Polaris RANGER XP 1000 2018 Service Manual Download

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9928487 R01 - 2018 RANGER XP 1000 Service Manual
© Copyright Polaris Industries Inc.

10.13

DOOR ASSEMBLY VIEW

REF

DESCRIPTION

TORQUE

HINGE, UPPER-LH

HINGE, UPPER-RH

HINGE, LOWER-LF

HINGE, LOWER-RH

STRIKER

DOOR ASSEMBLY-LH

DOOR ASSEMBLY-RH

DOOR RETAINER SPAER

WASHER

STRIKER HARDWARE

17 lb-ft (23 Nm)

DOOR RETAINER FASTENER

6 lb-ft (8 Nm)

DOOR RETAINER NUT

6 lb-ft (8 Nm)

BODY / FRAME

Summary of Contents for RANGER XP 1000 2018

Page 1: ...uthorized 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 Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Service Manual Service Literature Question Consumers please provide your feedback in writing to Pol...

Page 2: ... or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disasse...

Page 3: ...ademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the nearest Polaris dealer REVISION INDEX REV DATE CHANGES R01 11 28 17 Initial release 2018 VEHICLE UPDATES APPLICABLE MODEL UPDATE DESCRIPTION XP 10...

Page 4: ...1 GENERAL INFORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING EXHAUST CHAPTER 4 FUEL SYSTEM CHAPTER 5 PVT SYSTEM CHAPTER 6 TRANSMISSION CHAPTER 7 FINAL DRIVE CHAPTER 8 STEERING SUSPENSION CHAPTER 9 BRAKE SYSTEM CHAPTER 10 BODY FRAME CHAPTER 11 ELECTRICAL ...

Page 5: ...1 VEHICLE IDENTIFICATION 1 18 MODEL NUMBER DESIGNATION 1 18 VEHICLE IDENTIFICATION NUMBER VIN DESIGNATION 1 18 ENGINE DESIGNATION NUMBER 1 18 VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1 18 VEHICLE SPECIFICATIONS 1 19 2018 RANGER XP 1000 OVERVIEW 1 19 2018 RANGER XP 1000 SPECIFICATIONS 1 20 MISC SPECIFICATIONS AND CHARTS 1 21 CONVERSION TABLE 1 21 STANDARD BOLT TORQUE SPECIFICATION 1 22 METRIC BOLT...

Page 6: ...r 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 specified torque value When removing nuts bolts or screws from a component with several fasteners loosen them all about 1 4 turn before removing them to prevent distortion of that component Replace all oil...

Page 7: ...S99C1 CS 9928195 2018 RANGER XP 1000 R18RRE99F1 N1 R18RRS99F1 9928196 NOTE When ordering service parts be sure to use the correct parts manual REPLACEMENT KEYS Replacement keys can be made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number i e In this example the first two digits are...

Page 8: ...ted 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 may order special tools through Polaris official tool supplier Bosch Automotive Service Solutions by phone at 1 800 345 2233 or on line at http polaris service solutions com GENERAL INFORMATION ...

Page 9: ...lter Wrench PU 50105 Shock Spanner Wrench 2877408 ENGINE COOLING EXHAUST Oil Filter Wrench PU 50105 Oil Pressure Gauge PV 43531 Oil Pressure Gauge Adapter PU 52492 Engine Stand 2 Bore PU 50624 Engine Stand Adapter Mounts To The Engine PU 50562 Engine Stand Sleeve Adapter Use With 2 Bore Stand PU 50625 GENERAL INFORMATION 1 ...

Page 10: ...se With 2 375 Bore Stand PW 47054 Water Pump Mechanical Seal Installer PU 50564 Valve Spring Compressor Adapter PV 43513 A Flywheel Puller PA 49316 Piston Ring Compressor Pliers PV 43570 1 Valve Spring Compressor PV 1253 or PV 4019 Cylinder Holding Camshaft Timing Plate PU 50563 Crank Seal Installation Tool PU 52493 GENERAL INFORMATION ...

Page 11: ...Pressure Gauge Adapter PA 48838 Fuel Pressure Gauge Adapter PS 48762 Fuel Pump Service Tool PU 50326 PVT SYSTEM Drive Clutch Holding Fixture PU 52430 Drive Clutch Puller PU 52422 Clutch Compressor Tool PU 50518 A Clutch Bushing Replacement Kit 2871226 A Piston Pin Puller 2870386 Driven Clutch Separator Tool 2875911 GENERAL INFORMATION 1 ...

Page 12: ...Snorkel Tool PU 52547 Rear Driveshaft Seal Guide 2871699 Rear Output Seal Driver 2871698 Bearing Seal Driver 50 mm 2871282 Crankcase Sealant 2871557 3 bond or 3233901 Loctite 680 FINAL DRIVE Roll Pin Removal Tool 2872608 Axle Boot Clamp Tool PU 48951 CV Boot Clamp Pliers 8700226 GENERAL INFORMATION ...

Page 13: ...870975 BODY FRAME Multi Function Pliers 2876389 ELECTRICAL Digital Wrench Diagnostic Kit PU 47063 B Digital Wrench Vehicle Interface Cable PU 47469 Digital Wrench PC Interface Cable PU 47470 Digital Wrench SmartLink Module PU 47468 Digital Wrench SmartLink Kit PU 47471 Wireless Vehicle Link WVL PU 51435 GENERAL INFORMATION 1 ...

Page 14: ...ies Inc 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 Connector Test Kit PV 43526 Timing Light 2870630 Relay Bypass PU 49466 GENERAL INFORMATION ...

Page 15: ... ft lbs 16 Nm Spark Plug 9 ft lbs 12 Nm Valve Cover Fastener 7 ft lbs 10 Nm Outer Clutch Cover Fastener 35 in lbs 4 Nm Oxygen Sensor 18 ft lbs 24 Nm CHAPTER 3 ENGINE COOLING EXHAUST PART DESCRIPTION TORQUE SPECIFICATION Exhaust Stud w Spring 21 ft lbs 28 Nm Heat Shield Fastener 42 in lbs 5 Nm Muffler Mount Fastener 10 ft lbs 14 Nm Starter Motor Fastener 7 lb ft 10 Nm Engine Mount Fastener 40 ft lb...

Page 16: ...20 Nm Tensioner Mounting Fastener 7 ft lbs 10 Nm Intake Duct Hose Clamp 35 in lbs 4 Nm Intake Manifold Boot Clamp 17 in lbs 2 Nm Lower Intake Plenum Fastener 18 ft lbs 24 Nm Airbox Mount Fastener 35 in lbs 4 Nm Coolant Hose Clamp 35 in lbs 4 Nm Coolant Hose Mounting Bracket Fastener 3 5 lb ft 4 7 Nm Thermostat Cover Fastener 7 ft lbs 10 Nm Coolant Bleed Fastener 6 ft lbs 8 Nm CHAPTER 3 ENGINE COOL...

Page 17: ...et Duct Fastener 54 in lbs 6 Nm PVT Inlet Duct Fastener 54 in lbs 6 Nm PVT Hose Adapter Clamps 35 in lbs 4 Nm PVT Inlet Hose Clamp 35 in lbs 4 Nm PVT Cover to Transmission Fastener 50 ft lbs 68 Nm Shift Weight Fastener 20 in lb 2 Nm CHAPTER 6 TRANSMISSION PART DESCRIPTION TORQUE SPECIFICATION Solenoid 25 ft lbs 34 Nm Bearing Cover Retaining Fastener 9 ft lbs 12 Nm Snorkel Locking Fastener 9 ft lbs...

Page 18: ... Fastener 30 ft lbs 41 Nm Power Steering Unit Frame Fastener 14 ft lbs 19 Nm Upper Steering Shaft Pinch Fastener 25 ft lbs 34 Nm Lower Steering Shaft Pinch Fastener 25 ft lbs 34 Nm Steering Wheel Tilt Assembly Nut 40 ft lbs 54 Nm Steering Adjustment Shock Assembly Nut 7 ft lbs 10 Nm Steering Wheel Nut 65 ft lbs 88 Nm Steering Rack Mounting Nuts 40 ft lbs 54 Nm Tie Rod Jam Nut 13 ft lbs 18 Nm Tie R...

Page 19: ...linder Mounting Fastener 12 ft lbs 16 Nm Caliper Bleed Screw 4 ft lbs 5 5 Nm Brake Line Banjo Bolt 15 ft lbs 20 Nm Master Cylinder Banjo Fastener 15 ft lbs 20 Nm Front Caliper Mounting Fastener 28 ft lbs 38 Nm Rear Caliper Mounting Fastener 46 ft lbs 62 Nm Pedal Bracket Nuts 8 ft lbs 11 Nm Brake Disc Mounting Fastener 18 ft lbs 24 Nm GENERAL INFORMATION 1 ...

Page 20: ... Seat Slide Assembly Fastener 6 ft lbs 8 Nm Seat Shock Ball End Fastener 7 ft lbs 9 Nm Handle Grab Fastener 10 ft lbs 14 Nm CHAPTER 10 BODY FRAME PART DESCRIPTION TORQUE SPECIFICATION Frame Cab Fastener 65 ft lbs 61 Nm Weld Cab Frame Fastener 40 ft lbs 49 Nm Weld Seat Bolster Fastener 10 ft lbs 14 Nm Bolster Bracket Fastener 6 ft lbs 8 Nm Plate Windshield Mount Fastener 36 ft lbs 49 Nm Cargo Box L...

Page 21: ... 36 in lbs 4 Nm CHAPTER 11 ELECTRICAL PART DESCRIPTION TORQUE SPECIFICATION ECU Retaining Fastener 24 in lbs 2 7 Nm Battery Box Fastener 3 5 ft lbs 5 Nm Battery Bracket Fastener 3 5 ft lbs 5 Nm Starter Cable Wiring Nuts 48 in lbs 5 Nm Spark Plug 9 ft lbs 12 Nm Brake Switch 15 ft lbs 20 Nm CPS Retaining Fastener 9 ft lbs 12 Nm ETC Housing Retaining Fastener 5 ft lbs 7 Nm Oxygen Sensor 18 ft lbs 24 ...

Page 22: ...AKA09A0E3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0 Model Year A 2010 B 2011 C 2012 D 2013 E 2014 F 2015 G 2016 H 2017 J 2018 ENGINE DESIGNATION NUMBER 1205551 18 999cc Twin Cylinder Liquid Coole...

Page 23: ...y Weight 1565 lb 709 kg Ranger XP 1000 1875 lb 850 kg Northstar Edition Gross Vehicle Weight 3300 lb 1497 kg Ranger XP 1000 3600 lb 1633 kg Northstar Edition Cargo Box Capacity 1000 lb 453 kg Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm Maximum Weight Capacity Payload 1500 lb 680 kg Ranger XP 1000 1750 lb 795 kg Northstar Edition Includes riders cargo and accessories Hitch Towi...

Page 24: ...sory 15A Drive 20A Lights 30A EPS 30A HVAC if applicable 15A Alternator if applicable DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low Reverse Front 3 92 1 Rear 11 72 1 Front 9 65 1 Rear 28 84 1 Front 8 64 1 Rear 25 83 1 Front Drive Ratio 3 23 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission ...

Page 25: ... 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 lb x 0 454 kg kilogram kg x 2 2046 lbs cubic inches cu in x 16 387 cc cubic centimeters cc x 0 061 cubic inches US quarts x 0 946 liters L liters L x 1 057 US quarts US gallons x 3 785 liters L liters L x 0 26...

Page 26: ...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 1 1 3 1 5 2 1 5 2 M4 0 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 18 M8 7 9 5 10 13 18 25 26 35 33 45 M10 14 19 18 25 37 50 55 75 63 85 M12 26 35 33 45 63 85 ...

Page 27: ...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 7 16 14 U 3 4 2 3 4 7 16 20 25 64 METRIC TAP DRILL SIZES TAP SIZE DRILL SIZE DECIMAL NEAREST FRACTION 3 x 50 39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 ...

Page 28: ... 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 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 FRACTION DECIMAL MM TO INCHES 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 18 mm 0 7087 ...

Page 29: ...OLTS AND FASTENERS 2 32 ENGINE MAINTENANCE 2 33 ENGINE OIL LEVEL INSPECTION 2 33 ENGINE OIL AND FILTER REPLACEMENT 2 34 ENGINE CRANKCASE BREATHER HOSE INSPECTION 2 35 ENGINE CYLINDER LEAKDOWN TEST 2 35 VALVE CLEARANCE INSPECTION 2 36 CAM CHAIN TENSIONER INSPECTION 2 38 COOLING SYSTEM MAINTENANCE 2 39 LIQUID COOLING SYSTEM OVERVIEW 2 39 COOLANT STRENGTH TYPE 2 39 COOLANT LEVEL INSPECTION 2 39 COOLI...

Page 30: ...EERING MAINTENANCE 2 53 STEERING SYSTEM INSPECTION 2 53 STEERING WHEEL FREE PLAY 2 53 TIE ROD END INSPECTION 2 54 WHEEL TOE INSPECTION 2 54 WHEEL TOE ADJUSTMENT 2 55 SUSPENSION MAINTENANCE 2 56 SUSPENSION INSPECTION 2 56 SPRING PRE LOAD ADJUSTMENT 2 56 SHOCK POSITION ADJUSTMENT 2 56 BRAKE SYSTEM MAINTENANCE 2 57 BRAKE FLUID LEVEL INSPECTION 2 57 BRAKE FLUID REPLACEMENT BRAKE BLEEDING 2 57 BRAKE PA...

Page 31: ...Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wa...

Page 32: ...ng Wheel Free Play 0 8 1 0 in 20 25 mm Wheel Toe Out 1 4 1 4 in 6 4 6 4 mm Spring Adjustment Threaded Spanner Wrench Brake Pad Thickness 0 040 1 mm Brake Disc Thickness 0 170 4 32 mm Spark Plug Type NGK MR7F FLUID SPECIFICATIONS ITEM FLUID TYPE CAPACITY Engine Oil PS 4 5W 50 Full Synthetic PS 4 10W 40 Extreme Duty Full Synthetic 2 5 Qt 2 4 L Engine Coolant 50 50 Extended Life Antifreeze 5 0 Qt 4 7...

Page 33: ...finition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if...

Page 34: ...g nut torque Headlights Taillights Ensure all lights are operational Adjust headlight aim as required Brake System Check brake fluid level is between MIN and MAX Check brake pedal is not soft when pushed Verify brakes stop and hold the vehicle Inspect for leaks Frame Body Fasteners Check for loose body frame fasteners Engine Oil Level Verify oil level is in the SAFE range on the dipstick Intake Dr...

Page 35: ...ke Pads Parking Brake Pads INT L Inspect pad wear Fuel System Turn key on to pressurize fuel pump check lines fittings for leaks and abrasion XU D Parking Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Break In Perform a break in oil and filter change at 25 hours or one mon...

Page 36: ...bricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressure ...

Page 37: ...ake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicles...

Page 38: ...ct replace as needed XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D E Fuel System Check for leaks at fill cap fuel line rail and fuel pump D E Spark Plug Inspection Inspect replace as needed torque to specificat...

Page 39: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 40: ...lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressur...

Page 41: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 42: ... parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D E Fuel System Check for leaks at fill cap fuel line rail and fuel pump D E Spark Plug Inspection Inspect replace as needed torque to specification XU Radiato...

Page 43: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 44: ...lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressur...

Page 45: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 46: ...ct replace as needed D Clutches Drive and Driven Inspect clean replace worn parts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D E Fuel System Check for leaks at fill cap fuel line rail and fuel pump D E Spark P...

Page 47: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 48: ...lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressur...

Page 49: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 50: ...ts XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings XU D Parking Brake Cable Adjustment INT L Inspect adjust tension as needed XU Front Gearcase Lubricant Change lubricant XU Transmission Lubricant AGL Change lubricant D E Fuel System Check for leaks at fill cap fuel line rail and fuel pump D E Spark Plug Inspection Inspect replace as needed torque to specification XU Radiator In...

Page 51: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 52: ...lubricant if needed XU General Lubrication Lubricate all fittings pivots cables etc D E Throttle Pedal Inspect replace if it sticks E Throttle Body Intake Ducts Flange Inspect ducts for proper sealing air leaks Shift Cable Linkage Inspect adjust as needed D Steering Lubricate if applicable XU Front Rear Suspension Lubricate if applicable D Cooling System Inspect coolant strength seasonally pressur...

Page 53: ...Brake Cable Adjustment INT L Inspect adjust tension after first 25 hours XU E Engine Breather Inspect clean Battery Check terminals clean test XU E Engine Oil Filter Change Change oil and filter inspect used oil for contaminants XU Front Gearcase Lubricant Inspect add lubricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Perform these procedures more often for vehicl...

Page 54: ...sion Lubricant AGL Change lubricant D E Fuel System Check for leaks at fill cap fuel line rail and fuel pump D E Spark Plug Inspection Inspect replace as needed torque to specification XU Radiator Inspect clean external surfaces XU Cooling Hoses Inspect for leaks pressure test system XU Engine Mounts Inspect torque to specification Exhaust Silencer Pipe Inspect XU Wiring Inspect for wear routing s...

Page 55: ... Synthetic or Polaris PS 4 10W 40 Extreme Duty Full Synthetic 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 Under Front Hood Polaris 50 50 Extended Life Antifreeze Maintain coolant level in coolant reservoir bottle r Check level daily change coolant every two years More often under severe use such ...

Page 56: ...ction change fluid every two years Front Gearcase Polaris Demand Drive Fluid Add lubricant until it is visible at the fill hole threads w 8 5 oz 250 mL Initial level check at 25 hours or 1 month Change lubricant at 100 hours or every 12 months whichever comes first Transmission Polaris AGL Gearcase Lubricant Add lubricant until it is visible at the fill hole threads e More often under severe use s...

Page 57: ...n bar bushing and on the front propshaft yokes Apply grease until all traces of water have been purged out at each of these areas ITEM LUBE REC METHOD FREQUENCY Propshaft Yoke Premium U Joint Lubricant Grease middle q fitting Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the vehicle MAINTENANCE ...

Page 58: ...ase Specialized Lubricants 2871322 Premium All Season Grease 3 oz 24 count 2871423 Premium All Season Grease 14 oz 10 count 2871515 Premium U Joint Lubricant 3 oz 24 count 2871551 Premium U Joint Lubricant 14 oz 10 count 2871329 Dielectric Grease Nyogel Coolant 2880514 50 50 EL Anti Free Qt 12 count 2880513 50 50 EL Anti Free Gal 4 count 2880512 50 50 EL Anti Free 55 Gal Drum NOTE Each item can be...

Page 59: ...0465 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 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871329 Dielectric Grease Nyogel Coolant 2880514 50 50 EL Anti Freeze Quar...

Page 60: ...r tightness of wheel nuts and axle nuts check to be sure axle nuts are secured by cotter pins Air Filter inspect filter element condition replace if necessary Intake Pre Filter Screens Inspect both screens and clean with warm soapy water and low pressure compressed air if necessary Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for a...

Page 61: ...er q Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 5 Remove the dipstick and check the oil level 6 Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick Do...

Page 62: ...y 5 Remove all cargo from the cargo box CAUTION Always remove all cargo from the cargo box before lifting the box to access the engine 6 Pull up on the cargo box release lever to tilt the box 7 Using the Oil Filter Wrench PU 50105 turn the oil filter w counter clockwise to remove it Oil Filter Wrench PU 50105 2 5 64 mm 8 Using a clean dry cloth clean the filter sealing surface on the engine crankc...

Page 63: ...ded oil as necessary to bring the oil level within the SAFE range on dipstick Do not overfill 20 When finished reinstall the oil fill cap oil dipstick and lock the lever 21 Dispose of used oil and filter properly ENGINE CRANKCASE BREATHER HOSE INSPECTION The engine crankcase is equipped with a breather hose Inspect the breather hose for possible kinks or wear The hose is form fitted for proper fit...

Page 64: ...elt Removal page 5 6 procedure 4 Remove the spark plug wires q from the engine 5 Remove the four bolts w and rubber isolators e retaining the valve cover r Note the location and use of the grounding washer t for assembly NOTE Replace rubber isolators e upon assembly 6 The engine will need to be rotated four times to inspect all eight valve clearances Two valves can be measured at each camshaft lob...

Page 65: ...er seal and replace if necessary 13 Replace the rubber isolators around each T 40 bolt 14 Install valve cover and the four bolts Torque bolts to specification TORQUE Valve Cover Bolts 7 ft lbs 10 Nm 15 Install the spark plug wire s Ensure wires are pushed down all the way so they engage onto the spark plug s NOTE The engine will misfire if the spark plug wires are installed incorrectly The spark p...

Page 66: ...oner mounting bolts w 4 Push on the tensioner lock e and manually move the plunger in and out It should move freely If it does not move freely replace the tensioner assembly 5 Retract the plunger all the way in and install into the cylinder 6 Install the two mounting bolts Torque fasteners to specification TORQUE Tensioner Mounting Bolts 7 ft lbs 10 Nm 7 Install the plunger bolt Torque fastener to...

Page 67: ...ntifreeze hydrometer A 50 50 mixture of extended life antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat FLUID CAPA...

Page 68: ...ix coolant You may use a 50 50 or 60 40 mixture of antifreeze and distilled water as required for freeze protection in your area FLUID CAPACITY Recommended Anti Freeze Coolant Premium Pre Mixed Extended Life Antifreeze PN 2880514 Quart PN 2880513 Gallon 9 Reinstall the recovery bottle cap 10 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overh...

Page 69: ... 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 cooling system pressure 4 Place a drain pan under the lower radiator hose 5 Slide the clamp back and remove the lower radiator hose to drain the coolant from the radiator 6 Allow the coolant to complete...

Page 70: ...rbox 2 Release the three airbox cover latches and lift the cover up and out to access the air filter element 3 Remove the air filter element q 4 Inspect the airbox for oil or water deposits Wipe away any deposits with a clean shop towel NOTE If the filter has been soaked with fuel or oil it must be replaced DO NOTattempt to clean the air filter 5 Place the air filter into the airbox Reposition the...

Page 71: ...d area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousnessor death in a very short time Periodically clean spark arrestor to remove accumulated carbon 1 Remove the retaining screw q and nut w 2 Remove the spark arrestor e from the end of the silencer r 3 Use a non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If neces...

Page 72: ... SHIELD INSPECTION IMPORTANT Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly ITEM DESCRIPTION q Chassis Shield w Headpipe Shield Top e Headpipe Shield Bottom r Silencer Outlet Shield End t Silencer Shield Main y Silencer Outlet Shield Elbow MAINTENANCE ...

