q A ARM REAR UPPER u WASHER w A ARM REAR LOWER i NUT e BEARING CARRIER o PIVOT TUBE r BEARING a BUSHI...

Page 415: ...the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 1 Install the upper A arm onto the frame by mane...

Page 416: ...estroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 1 Install the lower A arm on the frame Torque new fasteners to specifica...

Page 417: ...yright Polaris Industries Inc 8 25 REAR STABILIZER BAR LINKAGE SERVICE REAR STABILIZER BAR ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q STABILIZER BAR t BUSHING w LINKAGE y BOLT e RUBBER...

Page 418: ...the four nuts retaining 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 stabil...

Page 419: ...new shock mounting fasteners to specification TORQUE Shock Mounting Bolts 40 lb ft 54 Nm SPRING REPLACEMENT 1 Remove the shock and note the spring preload cam setting 2 Using spring compressor compres...

Page 420: ...8 28 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc NOTES STEERING SUSPENSION...

Page 421: ...9 11 BRAKE PEDAL REMOVAL 9 11 INSTALLATION 9 11 FRONT BRAKE PAD SERVICE 9 12 PAD REMOVAL 9 12 PAD INSPECTION 9 13 PAD ASSEMBLY INSTALLATION 9 13 BRAKE BURNISHING PROCEDURE 9 14 FRONT CALIPER SERVICE 9...

Page 422: ...R INSTALLATION 9 28 REAR BRAKE DISC SERVICE 9 30 DISC RUNOUT 9 30 DISC INSPECTION 9 30 DISC REPLACEMENT 9 31 TROUBLESHOOTING BRAKE SYSTEM 9 32 BRAKE NOISE TROUBLESHOOTING 9 32 BRAKES SQUEAL POOR BRAKE...

Page 423: ...d pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads These pads contac...

Page 424: ...0 051 mm Front Brake Disc Runout 0 010 0 254 mm Front Caliper Piston Bore I D 1 373 34 87 mm 1 375 34 93 mm Front Caliper Piston O D 1 370 34 80 mm 1 368 34 75 mm REAR BRAKE SYSTEM ITEM STANDARD SERV...

Page 425: ...RVICE BRAKE SYSTEM ASSEMBLY VIEW REF DESCRIPTION q CALIPER BRAKE FRONT RH w LINE BRAKE FRONT RH e LINE BRAKE REAR MIDDLE r LINE BRAKE REAR RH t CALIPER BRAKE REAR RH y CALIPER BRAKE REAR LH u LINE BRA...

Page 426: ...9 6 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER BRAKE SYSTEM...

Page 427: ...01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 9 7 REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS BR...

Page 428: ...er 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 bleeder hose into the container...

Page 429: ...ght Polaris Industries Inc 9 9 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 should be no les...

Page 430: ...E allowing the fluid to drain 5 Discard seals and replace upon assembly NOTICE Make note of front and rear brake line orientation on the master cylinder 6 Dispose of brake fluid properly and DO NOT r...

Page 431: ...aining clip and clevis pin from the master cylinder to free it from the brake pedal 3 Slide the brake pedal and bushings off the pedal mount bracket INSTALLATION 1 If the pedal mount bracket B was rem...

Page 432: ...bolts and remove the caliper from the front hub NOTICE When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 4 Push caliper piston into caliper...

Page 433: ...cone 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 IMPORTANT If brake pads are contam...

Page 434: ...rque wheel nuts to specification TORQUE Wheel Lug Nuts Steel Wheels 36 ft lbs 49 Nm Wheel Lug Nuts Aluminum Wheels 30 ft lbs 90 41 Nm 90 BRAKE BURNISHING PROCEDURE It is required that a burnishing pro...

Page 435: ...t Polaris Industries Inc 9 15 FRONT CALIPER SERVICE CALIPER ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q Asm Brake Pad y Piston Brake w Asm Caliper Mount u Ring e Caliper Brake i Bolt r B...

Page 436: ...removal 4 Place a container below the caliper to catch brake fluid when removing line Remove brake line q from caliper 5 Loosen brake pad adjustment set screw w to allow brake pad removal after the c...

Page 437: ...re removed use a pick to carefully remove the square O rings e from the caliper O rings should be replaced during caliper service 5 Clean the caliper body piston and retaining bracket r with brake cle...

