Polaris RANGER XP 900 (2019) Service manual

2018-2019 RANGER XP/ CREW 900/1000
Service Manual
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.
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.
FOREWORD
®
technicians in a properly
Publication Printed July 2018 (PN 9929399 R01)
© Copyright 2018 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.
SAFETY WARNINGS
The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTICE provides key information by clarifying instructions.
injury.
CAUTION
injury.
CAUTION
NOTICE
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
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 7/13/18
For more detailed information on vehicle updates, refer to the applicable Model Year Update training module at: www.mytrainingandrewards.com .
Initial release
CHANGES
2018-2019 RANGER XP/ CREW 900/1000
Service Manual
Chapter Summary
CHAPTER 1: GENERAL INFORMATION
CHAPTER 2: MAINTENANCE
CHAPTER 3: ENGINE / COOLING / HVAC SYSTEM
CHAPTER 4: FUEL SYSTEM
CHAPTER 5: PVT SYSTEM
CHAPTER 6: TRANSMISSION
CHAPTER 7: FINAL DRIVE
CHAPTER 8: STEERING / SUSPENSION
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SERVICE RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIAL TOOLS WEBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS INDEX.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MASTER TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21
2018-19 RANGER XP 900 / EPS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
2018-19 RANGER XP 900 / EPS SPECIFICATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
2018-19 RANGER CREW XP 900 / EPS OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
2018-19 RANGER CREW XP 900 / EPS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
2018 RANGER XP 1000 HIGH LIFTER OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
2018 RANGER XP 1000 HIGH LIFTER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
2018 RANGER CREW XP 1000 / EPS OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27
2018 RANGER CREW XP 1000 / EPS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
CONVERSION TABLE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
STANDARD BOLT TORQUE SPECIFICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.31
METRIC BOLT TORQUE SPECIFICATION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.31
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
DECIMAL EQUIVALENTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
1.1
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. Notice, 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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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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GENERAL INFORMATION
PUBLICATION NUMBERS
MODEL MODEL NO.
2018 RANGER XP 900 / EPS
2018 RANGER XP 900 EU
2018 RANGER XP 900 EPS EU
2018 RANGER CREW XP 900 / EPS R18RVA87A1 / R18RVE87A9 9928295
2018 RANGER CREW XP 1000 / EPS
2019 RANGER XP 900 / EPS
2019 RANGER CREW XP 900 / EPS
R18RTA87A1, A9, B1, B9 / R18RTE87A1, A4, AB, AM, B4, BB
R17RTE87F1, FU / R17RTS87F1 / FU
R18RTS87C1, F1
R18RSE99AS, BS / R18RRE99A1, A9, AM, AS, AX, B9, BM, BS, BX
R19RTA87A1 / A9 / B1 / B9 R19RTE87A1 / A4 / AE / AH / AZ / B1 / B4 / BE / BH / BZ
R19RVA87A1 / B1 R19RVE87A9 / B9 / AH / BH
NOTICE
When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.
OWNER’S
MANUAL
9928295
9928407
9928407
9928300
9928851
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.
1
SERIES# PART NUMBER
20 4010278
21 4010278
22 4010321
23 4010321
27
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
4010321
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
1.3
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
CHAPTER 2 — MAINTENANCE
Oil Filter Wrench PU-50105
CHAPTER 3 — ENGINE / COOLING SYSTEM
Drive Clutch Puller 2872085
Shock Spanner Wrench 2871095
Engine Stand Adapter (Mounts To The Engine) PU-50562
GENERAL INFORMATION
1
Engine Stand Sleeve Adapter (Use With 2” Bore Stand) PU-50625
Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand) PW-47054
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
Engine Stand (2” Bore) PU-50624
Clutch Center Distance Tool PU-50658-A
1.5
GENERAL INFORMATION
CHAPTER 3 — ENGINE / COOLING SYSTEM
Oil Pressure Gauge Adapter
PU-52492
Oil Pressure Gauge PV-43531
Cylinder Holding & Camshaft Timing Plate PU-50563
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CHAPTER 3 — ENGINE / COOLING SYSTEM
Valve Spring Compressor Adapter PV-43513-A
Flywheel Puller PA-49316
GENERAL INFORMATION
Piston Ring Compressor Pliers PV-43570-1
1
Spring Puller PU-45485
Mityvac® Pressure Test Tool 2870975
Water Pump Mechanical Seal Installer PU-50564
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
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GENERAL INFORMATION
CHAPTER 3 — HVAC
Refrigerant Recovery / Recycle /Recharging Machine PU-51021
Crankshaft Pulley Holder PU-52254
CHAPTER 4 — FUEL SYSTEM
Fuel Pressure Gauge Kit PU-43506-A
Recharge Service Kit (for PU-51021) PU-51021-1
Fuel Pressure Gauge Adapter PS-48762
HVAC Belt Tool PU-52087
Fuel Pump Service Tool PU-50326
Digital Wrench® Diagnostic Kit PU-47063-B
1.8
Digital Wrench® Software PU-48731
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
Digital Wrench® Standard Interface Cable PU-47151
© Copyright Polaris Industries Inc.
CHAPTER 4 — FUEL SYSTEM
Digital Wrench® USB-Serial Adapter Cable PU-50621
Digital Wrench® SmartLink Module Kit PU-47471
GENERAL INFORMATION
Digital Wrench® PC Interface Cable PU-47470
1
Digital Wrench® Vehicle Interface Cable PU-47469
Digital Wrench® SmartLink Module PU-47468
Wireless Vehicle Link (WVL) PU-51435
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
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GENERAL INFORMATION
CHAPTER 5 — PVT SYSTEM
Clutch Bushing Replacement Tool Kit 2871025
Clutch Bushing Replacement Tool Kit 2871226
Clutch Holding Fixture 2871358-A
Drive Clutch Holding Tool 9314177-A
Drive Clutch Spider Removal and Installation Tool 2870341
Roller Pin Tool 2870910
Drive Clutch Puller PA-48595
Piston Pin Puller 2870386
Universal Clutch Compressor PU-50518
Drive Clutch Puller 2872085
Bushing Replacement Tool PA-47336
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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CHAPTER 6 — TRANSMISSION
Drive Clutch Puller PA-48595
Drive Clutch Puller 2872085
GENERAL INFORMATION
Clutch Center Distance Tool PU-50658-A
1
Snorkel Tool PA-50231
CHAPTER 7 — FINAL DRIVE
Roll Pin Removal Tool 2872608
Rear Output Seal Driver 2871698
Axle Boot Clamp Tool PU-48951
Rear Driveshaft Seal Guide 2871699
CV Boot Clamp Pliers 8700226
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
1.11
GENERAL INFORMATION
CHAPTER 8 — STEERING / SUSPENSION
Ball Joint Tool PU-50506
CHAPTER 9 — BRAKE SYSTEM
Mityvac® Pressure Test Tool 2870975
Spring Compressor Tool 2870623
Shock Spanner Wrench 2871095
CHAPTER 10 — BODY / FRAME
Multi-Function Pliers 2876389
1.12
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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CHAPTER 11 — ELECTRICAL
PV-43568 Fluke™ 77 Digital Multimeter PF-51237
Static Timing Light Harness 2871745
GENERAL INFORMATION
Hall Effect Sensor Probe Harness 2460761
1
Battery Conductance Analyzer (MDX-610P) PU-50296
Relay Bypass PU-49466
Connector Test Kit PV-43526
Timing Light 2870630
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
1.13
GENERAL INFORMATION
MASTER TORQUE LIST
CHAPTER 2 — MAINTENANCE
PART DESCRIPTION
Crankcase Drain Plug 12 lb-ft (16 Nm)
Spark Plug 7 lb-ft (10 Nm)
Valve Cover Bolts 7 lb-ft (10 Nm)
Outer Clutch Cover Screws
Tensioner Mounting Bolts
Plunger Bolt
Transmission Fill / Drain Plug
Front Gearcase Fill / Drain Plug
Radiator Hose Clamp 3 lb-ft (4 Nm)
Wheel Nuts (Steel Wheels)
Wheel Nuts (Cast Aluminum Wheels)
Front Wheel Hub Castle Nuts
Rear Wheel Hub Castle Nuts
Tie Rod Jam Nut
Shock Mounting Bolts 40 lb-ft (54 Nm)
CHAPTER 3 — ENGINE / COOLING SYSTEM
PART DESCRIPTION
Starter Motor Bolts 7 lb-ft (10 Nm)
Transmission Joint Bracket Bolts
Engine / Transmission Mounting Bolts Step 1–2
Engine / Transmission Mounting Bolts Step 3
Engine / Transmission Mounting Bolts Step 4–7
Front Engine Mount Fasteners
TORQUE
SPECIFICATION
45-50 lb-in (5 Nm)
7 ft-lb (10 Nm)
15 ft-lb (20 Nm)
10-14 lb-ft (14-19 Nm)
8-10 lb-ft (11-14 Nm)
60 lb-ft (81 Nm)
120 lb-ft (163 Nm)
80 lb-ft (108 Nm)
110 lb-ft (149 Nm)
13 lb-ft (18 Nm)
TORQUE
SPECIFICATION
44 lb-ft (60 Nm)
64 lb-ft (87 Nm)
5 lb-ft (7 Nm)
44 lb-ft (60 Nm)
40 lb-ft (54 Nm)
CHAPTER 3 — ENGINE / COOLING SYSTEM
PART DESCRIPTION
Intake Plenum Hose Clamps
Lower Intake Plenum Fastener
Fuel Rail Mounting Bolts
Crankcase Gallery Plug (M20)
Camshaft Carrier Bolts 7 lb-ft (10 Nm)
Connecting Rod Bolts Step 1
Connecting Rod Bolts Step 2
