Polaris Sportsman XP Touring 1000 Owner'S Manual Download Page 95

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MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical failures, a fuse may

need replacement. Locate and correct any short circuits that may have caused the blown fuse,

then replace the fuse. Raise the passenger seat to access the fuses. Spare fuses are provided

in the fuse box. The power steering fuse (if equipped) is located on the power steering wiring

harness near the fuse box.
If you suspect that a fuse or relay may not be working properly, please see your POLARIS

dealer.

Fuse

Feature Supported

Brake Lights

15A

Fuel Pump

15A

Drive System

20A

Accessories, 12V Power Receptacle

30A

Engine Control Module

15A

Lights

30A

Power Steering (if equipped)

Power Steering Fuse

(if equipped)

Summary of Contents for Sportsman XP Touring 1000

Page 1: ...2018 OWNER S MANUAL RANGER 1000 Diesel RANGER 1000 Diesel EPS RANGER CREW 1000 Diesel...

Page 2: ...e safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other rep...

Page 3: ...icle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARI...

Page 4: ...n the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions o...

Page 5: ...ntroduction 4 Safety 8 Features and Controls 21 Operation 35 Winch Guide 56 Emission Control Systems 64 Maintenance 65 Specifications 100 POLARIS Products 104 Troubleshooting 105 Warranty 108 Maintena...

Page 6: ...ential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not a...

Page 7: ...fety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid...

Page 8: ...one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ________________________________________________________________________ Frame VIN ____________...

Page 9: ...condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncert...

Page 10: ...a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear th...

Page 11: ...and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated...

Page 12: ...less driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for...

Page 13: ...letely inside the vehicle Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avo...

Page 14: ...gh or hilly terrain reduce speed and cargo 7185781 Clutch Cover Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage SEVERE INJURY or DEATH Always look for a...

Page 15: ...over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the s...

Page 16: ...s manual for traveling downhill and for braking on hills See page 47 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which wou...

Page 17: ...e the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or accidental starting FOR MORE INFORMATI...

Page 18: ...on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD p...

Page 19: ...Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle...

Page 20: ...lways keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system Improper Tire Mainte...

Page 21: ...ng hills as described in this owner s manual See page 47 Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling...

Page 22: ...nspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems Operating at Excessive Speeds Operating this vehi...

Page 23: ...imes Any illustrations without cab nets are only to allow component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section on page 10...

Page 24: ...engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle...

Page 25: ...ferential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD Differential Lock 2WD Differential Unlock Press the top of the rocker switch to engage All Wheel Drive AWD See...

Page 26: ...heel can be tilted upward or downward for rider preference Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is...

Page 27: ...seat upward to release the latch pins from the grommets Roll the seat forward to access the under seat area To completely remove a seat roll the seat forward and lift the seat tabs from the seat base...

Page 28: ...icle near the driver s seat Use only the recommended diesel fuel See page 37 Hood Latches Remove the hood to access the coolant overflow bottle the radiator cap and the headlight adjustment screws To...

Page 29: ...ssure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or...

Page 30: ...ps Promptly replace worn or damaged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 1 After entering the vehicle insert the lower net rod in...

Page 31: ...it clicks 3 Release the strap it will self tighten 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation befor...

Page 32: ...ff any fuel that splashes on the instrument cluster Rider Information Center The rider information display is located in the instrument cluster All segments will light up for 1 second at start up If t...

Page 33: ...il or hydraulic fluid pressure is sensed 12 Gear Position Indicator Displays gear selector position H High L Low N Neutral R Reverse Gear P Park Gear Signal Error shifter stuck between gears 13 Power...

Page 34: ...nce setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining...

Page 35: ...nt flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1...

Page 36: ...wing procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL...

Page 37: ...the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation...

Page 38: ...free operation 87 Tires Inspect condition and pressure 89 Wheels fasteners Inspect ensure fastener tightness 89 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 3...

Page 39: ...should be used Bio Diesel fuels see pages 38 39 NEVER mix kerosene used engine oil or residual fuels with diesel fuel Water and sediment in the fuel should not exceed 0 05 by volume Keep the fuel tan...

Page 40: ...suppliers Precautions and concerns regarding the use of bio fuels 1 Free methanol in FAME may result in corrosion of aluminum and zinc FIE components 2 Free water in FAME may result in plugging of fu...

Page 41: ...meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty The same applies to damages or other concerns induced b...

Page 42: ...aler to purchase a block heater kit NOTE Block heater is not recommended when the vehicle is operated above 25 F temperature Fuel Blending Guideline Temperature No 2 No 1 15 F 9 C 100 0 Down to 20 F 2...

