Polaris RANGER XP 1000 2018 Service Manual

Page 1

2018 RANGER XP 1000

Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized 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: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

Publication Printed November 2017 (PN 9928487 R01)

© Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

technicians in a properly

Page 2

SAFETY WARNINGS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander 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 disassembly, assembly and inspection of components.

Page 3

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

REVISION INDEX

REV DATE

R01 11/28/17

Initial release

2018 VEHICLE UPDATES

APPLICABLE

MODEL

XP 1000 Models All New Vehicle

For more detailed information on vehicle updates, refer to the applicable Model Year Update training module at:

www.mytrainingandrewards.com .

UPDATE DESCRIPTION

CHANGES

Page 4

2018 RANGER XP 1000

Service Manual

Chapter Summary

CHAPTER 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

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

REFERENCE INFORMATION ... . .. . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. 1.2

SERVICE RULES. . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . 1.2

PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . 1.3

REPLACEMENT KEYS . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . 1.3

SPECIAL TOOLS WEBSITE . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . 1.4

SPECIAL TOOLS INDEX. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. 1.5

MASTER TORQUE LIST. . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. 1.11

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 TORQUE SPECIFICATION. .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . .1.22

SAE TAP / DRILL SIZES . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. .1.23

METRIC TAP / DRILL SIZES . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . .1.23

DECIMAL EQUIVALENTS . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . .1.24

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

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GENERAL INFORMATION

REFERENCE INFORMATION

SERVICE RULES

In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual and familiarize themselves with the procedures before beginning. Notes, Cautions and Warnings have been included for clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are necessary to perform some procedures in this manual safely and correctly.

Use only genuine Polaris service parts, including fasteners that require replacement if removed. Do NOT substitute fasteners or hardware.

Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause damage to precision parts. Clean the vehicle before beginning service. Clean all parts before installing.

If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.

Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine damage or in the case of steering, driveline, and chassis components, can result in loss of control during operation of the vehicle, which may result in severe personal injury or death.

If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand tighten. Following the method and sequence indicated, tighten evenly to the 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 seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances.

Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore, they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand or compress them beyond what is required for installation.

Polaris lubricants and greases have been specially formulated to provide maximum performance and protection when applied properly. In some applications, warranty coverage may be void if improper lubricants are used.

Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating grease loses lubricity and may contain abrasive foreign matter. Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Polaris hardware from an authorized Polaris dealer. Working with batteries can be hazardous. Review all battery warnings and cautions.

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GENERAL INFORMATION

PUBLICATION PART NUMBERS

Some vehicle publications, such as the Owner’s Manual and Parts Manual are available on-line and can be downloaded from the Polaris website (www.polarisindustries.com).

MODEL MODEL NUMBER OWNER’S MANUAL

2018 RANGER XP 1000 R18RRE99AS / BS, R18RRU99AS / BS

2018 RANGER XP 1000 R18RRS99C1 / CS 9928195

2018 RANGER XP 1000 R18RRE99F1 / N1, R18RRS99F1

9928300

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 31 which would use key blank PN 4110141.

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

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

68 4010278

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GENERAL INFORMATION

SPECIAL TOOLS WEBSITE

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers 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/

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SPECIAL TOOLS INDEX

GENERAL INFORMATION

MAINTENANCE

Oil Filter Wrench

PU-50105

ENGINE / COOLING / EXHAUST

Oil Filter Wrench

PU-50105

Shock Spanner Wrench

2877408

Oil Pressure Gauge

PV-43531

Oil Pressure Gauge Adapter

PU-52492

Engine Stand (2” Bore)

PU-50624

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

Engine Stand Adapter (Mounts To The Engine)

PU-50562

Engine Stand Sleeve Adapter (Use With 2” Bore Stand)

PU-50625

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GENERAL INFORMATION

ENGINE / COOLING / EXHAUST

Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)

PW-47054

Flywheel Puller

PA-49316

Water Pump Mechanical Seal Installer

PU-50564

Piston Ring Compressor Pliers

PV-43570-1

Valve Spring Compressor Adapter

PV-43513-A

Valve Spring Compressor

PV-1253 or PV-4019

Cylinder Holding & Camshaft Timing Plate

PU-50563

Crank Seal Installation Tool

PU-52493

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FUEL SYSTEM

Fuel Pressure Gauge Kit

PU-43506-A

Fuel Pump Service Tool

PU-50326

Fuel Pressure Gauge Adapter

PA-48838

GENERAL INFORMATION

Fuel Pressure Gauge Adapter

PS-48762

PVT SYSTEM

Drive Clutch Holding Fixture

PU-52430

Clutch Bushing Replacement Kit

2871226–A

Drive Clutch Puller

PU-52422

Piston Pin Puller

2870386

Clutch Compressor Tool

PU-50518–A

Driven Clutch Separator Tool

2875911

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

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GENERAL INFORMATION

TRANSMISSION

Snorkel Tool

PU-52547

Bearing Seal Driver (50 mm)

2871282

Rear Driveshaft Seal Guide

2871699

Crankcase Sealant

2871557 (3 bond)

3233901 (Loctite® 680)

Rear Output Seal Driver

2871698

FINAL DRIVE

Roll Pin Removal Tool

2872608

Axle Boot Clamp Tool

PU-48951

CV Boot Clamp Pliers

8700226

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BRAKE SYSTEM

Mityvac® Pressure Test Tool

2870975

BODY / FRAME

Multi-Function Pliers

2876389

GENERAL INFORMATION

ELECTRICAL

Digital Wrench® Diagnostic Kit

PU-47063-B

Digital Wrench® SmartLink Module

PU-47468

Digital Wrench® Vehicle Interface Cable

PU-47469

Digital Wrench® SmartLink Kit

PU-47471

Digital Wrench® PC Interface Cable

PU-47470

Wireless Vehicle Link (WVL)

PU-51435

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

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GENERAL INFORMATION

ELECTRICAL

PV-43568 Fluke™ 77 Digital Multimeter

PF-51237

Battery Conductance Analyzer (MDX-610P)

PU-50296

Static Timing Light Harness

2871745

Connector Test Kit

PV-43526

Hall Effect Sensor Probe Harness

2460761

Timing Light

2870630

Relay Bypass

PU-49466

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GENERAL INFORMATION

MASTER TORQUE LIST

CHAPTER 2 — MAINTENANCE

TORQUE

PART DESCRIPTION

Crankcase Drain Plug 12 ft-lbs (16 Nm)

Spark Plug 9 ft–lbs (12 Nm)

Valve Cover Fastener 7 ft-lbs (10 Nm)

Outer Clutch Cover Fastener

Tensioner Mounting Fastener

Plunger Fastener

Transmission Fill / Drain Plug

Front Gearcase Fill / Drain Plug

Tie Rod Jam Nut

Battery Bracket Fastener 3.5 ft-lbs (5 Nm)

Coolant Hose Clamp 35 in-lbs (4 Nm)

Spark Arrestor Fastener

Wheel Lug Nuts

Wheel Hub Castle Nut (rear)

Wheel Hub Castle Nut (front)

Shock Mounting Fastener

Caliper Bleeder Screw 4 ft-lbs (5.5 Nm)

Battery Terminal Fastener 40 in-lbs (5 Nm)

CHAPTER 3 — ENGINE / COOLING / EXHAUST

PART DESCRIPTION

Crankcase Drain Plug

SPECIFICATION

35 in-lbs (4 Nm)

7 ft-lbs (10 Nm)

15 ft-lbs (20 Nm)

12 ft-lbs (16 Nm)

10 ft-lbs (14 Nm)

13 ft-lbs (18 Nm)

8 ft-lbs (11 Nm)

120 ft-lbs (163 Nm)

110 ft-lbs (149 Nm)

80 ft-lbs (108 Nm)

40 ft-lbs (54 Nm)

TORQUE

SPECIFICATION

12 ft-lbs (16 Nm)

CHAPTER 3 — ENGINE / COOLING / EXHAUST

TORQUE

PART DESCRIPTION

Exhaust Stud w/Spring

Heat Shield Fastener 42 in-lbs (5 Nm)

Muffler Mount Fastener

Starter Motor Fastener

Engine Mount Fastener 40 ft-lbs (54 Nm)

Engine Mount Isolator Nuts

Isolator Fastener

Exhaust Head Pipe Mounting Fastener

Exhaust Head Pipe Upper Heat Shield Fastener

Crankcase Oil Gallery Plug

Camshaft Carrier Fastener

Connecting Rod Fastener

Lower Crankcase Fastener (M10)

Lower Crankcase Fastener (M8)

Lower Crankcase Fastener (M6)

Upper Crankcase Fastener (M8)

SPECIFICATION

21 ft-lbs (28 Nm)

10 ft-lbs (14 Nm)

7 lb-ft (10 Nm)

22 ft-lbs (30 Nm)

40 ft-lbs (54 Nm)

18 ft-lbs (24 Nm)

6 ft-lbs (8 Nm)

22 ft-lbs (30 Nm)

7 ft-lb (10 Nm)

Step 1: 9 ft-lbs (12

Nm)

Step 2: 22 ft-lbs (30

Nm)

Step 3: Tighten

add’n 90°

Step 1: 9 ft-lb (12

Nm)

Step 2: 21 ft-lb (28

Nm)

Step 3: Tighten

add’n 90°

26 ft-lbs (35 Nm)

9 ft-lbs (12 Nm)

26 ft-lbs (35 Nm)

Spark Plug

Valve Cover Fastener 7 ft-lbs (10 Nm)

Outer Clutch Cover Fastener

Oxygen Sensor

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

9 ft–lbs (12 Nm)

35 in-lbs (4 Nm)

18 ft-lbs (24 Nm)

Upper Crankcase Fastener (M6)

Oil Pump Mounting Fastener

Oil Pump Pick-Up Retaining Fastener

7 ft-lbs (10 Nm)

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GENERAL INFORMATION

CHAPTER 3 — ENGINE / COOLING / EXHAUST

TORQUE

PART DESCRIPTION

Oil Sump Cover Fastener (M8)

Oil Sump Cover Fastener (M6)

Oil Cooler Retaining Fastener

One Way Clutch Retaining Fastener

Flywheel Retaining Fastener

SPECIFICATION

26 ft-lbs (35 Nm)

9 ft-lbs (12 Nm)

7 lb-ft (10 Nm)

9 ft-lbs (12 Nm)

Step 1: 133 ft-lbs

(180 Nm)

Step 2: Back out

bolt 180° & retorque

to spec.