Connecting Rod Bolts Step 3
Lower Crankcase Bolts Step 1 (M10)
Lower Crankcase Bolts Step 2 (M10)
Lower Crankcase Bolts Step 3 (M10)
Lower Crankcase Bolts (M8)
Lower Crankcase Bolts (M6)
Upper Crankcase Bolts (M8)
Upper Crankcase Bolts (M6)
Oil Pump Mounting Bolts 7 lb-ft (10 Nm)
Oil Pump Pick-Up Retaining Screws
Oil Sump Cover Bolts (M6)
Oil Sump Cover Bolts (M8)
Crankcase Drain Plug 12 lb-ft (16 Nm)
Oil Cooler Retaining Bolts 7 lb-ft (10 Nm)
TORQUE
SPECIFICATION
17 lb-in (2 Nm)
22 lb-ft (30 Nm)
5 lb-ft (7 Nm)
22 ft-lbs (30 Nm)
9 lb-ft (12 Nm)
22 lb-ft (30 Nm)
Additional 90°
9 lb-ft (12 Nm)
21 lb-ft (28 Nm)
Additional 90°
26 lb-ft (35 Nm)
9 lb-ft (12 Nm)
26 lb-ft (35 Nm)
7 lb-ft (10 Nm)
7 lb-ft (10 Nm)
9 lb-ft (12 Nm)
26 lb-ft (35 Nm)
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GENERAL INFORMATION
CHAPTER 3 — ENGINE / COOLING SYSTEM
PART DESCRIPTION
One Way Clutch Retaining Screws
Flywheel Retaining Bolt
Stator Cover Screws 9 lb-ft (12 Nm)
Cylinder Head Bolts Step 1
Cylinder Head Bolts Step 2
Cylinder Head Bolts Step 3
Cylinder Head Bolts (M6) 7 lb-ft (10 Nm)
Cam Chain Tensioner 30 lb-ft (40 Nm)
Camshaft Sprocket Bolts 11 lb-ft (15 Nm)
Valve Cover Bolts 7 lb-ft (10 Nm)
Engine Intake Duct Clamps
Air Box Fasteners
Exhaust Headpipe Mounting Bolts
Thermostat Cover Bolts 7 ± 1 lb-ft (10 ± 1 Nm)
Coolant Bleed Screw 7 ± 1 lb-ft (10 ± 1 Nm)
Water Pump Mounting Bolts
Water Pump Impeller Bolt
Water Pump Cover Bolts 7 lb-ft (10 Nm)
CHAPTER 3 — HVAC
ITEM
Alternator Mounting Fasteners
Alternator Cover Fasteners
Compressor Low Pressure Hose
Compressor High Pressure Hose
Compressor Mounting Fasteners
TORQUE
SPECIFICATION
9 lb-ft (12 Nm)
133 lb-ft (180 Nm)
9 lb-ft (12 Nm)
26 lb-ft (35 Nm)
Additional 180°
17 lb-in (2 Nm)
8 lb-ft (11 Nm)
18 lb-ft (24 Nm)
7 lb-ft (10 Nm)
7 lb-ft (10 Nm)
TORQUE VALUE
37 lb-ft (50 Nm)
48 lb-in (5.4 Nm)
25 lb-ft (34 Nm)
18 lb-ft (24 Nm)
37 lb-ft (50 Nm)
CHAPTER 3 — HVAC
ITEM
Compressor Oil Drain Plug
HVAC Timing Wheel Fasteners
HVAC Cover Mount Fasteners
HVAC Drive Pulley Fastener
Upper Condenser Hose 18 ft-lb (24 Nm)
Lower Condenser / Receiver-Drier Hose
Condenser Upper Mounting Bolt
Condenser Lower Mounting Bolts
Expansion Valve High / Low Pressure Hoses
Expansion Valve Tubes 22 ft-lb (30 Nm)
Heater Valve Fasteners
CHAPTER 4 — FUEL SYSTEM
PART DESCRIPTION
Fuel Tank Bracket Fasteners
Fuel Pump PFA Nut
ECU Retaining Screws 24 lb-in (2.7 Nm)
ETC Housing Retaining Bolts
Intake Boot Clamp 3 lb-ft (4 Nm)
CPS Retaining Bolt 9 lb-ft (12 Nm)
T-MAP Retaining Bolt
ECT Sensor 17 lb-ft (23 Nm)
Throttle Pedal Assembly Nuts
Throttle Pedal Bracket Nuts
Fuel Rail Mounting Screws
Ignition Coil Retaining Bolt
TORQUE VALUE
10 ft-lb (14 Nm)
9 lb-ft (12 Nm)
9 lb-ft (12 Nm)
44 lb-ft (60 Nm) + 180°
12 ft-lb (16 Nm)
14 ft-lb (19 Nm)
8 ft-lb (11 Nm)
12 ft-lb (16 Nm)
8 lb-ft (11 Nm)
TORQUE
SPECIFICATION
8 lb-ft (11 Nm)
70 lb-ft (95 Nm)
7 lb-ft (10 Nm)
7 lb-ft (10 Nm)
8 lb-ft (11 Nm)
18 lb-ft (24 Nm)
7 lb-ft (10 Nm)
8 lb-ft (11 Nm)
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
1.15
GENERAL INFORMATION
CHAPTER 5 — PVT SYSTEM
TORQUE
PART DESCRIPTION
SPECIFICATION
Inner Clutch Cover Bolts 10 lb-ft (14 Nm)
Drive Clutch Retaining
96 lb-ft (130 Nm)
Bolt
Driven Clutch Retaining
38 lb-ft (52 Nm)
Bolt (900)
Driven Clutch Retaining
43 lb-ft (58 Nm)
Bolt (1000)
Outer Clutch Cover
4 lb-ft (6 Nm)
Retaining Screws
PVT Duct Hose Clamps 3 lb-ft (4 Nm)
Grease Zerk Fitting 4 lb-ft (6 Nm)
Airbox Mounting Screws 8 lb-ft (11 Nm)
Shift Weight Nuts 20 lb-in (2.3 Nm)
Drive Clutch Spider 290 lb-ft (393 Nm)
Drive Clutch Jam Nut 250 lb-ft (339 Nm)
Drive Clutch Cover Bolts 9 lb-ft (12 Nm)
Driven Clutch Retaining
9–12 lb-ft (12–16 Nm)
Ring Bolts
Driven Clutch Torx
48 lb-in (5 Nm)
Screws
CHAPTER 6 — TRANSMISSION
TORQUE
PART DESCRIPTION
Engine / Transmission Mounting Bolts Step 1–2
Engine / Transmission Mounting Bolts Step 3
Engine / Transmission Mounting Bolts Step 4–7
Rear Transmission Transverse Bolt
Isolator Mount Bolts
Intake Plenum Hose Clamps
Lower Intake Plenum Fastener
SPECIFICATION
64 lb-ft (87 Nm)
5 lb-ft (7 Nm)
44 lb-ft (60 Nm)
40 lb-ft (54 Nm)
22 lb-ft (30 Nm)
17 lb-in (2 Nm)
22 lb-ft (30 Nm)
CHAPTER 6 — TRANSMISSION
TORQUE
PART DESCRIPTION
Differential Cover Screws (8.8 Fastener)
Differential Cover Screws (10.9 Fastener)
Bearing Cover Retaining Screws
SPECIFICATION
18–22 lb-ft (24–30 Nm)
28 ft-lbs (38 Nm)
8–10 lb-ft (11–14 Nm)
Snorkel Locking Screw 8–10 lb-ft (11–14 Nm)
Shift Fork Screws
Transmission Case Bolts
Sector Cover Bolts
Transmission Fill / Drain Plug
Bellcrank Nut
17 lb-ft (23 Nm)
15–20 lb-ft (20–27 Nm)
9–12 lb-ft (12–16 Nm)
10-14 lb-ft (14-19 Nm)
12–18 lb-ft (16–24 Nm)
CHAPTER 7 — FINAL DRIVE
TORQUE
PART DESCRIPTION
Ball Joint Pinch Bolts
Tie Rod End Fastener
Front Caliper Mounting
SPECIFICATION
42 lb-ft (57 Nm)
40 lb-ft (54 Nm)
30 lb-ft (41 Nm)
Bolts
Front Wheel Hub Castle
80 lb-ft (108 Nm)
Nuts
Wheel Nuts (Steel
60 lb-ft (81 Nm)
Wheels)
Wheel Nuts (Cast
120 lb-ft (163 Nm)
Aluminum Wheels)
Flex Bearing Mounting
40 lb-ft (54 Nm)
Fasteners
Front Gearcase Cover
7–11 lb-ft (10–15 Nm)
Plate Screws
Front Gearcase Mounting
30 lb-ft (41 Nm)
Bolts
Bearing Carrier Fasteners 40 lb-ft (54 Nm)
Rear Wheel Hub Castle
110 lb-ft (149 Nm)
Nuts
Rear Caliper Mounting
46 lb-ft (62 Nm)
Bolts
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GENERAL INFORMATION
CHAPTER 8 — STEERING / SUSPENSION
PART DESCRIPTION
Steering Gear Box Pinch Bolt
Steering Wheel Tilt Assembly Fasteners
Steering Wheel Nut 65 lb-ft (88 Nm)
EPS Unit Mount Bolts 30 lb-ft (41 Nm)
EPS Unit Frame Bolts 14 lb-ft (19 Nm)
EPS Unit Pinch Bolts 15 lb-ft (20 Nm)
Tie Rod Jam Nut
Shock Mounting Bolts 40 lb-ft (54 Nm)
Lower A-Arm Fasteners
Ball Joint Pinch Bolts
Wheel Nuts (Steel Wheels)
Wheel Nuts (Cast Aluminum Wheels)
Upper A-Arm Fasteners
Front Caliper Mounting Bolts
Stabilizer Bar Fasteners 17 lb-ft (23 Nm)
CHAPTER 9 — BRAKE SYSTEM
PART DESCRIPTION
Caliper Bleed Screws 47 lb-in (5.3 Nm)
Brake Line Banjo Bolts
Master Cylinder Mounting Bolts
Brake Pedal Mount Bracket Nuts
Front Caliper Mounting Bolts
Wheel Nuts (Steel Wheels)
Wheel Nuts (Cast Aluminum Wheels)
TORQUE
SPECIFICATION
48 lb-ft (65 Nm)
40 lb-ft (54 Nm)
13 lb-ft (18 Nm)
40 lb-ft (54 Nm)
42 lb-ft (57 Nm)
60 lb-ft (81 Nm)
120 lb-ft (163 Nm)
40 lb-ft (54 Nm)
30 lb-ft (41 Nm)
TORQUE
SPECIFICATION
15 lb-ft (20 Nm)
23 lb-ft (31 Nm)
18 lb-ft (24 Nm)
30 lb-ft (41 Nm)
60 lb-ft (81 Nm)
120 lb-ft (163 Nm)
CHAPTER 9 — BRAKE SYSTEM
PART DESCRIPTION
Front Brake Disc Mounting Bolts
Front Wheel Hub Castle Nuts
Rear Caliper Mounting Bolts
Rear Brake Disc Mounting Bolts
Rear Wheel Hub Castle Nuts
CHAPTER 10 — BODY / FRAME
PART DESCRIPTION
Half Door Hinge to Frame Fasteners
Half Door Hinge Fasteners
Full Door Hinge Fasteners
Heater Mounting Fasteners
Roof Fasteners 12–15 lb-in (1.35–1.7
Windshield Mount Fasteners
Tip Out Windshield Mount Fasteners
Wiper Motor Shaft Fastener
Wiper Arm Fastener
Cargo Box Hinge Fasteners
Front Brushguard Fasteners
Rear Brushguard Fasteners
Nerf Bar Fasteners 12–15 lb-ft (16–20 Nm)
Winch Fasteners
TORQUE
SPECIFICATION
18 lb-ft (24 Nm)
80 lb-ft (108 Nm)
46 lb-ft (62 Nm)
28 lb-ft (38 Nm)
110 lb-ft (149 Nm)
TORQUE
SPECIFICATION
8 lb-ft (10 Nm)
14 lb-ft (19 Nm)
17 lb-ft (23 Nm)
6–8 lb-ft (8–10 Nm)
Nm)
15 lb-ft (20 Nm)
20 lb-ft (27 Nm)
15 lb-ft (20 Nm)
10 lb-ft (14 Nm)
14 lb-ft (19 Nm)
30 lb-ft (41 Nm)
12 lb-ft (16 Nm)
25 lb-ft (34 Nm)
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GENERAL INFORMATION
CHAPTER 11 — ELECTRICAL
PART DESCRIPTION
Terminal Block Nuts
Starter Motor Fasteners
Thermostat Cover Bolts
TORQUE
SPECIFICATION
20-25 lb-in (2.3-2.8 Nm)
7 lb-ft (10 Nm)
7 ± 1 lb-ft (10 ± 1 Nm)
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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GENERAL INFORMATION
VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION
Example: A15SEA57AD
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
A 1 5 S E A 5 7 A D
* = 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: 4XASEA570F3000000
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
1
WORLD MFG. ID
MAKE /
CHASSIS
CATEGORY
ENGINE
ENGINE SIZE
MODIFIER
CHECK DIGIT
MODEL YEAR *
MFG. LOCATION
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A S E A
5 7 0 F 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; K= 2019
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
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GENERAL INFORMATION
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS
Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model number and serial number.
The engine model and serial number can be found on a decal applied to the MAG side of the cylinder headqor stamped into the crankcase on the PTO side of the engine
The VIN can be found stamped on a portion of the upper left frame raileabove the airbox.