Page 438: ...at pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounti...

Page 439: ...e Brake Bleeding Fluid Change procedure as outlined earlier in this chapter 5 Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts Steel Wheels 36 ft lbs 49 Nm Wheel Lug Nuts Alu...

Page 440: ...nout Service Limit 0 010 0 254 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 micrometer and measure disc thi...

Page 441: ...se 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 lb ft 24 Nm 5 Install wheel hub assembly washers a...

Page 442: ...er screw 2 3 turns 3 Clean caliper area before removal 4 Remove caliper mounting bolts and lift caliper off of disc NOTICE When removing caliper be careful not to damage brake line Support caliper so...

Page 443: ...stall rubber dust boots w 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other IMPORTANT If brake pads are contaminated with grea...

Page 444: ...after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool suffic...

Page 445: ...t Polaris Industries Inc 9 25 REAR CALIPER SERVICE CALIPER ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q Asm Brake Pad y Piston Brake w Asm Caliper Mount u Ring e Caliper Brake i Bolt r Bo...

Page 446: ...anjo bolt 5 If necessary loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed 6 After the fluid has drained into the container remove the two caliper...

Page 447: ...s or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit MEASUREMENT Rear Caliper Piston Bore I D Standard 1 505 38 23 mm Service Limit 1...

Page 448: ...make sure the dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease CALIPER INSTALLATION 1 Install...

Page 449: ...r braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation NO...

Page 450: ...MEASUREMENT Brake Disc RunoutService Limit 0 010 0 254 mm DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace disc if any are evident 2 Use a 0 1 micrometer and measure dis...

Page 451: ...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 lb ft 38 Nm 5 Install wheel hub assembly washers a...

Page 452: ...ster cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake Adjust pa...

Page 453: ...OVERHEATS BRAKES DRAG Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up under caliper seals Operator riding brakes BRAKES LOCK Ali...

Page 454: ...9 34 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc NOTES BRAKE SYSTEM...

Page 455: ...Y VIEW CREW 10 15 HEATER ASSEMBLY VIEW PKG ONLY 10 16 ROOF ASSEMBLY VIEW PKG ONLY 10 17 REAR PANEL ASSEMBLY VIEW PKG ONLY 10 18 DOOR REMOVAL INSTALLATION LE PKG ONLY 10 19 HEATER REMOVAL INSTALLATION...

Page 456: ...1000 Service Manual Copyright Polaris Industries Inc FRONT FLOOR REMOVAL 10 33 REAR FLOOR CREW 10 34 BRUSHGUARD REMOVAL INSTALLATION PKG ONLY 10 35 NERF BAR REMOVAL INSTALLATION PKG ONLY 10 36 WINCH R...

Page 457: ...eat components that are installed on the vehicle Remove the component from the vehicle before flame treating The vehicle body panels are plastic polyethylene material Therefore they must be flame trea...

Page 458: ...BUMPER REF DESCRIPTION REF DESCRIPTION REF DESCRIPTION q FRAME MAIN i SCREW h BRACKET ROUTING TRAY w BASE CAB SEAT o NUT FLANGE j TRAY ROUTING e SUPPORT CAB REAR a SCREW k RIVET r SUPPORT FLOOR LH s R...

Page 459: ...10 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 10 5 RANGER CREW BODY FRAME...

Page 460: ...IEWS DASH PANELS GLOVE BOX REF DESCRIPTION REF DESCRIPTION REF DESCRIPTION q DASH STORAGE u BRACKET DASH MOUNT f SEAL GLOVEBOX w PANEL DASH CONTROLS i CLIP U SPEED NUT g SCREW e DASH PANEL LOWER o SCR...

Page 461: ...10 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 10 7 HOOD FRONT FENDERS FRONT FASCIA BODY FRAME...

Page 462: ...FRONT BODY COMPONENTS 900 REF DESCRIPTION REF DESCRIPTION REF DESCRIPTION q HOOD y GROMMET LATCH s FENDER FLAIR FRONT LH w COVER HOOD GRILLE u LINER HOOD d FASCIA FRONT e BRACKET FRONT BUMPER i FENDER...

Page 463: ...10 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 10 9 FLOOR REAR FENDERS SKID PLATE STORAGE BODY FRAME...