Page 73: ...ne w at the fuel rail for signs of wear deterioration damage or leakage Replace line if necessary 3 Be sure fuel lines are routed and retained properly NOTE Make sure lines are not kinked or pinched FUEL PUMP FILTER INSPECTION The fuel pump assembly q is located in the fuel tank under the driver s seat NOTE The serviceable high volume high pressure fuel pump assembly includes a non serviceable pre...

Page 74: ...line fitting is removed from the fuel tank it must be replaced The fitting will not hold properly once it is removed 1 Check the fuel tank vent line q for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent line is routed properly and secured NOTE Be sure vent line is not kinked or pinched MAINTENANCE ...

Page 75: ...ing instructions to dry it out before operating The PVT drain 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 outer clutch cover 2 Allow the water to drain out completely 3 Reinstall the drain plug and O ring 4 Place the transmission in PARK apply the brak...

Page 76: ...om 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 TRANSMISSION FLUID REPLACEMENT The drain plug is located on the bottom of the transmission gearcase Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug 2 Place a drain pan under the transmissi...

Page 77: ...t into the mount Tighten the upper jam nut against the mount 7 Start engine and shift through all gears to ensure the shift cable is properly adjusted If transmission still ratchets after cable adjustment the transmission will require service FRONT GEARCASE FLUID LEVEL INSPECTION NOTE It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart The...

Page 78: ...allow fluid to drain completely 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O ring and torque to specification 6 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole FLUID CAPACITY Recommended Front Gearcase Fluid Polaris Demand Drive Fluid PN 2877922 Quart Capacity 6 75 oz 200 mL 7 Reins...

Page 79: ...emove the wheel t 6 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 7 Attach the wheel nuts q and finger tighten them 8 Carefully lower the vehicle to the ground NOTE Limited Edition models with aluminum wheels require a thin wall socket to loosen or tighten the wheel nuts without damaging the ...

Page 80: ...ith 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 depth has worn out TIRE PRESSURE INSPECTION Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle s tool kit CAUTION Maintain proper tire pressure Refer to the warning ...

Page 81: ... steering mechanism is not restricted or limited NOTE Check front end alignment whenever 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 Polaris MSD certified technician STEERING WHEEL FREE PLAY Check steering wheel for specified free play and ope...

Page 82: ...ront and rear Try to move the wheel and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut WHEEL TOE INSPECTION NOTE Make sure tire pressures are set the same on the right and left tires 1 Place machine on a smooth level surface and set steering wheel in a straight ahead positi...

Page 83: ...ch wheel This will tell you which tie rod needs adjusting NOTE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment Measure the distance the measurement should be equal CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot an...

Page 84: ...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 shocks Shock Spanner Wrench 2871095 SHOCK POSITION ADJUSTMENT The front and rear shock position may be adjusted to provide a stiffer suspension operation if necessary 1 Elevate vehicle and safely support the...

Page 85: ... in the reservoir The level should be between the MAX and MIN level lines 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches just below the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings BRAKE FLUID REPLACEMENT BRAKE B...

Page 86: ...o not release brake pedal before bleeder screw is tight or air may be drawn into master cylinder 11 Release brake pedal pressure Check level of fluid in reservoir and add if necessary 12 Repeat Steps 9 11 until brake pedal is firm and no air can be seen moving through the clear hose Add fluid as necessary to maintain level in reservoir Master Cylinder Fluid Level Between the MIN and MAX line CAUTI...

Page 87: ...ce disc if any are evident 2 Use a 0 1 micrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit 3 The disc s should be replaced if thickness is less than the specified service limit MEASUREMENT Brake Disc Thickness Standard 0 188 4 78 mm Service Limit 0 170 4 32 mm MEASUREMENT Brake Disc Thickness Variance Service Limit 0 002 0 ...

Page 88: ...s It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc aw...

Page 89: ...stall and tighten the red positive cable first Torque to specification TORQUE Battery Terminal Fasteners 40 in lbs 5 Nm 5 Install and tighten the black negative cable last CAUTION To reduce the chance of sparks disconnect the black negative cable first When reinstalling the battery connect the black negative cable last 6 Verify the cables are properly routed and reinstall the battery cover and fli...

Page 90: ...5 Remove spark plugs using a 5 8 spark plug socket with an extension 6 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 8 Measure gap with a wire gauge Adjust gap if necessary by carefully ...

Page 91: ...ght Polaris Industries Inc 2 63 THROTTLE PEDAL INSPECTION Inspect the throttle pedal w for free movement Be sure the throttle pedal returns normally when released Refer to PPS Test page 4 36 procedure if experiencing a lack of throttle response MAINTENANCE ...

Page 92: ...2 64 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc NOTES MAINTENANCE ...

Page 93: ...LE ENGINE COMPONENTS 3 20 FRONT ENGINE MOUNT ISOLATOR REPLACEMENT 3 20 ENGINE REMOVAL 3 21 ENGINE REMOVAL HVAC 3 22 ENGINE INSTALLATION 3 24 ENGINE INSTALLATION HVAC 3 27 ENGINE DISASSEMBLY INSPECTION TOP END 3 29 VALVE COVER REMOVAL 3 29 CAMSHAFT REMOVAL 3 29 CAMSHAFT SPROCKET INSPECTION 3 30 CAMSHAFT CAMSHAFT BORE INSPECTION 3 31 CYLINDER HEAD REMOVAL 3 32 CYLINDER HEAD WARP INSPECTION 3 33 CYLI...

Page 94: ...LLATION 3 65 LOWER CRANKCASE PREPARATION 3 66 CRANKCASE ASSEMBLY 3 67 STARTER ONE WAY CLUTCH ASSEMBLY 3 71 FLYWHEEL INSTALLATION 3 72 STATOR COVER INSTALLATION 3 72 ENGINE ASSEMBLY TOP END 3 73 CYLINDER HEAD ASSEMBLY 3 73 CYLINDER HEAD INSTALLATION 3 74 CAMSHAFT INSTALLATION TIMING 3 76 CAMSHAFT TIMING QUICK REFERENCE 3 80 VALVE CLEARANCE ADJUSTMENT 3 81 VALVE LASH TAPPET SELECTION 3 83 VALVE COVE...

Page 95: ...COMPRESSOR REPLACEMENT 3 114 COMPRESSOR OIL SPECIFICATIONS 3 114 COMPRESSOR OIL INSPECTION 3 115 ALTERNATOR INSPECTION 3 116 ALTERNATOR REPLACEMENT 3 116 HVAC COVER MOUNT REPLACEMENT 3 117 CONDENSER REPLACEMENT 3 118 CONDENSER REMOVAL 3 118 CONDENSER INSTALLATION 3 119 HIGH PRESSURE CUT OUT HPCO SWITCH OVERVIEW 3 121 HPCO SWITCH REPLACEMENT 3 121 EXPANSION VALVE EVAPORATOR COIL REPLACEMENT 3 121 H...

Page 96: ... INSUFFICIENT 3 128 INSUFFICIENT COOLING AIR FLOW AND COMPRESSOR OPERATION ARE NORMAL 3 128 COMPRESSOR DOES NOT OPERATE AT ALL OR OPERATES IMPROPERLY 3 128 GAUGE PRESSURE RELATED TROUBLESHOOTING 3 129 TEMPERATURE PRESSURE CHART 3 130 POOR A C PERFORMANCE 3 131 ENGINE COOLANT BYPASSING THE HEATER VALVE 3 131 ENGINE COOLING EXHAUST ...

Page 97: ...on Ring Compressor Pliers PV 43570 1 Valve Spring Compressor PV 1253 or PV 4019 Quick Release Valve Spring Compressor Adapter PV 43513 A Water Pump Mechanical Seal Installer PU 50564 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com ENGINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Oil Capacity 2 5 qt 2 4 L Oil Type PS 4 Full Synthetic 5W 50 2876244 quart 28762...

Page 98: ...4 Remove the crankcase gallery plug q and insert the oil pressure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 or PS 4 Extreme Duty at operating temperature and may vary considerably if any other oil is used or if engine is not up to temperature Oil Pressure Specifica...

Page 99: ...3 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 3 7 ENGINE OIL FLOW CHART ENGINE COOLING EXHAUST ...

Page 100: ...perate 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 unleaded fuel which has a minimum pump octane number of 87 R M 2 2 Check oil level indicated on dipstick Add oil if necessary Refer to ENGINE OIL LEVEL INSPECTION procedure 3 Drive slowly at first to graduall...

Page 101: ...ylinder Out of Round Limit 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 0019 119 82 0 05 mm Valve Valve Lash Cold Intake 006 002 0 15 0 05 mm Valve Lash Cold Exhaust 008 002 0 20 0 05 mm Valve Stem Diameter Intake 2155 2161 5 475 5 490 mm Valve Stem...

Page 102: ...End I D 7879 7885 20 015 20 030 mm 7897 20 06 mm 1 Marking Conn Rod Big End Bore I D 1 7318 1 7321 43 989 43 996 mm 2 Marking Conn Rod Big End Bore I D 1 7321 1 7323 43 996 44 003 mm 3 Marking Conn Rod Big End 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...

Page 103: ...LOWER CRANKCASE UPPER Start with 12 M10 Bolts Step 1 9 ft lb 12 Nm Step 2 21 ft lb 28 Nm Step 3 Tighten add n 90 M8 Bolts 26 ft lbs 35 Nm M8 Bolts 26 ft lbs 35 Nm M6 Bolts 7 ft lbs 10 Nm M6 Bolts 9 ft lbs 12 Nm CAM CARRIER VALVE COVER Camshaft Carrier Bolts 7 ft lb 10 Nm Valve Cover Bolts 7 ft lbs 10 Nm ENGINE COOLING EXHAUST ...

Page 104: ...L PAN CYLINDER HEAD M8 26 ft lbs 35 Nm Cylinder Head Bolts Torque in sequence Step 1 13 ft lbs 18 Nm Step 2 26 ft lb 35 Nm Step 3 Additional 180 Step 4 M6 bolts 7 ft lb 10 Nm M6 9 ft lbs 12 Nm STATOR COVER OIL COOLER Stator Cover Bolts 9 ft lbs 12 Nm Oil Cooler 18 ft lb 24 Nm ENGINE COOLING EXHAUST ...

Page 105: ...Polaris Industries Inc 3 13 INTAKE EXHAUST SERVICE INTAKE SYSTEM ASSEMBLY VIEW ITEM DESCRIPTION TORQUE q Fresh Air Intake Line NA w Engine Intake Elbow NA e Clutch Intake Elbow NA r Intake Duct Clamps 35 in lbs 4 Nm t Intake Hard Line NA ENGINE COOLING EXHAUST ...

Page 106: ...SCRIPTION TORQUE q Intake to Airbox Hose NA w Drain Cap NA e Airbox NA r Airbox Mount Fastener 35 in lbs 4 Nm t Air Filter NA y Airbox Cover NA u Intake Hard Line NA i Vent Hose NA o Airbox to Engine Tube NA a Engine Intake Housing NA s Intake Duct Clamps 35 in lbs 4 Nm ENGINE COOLING EXHAUST ...

Page 107: ... 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 Throttle Body e 6 Disconnect Turf Mode connector r 7 Disconnect Transmission t CPS Switch connector y and Speed Sensor u Remove clips from retaining tabs and position harness out of the way 8 Remove the Fuel L...

Page 108: ... Industries Inc 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 transmission bracket 11 Remove Intake Manifold from engine ENGINE COOLING EXHAUST ...

Page 109: ...lamps to orientation noted during removal 4 Tighten intake boot hose clamps o Torque to spec TORQUE Intake Manifold Boot Clamp 17 in lbs 2 Nm 5 Torque Lower Intake Plenum Fastener a to specification TORQUE Lower Intake Plenum Fastener 18 ft lbs 24 Nm 6 Install electrical harness to engine and plug in Fuel Injectors q TMAP sensor w and Throttle Body e 7 Connect Turf Mode connector r 8 Connect Trans...

Page 110: ...hanism i back into place Verify the connector tabs snap back into place by pulling out lightly on connector 11 Install engine intake hose to throttle body Torque clamp to specification TORQUE Intake Duct Hose Clamp 35 in lbs 4 Nm 12 Perform ETC Learn Procedure page 4 27 connecting battery as needed 13 Inspect engine while running to watch for any fuel leaks 14 Perform Cargo Box Installation page 1...

Page 111: ...ner 8 ft lbs 11 Nm w Spark Arrestor NA e Heat Shield Fasteners 42 in lbs 5 Nm r Heat Shield NA t Muffler Isolator Mounts NA y Oxygen Sensor 18 ft lbs 24 Nm u Exhaust Spherical Gasket NA i Exhaust Stud w Spring 21 ft lbs 28 Nm o Exhaust Head Pipe Mounting Bolts 18 ft lbs 24 Nm a Head Pipe Gasket NA s Muffler Mount Fasteners 10 ft lbs 14 Nm ENGINE COOLING EXHAUST ...

Page 112: ... Rings FRONT ENGINE MOUNT ISOLATOR REPLACEMENT 1 Remove the rear skid plate fasteners q and remove the skid plate from the vehicle 2 Using a commercially available transmission lift or pump jack lift the front engine mount to take the weight off the isolators 3 Remove the nuts w retaining the isolator mounts to the frame 4 Remove the isolator bolt e and remove the isolator 5 Install new isolator a...

Page 113: ...r q 6 Remove three fasteners w retaining the upper heat shield to the head pipe Remove the upper heat shield IMPORTANT DO NOT remove large heat shield secured to the close off panel 7 Remove six fasteners e retaining the head pipe to the cylinder head 8 Remove the thermostat housing hose r and the water pump hose t 9 Disconnect stator harness and disconnect the harness retainer from the engine mou...

Page 114: ... of 1x4 wood under the engine to support it 18 Remove PVT hoses outer cover and belt See Belt Removal page 5 6 19 Remove secondary clutch belt and primary clutch Remove inner clutch cover See PVT Inner Cover Disassembly page 5 12 20 Remove fasteners retaining engine to the engine mount bracket 21 Lift engine out of the chassis be careful not to snag any hoses or wiring 22 If replacing engine remov...

Page 115: ...Disconnect the two AC lines on the back of the AC compressor 7 Disconnect the orange alternator hot wire q from the terminal block 8 Remove passenger side coolant hose w on engine oil cooler 9 Remove clamps e and r at engine water pump Remove hoses from water pump 10 Refer to Engine Removal page 3 21 for next steps ENGINE COOLING EXHAUST ...

Page 116: ... 5416417 around crankshaft snout prior to installing PVT inner cover Loosely install fasteners retaining inner cover to the transmission and engine trans joint 5 Loosely install the three bolts y with washers retaining inner cover to engine 6 Torque PVT inner cover fasteners in sequence to specification TORQUE PVT Inner Cover Fasteners STEP 1 Torque to 37 ft lb 50 Nm STEP 2 Loosely install bolts b...

Page 117: ...bs 58 Nm 9 Install PVT hoses and outer PVT cover Torque fasteners to specification TORQUE Hose Clamps 35 in lbs 4 Nm Outer PVT Cover Fasteners 35 in lbs 4 Nm 10 Connect the starter wiring Torque starter cable nuts to specification TORQUE Starter Cable Wiring Nuts 48 in lbs 5 Nm 11 Install throttle body intake manifold assembly Tighten clamps e r retaining intake manifold to engine Install lower in...

Page 118: ...rs e retaining the head pipe to the cylinder head Torque fasteners to specification TORQUE Exhaust Head Pipe Mounting Bolts 18 ft lbs 24 Nm 19 Install the upper heat shield to the head pipe Install three fasteners w retaining the upper heat shield to the head pipe Torque to specification TORQUE Exhaust Head Pipe Upper Heat Shield Fasteners 6 ft lbs 8 Nm 20 21 Connect oxygen sensor 22 Connect the i...

Page 119: ...ose to oil cooler and install clamp e 4 Install orange alternator hot wire and torque fastening nut to specification TORQUE Alternator wire to Terminal Block 3 3 ft lbs 4 Nm 5 Connect both AC lines to the compressor Torque AC lines to specification TORQUE AC lines at compressor 18 ft lbs 24 Nm 6 Reinstall the battery cover and flip down the passenger seat 7 Fill coolant reservoir Bleed system as r...

Page 120: ...ght Polaris Industries Inc TORQUE Battery Terminal Fasteners 40 in lbs 5 Nm 10 Recharge the AC system Refer to Reclamation and Charging with Recovery Charging Unit page 3 111 and Refrigerant page 3 110 for procedure and sys tem capacity ENGINE COOLING EXHAUST ...

Page 121: ... from falling into the combustion chamber CAMSHAFT REMOVAL NOTE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the PTO cylinder is at Top Dead Center TDC to relieve most of the valve spring pressure The camshaft lobes should face out q and the slots on the end of the camshafts should line up 2 Remove the cam chain tensioner w from the cylinder Replace ...

Page 122: ...rclip or other tool hold cam chain up to keep it from falling down into the crankcase NOTE The crankcase has a built in lower guide to prevent the chain from falling off the crankshaft 9 Evenly loosen the four bolts retaining each rear camshaft carrier a and carefully lift the carriers off the camshafts 10 Mark the intake s and exhaust d camshafts to ensure proper assembly 11 Carefully remove cams...

Page 123: ... 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 38 41 mm 3 Visually inspect each camshaft journal for scoring wear or damage 4 Measure the diameter of the camshaft journals using a micrometer Compare to specification NOTE Replace camshafts if damaged or ...

Page 124: ...embly View page 3 13 Remove exhaust assembly Exhaust System Assembly View page 3 19 Remove Valve Cover Valve Cover Removal page 3 29 Remove Camshafts Camshaft Removal page 3 29 1 Remove the two outer M6 bolts q that retain the cylinder head w to the cylinder 2 Loosen the six cylinder head bolts e evenly 1 8 turn at a time until all are loose 3 Remove and discard the cylinder head bolts 4 Tap cylin...

Page 125: ...dry and free of any oil or grease upon assembly Clean sealing surfaces with rubbing alcohol or electrical contact cleaner Do not touch sealing surfaces of the new head gasket Lay a straight edge across the surface of the cylinder head q at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit ...

Page 126: ...e bucket 2 Compress the valve spring by hand using valve spring compressor adapter PV 43513 A 3 Push down on spring and remove split keepers e 4 Slowly release valve spring pressure and remove the compressor adapter 5 Remove the valve retainer r valve spring t valve stem seal y and valve spring seat u Discard the valve seal NOTE Replace valve seals whenever cylinder head is disassembled Hardened c...

Page 127: ...re faced or end ground if necessary They must be replaced if extensively worn burnt bent or damaged 5 Measure diameter of valve stem with a micrometer in three places then rotate 90 and measure again take six measurements total Compare to specifications MEASUREMENT Valve Stem Diameter Intake 2155 2161 5 475 5 490 mm Exhaust 2147 2153 5 455 5 470 mm 6 Measure valve guide inside diameter at the top ...

Page 128: ...tal scraper a coarse wire brush or abrasive cleaners to clean the cylinder head Damage may result 2 Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage Pay close attention to areas around spark plug and valve seats VALVE SEALING TEST 1 Clean and dry the combustion chamber area q 2 Pour a small amount of clean solvent into each intake port w and check for leaka...

Page 129: ... wide seat pressure is reduced causing carbon accumulation and possible compression loss If seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of the seat I...

Page 130: ...rea is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very narrow and is a normal condition Look for an eve...

Page 131: ...equired if an interference angle reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is full...

Page 132: ... 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 installation process or injury could result 2 Carefully pry the stator cover off the engine using the two pry areas as shown below 3 Inspect the condition of the stator windings q and output wires w If replacement is required refer to ...

Page 133: ...e bearing if removed WATER PUMP HOUSING REMOVAL NOTE The water pump housing can be serviced with the engine installed in the chassis Refer to Water Pump Service page 3 95 procedure 1 Remove the coolant lines from the thermostat housing cylinder inlet and oil cooler Leave them all attached to the water pump housing 2 Remove the three long gold colored bolts q retaining the water pump housing to the...

Page 134: ...r PA 49316 e on the threads of the flywheel left hand thread turn flywheel puller counterclockwise to install 6 Hold puller body and tighten the center bolt to remove the flywheel Starter One Way Clutch Inspection NOTE The starter one way clutch can be serviced with the engine installed in the chassis 7 Remove the stator cover and flywheel Refer to Stator Cover Removal Inspection page 3 40 procedu...

Page 135: ...h retaining screws 3 Remove the one way clutch and inspect both sides of drive rollers q Inspect the roller contact surface w inside the hub for wear damage or uneven surface 4 Inspect drive surface of starter gear e and bushing r 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 ENGINE COOLING EXHAUST ...

Page 136: ...l filter 4 Install the Cylinder Holding Camshaft Timing Plate PU 50563 e onto the cylinder The cylinder holding tool retains the cylinder and pistons when the engine is rotated 5 Rotate engine to access the crankcase sump cover 6 Remove the thirteen M6 t and three M8 bolts y retaining the sump cover r to the crankcase 7 Remove the sump cover u from the crankcase 8 Remove and clean oil pump pick up...

Page 137: ...sprocket bolt by removing the case plug 11 Lift the oil pump drive chain and remove the oil pump 12 Visually inspect the oil pump and drive sprocket d for wear or damage Replace oil pump drive chain and sprocket if worn or damaged If any part of the oil pump is damaged the entire assembly must be replaced Replace the oil pump seal f during crankcase assembly NOTE Oil pump assembly is non serviceab...

Page 138: ...ith a soft faced hammer to loosen Carefully lift up and remove the lower crankcase half BALANCE SHAFT REMOVAL INSPECTION 1 Perform Crankcase Disassembly Inspection page 3 44 procedure 2 Note timing marks on balance shaft and crankshaft drive gears Shafts must be properly timed upon assembly 3 Carefully rotate the balance shaft w and remove it from the crankcase 4 Inspect the balance shaft gear tee...

Page 139: ...TO 1 4939 1 4946 37 946 37 962 mm Service Limit 1 4921 37 900 mm CRANKSHAFT REMOVAL INSPECTION 1 Perform Crankcase Disassembly Inspection page 3 44 procedure 2 Perform Balance Shaft Removal Inspection page 3 46 procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts q Remove the end caps from the crankshaft 5 Carefully lift th...

Page 140: ...REMENT Crankshaft Maximum Runout Less than 001 0 025 mm 10 Visually inspect surface of crankshaft main and connecting rod journals Replace crankshaft if any journal is scratched or pitted 11 Measure each main journal and connecting rod journal in two locations 90 degrees apart Replace crankshaft if any journal is worn below the service limit specification i MAG End d Journal 4 Rod Bearing o Journa...