w
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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VEHICLE SPECIFICATIONS
2018-19 RANGER XP 900 / EPS OVERVIEW
CATEGORY DIMENSION / CAPACITY
Length
Width (cargo box)
Width (tires)
Height
Wheel Base 81 in / 205.7 cm Ground Clearance 12 in / 30.5 cm Turning Radius
Dry Weight 1360 lb / 617 kg
Cargo Box Capacity
Cargo Box Dimensions (inside dimensions)
Vehicle Payload (includes weight of riders, cargo and accessories)
Hitch Towing Capacity 2000 lb / 907 kg
Hitch Tongue Capacity 150 lb / 68 kg
116 in / 295 cm
60 in / 152.4 cm
58 in / 147.3 cm
76 in / 193 cm
161 in / 409 cm
49-State: 1000 lb / 454 kg 50-State: 600 lb / 272 kg
36.5 x 54 x 11.5 in (93 x 137 x 29 cm)
49-State: 1500 lb / 681 kg 50-State: 1100 lb / 499 kg
GENERAL INFORMATION
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GENERAL INFORMATION
2018-19 RANGER XP 900 / EPS SPECIFICATIONS
ENGINE
Platform
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Engine Idle Speed
Engine Max Operating RPM
Lubrication
Oil Requirements PS-4 or PS-4 Extreme Duty
Oil Capacity 2.5 Qt (2.4 L)
Coolant Capacity 5 Qt (4.7 L)
Exhaust System 2 to 1 Headpipe / Single Silencer
FUEL SYSTEM
Fuel System Type
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure
Fuel Capacity 10 Gal (37.8 L)
Fuel Requirement 87 Octane (minimum)
ELECTRICAL
Alternator Rated Output 660 Watts @ 3000 RPM
Headlights
Tail Lights L.E.D. (10): 0.2 Watts x 2
Brake Lights L.E.D. (10): 2.9 Watts x 2
Ignition System Bosch ME17 (ECU Controlled)
Spark Plug Gap 0.030 in. (0.75 mm)
Battery
DC Outlets
Relays *Not in Fuse/Relay Box
Circuit Breaker
Fuses *Not in Fuse/Relay Box
4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start
875 cc
2
93 x 64.4 mm
1250 ± 50 RPM
7250 RPM
Wet Sump
Bosch ME17 EFI
58 +/- 2 psi (400 +/- 14 kPa)
Halogen: Low 55W / High 60W x 2
Johnson Controls / 575 CCA / 12V
(2) - Standard 12 Volt
Chassis / EFI / Fan / Fuel Pump EPS (OPT) / Rear Diff Solenoid*
20 Amp: Fan Motor
10 Amp: Brake Lights:, Drive, Fuel Pump 20 Amp: Accessory, ECM, Lights 30 Amp: EPS (OPT)*
DRIVETRAIN
Transmission Type
Transmission Gear Ratio: High Low Reverse
Front Gearcase Lubricant Requirements
Transmission Lubricant Requirements
Clutch (PVT) Type
Clutch Center Distance
STEERING / SUSPENSION
Toe Out
Front Suspension
Front Travel
Rear Suspension Independent (IRS)
Rear Travel
WHEELS / BRAKES
Front Wheel Size / Type
Rear Wheel Size / Type
Front Tire Make / Model / Size
Rear Tire Make / Model / Size
Tire Air Pressure
Brake System 4 Wheel Hydraulic Disc
Brake Fluid DOT 4
Polaris Automatic PVT
Front: 4.03:1 / Rear: 12.05:1 Front: 8.56:1 / Rear: 25.59:1 Front: 7.67:1 / Rear: 22.92:1
Demand Drive Fluid
6.75 oz (200 mL)
AGL 41 oz (1200 mL)
Drive: Polaris, Basic, Non­Braking Bearing
Driven: Team Rapid Reaction
10.5 in (26.7 cm)
1/8 - 1/4 in (3.2 - 6.35 mm)
Dual A-arm
10 in (25.4 cm)
10 in (25.4 cm)
12 x 6 / Steel 12 x 6 / Cast Aluminum
12 x 8 / Steel 12 x 8 / Cast Aluminum
Carlisle / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12
Carlisle / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12
Front: 10 psi (69 kPa) Front: 12 psi (83 kPa) (Hunter/ NorthStar/Trail)
Rear: 12 psi (83 kPa)
For the clutch chart, see Clutch Chartpage 1.29 .
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
2018-19 RANGER CREW XP 900 / EPS OVERVIEW
CATEGORY DIMENSION / CAPACITY
Length
Width (cargo box)
Width (tires)
Height
Wheel Base 113 in / 287 cm Ground Clearance 12 in / 30.5 cm Turning Radius
Dry Weight 1570 lb / 712 kg
Cargo Box Capacity
Cargo Box Dimensions (inside dimensions)
Vehicle Payload (includes weight of operator, passenger, cargo and accessories)
Hitch Towing Capacity 2000 lb / 907 kg
Hitch Tongue Capacity 150 lb / 68 kg
148 in / 376 cm
60 in / 152.4 cm
58 in / 147.3 cm
76 in / 193 cm
214 in / 543.5 cm
49-State: 1000 lb / 454 kg 50-State: 600 lb / 272 kg
36 x 50 x 11.5 in (91 x 127 x 29 cm)
49-State: 1750 lb / 759 kg 50-State: 1350 lb / 712 kg
GENERAL INFORMATION
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GENERAL INFORMATION
2018-19 RANGER CREW XP 900 / EPS SPECIFICATIONS
ENGINE
Platform
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Engine Idle Speed
Engine Max Operating RPM
Lubrication
Oil Requirements PS-4 or PS-4 Extreme Duty
Oil Capacity 2.5 Qt (2.4 L)
Coolant Capacity 5.8 Qt (5.5 L)
Exhaust System 2 to 1 Headpipe / Single Silencer
FUEL SYSTEM
Fuel System Type
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure
Fuel Capacity 10 Gal (37.8 L)
Fuel Requirement 87 Octane (minimum)
ELECTRICAL
Alternator Rated Output 660 Watts @ 3000 RPM
Headlights
Tail Lights L.E.D. (10): 0.2 Watts x 2
Brake Lights L.E.D. (10): 2.9 Watts x 2
Ignition System Bosch ME17 (ECU Controlled)
Spark Plug Gap 0.030 in. (0.75 mm)
Battery
DC Outlets
Relays *Not in Fuse/Relay Box
Circuit Breaker
Fuses *Not in Fuse/Relay Box
4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start
875 cc
2
93 x 64.4 mm
1250 ± 50 RPM
7250 RPM
Wet Sump
Bosch ME17 EFI
58 +/- 2 psi (400 +/- 14 kPa)
Halogen: Low 55W / High 60W x 2
Johnson Controls / 575 CCA / 12V
(2) - Standard 12 Volt
Chassis / EFI / Fan / Fuel Pump EPS (OPT) / Rear Diff Solenoid*
20 Amp: Fan Motor
10 Amp: Brake Lights:, Drive, Fuel Pump 20 Amp: Accessory, ECM, Lights 30 Amp: EPS (OPT)*
DRIVETRAIN
Transmission Type
Transmission Gear Ratio: High Low Reverse
Front Gearcase Lubricant Requirements
Transmission Lubricant Requirements
Clutch (PVT) Type
Clutch Center Distance
STEERING / SUSPENSION
Toe Out
Front Suspension
Front Travel
Rear Suspension Independent (IRS)
Rear Travel
WHEELS / BRAKES
Front Wheel Size / Type
Rear Wheel Size / Type
Front Tire Make / Model / Size
Rear Tire Make / Model / Size
Tire Air Pressure
Brake System 4 Wheel Hydraulic Disc
Brake Fluid DOT 4
Polaris Automatic PVT
Front: 3.48:1 / Rear: 10.40:1 Front: 8.56:1 / Rear: 25.59:1 Front: 7.67:1 / Rear: 22.92:1
Demand Drive Fluid
6.75 oz (200 mL)
AGL 41 oz (1200 mL)
Drive: Polaris, Basic, Non­Braking Bearing
Driven: Team Rapid Reaction
10.5 in (26.7 cm)
1/8 - 1/4 in (3.2 - 6.35 mm)
Dual A-arm
10 in (25.4 cm)
10 in (25.4 cm)
12 x 6 / Steel 12 x 6 / Cast Aluminum
12 x 8 / Steel 12 x 8 / Cast Aluminum
Carlisle / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12
Carlisle / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12
Front: 14 psi (97 kPa)
Rear: 16 psi (110 kPa)
For the clutch chart, see Clutch Chartpage 1.29 .
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
2018 RANGER XP 1000 HIGH LIFTER OVERVIEW
CATEGORY DIMENSION / CAPACITY
Length
Width (cargo box)
Width (tires)
Height
Wheel Base 83 in / 210.8 cm Ground Clearance 13 in / 33 cm Turning Radius
Dry Weight 1562 lb / 709 kg
Cargo Box Capacity
Cargo Box Dimensions (inside dimensions)
Vehicle Payload (includes weight of riders, cargo and accessories)
Hitch Towing Capacity 2000 lb / 907 kg
Hitch Tongue Capacity 150 lb / 68 kg
123 in / 312cm
60 in / 152.4 cm
66.5 in / 169 cm
77 in / 195.6 cm
178 in / 452 cm
49-State: 1000 lb / 454 kg 50-State: 600 lb / 272 kg
36.5 x 54 x 11.5 in (93 x 137 x 29 cm)
49-State: 1500 lb / 681 kg 50-State: 1100 lb / 499 kg
GENERAL INFORMATION
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GENERAL INFORMATION
2018 RANGER XP 1000 HIGH LIFTER SPECIFICATIONS
ENGINE
Platform
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Engine Idle Speed
Engine Max Operating RPM
Lubrication
Oil Requirements PS-4 or PS-4 Extreme Duty
Oil Capacity 2.5 Qt (2.4 L)
Coolant Capacity 5 Qt (4.75 L)
Exhaust System 2 to 1 Headpipe / Single Silencer
FUEL SYSTEM
Fuel System Type
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure
Fuel Capacity 10 Gal (37.8 L)
Fuel Requirement 87 Octane (minimum)
ELECTRICAL
Alternator Rated Output 660 Watts @ 3000 RPM
Headlights
Tail Lights L.E.D. (10): 0.2 Watts x 2
Brake Lights L.E.D. (10): 2.9 Watts x 2
Ignition System Bosch ME17 (ECU Controlled)
Spark Plug Gap 0.030 in. (0.75 mm)
Battery
DC Outlets
Relays *Not in Fuse/Relay Box
Circuit Breaker
Fuses *Not in Fuse/Relay Box
4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start
999 cc
2
93 x 73.5 mm
1200 ± 100 RPM
8000 RPM
Wet Sump
Bosch ME17 EFI
58 ± 2 psi (400 ± 14 kPa)
Halogen: Low 55W / High 60W x 2
Johnson Controls / 575 CCA / 12V
(2) - Standard 12 Volt
Chassis / EFI / Fan / Fuel Pump EPS (OPT) / Rear Diff Solenoid*
20 Amp: Fan Motor
10 Amp: Brake Lights:, Drive, Fuel Pump 20 Amp: Accessory, ECM, Lights 30 Amp: EPS (OPT)*
DRIVETRAIN
Transmission Type
Transmission Gear Ratio: High Low Reverse
Front Gearcase Lubricant Requirements
Transmission Lubricant Requirements
Clutch (PVT) Type
Clutch Center Distance
STEERING / SUSPENSION
Toe Out
Front Suspension
Front Travel
Rear Suspension Independent (IRS)
Rear Travel
WHEELS / BRAKES
Front Wheel Size / Type
Rear Wheel Size / Type
Front Tire Make / Model / Size
Rear Tire Make / Model / Size
Tire Air Pressure
Brake System 4 Wheel Hydraulic Disc
Brake Fluid DOT 4
Polaris Automatic PVT
Front: 4.03:1 / Rear: 12.05:1 Front: 8.56:1 / Rear: 25.59:1 Front: 7.67:1 / Rear: 22.92:1
Demand Drive Fluid
6.75 oz (200 mL)
AGL 41 oz (1200 mL)
Drive: Polaris, Basic, Non­Braking Bearing
Driven: Team Rapid Reaction
10.5 in (26.7 cm)
1/8 - 1/4 in (3.2 - 6.35 mm)
Dual A-arm
8 in (20.3 cm)
8.8 in (22.4 cm)
14 x 7 / Cast Aluminum
14 x 8 / Cast Aluminum
High Lifter Outlaw 28 x 9.5 R14
High Lifter Outlaw2/ 28 x 11 R14
Front: 10 psi (69 kPa)
Rear: 12 psi (83 kPa)
2
/
For the clutch chart, see Clutch Chartpage 1.29
1.26
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
2018 RANGER CREW XP 1000 / EPS OVERVIEW
CATEGORY DIMENSION / CAPACITY
Length
Width (cargo box)
Width (tires)
Height
Wheel Base 113 in / 287 cm Ground Clearance 12 in / 30.5 cm Turning Radius
Dry Weight 1570 lb / 712 kg
Cargo Box Capacity
Cargo Box Dimensions (inside dimensions)
Vehicle Payload (includes weight of operator, passenger, cargo and accessories)
Hitch Towing Capacity 2000 lb / 907 kg
Hitch Tongue Capacity 150 lb / 68 kg
148 in / 376 cm
60 in / 152.4 cm
58 in / 147.3 cm
76 in / 193 cm
214 in / 543.5 cm
49-State: 1000 lb / 454 kg 50-State: 600 lb / 272 kg
36 x 50 x 11.5 in (91 x 127 x 29 cm)
49-State: 1750 lb / 759 kg 50-State: 1350 lb / 712 kg
GENERAL INFORMATION
1
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
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GENERAL INFORMATION
2018 RANGER CREW XP 1000 / EPS SPECIFICATIONS
ENGINE
Platform
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Engine Idle Speed
Engine Max Operating RPM
Lubrication
Oil Requirements PS-4 or PS-4 Extreme Duty
Oil Capacity 2.5 Qt (2.4 L)
Coolant Capacity 5.8 Qt (5.5 L)
Exhaust System 2 to 1 Headpipe / Single Silencer
FUEL SYSTEM
Fuel System Type
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure
Fuel Capacity 10 Gal (37.8 L)
Fuel Requirement 87 Octane (minimum)
ELECTRICAL
Alternator Rated Output 660 Watts @ 3000 RPM
Headlights
Tail Lights L.E.D. (10): 0.2 Watts x 2
Brake Lights L.E.D. (10): 2.9 Watts x 2
Ignition System Bosch ME17 (ECU Controlled)
Spark Plug Gap 0.030 in. (0.75 mm)
Battery
DC Outlets
Relays *Not in Fuse/Relay Box
Circuit Breaker
Fuses *Not in Fuse/Relay Box
4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start
999 cc
2
93 x 73.5 mm
1200 ± 100 RPM
8000 RPM
Wet Sump
Bosch ME17 EFI
58 ± 2 psi (400 ± 14 kPa)
Halogen: Low 55W / High 60W x 2
Johnson Controls / 575 CCA / 12V
(2) - Standard 12 Volt