Stator Cover Fastener 9 ft-lbs (12 Nm)

Cylinder Head Fastener

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)

CHAPTER 3 — ENGINE / COOLING / EXHAUST

TORQUE

PART DESCRIPTION

SPECIFICATION

Shock Mounting Fastener 40 ft-lbs (54 Nm)

Water Pump Impeller Fastener

Water Pump Mounting Fastener

7 ft-lbs (10 Nm)

(Apply Loctite® 204™ to

bolt threads)

7 ft-lbs (10 Nm)

Wheel Lug Nut 120 ft-lbs (163 Nm)

CHAPTER 4— FUEL SYSTEM

PART DESCRIPTION

TORQUE

SPECIFICATION

Fuel Pump Nut 70 lb-ft (95 Nm)

Fuel Rail Mounting Fastener

Fuel Tank Bracket Fastener

Lower Intake Plenum Fastener

5 ft-lbs (7 Nm)

6 ft-lbs (8 Nm)

18 ft-lbs (24 Nm)

Camshaft Sprocket Fastener

Cam Chain Tensioner

Tensioner Mounting

14 ft-lbs (19 Nm)

15 ft-lbs (20 Nm)

7 ft-lbs (10 Nm)

Fastener

Intake Duct Hose Clamp 35 in-lbs (4 Nm)

Intake Manifold Boot Clamp

Lower Intake Plenum Fastener

Airbox Mount Fastener

17 in-lbs (2 Nm)

18 ft-lbs (24 Nm)

35 in-lbs (4 Nm)

Coolant Hose Clamp 35 in-lbs (4 Nm)

Coolant Hose Mounting Bracket Fastener

Thermostat Cover Fastener

Coolant Bleed Fastener

3.5 lb-ft (4.7 Nm)

7 ft-lbs (10 Nm)

6 ft-lbs (8 Nm)

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GENERAL INFORMATION

CHAPTER 5 — PVT SYSTEM

PART DESCRIPTION

PVT Inner Cover Fastener

Driven Clutch Retaining Fastener

Drive Clutch Retaining Fastener

Outer PVT Cover Fasteners

Drive Clutch Cover Fastener

TORQUE

SPECIFICATION

37 ft-lbs (50 Nm)

STEP 1: Torque to

37 ft-lb (50 Nm)

STEP 2: Loosely

install bolts by

hand

STEP 3: Loosely

install bolts by

hand

STEP 4: Loosely

install bolts by

hand

STEP 5: Loosely

install nuts by hand

STEP 6: Torque to

50 ft-lb (68 Nm)

STEP 7: Loosely

install nuts by hand

STEP 8: Torque to

50 ft-lb (68 Nm)

STEP 9: Torque to

37 ft-lb (50 Nm)

43 ft-lbs (58 Nm)

96 ft-lbs (130 Nm)

35 in-lbs (4 Nm)

100 in-lbs (11 Nm)

CHAPTER 6 — TRANSMISSION

TORQUE

PART DESCRIPTION

Solenoid

Bearing Cover Retaining Fastener

Snorkel Locking Fastener 9 ft-lbs (12 Nm)

Differential Cover Fastener

Fork Retainer Fastener

Transmission Fill / Drain Plug

Bell Crank Nut

Speed Sensor 10 ft-lbs (14 Nm)

Rear Mount Bracket Fastener

Rear Transmission Mount Bracket Fastener

Rear Transmission Mount Fastener

Transmission Mount to Engine Fastener

Transmission Case Fastener

Sector Cover Fastener

Park Plate Fastener

SPECIFICATION

25 ft-lbs (34 Nm)

9 ft-lbs (12 Nm)

26 ft-lbs (35 Nm)

9 ft-lbs (12 Nm)

12 ft-lbs (16 Nm)

14 ft-lbs (19 Nm)

20 ft-lbs (27 Nm)

40 ft-lbs (54 Nm)

22 ft-lbs (30 Nm)

37 ft-lbs (50 Nm)

20 ft-lbs (27 Nm)

10 ft-lbs (14 Nm)

9 ft-lbs (12 Nm)

Driven Clutch Helix Fastener

PVT Outlet Duct Fastener

PVT Inlet Duct Fastener

PVT Hose Adapter Clamps

PVT Inlet Hose Clamp 35 in-lbs (4 Nm)

PVT Cover to Transmission Fastener

Shift Weight Fastener 20 in-lb (2 Nm)

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

32 ft-lbs (44 Nm)

54 in-lbs (6 Nm)

35 in-lbs (4 Nm)

50 ft-lbs (68 Nm)

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Page 18

GENERAL INFORMATION

CHAPTER 7 — FINAL DRIVE

PART DESCRIPTION

Front Gearcase Fill / Drain Plug

Carrier Fastener

Rear Prop Shaft (to transmission) Fastener

Front Gearcase Cover Plate Fastener

Front Gearcase Mounting Fastener

TORQUE

SPECIFICATION

10 ft-lbs (14 Nm)

40 ft-lbs (54 Nm)

22 ft-lbs (30 Nm)

9 ft-lbs (12 Nm)

30 ft-lbs (41 Nm)

CHAPTER 8 — STEERING / SUSPENSION

TORQUE

PART DESCRIPTION

Lower Steering Shaft to Rack Pinch Fastener

Power Steering Mount Fastener

Power Steering Unit Frame Fastener

Upper Steering Shaft Pinch Fastener

Lower Steering Shaft Pinch Fastener

Steering Wheel Tilt Assembly Nut

Steering Adjustment

SPECIFICATION

48 ft-lbs (65 Nm)

30 ft-lbs (41 Nm)

14 ft-lbs (19 Nm)

25 ft-lbs (34 Nm)

40 ft-lbs (54 Nm)

7 ft-lbs (10 Nm)

Shock Assembly Nut

Steering Wheel Nut 65 ft-lbs (88 Nm)

Steering Rack Mounting

40 ft-lbs (54 Nm)

Nuts

Tie Rod Jam Nut

Tie Rod Retaining Nut

Shock Mounting Fastener

Stabilizer Bar Link Nut

Upper A-Arm Fastener

Lower A-Arm Fastener

Ball Joint Nut

Stabilizer Bar Mount Fastener

Stabilizer Bar Link Fastener

13 ft-lbs (18 Nm)

30 ft-lbs (41 Nm) + 90°

40 ft-lbs (54 Nm)

45 ft-lbs (61 Nm)

31 ft-lbs (42 Nm)

17 ft-lbs (23 Nm)

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CHAPTER 9 — BRAKE SYSTEM

PART DESCRIPTION

TORQUE

SPECIFICATION

GENERAL INFORMATION

Master Cylinder Mounting Fastener

Caliper Bleed Screw 4 ft-lbs (5.5 Nm)

Brake Line Banjo Bolt 15 ft-lbs (20 Nm)

Master Cylinder Banjo Fastener

Front Caliper Mounting Fastener

Rear Caliper Mounting Fastener

Pedal Bracket Nuts

Brake Disc Mounting Fastener

12 ft-lbs (16 Nm)

15 ft-lbs (20 Nm)

28 ft-lbs (38 Nm)

46 ft-lbs (62 Nm)

8 ft-lbs (11 Nm)

18 ft-lbs (24 Nm)

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

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GENERAL INFORMATION

CHAPTER 10 — BODY / FRAME

TORQUE

PART DESCRIPTION

Cargo Box Bracket Fastener

SPECIFICATION

5 ft-lbs (7 Nm)

Door Hinge Fastener 17 lb-ft (23 Nm)

Door Retainer Fastener

6 lb-ft (8 Nm)

Torque until lock and

Rear Glass Fastener

ride clamps are fully

seated

Skid Plate Fastener

Instrument Cluster Fastener

Seat Base Fastener

6 ft-lbs (8 Nm)

12 in lbs (1 Nm)

10 ft-lbs (14 Nm)

Cross Bar Fastener 14 ft-lbs (19 Nm)

Dash Bracket Fastener

6 ft-lbs (8 Nm)

Dash, Storage Fastener 42 in-lbs (5 Nm)

Dash, Upper Storage

10 in-lbs (1 Nm)

Fastener

CHAPTER 10 — BODY / FRAME

TORQUE

PART DESCRIPTION

SPECIFICATION

Frame, Cab Fastener 65 ft-lbs (61 Nm)

Weld, Cab Frame

40 ft-lbs (49 Nm)

Fastener

Weld, Seat Bolster

10 ft-lbs (14 Nm)

Fastener

Bolster, Bracket Fastener

Plate, Windshield Mount

6 ft-lbs (8 Nm)

36 ft-lbs (49 Nm)

Fastener

Cargo Box Latch Bushing

13 ft lbs (18 Nm)

Fastener

Cargo Box Fastener 42 in-lbs (5 Nm)

Cargo Box Frame

5 ft lbs (7 Nm)

Fastener

Cargo Box Heat Shield

42 in-lbs (5 Nm)

Fastener M6X1.0

Cargo Box Heat Shield

18 in lbs (2 Nm)

Fastener 14X5/8

Dash, Main Fastener

42 in-lbs (5 Nm)

Glovebox Fastener 42 in-lbs (5 Nm)

Fender-Rear, Rocker

42 in-lbs (5 Nm)

Fastener

Seat-Back, Fastener 18 inch-lbs (2 Nm)

Buckle, Seat Mounting

40 ft-lbs (54 Nm)

Fastener

Seat Back Frame

10 ft lbs (14 Nm)

Fastener

Seat-Belt, Fastener 40 ft-lbs (54 Nm)

Seat Bracket Hinge

6 ft lbs (9 Nm)

Fastener

Seat Bracket Pivot

10 ft lbs (14 Nm)

Fastener

Seat Bracket Pivot

10 ft lbs (14 Nm)

Mounting Fastener

Seat, Frame Fastener 18 ft-lbs (24 Nm)

Seat Slide Assembly

6 ft lbs (8 Nm)

Fastener

Seat Shock Ball End

7 ft lbs (9 Nm)

Fastener

Handle, Grab Fastener 10 ft-lbs (14 Nm)

Inner Cargo Box Fastener 8 in lbs (1 Nm)

Outer Cargo Box Panel

8 in lbs (1 Nm)

Fastener

Lower Tailgate Support

10 ft lbs (14 Nm)

Fastener

Tailgate Latch Fastener

7 ft lbs (9 Nm)

Tailgate Support Fastener 42 in-lbs (5 Nm)

Tailgate Cap Fastener 22 in lbs (2 Nm)

Outer Tailgate Panel

22 in lbs (2 Nm)

Fastener

Front Bumper Fastener

Headliner Fastener

Body Fastener

Front Fender Fasteners

HVAC Unit Mounting

30 ft-lbs (41 Nm)

24 in-lbs (3 Nm)

42 in-lbs (5 Nm)

22 in lbs (3 Nm)

8 ft-lbs (11 Nm)

Fastener

HVAC Condenser

35 in-lbs (4 Nm)

Fastener

AC Hose Clamp Fastener 6 ft lbs (8 Nm)

AC Hose, Condenser to

12 ft-lbs (16 Nm)

Evaporator

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GENERAL INFORMATION

CHAPTER 10 — BODY / FRAME

TORQUE

PART DESCRIPTION

AC Suction Hose 18 ft-lbs (24 Nm)

AC Pressure Hose 18 ft-lbs (24 Nm)

HVAC Unit Mounting Bracket Fastener

Air Distributor Manifold Fastener

Filter Support Fastener 18 in-lbs (2 Nm)

Air Filter Band Clamp 24 in-lbs (3 Nm)

Upper Glovebox Mounting Fastener

Rear Close Off Panel Fastener

Side Net Fastener 6 ft-lbs (8 Nm)

Overhead Light Fastener 18 in lbs (2 Nm)

Roof Fastener 42 in lbs (5 Nm)

1/4 Turn Glovebox Latch 36 in lbs (4 Nm)