Page 141: ...112 1 6115 40 926 40 933 mm Service Limit 1 6104 40 906 mm 14 Whether installing a new crankshaft or re installing the original refer to the bearing selection chart provided in the Crankshaft Main Bearing Selection page 3 58 and Connecting Rod Bearing Selection page 3 58 procedures CRANKCASE INSPECTION 1 Remove the oil drain diverter q from the upper crankcase 2 Remove all traces of crankcase seal...

Page 142: ...r Warp Limit 002 0 05 mm 2 Inspect cylinder for wear scratches or damage IMPORTANT DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing 3 Inspect taper and out of round with a dial bore gauge 4 Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side on three different levels ...

Page 143: ...ause of the unique cylinder skirt and crankcase design 1 Perform ENGINE DISASSEMBLY INSPECTION TOP END and the ENGINE DISASSEMBLY INSPECTION LOWER END procedures 2 Rotate the engine so the cylinder is facing up 3 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 q from the cylinder 4 Carefully lift the cylinder and pistons from the upper crankcase 5 Remove the piston connecting rod assemb...

Page 144: ...slightly with a heat gun if pin cannot be removed by hand Discard circlips CAUTION DO NOTapply heat to piston rings or a loss of radial tension could result 3 Measure piston pin bore I D in two directions 90 apart Replace piston and piston pin if out of specification MEASUREMENT Piston Pin Bore I D 7877 7881 20 009 20 018 mm Service Limit 7893 20 05 mm 4 Measure piston pin O D in two directions 90...

Page 145: ...nd push up on opposite side Do not scratch ring lands 2 Repeat procedure for second compression ring w 3 The oil control ring e is a three piece design consisting of a top and bottom steel rail and a center expander section Remove top rail first then bottom rail then the expander PISTON RING TO GROOVE CLEARANCE INSPECTION 1 Measure piston ring to groove clearance q by placing the ring in the ring ...

Page 146: ...imit replace the rings MEASUREMENT Piston Ring Installed Gap Top Ring 010 014 0 25 0 35 mm Service Limit 1 6118 1 6122 40 942 40 950 mm Second Ring 1 6118 1 6122 40 942 40 950 mm Service Limit 028 0 70 mm Oil Control Rails 008 028 0 20 0 70 mm Service Limit 0354 0 9 mm NOTE Always check piston ring installed gap when installing new rings and or a new cylinder PISTON TO CYLINDER CLEARANCE Measure p...

Page 147: ... galling of surface or pitting 4 Measure small end I D in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service limit specification MEASUREMENT Connecting Rod Small End I D 7879 7885 20 015 20 030 mm Service Limit 7897 20 06 mm 5 Install matching rod cap on connecting rod without bearings and install the bolts 6 Tighten bolts snug...

Page 148: ...hart Rod Bearings CONNECTING ROD BIG END BORE DIAMETERS 1 2 3 1 7318 1 7321 43 989 43 996 mm 1 7321 1 7323 43 996 44 003 mm 1 7323 1 7326 44 003 44 010 mm 10 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart provided in the Connecting Rod Bearing Selection page 3 58 procedure in this chapter ENGINE COOLING EXHAUST ...

Page 149: ...ON 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 will refer to the balance shaft bearings which should now all be standard e Crankshaft Bearing Identification Letters six letters ENGINE COOLING EXHAUST ...

Page 150: ...rankshaft 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 reference the six numbers on the crankcase i and match that up with the main journal letters on the crankshaft u In this example you would use the number 2 as the crankcase codes case journals 1 2 3 4 You woul...

Page 151: ...7 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 with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before assembling the upper crankcase PISTON RING INSTALLATION NOTE Apply clean engine oil to all ring surfaces and ring lands upon installation Alwa...

Page 152: ...d 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 the end gap toward exhaust side of piston as shown below 6 Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand ENGINE COOLING EXHAUST ...

Page 153: ...g 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 they be installed with rods facing the same direction 3 Place piston q on connecting rod w Push piston pin e through rod and piston until it seats against the installed circlip NOTE Do not tap on pin or cau...

Page 154: ...dure 3 Note the piston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side NOTE Orientation arrow is also located on the bottom side of piston as an additional reference 4 Carefully compress the piston rings with your fingers and install the piston assemblies into the cylinder from the bottom side Use piston ring compressor pliers PV 43570 1 to aid in ass...

Page 155: ...ice Manual Copyright Polaris Industries Inc 3 63 11 Install the Cylinder Holding Camshaft Timing Plate w PU 50563 onto the cylinder The cylinder holding tool retains the cylinder and pistons when the engine is rotated ENGINE COOLING EXHAUST ...

Page 156: ...o place Repeat for all main bearings 4 Align tab of new connecting rod bearings w with the slot in the connecting rod stem and connecting rod end cap Press bearing insert firmly into place Repeat for the other connecting rod 5 Install oil drain diverter e into the upper crankcase 6 Apply Polaris PS 4 engine oil to each rod bearing journal r and main bearing journal t of crankshaft 7 Loop cam chain...

Page 157: ...d bolts to specification TORQUE Connecting Rod Bolts Step 1 9 ft lbs 12 Nm Step 2 22 ft lbs 30 Nm Step 3 Tighten add n 90 BALANCE SHAFT INSTALLATION 1 Clean the upper crankcase balance shaft bearing bore surfaces 2 Align tab of new balance shaft bearings q with the slot in each bearing bore of crankcase Press bearing insert firmly into place 3 Apply Polaris PS 4 engine oil to both balance shaft jo...

Page 158: ...l traces of crankcase sealant from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 2 Clean bolt hole threads to remove any oil or crankcase sealant 3 Inspect crankcase bearing bores Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case 4 Be sure alignment pins are in place where used 5 Refer to Engine Oil Flow...

Page 159: ...ve any oil 5 Apply a thin continuous film of Crankcase Sealant PN 2871557 to upper crankcase mating surface e as shown Do not allow sealant to dry before assembly NOTE DO NOT block oil passages r with crankcase sealant 6 Carefully place lower crankcase on upper case making sure the oil pump drive chain is fed through the lower crankcase 7 Tap lower crankcase with a rubber hammer to seat the case h...

Page 160: ...ft lbs 12 Nm 11 Rotate the engine so the cylinder is facing up 12 Install the eleven M6 o and two M8 i upper crankcase bolts Tighten all bolts lightly by hand 13 Torque the upper crankcase bolts in sequence to specification start with 12 Repeat the sequence to verify final torque TORQUE Upper Crankcase Bolts M8 Bolts 26 ft lbs 35 Nm M6 Bolts 7 ft lbs 10 Nm 14 Rotate the engine so the cylinder is f...

Page 161: ...ean the gasket sealing surfaces on oil sump cover and crankcase to remove old gasket material and any oil NOTE Gasket surfaces must be DRY and oil free Use care upon assembly to keep oil away 21 Apply a thin continuous film of Crankcase Sealant PN 2871557 to sump cover mating surface g as shown Do not allow sealant to dry before assembly NOTE Dipstick must be removed before oil pan is assembled to...

Page 162: ...m M6 Bolts 9 ft lbs 12 Nm 25 Install the crankcase drain plug if previously removed Torque drain plug to specification TORQUE Crankcase Drain Plug 12 ft lbs 16 Nm 26 Install the oil cooler l Use new O rings 1 upon installation 27 Torque fasteners to specification in sequence shown TORQUE Oil Cooler Retaining Bolts 7 lb ft 10 Nm 28 Proceed to Flywheel Installation page 3 72 and then Cylinder Head I...

Page 163: ...pecification TORQUE One Way Clutch Retaining Screws 9 ft lbs 12 Nm 4 Reassemble starter one way clutch and gear using the following illustration q Torque Limit Gear Pin t Flywheel w Starter Gear y One Way Clutch Retaining Screws 9 ft lbs 12 Nm e One Way Clutch Asm u Torque Limit Gear Asm rFlywheel Retaining Bolt Step 1 133 ft lbs 180 Nm Step 2 Back out bolt 180 retorque to spec 5 If starter gear w...

Page 164: ...lly on taper 6 Install flywheel retaining bolt q Using a commercially available strap wrench hold flywheel w and torque the retaining bolt to specification NOTE If the Cylinder Holding Camshaft Timing Plate PU 50563 is installed remove it before tightening the flywheel TORQUE Flywheel Retaining Bolt Step 1 133 ft lbs 180 Nm Step 2 Back out bolt 180 retorque to spec 7 Wipe off excess Loctite and le...

Page 165: ...nd square with the guide NOTE Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring e and retainer r in clean engine oil 6 Install the valve spring with widely spaced coils y on the top and tightly spaced coils u facing down toward the cylinder head NOTE Valve springs to be installed with paint mark facing up i 7 Place the valve retainer...

Page 166: ...cylinder head is removed nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 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 NOTE Do not touch sealing surfaces of gasket 4 Guide cam chain w through a n...

Page 167: ...00 Service Manual Copyright Polaris Industries Inc 3 75 TORQUE Cylinder Head Torque Procedure Torque in sequence Step 1 13 ft lbs 18 Nm Step 2 26 ft lb 35 Nm Step 3 Additional 180 Step 4 M6 bolts 7 ft lb 10 Nm ENGINE COOLING EXHAUST ...

Page 168: ...r head The PTO camshaft lobes t should face out as shown 5 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when installed properly 6 Install the four bolts that retain each rear camshaft carrier y and tighten the bolts evenly until snug 7 Install the Cylinder Holding Camshaft Timing Plate PU 50563 into the end of camshafts as shown Use a 13 1...

Page 169: ...ning bolts upon assembly Install the top bolt i in each camshaft sprocket u Do not torque the bolts at this time NOTE Use new sprocket retaining bolts upon assembly 13 Verify cam timing is correct Flywheel TDC mark should still be aligned see Step 1 and cam sprocket markings should line up as shown ENGINE COOLING EXHAUST ...

Page 170: ...ining 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 bolts 20 Torque the camshaft carriers bolts in sequence to specification TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 21 Apply Polaris PS 4 engine oil to the cam chain tensioner bore prior to assembly Use a new tensioner sealing washer ...

Page 171: ...3 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 3 79 23 Rotate crankshaft through two revolutions and verify camshaft timing is correct ENGINE COOLING EXHAUST ...

Page 172: ...ICK REFERENCE q Intake Cam r Align marks with surface w Exhaust Cam t CPS Mounting Hole e Align marks with surface y Align Flywheel Mark in Mounting Hole IMPORTANT DO NOT use the V mark located on the flywheel opposite of the I mark Only the I mark should be used as a TDC reference ENGINE COOLING EXHAUST ...

Page 173: ...fts Carrier openings should face each other when installed properly 5 Install the four bolts r that retain each rear camshaft carrier t and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 6 Rotate the camshaft until the cam lobes above the valves you are inspecting are facing up y 7 Measure the valve clearance u using a thickness feeler gauge Record the measur...

Page 174: ...lve clearance measurement recorded for that valve along with the 3 digit tappet number 13 Refer to the appropriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 14 Install the appropriate tappet NOTE Lubricate the outer portion of the valve tappet upon installation 15 Repeat steps 10 14 until all necessary valves have been adjusted 16 Reinstall the c...

Page 175: ...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 3 digit tappet number by 100 i e 450 100 4 5 mm 3 Add the results of step 1 and step 2 i e 0 09 mm 4 5 mm 4 59 mm 4 Multiply that answer by 100 to obtain the correct new tappet i e 4 59 mm x 100 459 5 Re...

Page 176: ...ark plugs q and torque to specification 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Install valve cover seal w 5 Install the four valve cover shoulder bolts e and new isolators r using a T40 driver 6 Torque valve cover bolts to specification TORQUE Spark Plugs 9 ft lbs 12 Nm Valve Cover Bolts 7 ft lbs 10 Nm ENGINE COOLING EXHAUST ...

Page 177: ...CE COOLING SYSTEM ASSEMBLY VIEW q Thermostat housing y Filler Neck s Oil Cooler Inlet Hose w Water Pump u Radiator d Oil Cooler Outlet Hose e Engine Hoses i Pressure Cap f Bypass Hose r Lower Radiator Hose o Upper Radiator Hose g Water Pump Outlet Hose t Fan Assembly a Recovery Bottle ENGINE COOLING EXHAUST ...

Page 178: ...your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use COOLING SYSTEM PRESSURE TEST 1 Remove the hood from the front cab WARNING Never remove pressu...

Page 179: ...ever remove pressure cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 2 Remove pressure cap q and test using a pressure cap tester commercially available 3 The pressure cap relief pressure is 13 psi Replace cap if it does not meet this specification ENGINE COOLING EXHAUST ...

Page 180: ...p up 4 Drain radiator by removing lower radiator hose r Be sure to catch and dispose of coolant properly WARNING The cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 5 Remove the upper radiator hose from the radiator 6 Disconnect the small radiator bypass hose t 7 Remove four fasteners y securing the radiator fan to the radiator Separate the f...

Page 181: ...ure to properly fill and bleed cooling system as outlined in this chapter e Upper Radiator Hose y To Radiator Fitting r Lower Radiator Hose u Fan Motor Assembly t Recovery Bottle i Radiator RADIATOR FAN REMOVAL 1 Remove Radiator See Radiator Removal Installation page 3 88 2 Disconnect cooling fan electrical connector 3 Tilt radiator fan toward the front of the vehicle then lift fan up and out ENGI...

Page 182: ... from thermostat housing q 5 Remove the rear bolt w retaining the thermostat cover 6 Remove the cargo box access panel 7 Using an 8 mm swivel socket and long extension remove the front bolt e retaining the thermostat cover 8 Lift the cover from the housing and remove the thermostat NOTE Thermostat has a pop off relief to allow the bypass system to operate until thermostat opens 9 Install a new the...

Page 183: ...er remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Remove 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 radiator filler neck 5 Tilt the rear cargo box to the raised position 6 Re...

Page 184: ...ys allow the engine to cool before removing the pressure cap 11 Remove the pressure cap Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck 12 Open the bleed screw to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 13 Tighten the bleed screw to specification top off coolant and properly install the pressure ca...

Page 185: ...ter 8 Elevate the rear of the vehicle off the ground using a suitable ATV lift and remove the right rear wheel 9 Remove the right rear shock lower mounting bolt Discard the nut Swing and support right rear shock rearward to gain access to water pump area 10 Remove the five coolant hoses that are attached to the water pump Note location and routing for installation Be sure to catch and dispose of c...

Page 186: ...se and note orientation of the water pump drive slot e 6 Rotate water pump drive tab r so it matches the angle of the drive slot in the engine CAUTION The water pump drive tab and slot must be aligned properly during installation Severe engine or water pump damage will occur if the tab and slot are not in alignment during water pump installation 7 Maneuver water pump up through the access hole in ...

Page 187: ...er 16 Install the hood and seats WATER PUMP SERVICE NOTE The water pump cover gasket can be replaced while the water pump housing is still installed in the engine 1 Remove water pump assembly as outlined in this chapter Engine Disassembly Inspection Bottom End Water Pump Housing Removal 2 Remove the three bolts retaining water pump cover q to water pump housing w Discard cover gasket e 3 Place the...

Page 188: ...ased separately 10 Thoroughly clean mechanical seal and oil seal bores 11 Install a NEW oil seal into the water pump housing until fully seated 12 Fully install the water pump shaft and two washers into the housing 13 Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure 14 Install a NEW mechanical seal into the water pump housing using special tool PU 5056...

Page 189: ...o specification TORQUE Water Pump Mounting Bolts 7 ft lbs 10 Nm 21 Install two new water pump O rings and lubricate them with fresh engine oil 22 Install water pump assembly into engine Water Pump Assembly View o Bolt f Washers k Oil Seal a Loctite 204 g Drive Tab l Impeller s Mechanical Seal h Water Pump Shaft 1 Washer d O Rings j Water Pump Housing ENGINE COOLING EXHAUST ...

Page 190: ...ailure 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 Obstruction in air intake Air box removed reinstall all intake components Incorrect flywheel installation or sheared flywheel key Restricted exhaust system Cam worn excessively Engine Has Low Power Spark pl...

Page 191: ...LESHOOTING 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 air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose impeller ...

Page 192: ... 14 ft lb 19 Nm Condenser Lower Mounting Bolts 8 ft lb 11 Nm HPCO Switch 6 ft lb 8 Nm Heater Evaporator Unit Mounting Fasteners 10 lb ft 14 Nm Expansion Valve High Low Pressure Hoses 12 ft lb 16 Nm Expansion Valve Tubes 22 ft lb 30 Nm Heater Valve Fasteners 8 lb ft 11 Nm SPECIAL TOOLS HVAC TOOL DESCRIPTION PART NUMBER Refrigerant Recovery Recycle Recharging Machine PU 51021 Recharge Service Kit fo...

Page 193: ...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 evaporator coil As the refrigerant passes through the expansion valve an extreme pressure and temperature drop occurs It becomes a low temperature low pressure liquid and saturated vapor The low pressure li...

Page 194: ... 8 Nm e HVAC MOUNTING BRACKET NA r AC HOSE CLAMP FASTENER 6 ft lbs 8 Nm t AC HOSE CLAMP NA y AC PRESSURE HOSE 18 ft lbs 24 Nm u HVAC CONDENSER NA i HVAC CONDENSER MOUNTING FASTENER 35 in lbs 4 Nm o AC HOSE CONDENSER TO EVAPORATOR 12 ft lbs 16 Nm a HEATER RETURN HOSE NA s HEATER SUPPLY HOSE NA d AC SUCTION HOSE NA f HVAC MOUNTING WASHER NA g HVAC MOUNTING FASTENER 8 ft lbs 11 Nm h MAIN HVAC ASSEMBL...

Page 195: ...TING ASSEMBLY CENT RH N A 4 AIR DISTRIBUTOR MANIFOLD N A 5 STRAP PANDUIT N A 6 AIR DISTRIBUTOR MANIFOLD FASTENER 18 in lbs 2 Nm 7 FRESH AIR HOSE N A 8 FILTER SUPPORT N A 9 FILTER SUPPORT FASTENER 18 in lbs 2 Nm 10 AIR FILTER N A 11 AIR FILTER BAND CLAMP 24 in lbs 3 Nm 12 CENTER DASH DUCTING ASSEMBLY N A 13 DEFROST VENT N A 14 DUCTING ASSEMBLY LH N A ENGINE COOLING EXHAUST ...

Page 196: ...3 104 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc A C SYSTEM DIAGRAM ENGINE COOLING EXHAUST ...

Page 197: ...y cause serious 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 134a in the air Any servicing work that involves release or addition of R 134a to the system must be done by a competent refrigeration dealer who has the proper equipment knowledge and ex...

Page 198: ...into the cab The unit contains the heat and A C coils thermostat and expansion valve Heater Coil The heater coil u supplies the warm air into the cab by passing air through the coil Evaporator Coil The evaporator coil i cools 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 ...

Page 199: ...rate as it is controlled by the ignition power A C Switch The rocker switch f will be illuminated when the A C is engaged Potentiometer The potentiometer g controls the Heater Valve from fully Off to fully On This can be used in conjunction with the A C for defrost of the windows and temperature control Heater Valve The heater valve h is used to control the amount of engine coolant that flows to t...

Page 200: ...lt the rear cargo box to the upright position 3 Disconnect the upper duct q 4 Remove the fasteners holding the alternator cover to the vehicle 5 Inspect the drive belt for cracks damage wear separation or oil Check for debris or buildup in the drive belt splines If any of these conditions exist replace the belt IMPORTANT ALWAYS use the specified drive belt Using a non specified belt can shorten th...

Page 201: ...rn fasteners 3 Remove the two fasteners q and two fasteners w Remove the supporting brackets 4 Remove the two push rivets e retaining the condenser cover 5 Tilt the condenser cover upwards on the folding crease r to gain access to the condenser 6 Clean condenser as needed CAUTION Do not use high pressure washers to clean the condenser or damage to cooling fins may result NOTE Front fascia removed ...

Page 202: ...h 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 other refrigerant will contaminate and damage your A C Recovery Recycling Recharging Machine q as well as the A C system on the vehicle System Capacity R134a 1 6 lbs 726 kg ENGINE COOLING EXHAUST ...

Page 203: ...l 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 addition of R 134a to the system must be done by a competent refrigeration dealer who has the proper equipment knowledge and experience to service refrigeration equipment 2 Use an approved recovery chargin...

Page 204: ...rive 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 upright position 3 Remove the fasteners holding the alternator cover to the vehicle 4 Cut the compressor drive belt to remove it from the vehicle 5 To aid with belt installation remove the fasteners holding the ...

Page 205: ... 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 properly routed around all of the pulleys 12 Remove the belt installation tool from the crankshaft drive pulley 13 Torque the alternator fasteners to specification in the sequence as shown TORQUE Alternator Mounting Fasteners 37 lb ft 50 Nm 14 Install the inner altern...

Page 206: ...pressor 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 9 Recharge the A C system COMPRESSOR OIL SPECIFICATIONS The compressor is factory filled with 150 170 cc s of PAG 100 oil Poly Alkelene Glycol It is only necessary to check replenish or replace the compressor oil in the following cases When the evaporator condenser or ...

Page 207: ...r at maximum speed 3 Run the compressor for at least 20 minutes at idle 4 Remove the compressor from the vehicle 5 Remove the oil drain plug q and drain the oil through the connectors w and the oil drain hole 6 Tighten the oil drain plug to specification TORQUE Compressor Oil Drain Plug 10 ft lb 14 Nm NOTE Extract the remaining oil through the discharge side connector by rotating the drive pulley ...

Page 208: ...ut 14 4 0 3 V WARNING Loose clothing hair or other items can be caught in the compressor drive belt Take care not to allow loose items to get caught in the moving compressor drive belt ALTERNATOR REPLACEMENT 1 Disconnect the negative battery cable before servicing the electrical system 2 Remove the compressor drive belt Refer to Compressor Drive Belt Replacement page 3 112 procedure 3 Disconnect t...

Page 209: ... 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 engine 7 For installation reverse removal procedure 8 Torque NEW timing wheel fasteners to specification TORQUE HVAC Timing Wheel Fasteners 9 lb ft 12 Nm 9 Torque the HVAC cover mount fasteners to specific...

Page 210: ...y turn the 1 4 turn fasteners 3 Remove the two fasteners q and two fasteners w Remove the supporting brackets 4 Remove the two push rivets e retaining the condenser cover 5 Tilt the condenser cover upwards on the folding crease r to gain access to the condenser 6 Remove both AC lines t and y NOTE Front body panels removed for clarity 7 Remove the two push rivets u retaining the shroud and lift the...

Page 211: ...ser forward to release from radiator support and lift straight up to remove NOTE Receiver Drier is contained within the condenser and is not replaced separately CONDENSER INSTALLATION 1 Install the condenser straight down and into radiator support bracket 2 Reinstall the two condenser retaining fasteners i 3 Install the front shroud and two push rivets u ENGINE COOLING EXHAUST ...