Chassis / EFI / Fan / Fuel Pump EPS (OPT) / Rear Diff Solenoid*
20 Amp: Fan Motor
10 Amp: Brake Lights:, Drive, Fuel Pump 20 Amp: Accessory, ECM, Lights 30 Amp: EPS (OPT)*
DRIVETRAIN
Transmission Type
Transmission Gear Ratio: High Low Reverse
Front Gearcase Lubricant Requirements
Transmission Lubricant Requirements
Clutch (PVT) Type
Clutch Center Distance
STEERING / SUSPENSION
Toe Out
Front Suspension
Front Travel
Rear Suspension Independent (IRS)
Rear Travel
WHEELS / BRAKES
Front Wheel Size / Type
Rear Wheel Size / Type
Front Tire Make / Model / Size
Rear Tire Make / Model / Size
Tire Air Pressure
Brake System 4 Wheel Hydraulic Disc
Brake Fluid DOT 4
Polaris Automatic PVT
Front: 4.03:1 / Rear: 12.05:1 Front: 8.56:1 / Rear: 25.59:1 Front: 7.67:1 / Rear: 22.92:1
Demand Drive Fluid
6.75 oz (200 mL)
AGL 41 oz (1200 mL)
Drive: Polaris, Basic, Non­Braking Bearing
Driven: Team Rapid Reaction
10.5 in (26.7 cm)
1/8 - 1/4 in (3.2 - 6.35 mm)
Dual A-arm
10 in (25.4 cm)
10 in (25.4 cm)
12 x 6 / Steel
12 x 8 / Steel
Carlisle / PXT / 26 x 9 R12
Carlisle / PXT / 26 x 11 R12
Front: 10 psi (69 kPa)
Rear: 16 psi (110 kPa)
For the clutch chart, see Clutch Chartpage 1.29
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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
GENERAL INFORMATION
CLUTCH CHART
YEAR/MODEL ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING
2018-19 900 Models (Except EBS Models)
2018-19 900 CREW Models
2018-19 HUNTER PKG/EDITION w/EBS
2018-19 HUNTER/ TRAIL EDITION w/ EBS
2018 1000 Models 0-1800 Meters
0-1800 Meters (0-6000 Feet)
1800-3700 Meters (6000 - 12000 Feet)
0-1800 Meters (0-6000 Feet)
1800-3700 Meters (6000 - 12000 Feet)
0-1800 Meters (0-6000 Feet)
1800-3700 Meters (6000 - 12000 Feet)
0-1800 Meters (0-6000 Feet)
1800-3700 Meters (6000 - 12000 Feet)
(0-6000 Feet)
1800-3700 Meters (6000 - 12000 Feet)
27-81 (5140011)
30-75 (5139684)
27-89 (5138015)
27-83 (5632754)
27-81 (5140011)
30-75 (5139684)
27-81 (5140011)
30-75 (5139684)
27-98 (5140604)
27-89 (5138015)
Wht / Blu (7044111)
Wht / Blu (7044111)
Wht / Blu (7044111)
Wht / Blu (7044111)
Wht / Blu (7044111)
Wht / Blu (7044111)
Wht / Blu (7044111)
Wht / Blu (7044111)
Black (7044655)
Black (7044655)
7044021
7044021
7044015
7044015
3234452
3234452
3234452
3234452
3235964
3235964
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GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
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
mm
inch x 2.54
mile (mi)
km x 0.6214 = mile
ounces (oz)
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 12 = in-lbs
x 1.356 = Nm
= ft-lbs
= mm
x 0.03937 = inch
= cm
x 1.6 = km
x 28.35
x .03381
x 0.035
x 2.2046 = lbs
x 16.387
x 0.946
x 1.057
x 0.264
x 0.145
= grams (g)
= fluid ounces
= ounces
= cc
= liters (L)
= US quarts
= US gallons
PSI
= cylinder volume
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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
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
4.6 4.8 8.8 / 8.9 10.9 12.9
FT-LB (NM) DRY THREADS
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)
GRADE 5
FT-LB (NM)
GRADE
GENERAL INFORMATION
GRADE 8
FT-LB (NM)
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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
#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
53
45
43
42
38
33
29
29
24
21
7
3
F 2–12
I
U 3–4
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
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
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
11 x 1.50
12 x 1.50
12 x 1.75 13/32 0.406 13/32
#39
3/32
#30
1/8 0.125 1/8
#20
#9
16/64
17/64
5/16
11/32
3/8
13/32
0.0995
0.0937
0.1285
0.161
0.196
0.234
0.265
0.3125
0.3437
0.375
0.406
NEAREST
FRACTION
3/32
3/32
1/8
5/32
13/64
15/64
9/32
17/64
5/16
11/32
11/32
3/8
13/32
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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″
GENERAL INFORMATION
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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GENERAL INFORMATION
NOTES
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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 CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
BREAK-IN PERIOD.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
MAINTENANCE CHART KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
10 - 50 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
50 - 500 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
GREASE LUBRICATION POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
ENGINE MAINTENANCE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
ENGINE CRANKCASE BREATHER HOSE INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
ENGINE CYLINDER LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
EXHAUST - SPARK ARRESTOR... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
COOLING SYSTEM MAINTENANCE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
LIQUID COOLING SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLANT STRENGTH / TYPE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLANT LEVEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLING SYSTEM HOSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
RADIATOR INSPECTION / CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
FUEL SYSTEM AND AIR INTAKE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
FUEL SYSTEM WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
FUEL LINES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
ENGINE INTAKE PRE-FILTER SCREEN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
AIR FILTER SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
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MAINTENANCE
ENGINE AIR INTAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
EXHAUST HEAT SHIELD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
TRANSMISSION AND FRONT GEARCASE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
TRANSMISSION LUBRICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
FRONT GEARCASE LUBRICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
PVT / FINAL DRIVE / WHEEL AND TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
PVT INTAKE PRE-FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
PVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
STEERING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
STEERING INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
WHEEL TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
SUSPENSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
SHOCK POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BRAKE SYSTEM MAINTENANCE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BRAKE PAD / DISC INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
ELECTRICAL AND IGNITION SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
BATTERY INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
CHASSIS / ENGINE ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
SPARK PLUG SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
2.2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
MAINTENANCE
GENERAL INFORMATION - 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.
SPECIAL TOOLS - MAINTENANCE
2
TOOL DESCRIPTION
Oil Filter Wrench
Shock Spanner Wrench
Bosch Automotive Service Solutions: 1-800-328-6657 or https://polaris.service-solutions.com/
PU-50105
2871095
PART NUMBER
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
2.3
MAINTENANCE
SERVICE SPECIFICATIONS - MAINTENANCE
GENERAL SPECIFICATIONS
ITEM
Battery Type / CCA
Brake Pad Thickness, Front
Brake Disc Thickness, Front
Brake Pad Thickness, Rear
Brake Disc Thickness, Rear
Fuel Pressure (KOEO) 58 ± 2 psi (400 ± 14 kPa) -
Idle Speed
Oil Pressure (Minimum)
Spark Plug Type / Gap NGK MR7F / 0.030 in (0.75 mm) -
Tire Pressure (Base / CREW)
Tire Tread Depth (Minimum) - 0.118 in (3 mm)
Cylinder Leakage -
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) -
Wheel Toe Out
Johnson Controls / 575 CCA / 12V
0.297 ± .007" (7.54 ± .178 mm) 0.150" (3.8 mm)
0.298 ± .007" (7.56 ± .178 mm) 0.150" (3.8 mm)
10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum)
Front: 10 psi (69 kPa) / 14 psi (97 kPa)
Rear: 12 psi (83 kPa) / 16 psi (110 kPa)
STANDARD SERVICE LIMIT
-
0.188" ( 4.78 mm) 0.170" (4.32 mm)
0.188" (4.78 mm) 0.170" (4.32 mm)
1250 ± 50 RPM
1/8-1/4 in (3.2-6.4 mm) -
-
-
-
20%
FLUID SPECIFICATIONS
ITEM
Engine Oil PS-4 2W-50 Synthetic 2.5 Qt (2.4 L)
Transmission Oil AGL Gearcase Lubricant 41 oz (1200 mL)
Front Gearcase
Engine Coolant 50 / 50 Extended Life Antifreeze 5 Qt (4.7 L)
Fuel
Brake / Clutch Fluid DOT 4
Demand Drive Fluid
87 Octane (minimum) 10 Gal (37.8 L)
2.4
FLUID TYPE CAPACITY
6.75 oz (200 mL)
-
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
PERIODIC MAINTENANCE CHART
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.
NOTICE
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
MAINTENANCE CHART KEY
The following symbols denote potential items to be aware of during maintenance:
■ = CAUTION: Due to the nature of these
adjustments, it is recommended this service be performed by an authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTICE
Inspection may reveal the need for replacement parts.
Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked ■ could
result in component failure and lead to serious injury or
death. Have an authorized Polaris dealer perform these
services.
2
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.
BREAK-IN PERIOD
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. 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.
• Pull only light loads.
• 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.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
2.5
MAINTENANCE
PRE-RIDE INSPECTION
The following items should be inspected pre-ride:
ITEM
Air Filter
Steering System
Front / Rear Suspension
Tires
Wheels / Lug Nuts
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
Headlights / Taillights
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
2.6
• Ensure all lights are operational
• Adjust headlight aim as required
• Check brake fluid level is between MIN and MAX
• Check brake pedal is not soft when pushed
• Verify brakes stop and hold the vehicle
• Inspect for leaks
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
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
MAINTENANCE
ITEM
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
INSPECTION / CHECK
Clean when driving in mud and water; replace a cracked or damaged arrester before operating
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
2.7
MAINTENANCE
10 - 50 HOUR MAINTENANCE INTERVAL
MAINTENANCE INTERVAL
ITEM
Brake Pad Wear 10 H
Battery
Fuel System
Demand Drive Fluid
(Extreme Use)
Front Gearcase Lubricant
(Demand Drive Fluid)
Transmission Lubricant
(AGL Gearcase Lubricant)
Engine Oil & Filter Change
E
(Break-In Period)
General Lubrication 50 H 3 M
Shift Cable / Linkage
Steering
Front / Rear Suspension
(WHICHEVER COMES FIRST)
HRS
25 H
25 H
25 H 1 M
25 H 1 M
25 H 1 M
25 H
50 H 6 M
50 H 6 M
50 H 6 M
CALEN-
DAR
Monthly 100 (160) Inspect periodically
Monthly 200 (320)
Monthly 200 (320)
MILES
REMARKS
(KM)
Check terminals; clean; test
Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
-
-
-
-
250 (400)
500 (800) Lubricate all grease fittings, pivots, etc.