Page 464: ...10 10 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc RANGER CREW BODY FRAME...

Page 465: ...BELTS REF DESCRIPTION REF DESCRIPTION REF DESCRIPTION q ASM SEAT BOTTOM u SCREW f NUT FLANGE w ASM SEAT BOTTOM i ASM SEAT BELT g BUCKLE SEAT BELT e ASM SEAT BACK o ASM SEAT BELT h CAP BOLT HEAD r ASM...

Page 466: ...10 12 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc RANGER CREW BODY FRAME...

Page 467: ...o ASM SEAT CENTER k CLAMP w BRACKET SEAT HINGE a GROMMET l SCREW e SCREW s ASM SEAT BELT CENTER 1 NUT r PIN SEAT LATCH d ASM SEAT BELT 2 NUT t ASM SEAT BOTTOM f COVER SEAT BELT MNT 2 BUCKLE SEAT BELT...

Page 468: ...icles with bucket seats and doors do not include Side Nets Hip Bolster or Head Rests REF DESCRIPTION REF DESCRIPTION REF DESCRIPTION q FRAME CAB REAR i HANDLE GRAB h PLUG FENDER w FRAME CAB FRONT LH o...

Page 469: ...Side Nets Hip Bolster or Head Rests REF DESCRIPTION REF DESCRIPTION REF DESCRIPTION q FRAME CAB REAR o NUT NYLOK k NUT w SCREW a HIP BOLSTER PSGR l PLUG FENDER e NUT FLANGE s HIP BOLSTER DRVR 1 BOLT r...

Page 470: ...GULAR 2 FLOOR FRONT w GROMMET ELECTRICAL d DUCT UPPER 2 COVER DRIVE SHAFT e SEAL HVAC f STRAP PANDUIT 2 HOSE 1 2 HEATER r DISTRIBUTOR g VENT SQUARE 2 HOSE 1 2 HEATER t RIVET h DASH STORAGE 2 FOAM HOSE...

Page 471: ...EW 900 1000 Service Manual Copyright Polaris Industries Inc 10 17 ROOF ASSEMBLY VIEW PKG ONLY REF PART DESCRIPTION REF PART DESCRIPTION q KIT SEAL ROOF y WASHER w ROOF u CLIP DART e HEADLINER i CLIP N...

Page 472: ...1000 Service Manual Copyright Polaris Industries Inc REAR PANEL ASSEMBLY VIEW PKG ONLY REF PART DESCRIPTION REF PART DESCRIPTION q PANEL GLASS u SEAL GLASS w SLEEVE i SCREW e HANDLE o WASHER r SHIM a...

Page 473: ...l Install fasteners and torque to specification TORQUE Half Door Hinge to Frame Fasteners 8 lb ft 10 Nm Half Door Hinge Fasteners 14 lb ft 19 Nm Full Doors 1 Remove the fasteners that hold the door to...

Page 474: ...glove box Refer to Dash Panels Glove Box Removal page 10 30 procedure 3 Disconnect the fan harness from the main harness 4 Remove the fasteners holding the HVAC duct to the heater system 5 Disconnect...

Page 475: ...eople should work together to remove and install the rear panel windshield 1 Rotate the LOCK RIDE handles counterclockwise into the unlocked position 2 Rotate the top of the rear window slightly away...

Page 476: ...ing the bottom windshield mounts to the frame 3 Lift the windshield off the vehicle and store in an upright position 4 For installation reverse removal procedure Torque windshield mount fasteners to s...

Page 477: ...r Removal Installation 1 Remove the fasteners holding the wiper motor cover to the assembly 2 Disconnect the wiper fluid line and electrical switch connectors from the wiper motor assembly 3 Remove th...

Page 478: ...s connector to the light 3 Remove the fasteners holding the light assembly to the roof 4 For installation reverse removal procedure Seat Heater 1 Remove the applicable seat 2 The seat heater element i...

Page 479: ...10 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 10 25 REAR CARGO BOX SERVICE TAILGATE CARGO BOX PANELS ASSEMBLY VIEW BODY FRAME...

Page 480: ...OX SUPPORT ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q SUPPORT BOX s BOLT w LATCH BOX d SCREW e BUMPER BOX f SCREW r BUSHING BOX LATCH g SCREW t SPRING LATCH h NUT FLANGE y SPRING LATCH...