SPECIFICATION

6 ft-lbs (8 Nm)

18 in-lbs (2 Nm)

10 in-lbs (1 Nm)

42 in-lbs (5 Nm)

CHAPTER 11 — ELECTRICAL

TORQUE

PART DESCRIPTION

ECU Retaining Fastener

Battery Box Fastener 3.5 ft-lbs (5 Nm)

Battery Bracket Fastener

Starter Cable Wiring Nuts 48 in-lbs (5 Nm)

Spark Plug 9 ft–lbs (12 Nm)

Brake Switch

CPS Retaining Fastener 9 ft-lbs (12 Nm)

ETC Housing Retaining Fastener

Oxygen Sensor 18 ft-lbs (24 Nm)

T-MAP Retaining Fastener

ECT Sensor

Speed Sensor 10 ft-lbs (14 Nm)

Headlight Fastener 5 ft-lbs (7 Nm)

SPECIFICATION

24 in lbs (2.7 Nm)

3.5 ft-lbs (5 Nm)

15 ft-lbs (20 Nm)

5 ft-lbs (7 Nm)

3 ft-lbs (4.5 Nm)

16 ft-lbs (22 Nm)

Battery Terminal Fastener 40 in-lbs (5 Nm)

Alternator Hot Wire at Terminal Block

Terminal Block Fasteners

Ignition Coil Retaining Bolt

Tail Light Fasteners

Starter Motor Fasteners

3.3 ft-lbs (4 Nm)

3 lb-ft (4 Nm)

8 lb-ft (11 Nm)

4 lb-ft (5 Nm)

7 lb-ft (10 Nm)

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

MODEL NUMBER DESIGNATION

Example: R18RRE99AS

GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**

R 1 8 R R E 9 9 A S

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

Example: 4XAKA09A0E3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

WORLD MFG. ID

CHASSIS

DRIVELINE

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 SIZE

ENGINE

MODIFIER

ENGINE DESIGNATION NUMBER

1205551 - 18: 999cc Twin Cylinder, Liquid Cooled, 4-Stroke DOHC, Electric Start

VEHICLE AND ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

The engine serial number can be found on a decal applied to the front of the engine crankcase crankcase on the PTO side of the engine

The VIN can be found stamped on a portion of the left rear frame

, above the PVT cover.

or stamped into the

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VEHICLE SPECIFICATIONS

GENERAL INFORMATION

2018 RANGER XP 1000 OVERVIEW

CATEGORY DIMENSION / CAPACITY

Length

Width 62.5 in / 159 cm

Height

Wheel Base 81 in / 206 cm

Ground Clearance 13 in / 33 cm

Dry Weight

Gross Vehicle Weight

Cargo Box Capacity 1000 lb / 453 kg

Cargo Box Dimensions (Inside)

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 2500 lb / 1134 kg

Hitch Tongue Capacity 150 lb / 68 kg

120 in / 305 cm

77 in / 195 cm

1565 lb / 709 kg (Ranger XP

1000) 1875 lb / 850 kg (Northstar Edition)

3300 lb / 1497 kg (Ranger XP

1000) 3600 lb / 1633 kg (Northstar Edition)

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

1500 lb / 680 kg (Ranger XP

1000) 1750 lb / 795 kg (Northstar Edition) (Includes riders, cargo and accessories)

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Page 24

GENERAL INFORMATION

2018 RANGER XP 1000 SPECIFICATIONS

ENGINE

Platform

Engine Displacement 61 ci (999 cc)

Number of Cylinders

Bore & Stroke 93 mm x 73.5 mm Compression Ratio

Engine Idle Speed

Engine Max Speed

Valve Clearance (Int) .006 ± .002 in (0.15 ± 0.05 mm)

Valve Clearance (Exh) .010 ± .002 in (0.25 ± 0.05 mm)

Engine Hot Light

Lubrication

Oil Requirements PS-4 5W-50 Full Synthetic

Oil Capacity 2.5 Qt. (2.4 L)

Coolant Capacity 5.0 Qt (4.75 L)

4-Stroke, DOHC, Twin Cylinder

10.8:1

1250 ± 100 RPM

8000 RPM

Instrument Cluster Indicator

Wet Sump

FUEL SYSTEM

Type

Fuel Delivery Electronic Fuel Pump (in-tank)

Fuel Pressure

Fuel Capacity / Requirement

Bosch ME17 EFI

58 ± 2 PSI (400 ± 14 kPa)

11.5 Gal (43.5 L)

87 Octane (minimum)

ELECTRICAL

Alternator Max Output 660 Watts @ 3000 RPM

Main Headlights Dual Beam Halogen

Taillights 10 L.E.D. (.28W)

Brake Lights 10 L.E.D. (3.1W)

Ignition System Digital CDI

Spark Plug / Gap

Battery / Amp Hr

DC Outlet Standard 12 Volt

Relays

Fuses

NGK MR7F / 0.7-0.8 mm

12 V Flooded, 575 CCA

AC Comp, AC Switch, HVAC Power, Fuel Pump, Chassis, EFI, Access, EPS, Start

20A EFI 20A ECM 20A Chassis 15A Fuel Pump 20A Accessory 15A Drive 20A Lights 30A EPS 30A HVAC (if applicable) 15A Alternator (if applicable)

DRIVETRAIN

Transmission Type

Shift Type

Transmission Gear Ratios: High Low Reverse

Front Drive Ratio 3.23:1 Front Gearcase Lubricant

Requirement

Transmission Lubricant Requirement

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Front 3.92:1 / Rear 11.72:1 Front 9.65:1/ Rear 28.84:1 Front 8.64:1 / Rear 25.83:1

Demand Drive Fluid

8.5 oz (250 mL)

AGL Gearcase Lubricant 44 oz (1300 mL)

STEERING / SUSPENSION

Steering Wheel FreePlay

Wheel Toe Out

Front Suspension Independent Dual A-Arm

Front Travel

Rear Suspension Independent Dual A-Arm

Rear Travel

Spring Adjustment Threaded Spanner Wrench

0.8-1.0 in (20-25 mm)

1/4-1/4 in (6.4-6.4 mm)

11.0 in (27.9 cm)

11.0" (27.94 cm)

WHEELS / BRAKES

Front Wheel Type / Size

Rear Wheel Type / Size

Front Tire Size / Model 27 x 9 R12 Rear Tire Size / Model 27 x 11 R12 Front Tire Air Pressure 10 psi / 69 kPa (Ranger XP 1000)

Rear Tire Air Pressure 14 psi / 96 kPa (Ranger XP 1000)

Brake System Front & Rear

Brake Fluid DOT 4

Alum / 12 x 6

Alum / 12 x 8

14 psi / 96 kPa (Northstar Edition)

16 psi / kPa (Northstar Edition)

Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper

CLUTCHES

ALTITUDE

0-1800 Meters (0-6000 Feet)

1800-3700 Meters (6000 - 12000 Feet)

SHIFT WEIGHT

32–106 (1323458)

32–97 (1323520)

DRIVE SPRING

Black (7044938)

DRIVEN SPRING

7044761

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MISC. SPECIFICATIONS AND CHARTS

GENERAL INFORMATION

CONVERSION TABLE

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs

in-lbs x 0.0833 = ft-lbs

ft-lbs

in-lbs x 0.0115 = kg-m

Nm x 0.7376 = ft-lbs

kg-m x 7.233

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi)

km x 0.6214 = mile

ounces (oz)

x 12 = in-lbs

x 1.356 = Nm

= ft-lbs

= mm

x 0.03937 = inch

= cm

x 1.6 = km

x 28.35

= grams (g)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

grams (g)

pounds (lb) x 0.454 = kg

kilogram (kg)

cubic inches (cu in)

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

liters (L)

US gallons x 3.785 = liters (L)

liters (L)

PSI x 6.895 = kilopascals (kPa)

kilopascals (kPa)

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x .03381

x 0.035

x 2.2046 = lbs

x 16.387

x 0.946

x 1.057

x 0.264

x 0.145

= fluid ounces

= ounces

= cc

= liters (L)

= US quarts

= US gallons

PSI

= cylinder volume

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Page 26

GENERAL INFORMATION

STANDARD BOLT TORQUE SPECIFICATION

BOLT SIZE

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

GRADE 2

FT-LB (NM)

5 (7) 8 (11) 12 (16)

6 (8) 10 (14) 14 (19)

11 (15) 17 (23) 25 (35)

12 (16) 19 (26) 29 (40)

20 (27) 30 (40) 45 (62)

23 (32) 35 (48) 50 (69)

30 (40) 50 (69) 70 (97)

35 (48) 55 (76) 80 (110)

50 (69) 75 (104) 110 (152)

55 (76) 90 (124) 120 (166)

METRIC BOLT TORQUE SPECIFICATION

BOLT

SIZE

4.6 4.8 8.8 / 8.9 10.9 12.9

GRADE 5

FT-LB (NM)

GRADE

FT-LB (NM) DRY THREADS

GRADE 8

FT-LB (NM)

M10

M12

M14

M16

M18

0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)

0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

26 (35) 33 (45) 63 (85) 97 (130) 111 (150)