500 (800) Inspect, lubricate, adjust
500 (800)
500 (800)
Change fluid every 25 hours if ADC is subjected to extreme use
Initial fluid level inspection; add lubricant if needed
Initial fluid level inspection; add lubricant if needed
Perform a break-in oil and filter change at 25 hours or one month; perform every 100 hours or 6 months thereafter
Lubricate
Lubricate
2.8
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
50 - 500 HOUR MAINTENANCE INTERVAL
MAINTENANCE INTERVAL
ITEM
■ Throttle Pedal 50 H 6 M
E
Air Intake Ducts / Adapters
E
Drive Belt 50 H 6 M
Cooling System
Radiator 50 H 6 M
Oil Lines, fasteners
Engine Oil and Filter Change
E
Front Gearcase Lubricant
(Demand Drive Fluid)
Transmission Lubricant
(AGL Gearcase Lubricant)
■ Fuel System
E
Cooling Hoses
Engine Mounts
Exhaust Silencer / Pipe
Drive Shafts 100 H 12 M
■ Spark Plug
E
Wiring
Clutches (Drive and Driven)
Wheel Bearings
Ratcheting Cam Chain Tensioner
Brake Fluid 200 H 24 M
Suspension Bushings
Spark Arrestor
Spark Plug Replacement
E
Valve Clearance 500 H
E
Coolant
Toe Adjustment
Headlight Aim
(WHICHEVER COMES FIRST)
HRS CALENDAR
50 H 6 M
50 H 6 M
50 H 6 M
100 H 6 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
100 H 12 M
200 H
250 H 24 M
300 H 36 M
500 H 36 M
-
-
-
60 M
MAINTENANCE
REMARKS
MILES (KM)
500 (800)
500 (800) Inspect ducts for proper sealing/air leaks
500 (800) Inspect; replace as needed
500 (800)
500 (800) Inspect; clean external surfaces
500 (800) Inspect for leaks and loose fittings
1000 (1600) Replace oil and filter during engine oil change
1000 (1600) Change lubricant
1000 (1600) Change lubricant
1000 (1600)
1000 (1600) Inspect for leaks
1000 (1600) Inspect, torque to specification
1000 (1600) Inspect
1000 (1600) Remove and grease
1000 (1600) Inspect; replace as needed
1000 (1600)
1000 (1600) Inspect; clean; replace worn parts
1000 (1600) Inspect; replace as needed
2000 (3200) Check; replace as needed
2000 (3200) Change every two years (DOT 4)
2000 (3200) Inspect; replace if necessary
3000 (4800)
5000 (8000) Replace; torque to specification
5000 (8000) Inspect; adjust as needed
-
-
-
Inspect for free movement; replace pedal assembly if needed
Inspect coolant strength seasonally; pressure test system yearly
Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail, and fuel pump; replace lines every two years
Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
Clean out
Replace coolant
Inspect periodically; adjust when parts are replaced
Adjust as needed
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
2.9
MAINTENANCE
MAINTENANCE QUICK REFERENCE
ITEM LUBE REC. METHOD
Oil Fill Capqq: Oil Filterww/ Dipstickee:
- Behind Engine Access Panel
Engine Coolant Reservoir Radiator Cap Radiator
* More often under severe use, such as operation in water or under severe loads.
t
y
r
Polaris PS-4 or Polaris PS-4 Extreme Duty
Polaris 50/50 Coolant
Remove cargo box panel and add oil to proper level on dipstick
Remove hood panel. Maintain coolant level in coolant reservoir bottle and radiator.
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
2.10
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
MAINTENANCE
ITEM LUBE REC. METHOD
Brake Fluid
Front Gearcase
Transmission Polaris AGL
* More often under severe use, such as operation in water or under severe loads.
Polaris DOT 4 Brake Fluid
Polaris Demand Drive
Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir
Add lubricant until it is visible at the fill hole threads ≈ 7.5 oz. (222 mL)
Add lubricant until it is visible at the fill hole threads
q
w
e
FREQUENCY*
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
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
2.11
MAINTENANCE
GREASE LUBRICATION POINTS
There are grease fittings at each A-arm pivot point, each rear stabilizer bar bushing, and on the propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.
ITEM
A-arm Pivot Bushings
q
Stabilizer Bar Bushings
w
Propshaft Yoke
e
METHOD RECOMMENDED LUBE
Grease all fittings on each side of the vehicle
Grease the fitting (3 pumps maximum)
NON-CREW MODELS CREW MODELS
Polaris All Season Grease
FREQUENCY
Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle
2.12
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
SERVICE PRODUCTS AND LUBRICANTS
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS
MAINTENANCE
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.)
NOTICE
The number count indicated by each part number in the
table above indicates the number of units that are
shipped with each order.
2
NOTICE
Each item can be purchased separately at your local
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
Polaris dealer.
2.13
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 Inspectionpage 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.
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
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.
This procedure may require a few attempts to obtain
. Replace if worn or damaged.
e
.
y
the proper adjustment.
attached to the transmission
q
NOTICE
r
, and
t
2.14
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.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
ENGINE MAINTENANCE
MAINTENANCE
ENGINE OIL LEVEL
The 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:
Access the oil dipstick and oil fill cap by tilting the rear cargo box.
Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil.
FLUID CAPACITY
Recommended Engine Oil:
PS-4 Synthetic (PN 2876244)
Ambient Temp Range: -35° F to 100° F
PS-4 Extreme Duty Synthetic (PN 2878920)
Ambient Temp Range: 0° F to 120° F
Capacity: 2.5 Qt (2.4 L)
1. Remove all cargo from the cargo box.
CAUTION
Always remove all cargo from the cargo box before
lifting the box to access the engine.
2. Position the vehicle on a level surface and place the transmission in PARK.
3. Stop the engine and allow it to cool down before removing the dipstick.
4. Pull up on the cargo box release lever to tilt the box.
5. From the right side of the vehicle, unlock the dipstick lever clean cloth.
. Remove the dipstick and wipe it dry with a
q
6. Reinstall the dipstick and push it into place. Do not lock the dipstick
NOTICE
Make certain the dipstick is inserted all the way into the
dipstick tube to keep the depth of the dipstick
consistent.
7. Remove the dipstick and check the oil level.
8. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill (see NOTICE below).
NOTICE
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.
9. Add engine oil through the oil fill capwlocated on top of the valve cover.
10.When finished, reinstall dipstick and lock the lever.
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
ENGINE OIL AND FILTER CHANGE
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.
2.15
MAINTENANCE
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
4. Place a drain pan under the engine crankcase and remove the drain plug. Allow the oil to drain completely.
5. Remove all cargo from the cargo box.
serious burns may result.
CAUTION
Always remove all cargo from the cargo box before
lifting the box to access the engine.
6. Pull up on the cargo box release lever to tilt the box.
7. Gently press the clutch outlet duct to gain access to the oil filter
w
.
out of the way
q
8. Using the Oil Filter Wrench (PU-50105), turn the oil filterwcounter-clockwise to remove it.
Oil Filter Wrench:
PU-50105: 2.5” (64 mm)
9. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase.
10.Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it to specification.
TORQUE
Oil Filter:Turn by hand until filter O-ring contacts sealing surface, then turn an additional 3/4 turn.
11. Replace the sealing washer on drain plug.
NOTICE
The sealing surface on the drain plug should be clean
and free of burrs, nicks or scratches.
2.16
12.Reinstall the engine crankcase drain plug. Torque drain plug to specification.
TORQUE
Crankcase Drain Plug:
12 lb-ft (16 Nm)
13.Remove oil fill cap (refer to Engine Oil Levelpage
2.15 procedure). Fill engine with recommended
engine oil.
FLUID CAPACITY
Recommended Engine Oil:
PS-4 Synthetic (PN 2876244)
Ambient Temp Range: -35° F to 100° F
PS-4 Extreme Duty Synthetic (PN 2878920)
Ambient Temp Range: 0° F to 120° F
Capacity: 2.5 Qt (2.4 L)
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© Copyright Polaris Industries Inc.
MAINTENANCE
14.Verify the transmission is still in PARK.
15.Start the engine and allow it to idle for 30 seconds.
16.Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.
17.Unlock the dipstick lever. Remove the dipstick and wipe it dry with a clean cloth (refer to Engine Oil Levelpage 2.15 procedure).
18.Reinstall the dipstick and push it into place. Do not lock the dipstick
NOTICE
Make certain the dipstick is inserted all the way into the
dipstick tube to keep the depth of the dipstick
consistent.
19.Remove the dipstick and check the oil level.
20.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 hoseqfrom the crankcase fitting to the airboxe.
w
NOTICE
Make sure hoses are not kinked or pinched.
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.
2
21.When finished, reinstall the oil fill cap, oil dipstick and lock the lever.
22.Dispose of used oil and filter properly.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
Cylinder Leakage Service Limit:
20%
If leakage exceeds service limit, inspect the engine for
the cause.
2.17
MAINTENANCE
VALVE CLEARANCE INSPECTION
NOTICE
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
5.12 procedure).
NOTICE
Replace rubber isolators (F) upon assembly.
6. The engine will need to be rotated four times to inspect all eight valve clearances. Two valves can be measured at each camshaft lobe position.
4. Remove the spark plug wiresqfrom the engine.
5. Remove the four T-40 boltswand rubber isolators retaining the valve coverr. Note the location and use of the grounding washertfor assembly.
NOTICE
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.
e
2.18
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MAINTENANCE
9. If the valve clearance is out of specification, refer to “Valve Clearance Adjustment”page 3.93
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 to the spark plug threads and reinstall the spark plugs. Torque spark plugs to specification.
TORQUE
Spark Plug:
7 lb-ft (10 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 T-40 bolts. Torque bolts to specification.
TORQUE
Valve Cover Bolts:
7 lb-ft (10 Nm)
CAM CHAIN TENSIONER INSPECTION
1. Locate the cam chain tensioner on the MAG side of the engine near the starter.
2. Remove the plunger boltqand the spring.
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 manually move the
e
2
15.Install the spark plug wire (s). Ensure wires are pushed down all the way so they engage onto the spark plug(s).
NOTICE
The engine will misfire if the spark plug wires are
installed incorrectly. The spark plug wires are marked
with PTO and MAG and should be installed to the
16.Install the outer clutch cover and eight retaining screws (Refer to “Belt Installation”page 5.13 procedure). Torque the screws to specification.
corresponding cylinder.
TORQUE
Outer Clutch Cover Screws:
45-50 lb-in (5 Nm)
17.Connect the negative (-) battery cable to the battery.
18.Start the engine to ensure proper operation.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
5. Retract the plunger all the way in and install into the cylinder.
2.19
MAINTENANCE
6. Install the two mounting bolts. Torque fasteners to specification.
TORQUE
Tensioner Mounting Bolts:
7 ft-lb (10 Nm)
7. Install the plunger bolt. Torque fastener to specification.
TORQUE
Plunger Bolt:
15 ft-lb (20 Nm)
EXHAUST - SPARK ARRESTOR
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
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
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.
r
.
gloves.
time.
and nutw.
q
from the end of the
e
2.20
TORQUE
Spark Arrestor:
8 lb-ft (11 Nm)
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© Copyright Polaris Industries Inc.
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.
NOTICE
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.
• 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)
COOLANT LEVEL INSPECTION
The recovery bottleqand radiator pressure capware located under the hood.
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
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.
2.21
MAINTENANCE
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
4. If the coolant level is below the “MIN” mark, inspect the coolant level in the radiator.
NOTICE
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.
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.
10. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating.
COOLING SYSTEM HOSES
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.
5. Remove the pressure cap. Using a funnel, add coolant to the top of the radiator filler neck.
6. Reinstall the pressure cap.
NOTICE
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)
9. Reinstall the recovery bottle cap.
2.22
3. Check tightness and condition of all hose clamps. Do not over-tighten hose clamps at radiator, or radiator fitting may distort.
TORQUE
Radiator Hose Clamp:
3 lb-ft (4 Nm)
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MAINTENANCE
RADIATOR INSPECTION / CLEANING
1. Check radiator air passages for restrictions or damage.
Radiator
q
Shroud
w
Fan
e
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.
5. Slide the clamp back and remove the lower radiator hose to drain the coolant from the radiator.
2
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.
9. Refer to “Cooling System Bleeding
Procedure”page 3.110.
FLUID CAPACITY
Recommended Anti-Freeze/Coolant:
Premium Pre-Mixed Extended Life Antifreeze
(PN 2880514) (Quart)
(PN 2880513) (Gallon)
COOLANT DRAIN / FILL
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
3. Slowly remove the pressure cap to relieve any cooling system pressure.
4. Place a drain pan under the lower radiator hose.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
cap.
2.23
MAINTENANCE
FUEL SYSTEM AND AIR INTAKE MAINTENANCE
FUEL SYSTEM WARNING
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 waterand 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 ordeath in a short time.
Never drain the fuel when the engine is hot.Severe
burns may result.
FUEL PUMP / FUEL FILTERS
The fuel pump assemblyqis located in the fuel tank under the driver’s seat.
NOTICE
The serviceable, high-volume, high-pressure, fuel
pump assembly includes a non-serviceable preliminary
filter
. The fuel pump must be replaced as an
assembly. Refer to “Fuel Pump Replacement”page
w
4.18 procedure.
2.24
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© Copyright Polaris Industries Inc.
MAINTENANCE
FUEL LINES
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,
w
VENT LINE
NOTICE
If the vent line fitting is removed from the fuel tank, it
must be replaced. The fitting will not hold properly once
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.