Page 212: ...ser to Evaporator t 12 ft lbs 16 Nm AC Pressure Hose y 18 ft lbs 24 Nm Reinstall the condenser cover r 5 Install both push rivets e retaining the condenser cover 6 Reinstall the support brackets Torque fasteners w and q to specification TORQUE Support Bracket Fasteners 42 in lbs 5 Nm 7 Reinstall the hood panel and lock the 1 4 turn fasteners ENGINE COOLING EXHAUST ...

Page 213: ...tact with a flame R 134a refrigerant gives a toxic gas 2 Remove the pressure switch w 3 Install pressure switch and torque the HPCO switch to specification TORQUE HPCO Switch 6 ft lb 8 Nm EXPANSION VALVE EVAPORATOR COIL REPLACEMENT 1 Remove the refrigerant from the A C system WARNING In the event of a leak wear safety goggles Escaping refrigerant can cause severe injuries to eyes In contact with a...

Page 214: ...gerant from the A C system WARNING In the event of a leak wear safety goggles Escaping refrigerant can cause severe injuries to eyes In contact with a flame R 134a refrigerant gives a toxic gas 2 Drain the cooling system Refer to Radiator Removal Installation page 3 88 procedure 3 Remove the upper and lower dash Refer to Dash Panels Glove Box Removal page 10 31 procedure 4 Disconnect the blower un...

Page 215: ...nit HEATER EVAPORATOR UNIT INSTALLATION 1 Reinstall the HVAC unit and torque the mounting fasteners to specification TORQUE Heater Evaporator Unit Mounting Fasteners 10 lb ft 14 Nm 2 Reinstall both AC hoses 3 Reinstall both heater hoses and install heater hose clamps 4 Install the air distributor manifold fasteners q and torque to specification TORQUE Air Distributor Manifold Fasteners 18 in lbs 2...

Page 216: ...e Refer to Heater Evaporator Unit Replacement procedure 3 Remove the evaporator coil Refer to Expansion Valve Evaporator Replacement page 3 121 procedure 4 Remove the fasteners holding the heater coil to the sides of the heater evaporator unit top cover 5 For installation reverse removal procedure Tighten heater coil mounting fasteners until fully secure 6 Recharge the A C system BLOWER UNIT REPLA...

Page 217: ... Refer to the chart below MALFUNCTION DETECTION INTERVAL STATUS LED Temperature sensor open and short detection Continuous 1x per second Clutch circuit open short or over current At A C start up 2x per second Compressor clutch short to ground Continuous 3x per second NOTE The EDT will attempt to restart every 20 seconds until the fault is repaired HEATER VALVE REPLACEMENT 1 Remove the passenger se...

Page 218: ...erpreted 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 not be functioning properly the whole panel must be replaced A C SWITCH TESTING The AC switch turns the Air Conditioning system on and off The AC Switch can be tested using an ohmmeter 1 Disconnect harness from ...

Page 219: ...3 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 3 127 HVAC BREAKOUT DIAGRAM ENGINE COOLING EXHAUST ...

Page 220: ...ondition Clean or replace filters INSUFFICIENT COOLING AIR FLOW AND COMPRESSOR OPERATION ARE NORMAL SYMPTOM POSSIBLE CAUSE SOLUTION 1 System low on refrigerant The high side pressure will be low and bubbles may be present in sight glass on receive drier Repair any leaks and recharge the A C system 2 Excessive refrigerant The high pressure side pressure will be high Recover and recharge system to t...

Page 221: ...nsion 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 replace thermostat 5 Receiver drier restriction Excessive frost on receiver drier Replace receiver drier High pressure side too high 1 Poor condenser performance Dirty or clogged condenser fins Condenser...

Page 222: ... 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 coil not the coil surface For an estimate of the temperature of the air coming off the coil add 8 10 F 13 to 12 C to the temperature on the chart Condenser Temperatures are not ambient temperatures but cond...

Page 223: ...ition 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 heater valve is leaking by and needs to be replaced 4 Push the A C switch to the OFF position Turn the fan switch to position 1 Turn the temperature control to the High A C position 5 Listen for the heater va...

Page 224: ...3 132 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc NOTES ENGINE COOLING EXHAUST ...

Page 225: ...P MODELS 4 12 VENT LINE TERMINATION FITTING 4 13 FUEL LINE QUICK CONNECT REMOVAL 4 14 FUEL TANK SERVICE 4 16 FUEL TANK ASSEMBLY VIEW 4 16 FUEL TANK REMOVAL 4 17 FUEL TANK INSTALLATION 4 18 FUEL PUMP SERVICE 4 21 OPERATION OVERVIEW 4 21 FUEL SENDER TEST 4 21 FUEL PUMP TEST 4 22 FUEL PUMP REPLACEMENT 4 23 ELECTRONIC CONTROL UNIT ECU 4 26 ECU OPERATION OVERVIEW 4 26 ECU SERVICE 4 26 ECU REPLACEMENT 4...

Page 226: ...L INJECTOR REPLACEMENT 4 38 OXYGEN SENSOR 4 40 OXYGEN SENSOR INFORMATION 4 40 OXYGEN SENSOR REPLACEMENT 4 40 FUEL SYSTEM DIAGNOSIS 4 41 INSTRUMENT CLUSTER TROUBLE CODE DISPLAY 4 41 CYLINDER MISFIRE DETECTION 4 46 FUEL SYSTEM TROUBLESHOOTING 4 47 DIGITAL WRENCH OPERATION 4 48 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 48 SPECIAL TOOLS 4 48 DIAGNOSTIC SOFTWARE VERSION 4 48 ECU REPLACEMENT 4 48 GU...

Page 227: ...ssues 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 running or ignition switch is on Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system Dirt even in small quantities can cause significant problems Do not ...

Page 228: ...auge Kit PU 43506 A NOTE 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 The Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure once you have completed the fuel pressure test Fuel Pressure Gauge Adapter PS 48762 Used in conjunc...

Page 229: ...e 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 diagnostic connector lift up the passenger seat and remove the divider Digital Wrench Download Website Located at www polaris diagsys com Download Digital Wrench Updates NOTE For the most recent in...

Page 230: ...n the ECU computer chip and the ECU adjusts the fuel delivery and ignition timing based on these values During operation the ECU has the ability to re adjust temporarily providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a riche...

Page 231: ...nic Throttle Control ETC Located between the intake boot and intake plenum 3 Crankshaft Position Sensor CPS Located on top of the stator cover 4 Temperature Manifold Absolute Pressure Sensor T MAP Located on top of the intake plenum 5 Engine Coolant Temperature Sensor ECT Located on the cylinder head below the intake manifold 6 Pedal Position Sensor PPS Located on the side of the throttle pedal as...

Page 232: ... top by the fuel rail 8 Fuel Rail Assembly Located on the intake plenum on top of the fuel injectors 9 Fuel Supply Line Connected to the left end of the fuel rail and top of the fuel pump 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 airbox behind the driver s seat FUEL SYSTEM ...

Page 233: ...k 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 clutch q The fuel line then continues under the clutch outlet duct where it connects to the fuel rail NOTE Image orientation is from the rear driver side of the vehicle with the cargo box in the raised position FUEL SYSTEM ...

Page 234: ...lease the line 3 Disconnect the fuel line connector e securing the fuel line to the clutch 4 Pull the fuel line outward to remove 5 To reinstall the line verify the connections are clean and free of debris 6 Place the fuel line back over the fitting and slide the connector locking mechanism back into place Verify the connector tabs snap back into place by pulling out lightly on connector 7 Be sure...

Page 235: ...NT LINE ROUTING The fuel tank is vented through a vent line The vent line is routed from the fuel tank underneath the driver seat and secured into a vertical section of the frame with a vent line termination fitting NOTE Image orientation is from the front driver side of the vehicle FUEL SYSTEM ...

Page 236: ...izontal section of the frame r The line connects to a Purge Valvey before it routes into the throttle body The Fresh Air Line is secured into a vertical section of the frame with a Vent Line Termination Fitting e and runs through the Canister Filter w and into the Evaporative Emissions Canister q NOTE Image orientation is from the front passenger side of the vehicle NUMBER PART DESCRIPTION q Evapo...

Page 237: ...nspected and tested using a Mity Vac to ensure proper venting Connect the Mity Vac to the fitting and give it 5 pumps The gauge should return to 0 immediately or there is an obstruction NOTE If the vent line fitting is removed from the frame it must be replaced The ears on the clip arrows will not hold properly once it is removed FUEL SYSTEM ...

Page 238: ... a small straight blade screwdriver Screwdriver Method 1 Insert a 1 flat blade screw driver into the pry slot on the top of the retaining clip IMPORTANT To prevent damage to the retaining clip be sure to use a flat blade screwdriver that fits into the pry slot 2 Gently pry the retaining clip upwards into the open position 3 Remove quick connect from the fuel fitting Hand Method 4 Gently pull outwa...

Page 239: ...ertion of a hard line end The retaining clip is designed to lock only when a hard line end has been fully inserted 2 Retaining tabs are deformed and no longer lock into the body of the quick connect 3 Broken retaining tabs or any sign of cracks in the retaining clip The retaining clip is responsible for holding the quick connect on the line when under fuel pressure 4 Quick connect has been twisted...

Page 240: ...is Industries Inc FUEL TANK SERVICE FUEL TANK ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION q Fuel Tank Asm y Tank Vent Rollover Valve w Fuel Inlet u Fuel Pump Regulator e Fuel Cap i Fuel Level Float Arm r Gasket o Preliminary Fuel Filter t Fuel Sender Nut FUEL SYSTEM ...

Page 241: ...mpting to remove it from the vehicle 3 Remove fasteners and driver side body panel 4 Install fuel cap 5 While holding a shop towel overain the fuel line connectors disconnect the fuel line q from the fuel pump Refer to Fuel Line Removal Installation page 4 10 procedure NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 6 Remove ...

Page 242: ... taking care not to damage brake lines or the wire harness 2 Install seat base fastener y Torque to specification TORQUE Seat Base Fastener 10 ft lbs 14 Nm 3 Install three plastic tie straps t to retain the wire harness to the fuel tank 4 Install fuel tank brackets and two fasteners retaining fuel tank to chassis Torque fasteners to specification TORQUE Fuel Tank Bracket Fasteners 6 ft lbs 8 Nm 5 ...

Page 243: ...steners r TORQUE Battery Box Fasteners 3 5 ft lbs 5 Nm 9 Install Battery Install Battery Bracket e and Battery Bracket Fastener w Torque Fastener to specification TORQUE Battery Bracket Fastener 3 5 ft lbs 5 Nm 10 Connect Positive and Negative battery cables Test the fuel pump by turning on the key and listening for the pump to activate 11 Install battery cover FUEL SYSTEM ...

Page 244: ...9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 12 Install Driver Seat Engage front seat base tabs Push seat down until properly seated 13 Fold down passenger seat FUEL SYSTEM ...

Page 245: ...ngine 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 SENDER TEST 1 Remove the fuel pump assembly from the fuel tank Refer to Fuel Pump Replacement procedure 2 Using an Ohm meter measure the resistance of the fuel sender as shown below ITEM POSITION READING q EMPTY po...

Page 246: ...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 working properly Turn the key switch off and turn the relief valve on the tester to relieve the system pressure Fuel Pressure 58 2 psi 400 14 kPa NOTE If the fuel pressure is out of specification replace t...

Page 247: ...ion key off 2 Remove the driver seat and storage bin to access the fuel pump WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications 3 Be sure the top of the fuel tank is clean If it requires cleaning hand wash the top of the tank around the fuel pump to ensure no debris will enter the fuel system when ...

Page 248: ...ift and tilt the pump to ensure that the float arm is not bent when removed from the tank 9 Transfer old fuel pump to a suitable container capable of safely holding fuel Fuel pump will retain some fuel 10 Inspect the inside of the fuel tank for debris may require flashlight and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fue...

Page 249: ...properly aligned Verify orientation marks are still aligned between fuel pump and fuel tank 18 Torque nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench TORQUE Fuel Pump Nut 70 lb ft 95 Nm 19 Verify alignment of fuel pump and tank orientation marks 20 Connect the fuel supply line to the pump Refer to Fuel Line Removal Installation page 4 10 procedure NOTE...

Page 250: ...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 light by referencing the Instrument Cluster Trouble Code Display page 4 41 and Diagnostic Trouble Code Table or by using Digital Wrench The ECU requires a minimum of 7 0 volts to operate The memory in th...

Page 251: ...nition turned off disconnect the wire harness from the ECU Lift the connector locking lever and rotate it up until the connector is free from the ECU NOTE Upon removing the ECU connector you should hear a click when the connector is fully open 6 Remove the ECU from the vehicle 7 To reinstall reverse this procedure and tighten the mounting screws to specification NOTE Upon installing the ECU connec...

Page 252: ...r adjustments may be performed If a problem is encountered and you determine the ETC to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ETC without factory authorization Use Digital Wrench to perform all troubleshooting of this component Use a Volt Ohm meter to test the vehicle harness continuity between the ETC connector and ECU connector Ref...

Page 253: ...witch is improperly functioning the switch will default to Standard mode 1 Disconnect the drive mode switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test the resistance between pins 3 and 11 3 If the resistance is out of specification for any mode replace the switch The Drive Mode Switch is a three way rocker switch with internal resistors ...

Page 254: ...E CONTROL SWITCH REPLACEMENT The switch is a rocker switch and will be mounted on either the dash or in the headlight pod of an ATV Remove the component it is mounted to remove the connector and disengage the switch from the panel by depressing the retention tabs Reverse to install FUEL SYSTEM ...

Page 255: ...crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS TEST The CPS is a sealed non serviceable assembly If fault code diagnosis indicates a problem with this sensor test as follows 1 Locate the CPS harness connect...

Page 256: ...p e 4 Remove CPS retaining fastener w and remove the sensor from the stator cover 5 Install new sensor using a light coating of oil on the O ring to aid installation 6 Torque CPS retaining fastener to specification TORQUE CPS Retaining Fastener 9 ft lbs 12 Nm 7 Route CPS wire lead through wire clip e and reconnect CPS harness connector q NOTE Make sure CPS harness connector standoff r remains prop...

Page 257: ...during operation The T MAP sensor provides the ECU with engine load data T MAP SENSOR TEST The T MAP sensor is a non serviceable item If it is faulty it must be replaced NOTE This sensor should only be tested using the Digital Wrench Diagnostic Software dealer only T MAP SENSOR REPLACEMENT 1 Lift the rear cargo box to the raised position 2 Disconnect the vehicle harness q from the T MAP sensor 3 R...

Page 258: ...ation 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 the harness from the ECT sensor and start the engine After a few seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are...

Page 259: ...EMOVAL INSTALLATION procedure 4 Disconnect the vehicle harness q from the ECT sensor 5 Using a wrench loosen and remove ECT sensor from engine 6 Apply thread sealant to the new sensor threads and install it into the cylinder head 7 Torque the new ECT sensor to specification and connect the vehicle harness to the sensor TORQUE ECT Sensor 16 ft lbs 22 Nm 8 Reconnect the fuel line to the fuel rail 9 ...

Page 260: ...n 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 1 PEDAL POSITION VOLTAGE READING Pedal Released 1 2 V Pedal WOT 4 2 V SENSOR 2 PEDAL POSITION VOLTAGE READING Pedal Released 0 6 V Pedal WOT 2 1 V The Pedal Position Sensor is calibrated to the throttle ...

Page 261: ...e 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 Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directl...

Page 262: ...on 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 clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death 4 Remove the passenger seat and storage bin and disconnect the negative battery cable 5 Remove the pla...

Page 263: ...d 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 assembly into the intake plenum 15 Install the fuel rail mounting fasteners and torque to specification TORQUE Fuel Rail Mounting Fasteners 5 ft lbs 7 Nm 16 Reinstall the fuel line to the fuel rail 17 Connect the ...

Page 264: ...fy if there are any stored codes for the oxygen sensor NOTE 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 occur Short drive cycles and cold temperatures will both affect the delay time of the O2 sensor increases the delay The delay time ensures the oxygen sensor heater has run long enough to provide accurate data O...

Page 265: ...ble 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 three numbers will appear in the information area The first number located far left can range from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes pres...

Page 266: ...o 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 Speed This is applicable when the EPS module gets the engine speed from the ECM Error in Engine Speed Computation 190 31 P121C Received Engine Speed Has Error 19 C1066 Engine Speed Error in Engine Speed Compu...

Page 267: ...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 Correlation Fault 65613 2 P1135 Throttle Position Sensor 2 Voltage Too High 520198 3 P0223 Voltage Too Low 4 P0222 Signal Out of Range 2 P0221 All Wheel Drive Control Circuit AWD Driver Circuit Open Grounded 520207 ...

Page 268: ...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 Condition Exists 520280 31 P151E Throttle Body Control Mechanical Stop Adaptation Failure Condition Exists 520281 31 P152A Throttle Body Control Repeated Adaptation Failed Condition Exists 520282 31 P152B Throttl...

Page 269: ...ists 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 Disruption Condition Exists 520311 31 P1537 Drive Model Select Switch Data Erratic Intermittent or Incorrect 524067 2 P153C Voltage Above Normal or Shorted to High Source 3 P153A Voltage Below Normal or Shorte...

Page 270: ...ow 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 to occur The check engine light will remain illuminated until there are 4000 engine revolutions i e 4000 RPM for one minute without a significant misfire being detected Once this condition is met the check e...

Page 271: ...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 warm Electronic Throttle Control ETC tampering or damage Pedal Position Sensor PPS tampering or damage Faulty electrical connection Symptom Idle Too Low if 1100 RPM when warm Electronic Throttle Control ETC ta...

Page 272: ...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 have the latest updates or enhancements New reprogramming files and guided diagnostic procedures are added to these updates as they become available For information on how to determine if you have the latest u...

Page 273: ...d plug To access the diagnostic connector lift up the passenger seat and remove the divider 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 to your laptop Refer to Special Tools Fuel System page 4 4 2 Remove the protective cap from the Digital Wrench connector 3 Connect the Veh...

Page 274: ...e Digital Wrench start up screen 2 Proceed to http polaris diagsys com to see if a newer update is available 3 If a newer update is available it should be downloaded before using Digital Wrench NOTE Always operate with the latest update DIGITAL WRENCH UPDATES Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through...

Page 275: ...sion and update download the file Refer to Digital Wrench Version and Update ID page 4 50 procedure 7 Click on the link shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or open the file from where they are Select save and download them to your PC before running the install 8 When the update is complete the version shown on the r...

Page 276: ...4 52 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc DIGITAL WRENCH FEATURE MAP FUEL SYSTEM ...

Page 277: ...Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations Refer to Digital Wrench Updates page 4 50 procedure CLOSE NON ESSENTIAL PROGRAMS Polaris recommends that you DO NOT install non essential programs on a Service Department laptop Camera detection software Virus Scanners Tool Bars etc may clog up memory if runn...

Page 278: ...lect 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 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be invalid NOTE All characters are letters there are no numbers in a request code NOTE Request Codes and Authorization Key...

Page 279: ... 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 Authorization Key in the box located on the Digital Wrench screen Click the Continue button and follow instructions provided on the screen to complete reprogramming procedure 14 At this point the reflash proce...

Page 280: ...unctions 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 and Warranty drop down menu Select Mobile Digital Wrench App Download Tap on the link to download the app Android Device Minimum Specifications Minimum operating system Android 3 1 Honeycomb or higher Andro...

Page 281: ... ASSEMBLY VIEW 5 10 PVT DUCT REMOVAL INSTALL 5 11 OUTLET DUCT REMOVAL INSTALLATION 5 11 INLET DUCT REMOVAL INSTALL 5 11 PVT INNER COVER DISASSEMBLY 5 12 PVT INNER COVER ASSEMBLY 5 13 DRIVE CLUTCH SERVICE 5 18 DRIVE CLUTCH ASSEMBLY VIEW 5 18 CLUTCH DISASSEMBLY 5 20 BEARING INSPECTION 5 20 BUTTON TO TOWER CLEARANCE INSPECTION 5 21 SPIDER REMOVAL 5 21 ROLLER PIN AND THRUST WASHER INSPECTION 5 21 SHIF...

Page 282: ...EN CLUTCH DISASSEMBLY EBS 5 31 HELIX AND MOVABLE SHEAVE BUSHING INSPECTION 5 32 BUSHING SERVICE 5 32 MOVABLE SHEAVE BUSHING REMOVAL 5 32 MOVABLE SHEAVE BUSHING INSTALLATION 5 32 HELIX BUSHING REMOVAL 5 33 HELIX BUSHING INSTALLATION 5 33 DRIVEN CLUTCH ASSEMBLY 5 34 TROUBLESHOOTING 5 35 OVERHEATING DIAGNOSIS 5 38 PVT SYSTEM ...

Page 283: ...ft 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 Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning S...

Page 284: ...rive Clutch Button to Tower Clearance 000 010 0 020 0 508 mm Drive Clutch Shaft Diameter 1 413 35 913 mm 1 416 35 975 mm Flange Sleeve Shaft Diameter 1 693 42 98 mm 1 692 42 993 mm Vespel Thrust Washer Thickness 0 030 0 040 0 76 0 96 mm 0 020 0 50 mm Drive Clutch Helix Thickness Greater than 0 146 3 71 mm 0 146 3 71 mm CLUTCH CHART CLUTCHES ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 0 1800 M...

Page 285: ...M 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 system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting PVT BREAK IN DRI...

Page 286: ...ire clutch outlet duct including the outlet duct screen when replacing a drive belt Remove any debris found in the outlet duct or outlet duct screen 1 Remove the nine fasteners q that retain the outer clutch cover NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement 2 Pull the clutch cover forward and slide towards the front of the vehicle as shown PVT SYSTEM ...

Page 287: ...utch spreader tool part number 2875911 is found in vehicle tool kit 7 Walk the belt out of the driven clutch and drive clutch Remove the belt from the vehicle BELT INSPECTION 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 2 Inspect belt for loose ...

Page 288: ...lt into the clutch 3 Remove the clutch spreader tool from driven clutch 4 Rotate spin the driven clutch and belt approximately 5 7 times clockwise to properly seat the belt in the driven clutch 5 Install the clutch cover into wheel well as shown 6 Rotate clutch cover over A Arm w as shown Use care not to damage intake boots or electrical harness 7 Pull clutch cover backwards and align with bolt ho...