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

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GENERAL INFORMATION

SAE TAP / DRILL SIZES

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64 50 5/8–11 17/32

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

#8–32

THREAD

SIZE DRILL SIZE

1/2–20 29/64

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

7/8–14 13/16

1 1/8–7 63/64

1 1/8–12 1 3/64

METRIC TAP / DRILL SIZES

TAP SIZE DRILL SIZE DECIMAL

3 x .50

3 x .60

4 x .70

4 x .75

5 x .80 #19 0.166 11/64

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277

8 x 1.25

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

#39

3/32

#30

1/8 0.125 1/8

#20

16/64

17/64

5/16

11/32

0.0995

0.0937

0.1285

0.161

0.196

0.234

0.265

0.3125

0.3437

NEAREST

FRACTION

3/32

1/8

5/32

13/64

15/64

9/32

17/64

5/16

11/32

#8–36

#10–24

#10–32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1/4–28

5/16–18

5/16–24

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

7/16–20 25/64

F 2–12

U 3–4

1 1/4–7 1 7/64

1 1/4–12 1 11/64

1 1/2–6 1 11/32

1 3/4–12 1 43/64

2–4 1/2 1 25/32

2 1/4–4 1/2 2 1/32

1 59/64

2 3/4

11 x 1.50

12 x 1.50

12 x 1.75 13/32 0.406 13/32

3/8

13/32

0.375

0.406

3/8

13/32

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GENERAL INFORMATION

DECIMAL EQUIVALENTS

FRACTION DECIMAL MM TO INCHES

1/64 0.0156″

1/32

3/64

1/16 0.0625″

5/64

3/32

7/64 0.1094″ 3 mm = 0.1181″

1/8

9/64

5/32 0.1563″ 4 mm = 0.1575″

11/64 0.1719″

3/16

13/64

7/32 0.2188″

15/64

1/4

17/64 0.2656″ 7 mm = 0.2756″

9/32

19/64

5/16 0.3125″ 8 mm = 0.3150″

21/64

11/32

23/64 0.3594″

3/8 0.375″

25/64

13/32

27/64 0.4219″ 11 mm = 0.4331″

7/16

29/64

15/32 0.4688″ 12 mm = 0.4724″

31/64

1/2

33/64 0.5156″

17/32 0.5313″

35/64

9/16

37/64 0.5781″ 15 mm = 0.5906″

19/32

39/64

5/8

0.0312″ 1 mm = 0.0394″

0.0469″

0.0781″ 2 mm = 0.0787″

0.0938″

0.1250″

0.1406″

0.1875″ 5 mm = 0.1969″

0.2031″

0.2344″ 6 mm = 0.2362″

0.25″

0.2813″

0.2969″

0.3281″

0.3438″ 9 mm = 0.3543″

0.3906″ 10 mm = 0.3937″

0.4063″

0.4375″

0.4531″

0.4844″

0.500″ 13 mm = 0.5118″

0.5469″ 14 mm = 0.5512″

0.5625″

0.5938″

0.6094″

0.625″ 16 mm = 0.6299″

FRACTION DECIMAL MM TO INCHES

41/64 0.6406″

21/32

43/64

11/16 0.6875″

45/64

23/32

47/64 0.7344″ 19 mm = 0.7480″

3/4

49/64

25/32

51/64 0.7969″

13/16

53/64

27/32 0.8438″

55/64 0.8594″ 22 mm = 0.8661″

7/8

57/64 0.8906″ 23 mm = 0.9055″

29/32

59/64

15/16 0.9375″ 24 mm = 0.9449″

61/64 0.9531″

31/32

63/64

1 1.000″

0.6563″ 17 mm = 0.6693″

0.6719″

0.7031″ 18 mm = 0.7087″

0.7188″

0.750″

0.7656″

0.7813″ 20 mm = 0.7874″

0.8125″ 21 mm = 0.8268″

0.8281″

0.875″

0.9063″

0.9219″

0.9688″ 25 mm = 0.9843″

0.9844″

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MAINTENANCE

CHAPTER 2

MAINTENANCE

GENERAL INFORMATION - MAINTENANCE . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . 2.3

SERVICE NOTES - MAINTENANCE . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . 2.3

SPECIAL TOOLS - MAINTENANCE. . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . 2.3

SERVICE SPECIFICATIONS - MAINTENANCE . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . 2.4

PERIODIC MAINTENANCE. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . 2.5

PERIODIC MAINTENANCE OVERVIEW . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . 2.5

BREAK-IN PERIOD. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. 2.5

PRE-RIDE INSPECTION . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . 2.6

MAINTENANCE INTERVALS . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . 2.7

MAINTENANCE QUICK REFERENCE . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . ..2.27

GREASE LUBRICATION POINTS.. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .2.29

MAINTENANCE LUBRICANTS . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . .2.30

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS. . .. . . . .. . . . . . . . . . . .. . . . .. . . .2.31

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .2.32

PRE-RIDE / DAILY INSPECTION . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . .2.32

FRAME, NUTS, BOLTS, 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

COOLING SYSTEM HOSE INSPECTION . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . .2.40

RADIATOR INSPECTION . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .2.41

COOLANT REPLACEMENT . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . .2.41

AIR INTAKE AND EXHAUST MAINTENANCE. . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .2.42

AIR FILTER REPLACEMENT . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .2.42

EXHAUST SPARK ARRESTOR INSPECTION . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . ..2.43

EXHAUST HEAT SHIELD INSPECTION . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. .2.44

FUEL SYSTEM MAINTENANCE . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .2.45

FUEL LINE INSPECTION .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .2.45

FUEL PUMP / FILTER INSPECTION . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .2.45

FUEL TANK VENT LINE INSPECTION . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . .2.46

PVT SYSTEM MAINTENANCE . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . ..2.47

DRIVE BELT INSPECTION . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . .2.47

PVT SYSTEM DRYING . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . ..2.47

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MAINTENANCE

TRANSMISSION AND FRONT GEARCASE MAINTENANCE . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . .2.48

TRANSMISSION FLUID LEVEL INSPECTION . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .2.48

TRANSMISSION FLUID REPLACEMENT . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . .2.48

SHIFT CABLE INSPECTION / ADJUSTMENT . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . .2.49

FRONT GEARCASE FLUID LEVEL INSPECTION . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .2.49

FRONT GEARCASE FLUID REPLACEMENT . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . .2.50

FINAL DRIVE MAINTENANCE .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . .2.51

DRIVE SHAFT BOOT INSPECTION . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . .2.51

WHEEL REPLACEMENT . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . ..2.51

TIRE INSPECTION . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. .2.52

TIRE PRESSURE INSPECTION . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . .2.52

STEERING 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 PAD INSPECTION . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . 2.59

BRAKE DISC INSPECTION. . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . .2.59

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . .2.59

ELECTRICAL MAINTENANCE . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .2.60

BATTERY MAINTENANCE .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . ..2.60

BATTERY REPLACEMENT . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . .2.60

CHASSIS / ENGINE ELECTRICAL GROUND . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . .2.61

SPARK PLUG REPLACEMENT . . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .2.62

THROTTLE PEDAL INSPECTION . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .2.63

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GENERAL INFORMATION - MAINTENANCE

MAINTENANCE

SERVICE NOTES - MAINTENANCE

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

IMPORTANT

Service and adjustments are critical. If you’re not

familiar with safe service and adjustment procedures,

have a qualified dealer technician perform these

operations.

WARNING

Gasoline is extremely flammable and explosive under

certain conditions.

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 wash it off with soap and water and

change clothing.

Never start the engine or let it run in an enclosed area.

Engine exhaust fumes are poisonous and can result in

loss of consciousness or death in a short time.

Never drain the fuel when the engine is hot. Severe

burns may result.

SPECIAL TOOLS - MAINTENANCE

TOOL DESCRIPTION

Oil Filter Wrench PU-50105

Shock Spanner Wrench 2877408

Bosch Automotive Service Solutions: 1-800-328-6657 or https://polaris.service-solutions.com/

PART NUMBER

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MAINTENANCE

SERVICE SPECIFICATIONS - MAINTENANCE

GENERAL SPECIFICATIONS

ITEM

Cylinder Leakage -

Intake Valve Clearance (Cold) .006 ± .002 in (0.15 ± 0.05 mm) -

Exhaust Valve Clearance (Cold) .010 ± .002 in (0.25 ± 0.05 mm) -

Front Tire Air Pressure

Rear Tire Air Pressure

Steering Wheel Free-Play 0.8-1.0 in (20-25 mm) -

Wheel Toe Out

Spring Adjustment Threaded Spanner Wrench -

Brake Pad Thickness

Brake Disc Thickness

Spark Plug Type

ITEM

10 psi / 69 kPa (Ranger XP 1000) 14 psi / 96 kPa (Northstar Edition)

14 psi / 96 kPa (Ranger XP 1000) 16 psi / kPa (Northstar Edition)

1/4-1/4 in (6.4-6.4 mm) -

NGK MR7F

FLUID SPECIFICATIONS

STANDARD SERVICE LIMIT

20%

- 0.040 (1 mm)

- 0.170 (4.32 mm)

FLUID TYPE CAPACITY

Engine Oil

Engine Coolant

Front Gearcase Fluid Demand Drive Fluid

Transmission Fluid AGL Gearcase Lubricant

Brake Fluid DOT 4

Grease Fittings

U-Joint Lubricant Premium U-Joint Lubricant

Fuel

PS-4 5W-50 Full Synthetic / PS-4 10W-40 Extreme Duty Full Synthetic

50 / 50 Extended Life Antifreeze

Premium All-Season Grease

87 Octane (minimum) 11.5 Gal (43.5 L)

2.5 Qt. (2.4 L)

5.0 Qt (4.75 L)

8.5 oz (250 mL)

44 oz (1300 mL)

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PERIODIC MAINTENANCE

MAINTENANCE

PERIODIC MAINTENANCE OVERVIEW

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.

NOTE

Service and adjustments are critical. If you’re not

familiar with safe service and adjustment procedures,

have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• 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

BREAK-IN PERIOD

The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 25 hours or one month.

• See “Owner’s Manual” for additional break-in information.

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 it continues to rise, discontinue use and determine the cause or see your dealer.

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MAINTENANCE

PRE-RIDE INSPECTION

The following items should be inspected pre-ride:

ITEM

Air Filter

Steering System

Front / Rear Suspension

Tires

Wheels / Lug Nuts

Headlights / Taillights

INSPECTION / CHECK

• Air Filter / Air box is clean

• Filter is properly installed

• Air Box cover is secured and fastened

• Check for proper EPS operation

• Check for tightness/play in the steering wheel when turned lock to lock

• Inspect bushings

• Check for damaged to the control arms / trailing arms

• Check for leaking shocks

• Check for proper air pressure in all tires

• Inspect for tire damage / nails in tire

• Verify there is adequate tread depth

• Ensure rim is not cracked / bent

• Verify proper lug nut torque

• Ensure all lights are operational

• Adjust headlight aim as required

• Check brake fluid level is between MIN and MAX

Brake System

Frame / Body Fasteners Check for loose body / frame fasteners

Engine Oil Level Verify oil level is in the SAFE range on the dipstick

Intake Drain

Coolant Level

Auxiliary Brake (if equipped) Inspect / adjust as needed

Engine Intake Pre-Filter Screen (LH side) Inspect / clean often

PVT Intake Pre-Filter Screen (RH side) Inspect / clean often

Power Steering Unit Inspect / clean often

Spark Arrester

• Check brake pedal is not soft when pushed

• Verify brakes stop and hold the vehicle

• Inspect for leaks

Inspect / drain intake as needed

• Verify coolant level is filled to the FULL COLD mark on coolant reservoir (if engine is cold)

• Inspect hoses and radiator for leaks

Clean when driving in mud and water; replace a cracked or damaged arrester before operating

2.6

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MAINTENANCE

MAINTENANCE INTERVALS

The maintenance interval charts outline required maintenance and inspection based on vehicle hours / miles. Each table states the number of hours / miles that service is required on the vehicle. Some items or components may need to be serviced more often due to severe use, such as operation in water or under severe loads. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.

25 Hour / 250 mile (400 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change (Break-In)

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Initial fluid level inspection; add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Perform a break-in oil and filter change at 25 hours or one month; perform every 50 hours or 6 months thereafter

Initial fluid level inspection; add lubricant if needed

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MAINTENANCE

50 Hour / 500 mile (800 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

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75 Hour / 750 mile (1200 km)Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

100 Hour / 1000 mile (1600 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

XU / D

D / E

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Front Wheel Bearings Inspect; replace as needed

XU Shocks

Cam Chain Tensioner

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

Visually inspect shock seals; change oil and seals if leaking

Inspect/clean; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

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125 Hour / 1250 mile (2000 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

150 Hour / 1500 mile (2400 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

2.12

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175 Hour / 1750 mile (2800 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

200 Hour / 2000 mile (3200 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

XU / D

D / E

XU / D Shocks

D / E Valve Clearance

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring Inspect routing and for wear; inspect connectors subjected to water/mud.