Be sure vent line is not kinked or pinched.
it is removed.
NOTICE
for signs of wear,
q
2
3. Be sure fuel lines are routed and retained properly.
NOTICE
Make sure lines are not kinked or pinched.
Throttle Pedal Inspection
Inspect the throttle pedal sure the throttle pedal returns normally when released. Refer to “Pedal Position Sensor (PPS) Test”page 4.30 procedure if experiencing a lack of throttle response.
for free movement. Be
w
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2.25
MAINTENANCE
ENGINE INTAKE PRE-FILTER SCREEN SERVICE
It is recommended that the engine intake pre-filter be inspected daily. The filter should be inspected using the following procedure:
1. The engine intake pre-filter is located just behind the driver hip bolster on the left side of the vehicle. The pre-filter is adhered to the back of the body panel.
2. Inspect the pre-filter. Wipe away any deposits with a clean cloth.
3. If necessary, remove the body panel and clean the pre-filter with soapy water and dry with low pressure compressed air.
3. Remove the air filter elementq.
NOTICE
Leave the front portion of the lower airbox cover in the
hinges. It is not necessary to remove the lower cover
when servicing the air filter.
4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel.
NOTICE
If the filter has been soaked with fuel or oil it must be
replaced.
AIR FILTER SERVICE
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 (5) airbox cover latches and lower the bottom cover to access the air filter element.
5. Inspect the air filter and replace if necessary.
NOTICE
DO NOT attempt to clean the air filter.
6. Place the air filter into the airbox. Reposition the lower airbox cover and install the five retaining latches.
NOTICE
Make sure the hinge pins are properly seated when
reassembling the airbox
2.26
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ENGINE AIR INTAKE EXPLODED VIEW
MAINTENANCE
2
REF
q
w
e
r
t
y
u
i
DESCRIPTION
LID, AIRBOX
BASE, AIRBOX
CLIP, AIRBOX
BRACKET, AIRBOX MOUNT
HOSE, ENGINE INTAKE
HOSE, ENGINE VENT
HOSE, AIRBOX INTAKE
CLAMP, HOSE
REF
o
a
s
d
f
g
h
j
DESCRIPTION
CLAMP, HOSE
CLAMP, SPRINGBAND
FILTER, MAIN AIRBOX
PLUG, DRAIN
HOSE, INTAKE BOOT
FENDER, INTAKE REAR
DUCT, AIR INTAKE
CLAMP, HOSE
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2.27
MAINTENANCE
EXHAUST HEAT SHIELD INSPECTION
Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly.
IMPORTANT
2.28
ITEM DESCRIPTION
q
w
e
Close-off Bracket
Chassis Shield
Silencer Shield, Main
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TRANSMISSION AND FRONT GEARCASE MAINTENANCE
MAINTENANCE
TRANSMISSION LUBRICATION
NOTICE
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.
Transmission Lubricant Level Check
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.
q
7. Remove drain plugwand allow lubricant to drain completely.
2
8. Clean the drain plug magnetic surface.
9. Reinstall drain plug with a new O-ring and torque to specification.
10. 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.
FLUID CAPACITY
Recommended Transmission Lubricant:
AGL Gearcase Lubricant
(PN 2878068) (Quart)
Capacity: 41 oz (1200 mL)
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)
Transmission Lubricant Change
The drain plug is located on the bottom of the transmission gearcase. Access the drain plug through the drain hole in the skid plate.
5. Remove the fill plug.
6. Place a drain pan under the transmission drain plug.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
11. Reinstall fill plug with a new O-ring and torque to specification.
TORQUE
Transmission Fill / Drain Plug:
10-14 lb-ft (14-19 Nm)
12. Check for leaks. Dispose of used lubricant properly.
2.29
MAINTENANCE
FRONT GEARCASE LUBRICATION
NOTICE
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.
Front Gearcase Fluid Level Check
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
q
8. Remove the drain plug completely.
9. Clean the drain plug magnetic surface.
10. Reinstall drain plug with a new O-ring and torque to specification.
11. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.
and allow fluid to drain
w
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive Fluid
(PN 2877922) (Quart)
Capacity: 8.0 oz (240 mL)
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)
Front Gearcase Fluid Change:
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.
6. Remove the fill plug.
7. Place a drain pan under the front gearcase drain plug.
12. 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)
13. Check for leaks. Dispose of used fluid properly.
2.30
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PVT / FINAL DRIVE / WHEEL AND TIRE MAINTENANCE
MAINTENANCE
PVT INTAKE PRE-FILTER SERVICE
It is recommended that the PVT intake pre-filter be inspected daily. The filter should be inspected using the following procedure:
1. The PVT intake pre-filter is located just behind the passenger hip bolster on the right side of the vehicle. The pre-filter is adhered to the back of the body panel.
2. Inspect the pre-filter. Wipe away any deposits with a clean cloth.
3. If necessary, remove the body panel and clean the pre-filter with soapy water and dry with low pressure compressed air.
PVT DRYING
NOTICE
After operating in water, the vehicle’s PVT system
should be checked immediately. Use the following
instructions to dry it out before operating.
The PVT drain plug is located at the bottom of the outer clutch cover. Access the drain plug through the left rear wheel well.
1. Using a flat blade screwdriver, remove the PVT drain plug
and O-ring from the outer clutch cover.
q
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.
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
NOTICE
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 (Refer to “PVT System Service”page 5.7 for service and removal procedures).
NOTICE
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.
2.31
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.
w
q
for
WHEEL REMOVAL
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 capw, cotter pin
and loosen the hub nutrslightly.
e
NOTICE
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
q
WHEEL INSTALLATION
1. Verify the transmission is still in PARK.
2. Install the wheel on the wheel hub with the valve stem toward the outside. Be sure rotation arrow on the tire (if applicable) point toward forward rotation.
3. Attach the wheel nuts
4. Carefully lower the vehicle to the ground.
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.
5. Torque wheel nuts specification.
Wheel Nuts (Steel Wheels):
60 lb-ft (81 Nm)
Wheel Nuts (Cast Aluminum Wheels):
120 lb-ft (163 Nm)
Front Wheel Hub Castle Nuts:
80 lb-ft (108 Nm)
Rear Wheel Hub Castle Nuts:
110 lb-ft (149 Nm)
Do not lubricate the stud or the lug nut.
6. If wheel hub nut was removed, install a new cotter pineafter 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.
and finger tighten them.
q
NOTICE
and/or hub nutrto the proper
q
TORQUE
NOTICE
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.
q
2.32
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
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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© Copyright Polaris Industries Inc.
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.
TIRE PRESSURE
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
Base: 10 psi (69 kPa) CREW: 14 psi (97 kPa)
pressure decal applied to the vehicle.
Tire Pressure Inspection (Cold)
Front Rear
Base: 12 psi (83 kPa) CREW: 16 psi (110 kPa)
2
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.
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2.33
MAINTENANCE
STEERING MAINTENANCE
STEERING INSPECTION
Steering system components should be checked periodically for loose fastenersq, worn tie rod endsw, loose steering shaft U-joints and general damage. Also check to make sure all cotter pins
are in place. If cotter pins are removed, they must
r
be replaced.
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.
NOTICE
Check front end alignment whenever steering
components are replaced.
, worn A-arm ball joints
e
TIE ROD END / WHEEL HUB 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.
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.
2.34
• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).
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MAINTENANCE
WHEEL TOE ALIGNMENT INSPECTION
NOTICE
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.
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.
2
NOTICE
It is important the height of both marks be equally
positioned to get an accurate measurement.
3. Measure the distance between the marks and record the measurement. Call this measurement “A”.
4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.
5. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8-1/4 in (3.2-6.4 mm) toe out. This means the front of the tire (A) is 1/8-1/4 in (3.2-6.4
mm) wider than the measurement at the rear (B).
MEASUREMENT
Wheel Toe-Out (A) - (B):
1/8-1/4 in (3.2-6.4 mm)
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
NOTICE
Be sure steering wheel is straight ahead before
determining which tie rod needs adjustment.
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.
2.35
MAINTENANCE
• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment Inspection”.
IMPORTANT
When tightening the tie rod end jam nuts, the rod ends
must be held parallel to prevent rod end damage and
premature wear. Damage may not be immediately
• After alignment is complete, torque jam nuts to specification.
apparent if done incorrectly.
TORQUE
Tie Rod Jam Nut:
13 lb-ft (18 Nm)
2.36
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
SUSPENSION MAINTENANCE
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 camqeither direction to increase or decrease spring tension. Always adjust both left and right sides equally.
NOTICE
Adjusting all shock cams equally will only affect ride
height as the weight transfer will not be changed.
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.
WARNING
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 holesw.
FRONT SHOCK
q
from
2
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
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
REAR SHOCK
4. Reinstall the upper shock mounting bolts and torque to specification.
TORQUE
Shock Mounting Bolts:
40 lb-ft (54 Nm)
2.37
MAINTENANCE
BRAKE SYSTEM MAINTENANCE
BRAKE FLUID 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.
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.
can be accessed
q
BRAKE PAD / DISC INSPECTION
1. Check the brake padsqfor wear, damage, or 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)
4. Check surface condition of the brake discs.
5. Measure the thickness of the front and rear brake discs.
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.
2.38
6. The disc (s) should be replaced if thickness is less than the specified service limit.
MEASUREMENT
Brake Disc Thickness (Minimum):
0.170" (4.32 mm)
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
ELECTRICAL AND IGNITION SYSTEM MAINTENANCE
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.
NOTICE
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.
BATTERY REMOVAL
1. Remove the passenger seat (right rear passenger seat on the CREW models) and storage container to access the batteryq.
2. Disconnect the black (negative) battery cablew.
3. Disconnect the red (positive) battery cablee.
CAUTION
To reduce the chance of sparks, disconnect the black
(negative) cable first. When reinstalling the battery,
connect the black (negative) cable last.
4. Remove the fastener down strap and lift the battery out of the vehicle.
retaining the battery hold-
r
BATTERY INSTALLATION
NOTICE
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. Follow the battery
charging procedure in Chapter 10 “Electrical” before
1. Ensure the battery is fully charged.
2. Place the battery down strap and retaining fastener
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Install and tighten the red (positive) cable Torque to specification.
installing the battery.
in the vehicle. Install the hold-
q
r
.
e
first.
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
TORQUE
Battery Terminal Bolt:
6 lb-ft (8 Nm)
2.39
MAINTENANCE
5. Install and tighten the black (negative) cablewlast.
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 storage container and 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 below the starter solenoid
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.
next to the battery.
w
, located
q
SPARK PLUG SERVICE
Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart.
1. Tilt the rear cargo box to access the top of the engine.
CAUTION
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 capsq.
NOTICE
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.
NOTICE
Spark plug wells have drain holes built into the cylinder
head to allow water to drain out.
2.40
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.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
9. If necessary, replace spark plug with proper type.
CAUTION
Severe engine damage may occur if the incorrect spark
plug is used.
MAINTENANCE
Recommended Spark Plugs:
NGK MR7F
10.Apply anti-seize compound to the spark plug threads.
11.Install spark plugs and torque to specification.
TORQUE
Spark Plug:
7 lb-ft (10 Nm)
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.