Page 481: ...caution when removing the box It is recommended to have two people carefully remove the box from the frame 6 Lift the cargo box from the frame Two people or an appropriate overhead hoist may be needed...

Page 482: ...etween the locks and slide hood forward to disengage the front of the hood from the front fascia FRONT BUMPER REMOVAL 1 Remove the two fasteners A retaining the bottom of the bumper to the frame 2 Rem...

Page 483: ...ach side 6 Carefully pull the front fascia straight out to remove it from the vehicle FRONT FENDERS REMOVAL 1 Remove the hood Refer to Hood Removal page 10 28 procedure 2 Remove the push rivets E reta...

Page 484: ...bottom of the control dash panel and remove the panel 5 Open the glove box and remove the four T 25 Torx head screws N 6 Remove the ten T 40 Torx head screws O retaining the bottom of the lower dash 7...

Page 485: ...KER PANEL REMOVAL 1 Remove the seat bottom and under seat storage box 2 Remove the five T 40 Torx head screws P 3 Remove the two push rivets Q NOTICE If removing the Left Hand panel loosen the hose cl...

Page 486: ...panel assembly from the vehicle 7 Cover the fuel fill hose to prevent leakage and to prevent debris from entering the fuel tank WARNING Gasoline is extremely flammable and explosive under certain cond...

Page 487: ...10 30 procedure 2 Remove the main floor Refer to Main Floor Removal page 10 33 procedure 3 Remove the clip and pin T securing the brake pedal to the master cylinder push rod Remove the fasteners retai...

Page 488: ...dure 2 Remove both front rocker panels Refer to Rocker Panel Removal page 10 31 procedure 3 Remove the battery 4 Remove four T 25 Torx fasteners A Fig 1 securing the fuse box to the center under seat...

Page 489: ...anel out of the vehicle 12 Installation is the reverse order of removal BRUSHGUARD REMOVAL INSTALLATION PKG ONLY Front Brushguard 1 Remove the fastener holding the LH and RH ends of the brushguard to...

Page 490: ...s to specification TORQUE Rear Brushguard Fasteners 12 lb ft 16 Nm NERF BAR REMOVAL INSTALLATION PKG ONLY 1 Remove the fasteners holding the front nerf bar mounting bracket to the frame 2 Remove the f...

Page 491: ...the fasteners that hold the fairlead to the front bumper 3 Remove the front bumper Refer to Front Bumper Removal page 10 28 procedure 4 Remove the blue and yellow cables to the winch motor 5 Remove t...

Page 492: ...10 38 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc NOTES BODY FRAME...

Page 493: ...DIFFERENTIAL SOLENOID OVERVIEW 11 11 DIFFERENTIAL SOLENOID CIRCUIT OPERATION 11 11 DIFFERENTIAL SOLENOID REPLACEMENT 11 12 INSTRUMENT CLUSTER SERVICE 11 13 OVERVIEW 11 13 RIDER INFORMATION DISPLAY 11...

Page 494: ...FLOW CHART 11 35 ELECTRICAL DIAGNOSTICS 11 36 ELECTRICAL SERVICE NOTES 11 36 DIGITAL MULTI METER DMM NOTES 11 36 STATIC AND DYNAMIC TESTING 11 36 STATIC TESTING 11 36 DYNAMIC TESTING 11 36 CONNECTOR P...

Page 495: ...STARTER SOLENOID OPERATION 11 48 STARTING SYSTEM TESTING FLOW CHART 11 49 ELECTRONIC POWER STEERING EPS 11 50 EPS OPERATION 11 50 PROPER EPS SYSTEM DIAGNOSING 11 50 EPS TORQUE OFFSET PROCEDURE 11 50...

Page 496: ...nd resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical problems Readings obtained with other meters may dif...

Page 497: ...lutions com SERVICE SPECIFICATIONS ELECTRICAL PART DESCRIPTION SERVICE SPECIFICATION Seat Belt Switch Normally Open Drive Mode Switch Performance 2300 Drive Mode Switch Standard 3700 Drive Mode Switch...

Page 498: ...e switch contacts and re test Replace switch if necessary 4 Refer to Brake Bleeding Fluid Change page 9 8 if replacing the brake switch as the brake bleeding procedure will need to be performed HEADLA...

Page 499: ...y 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 the connecto...