Front Wheel Bearings Inspect; replace as needed

D Brake Fluid

Spark Arrestor

Cam Chain Tensioner

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Change shock oil and inspect seals

Change every two years (DOT 4)

Clean daily if driven in mud / water; replace a damaged arrestor before operating

Inspect/clean; replace as needed

Inspect; adjust as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

2.14

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225 Hour / 2250 mile (3600 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

250 Hour / 2500 mile (4000 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

2.16

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275 Hour / 2750 mile (4400 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

300 Hour / 3000 mile (4800 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

XU / D

D / E

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring

Front Wheel Bearings Inspect; replace as needed

XU Shocks

Cam Chain Tensioner

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

Visually inspect shock seals; change oil and seals if leaking

Inspect/clean; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

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325 Hour / 3250 mile (5200 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

350 Hour / 3500 mile (5600 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

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375 Hour / 3750 mile (6000 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

400 Hour / 4000 mile (6400 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

XU / D

D / E

XU / D Shocks

D / E Valve Clearance

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring

Front Wheel Bearings Inspect; replace as needed

D Brake Fluid

Spark Arrestor

Cam Chain Tensioner

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

Change shock oil and inspect seals

Change every two years (DOT 4)

Clean daily if driven in mud / water; replace a damaged arrestor before operating

Inspect/clean; replace as needed

Inspect; adjust as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

2.22

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425 Hour / 4250 mile (6400 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

450 Hour / 4500 mile (6800 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

2.24

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475 Hour / 4750 mile (7200 km) Service

COMPONENT REMARKS

XU / D

XU / E

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Inspect / add lubricant if needed

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Inspect / add lubricant if needed

MAINTENANCE

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MAINTENANCE

500 Hour / 5000 mile (7600 km) Service

ITEM

XU / D

XU / E

D / E Throttle Pedal

XU / D

D / E

XU / D Shocks

D / E Valve Clearance

D / E

Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit

Fuel System

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours

Engine Breather Inspect; clean

Battery

XU General Lubrication

Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

Steering Lubricate (if applicable)

Front / Rear Suspension Lubricate (if applicable)

Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt

Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension as needed

XU Front Gearcase Lubricant

Transmission Lubricant (AGL) Change lubricant

Fuel System Check for leaks at fill cap, fuel line / rail, and fuel pump.

Spark Plug Inspection Inspect; replace as needed; torque to specification

XU Radiator

Cooling Hoses Inspect for leaks; pressure test system

Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

Wiring

Clutches (Drive and Driven) Inspect; clean; replace worn parts

Front Wheel Bearings Inspect; replace as needed

D Brake Fluid

Spark Arrestor

Spark Plug Replacement Replace; torque to specification

XU Coolant

Toe Adjustment Inspect periodically; adjust when parts are replaced

Cam Chain Tensioner

REMARKS

Turn key on to pressurize fuel pump; check lines / fittings for leaks and abrasion

Check terminals; clean; test

Lubricate all fittings, pivots, cables, etc.

Inspect; replace if it sticks

Inspect; replace as needed

Change lubricant

Inspect; clean external surfaces

Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

Change shock oil and inspect seals

Change every two years (DOT 4)

Clean daily if driven in mud / water; replace a damaged arrestor before operating

Inspect; adjust as needed

Replace coolant

Inspect/clean; replace as needed

XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California)

When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.

2.26

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MAINTENANCE QUICK REFERENCE

MAINTENANCE

ITEM LUBE REC METHOD

Oil Fill Cap

- Under Cargo Box

Oil Filter

- On Front Side of Engine

Engine Coolant

- Under Front Hood

* More often under severe use, such as operation in water or under severe loads.

/ Dipstickee:

Polaris PS-4 5W-50 Full Synthetic or Polaris PS-4 10W-40 Extreme Duty Full Synthetic

Polaris 50 / 50 Extended Life Antifreeze

Add oil to proper level on dipstick

Maintain coolant level in coolant reservoir bottle

FREQUENCY*

Perform a break-in oil and filter change at 25 hrs or one month; perform every 50 hrs thereafter

Check level daily; change coolant every two years

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MAINTENANCE

ITEM LUBE REC METHOD

Maintain fluid level between

Brake Fluid

Front Gearcase

Transmission

* More often under severe use, such as operation in water or under severe loads.

Polaris DOT 4

Polaris Demand Drive Fluid

Polaris AGL Gearcase Lubricant

“MAX and “MIN” lines on the master cylinder reservoir

Add lubricant until it is visible at the fill hole threads (250 mL)

Add lubricant until it is visible at the fill hole threads

~8.5 oz.

Check level during pre-ride inspection; change fluid every two years

Initial level check at 25 hours or 1 month; Change lubricant at 100 hours or every 12 months, whichever comes first

FREQUENCY*

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MAINTENANCE

GREASE LUBRICATION POINTS

There are grease fittings at each front and rear torsion 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

Propshaft Yoke

Premium U-Joint Lubricant

Grease middle

fitting

FREQUENCY

Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle

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MAINTENANCE

MAINTENANCE LUBRICANTS

PART # DESCRIPTION

Engine Lubricants

2876244

2876245

2878920

2878919

2540086

2879723

2879324

Gearcase / Transmission Lubricants

2878068

2878069

2878070

2877922

2877923

Grease / Specialized Lubricants

2871322

2871423

2871515

2871551

2871329

Coolant

2880514

2880513

2880512

PS-4 Full Synthetic 5W-50 (Qt)

PS-4 Full Synthetic 5W-50 (Gal)

PS-4 Extreme Duty Full Synthetic 10W-50 (Qt)

PS-4 Extreme Duty Full Synthetic 10W-50 (Gal)

Engine Oil Filter

Engine Oil Change Kit (PS-4)

Engine Oil Change Kit (PS-4 Extreme Duty)

AGL Gearcase Lubricant (Qt) (12 count)

AGL Gearcase Lubricant (Gal) (4 count)

AGL Gearcase Lubricant (2.5 Gal) (2 count)

Demand Drive Fluid (Qt)

Demand Drive Fluid (2.5 Gal)

Premium All-Season Grease (3 oz) (24 count)

Premium All-Season Grease (14 oz) (10 count)

Premium U-Joint Lubricant (3 oz) (24 count)

Premium U-Joint Lubricant (14 oz) (10 count)

Dielectric Grease (Nyogel™)

50/50 EL Anti-Free (Qt) (12 count)

50/50 EL Anti-Free (Gal) (4 count)

50/50 EL Anti-Free (55 Gal Drum)

PART # DESCRIPTION

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652

2872189

2871557

Loctite® Threadlock 242 (6 mL) (12 count)

Premium Carbon Clean (12 oz) (12 count)

Fuel Stabilizer (16 oz) (12 count)

DOT 4 Brake Fluid (12 count)

Crankcase Sealant, 3-Bond 1215 (5 oz)

NOTE

The number count indicated by each part number in the

table above indicates the number of units that are

shipped with each order.

NOTE

Each item can be purchased separately at your local

Polaris dealer.

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MAINTENANCE

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS

PART NO. DESCRIPTION

Engine Lubricant

2870791

2876244

2876245

2878920

2878919

2540086

2879723

2879324

Gearcase / Transmission Lubricants

2878068

2878069

2878070

2877922

2877923

2870465

Grease / Specialized Lubricants

2871312 Grease Gun Kit

2871322

2871423

2871460

2871515

2871551

2871329

Coolant

2880514

2880513

2880512

Fogging Oil (12 oz. Aerosol)

PS-4 Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Synthetic 4-Cycle Engine Oil (Gallon)

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Gallon)

Engine Oil Filter

Engine Oil Change Kit (PS-4)

Engine Oil Change Kit (PS-4 Extreme Duty)

AGL Gearcase Lubricant (1 Qt.) (12 Count)

AGL Gearcase Lubricant (1 Gal.) (4 Count)

AGL Gearcase Lubricant (2.5 Gal.) (2 Count)

Demand Drive Fluid (Quart)

Demand Drive Fluid (2.5 Gallon)

Oil Pump for 1 Gallon Jug

Premium All Season Grease (3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Starter Drive Grease (12 Count)

Premium U-Joint Lube (3 oz.) (24 Count)

Premium U-Joint Lube (14 oz.) (10 Count)

Dielectric Grease (Nyogel™)

50/50 EL Anti-Freeze (Quart) (12 Count)

50/50 EL Anti-Freeze (Gallon) (4 Count)

50/50 EL Anti-Freeze (55 Gal Drum)

PART NO. DESCRIPTION

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652

2872189

2871557

Loctite® Threadlock 242 (6 ml.) (12 count)

Premium Carbon Clean (12 oz.) (12 count)

Fuel Stabilizer (16 oz.) (12 count)

DOT 4 Brake Fluid (12 count)

Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE

The number count indicated by each part number in the

table above indicates the number of units that are

shipped with each order.

NOTE

Each item can be purchased separately at your local

Polaris dealer.

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MAINTENANCE

GENERAL VEHICLE INSPECTION AND MAINTENANCE

PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Engine Oil - Check for proper level on dipstick (refer to Engine Oil Level Inspection, page 2.33 procedure)

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation, fluid level and adjustment

• Throttle Pedal - check for proper operation

• Headlights/Taillights/Brakelights - check operation of all indicator lights, instrument cluster and switches

• Ignition switch - check for proper function

• Wheels - check for 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 any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

• Drive Shaft Boots - Inspect inner and outer boots for tears or damage on both front and rear drive shafts

• Check all suspension components for wear or damage

FRAME, NUTS, BOLTS, AND FASTENERS

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

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ENGINE MAINTENANCE

MAINTENANCE

ENGINE OIL LEVEL INSPECTION

This engine has a wet-sump design, meaning the engine oil is contained in the bottom of the crankcase. To check the oil level, follow the procedure listed below:

FLUID CAPACITY

Recommended Engine Oil:

Capacity: 2.5 Qt (2.4 L)

PS-4 5W-50 Full Synthetic

Ambient Temp Range: -35° F to 100° F

PS-4 10W-40 Extreme Duty Full Synthetic

Ambient Temp Range: 0° F to 120° F

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down before removing the dipstick.

3. Raise the cargo box. Unlock the dipstick lever Remove the dipstick and wipe it dry with a clean cloth.

6. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill (see NOTE below).

NOTE

A rising oil level between checks during cold weather

operation can indicate contaminants such as gas or

moisture collecting in the crankcase. If the oil level is

over the upper mark, change the oil immediately.

7. With the cargo box raised, add engine oil through the oil fill cap the cargo box.

located on top of the valve cover, under

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.

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

8. When finished, reinstall dipstick and lock the lever. Lower the cargo box and secure in position.

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MAINTENANCE

ENGINE OIL AND FILTER REPLACEMENT

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover. Access the oil dipstick and oil fill cap by tilting the rear cargo box.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase.

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down.

3. Clean the area around the crankcase drain plug.

CAUTION

Use caution when performing this procedure. Do not

allow hot engine oil to come into contact with skin, as

serious burns may result.

4. Place a drain pan under the engine crankcase and remove the drain plug. Allow the oil to drain completely.

7. Using the Oil Filter Wrench (PU-50105), turn the oil filter

8. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase.

9. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it to specification.

counter-clockwise to remove it.

Oil Filter Wrench:

PU-50105: 2.5” (64 mm)

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.