2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
2.41
MAINTENANCE
NOTES
2.42
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING / HVAC SYSTEM
CHAPTER 3
ENGINE / COOLING / HVAC SYSTEM
900 / 1000 ENGINE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
GENERAL INFORMATION - ENGINE (900 / 1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
SERVICE NOTES - ENGINE / COOLING SYSTEM (900/1000) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
SPECIAL TOOLS - ENGINE / COOLING SYSTEM (900/1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
TORQUE SPECIFICATIONS - ENGINE / COOLING SYSTEM (900/1000). . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
SERVICE SPECIFICATIONS - ENGINE / COOLING SYSTEM (900/1000) . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
900 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
1000 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES (900 / 1000) . . . . . . . . . . . . . .3.12
MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE .. . . . . . . . . . . . . . . . .3.12
BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS. . . . . . . . . . .3.16
CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP... . . . . . . . . . . . . .3.17
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER . . . . . . . . . . . . . .3.18
SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER . . . .3.19
ENGINE SERVICE (900 / 1000).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
ENGINE INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
OIL PRESSURE TEST... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
ENGINE OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30
ENGINE DISASSEMBLY / INSPECTION - TOP END (900 / 1000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CAMSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
CAMSHAFT SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
CAMSHAFT / CAMSHAFT BORE INSPECTION (900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
CAMSHAFT / CAMSHAFT BORE INSPECTION (1000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
COMBUSTION CHAMBER CLEANING .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
VALVE SEAT RECONDITIONING (900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
VALVE SEAT RECONDITIONING (1000).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
ENGINE DISASSEMBLY / INSPECTION - LOWER END (900 / 1000) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
STATOR COVER REMOVAL / INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
WATER PUMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
STARTER ONE-WAY CLUTCH DISASSEMBLY ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
3
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.1
ENGINE / COOLING / HVAC SYSTEM
CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
CRANKCASE INSPECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CYLINDER / PISTON REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
PISTON DISASSEMBLY / INSPECTION (900)... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
PISTON DISASSEMBLY / INSPECTION (1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
PISTON RING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
PISTON RING TO GROOVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
PISTON RING TO GROOVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
PISTON RING INSTALLED GAP (900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
PISTON RING INSTALLED GAP (1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61
PISTON-TO-CYLINDER CLEARANCE (900) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
PISTON-TO-CYLINDER CLEARANCE (1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
ENGINE ASSEMBLY - LOWER END (900 / 1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
CRANKSHAFT MAIN BEARING SELECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
UPPER CRANKCASE PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66
PISTON RING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
CYLINDER / PISTON INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.69
CRANKSHAFT INSTALLATION (900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.70
CRANKSHAFT INSTALLATION (1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71
BALANCE SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
LOWER CRANKCASE PREPARATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.74
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74
STARTER ONE-WAY CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.78
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
ENGINE ASSEMBLY - TOP END (900 / 1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.82
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.83
CAMSHAFT INSTALLATION / TIMING (900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84
CAMSHAFT INSTALLATION / TIMING (1000) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.89
CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.92
VALVE CLEARANCE ADJUSTMENT... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.93
VALVE COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.95
VALVE LASH - TAPPET SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.96
INTAKE / EXHAUST SERVICE (900 / 1000) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97
INTAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97
INTAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98
INTAKE MANIFOLD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100
INTAKE MANIFOLD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
EXHAUST REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.104
3.2
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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ENGINE / COOLING / HVAC SYSTEM
COOLING SYSTEM SERVICE (900 / 1000) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.105
COOLING SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.105
WATER PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.106
COOLING SYSTEM SPECIFICATIONS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
COOLING SYSTEM PRESSURE TEST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
RADIATOR CAP PRESSURE TEST.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
RADIATOR FAN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
RADIATOR REMOVAL / COOLANT DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.109
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.110
WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.111
WATER PUMP INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.111
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.113
TROUBLESHOOTING - ENGINE / COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.115
ENGINE TROUBLESHOOTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.115
COOLING SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.116
HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.117
GENERAL INFORMATION - HVAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.117
HVAC SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.117
SPECIAL TOOLS - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.117
HVAC SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.118
AIR CONDITIONING DESCRIPTION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.118
HVAC ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.119
A/C SYSTEM DIAGRAM... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.120
SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
HVAC SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
HVAC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
COMPRESSOR DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
A/C CONDENSER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
HVAC FILTER INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125
RECLAMATION AND CHARGING WITH RECOVERY / CHARGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.126
HVAC SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
COMPRESSOR DRIVE BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
COMPRESSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.129
COMPRESSOR OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
COMPRESSOR OIL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
ALTERNATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.131
ALTERNATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.132
HVAC COVER MOUNT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.133
CONDENSER REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.134
RECEIVER / DRIER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.135
PRESSURE RELIEF VALVE REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
HIGH PRESSURE CUT-OUT (HPCO) SWITCH OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
HPCO SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
HEATER / EVAPORATOR UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
EXPANSION VALVE / EVAPORATOR COIL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.137
HEATER COIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.139
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3.3
ENGINE / COOLING / HVAC SYSTEM
BLOWER UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.139
A/C THERMOSTAT OVERVIEW .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.139
HEATER VALVE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.140
HVAC CONTROL SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
HVAC CONTROL OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
A/C SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
FAN SWITCH TESTING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
TEMPERATURE POTENTIOMETER TESTING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
HVAC BREAKOUT DIAGRAM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.142
TROUBLESHOOTING - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.143
BLOWER MOTOR DOES NOT OPERATE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.143
BLOWER MOTOR OPERATES NORMALLY BUT AIR FLOW IS INSUFFICIENT . . . . . . . . . . . . . . . . . . . . . 3.143
INSUFFICIENT COOLING (AIR FLOW AND COMPRESSOR OPERATION ARE NORMAL) ... . . . . . . . 3.144
COMPRESSOR DOES NOT OPERATE AT ALL OR OPERATES IMPROPERLY . . . . . . . . . . . . . . . . . . . . . 3.144
GAUGE PRESSURE RELATED TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.146
TEMPERATURE / PRESSURE CHART .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.147
POOR A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.148
ENGINE COOLANT BYPASSING THE HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.148
3.4
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
900 / 1000 ENGINE
ENGINE / COOLING / HVAC SYSTEM
GENERAL INFORMATION - ENGINE (900 /
1000)
SERVICE NOTES - ENGINE / COOLING SYSTEM (900/1000)
The following components can be serviced or removed with the engine installed:
• Camshaft(s)
• Camshaft Sprocket(s)
• Cylinder Head
• Flywheel
• Oil Cooler
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
• Water Pump
The following components require engine removal for service:
• Camshaft Timing Chain
• Connecting Rod(s)
• Counterbalance Shaft / Bearings
• Crankcase
• Crankshaft / Main Bearings
• Crankshaft Seal (PTO)
• Cylinder
• Oil Pump / Oil Pump Sprocket or Chain
• Piston / Rings
SPECIAL TOOLS - ENGINE / COOLING SYSTEM (900/1000)
TOOL DESCRIPTION PART NUMBER
Drive Clutch Puller 2872085
Engine Stand Adapter (Mounts To The Engine)
Engine Stand Sleeve Adapter (Use With 2” Bore Stand)
Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)
Engine Stand (2” Bore)
Clutch Center Distance Tool PU-50658-A
Oil Pressure Gauge Adapter
Oil Pressure Gauge
Cylinder Holding & Camshaft Timing Plate
Valve Spring Compressor Adapter
Flywheel Puller
Piston Ring Compressor Pliers
Spring Puller
Mityvac® Pressure Test Tool
Water Pump Mechanical Seal Installer
Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/
PU-50562
PU-50625
PW-47054
PU-50624
PU-50565
PV-43531
PU-50563
PV-43513-A
PA-49316
PV-43570-1
PU-45485
2870975
PU-50564
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3.5
ENGINE / COOLING / HVAC SYSTEM
TORQUE SPECIFICATIONS - ENGINE / COOLING SYSTEM (900/1000)
PART DESCRIPTION
Starter Motor Bolts
Transmission Joint Bracket Bolts
Engine / Transmission Mounting Bolts Step 1–2
Engine / Transmission Mounting Bolts Step 3
Engine / Transmission Mounting Bolts Step 4–7
Front Engine Mount Fasteners
Intake Plenum Hose Clamps
Lower Intake Plenum Fastener
Fuel Rail Mounting Bolts 5 lb-ft (7 Nm)
Crankcase Gallery Plug 22 lb-ft (30 Nm)
Camshaft Carrier Bolts
Connecting Rod Bolts Step 1 (900)
Connecting Rod Bolts Step 2 (900)
Connecting Rod Bolts Step 3 (900)
Connecting Rod Bolts Step 1 (1000)
Connecting Rod Bolts Step 2 (1000)
Connecting Rod Bolts Step 3 (1000)
Lower Crankcase Bolts Step 1 (M10)
Lower Crankcase Bolts Step 2 (M10)
Lower Crankcase Bolts Step 3 (M10)
Lower Crankcase Bolts (M8)
TORQUE
SPECIFICATION
7 lb-ft (10 Nm)
44 lb-ft (60 Nm)
64 lb-ft (87 Nm)
5 lb-ft (7 Nm)
44 lb-ft (60 Nm)
40 lb-ft (54 Nm)
17 lb-in (2 Nm)
22 lb-ft (30 Nm)
7 lb-ft (10 Nm)
9 lb-ft (12 Nm)
22 lb-ft (30 Nm)
Additional 90°
9 lb-ft (12 Nm)
13 lb-ft (18 Nm)
Additional 105°
9 lb-ft (12 Nm)
21 lb-ft (28 Nm)
Additional 90°
26 lb-ft (35 Nm)
PART DESCRIPTION
Lower Crankcase Bolts (M6)
Upper Crankcase Bolts (M8)
Upper Crankcase Bolts (M6)
Oil Pump Mounting Bolts 7 lb-ft (10 Nm)
Oil Pump Pick-Up Retaining Screws
Oil Sump Cover Bolts (M6)
Oil Sump Cover Bolts (M8)
Crankcase Drain Plug 12 lb-ft (16 Nm)
Oil Cooler Retaining Bolts 7 lb-ft (10 Nm)
One Way Clutch Retaining Screws
Flywheel Retaining Bolt 133 lb-ft (180 Nm)
Stator Cover Screws
Cylinder Head Bolts Step 1
Cylinder Head Bolts Step 2
Cylinder Head Bolts Step 3
Cylinder Head Bolts (M6) 7 lb-ft (10 Nm)
Cam Chain Tensioner Spring Bolt (900)
Cam Chain Tensioner Mounting Bolts (900)
Cam Chain Tensioner (1000)
Camshaft Sprocket Bolts (900)
Camshaft Sprocket Bolts (1000)
Spark Plug (900/1000) 7 lb-ft (10 Nm)
TORQUE
SPECIFICATION
9 lb-ft (12 Nm)
26 lb-ft (35 Nm)
7 lb-ft (10 Nm)
7 lb-ft (10 Nm)
9 lb-ft (12 Nm)
26 lb-ft (35 Nm)
9 lb-ft (12 Nm)
9 lb-ft (12 Nm)
9 lb-ft (12 Nm)
26 lb-ft (35 Nm)
Additional 180°
15 ft-lb (20 Nm)
7 ft-lb (10 Nm)
30 lb-ft (40 Nm)
11 lb-ft (15 Nm)
14 lb-ft (19 Nm)
3.6
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING / HVAC SYSTEM
PART DESCRIPTION
Valve Cover Bolts
Engine Intake Duct Clamps
Air Box Fasteners
Exhaust Headpipe Mounting Bolts
Thermostat Cover Bolts
Coolant Bleed Screw
Water Pump Mounting Bolts
Water Pump Impeller Bolt 7 lb-ft (10 Nm)
Water Pump Cover Bolts 7 lb-ft (10 Nm)
TORQUE
SPECIFICATION
7 lb-ft (10 Nm)
17 lb-in (2 Nm)
8 lb-ft (11 Nm)
18 lb-ft (24 Nm)
7 ± 1 lb-ft (10 ± 1 Nm)
7 ± 1 lb-ft (10 ± 1 Nm)
7 lb-ft (10 Nm)
3
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.7
ENGINE / COOLING / HVAC SYSTEM
SERVICE SPECIFICATIONS - ENGINE / COOLING SYSTEM (900/1000)
900 ENGINE
CAMSHAFT / CYLINDER HEAD / CYLINDER
Cam Lobe Height - Intake (Standard) 1.5256" ± 0.0015" (38.75 ± 0.04 mm)
Cam Lobe Height - Intake (Service Limit) 1.5220" (38.66 mm)
Cam Lobe Height - Exhaust (Standard) 1.4961" ± 0.0015" (38.00 ± 0.04 mm)
Cam Lobe Height - Exhaust (Service Limit) 1.4925" (37.91 mm)
Camshaft Journal O.D. - All (Standard) 0.9035" - 0.9046" (22.949 - 22.978 mm)
Camshaft
Cylinder Head
Valve Seat
Valve Guide Valve Guide Inner Diameter
Valve
Valve Spring
Cylinder
Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)
Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)
Camshaft Oil Clearance (Standard) 0.0009" - 0.0028" (0.022 - 0.072 mm)
Camshaft Oil Clearance (Service Limit) 0.0039" (0.1 mm)
Camshaft End Play (Standard) 0.0040" - 0.0100" (0.101 - 0.254 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0039" (0.1 mm)
Cylinder Head - Standard Height 4.717" ± 0.0019" (119.8 ± 0.05 mm)
Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)
Valve Seat - Contacting Width - Intake (Service Limit) 0.0551" (1.4 mm)
Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)
Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)
Valve Seat Angles
Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.15 ± 0.05 mm)
Valve Lash (Cold) - Exhaust 0.010" ± 0.002" (0.25 ± 0.05 mm)
Valve Stem Diameter - Intake
Valve Stem Diameter - Exhaust
Valve Stem Oil Clearance - Intake
Valve Stem Oil Clearance - Exhaust Valve Overall Length - Intake 3.7704" (95.77 mm)
Valve Overall Length - Exhaust 3.8023" (96.58 mm)
Valve Spring Free Length (Standard) 1.7213" (43.72 mm)
Valve Spring Free Length (Service Limit) 1.6830" (42.75 mm)
Cylinder - Surface Warp Limit (mating with cylinder head)
Cylinder Bore - Standard 3.6614" ± 0.0003" (93 mm ± 0.008 mm)
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.0014" - 0.0026" (0.035 - 0.065 mm)
30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
0.2165" - 0.2171" (5.500 - 5.515 mm)
0.2155" - 0.2161" (5.475 - 5.490 mm)
0.2147" - 0.2153" (5.455 - 5.470 mm)
0.0003" - 0.0015" (0.010 - 0.040 mm)
0.0011" - 0.0023" (0.030 - 0.060 mm)
0.002" (0.05 mm)
3.8
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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ENGINE / COOLING / HVAC SYSTEM
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
Piston
Piston Pin
Piston Ring
Connecting Rod
Crankshaft
Balance Shaft
Piston - Standard O.D. - Measured 90 degrees to pin,
0.51 in. (13 mm) up from piston skirt. See text.