Page 43: ...ing bio diesel blended fuels containing more than 20 bio diesel can affect engine life and cause deterioration of hoses tubes injectors injector pump and seals Use the following guidelines if bio dies...

Page 44: ...VER operate the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood NEVER expose the engine to the rain The standard range of ambient temperatures for the norm...

Page 45: ...hicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine For maximum engine life allow the engine to...

Page 46: ...on in PARK 6 Start the engine and allow it to warm up 7 Apply the service brakes and shift the transmission into gear 8 Check your surroundings and determine your path of travel 9 Keeping both hands o...

Page 47: ...and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 9 Vehicle handling may change with a passenger and or cargo on board Allow more...

Page 48: ...weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and...

Page 49: ...Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill i...

Page 50: ...a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause t...

Page 51: ...ys check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping...

Page 52: ...n PARK 4 Turn the engine off 5 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 6 Remove the ignition switch key to prevent unauthorized use Parking...

Page 53: ...in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Al...

Page 54: ...g capacity chart below and the specifications charts beginning on page 100 6 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of...

Page 55: ...y and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 5 Stand clear and pull up on the ca...

Page 56: ...g to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging A...

Page 57: ...ore engaging the differential Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and oper...

Page 58: ...e winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Alwa...

Page 59: ...n through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the...

Page 60: ...strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to...

Page 61: ...rts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the loa...

Page 62: ...VER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 62 For your safety always follow these guidelines when winching a vehi...

Page 63: ...horized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mountin...

Page 64: ...ng This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with...

Page 65: ...tivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models us...

Page 66: ...d online at www gpoaccess gov ecfr Exhaust Emission Control System Exhaust emissions are controlled by engine design A fuel injection system controls fuel delivery The engine and fuel injection compon...

Page 67: ...aintenance Log beginning on page 113 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can pe...

Page 68: ...Headlamp tail lamp Daily Verify proper operation D Brake pad wear 10 H Monthly 100 160 Inspect periodically Battery 25 H Monthly 200 320 Check terminals clean test Air filter 25 H Monthly 200 320 Insp...

Page 69: ...uel pump replace lines every two years Radiator if applicable 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling Hoses if applicable 100 H 12 M 1000 1600 Inspect for leaks Engine mounts 100...

Page 70: ...l for this vehicle Always use the correct viscosity grade based on the ambient temperature expected during operation See the chart below NOTICE Mixing brands or using a non recommended oil may cause s...

Page 71: ...ehicle on a level surface 3 Place the transmission in PARK 4 Stop the engine 5 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box 6 Remove the dipstick Wipe it dry...

Page 72: ...lear and pull up on the cargo box release lever Lift the front of the cargo box 5 Locate the crankcase drain plug access hole in the skid plate 6 Clean the area around the crankcase drain plug CAUTION...

Page 73: ...the engine and wait 15 seconds before removing the dipstick 16 Remove the dipstick Wipe it dry with a clean cloth 17 Reinstall the dipstick completely Remove the dipstick and check the oil level 18 Re...

Page 74: ...d the recommended oil as needed 5 Reinstall the fill plug Torque to specification Oil Change The drain plug is located near the bottom of the gearcase 1 Remove the level check fill plug 2 Place a drai...

Page 75: ...ocated on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Check the oil level 4 Add the recommended oil as needed...

Page 76: ...This antifreeze is already premixed and ready to use Do not dilute with water See page 104 for the part numbers of POLARIS products To ensure that the coolant maintains its ability to protect the engi...

Page 77: ...ystem Your POLARIS dealer can inspect the cooling system Radiator Coolant Level Changing Procedure 1 Remove the hood See page 26 CAUTION Escaping steam can cause burns Never remove the pressure cap wh...

Page 78: ...itional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the...

Page 79: ...revent vehicle movement Place the transmission in neutral 2 Lift the cargo box 3 Remove the clutch cover screws using an 8mm socket with ratcheting wrench and extension 4 Push the cover upward and the...

Page 80: ...and engine If any seals appear to be damaged your vehicle requires prompt service Your POLARIS dealer can assist Tip Belt slip is responsible for creating excessive heat that destroys belts wears clut...

Page 81: ...fore operating 1 Position the vehicle on a level surface Place the transmission in PARK Stop the engine 2 Remove the clutch cover drain plug Allow the water to drain completely Reinstall the drain plu...

Page 82: ...e very least to water below the floorboard 2 Inspect the air box for water NOTICE Do not attempt to start the engine if water is present in the air box Engine damage will result Take the vehicle in fo...

Page 83: ...and lower the bottom to expose the air filter 3 Remove the air filter 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean cloth 5 Install a new filter if needed Do not...

Page 84: ...rge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in Park Start the engine 3 Press the brake pedal and the...