Page 289: ...eeded 4 Remove the drive belt 5 Remove the Driven Clutch Bolt and washer 6 Add shims q to move the belt closer to the inner sheave of the drive clutch or remove shims to move the belt closer to the outer sheave of the drive clutch IMPORTANT Ensure the driven clutch taper and transmission taper are clean and free of debris 7 Reinstall the washers and Driven Clutch Bolt Torque to specification TORQU...

Page 290: ...NA w DRAIN PLUG NA s INLET DUCT FASTENERS 54 in lbs 6 Nm e OUTER CLUTCH COVER NA d PVT HOSE ADAPTER CLAMPS 35 in lbs 4 Nm r SEAL OUTER COVER NA f PVT INLET HOSE TO TUNNEL NA t INNER CLUTCH COVER NA g PVT INLET HOSE CLAMP 35 in lbs 4 Nm y O RING NA h INTAKE CLUTCH DUCT NA u SEAL INLET DUCT NA j PVT INLET HOSE CLAMP 35 in lbs 4 Nm i OUTLET DUCT NA k PVT HOSE JOINT NA o OUTLET DUCT FASTENERS 54 in lb...

Page 291: ... clutch cover 3 Inspect bottom of the duct for damage and replace if necessary 4 Reinstall duct e and fasteners w Torque to specification TORQUE PVT Outlet Duct Fasteners 54 in lbs 6 Nm INLET DUCT REMOVAL INSTALL 1 Remove the Inlet Duct fasteners q 2 Remove the Inlet Duct w and the duct seal e Inspect for damage and replace if necessary 3 Reinstall the duct seal e and duct assembly w 4 Install fas...

Page 292: ...ng Tool on the Drive Clutch Drive Clutch Holding Tool PU 52430 8 Remove the Drive Clutch retaining bolt y using a Torx T 60 internal driver 9 Remove the Movable Sheave assembly NOTE The stationary sheave of the drive clutch can remain in the vehicle if not being serviced Use a rocking motion while pulling on the movable sheave by hand to slide the spider and movable sheave off the stationary post ...

Page 293: ...ts i that retain the inner clutch cover to the engine Remove bolts o and a that secure the clutch cover to the transmission NOTE The transmission will need to be lowered until sufficient clearance is gained to remove the lowest mounting bolt o 13 Remove the inner clutch cover from the vehicle PVT INNER COVER ASSEMBLY 1 Inspect the inner clutch cover Replace if cracked or damaged 2 Inspect the seal...

Page 294: ...q to specification TORQUE Clutch Cover Fasteners 37 ft lbs 50 Nm 5 Install the two fasteners w Do not torque 6 Insert the two fasteners e through the transmission 7 Install the two fasteners r into the engine by hand 8 Install the two fastening nuts t 9 Torque the two fasteners y TORQUE Clutch Cover Fasteners 50 ft lbs 68 Nm PVT SYSTEM ...

Page 295: ...el line clip a to clutch cover 14 Clean the inside of the drive clutch and the engine crankshaft with alcohol Allow parts to dry before proceeding 15 Install the Driven Clutch assembly Ensure the Driven Clutch assembly is nearly flush with the Transmission Input shaft WARNING The Driven Clutch Bolt will engage the threads of the Input Shaft without the Driven Clutch being fully mated to the Input ...

Page 296: ...ining Bolt 43 lb ft 58 Nm 18 Install the Drive Clutch Stationary Sheave Ensure the Sheave is fully seated 19 Install the Drive Clutch assembly and Drive Clutch bolt h IMPORTANT Ensure proper orientation of washers Orientation should be as follows Clutch Spider Yellow Washer Silver Belleville Washer with dome side facing outwards towards Outer Post and Outer Post TORQUE Drive Clutch Retaining Bolt ...

Page 297: ...clamps 22 Install the drive belt 23 Perform clutch alignment Refer to Driven Clutch Alignment page 5 9 24 Install the outer clutch cover Refer to Belt Installation page 5 8 25 Install the intake duct Torque the intake duct clamps j to specification Install the breather hose and clamp TORQUE PVT Duct Hose Clamps 35 in lbs 4 Nm PVT SYSTEM ...

Page 298: ...Clutch Bolt 96 ft lbs 130 Nm w Drive Clutch Cover Bolts 100 in lbs 11 Nm e Drive Clutch Cover NA r Outer Clutch Post NA t Spring NA y Belleville Washer Dome side facing outer post u Washer NA i Spider NA o Sheave Assembly NA a Bushing NA s EBS Spring One Way d Clutch Spacer NA f Spacer Flange Orientation as shown g Bushing Sleeve NA h Clutch Washers NA PVT SYSTEM ...

Page 299: ...RQUE NOTE j One way Bearing Ensure Clockwise Rotation k EBS Flange Sleeve Ensure EBS cam is fully matted l Drive Helix NA 1 Stationary Sheave NA 2 Shift Weight NA 2 Clutch Button NA 2 Clutch Spider Roller Washer NA 2 Spider Roller NA 2 Spider Pin NA 2 Weight Bushing Must not protrude once seated PVT SYSTEM ...

Page 300: ...mbly 2 Remove cover bolts q evenly in a cross pattern and remove cover plate w 3 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 4 Remove and inspect the clutch spring r Refer to Drive Clutch Spring Inspection page 5 24 procedure 5 Remove and inspect belleville washer t and washer y Replace if necessary IMPORTANT Belleville w...

Page 301: ...utch if worn damaged or cracked SPIDER REMOVAL 1 Remove the spider assembly If the spider cannot be removed by hand use a conventional 3 jaw puller as shown to remove the spider from the clutch assembly IMPORTANT Do not pull on the outer fingers of the spider or damage may occur Position 3 jaw puller in the positions shown u ROLLER PIN AND THRUST WASHER INSPECTION 1 Inspect all rollers e roller pi...

Page 302: ... nuts WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly Refer to Roller Pin and Thrust Washer Inspection page 5 21 procedure CLUTCH INSPECTION NOTE Remove cover spring and spider following instructions for drive clutch disassembly...

Page 303: ...painted Measure the free length of the spring and compare to specification Replace if necessary MEASUREMENT EBS Spring Free Length 0 76 in 17 78 mm 5 Inspect the moveable clutch sheave i for damage or wear 6 Inspect the Helix for wear The Helix should be replaced if any cracking or grooving is found Measure the Helix and replace if it is found to be worn beyond specification MEASUREMENT Helix Serv...

Page 304: ...the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged MEASUREMENT Shaft Diameter 1 413 35 913 mm Service Limit 1 416 35 975 mm 9 Visually inspect Vespel thrust washers for damage Measure the thickness and compare to specification Replace if worn or damaged MEASUREMENT Thrust Washer Thickness Standard 0 030 0 040 0 76 0 96 mm Service Limit ...

Page 305: ...andle end of the Piston Pin Puller PN 2870386 q securely into bench vise and lightly grease puller threads 3 Remove nut from puller rod and set aside 4 Install main adapter w onto puller 5 With towers pointing toward the vise slide sheave onto puller rod 6 Install removal tool e PN 5020634 into center of sheave with A side toward sheave 7 Install nut onto end of puller rod and hand tighten Turn pu...

Page 306: ...side out as shown or damage to the cover may result 2 From inside of clutch cover insert removal tool PN 5020634 w into cover bushing 3 With outside of cover toward vise slide cover onto puller 4 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 5 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 6 Remove nut ...

Page 307: ...CAUTION Do not apply oil or grease to the bushings Reassemble the drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly 1 Install the plastic Helix ensuring it is fully seated and engaged with the drive lugs of the Stationary Sheave 2 Install the EBS flange sleeve assembly ensuring the flange is seated flush with the Stat...

Page 308: ...splines are aligned properly an arbor press may be used to properly seat the clutch spider 5 Install washer o belleville washer a and clutch spring s IMPORTANT Belleville washer must be installed with dome facing the outer post 6 Install the clutch cover d and clutch cover bolts f Hand tighten bolts 7 Install cover bolts g and torque in a cross pattern evenly to specification PVT SYSTEM ...

Page 309: ...ght Polaris Industries Inc 5 29 TORQUE Drive Clutch Cover Bolts 100 in lbs 11 Nm 8 Install drive clutch assembly and drive clutch bolt h Use drive clutch holding tool Drive Clutch Holding Fixture PU 52430 TORQUE Drive Clutch Bolt 96 ft lbs 130 Nm PVT SYSTEM ...

Page 310: ...F DESCRIPTION TORQUE NOTE q Driven Clutch Bolt 43 ft lbs 58 Nm w Washer 0 8 e Shim NA r Bushing NA t Stationary Sheave NA y Helix NA u Bushing NA i Spring NA o Spring Cup NA a Bushing NA s Moveable Sheave NA d Helix Fasteners 32 ft lbs 44 Nm f E Clip Fully Seat in Grooves g Roller NA h Washer NA j Roller Pin NA k Spring Pin NA PVT SYSTEM ...

Page 311: ...8 A 3 Spin the compressor down until it just starts to contact the helix cover Remove the three fasteners q that secure the cam helix assembly using a T50 Torx driver Remove the universal clutch compressor and stationary sheave CAUTION The helix cover is loaded by the spring Not using a proper compressor may result in personal injury or damage to the clutch 4 Remove spring cap w and clutch spring ...

Page 312: ... Replace the Helix bushing if more brass than Teflon is visible on the bushing Refer to Bushing Service page 5 32procedure BUSHING SERVICE MOVABLE SHEAVE BUSHING REMOVAL 1 Install hand end of Piston Pin Puller PN 2870386 securely into the bench vise and lightly grease the puller threads 2 Install main adapter q onto puller 3 Slide the sheave onto the puller as shown 4 Install the bushing adapter w...

Page 313: ...rt the piston pin puller in a vise 4 Using a pry bar located between the fingers of the helix turn the helix counter clockwise to remove the bushing 5 Remove the nut from the puller rod and set aside 6 Remove the bushing and bushing removal tool from the puller Discard the bushing HELIX BUSHING INSTALLATION 1 Apply Loctite 648R evenly to bushing bore in cover 2 From the bottom of the Helix insert ...

Page 314: ...revious hole orientation IMPORTANT Using previous hole orientation will ensure the driven clutch maintains balance 4 Using clutch compressor PU 50518 compress the driven clutch assembly CAUTION The helix cover is loaded by the spring Not using a proper compressor may result in personal injury or damage to the clutch 5 Torque the three T50 torx fasteners a to specification TORQUE 32 ft lbs 44 Nm 6 ...

Page 315: ...e specified operating range Incorrect drive clutch spring too high of rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move...

Page 316: ...Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVTsystem Inspect and clean PVT noise Belt worn or separated thin spots loose belt Broken or worn clutch components cover hitting clutches Replace belt Inspect and repair as n...

Page 317: ...g 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 Inspect the flange sleeve bushing drive helix and stationary shaft for smoot operation Verify EBS spring is in the proper position Clunking noise on drive away Normal operation No action needed PVT SYSTEM ...

Page 318: ...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 Climbing over large objects from a stopped position Shift the transmission to Low carefully use quick firm throttle application and avoid excessive slipping of the PVTsystem WARNING Excessive throttle may...

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Page 321: ...HIFT LEVER REMOVAL INSTALLATION 6 5 SHIFT CABLE INSPECTION 6 5 SHIFT CABLE ADJUSTMENT 6 6 TRANSMISSION SERVICE 6 7 DIFFERENTIAL OPERATION 6 7 TRANSMISSION REMOVAL 6 9 TRANSMISSION INSTALLATION 6 12 TRANSMISSION DISASSEMBLY 6 15 GEAR CLUSTER DISASSEMBLY 6 17 SNORKEL TUBE REMOVAL DISASSEMBLY 6 17 PLANETARY DIFFERENTIAL DISASSEMBLY 6 19 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT 6 20 PLANETARY DIFFER...

Page 322: ...al Unlock Locking the rear differential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain SPECIAL TOOLS TRANSMISSION PART NUMBER TOOL DESCRIPTION PU 52547 Snorkel Tube Tool 2871699 Rear Driveshaft Seal Guide 2871698 Rear Output Seal Driver 2871282 Bearing Seal Driver 50 mm Bosch Automotive Service Sol...

Page 323: ...ner Fastener 9 ft lbs 12 Nm t Transmission Case Fastener QTY 14 20 ft lbs 27 Nm y Speed Sensor Fastener 10 ft lbs 14 Nm u Rear Mount Bracket Fastener QTY 2 20 ft lbs 27 Nm i Bearing Cover Fastener 9 ft lbs 12 Nm o Bearing Cover Fastener QTY 3 9 ft lbs 12 Nm a Differential Cover Fastener QTY 6 26 ft lbs 35 Nm s Bellcrank Nut 14 ft lbs 19 Nm d Sector Cover Fastener QTY 5 10 ft lbs 14 Nm f Park Plate...

Page 324: ...NSMISSION 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 secured into a vertical section of the frame with a vent line termination fitting TRANSMISSION ...

Page 325: ...nect cable end from the lever 5 Remove the retaining ring o and slide the shift lever r off the mounting bracket and out from the frame 6 Remove both bushings a from the shift lever and service as needed 7 Perform the previous steps in reverse order to reinstall the shift lever lever cable dash panel shift knob SHIFT CABLE INSPECTION Shift cable adjustment may be necessary if symptoms include No g...

Page 326: ...e upper jam nut y 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 proper cable adjustment NOTE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount Tighten t...

Page 327: ...lectrical 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 of the planetary differential assembly This unlocks the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When Differential Lock is selected ...

Page 328: ...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 Shift Fork Retainer Fastener a Torsion Spring s Retainer d Shift Fork f Solenoid Spring g Solenoid TRANSMISSION ...

Page 329: ...ion lubricant see Transmission Fluid Replacement page 2 48 4 Remove both rear drive shafts from the transmission Refer to Rear Drive Shaft Removal page 7 43 procedure 5 Remove the outer clutch cover and belt Refer to Belt Removal page 5 6 procedure 6 Remove drive and driven clutch and inner clutch cover Refer to PVT Inner Cover Disassembly page 5 12 procedure 7 Remove the vent line from the transm...

Page 330: ...retaining intake manifold r to engine 12 Remove lower manifold mounting fastener to transmission mount bracket 13 Disconnect the transmission shift cable by removing the clip and sliding the washer and shift cable off the bellcrank 14 Mark the location of the shift cable and upper jam nut y Loosen the lower jam nut t and remove the shift cable assembly from the bracket 15 Place a piece of 1x4 wood...

Page 331: ... RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 6 11 16 Remove the two fasteners i retaining the rear isolator to the frame bracket 17 Lift the transmission out the top of the vehicle chassis TRANSMISSION ...

Page 332: ...isolator bolt u through the transmission bracket and isolator Torque fasteners to specification TORQUE Rear Transmission Mount Bracket Fastener 40 ft lbs 54 Nm 4 Inspect seal 5416417 prior to installing PVT inner cover Replace seal if damaged Install seal to the groove in the clutch cover around crankshaft opening and o ring 5415647 to transmission in the groove around the input shaft Loosely inst...

Page 333: ...Install the drive clutch belt and driven clutch Install washer and shims on transmission input shaft before installing driven clutch mounting bolt Torque fasteners to specification TORQUE Drive Clutch Bolt 96 ft lbs 130 Nm Driven Clutch Bolt 43 ft lbs 58 Nm 8 Install PVT hoses and outer PVT cover Torque fasteners to specification TORQUE Hose Clamps 35 in lbs 4 Nm Outer PVT Cover Fasteners 35 in lb...

Page 334: ...th the upper shift cable jam nut q 14 Connect the transmission shift cable to the bellcrank Install the clip and sliding the washer 15 Install two bolts securing the Rear Prop Shaft to the transmission Torque to specification TORQUE Rear Prop Shaft to transmission Fasteners 22 ft lbs 30 Nm 16 Install cargo box Torque fasteners to specification TORQUE Cargo Box Bracket Fasteners 5 ft lbs 7 Nm 17 Ch...

Page 335: ...emove sector cover bolts t and remove the cover 5 Remove detent spring detent pawl and detent star Note the master spline on the detent star and the shift shaft 6 Remove the two sector gears NOTE Note the timing marks on the shift gears for reassembly purposes 7 Remove transmission case bolts a 8 Using the three indicated by arrows designated pry points shown in the image separate the transmission...

Page 336: ... and idler shaft assembly k 13 Remove the four screws retaining the pinion shaft plate l NOTE One screw is longer 1 and than the others and must be put back in the correct location 14 Remove the pinion shaft assembly 2 15 Inspect all gear and shaft assemblies for damage 16 Check the bearings for damage and that they are easy to turn Replace any questionable bearings 17 To disassemble the shift sha...

Page 337: ...emble the other end of the reverse shaft Remove the bearing Park Low shift dog retaining ring washer low gear and needle bearing from the reverse shaft SNORKEL TUBE REMOVAL DISASSEMBLY CAUTION The pinion shaft must be removed prior to removing the snorkel tube assembly Failure to remove pinion shaft will result in damage to the snorkel tube or LH gearcase 1 Use the snorkel tube tool to remove the ...

Page 338: ...Industries Inc 3 Once the three snap rings e s f are removed use an arbor press to remove the snorkel tube and other components from the shaft CAUTION Support the end face of the gear teeth when pushing the shaft through or damage to the gear teeth may occur TRANSMISSION ...

Page 339: ... 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 Inspect the female side gear w male side gear e planet gears r and ring gear t Replace components or bushings as needed Bushing replacement can be performed on all necessary differential components If bushing replacement ...

Page 340: ...ng 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 flush to 1mm past the end of the ring gear hub as shown Planet Gear Bushing Replacement 1 Press the old bushing out of the planet gear 2 Thoroughly clean the bore of the planet gear and check for any unwanted burs 3 Press the new bushing into...

Page 341: ... bushing into the differential cover 4 Install the bushing flush to 1mm past the end of the differential cover as shown Female Side Gear Bushing Replacement 1 Locate the bushing split Using a small chisel or flat blade screwdriver peel back and remove the old bushing from the side gear being careful not to damage the side gear 2 Thoroughly clean the bore of the side gear and check for any unwanted...

Page 342: ...ly made scribe marks q 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification NOTE The are two possible grades for the differential cover screws The grade can be located on the head of the fastener The two possible fasteners are grade 8 8 and grade 10 9 Torque the screws according to their corresponding grade TORQUE Differential...

Page 343: ...yright Polaris Industries Inc 6 23 GEAR SHAFT BEARING INSPECTION Inspect all of the gears shafts and bearings shown for excessive wear or damage IMPORTANT If gear replacement is required also replace the corresponding gear and or gear shaft TRANSMISSION ...

Page 344: ...el shaft flush to the shoulder install 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 NOTE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium gr...

Page 345: ...onger locking screw k out at this point NOTE DO NOT install the longer screw k 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 TORQUE Bearing Cover Retaining Screws 9 ft lbs 12 Nm 11 Temporarily install the RH case with a couple fasteners to hold the pinion shaft square to establish a...

Page 346: ...ocking Screw 9 ft lbs 12 Nm TRANSMISSION ASSEMBLY NOTE The snorkel shaft and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after assembling the transmission IMPORTANT Thoroughly clean the mating surfaces of the transmission case halves so they are free of 3 Bond sealant Failure to properly clean the surfaces may lead to transmission case leaks ...

Page 347: ...a Gear 49T s Bearing d Washer f Bearing g Chain h Input Shaft j Bearing 5 Install the idler gear shaft assembly r and gear cluster assembly t into the transmission housing all at the same time 6 Install the rear output shaft assembly y Rotate output shaft assembly to align slots with engagement dog Ensure bearing is fully seated upon assembly 7 Assemble shift shaft rail if previously disassembled ...

Page 348: ...ift drum i into the transmission housing Lift up on the shift shaft rail u and move the rail assembly towards the shift drum to allow the shift fork ends to be installed into the shift drum i 11 The shift drum has several components listed below The orientation of the torsion spring s is important when rebuilding the shift drum After assembly of cam d torsion spring s washer a and retaining ring o...

Page 349: ...s g Torque bolts to specification TORQUE Transmission Case Bolts 20 ft lbs 27 Nm NOTE If using NEW left hand gearcase holes are not threaded for self tapping screws to form threads 14 Install new seals into the transmission case halves The snorkel shaft seal h should be pressed in until it seats against the housing counter bore The input shaft seal j should be pressed in until it seats flush with ...

Page 350: ...nt of white lithium grease on the O rings shift shafts and component contact surfaces prior to installing the sector cover 20 Clean the transmission and gear sector cover mating surfaces thoroughly 21 Apply Loctite 680 Sealant PN 3233901 onto the cover and transmission case mating surface 22 Install the sector cover and align the transmission case dowel 2 with the alignment hole Install and torque...

Page 351: ...check clutch to make sure the belt moves freely Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions prop...

Page 352: ......

Page 353: ...TION 7 16 PROPSHAFT U JOINT SERVICE 7 17 PROPSHAFT U JOINT DISASSEMBLY 7 17 PROPSHAFT U JOINT ASSEMBLY 7 18 FRONT GEARCASE SERVICE 7 20 FRONT GEARCASE ASSEMBLY VIEW 7 20 ALL WHEEL DRIVE AWD OPERATION 7 21 ALL WHEEL DRIVE AWD DIAGNOSIS 7 22 FRONT GEARCASE REMOVAL 7 23 FRONT GEARCASE DISASSEMBLY INSPECTION 7 23 FRONT GEARCASE ASSEMBLY 7 26 FRONT GEARCASE INSTALLATION 7 29 FRONT GEARCASE ADC 7 30 FRO...

Page 354: ...0 Service Manual Copyright Polaris Industries Inc DRIVE SHAFT SERVICE 7 45 DRIVE SHAFT CUTAWAY VIEW 7 45 DRIVE SHAFT CV JOINT HANDLING TIPS 7 45 OUTER CV JOINT BOOT REPLACEMENT 7 46 INNER PLUNGING JOINT BOOT REPLACEMENT 7 48 FINAL DRIVE ...

Page 355: ...ON Switching to 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 DESCRIPTION PART NUMBER Roll Pin Removal Tool 2872608 Axle Boot Clamp Tool PU 48951 CV Boot Clamp Pliers 8700226 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service soluti...

Page 356: ...E ROUTING The front gearcase vent line runs along the front passenger side frame It is secured along the front frame by four retention clips two horizontal and two vertical as shown The vent line ends its routing secured into a horizontal section of the frame with a vent line termination fitting FINAL DRIVE ...

Page 357: ... 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 e Remove the front wheel from the vehicle 5 Remove the two brake caliper mounting bolts r CAUTION Do not hang caliper by the brake line Use wire to hang caliper to prevent damage to brake line 6 Remove the castle nut and ...

Page 358: ...lace front bearing carrier if damaged Bearing Installation 1 Thoroughly clean the front bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 2 Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 3 Apply Loctite 603 retaining compound to the...