TORQUE

Oil Filter:Turn by hand until filter O-ring contacts sealing surface, then turn an additional 3/4 turn.

10.Replace the sealing washer on drain plug.

NOTE

The sealing surface on the drain plug should be clean

and free of burrs, nicks or scratches.

11. Reinstall the engine crankcase drain plug. Torque drain plug to specification.

TORQUE

Crankcase Drain Plug:

12 ft-lbs (16 Nm)

12.Remove oil fill cap (refer toEngine Oil Level Inspection, page 2.33 procedure). Fill engine with recommended engine oil.

FLUID CAPACITY

Recommended Engine Oil:

PS-4 5W-50 Full Synthetic

Ambient Temp Range: -35° F to 100° F

PS-4 10W-40 Extreme Duty Full Synthetic

Ambient Temp Range: 0° F to 120° F

Capacity: 2.5 Qt. (2.4 L)

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MAINTENANCE

13.Verify the transmission is still in PARK.

14.Start the engine and allow it to idle for 30 seconds.

15.Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.

16.Unlock the dipstick lever. Remove the dipstick and wipe it dry with a clean cloth (refer to Engine Oil Level Inspection, page 2.33 procedure).

17.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.

18.Remove the dipstick and check the oil level.

19.Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

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.

Follow the breather hose to the airboxe.

Make sure hoses are not kinked or pinched.

from the crankcase fitting

NOTE

20.When finished, reinstall the oil fill cap, oil dipstick and lock the lever.

21.Dispose of used oil and filter properly.

ENGINE CYLINDER LEAKDOWN TEST

A cylinder leak-down test is the best indication of engine condition. Follow tester manufacturer’s instructions to perform a cylinder leak-down test. Never use high pressure leakage testers as crankshaft seals may dislodge and leak.

Cylinder Leakage Service Limit:

20%

If leakage exceeds service limit, inspect the engine for

the cause.

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MAINTENANCE

VALVE CLEARANCE INSPECTION

NOTE

Valve clearance inspection should be performed on a

cold engine, at room temperature.

1. Tilt the rear cargo box to access the valve cover.

2. Disconnect the negative (-) battery cable.

3. Remove the eight screws that retain the outer clutch cover and remove the cover from the vehicle in order to rotate the engine (refer to Belt Removal, page 5.6 procedure).

NOTE

Replace rubber isolatorseupon 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 lobe position.

4. Remove the spark plug wiresqfrom the engine.

5. Remove the four bolts retaining the valve coverr. Note the location and use of the grounding washer

and rubber isolators

for assembly.

NOTE

Remove spark plugs to aid engine rotation.

7. Rotate the drive clutch counter-clockwise until the cam lobes above the valves you are inspecting are facing up.

8. Measure the valve clearance using a feeler gauge.

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9. If the valve clearance is out of specification, refer to

Valve Clearance Adjustment, page 3.81 procedure.

MEASUREMENT

Intake Valve Clearance (cold):

0.006 ± .002 in (0.15 ± 0.05 mm)

Exhaust Valve Clearance (cold):

0.010 ± .002 in (0.25 ± 0.05 mm)

10.Repeat steps 7-9 until all eight valves have been inspected.

11. If previously removed, apply anti-seize compound (900 models only) to the spark plug threads and reinstall the spark plugs. Torque spark plugs to specification.

TORQUE

Spark Plug:

9 ft–lbs (12 Nm)

12.Inspect the valve cover 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.

MAINTENANCE

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 plug wires are marked

with PTO and MAG and should be installed to the

corresponding cylinder.

16.Install the outer clutch cover and eight retaining screws (Refer to Belt Installation, page 5.8 procedure). Torque the screws to specification.

TORQUE

Outer Clutch Cover Screws:

35 in-lbs (4 Nm)

17.Connect the negative (-) battery cable to the battery.

18.Start the engine to ensure proper operation.

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MAINTENANCE

CAM CHAIN TENSIONER INSPECTION

1. Locate the cam chain tensioner on the MAG side of the engine near the starter.

2. Remove the plunger bolt

3. Remove the two tensioner mounting boltsw.

4. Push on the tensioner lock plunger in and out. It should move freely. If it does not move freely, replace the tensioner assembly.

and the spring.

and manually move the

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 specification.

TORQUE

Plunger Bolt:

15 ft-lbs (20 Nm)

5. Retract the plunger all the way in and install into the cylinder.

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COOLING SYSTEM MAINTENANCE

MAINTENANCE

LIQUID COOLING SYSTEM OVERVIEW

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back from the tank past the pressure cap and into the radiator.

NOTE

Some coolant level drop on new machines is normal as

the system is purging itself of trapped air. Observe

coolant levels often during the break-in period.

Overheating of engine could occur if air is not fully purged from system.

Polaris Premium 50/50 Extended Life coolant is already premixed and ready to use. Do not dilute with water.

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze hydrometer.

COOLANT LEVEL INSPECTION

The recovery bottleqand radiator pressure capware located under the hood.

With the engine at operating temperature, the coolant level should be between the “MAX” and “MIN” marks on the recovery bottle. If not, perform the following:

1. Position the vehicle on a level surface

2. Remove the hood from the front cab.

3. Check the coolant level in the recovery bottle. The coolant level must be maintained between the “MAX” and “MIN” levels indicated on the recovery bottle.

• 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 CAPACITY

Recommended Anti-Freeze/Coolant:

Premium Pre-Mixed Extended Life Antifreeze

(PN 2880514) (Quart)

(PN 2880513) (Gallon)

4. If the coolant level is below the “MIN” mark, inspect the coolant level in the radiator.

NOTE

If overheating is evident, allow system to cool

completely and check coolant level in the radiator and

inspect for signs of trapped air in system.

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MAINTENANCE

CAUTION

Never remove the pressure cap when the engine is

warm or hot. Escaping steam can cause severe burns.

The engine must be cool before removing the pressure

cap.

5. Remove the pressure cap. Using a funnel, add coolant to the top of the radiator filler neck.

6. Reinstall the pressure cap.

NOTE

Use of a non-standard pressure cap will not allow the

recovery system to function properly.

7. Remove the recovery bottle cap and add coolant using a funnel.

8. Fill the recovery bottle to the “MAX” mark with the recommended pre-mix 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)

COOLING SYSTEM HOSE INSPECTION

1. Inspect all vehicle hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

2. Inspect all engine hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

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 overheating.

3. Check tightness and condition of all hose clamps. Do not over-tighten hose clamps at radiator, or radiator fitting may distort.

TORQUE

Coolant Hose Clamp:

35 in-lbs (4 Nm)

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MAINTENANCE

RADIATOR INSPECTION

1. Check radiator air passages for restrictions or damage.

ITEM DESCRIPTION

Radiator

Shroud

Fan

COOLANT REPLACEMENT

1. Allow the vehicle to cool down if recently operated.

2. Remove the hood from the front cab.

CAUTION

Escaping 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.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with low pressure compressed air or low pressure water.

CAUTION

Washing the vehicle with a high-pressure washer could

damage the radiator fins and impair the radiators

effectiveness. Use of a high-pressure washer is not

recommended.

6. Allow the coolant to completely drain. Properly dispose of the used coolant.

7. Reinstall coolant hose and reposition the spring clamp.

8. Remove the pressure cap. Using a funnel, add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level.

Refer to Cooling System Bleeding Procedure, page

3.91.

FLUID CAPACITY

Recommended Anti-Freeze/Coolant:

Premium Pre-Mixed Extended Life Antifreeze

(PN 2880514) (Quart)

(PN 2880513) (Gallon)

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MAINTENANCE

AIR INTAKE AND EXHAUST MAINTENANCE

AIR FILTER REPLACEMENT

Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often.

1. Tilt the rear cargo box to access the airbox.

2. Release the three airbox cover latches and lift the cover up and out to access the air filter element.

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 NOT attempt to clean the air filter.

5. Place the air filter into the airbox. Reposition the lower airbox cover and install the three retaining latches.

NOTE

Make sure the hinge pins are properly seated when

reassembling the airbox

3. Remove the air filter elementq.

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EXHAUST SPARK ARRESTOR INSPECTION

WARNING

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system becomes

very hot. Serious burns could result from contact with

the exhaust components. Allow components to cool

sufficiently before proceeding. Wear eye protection and

gloves.

Never run the engine in an enclosed area. Exhaust

contains poisonous carbon monoxide gas that can

cause loss of consciousnessor death in a very short

time.

Periodically clean spark arrestor to remove accumulated carbon.

1. Remove the retaining screw

2. Remove the spark arrestor silencer

3. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from screen with compressed air.

4. Inspect the screen for wear and damage. Replace if needed.

5. Reinstall the arrestor and torque the retaining screw to specification.

and nutw.

from the end of the

MAINTENANCE

TORQUE

Spark Arrestor:

8 ft-lbs (11 Nm)

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MAINTENANCE

EXHAUST HEAT SHIELD INSPECTION

Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly.

IMPORTANT

ITEM DESCRIPTION

Chassis Shield

Headpipe Shield, Top

Headpipe Shield, Bottom

Silencer Outlet Shield, End

Silencer Shield, Main

Silencer Outlet Shield, Elbow

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FUEL SYSTEM MAINTENANCE

MAINTENANCE

FUEL LINE INSPECTION

1. Check the quick-connect fuel lineqat the fuel pump for signs of wear, deterioration, damage or leakage. Replace line if necessary.

2. Tilt the rear cargo box and check the quick-connect fuel line deterioration, damage or leakage. Replace line if necessary.

at the fuel rail for signs of wear,

FUEL PUMP / FILTER INSPECTION

The fuel pump assemblyqis located in the fuel tank under the driver’s seat.

NOTE

The serviceable, high-volume, high-pressure, fuel

pump assembly includes a non-serviceable preliminary

filter

assembly. Refer to Fuel Pump Replacement, page

. The fuel pump must be replaced as an

4.23 procedure.

3. Be sure fuel lines are routed and retained properly.

NOTE

Make sure lines are not kinked or pinched.

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MAINTENANCE

FUEL TANK VENT LINE INSPECTION

NOTE

If the vent line fitting is removed from the fuel tank, it

must be replaced. The fitting will not hold properly once

it is removed.

1. Check the fuel tank vent line deterioration, damage or leakage. Replace every two years.

2. Be sure vent line is routed properly and secured.

for signs of wear,

NOTE

Be sure vent line is not kinked or pinched.

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PVT SYSTEM MAINTENANCE

DRIVE BELT INSPECTION

1. Remove PVT Cover.

2. 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.

3. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary.

4. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. Refer to “PVT Troubleshooting”, page

5.35 for possible causes.

PVT SYSTEM DRYING

IMPORTANT

After operating in water, the vehicle’s PVT system

should be checked immediately. Use the following

instructions to dry it out before operating.

MAINTENANCE

2. Allow the water to drain out completely.

3. Reinstall the drain plug and O-ring.

4. Place the transmission in PARK, apply the brake and start the engine.

5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.

NOTE

Do not hold the throttle pedal wide open for more than 5

seconds.

6. Allow the engine RPM to return to idle, then shift the transmission into low gear.

7. Test the PVT system for belt slippage. If the belt slips, repeat the process or remove the outer clutch cover to inspect the PVT system.