Page 500: ...ity in each gear position and compare to the specifications below SEAT BELT SWITCH The vehicle is equipped with a seat belt interlock switch to prevent the vehicle from exceeding 15 MPH 24 KPH unless...

Page 501: ...on the center dash If the drive mode switch is improperly functioning the switch will default to Standard mode 1 Disconnect the drive mode switch harness by depressing the connector locks and pulling...

Page 502: ...ols Required Static Timing Light Harness 2871745 Hall Sensor Probe Harness 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires...

Page 503: ...en 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 the Rear Diff Solenoid Relay...

Page 504: ...Inc DIFFERENTIAL SOLENOID REPLACEMENT 1 Disconnect the wire harness from the solenoid 2 Remove the nut q holding the solenoid to the transmission 3 To install reverse the removal procedure Torque the...

Page 505: ...tions NOTICE 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 Certain p...

Page 506: ...nitially 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 and adjustab...

Page 507: ...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 trip meter 1...

Page 508: ...nits 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 odometer is displayed 8 Press and hold the MODE button u...

Page 509: ...ODE The diagnostic mode is accessible only when the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycl...

Page 510: ...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 Input...

Page 511: ...g key on the rubber mount is lined up with the keyway in the dash panel 3 Hold the dash panel securely and insert the instrument cluster into the dash panel Twist the instrument cluster gently in a cl...

Page 512: ...nctional 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 using an ohm meter See specifications below TEST CONNECT METER LEADS TO OHM...

Page 513: ...t housing Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height 6 Once the beam is set to the position tighten the adjustment screw Re...

Page 514: ...ch side of the headlight housing 6 Remove the adjustment screw 7 Carefully push on the face of the headlight housing to disengage the housing tabs from the front fascia brackets 8 Remove the headlight...

Page 515: ...sembly 3 Remove the LED lamp from the rear cargo box and disconnect the tail light brake light wire harness NOTICE Before replacing the LED lamp assembly use a digital multi meter to test the harness...

Page 516: ...11 24 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc COOLING SYSTEM SERVICE COOLING SYSTEM BREAK OUT DIAGRAM ELECTRICAL...

Page 517: ...seconds the fan 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...

Page 518: ...oltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plug s IGNITION COIL HT LEAD REPLACEMENT NOTICE The engine will misfire if the spark plug wires...

Page 519: ...using an ohm meter Use the following illustration and specification table to test the ignition coil resistance Ignition Coil Resistance Readings TEST PIN CONNECTION RESISTANCE Primary Between 1 2 Bet...

Page 520: ...ponents 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 drive system A separa...

Page 521: ...11 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 11 29 FUSE BOX DETAIL VIEW ELECTRICAL...

Page 522: ...use protected 12 Vdc constant battery 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...

Page 523: ...SOLENOID RELAY COLOR FUNCTION Red 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 Rea...

Page 524: ...rcomes all system loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before per...

Page 525: ...ound Open Line OL NOTICE Any measurement other than Infinity 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 di...

Page 526: ...efer to Front Fascia Removal page 10 28 procedure 4 Carefully remove the front fascia assembly from the vehicle to access the regulator rectifier 5 If replacing the regulator rectifier remove the two...

Page 527: ...Copyright Polaris Industries Inc 11 35 CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in...

Page 528: ...ters beside a DMM will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM...

Page 529: ...onnector is held upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it...

Page 530: ...part of the circuit This means if you are testing internal resistance of a component it cannot be connected to the harness If you are measuring a wire typically from the ECU to a sensor both the sens...

Page 531: ...t can also be used to help diagnose concerns about blowing fuses Ensure you are able to duplicate the concern before testing so that your results point you in the right direction Testing for Intermitt...

Page 532: ...TIONS Intermittent conditions are very difficult to diagnose as when you are testing the circuit you may not have the circuit failing to indicate where the issue is Intermittent electrical failures ar...

Page 533: ...roperly installed accessories tapping into un switched B instead of switched there can be electronic component failures that can cause this as well TESTING PROCEDURE 1 Remove the negative cable from t...

Page 534: ...ork such as move a solenoid or light a bulb Voltage coming into the load should be near battery voltage with current flowing There will be some loss from moving through electrical contacts in connecto...

Page 535: ...ith water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes and get prompt med...