Piston Pin Bore I.D. (Standard) 0.7876" - 0.7878" (20.004 - 20.009 mm)
Piston Pin Bore I.D. (Service Limit) 0.7893" (20.05 mm)
Piston Pin O.D. (Standard) 0.7872" - 0.7874" (19.995 - 20.000 mm)
Piston Pin O.D. (Service Limit) 0.7866" (19.98 mm)
Top Ring (Standard) 0.008" - 0.014" (0.20 - 0.36 mm)
Top Ring (Service Limit) 0.020" (0.5 mm)
Installed Gap
Ring to Groove Clearance
Connecting Rod Small End I.D. (Standard) 0.7879" - 0.7884" (20.015 - 20.025 mm)
Connecting Rod Small End I.D. (Service Limit) 0.7897" (20.06 mm)
1 - Marking Connecting Rod Big End Bore I.D. 1.7318" - 1.7321" (43.989 - 43.996 mm)
2 - Marking Connecting Rod Big End Bore I.D. 1.7321" - 1.7323" (43.996 - 44.003 mm)
3 - Marking Connecting Rod Big End Bore I.D. 1.7323" - 1.7326" (44.003 - 44.010 mm)
B - Marking Main Journal O.D. (Standard) 1.6140" - 1.6143" (40.996 - 41.004 mm)
G - Marking Main Journal O.D. (Standard) 1.6137" - 1.6140" (40.988 - 40.995 mm)
Y - Marking Main Journal O.D. (Standard) 1.6134" - 1.6137" (40.980 - 40.987 mm)
Main Journal O.D. (Service Limit) 1.6126" (40.960 mm)
B - Marking Rod Journal O.D. (Standard) 1.6118" - 1.6122" (40.942 - 40.950 mm)
G - Marking Rod Journal O.D. (Standard) 1.6115" - 1.6118" (40.934 - 40.941 mm)
Y - Marking Rod Journal O.D. (Standard) 1.6112" - 1.6115" (40.926 - 40.933 mm)
Rod Journal O.D. (Service Limit) 1.6104" (40.906 mm)
Crankshaft Runout Limit (PTO and MAG) Less than 0.001" (0.025 mm)
Auxiliary Sprocket Installed Depth 4.9527" ± 0.0078" (125.8 ± 0.2 mm)
Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm)
Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm)
Second Ring (Standard) 0.015" - 0.025" (0.37 - 0.63 mm)
Second Ring (Service Limit) 0.028" (0.70 mm)
Oil Control Rails (Standard) 0.010" - 0.040" (0.25 - 1.02 mm)
Oil Control Rails (Service Limit) 0.059" (1.50 mm)
Top Ring (Standard) 0.0012" - 0.0037" (0.030 - 0.095 mm)
Second Ring (Standard) 0.0012" - 0.0030" (0.030 - 0.076 mm)
Service Limit
3.6592 ± 0.0003" (92.950 ± 0.008 mm)
0.0047" (0.12 mm)
3
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.9
ENGINE / COOLING / HVAC SYSTEM
1000 ENGINE
CAMSHAFT / CYLINDER HEAD / CYLINDER
ITEM
Cam Lobe Height - Intake 1.5390 - 1.5429" (39.09 - 39.19 mm) 1.5370" (39.04 mm)
Cam Lobe Height - Exhaust 1.5142 - 1.5181" (38.46 - 38.56 mm) 1.5122" (38.41 mm)
Camshaft
Cylinder
Cylinder Head
Valve
Valve Guide
Valve Seat
Camshaft Journal O.D. - All
Camshaft Carrier Bore I.D. - All
Camshaft Oil Clearance
Camshaft End Play .0040 - .0100" (0.101 - 0.254 mm) .0157" (0.4 mm)
Cylinder - Surface Warp Limit (cylinder head surface)
Cylinder Bore - Standard 3.6614 ± .0003" (93 mm ± 0.008 mm)
Cylinder Out of Round Limit
Cylinder Taper Limit
Cylinder to Piston Clearance .0009 - .0019" (0.025 - 0.050 mm)
Cylinder Head - Surface Warp Limit
Cylinder Head - Standard Height 4.717 ± .0019" (119.82 ± 0.05 mm)
Valve Lash (Cold) - Intake .006 ± .002" (0.15 ± 0.05 mm)
Valve Lash (Cold) - Exhaust .010 ± .002" (0.25 ± 0.05 mm)
Valve Stem Diameter - Intake
Valve Stem Diameter - Exhaust
Valve Stem Oil Clearance - Intake
Valve Stem Oil Clearance - Exhaust
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
Valve Stem Overall Length - Exhaust 3.8023" (96.58 mm)
Valve Guide Inner Diameter
Valve Seat - Contacting Width - Intake .0393 ± .0039" (1.0 ± 0.10 mm) .0551" (1.4 mm)
Valve Seat - Contacting Width - Exhaust .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm)
Valve Seat Angles
STANDARD SERVICE LIMIT
.9036 - .9055" (22.954 - 22.999 mm) .9033" (22.944 mm)
.9055 - .9063" (23.000 - 23.021 mm) .9072" (23.044 mm)
.0000 - .0026" (0.001 - 0.067 mm) .0039" (0.1 mm)
-
-
-
-
.2155 - .2161" (5.475 - 5.490 mm)
.2147 - .2153" (5.455 - 5.470 mm)
.0003 - .0015" (0.010 - 0.040 mm)
.0011 - .0023" (0.030 - 0.060 mm)
.2165 - .2171" (5.500 - 5.515 mm)
30.0° ± 1.5°
45.0° ± 0.5°
60.0° ± 1.5°
.002″ (0.05 mm)
-
.001″ (0.025 mm)
.001″ (0.025 mm)
-
.0039″ (0.1 mm)
-
-
-
-
-
-
-
-
-
-
-
3.10
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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ENGINE / COOLING / HVAC SYSTEM
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
ITEM
Piston
Piston Ring
Connecting Rod
Crankshaft
Balance Shaft
Standard O.D. - Measured 90° to pin, 0.39 in. (10 mm) up from piston skirt
Piston Pin Bore I.D. (Standard) .7877 - .7881" (20.009 - 20.018 mm) .7893" (20.05 mm)
Piston Pin O.D.
Top Ring .010 - .014" (0.25 - 0.35 mm) .0196" (0.5 mm)
Installed Gap
Ring to Groove Clearance
Connecting Rod Small End I.D. .7879 - .7885" (20.015 - 20.030 mm) .7897" (20.06 mm)
1 - Marking Conn. Rod Big End Bore I.D. 1.7318 - 1.7321" (43.989 - 43.996 mm)
2 - Marking Conn. Rod Big End Bore I.D. 1.7321 - 1.7323" (43.996 - 44.003 mm)
3 - Marking Conn. Rod Big End Bore I.D. 1.7323 - 1.7326" (44.003 - 44.010 mm)
B - Marking
G - Marking
Y - Marking
B - Marking
G - Marking
Y - Marking
Crankshaft Runout Limit (PTO and MAG)
Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm)
Second Ring .015 - .025" (0.37 - 0.63 mm) .028" (0.70 mm)
Oil Control Rails
Top Ring
Second Ring
Main Journal O.D.
Main Journal O.D.
Main Journal O.D.
Rod Journal O.D.
Rod Journal O.D.
Rod Journal O.D.
3.6597 ± .0003" (92.959 ± 0.008 mm)
.7873 - .7875" (20.000 - 20.005 mm) .7866" (19.98 mm)
1.6140 - 1.6143" (40.996 - 41.004 mm) 1.6129" (40.970 mm)
1.6137 - 1.6140" (40.988 - 40.995 mm) 1.6129" (40.970 mm)
1.6134 - 1.6137" (40.980 - 40.987 mm) 1.6129" (40.970 mm)
1.6118 - 1.6122" (40.942 - 40.950 mm) 1.6104" (40.906 mm)
1.6115 - 1.6118" (40.934 - 40.941 mm) 1.6104" (40.906 mm)
1.6112 - 1.6115" (40.926 - 40.933 mm) 1.6104" (40.906 mm)
STANDARD SERVICE LIMIT
.008 - .028" (0.20 - 0.70 mm) .0354" (0.9 mm)
.0007 - .0023" (0.020 - 0.060 mm) .0047" (0.12 mm)
-
-
-
-
-
Less than .001″ (0.025
mm)
3
FLUID CAPACITY
Oil Capacity *: 2.5 Qt (2.4 L)
Oil Type: 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
Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature)
10 PSI (69 kPa) @ 1200 RPM
40 PSI (276 kPa) @ 7000 RPM
*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.11
ENGINE / COOLING / HVAC SYSTEM
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES (900 / 1000)
MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE
Cam Carrier
3.12
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Crankcase Split-Line (Bottom)
ENGINE / COOLING / HVAC SYSTEM
3
Crankcase Split-Line (Top)
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3.13
ENGINE / COOLING / HVAC SYSTEM
Cylinder Head
Sump Cover
3.14
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
Stator Cover
ENGINE / COOLING / HVAC SYSTEM
3
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.15
ENGINE / COOLING / HVAC SYSTEM
BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS
3.16
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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ENGINE / COOLING / HVAC SYSTEM
CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP
3
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.17
ENGINE / COOLING / HVAC SYSTEM
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER
3.18
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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ENGINE / COOLING / HVAC SYSTEM
SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER
3
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
3.19
ENGINE / COOLING / HVAC SYSTEM
ENGINE SERVICE (900 / 1000)
ACCESSIBLE ENGINE COMPONENTS
The following components can be serviced or removed with the engine installed:
• Camshaft(s)
• Camshaft Sprocket(s)
• Cylinder Head
• Flywheel
• Oil Cooler
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
• Water Pump
The following components require engine removal for service:
• Camshaft Timing Chain
• Connecting Rod(s)
• Counterbalance Shaft / Bearings
• Crankcase
• Crankshaft / Main Bearings
• Crankshaft Seal (PTO)
• Cylinder
• Oil Pump / Oil Pump Sprocket or Chain
• Piston / Rings
ENGINE REMOVAL
NOTICE
Some engine repair procedures can be performed without removing the engine assembly from the vehicle. Refer to “Accessible Engine Components”page 3.20
for further information.
The use of an overhead or portable engine hoist is the
only recommended method for removing and installing
the engine.
Have an assistant help guide the engine in and out of
the vehicle while using an engine hoist to prevent
personal injury or damage to vehicle components.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
1. If vehicle was recently operated, allow it to cool down before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Drain the engine oil and coolant prior to engine removal. Refer to Engine Oil and Filter
Changepage 2.15 and “Radiator Removal / Coolant Drain”page 3.108 procedures.
4. Remove rear cargo box from vehicle. Refer to “Cargo Box Removal”page 10.27 procedure.
5. Lift up the passenger seat and disconnect the (-) negative battery cable from the battery.
6. Remove the PVT outer cover, drive and driven clutch, and inner cover. Refer to PVT
Disassemblypage 5.9 procedure.
Correct Drive Clutch Puller P/N 2872085
3.20
CAUTION
Be sure to use the correct Drive Clutch Puller (PN
2872085) to prevent damage to crankshaft.
7. Remove the exhaust system from the vehicle. Refer
“Exhaust Removal / Installation”page 3.104
procedure.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
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