Page 359: ... the front bearing carrier 3 Install pinch bolts q and torque to specification TORQUE Ball Joint Pinch Bolts 42 lb ft 57 Nm 4 Install the steering tie rod end w onto the front bearing carrier and torque the fastener e to specification TORQUE Tie Rod End Fastener 40 lb ft 54 Nm 5 Apply grease to the drive shaft splines 6 Install front wheel hub assembly cone washers and hand tighten the castle nut ...

Page 360: ...sary to align holes for the cotter pin TORQUE Front Hub Castle Nut 80 lb ft 108 Nm 9 Install wheel and four wheel nuts u Torque wheel nuts to specification TORQUE Wheel Nuts Steel 60 lb ft 81 Nm Wheel Nuts Cast Alum 120 lb ft 163 Nm 10 Rotate wheel and check for smooth operation Bend both ends of cotter pin around the end of the shaft Install the center cap and or rubber dust cap FINAL DRIVE ...

Page 361: ...service procedure 2 Remove the drive shaft from the front bearing carrier 3 With a short sharp jerk remove drive shaft from the front gearcase 4 Refer to the DRIVE SHAFT SERVICE procedure if repairing the drive shaft FRONT DRIVE SHAFT INSTALLATION 1 Install new spring ring on the end of the drive shaft Apply an anti seize compound to splines 2 Align splines of drive shaft with front gearcase and r...

Page 362: ...P 1000 Service Manual Copyright Polaris Industries Inc PROP SHAFT SERVICE FRONT PROP SHAFT REMOVAL 1 Flip up passenger seat 2 Remove Driver Seat Lift up on Release Lever q Tilt seat forward Slide seat rearward to remove FINAL DRIVE ...

Page 363: ...e battery cover 4 Disconnect Positive and Negative battery cables 5 Remove Battery Bracket Fastener w and Bracket e Remove Battery 6 Remove Battery Box Fasteners r and remove Battery Box 7 Remove eight push rivets t and remove center console 8 Remove two push rivets from hard intake FINAL DRIVE ...

Page 364: ... to the side 10 Loosen four Worm Clamps i retaining the hard intake line from the rubber lines 11 Slide the plastic intake rearward then frontward to angle out driverside of vehicle 12 Remove two carrier bolts o 13 Remove front propshaft pin 14 Slide prop shaft forward enough to allow clearance to lift back of prop shaft up and out the opening in the footwell FINAL DRIVE ...

Page 365: ...Torque Carrier Bolts to specification TORQUE Carrier Bolts 40 ft lbs 54 Nm 5 Install the plastic intake Engage the rear rubber lines to the plastic intake Engage the front rubber boots over the plastic intake NOTE Use a small pic to help aid in getting the rubber lines to engage of all sides of the plastic intake 6 Tighten four Hose Clamps i retaining the hard intake line from the rubber lines Tor...

Page 366: ...0 Install Battery Box and two Battery Box Fasteners r TORQUE Battery Box Fasteners 3 5 ft lbs 5 Nm 11 Install Battery Install Battery Bracket e and Battery Bracket Fastener w Torque Fastener to specification TORQUE Battery Bracket Fastener 3 5 ft lbs 5 Nm 12 Connect Positive and Negative battery cables 13 Install battery cover FINAL DRIVE ...

Page 367: ...487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 7 15 14 Install Driver Seat Engage front seat base tabs Push seat down until properly seated 15 Fold down passenger seat FINAL DRIVE ...

Page 368: ...ide of the vehicle 3 Disengage the Rear Prop Shaft from the transmission Remove the Rear Prop Shaft through the opening in the floor REAR PROP SHAFT INSTALLATION 1 Install the Rear Prop Shaft through the opening in the floor 2 Install two fasteners securing the Rear Prop Shaft to the transmission NOTE Access the Rear Prop Shaft from the rear driver side of the vehicle TORQUE Rear Prop Shaft Fasten...

Page 369: ...ation 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 with a larger ID than the U joint cap OD on one end 3 Place a remover adapter e on other end of U joint with a smaller OD than the U joint cap 4 Position clamp r over receiving cup adapter and remover adapter 5 Tighten clamp with hand tools to...

Page 370: ...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 by hand 5 Place clamp and installer adapters r with smaller OD than caps over each cap 6 Tighten clamp to install caps simultaneously into yoke bores 7 Push U joint side to side during clamping to seat into caps properly 8 Tighten clamp unti...

Page 371: ...acing 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 Install second retaining ring i with sharp square edge facing away from U joint 13 Verify the U joint moves freely and does not bind FINAL DRIVE ...

Page 372: ... 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 Spacer a Oil Seal 2 Armature Plate s Retaining Ring Internal 2 AWD Coil d Cover Screws M6 T30 Torx 2 Grommet f Cover Plate Assembly 2 Fill Plug g Gearcase Housing 3 Drain Plug Magnetic h Clutch Housing Ring ...

Page 373: ...hile 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 volt DC input which creates a magnetic field This magnetic field attracts an armature plate that is keyed to the roll cage w When the ring gear q and roll cage w are spinning vehicle is moving the energized coil and armature plate wi...

Page 374: ...ent 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 Check to make sure the coil t is seated in the U shaped y insert that is pressed into the gearcase cover u The top of the coil should be seated below the U shaped insert The U shaped insert controls...

Page 375: ...08 to drive the roll pin 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 coil pigtail 6 Remove the bolts q retaining the front gearcase to the skid plate frame 7 Remove the vent hose from the front gearcase 8 Remove the front gearcase from the left...

Page 376: ...late assembly NOTE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate r Refer to AWD DIAGNOSIS for detailed inspection process 5 Remove the torsion spring retainer t and torsion spring y from the top of the ring gear 6 Remove the clutch housing ring gear and roll cage assembly u from the gearcase housing FINAL DRIVE ...

Page 377: ... 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 all the rollers NOTE Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 12 Thoroughly clean all parts and inspect the rollers h for nicks and scratches ...

Page 378: ...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 components 2 Install pinion shaft assembly and install internal snap ring NOTE If bearing replacement was required press new bearing onto the pinion shaft and install a new external snap ring 3 Install a new pinion...

Page 379: ...es 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 gear 7 Align spring retainer dowel pin t with ring gear dowel pin y and install the retainer on top of the torsion spring 8 Check the action of the torsion spring by rotating in both directions to ensure the...

Page 380: ...all the ring gear and roll cage assembly i into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTE Be sure the square O ring is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 12 Carefully install the LH output hub assembly o into the cover plate Take care not to damage the new cover plate seal while installing the output hub 13 Install ...

Page 381: ...stall new gearcase mounting bolts q and torque to specification TORQUE Front Gearcase Mounting Bolts 30 ft lbs 41 Nm 5 Drive a new roll pin into the front propshaft yoke 6 Install the front drive shafts into the front gearcase Refer to FRONT DRIVE SHAFT INSTALLATION procedure 7 Connect the AWD harness and tie the harness to the brake lines with a plastic tie strap 8 Add the proper lubricant to the...

Page 382: ...ter 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 slows the driveline and rear wheels The ADC coil detects the speed difference and locks the front wheels to the driveline The front wheels can now assist in controlling the descent Turning on the ADC Coil appl...

Page 383: ...r plate assembly 3 Remove the outer cover plate assembly NOTE 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 assembly e 5 Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or damaged 6 Remove and inspect the armature plates...

Page 384: ...nspect for wear 10 Remove the LH output hub s 11 Inspect the bearing and 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 the rollers a for nicks scratches and flat spots Inspect the roll cage o for damage or cracks The rollers must slide up and down f...

Page 385: ...mature plate for a consistent wear pattern Uneven wear of the armature plate indicates a warped plate which may cause intermittent operation NOTE See FRONT GEARCASE DIAGNOSIS later in this chapter for more details 16 Drill a hole in the input shaft seal d and remove the seal using a pry bar or seal puller 17 Remove the snap ring f retaining the input shaft assembly 18 Remove the input shaft assemb...

Page 386: ...spect bearings on output and pinion shafts To replace press new bearing onto shaft NOTE 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 or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Inst...

Page 387: ...nstalled 9 Install the pins a roll cage o and ring gear assembly i into the gearcase housing 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 directions to ensure the spring and retainer are installed properly 12 Install the armature plates t Be sure the armature...

Page 388: ...a new o ring onto the gearcase NOTE Verify the square 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 gearcase with fluid FLUID CAPACITY Demand Drive Hub Fluid 8 97 oz 265 ml 17 Install the drain plug Torque to specification TORQUE Fill Drain Plug 10 ft lb...

Page 389: ...as 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 with ADC mode on to determine if problem has been fixed If not continue onto additional problems listed No power from vehicle to front differential blown fuse Unhook wire connector to front differential Us...

Page 390: ...pring Always replace both do not take springs off old cage and put onto new cage Drive vehicle with ADC mode on to determine if problem has been fixed If not continue onto additional problems listed Torsion Spring Make sure Spring is installed properly Make sure Spring is able to index properly in both directions Plastic retainer should index with some force from spring Retainer should also index ...

Page 391: ... band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 4 Check to make sure the coil t is seated in the U shaped y insert that is pressed into the gearcase cover u The top of the coil should be seated below the U shaped insert The U shaped...

Page 392: ...ition 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 area 3 Remove wheel nuts washers and wheel 4 Remove the cotter pin q castle nut w and washers e 5 Remove the two rear brake caliper mounting bolts and remove the caliper from the bearing carrier CAUTION Do ...

Page 393: ...ing carrier if damaged 4 Inspect the bearing carrier bushings and replace if worn or damaged 5 Thoroughly 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 housing CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 7 Apply Loct...

Page 394: ...Torque the upper and lower bearing carrier fasteners to specification TORQUE Bearing Carrier Fasteners 40 lb ft 54 Nm 5 Install the wheel hub assembly onto the drive shaft 6 Install the washers r with domed side out and the wheel hub castle nut t Torque the wheel hub castle nut to specification and install a NEW cotter pin y TORQUE Rear Wheel Hub Castle Nuts 110 lb ft 149 Nm 7 Install the rear bra...

Page 395: ...ake caliper mounting bolts and remove the caliper from the bearing carrier CAUTION Do not hang the caliper by the brake line Use mechanics wire to hang the caliper to prevent possible damage to the brake line 6 Remove the upper A arm fastener 7 Slide the wheel hub out from the bearing carrier and drive shaft 8 Remove the upper bearing carrier fastener and tilt the carrier down while removing the e...

Page 396: ... anti seize compound to the splines 2 Align splines of the drive shaft with the transmission and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Rotate the bearing carrier onto the drive axle and rotate into upper A arm 4 Install the upper bearing carrier fastener 5 Refer toRear Bearing Carrier Installation page 7 42 procedure to reassembl...

Page 397: ...assembly or potential damage to the drive shaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other susp...

Page 398: ...d slide the boot down the shaft 3 Clean the grease from the face of the joint 4 Place the drive shaft in a soft jawed vise 5 Using a soft faced hammer or brass drift strike inner race of the joint to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding NOTE Tap on inner race only 6 Make sure circlip is on the shaft and not left in the joint 7 Remove the CV bo...

Page 399: ...o reassembly 11 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in it s groove machined in the shaft 12 Install a NEW circlip on the end of the shaft 13 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer fa...

Page 400: ...to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the shaft 21 Install and tighten the small clamp on the boot using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 INNER PLUNGING JOINT BOOT REPLACEMENT 1 Use a side cutters t...

Page 401: ... grease in the joint is obviously contaminated with water and or dirt the joint should be replaced 8 Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 9 Visually inspect joint for damage Replace if needed 10 Clean the splines on the end of the shaft and apply a light coat of grease prior to reassemb...

Page 402: ...e 17 Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft 18 Remove excess grease from plunging joint s external surfaces and place the excess grease in the boot 19 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 20 Install and tighten the smal...

Page 403: ...ALLATION 8 8 STEERING INSPECTION 8 9 TIE ROD END WHEEL HUB INSPECTION 8 10 WHEEL TOE INSPECTION 8 10 WHEEL TOE ADJUSTMENT 8 11 FRONT A ARM SERVICE 8 12 FRONT LOWER A ARM REMOVAL INSTALLATION 8 12 A ARM BUSHING REPLACEMENT 8 13 FRONT UPPER A ARM REMOVAL INSTALLATION 8 13 BALL JOINT SERVICE 8 15 BALL JOINT SERVICE PREPARATION 8 15 BALL JOINT REMOVAL 8 16 BALL JOINT INSTALLATION 8 17 REAR A ARM SERVI...

Page 404: ...reuse old hardware Serious injury or death could result if fasteners come loose during operation CAUTION New ball joint bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly SPECIAL TOOLS STEERING SUSPENSION TOOL DESCRIPTION PART NUMBER Ball Joint Tool PU 50506 Spring Compressor Tool 2870623 Shock Spanner Wrench 2871095 Bos...

Page 405: ... Steering Shaft Upper NA j Steering Adjustment Shock Assembly Bolt NA t Steering Gear Box Asm NA k Steering Adjustment Shock Assembly Nut 7 ft lbs 10 Nm y Tilt Steering Asm NA l Steering Rack Mount Nuts 40 ft lbs 54 Nm u Power Steering Asm NA 1 Steering Wheel Tilt Assembly Nut 40 ft lbs 54 Nm i Steering Wheel Cap NA 2 Lower Steering Shaft Nut NA o Tilt Assembly NA 2 Nut 65 ft lbs 88 Nm a Tie Rod J...

Page 406: ...upper steering shaft w 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 steering wheel upper steering shaft and pivot out as an assembly 6 Remove the steering wheel cap 7 Loosen the nut and back it half way off the steering shaft 8 Place the assembly in a vise 9 Using a large br...

Page 407: ...Remove the pinch bolt w retaining the lower portion of the steering shaft e to the steering rack assembly q 2 Remove the nuts r retaining the both tie rod ends to the steering knuckle 3 Remove the three fasteners t retaining the steering rack to the frame 4 Remove Steering Rack from vehicle STEERING SUSPENSION ...

Page 408: ... into the vehicle Install three nuts t retaining the steering rack to the frame Torque to specification TORQUE Steering Rack Mounting Nuts 40 ft lbs 54 Nm 3 Install the steering shaft e to the steering rack assembly q Install the pinch bolt w and nut Torque to specification TORQUE Lower Steering Shaft to Rack Pinch Bolt 48 ft lbs 65 Nm 4 Install the tie rod ends into the steering knuckle as shown ...

Page 409: ...aring onto the steering shaft and install the steering shaft through the pivot tube NOTE Use care not to allow any of the Loctite to get in the bearing Be sure the lower spacers are still on the steering shaft I DESCRIPTION TORQUE q Steering Wheel Cap NA w Nut 65 ft lbs 88 Nm e Steering Wheel NA r Hub Insert NA t Bushing NA y Steering Shaft Upper NA u Tilt Assembly NA 8 Apply Loctite 271 Red to th...

Page 410: ...ecification TORQUE Power Steering Mount Fasteners 30 ft lbs 41 Nm 2 Align the skip tooth spline on the power steering output shaft with the opening in the lower power steering shaft 3 Install power steering and mount assembly to the frame and torque fasteners to specification TORQUE Power Steering Unit Frame Fasteners 14 ft lbs 19 Nm 4 Install the pinch bolt retaining the lower power steering shaf...

Page 411: ...strument 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 periodically for loose fasteners q worn tie rod ends w loose steering shaft U joints e worn A arm ball joints and general damage Also check to make sure all cotter pins r are in place If cotter pins are removed they must be replace...

Page 412: ...front and rear Try to move the wheel and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut WHEEL TOE INSPECTION NOTE Make sure tire pressures are set the same on the right and left tires 1 Place machine on a smooth level surface and set steering wheel in a straight ahead posit...

Page 413: ...heel This will tell you which tie rod needs adjusting NOTE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment Measure the distance the measurement should be equal CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and ma...

Page 414: ...ehicle 5 Examine A arm bushings and pivot tube Replace if worn Discard hardware 6 If not replacing the A arm thoroughly clean the A arm and pivot tube 7 Install new ball joint into A arm Refer to Ball Joint Service section 8 Install new lower A arm assembly onto vehicle frame Torque new bolt to specification 9 Insert lower A arm ball joint end into the bearing carrier Install lower ball joint pinc...

Page 415: ...le using the punch and hammer 2 Install new Pivot Cap q Bushings w and Pivot Shaft e into new A arm A light press force may be needed FRONT UPPER A ARM REMOVAL INSTALLATION 1 Elevate and safely support the front of the vehicle and remove the front wheel 2 Remove lower shock fastener q and stabilizer bar link w from upper A arm 3 Carefully drill out brake line retention grommets CAUTION Do not dama...

Page 416: ...ration 8 If not replacing the A arm thoroughly clean the A arm and pivot tube 9 Install new ball joint into A arm Refer to Ball Joint Service section 10 Insert new A arm bushings and pivot tube into new A arm 11 Install new upper A arm assembly onto vehicle frame Torque new bolt to specification TORQUE Front Upper A arm Bolts 40 ft lbs 54 Nm 12 Install brake line routing clips and grommets in the ...

Page 417: ...he A arm does not need to be removed to perform this procedure if ball joint tool PU 50506 is used 1 Properly lift and support the vehicle by the frame 2 Remove the appropriate front 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 procedure 4 Remove and discard the ...

Page 418: ...y 2 Install Spacer q over the top of the ball joint face 3 Place Removal Adaptor w over the ball joint shaft 4 Install the Press Asm e onto the A arm to engage the ball joint Removal Adapter NOTE Be sure the Press Asm opening is only contacting the Spacer q and not the ball joint face 5 Tighten the Press Asm screw and fully remove the ball joint from the A arm STEERING SUSPENSION ...

Page 419: ... a new retaining ring NOTE Image for reference only 7 Repeat the ball joint service procedure for any additional A arm ball joint replacements 8 Insert upper lower A arm ball joint end into the bearing carrier Install new pinch bolts and nuts Torque to specification 9 If needed install new brake caliper mounting bolts and torque to specification CAUTION New bolts have a pre applied locking agent w...

Page 420: ...ink 4 Remove the four wheel nuts and remove the wheel 5 Remove the fastener w retaining the lower portion of the rear shock to the lower A arm 6 Remove the fastener e and nut retaining the upper A arm to the bearing carrier 7 Drill out the rivet r retaining the brake line clamp to the upper A arm 8 Using a 15 mm socket and open end wrench remove the two fasteners t retaining the upper A arm to the...

Page 421: ... new fastener to specification TORQUE Shock Mounting Bolts 40 lb ft 54 Nm 4 Attach the lower stabilizer bar link to the lower A arm Torque new fastener to specification 5 Attach the stabilizer bar to the frame Torque fasteners to specification TORQUE Stabilizer Bar Fasteners 17 lb ft 23 Nm 6 Install wheel and torque wheel nuts to specification TORQUE Wheel Nuts Steel 60 lb ft 81 Nm Wheel Nuts Alum...

Page 422: ...ning the rear stabilizer bar to the frame 3 Remove the nut q from the lower portion of the stabilizer bar link 4 Remove the four wheel nuts and remove the wheel 5 Remove the fastener w retaining the lower portion of the rear shock to the lower A arm 6 Remove the fastener retaining the lower A arm to the bearing carrier and frame 7 Remove the lower A arm from the vehicle STEERING SUSPENSION ...

Page 423: ...r Fasteners 17 lb ft 23 Nm 6 Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm WARNING Upon A arm installation completion test vehicle at low speeds before putting into service STABILIZER BAR SERVICE REAR STABILIZER BAR REMOVAL INSTALLATION REMOVAL 1 Elevate and safely support the vehicle with weight removed from the rear wheel s 2 Identify mark top side ...

Page 424: ...ounting Bolts 40 lb ft 54 Nm SHOCK SPRING REPLACEMENT 1 Remove the shock and note the spring preload cam setting 2 Using spring compressor compress the shock spring far enough to remove spring retainer Spring Compressor 2870623 3 Remove the spring and adjusting cam from the existing shock and install components onto the new shock 4 Install the spring retainer If needed use the spring compressor to...

Page 425: ... REMOVAL 9 14 FRONT BRAKE PAD INSPECTION 9 15 FRONT BRAKE PAD INSTALLATION 9 15 BRAKE BURNISHING PROCEDURE 9 16 FRONT CALIPER SERVICE 9 17 FRONT CALIPER ASSEMBLY VIEW 9 17 FRONT CALIPER REMOVAL 9 18 FRONT CALIPER DISASSEMBLY 9 19 FRONT CALIPER INSPECTION 9 20 FRONT CALIPER ASSEMBLY 9 20 FRONT CALIPER INSTALLATION 9 21 FRONT BRAKE DISC SERVICE 9 22 DISC RUNOUT 9 22 BRAKE DISK INSPECTION 9 22 BRAKE ...

Page 426: ...BRAKE DISC SERVICE 9 32 DISC RUNOUT 9 32 BRAKE DISK INSPECTION 9 32 BRAKE DISC REPLACEMENT 9 33 TROUBLESHOOTING BRAKE SYSTEM 9 34 BRAKE NOISE TROUBLESHOOTING 9 34 BRAKES SQUEAL POOR BRAKE PERFORMANCE 9 34 PEDAL VIBRATION 9 34 CALIPER OVERHEATS BRAKES DRAG 9 34 BRAKES LOCK 9 34 BRAKE SYSTEM ...

Page 427: ... 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 contact the brake discs and move the calipers in their floating bracket pulling the stationary side pads into the brake discs The resulting friction reduces brake disc and vehicle speed The friction applied to the br...

Page 428: ... 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 SERVICE LIMIT Rear Brake Pad Thickness 0 298 007 7 56 178 mm 0 150 3 8 mm Rear Brake Disc Thickness 0 188 4 78 mm 0 170 4 32 mm Rear Brake Disc Thickness Variance 0 002 0 051 mm Rear Brake Disc Runout 0 010 0 2...

Page 429: ...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 BRAKE REAR LH i FITTING CROSS o CYLINDER BRAKE MASTER a LINE BRAKE FRONT LH s CALIPER BRAKE LH d SCRAPER BRAKE SYSTEM ...

Page 430: ...9 6 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER BRAKE SYSTEM ...

Page 431: ...928487 R01 2018 RANGER XP 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 BRAKE SYSTEM ...

Page 432: ...9 8 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc BRAKE LINE CLOCKING ITEM DESCRIPTION q To Tee Block w To Right Front Caliper e To Left Front Caliper BRAKE SYSTEM ...