Page 536: ...oad Test OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging Refer to the following c...

Page 537: ...s Do not exceed 10 amps when charging the battery NOTICE Charge the battery using an automatic charger that will not exceed 14 6 Vdc An automatic charger will signal when charging is complete Allow th...

Page 538: ...op 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 readi...

Page 539: ...lot hole to properly align the starter drive bendix with the flywheel This helps prevent binding and starter damage TORQUE Starter Motor Fasteners 7 lb ft 10 Nm 6 Torque upper starter mounting bolt to...

Page 540: ...ing must occur The brake must be applied to close the brake pressure switch and provide 12V power to the key switch and ECU The key switch must be turned to the start position to provide 12V power to...

Page 541: ...11 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 11 49 STARTING SYSTEM TESTING FLOW CHART ELECTRICAL...

Page 542: ...unction Indicator Light MIL on the instrument cluster will illuminate During this time the vehicle will have no power steering operation You will be able to connect and communicate with the vehicle s...

Page 543: ...11 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 11 51 EPS SYSTEM BREAKOUT ELECTRICAL...

Page 544: ...11 52 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON ELECTRICAL...

Page 545: ...11 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc 11 53 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF ELECTRICAL...

Page 546: ...11 54 9929399 R01 2018 2019 RANGER XP CREW 900 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING USING DIGITAL WRENCH ELECTRICAL...

Page 547: ...per Rear Assembly 9 28 Assembly View 9 25 Disassembly 9 26 Inspection 9 27 Installation 9 28 Removal 9 26 Brake Disc Front Inspection 9 20 Replacement 9 21 Runout 9 20 Brake Disc Rear Inspection 9 30...

Page 548: ...Bypass Test 11 25 Fan Control Circuit Operation Testing 11 25 Pressure Test 3 107 Radiator Cap Pressure Test 3 107 Radiator Fan Removal 3 108 Radiator Removal 3 108 Specifications 3 107 Thermostat Rep...

Page 549: ...tallation 3 69 Cylinder Head Assembly 3 81 Cylinder Head Disassembly 3 37 Cylinder Head Inspection 3 37 Cylinder Head Installation 3 83 Cylinder Head War Inspection 3 37 Cylinder Inspection 3 56 Cylin...

Page 550: ...Tools 10 3 Front A Arms Assembly View 8 14 Assembly View High Lifter 8 15 Lower A Arm Installation 8 16 Lower A Arm Removal 8 16 Upper A Arm Installation 8 17 Upper A Arm Removal 8 17 Front Bearing Ca...

Page 551: ...or Unit Replacement 3 136 Heater Coil Replacement 3 139 Heater Valve Replacement 3 140 HPCO Switch Overview 3 136 HPCO Switch Replacement 3 136 Pressure Relief Valve Replacement 3 136 Receiver Drier R...

Page 552: ...ntenance Inspection 5 4 Overheating Diagnostics 5 5 Service Notes 5 2 Service Specifications 5 3 Special Tools 5 2 Troubleshooting 5 32 R Radiator Fan Removal 3 108 Radiator Cap Pressure Test 3 107 Re...

Page 553: ...3 45 Replacement 11 33 Tests 11 33 Steering Inspection 2 34 8 10 Steering Assembly Assembly View 8 4 Power Steering Unit Installation 8 9 Power Steering Unit Removal 8 9 Steering Shaft Bearing Replac...

Page 554: ...bleshooting Brake Caliper Overheads Brakes Drag 9 33 Brake Noise 9 32 Brake Pedal Vibration 9 32 Brakes Lock 9 33 Brakes Squeal Poor Brake Performance 9 32 Cooling System 3 116 Engine 3 115 EPS Non Fu...

Page 555: ...2018 19 RANGER 900 XP EPS CHASSIS...

Page 556: ...2018 RANGER 1000 XP CREW EPS CHASSIS...

Page 557: ...2018 19 RANGER 900 XP EU...

Page 558: ...2018 RANGER 1000 XP EPS HVAC CHASSIS...

Page 559: ...2018 RANGER 1000 XP MUDDER...

Page 560: ...2018 RANGER 1000 XP EPS CHASSIS...

Page 561: ...2018 19 RANGER 900 XP CREW EPS CHASSIS...

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Polaris RANGER XP 1000 2018-2019, Service Manual

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