NOTE

If the vehicle has ingested a large amount of water into

the PVT system and has not been operated for a period

of time, be sure to check the PVT system components

for water damage.

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

and O-ring from the outer clutch cover.

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MAINTENANCE

TRANSMISSION AND FRONT GEARCASE MAINTENANCE

TRANSMISSION FLUID LEVEL INSPECTION

NOTE

It is important to follow the transmission maintenance

intervals described in the Periodic Maintenance Chart.

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the lubricant.

• Check vent hose to be sure it is routed properly and unobstructed.

The fill plug is located on the rear portion of the transmission gearcase. Access the fill plug at the rear of the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug

and check the lubricant level.

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 transmission drain plug.

3. Remove drain plug 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 lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

and allow lubricant to drain

3. If lubricant level is not even with bottom threads, add recommended lubricant as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

TORQUE

Transmission Fill / Drain Plug:

10-14 lb-ft (14-19 Nm)

2.48

FLUID CAPACITY

Recommended Transmission Lubricant:

AGL Gearcase Lubricant

(PN 2878068) (Quart)

Capacity: 41 oz (1200 mL)

7. Reinstall fill plug with a new O-ring and torque to specification.

TORQUE

Transmission Fill / Drain Plug:

10-14 lb-ft (14-19 Nm)

8. Check for leaks. Dispose of used lubricant properly.

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MAINTENANCE

SHIFT CABLE INSPECTION / ADJUSTMENT

Shift cable adjustment may be necessary if symptoms include:

• No gear position or AWD display on instrument cluster

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear lash (noise)

• Gear selector moving out of desired range

1. Locate the shift cable case in the right rear wheel well area.

2. Inspect shift cable, clevis pin, pivot bushings dust boot

. Replace if worn or damaged.

attached to the transmission

, and

FRONT GEARCASE FLUID LEVEL INSPECTION

NOTE

It is important to follow the front gearcase maintenance

intervals described in the Periodic Maintenance Chart.

The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

The fill plug is located on the bottom right side of the front gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Locate the gearcase fill plug

wheel well area.

through the right front

3. If adjustment is required, loosen the upper jam nut and pull the cable out of the mountwto move the lower jam nut

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 lower jam nut 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.

3. Remove the fill plug and check the fluid level.

4. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill.

5. Reinstall the fill plug and torque to specification.

TORQUE

Front Gearcase Fill / Drain Plug:

8-10 lb-ft (11-14 Nm)

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MAINTENANCE

FRONT GEARCASE FLUID REPLACEMENT

The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase.

1. Remove the fill plug.

2. Place a drain pan under the front gearcase drain plug.

3. Remove the drain plug completely.

and allow fluid to drain

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. Reinstall fill plug with a new O-ring and torque to specification.

TORQUE

Front Gearcase Fill / Drain Plug:

8-10 lb-ft (11-14 Nm)

8. Check for leaks. Dispose of used fluid properly.

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FINAL DRIVE MAINTENANCE

MAINTENANCE

DRIVE SHAFT BOOT INSPECTION

Inspect the front and rear drive shaft boots damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Check to see the boot clamps

are properly positioned.

for

WHEEL REPLACEMENT

1. Position the vehicle on a level surface.

2. Place the transmission in PARK and stop the engine.

3. Loosen the wheel nuts removal is required, remove the wheel cap

and loosen the hub nutrslightly.

NOTE

Limited Edition models with aluminum wheels require a

thin wall socket to loosen or tighten the wheel nuts

without damaging the finish of the rim. The wheel nut

requires a 19 mm thin wall socket with an O.D. less

than 24.7 mm to allow it to clear the rim.

slightly. If wheel hub

, cotter

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

8. Carefully lower the vehicle to the ground.

and finger tighten them.

NOTE

Limited Edition models with aluminum wheels require a

thin wall socket to loosen or tighten the wheel nuts

without damaging the finish of the rim. The wheel nut

requires a 19 mm thin wall socket with an O.D. less

than 24.7 mm to allow it to clear the rim.

9. Torque wheel nuts specification.

and/or hub nutrto the proper

TORQUE

Wheel Lug Nuts (Aluminum Wheels):

120 ft-lbs (163 Nm)

Wheel Hub Castle Nut (front):

80 ft-lbs (108 Nm)

Wheel Hub Castle Nut (rear):

110 ft-lbs (149 Nm)

NOTE

Do not lubricate the stud or the lug nut.

10.If wheel hub nut was removed, install a new cotter pin

after the hub castle nut has been tightened. If the

holes do not line up, turn the castle nut counterclockwise until the cotter pin can be installed.

CAUTION

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered wheel

nuts, make sure tapered end of nut goes into taper on

wheel.

4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts

and remove the wheelt.

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MAINTENANCE

TIRE INSPECTION

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect vehicle handling.

MEASUREMENT

Tire Lug Service Limit:

Replace if 1/8″ (3 mm) or less.

WARNING

Operating with worn tires will increase the possibility of

the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident. Always replace tires

when the usable tread 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 tire pressure decal applied to the

vehicle.

Tire Pressure Inspection (Cold)

Front

Rear

2.52

RANGER XP 1000

10 psi / 69 kPa 14 psi / 96 kPa

14 psi / 96 kPa 16 psi / kPa

NORTHSTAR

EDITION

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STEERING MAINTENANCE

MAINTENANCE

STEERING SYSTEM INSPECTION

Steering system components should be checked periodically for loose fasteners rod fasteners arm ball joints and general damage.

Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

, loose steering shaft U-jointse, worn A-

, worn tie rod ends / tie

STEERING WHEEL FREE-PLAY

Check steering wheel for specified free-play and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be about 0.8-1.0″ (20-25 mm) of freeplay.

4. If there is excessive free-play or the steering feels rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints

• Steering Gearbox

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.

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TIE ROD END INSPECTION

• To check for play in the tie rod endq, grasp the steering tie rod, pull in all directions feeling for movement.

• Replace any worn steering components. Steering should move freely through entire range of travel without binding.

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front wheel/ hub assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

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 position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires approximately 10 in (25.4 cm) from the floor or as close to the hub/axle center line as possible

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).

NOTE

It is important the height of both marks be equally

positioned to get an accurate measurement.

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MAINTENANCE

3. Measure the distance between the marks and record the measurement. Call this measurement

4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

5. Measure the distance between the marks and record. Call this measurement from measurementw, this is the vehicle toe. The recommended vehicle toe tolerance is toe out. This means the front of the tire measurement at the rear

. Subtract measurement

is wider than the

WHEEL TOE ADJUSTMENT

If toe alignment is incorrect, repeat steps 3-5 of “Wheel Toe Alignment Inspection”, but instead measure the distance between vehicle center and each 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.

MEASUREMENT

Wheel Toe-Out:

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 may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Wheel Toe Inspection, page 2.54.

IMPORTANT

When tightening the tie rod end jam nuts, the rod ends

must be held parallel to prevent rod end damage and

premature wear. Damage may not be immediately

apparent if done incorrectly.

• After alignment is complete, torque jam nuts to specification.

TORQUE

Tie Rod Jam Nut:

13 ft-lbs (18 Nm)

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MAINTENANCE

SUSPENSION MAINTENANCE

SUSPENSION INSPECTION

Compress and release the suspension. Damping should be smooth throughout the range of travel.

• Check all suspension components and mounting fasteners for wear or damage.

• Inspect each shock body for leakage.

SPRING PRE-LOAD ADJUSTMENT

The front and rear shock absorber springs are adjustable. Rotate the adjuster cam increase or decrease spring tension. Always adjust both left and right sides equally.

NOTE

Adjusting all shock cams equally will only affect ride

height as the weight transfer will not be changed.

either direction to

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 main frame.

CAUTION

Serious injury may result if machine tips or falls. Be

sure machine is secure before adjusting.

2. Remove the upper shock mounting bolts each side of the vehicle.

3. Reposition the upper shock mounts to the outside mounting holes

FRONT SHOCK

from

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

REAR SHOCK

4. Reinstall the upper shock mounting bolts and torque to specification.

TORQUE

Shock Mounting Bolts:

40 ft-lbs (54 Nm)

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BRAKE SYSTEM MAINTENANCE

MAINTENANCE

BRAKE FLUID LEVEL INSPECTION

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake master cylinder reservoir through the front left wheel well.

can be accessed

BRAKE FLUID REPLACEMENT / BRAKE BLEEDING

NOTE

When bleeding the brakes or replacing the fluid always

start with the furthest caliper from the master cylinder.

This procedure should be used to change fluid or bleed

brakes during regular maintenance.

1. Position the vehicle on a level surface.

2. Place the gear selector in Park.

3. View the brake fluid level 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.

CAUTION

Always wear safety glasses.

CAUTION

Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact with finished

surfaces.

1. Locate master cylinder reservoir hand wheel well area. Clean reservoir cover thoroughly.

in the front left-

2. Remove cover from reservoir.

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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.

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.

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 service. Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2" (1.3 cm).

17.Check brake system for fluid leaks.

8. Place a small amount of fresh brake fluid into a small, clear container and place the other end of bleeder hose into the container.

9. Have an assistant slowly pump the brake pedal until pressure builds and then hold.

10.Quickly open and close the bleed screw while holding pressure on the brake pedal.

NOTE

Do not release brake pedal before bleeder screw is

tight or air may be drawn into master cylinder.

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MAINTENANCE

BRAKE PAD INSPECTION

1. Check the brake pads looseness.

2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material is worn below specification.

MEASUREMENT

Brake Pad Thickness (Minimum):

0.150" (3.8 mm)

for wear, damage, or

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” (0.051 mm)

difference between measurements

BRAKE HOSE AND FITTING INSPECTION

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

BRAKE DISC INSPECTION

1. Visually inspect disc for scoring, scratches or gouges. Replace disc if any are evident.

2. Use a 0-1" micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit.

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MAINTENANCE

ELECTRICAL MAINTENANCE

BATTERY MAINTENANCE

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related

accessories contain lead and lead compounds, and

other chemicals known to the State of California to

cause cancer and birth defects or other reproductive

harm.

WASH HANDS AFTER HANDLING.

WARNING

Battery electrolyte is poisonous. 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. away. Ventilate

when charging or using in an enclosed space.

Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

BATTERY REPLACEMENT

REMOVAL

1. Flip up passenger seat. .

2. Remove battery cover.

NOTE

Batteries must be fully charged before use or battery

life will be reduced by 10-30% of full potential. Charge

battery according to “Charging Procedure” provided in

Chapter 10. Do not use the vehicle’s stator/alternator to

charge a new battery.

2.60

3. Disconnect the black (negative) battery cablew.

4. Disconnect the red (positive) battery cablee.

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CAUTION

To reduce the chance of sparks, disconnect the black

(negative) cable first. When reinstalling the battery,

connect the black (negative) cable last.

5. Remove Battery Bracket Fastener Remove Battery.

INSTALLATION

and Brackete.

NOTE

Using a new battery that has not been fully charged can

damage the battery and result in a shorter life. It can

also hinder vehicle performance. SeeBattery Charging

Procedure , page 11.48 before installing the battery.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Install 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 flip down passenger seat.