Page 85: ...3 1 Raise the cargo box 2 The belt tension is correct with 5 16 1 2 in 7 10 mm of belt deflection at the mid span of the belt when 20 lbf 89 N is applied to the belt 3 If the belt tension is not corre...

Page 86: ...drain to catch fluids water and fuel 3 Slightly loosen the bleed screw to relieve fuel pressure in the filter Do not tighten the screw at this time 4 Reach under the fuel filter and slightly loosen t...

Page 87: ...eginning on page 65 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Apply the brakes Engage the park brake Shift the transmission to neutral 2 Start the engine Allow it to warm up thor...

Page 88: ...he air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years...

Page 89: ...friction between the brake pad and caliper 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 0 030 0 762 mm Steering Wheel Inspection Check the steering...

Page 90: ...osition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 40 ft lbs 54 2 Nm Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adj...

Page 91: ...size and type of tires for this vehicle when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the fo...

Page 92: ...n the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts...

Page 93: ...mp Headlight Lamp Replacement Access a headlamp wiring harness through the front wheel well CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 1 Unplug the headlamp fr...

Page 94: ...4 Apply the brakes Start the engine Turn on the headlights 5 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include th...

Page 95: ...cess the fuses Spare fuses are provided in the fuse box The power steering fuse if equipped is located on the power steering wiring harness near the fuse box If you suspect that a fuse or relay may no...

Page 96: ...rter life It can also hinder vehicle performance Follow the battery charging instructions on page 95 before installing the battery 1 Ensure that the battery is fully charged 2 Place the fully charged...

Page 97: ...a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 If the voltage is less than 12 8...

Page 98: ...arsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and poli...

Page 99: ...nd pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Storage Tips NOTICE Starting the engine during the storage period will disturb...

Page 100: ...evels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 65 Front gearcase fluid Transmission fluid Brake fluid change every two years and any time the fluid looks...

Page 101: ...porting the vehicle 1 Place the transmission in PARK 2 Stop the engine 3 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 4 Secure the fuel cap hood...

Page 102: ...116 in 295 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 81 in 205 7 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm...

Page 103: ...ission Gear Ratio Low Front 7 62 1 Rear 22 79 1 Transmission Gear Ratio Reverse Front 6 83 1 Rear 20 41 1 Front Drive Ratio 3 818 1 Tire Size Front 25 x 10 12 26 x 9 12 for select models Tire Size Rea...

Page 104: ...th 148 in 376 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 113 in 287 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 c...

Page 105: ...Front 3 10 1 Rear 9 26 1 Transmission Gear Ratio Low Front 7 62 1 Rear 22 79 1 Transmission Gear Ratio Reverse Front 6 83 1 Rear 20 41 1 Front Drive Ratio 3 818 1 Tire Size Front 26 x 9 12 Tire Size R...

Page 106: ...8 l Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz...

Page 107: ...ast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmissio...

Page 108: ...Clogged air filter Replace Water is present in fuel Drain the fuel system and refuel replace fuel filter water separator Old or non recommended fuel Replace with fresh recommended fuel Water or fuel...

Page 109: ...ce Other mechanical failure Your POLARIS dealer can assist Possible Cause Solution Poor fuel quality or incorrect fuel Replace with recommended fuel Clogged fuel filter Replace Clogged air filter Repl...

Page 110: ...sions Limitations Of Warranties And Remedies This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFEC...

Page 111: ...CLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED W...

Page 112: ...r vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warra...

Page 113: ...cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The MY 2014 2016 heavy duty off road engines are warranted for the periods listed below If any emission related part on...

Page 114: ...unit ECU if equipped Sensors associated with ECU operation Emission control information labels Turbocharger if equipped Fuel limiting device Parts components that are scheduled to be replaced as part...

Page 115: ...113 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 116: ...114 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 117: ...75 Coolant Adding or Changing 74 Cooling Fan 74 Cooling System 74 75 D Differential Lock Switch 23 Differential Locking 55 Disengaging AWD 54 Display Information 32 34 Drive Belt Wear 105 Drivetrain...

Page 118: ...ine 70 71 Front Gearcase 73 Main Gearcase 72 Transmission 72 Oil Level Engine 69 Front Gearcase 73 Main Gearcase 72 Transmission 72 Oil Recommendation Engine 68 Operation on Public Lands 64 Operator S...

Page 119: ...reeplay 85 Throttle Freeplay Adjustment 85 Throttle Freeplay Inspection 85 Throttle Pedal 24 Throttle System 85 Tilt Steering 24 Tire Tread Depth 89 Tires 89 90 Torque Axle Nuts 89 Torque Wheel Nut 89...

Page 120: ......

Page 121: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9928298 Rev 01 Printed in USA...

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Polaris Sportsman XP Touring 1000, Owner'S Manual

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