Page 433: ...om reservoir 3 If changing fluid remove old fluid from reservoir with a Mity Vac pump or similar tool Mity Vac 2870975 4 Add brake fluid to the indicated MAX level of reservoir Polaris DOT 4 Brake Fluid P N 2872189 5 Begin bleeding procedure with caliper furthest from master cylinder 6 Install a box end wrench on caliper bleeder screw 7 Attach a tight fitting clear hose to the bleeder fitting 8 Pl...

Page 434: ... CAUTION Maintain at least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 13 Tighten bleeder screw and remove bleeder hose Torque bleed screw to specification TORQUE Caliper Bleed Screws 4 ft lbs 5 5 Nm 14 Repeat Steps 9 13 for the remaining brake calipers 15 Install master cylinder reservoir cover 16 Field test machine at low speed before putting into...

Page 435: ...linder to the frame 3 Remove master cylinder and place a fluid catch container under the master cylinder brake lines CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 4 Loosen the brake line banjo bolt r and brake switch t allowing the fluid to drain 5 Discard seals and replace upon assembly NOTE Make note of front and rear brake l...

Page 436: ...jo Bolt 15 ft lbs 20 Nm TORQUE Brake Switch 15 ft lbs 20 Nm 4 Attach the master cylinder to the frame and torque mounting fasteners to specification TORQUE Master Cylinder Mounting Fasteners 12 ft lbs 16 Nm 5 Attach the master cylinder to the brake pedal lever by installing the clevis pin and retaining clip 6 Follow the Brake Fluid Replacement Brake Bleeding page 9 9 procedure 7 Field test unit fo...

Page 437: ... cylinder arm to free it from the brake pedal 3 Slide the brake pedal and bushings off the pedal mount bracket BRAKE PEDAL INSTALLATION 1 If the pedal mount bracket was removed torque retaining nuts to specification TORQUE Brake Pedal Mount Bracket Nuts 18 lb ft 24 Nm 2 Install brake pedal to the pedal mount bracket and secure with pin and clip 3 Install the clevis pin and retaining clip securing ...

Page 438: ...g bolts and remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into calipe...

Page 439: ...one grease and install rubber dust boots w 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper w onto front hub and torque mounting bolts q to specification TORQUE Front Caliper Mounting Bolts 3...

Page 440: ...oir 7 Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed 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 sufficiently during the ...

Page 441: ...stries Inc 9 17 FRONT CALIPER SERVICE FRONT CALIPER ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q Brake Pad Assembly y Brake Piston w Caliper Mount Assembly u Ring e Brake Caliper i Bolt r Pin Seal Boot o Bleeder Screw t Pin Bushing Boot a Plug Cap BRAKE SYSTEM ...

Page 442: ...l CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before 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 caliper is removed 6 Remove the two caliper mounting bolts and caliper e BR...

Page 443: ...ea 3 Use a commercially available caliper piston pliers to extract the pistons from the caliper NOTE Do not remove the caliper pistons with a standard pliers The piston sealing surfaces will become damaged if a standard pliers is used 4 Once the pistons are 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 cal...

Page 444: ...80 mm Service Limit 1 368 34 75 mm 3 Inspect brake disc and pads as outlined in this chapter FRONT CALIPER ASSEMBLY 1 Install new O rings in the caliper body Be sure the grooves are clean and free of residue or brakes may drag upon assembly 2 Coat 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...

Page 445: ...e Banjo Bolts 15 ft lbs 20 Nm 3 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow the Brake Bleeding Fluid Change procedure as outlined earlier in this chapter 5 Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm 6 Field test unit for proper braking action before putting into service Inspect for fl...

Page 446: ...ice Limit 0 010 0 254 mm BRAKE DISK 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 thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit MEASUREMENT Brake Disc Thickness Standard 0 188 4 78 mm Service Limit 0 170 4 32 mm MEASUREMENT B...

Page 447: ... new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal TORQUE Brake Disc Mounting Bolts 18 ft lbs 24 Nm 5 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Front Wheel Hub Castle Nut 80 ft lbs 108 Nm 6 Install front brake caliper Refer to Front Caliper Installation page 9 21 pr...

Page 448: ...ster screw 2 3 turns 3 Clean caliper area before removal 4 Remove caliper mounting bolts and lift caliper off of disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper piston into caliper bore slowly with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when...

Page 449: ...and install rubber dust boots w 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper and torque bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 4 Install the pad adjustme...

Page 450: ...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 sufficiently during the procedure Do not allow pads or disc to become hot or warping may result Repeat this procedure 10 times Do not make more than 3 stops per 1 mile 1 6 km BRAKE SYSTEM ...

Page 451: ...ustries Inc 9 27 REAR CALIPER SERVICE REAR CALIPER ASSEMBLY VIEW REF PART DESCRIPTION REF PART DESCRIPTION q Brake Pad Assembly y Brake Piston w Caliper Mount Assembly u Ring e Brake Caliper i Bolt r Pin Seal Boot o Bleeder Screw t Pin Bushing Boot a Plug Cap BRAKE SYSTEM ...

Page 452: ...eel 3 Clean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removing the brake line Use a wrench to remove the brake line banjo bolt q 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 mounting bolts and brake calip...

Page 453: ... and slip brake pads q past the edge and remove from the caliper 3 Remove mount bracket w and dust boots y u 4 Using a hammer and a small punch remove the piston t from the caliper body i Remove the square O rings r and e from the caliper body i 5 Clean the caliper body piston and retaining bracket a with brake cleaner or alcohol NOTE Be sure to clean caliper body seal grooves BRAKE SYSTEM ...

Page 454: ...m Service Limit 1 498 38 05 mm 3 Inspect the brake disc and pads as outlined in this chapter REAR CALIPER ASSEMBLY 1 Install new caliper seals q in the caliper body w Be sure groove is clean and free of residue or brakes may drag upon assembly 2 Coat piston with clean Polaris DOT 4 Brake Fluid Install piston e with a twisting motion while pushing inward Piston should slide in and out of bore smoot...

Page 455: ...rn until stationary pad contacts disc then back off 1 2 turn 4 Follow the BRAKE BLEEDING FLUID CHANGE procedure as outlined earlier in this chapter 5 Install wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts 120 ft lbs 163 Nm 6 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when peda...

Page 456: ...ce Limit 0 010 0 254 mm BRAKE DISK 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 thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit MEASUREMENT Brake Disc Thickness Standard 0 188 4 78 mm Service Limit 0 170 4 32 mm MEASUREMENT Br...

Page 457: ...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 and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Rear Wheel Hub Castle Nut 110 lb ft 149 Nm 6 Install rear brake caliper Refer to REAR CALIPER INSTALLATION procedure Fo...

Page 458: ...g Operator error riding the brake Adjust pad stop Set to proper level Clean compensating port Inspect Repair as necessary Clean piston s seal Educate operator Loose wheel hub or bearings Check wheel and hub for abnormal movement Brake disc warped or excessively worn Replace disc Brake disc misaligned or loose Inspect and repair as necessary Noise is from other source axle hub disc or wheel If nois...

Page 459: ...ATER LINES 10 16 HVAC DUCTING 10 17 REAR PANEL ASSEMBLY VIEW 10 18 CARGO BOX ASSEMBLY VIEW 10 19 TAILGATE ASSEMBLY 10 19 CARGO BOX ASSEMBLY 10 20 CARGO BOX FRAME ASSEMBLY 10 21 CAB FRAME SERVICE 10 22 DOOR REMOVAL INSTALLATION 10 22 ROOF REMOVAL INSTALLATION 10 22 REAR PANEL REMOVAL INSTALLATION 10 23 REAR CARGO BOX SERVICE 10 24 CARGO BOX REMOVAL 10 24 CARGO BOX INSTALLATION 10 24 BODY COMPONENT ...

Page 460: ...R XP 1000 Service Manual Copyright Polaris Industries Inc LOWER DASH PANEL REMOVAL 10 33 ROCKER PANEL REMOVAL 10 34 FLOOR REMOVAL INSTALLATION 10 35 FLOOR REMOVAL 10 35 FLOOR INSTALLATION 10 36 ACCESSORY SERVICE 10 37 BODY FRAME ...

Page 461: ...mponents 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 treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or ca...

Page 462: ...S ASSEMBLY VIEW ITEM DESCRIPTION TORQUE q FRAME MAIN NA w WELD CROSSBAR NA e WELD SEAT BASE MAIN NA r WELD SEAT SUPPORT MOUNT PASSENGER NA t GROMMET SEAT BASE NA y PLATE SKID NA u SKID PLATE FASTENERS 6 ft lbs 8 Nm i SEAT BASE FASTENERS 10 ft lbs 14 Nm o CROSS BAR FASTENERS 14 ft lbs 19 Nm a WASHER SKID PLATE NA BODY FRAME ...

Page 463: ...N TORQUE q DASH GAUGE HOOD NA w TUFLOK RIVET NA e DASH GAUGE BEZEL NA r DASH CENTER TRAY NA t GLOVEBOX PIN HINGE NA y RUBBER GROMMET NA u COVER UPPER GLOVEBOX NA i UPPER GLOVEBOX FASTENER 10 in lbs 1 Nm o UPPER GLOVEBOX BIN NA a DASH UPPER NA s DASH STORAGE FASTENER 42 in lbs 5 Nm d LOWER STORAGE BIN NA f DASH LOWER STORAGE NA BODY FRAME ...

Page 464: ...ASH LH NA r DRIP PLATE NA t PUSH RIVET NA y DASH BRACKET FASTENER 6 ft lbs 8 Nm u BRACKET DASH RH NA i DASH MAIN FASTENER 42 in lbs 5 Nm o UPPER GLOVEBOX FASTENER 42 in lbs 5 Nm a HINGE PIN GLOVEBOX NA s GLOVEBOX SEAL SEAM NA d GLOVEBOX LATCH 1 4 TURN 36 in lbs 4 Nm f UPPER GLOVEBOX COVER NA g DASH CONTROLS NA h DASH MAIN FASTENING NUT NA BODY FRAME ...

Page 465: ... DESCRIPTION TORQUE q LINER UNDER HOOD NA w HOOD NA e FENDER FRONT RH 22 in lbs 3 Nm r FENDER FLARE RH NA t GRILL UPPER NA y FRONT FASCIA 42 in lbs 5 Nm u FENDER FRONT LH 22 in lbs 3 Nm i FENDER FLARE LH NA o GROMMET LATCH NA a WASHER NA s LATCH 1 4 TURN NA d FRONT FASCIA AND GRILL FASTENERS 42 in lbs 5 Nm BODY FRAME ...

Page 466: ...ustries Inc FLOORS FENDER ASSEMBLY VIEW REF DESCRIPTION TORQUE q DRIVER FLOOR NA w LH FENDER FLARE NA e FLOOR UPPER CLOSEOFF NA r FLOOR FASTENER 42 in lbs 5 Nm t PUSH RIVET NA y LINDER UNDER HOOD NA u RH FENDER FLARE NA i COVER TUNNEL FLOOR NA o PASSENGER FLOOR NA BODY FRAME ...

Page 467: ...SE OFF PANEL FASTENER 42 in lbs 5 Nm e RIGHT REAR UPPER FENDER FLARE NA r REAR CLOSE OFF PANEL NA t LEFT REAR UPPER FENDER FLARE NA y PUSH RIVET NA u LEFT REAR ROCKER PANEL NA i PLUG COMPARTMENT NA o RH BIN STORAGE NA a PUSH RIVET NA s REAR LOWER CLOSE OFF PANEL NA d M6 NUT NA f RIGHT REAR ROCKER PANEL NA g COVER SEAT PIVOT NA BODY FRAME ...

Page 468: ...E q PASSENGER SEAT BACK ASSEMBLY NA w SEAT BELT WASHER NA e SEAT BELT FASTNER 40 ft lbs 54 Nm r SEAT BUCKLE FASTNER 40 ft lbs 54 Nm t SEAT BUCKLE WASHER NA y SEAT BUCKLE FASTENING NUT NA u DRIVER SEAT BACK ASSEMBLY NA i DRIVER SEAT BOTTOM ASSEMBLY NA o DRIVER SEAT BUCKLE NA a PASSENGER SEAT BUCKLE NA s PASSENGER SEAT BOTTOM NA BODY FRAME ...

Page 469: ...10 NA y SEAT BRACKET PIVOT NA u SEAT BRACKET PIVOT WASHER NA i SEAT BRACKET PIVOT FASTENER 10 ft lbs 14 Nm o SEAT SHOCK BALL END FASTENER 7 ft lbs 9 Nm a SEAT SHOCK NA s SEAT BACK FASTENER 18 inch lbs 2 Nm d SEAT SLIDE ASSEMBLY FASTENER 6 ft lbs 8 Nm f SEAT SLIDE ASSEMBLY NA g SEAT PIVOT BRACKET MOUNTING FASTENER 10 ft lbs 14 Nm h SEAT SLIDE ASSEMBLY FASTENER 6 ft lbs 8 Nm j SEAT BACK FRAME FASTEN...

Page 470: ...A r HIP BOLSTER NA t HEADREST NA y PLATE WINDSHIELD MOUNT NA u HANDLE GRAB NA i HANDLE GRAB FASTENERS 10 ft lbs 14 Nm o FRAME CAB FASTENERS 65 ft lbs 61 Nm a FRAME CAB NUT NA s WELD CAB FRAME FASTNERS 40 ft lbs 49 Nm d WELD CAB FRAME NUT NA f WELD SEAT BOLSTER FASTENERS 10 ft lbs 14 Nm g BOLSTER BRACKET FASTENERS 6 ft lbs 8 Nm h RIVET NA j PLATE WINDSHIELD MOUNT FASTENERS 36 ft lbs 49 Nm BODY FRAM...

Page 471: ...EF DESCRIPTION TORQUE q HINGE UPPER LH NA w HINGE UPPER RH NA e HINGE LOWER LF NA r HINGE LOWER RH NA t STRIKER NA y DOOR ASSEMBLY LH NA u DOOR ASSEMBLY RH NA i DOOR RETAINER SPAER NA o WASHER NA a STRIKER HARDWARE 17 lb ft 23 Nm s DOOR RETAINER FASTENER 6 lb ft 8 Nm d DOOR RETAINER NUT 6 lb ft 8 Nm BODY FRAME ...

Page 472: ...Manual Copyright Polaris Industries Inc ROOF ASSEMBLY VIEW REF DESCRIPTION TORQUE q CLIP DART NA w HEADLINER NA e WASHER NA r HEADLINER FASTENER 24 in lbs 3 Nm t OVERHEAD LIGHT FASTENER 18 in lbs 2 Nm y OVERHEAD LIGHT NA u PUSH RIVET NA BODY FRAME ...

Page 473: ...rvice Manual Copyright Polaris Industries Inc 10 15 REF DESCRIPTION TORQUE q ROOF ASSEMBLY NA w ROOD SIDE SEAL NA e ROOF FASTENER NA r REAR ROOF SEAL NA t ROOF FASTENER 42 in lbs 5 Nm y ROOF FASTENER CLIP NA u FRONT ROOF SEAL NA BODY FRAME ...

Page 474: ...ft lbs 8 Nm e HVAC MOUNTING BRACKET NA r AC HOSE CLAMP FASTENER 6 ft lbs 8 Nm t AC HOSE CLAMP NA y AC PRESSURE HOSE 18 ft lbs 24 Nm u HVAC CONDENSER NA i HVAC CONDENSER MOUNTING FASTENER 35 in lbs 4 Nm o AC HOSE CONDENSER TO EVAPORATOR 12 ft lbs 16 Nm a HEATER RETURN HOSE NA s HEATER SUPPLY HOSE NA d AC SUCTION HOSE NA f HVAC MOUNTING WASHER NA g HVAC MOUNTING FASTENER 8 ft lbs 11 Nm h MAIN HVAC A...

Page 475: ... 3 DUCTING ASSEMBLY CENT RH N A 4 AIR DISTRIBUTOR MANIFOLD N A 5 STRAP PANDUIT N A 6 AIR DISTRIBUTOR MANIFOLD FASTENER 18 in lbs 2 Nm 7 FRESH AIR HOSE N A 8 FILTER SUPPORT N A 9 FILTER SUPPORT FASTENER 18 in lbs 2 Nm 10 AIR FILTER N A 11 AIR FILTER BAND CLAMP 24 in lbs 3 Nm 12 CENTER DASH DUCTING ASSEMBLY N A 13 DEFROST VENT N A 14 DUCTING ASSEMBLY LH N A BODY FRAME ...

Page 476: ... REAR PANEL GLASS NA w SLEEVE NA e HANDLE REAR WINDSHIELD NA r SHIM NA t WINDSHIELD BASE NA y MOUNT REAR WINDSHIELD NA u SEAL REAR GLASS NA i REAR GLASS FASTENER Torque until lock and ride clamps are fully seated o REAR GLASS FASTENER NUT Torque until lock and ride clamps are fully seated a WASHER NA s WASHER NA d WASHER NA BODY FRAME ...

Page 477: ... w INNER TAILGATE PANEL NA e TAILGATE SUPPORT BRACKET NA r TAILGATE ROD LEFT AND RIGHT ROD t TAILGATE SUPPORT FASTENER 42 in lbs 5 Nm y TAILGATE LATCH NA u TAILGATE CAP NA i TAILGATE LOWER PANEL FASTENER 42 in lbs 5 Nm o TAILGATE OUTER PANEL NA a OUTER TAILGATE PANEL FASTENER 22 in lbs 2 Nm s TAILGATE OUTER PANEL NA d TAILGATE CABLE NA f TAILGATE ROD CLIP NA g TAILGATE LATCH SPRING NA BODY FRAME ...

Page 478: ... OUTER CARGO BOX PANEL FASTENER 8 in lbs 1 Nm y PUSH RIVET NA u CARGO BOX FASTENER 42 in lbs 5 Nm i CARGO BOX OUTER PANEL NA o PUSH RIVET NA a CARGO BOX OUTER TRIM PANEL NA s LOWER TAILGATE SUPPORT FASTENER M8X1 25 10 ft lbs 14 Nm d TAILGATE SUPPORT BRACKET NA f TAILGATE SUPPORT FASTENER M6x1 0 42 in lbs 5 Nm g TAILGATE LATCH FASTENER 7 ft lbs 9 Nm h TAILGATE LATCH NA j TAILGATE SUPPORT FASTENER M...

Page 479: ...s 2 Nm e CARGO BOX LATCH BUSHING FASTENING NUT 13 ft lbs 18 Nm r CARGO BOX LATCH BUSHING NA t LATCH SPRING NA y CARGO BOX LATCH BUSHING FASTENER 13 ft lbs 18 Nm u HITCHPIN CLIP NA i CARGO BOX SHOCK CABLE NA o CARGO BOX SHOCK NA a CLEVIS PIN NA s CARGO BOX FRAME FASTENER 5 ft lbs 7 Nm d CARGO BOX FRAME FASTENING NUT 5 ft lbs 7 Nm f CARGO BOX SUPPORT FRAME NA g CARGO BOX LATCH HANDLE NA h BOX BUMPER...

Page 480: ...f the hinge 2 Reinstall by gently installing the door over both hinges Ensure proper door alignment ROOF REMOVAL INSTALLATION 1 Remove the clips q and fasteners w holding the headliner to the roof 2 If equipped remove the two fasteners e holding the overhead light to the headliner Remove the headliner 3 Remove the fasteners r holding the roof to the frame BODY FRAME ...

Page 481: ...ate the LOCK RIDE handles counterclockwise into the unlocked position 2 Rotate the top of the rear window slightly away from the vehicle then lift the windshield up and away from the vehicle NOTE Store windshield in an upright position in a location where it will not be bumped into and where it will not be subject to things falling on it Polaris recommends that the lower frame of the glass be set ...

Page 482: ...s stable with the shock removed 5 Remove the two hinge fasteners that retain the cargo box to the frame CAUTION Use caution when removing the box It is recommended to have two people carefully remove the box from the frame 6 Lift the cargo box from the frame Two people or an appropriate overhead hoist may be needed to remove the box from the frame CARGO BOX INSTALLATION 1 Place the cargo box onto ...

Page 483: ...n Release Lever q 3 Tilt seat forward 4 Slide seat rearward to remove FRONT BUMPER REMOVAL 1 Remove the two fasteners retaining the bottom of the bumper to the frame 2 Remove the two fasteners w retaining the top of the bumper to the frame 3 Carefully pull the bumper straight out to remove it from the vehicle TORQUE Front Bumper Fasteners 30 ft lbs 41 Nm BODY FRAME ...

Page 484: ...aight up and out 2 Remove the three push rivets q and the T 30 torx fastener w 3 Remove the two push rivets e behind the front fascia 4 Pull upper fender straight out as shown UPPER FENDER INSTALLATION 1 Install the fender straight on as shown CAUTION Ensure all alignment clips on the back of the fender are properly inserted or damage may occur to upper fender 2 Install the two push rivets q behin...

Page 485: ...ner w and torque to specification TORQUE Front Fender Fasteners 22 in lbs 3 Nm 4 Install the hood by inserting into slots and locking down with 1 4 turn fasteners LOWER FENDER SERVICE 1 Remove the upper fender 2 Remove the four push rivets q 3 Remove the five T 40 torx fasteners w 4 Pull the lower fender straight out from vehicle to remove BODY FRAME ...

Page 486: ...is Industries Inc LOWER FENDER INSTALLATION 1 Install the lower fender straight on as shown 2 Install the five T 40 torx fasteners q and torque to specification TORQUE Body Fastener 42 in lbs 5 Nm 3 Install the four push rivets w 4 Reinstall the upper fender BODY FRAME ...

Page 487: ...r SeeFront Fender Service page 10 26 1 Remove the three push rivets q and T 40 torx fastener w Repeat procedure on passenger side 2 Remove the two T 40 torx fasteners e 3 Disconnect the headlight connector Remove the three T 25 torx fasteners r Remove the headlight assembly 4 Pull the front fascia straight up to remove as shown NOTE Front Bumper removed for clarity BODY FRAME ...

Page 488: ...front fascia straight down and align with fastener holes NOTE Front Bumper removed for clarity 2 Reinstall the headlight assembly Install the three T 25 torx fasteners q Do not tighten Connect the headlight connector 3 Install the two T 40 torx fasteners w Torque to specification TORQUE Body Fasteners 42 in lbs 5 Nm BODY FRAME ...

Page 489: ...UE Body Fastener 42 in lbs 5 Nm 5 Perform Headlight Adjustment SeeHeadlight Adjust ment page 11 21 6 Reinstall upper fender SeeFront Fender Service page 10 26 DASH PANELS GLOVE BOX REMOVAL UPPER DASH REMOVAL 1 Remove the two push rivets q from the instrument panel cover w and rotate the cover forward 2 Un clip the two retaining tabs e from the instrument cluster panel BODY FRAME ...