CHASSIS / ENGINE ELECTRICAL GROUND

Inspect the ground cable connections. Remove ground terminals and clean if necessary.

1. Remove the passenger seat base and storage bin to access the chassis ground terminal the starter solenoid

next to the battery.

, located below

1. Ensure the battery is fully charged.

2. Place the battery in the vehicle. Install Bracket Battery Bracket Fastener specification.

. Torque fastener to

TORQUE

Battery Bracket Fastener:

3.5 ft-lbs (5 Nm)

and

2. Inspect the chassis ground terminals. Be sure they are clean and tight.

3. Inspect the engine ground terminal, attached to the upper starter mounting bolt. The other end of the engine ground cable is attached to the chassis ground terminal).

4. Inspect the engine ground terminals. Be sure they are clean and tight.

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SPARK PLUG REPLACEMENT

Inspect and replace the spark plugs at the intervals outlined in the Maintenance Intervals, page 2.7.

1. Tilt the rear cargo box to access the top of the engine.

WARNING

A hot engine can cause serious burns. Allow engine to

cool or wear protective gloves when removing the spark

plugs.

2. Remove the spark plug caps

9. If necessary, replace spark plug with proper type.

CAUTION

Severe engine damage may occur if the incorrect spark

plug is used.

Recommended Spark Plugs:

NGK MR7F

10.Apply anti-seize compound to the spark plug threads.

11. Install spark plugs and torque to specification.

TORQUE

Spark Plug:

9 ft–lbs (12 Nm)

12.Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals (B). Ensure wires are pushed down all the way so they engage onto the spark plugs.

NOTE

MAG and PTO reference decals on spark plug wires for

reassembly.

3. Clean out plug wells with compressed air to remove any loose dirt or debris.

4. Rinse plug wells with water and dry with compressed air.

NOTE

Spark plug wells have drain holes built into the cylinder

head to allow water to drain out.

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 bending the side electrode.

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THROTTLE PEDAL INSPECTION

Inspect the throttle pedalwfor 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

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MAINTENANCE

NOTES

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ENGINE / COOLING / EXHAUST

CHAPTER 3

ENGINE / COOLING / EXHAUST

GENERAL INFORMATION - ENGINE .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . 3.5

SPECIAL TOOLS - ENGINE / COOLING SYSTEM. . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . . 3.5

ENGINE LUBRICATION SPECIFICATIONS . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . . 3.5

OIL PRESSURE TEST. . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . 3.6

ENGINE OIL FLOW CHART . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . 3.7

ENGINE BREAK-IN PERIOD . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . 3.8

ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . 3.9

SERVICE SPECIFICATIONS - ENGINE / COOLING .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . 3.9

ENGINE TORQUE SPECIFICATIONS... . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . 3.11

INTAKE / EXHAUST SERVICE . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . .3.13

INTAKE SYSTEM ASSEMBLY VIEW .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . .3.13

INTAKE MANIFOLD REMOVAL . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . ..3.15

INTAKE MANIFOLD INSTALLATION . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . ..3.17

EXHAUST SYSTEM ASSEMBLY VIEW . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .3.19

ENGINE SERVICE . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . .3.20

ACCESSIBLE 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

CYLINDER HEAD DISASSEMBLY . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . ..3.34

VALVE INSPECTION . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . ..3.35

COMBUSTION CHAMBER CLEANING . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .3.36

VALVE SEALING TEST . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . .3.36

VALVE SEAT RECONDITIONING . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .3.37

ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .3.40

STATOR COVER REMOVAL / INSPECTION . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .3.40

WATER PUMP HOUSING REMOVAL . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .3.41

FLYWHEEL REMOVAL .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . .3.42

STARTER ONE-WAY CLUTCH DISASSEMBLY . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. ..3.43

CRANKCASE DISASSEMBLY / INSPECTION.. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .3.44

BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. .3.46

CRANKSHAFT REMOVAL / INSPECTION . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . ..3.47

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CRANKCASE INSPECTION . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . .3.49

CYLINDER INSPECTION .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .3.50

CYLINDER / PISTON REMOVAL. .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .3.51

PISTON DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . .3.52

PISTON RING REMOVAL... . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . .3.53

PISTON RING TO GROOVE CLEARANCE INSPECTION . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . .3.53

PISTON RING INSTALLED GAP . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . .3.54

PISTON-TO-CYLINDER CLEARANCE . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . .3.54

CONNECTING ROD INSPECTION . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . ..3.55

ENGINE ASSEMBLY - LOWER END . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . .3.57

BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . .3.57

CONNECTING ROD BEARING SELECTION . . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . .3.58

CRANKSHAFT MAIN BEARING SELECTION . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . .3.58

UPPER CRANKCASE PREPARATION. . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .3.59

PISTON RING INSTALLATION . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . .3.59

PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . .3.61

CYLINDER / PISTON INSTALLATION. .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. .3.62

CRANKSHAFT INSTALLATION . . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .3.64

BALANCE SHAFT INSTALLATION . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . .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 COVER INSTALLATION. . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .3.84

COOLING SYSTEM SERVICE . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . .3.85

COOLING SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . .3.85

COOLING SYSTEM SPECIFICATIONS . . . . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .3.86

COOLING SYSTEM PRESSURE TEST . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .3.86

RADIATOR CAP PRESSURE TEST. .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . .3.87

RADIATOR REMOVAL / INSTALLATION . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . ..3.88

RADIATOR FAN REMOVAL.. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . ..3.89

THERMOSTAT REPLACEMENT . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .3.90

COOLING SYSTEM BLEEDING PROCEDURE . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . .3.91

WATER PUMP REMOVAL . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .3.93

WATER PUMP INSTALLATION . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. ..3.94

WATER PUMP SERVICE .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . .3.95

TROUBLESHOOTING - ENGINE / COOLING SYSTEM .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . .3.98

ENGINE TROUBLESHOOTING. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .3.98

COOLING SYSTEM TROUBLESHOOTING . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .3.99

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HVAC SYSTEM . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . 3.100

GENERAL INFORMATION - HVAC.. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . 3.100

HVAC SYSTEM FASTENER TORQUES . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . 3.100

SPECIAL TOOLS - HVAC . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . . 3.100

HVAC SYSTEM TIMING . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . 3.100

HVAC SYSTEM OVERVIEW . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. 3.101

AIR CONDITIONING DESCRIPTION. . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . 3.101

HVAC ASSEMBLY VIEW.. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . 3.102

HVAC AND HEATER LINES . . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. 3.102

HVAC DUCTING. . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . 3.103

A/C SYSTEM DIAGRAM .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . 3.104

SAFETY EQUIPMENT .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . 3.105

HVAC SYSTEM COMPONENTS . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . 3.105

HVAC MAINTENANCE . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . 3.108

COMPRESSOR DRIVE BELT INSPECTION .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . 3.108

A/C CONDENSER CLEANING . . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . 3.109

HVAC FILTER INSPECTION / REPLACEMENT . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. 3.110

REFRIGERANT . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . 3.110

RECLAMATION AND CHARGING WITH RECOVERY / CHARGING UNIT . . . . .. . . . .. . . . . . .. . . . .. . . . ..3.111

HVAC SYSTEM SERVICE . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. 3.112

COMPRESSOR DRIVE BELT REPLACEMENT . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . 3.112

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

HEATER / EVAPORATOR UNIT REPLACEMENT . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . 3.122

HEATER / EVAPORATOR UNIT REMOVAL . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . . 3.122

HEATER / EVAPORATOR UNIT INSTALLATION . . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. . . 3.123

HEATER COIL REPLACEMENT . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . 3.124

BLOWER UNIT REPLACEMENT . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . 3.124

A/C THERMOSTAT OVERVIEW . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . 3.125

HEATER VALVE REPLACEMENT. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . . . .. . . . .. 3.125

HVAC CONTROL SERVICE . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . . 3.126

HVAC CONTROL OPERATION OVERVIEW . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . 3.126

A/C SWITCH TESTING . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . 3.126

FAN SWITCH TESTING .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . . . . .. . 3.126

TEMPERATURE POTENTIOMETER TESTING .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . 3.126

HVAC BREAKOUT DIAGRAM .. . . . .. .. . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . .. . . 3.127

TROUBLESHOOTING - HVAC. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . 3.128

BLOWER MOTOR DOES NOT OPERATE . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . 3.128

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BLOWER MOTOR OPERATES NORMALLY BUT AIR FLOW IS 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

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GENERAL INFORMATION - ENGINE

ENGINE / COOLING / EXHAUST

SPECIAL TOOLS - ENGINE / COOLING SYSTEM

TOOL DESCRIPTION PART NUMBER

Engine Stand (2″ Bore)

Engine Stand Adapter (Mounts To The Engine)

Engine Stand Sleeve Adapter (Use With 2” Bore Stand)

Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)

Cylinder Holding & Camshaft Timing Plate

Flywheel Puller

Mity Vac™ Pressure Test Tool

Oil Filter Wrench PU-50105

Oil Pressure Gauge

Oil Pressure Gauge Adapter

Piston Ring Compressor Pliers

Valve Spring Compressor

Valve Spring Compressor Adapter

PU-50624

PU-50562

PU-50625

PW-47054

PU-50563

PA-49316

2870975

PV-43531

PU-52492

PV-43570-1

PV-1253 or PV-4019 (Quick Release)

PV-43513-A

ENGINE LUBRICATION SPECIFICATIONS

FLUID CAPACITY

Oil Capacity *

2.5 qt (2.4 L)

Oil Type

PS-4 Full Synthetic 5W-50

2876244 (quart)

2876245 (gallon)

(-35° F to 100° F)

PS-4 Extreme Duty

2878920 (quart)

2878919 (gallon)

Oil Filter Wrench

PU-50105 or 2.5″ (64 mm)

Oil Filter

PN 2540086

Oil Pressure Minimum Specification (using Polaris

engine oil at operating temperature)

10 PSI @ 1200 RPM 40 PSI @ 7000 RPM

*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

Water Pump Mechanical Seal Installer

Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/

PU-50564

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OIL PRESSURE TEST

1. Attach the Oil Pressure Gauge Adapter (PU-52492) to the Oil Pressure Gauge (PV-43531).

Oil Pressure Gauge Adapter: PU-52492

Oil Pressure Gauge: PV-43531

2. Raise the dropbox to access the engine.

3. Clean the area around the main oil gallery plug , located in the upper crankcase on the MAG side of the engine.

4. Remove the crankcase gallery plug oil pressure adapter.

and insert the

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 Specification (Engine Hot):

Minimum @ 1200 RPM: 10 PSI Minimum @ 7000 RPM: 40 PSI

6. Upon assembly, torque the crankcase gallery plug to specification.

TORQUE

Crankcase Oil Gallery Plug:

22 ft-lbs (30 Nm)

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ENGINE BREAK-IN PERIOD

The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION

Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic

4-Cycle Engine Oil.Never substitute or mix oil brands.

Serious engine damage and voiding of warranty can

result. Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

1. Fill fuel tank with 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 gradually bring engine up to operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important bolt torques.

6. Change oil and oil filter after 25 hour break-in period.

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