Page 490: ...replacing the instrument cluster TORQUE Instrument Cluster Screws 12 in lbs 1 Nm 4 Remove the two push rivets w on the upper center storage cover and unlock the two retaining tabs u 5 Open upper storage compartment lid and remove the four retaining screws i Lift the storage compartment o out NOTE Upper Storage Compartment Fastener 10 in lbs 1 Nm 6 Remove all push rivets s from upper dash panel and...

Page 491: ...f the control dash panel and un clip the top clips to remove the panel 4 Remove the six plastic rivets r retaining lower storage compartment and remove lower storage compartment 5 Remove the seven T 40 Torx and four T 25 Torx screws t retaining the lower dash y 6 Remove the four push rivets u on top of the main dash 7 Remove the five T 40 Torx i bolts retaining the main dash to the body 8 Tilt the...

Page 492: ...e two T 40 fasteners w retaining the lower fender cover TORQUE Lower fender fasteners 42 in lbs 5 Nm 2 Remove the two push rivets e on the back side of the rear upper fender Lift up and remove the upper fender 3 Remove the remaining eight T 40 fasteners r and push rivet t retaining the lower fender Remove the lower fender TORQUE Lower fender fasteners 42 in lbs 5 Nm BODY FRAME ...

Page 493: ...ry cover 4 Remove both push rivets retaining the back of the floor tunnel 5 Remove the push rivets q retaining the center console and remove the cover from the vehicle 6 Remove the T 40 torx fasteners w and the push rivets e retaining the passenger floor 7 Remove the push rivets r and the T 40 torx fasteners t Lift and remove the passenger floor from the vehicle 8 Remove the T 40 torx fasteners y ...

Page 494: ...1 Install the driver s floor and the T 40 torx fasteners q Torque to specification TORQUE Body Fasteners 42 in lbs 5 Nm 2 Install the push rivets w and the T 40 torx fasteners e Torque to specification TORQUE Body Fasteners 42 in lbs 5 Nm 3 Install the passenger floor Install the push rivets r and the T 40 torx fasteners Torque to specification TORQUE Body Fasteners 42 in lbs 5 Nm BODY FRAME ...

Page 495: ...tall the push rivets y and T 40 torx fasteners Torque to specification TORQUE Body Fasteners 42 in lbs 5 Nm 5 Install the center console Install the push rivets i retaining the center console ACCESSORY SERVICE Refer to accessory kit instructions for accessory removal and installation BODY FRAME ...

Page 496: ...10 38 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc NOTES BODY FRAME ...

Page 497: ...1 10 REAR DIFF SOLENOID SERVICE 11 11 DIFFERENTIAL SOLENOID OVERVIEW 11 11 DIFFERENTIAL SOLENOID CIRCUIT OPERATION 11 11 DIFFERENTIAL SOLENOID REPLACEMENT 11 12 INSTRUMENT CLUSTER SERVICE 11 13 INSTRUMENT CLUSTER OVERVIEW 11 13 SPEEDOMETER 11 14 TACHOMETER 11 14 MODE AND TOGGLE BUTTONS 11 14 INDICATOR LAMPS 11 14 RIDER INFORMATION CENTER 11 15 MODE INFORMATION DISPLAYS 11 15 ACCESSING MENUS AND OP...

Page 498: ...Y OPERATION 11 31 CHARGING SYSTEM SERVICE 11 33 CURRENT DRAW KEY OFF 11 33 CHARGING SYSTEM BREAK EVEN TEST 11 33 CHARGING SYSTEM STATOR ALTERNATOR TESTS 11 34 STATOR REPLACEMENT 11 34 ALTERNATOR REPLACEMENT 11 35 REGULATOR RECTIFIER REPLACEMENT 11 37 CHARGING SYSTEM TESTING FLOW CHART 11 38 ELECTRICAL DIAGNOSTICS 11 39 ELECTRICAL SERVICE NOTES 11 39 DIGITAL MULTI METER DMM NOTES 11 39 STATIC AND D...

Page 499: ...AGE DROP TEST 11 49 STARTER MOTOR REMOVAL 11 49 STARTER MOTOR INSTALLATION 11 50 STARTER SOLENOID BENCH TEST 11 50 STARTER SOLENOID OPERATION 11 51 STARTING SYSTEM TESTING FLOW CHART 11 52 ELECTRONIC POWER STEERING EPS 11 53 EPS OPERATION 11 53 PROPER EPS SYSTEM DIAGNOSING 11 53 EPS TORQUE OFFSET PROCEDURE 11 53 EPS SYSTEM BREAKOUT 11 54 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL O...

Page 500: ... more information Voltage amperage and 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 differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested D...

Page 501: ...ICE SPECIFICATIONS ELECTRICAL PART DESCRIPTION SERVICE SPECIFICATION Seat Belt Switch Normally Open Drive Mode Switch Performance 4750 Ω Drive Mode Switch Standard 25 000 Ω Drive Mode Switch Work 1600 Ω AWD Hub Coil Resistance 24 Ω 5 Fuel Sender Resistance Empty 90 4 5 Ω Fuel Sender Resistance Full 6 1 Ω CTS Resistance 77 F 29 9 kΩ 6 CTS Resistance 248 F 1 22 kΩ 2 Current Draw Key Off Max 01 DCA 1...

Page 502: ...acts and re test Replace switch if necessary 4 If brake switch is being replaced the brake system will need to be bled See Brake Fluid Replacement Brake Bleeding page 9 9 HEADLAMP SWITCH 1 Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs HIGH LOW OFF If any of the tests fail replace ...

Page 503: ...START There should be continuity between switch pins B and C A and D AWD 2WD TURF SWITCH 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs AWD 2WD TURF If any of the tests fail replace the switch assembly Move the switch to AWD There should be continuity between switch pins 2 an...

Page 504: ... 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 the driver seat belt is secured in the seat belt lock The switch is powered by the EFI Relay sending a signal to the ECU 1 Disconnect the seat belt switch harness by depressing the connector locks and pulli...

Page 505: ...enter 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 on the connector Do not pull on the wiring 2 Test the resistance between pins 2 and 9 3 If the resistance is out of specification for any mode replace the switch Drive Mode Switch Performance 4750 Ω Standard ...

Page 506: ...quired 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 from the Static Timing Light Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness 2460761 3 Pass a screwdriver back and forth in front of the sensor tip 4 Be sure connections are good ...

Page 507: ... 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 allowing it to enable the differential solenoid If the rear diff fails to switch from operational modes Check the solenoid and relay connectors Look for loose wires or bad connections Check for power from t...

Page 508: ...IFFERENTIAL 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 solenoid fastener to specification TORQUE Differential Solenoid Nut 25 lb ft 34 Nm ELECTRICAL ...

Page 509: ...ggle Buttons e Indicator Lamps y Rider Information Center NOTE Some features are not applicable to all models CAUTION 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 products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster D...

Page 510: ...e system will automatically reduce engine power Electric Power Steering EPS Warning if equipped This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperative Your dealer can assist Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the ...

Page 511: ...uel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated The outline of the fuel display will flash Refuel immediately t Speed Limitation if equipped This vehicle may be equipped with a maximum speed limitation function This would be displayed on the screen as LIM followed by the speed LIM 30 for example MODE INFO...

Page 512: ... Press either toggle button to cycle to the BL COLOR option Press MODE to select 3 Press either toggle button to cycle to the desired setting 4 Press MODE to save and exit to the settings menu BACKLIGHT BRIGHTNESS The information center backlight can be set to either blue or red 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the BL LEVEL option...

Page 513: ...efore traveling 1 Press either toggle button to cycle to the trip time option TT 2 Press and hold either toggle button until the meter resets to zero PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory As hours of engine operation increase the counter decreases The wrench icon will flash for about 10 seconds when the counter reaches zero 0 and each t...

Page 514: ...Suspect Parameter Number SPN e Code Count 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the DIAGCODE option Press MODE to select 3 More than one diagnostic code may be present Press the toggle UP button to see if more codes are present Press MODE to select a code NOTE If the displayed code is an engine fault code the CHECK ENGINE lamp will bli...

Page 515: ... panel cover w and rotate the cover forward 2 Un clip the two retaining tabs e from the instrument cluster panel 3 Disconnect plug connection r and remove the three bolts t retaining the instrument cluster to trim piece NOTE It is only necessary to remove the three bolts when replacing the instrument cluster TORQUE Instrument Cluster Screws 12 in lbs 1 Nm ELECTRICAL ...

Page 516: ...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 OHMS READING AWD Coil GY to BN WH 23 Ω AWD Coil GY to Ground Open Line OL AWD Hub Coil Resistance 23 Ω 5 3 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connected prop...

Page 517: ... engine and turn the headlight switch to the LOW position 4 The most intense part of the LOW beam headlight beam should be aimed 2 in 5 cm q below the mark placed on the wall NOTE Rider weight must be included in the seat while performing this procedure 5 Adjust the beam to the desired position by loosening or tightening the adjustment screws and moving the lamp to the appropriate height 6 Adjust ...

Page 518: ...11 22 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 7 Tighten Headlight adjustment screws q TORQUE Headlight Fasteners 5 ft lbs 7 Nm ELECTRICAL ...

Page 519: ... and rotate it clockwise 90 to lock it in place NOTE Make sure the tab on the bulb locates properly in the housing 6 Install the harness onto the new headlight bulb and install the hood HEADLIGHT HOUSING REMOVAL 1 Remove the hood from the front cab 2 Remove the front fenders See Front Fender Service page 10 26 3 Disconnect the harness from the bulb Refer to Headlight Bulb Replacement page 11 23 pr...

Page 520: ...page 11 21 5 Install the front fenders See Front Fender Service page 10 26 6 Install the hood TAIL LIGHT SERVICE 1 Open the rear tailgate 2 Remove the two screws retaining the LED lamp assembly 3 Remove the LED lamp from the rear cargo box and disconnect the tail light brake light wire harness NOTE Before replacing the LED lamp assembly use a digital multi meter to test the harness to ensure the l...

Page 521: ...11 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 11 25 COOLING SYSTEM SERVICE COOLING SYSTEM BREAK OUT DIAGRAM ELECTRICAL ...

Page 522: ...he 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 slowly check the fan motor wiring ground motor condition circuit breaker and mechanical relay for proper operation Repair or replace as necessary 4 If the fan runs with the sensor harness disconnected but will...

Page 523: ...e voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plug s IGNITION COIL HT LEAD REPLACEMENT NOTE The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG from the factory and should be installed to the corresponding cylinder and ignition coil post 1 Disconnect the negative batt...

Page 524: ...hm 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 Between 2 3 0 4 Ω Secondary PTO Between High Tension Lead Caps 2 30k Ω 5 Secondary MAG Between High Tension Lead Caps 2 73k Ω 5 Primary Test Secondary Test ELECTRICAL ...

Page 525: ... 12 Power Out Lights 20A Fuse 13 Power In 19 Power Out HVAC 30A Fuse 14 Power In 20 Power Out AC Comp Clutch Relay 15 Coil High 16 Power In 21 Power Out 22 Coil Low AC Switch Relay 17 Coil High 18 Power In 23 Power Out 24 Coil Low HVAC Power Relay 25 Coil High 26 Power In CIRCUIT PIN FUNCTION 31 Power Out 32 Coil Low Fan 30A Fuse 27 Power In 33 Power Out Fuel Pump 15A Fuse 28 Power In 34 Power Out...

Page 526: ...11 30 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc ELECTRICAL ...

Page 527: ...otected 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 EFI system circuits FAN RELAY provides power to the following system Fan Motor FAN RELAY COLOR FUNCTION Red 20 Amp circuit breaker protected 12 Vdc constant battery power Orange White ECU ground input to e...

Page 528: ...ID 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 Rear Diff Solenoid Blue Ground to energize the Rear Diff Solenoid NOTE The Rear Diff Solenoid Relay is mounted separately attached to the rear portion of the main frame under the rear cargo box ELECTRICAL ...

Page 529: ... 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 performing this test WARNING Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will result Do not run test for extended period of time Do not run test with high amper...

Page 530: ...nd Open Line OL NOTE 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 dial to measure AC Voltage 5 Start the engine and let it idle 6 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the ...

Page 531: ... holding the alternator cover to the vehicle 4 Cut the compressor drive belt to remove it from the vehicle 5 To aid with belt installation remove the fasteners holding the inner alternator cover to the engine Disconnect the air outlet hose and remove the cover from the vehicle 6 Disconnect the alternator 7 Loosen the three alternator fasteners and remove the alternator INSTALLATION 1 Install new a...

Page 532: ...ol and then turn the tool counter clockwise using 3 8 in drive ratchet until the belt is fully seated on the pulley 7 Verify the belt is properly routed around all of the pulleys 8 Remove the belt installation tool from the crankshaft drive pulley 9 Torque the alternator fasteners to specification in the sequence as shown TORQUE Alternator Mounting Fasteners 37 lb ft 50 Nm 10 Install the inner alt...

Page 533: ...ccess the regulator rectifier 5 If replacing the regulator rectifier remove the two retaining screws and disconnect the wire harness Remove the regulator and heat sink plate from the vehicle 6 Reverse this procedure to install the new regulator rectifier and heat sink plate NOTE If the regulator rectifier case temperature exceeds 230 F or 110 C the unit will turn itself off to cool down The unit w...

Page 534: ...opyright Polaris Industries Inc CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not exposed or pinched ELECTRICAL ...

Page 535: ...side 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 and your knowledge STATIC AND DYNAMIC TESTING There are many methods for testing a DC circuit These methods fall into one of two categories either static or dynamic STATIC TESTING The two most common forms o...

Page 536: ...or 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 by replacing the terminal or attempting to adjust tighten the tang in the female terminal For a video demonstration scan the QR code below or right click it and select open in new tab BACK PROBING Back prob...

Page 537: ...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 sensor and ECU would need to be unplugged Most Ohmmeters provides a precise amount of current to determine resistance Any other sources will make your reading inaccurate Ensure you are making good contact by us...

Page 538: ...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 Intermittent Conditions page 11 43 TESTING PROCEDURE 1 Consult the wiring diagram Determine which circuit you will be testing 2 Ensure that any static voltage checks advised in relation to the DTC or concern you are diag...

Page 539: ...ONS 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 are almost always related to a poor connection that only goes open in specific situations such as going over a certain kind of bump at a certain temperature or when the machine is torque loaded in one way...

Page 540: ...operly 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 the battery 2 Connect a jumper from the negative battery cable terminal to the negative battery post 3 Ensure your meter leads and selector dial are set to measure amperage 4 Connect your red lead to th...

Page 541: ...uch 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 connectors and relays but it will be minimal NOTE You will need to backprobe to perform this test For information about doing this safely refer to Connector Probing Guidelines page 11 40 Voltage should be near ful...

Page 542: ...rious burns can result from contact with the skin eyes or clothing ANTIDOTE External Flush with 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 medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when chargi...

Page 543: ... CIRCUIT VOLTAGE LOAD TEST 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 chart and LOAD TEST NOTE Maintenance Free batteries should be kept at a high state of charge during storage If the battery is stored or used at a low state of charge hard crystal sulfatio...

Page 544: ...ot exceed 10 amps when charging the battery NOTE Charge the battery using an automatic charger that will not exceed 14 6 Vdc An automatic charger will signal when charging is complete Allow the battery to stand disconnected for at least 1 2 hours after being properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced WARNING An overheated bat...

Page 545: ...rop 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 reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connect...

Page 546: ...o 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 specification 7 Install the negative battery cable to the upper starter mounting bolt stud Torque nut to specification 8 Install the thermostat cover and mounting bolts Torque the bolts to specification TORQUE...

Page 547: ...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 the starter solenoid via the Green White wire Once the pull in coil is energized the solenoid provides a current path for 12V power to reach the starter motor ELECTRICAL ...

Page 548: ...11 52 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc STARTING SYSTEM TESTING FLOW CHART ELECTRICAL ...

Page 549: ...function 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 Engine Controller but not the Power Steering Controller while using Digital Wrench NOTE DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS WARNING Electronic Power Steering EPS units are not interchangeable ...

Page 550: ...11 54 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc EPS SYSTEM BREAKOUT ELECTRICAL ...

Page 551: ...11 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 11 55 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON ELECTRICAL ...

Page 552: ...11 56 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF ELECTRICAL ...

Page 553: ...11 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc 11 57 EPS TROUBLESHOOTING USING DIGITAL WRENCH ELECTRICAL ...

Page 554: ...11 58 9928487 R01 2018 RANGER XP 1000 Service Manual Copyright Polaris Industries Inc NOTES ELECTRICAL ...

Page 555: ...pection 9 30 Installation 9 31 Removal 9 28 Brake Disc Front Inspection 9 22 9 32 Replacement 9 23 Runout 9 22 9 32 Brake Disc Rear Replacement 9 33 Brake Line Clocking 9 8 Brake Line Routing 9 6 Brake Pads Front Inspection 9 15 Installation 9 15 Removal 9 14 Brake Pads Rear Inspection 9 25 Installation 9 25 Removal 9 24 Brake Pedal Replacement 9 13 Brake System Assembly View 9 5 Brake Burnishing ...

Page 556: ...rankcase Assembly 3 67 Disassembly Inspection 3 44 Inspection 3 49 Lower Crankcase Preparation 3 66 Upper Crankcase Preparation 3 59 Crankshaft Bearing Journal Inspection 3 47 Installation 1000 3 64 Main Bearing Selection 3 58 Removal Inspection 3 47 Crankshaft Position Sensor CPS CPS Replacement 4 32 CPS Test 4 31 Operation Overview 4 31 Current 11 44 Cylinder Inspection 3 50 Installation 3 62 Mi...

Page 557: ...ead Installation 3 74 Cylinder Head Removal 3 32 Cylinder Head War Inspection 3 33 Cylinder Inspection 3 50 Cylinder Removal 3 51 Flywheel Installation 3 72 Flywheel Removal 3 42 Installation 3 24 Limiting Misfire 4 46 Lower Crankcase Preparation 3 66 Mount Replacement 3 20 Oil Flow Chart 3 7 Piston Con Rod Assembly 3 61 Piston Disassembly Inspection 3 52 Piston Removal 3 51 Piston Ring Installati...

Page 558: ...13 Front Bearing Carrier Bearing Replacement 7 6 Installation 7 7 Removal Inspection 7 5 Front Body Component Front Bumper Removal 10 25 Front Drive Shaft Installation 7 9 Removal 7 9 Front Fascia Assembly View 10 7 Front Fenders Assembly View 10 7 Front Gearcase Assembly 7 26 Assembly View 7 20 AWD Diagnosis 7 22 AWD Operation 7 21 Disassembly Inspection 7 23 Disassembly Inspection ADC 7 31 Insta...

Page 559: ...nifold Installation 3 17 Removal 3 15 Intermittent 11 43 K Keys Replacement 1 3 L Lubrication Specifications 3 5 M Maintenance Grease Lubrication Points 2 29 Lubricants 2 30 Quick Reference Chart 2 27 Service Notes 2 3 Service Specifications 2 4 Special Tools 2 3 Maintenance Intervals 2 7 Master Cylinder Installation 9 12 Removal 9 11 Meter 11 39 Metric Bolt Torque Specification 1 22 Metric Displa...

Page 560: ...embly View 10 10 Seats Assembly View 10 10 Lower Seat Base Removal 10 25 Sensor Oxygen 4 40 Speed 11 10 Service 11 39 Service Notes Body Frame 10 3 Brake System 9 3 Electrical 11 4 Final Drive 7 3 Fuel System 4 3 Maintenance 2 3 PVT System 5 3 Steering Suspension 8 2 Transmission 6 2 Service Rules 1 2 Service Specifications Brake System 9 4 Electrical 11 5 Final Drive 7 3 Fuel System 4 5 Maintenan...

Page 561: ...Adjustment 2 56 Spring Pre Load Adjustment 2 56 Switch AWD 2WD TURF 11 7 Brake 11 6 Drive Mode 11 9 Gear Position 11 8 Headlamp 11 6 Ignition 11 7 Seat Belt Interlock 11 8 Switches Mode Button 11 14 T T MAP Sensor Operation Overview 4 33 Sensor Replacement 4 33 Sensor Test 4 33 Tachometer 11 14 Tail Lights LED Lamp Replacement 11 24 Service 11 24 Tailgate Assembly View 10 19 Tap Drill Sizes Metric...

Page 562: ...4 Valve Clearance Valve Lash Tappet Selection 3 83 Valve Clearance Tappet Selection 3 83 Valve Cover Removal 3 29 Valve Cover Installation 3 84 Vehicle Information Vehicle Overview 1 19 Vehicle Specifications 1 20 VIN Number 1 18 Vent Line Termination Fitting 4 13 Vent Line Routing Front Gearcase 7 4 Transmission 6 4 VIN 1 18 Location 1 18 VIN Number 1 18 Voltage Drop 11 45 Voltage Drop Test 11 49...

Page 563: ...STEERING ASSEMBLY EPS POWER A PIN FUNCTION A B BATTERY BATTERY EPS SENSOR B PIN FUNCTION 1 2 3 4 5 6 7 8 ENGINE RPM NEG REF ENGINE RPM IGNITION SIGNAL CAN BUS LOW VEHICLE SPEED VEHICLE SPEED NEG REF EPAS SYSTEM FAULT SIGNAL CAN BUS HIGH A B ELECTRONIC THROTTLE CONTROL 1 2 3 4 5 6 TPS 1 TPS RETURN 1 ETC MOTOR TPS 2 ETC MOTOR 3 3V TPS SUPPLY PIN FUNCTION 1 2 3 SENSOR CRANK POSITION N S E155 RD DB E1...

Page 564: ...NEG REF EPAS SYSTEM FAULT SIGNAL CAN BUS HIGH A B ELECTRONIC THROTTLE CONTROL 1 2 3 4 5 6 TPS 1 TPS RETURN 1 ETC MOTOR TPS 2 ETC MOTOR 3 3V TPS SUPPLY PIN FUNCTION 1 2 3 SENSOR CRANK POSITION N S E155 RD DB E155 RD DB E156 RD DB E156 RD DB K116 OG K116 OG K116 OG E246 BN WH E246 BN WH REE RD DB REE RD DB SPLICE BRAKE PRESSURE SWITCH 1 2 30D OG 30D OG A B B5B RD WH B5B RD WH REG RD DB REG RD DB E14...

Page 565: ... LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE WHITE YELLOW TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS EXAMPLE RD YE RED WITH YELLOW TRACE FILE NAME 2413818 RSD E ENGINE GROUND C CHASSIS GROUND NC SWITCH NORMALLY CLOSED NO SWITCH NORMALLY OPEN HARNESS 2413818 02 CL CLEAR ...

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