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.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

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

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.

1.2

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

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.

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

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/

1.4

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

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

1.6

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

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.

1.7

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

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

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.

1.9

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

1.10

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

CHAPTER 6 — TRANSMISSION

Drive Clutch Puller PA-48595

Drive Clutch Puller 2872085

GENERAL INFORMATION

Clutch Center Distance Tool PU-50658-A

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

CHAPTER 11 — ELECTRICAL

PV-43568 Fluke™ 77 Digital Multimeter PF-51237

Static Timing Light Harness 2871745

GENERAL INFORMATION

Hall Effect Sensor Probe Harness 2460761

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)

9 lb-ft (12 Nm)

26 lb-ft (35 Nm)

1.14

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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)

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)

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)

8 lb-ft (11 Nm)

18 lb-ft (24 Nm)

7 lb-ft (10 Nm)

8 lb-ft (11 Nm)

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

1.16

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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)

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.17

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)

1.18

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

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.

1.19

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.

1.20

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.21

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

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)

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 .

1.22

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.23

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

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)

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 .

1.24

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.25

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

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)

For the clutch chart, see Clutch Chartpage 1.29

1.26

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.27

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

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)

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

1.28

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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)

Black (7044655)

7044021

7044015

3234452

3235964

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.29

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

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

1.30

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

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)

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.31

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

F 2–12

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

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

1/8

5/32

13/64

15/64

9/32

17/64

5/16

11/32

3/8

13/32

1.32

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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″

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

1.33

GENERAL INFORMATION

NOTES

1.34

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

2.1

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

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

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

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.

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

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

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 1 M

25 H

50 H 6 M

CALEN-

DAR

Monthly 100 (160) Inspect periodically

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)

Change fluid every 25 hours if ADC is subjected to extreme use

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

2.8

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

50 - 500 HOUR MAINTENANCE INTERVAL

MAINTENANCE INTERVAL

ITEM

■ Throttle Pedal 50 H 6 M

Air Intake Ducts / Adapters

Drive Belt 50 H 6 M

Cooling System

▶

Radiator 50 H 6 M

Oil Lines, fasteners

▶

Engine Oil and Filter Change

Front Gearcase Lubricant

▶

(Demand Drive Fluid)

Transmission Lubricant

▶

(AGL Gearcase Lubricant)

■ Fuel System

Cooling Hoses

▶

Engine Mounts

▶

Exhaust Silencer / Pipe

Drive Shafts 100 H 12 M

■ Spark Plug

Wiring

▶

Clutches (Drive and Driven)

■

Wheel Bearings

■

Ratcheting Cam Chain Tensioner

■

Brake Fluid 200 H 24 M

Suspension Bushings

Spark Arrestor

■

Spark Plug Replacement

■

Valve Clearance 500 H

▶

Coolant

Toe Adjustment

■

Headlight Aim

(WHICHEVER COMES FIRST)

HRS CALENDAR

50 H 6 M

100 H 6 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)

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

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.

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

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

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

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

Stabilizer Bar Bushings

Propshaft Yoke

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

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.

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.

the proper adjustment.

attached to the transmission

NOTICE

, and

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

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

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.

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

out of the way

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)

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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.

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.

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.

2.18

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

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.

gloves.

time.

and nutw.

from the end of the

2.20

TORQUE

Spark Arrestor:

8 lb-ft (11 Nm)

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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.

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)

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

MAINTENANCE

RADIATOR INSPECTION / CLEANING

1. Check radiator air passages for restrictions or damage.

Radiator

Shroud

Fan

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.

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

4.18 procedure.

2.24

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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,

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,

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

ENGINE AIR INTAKE EXPLODED VIEW

MAINTENANCE

REF

DESCRIPTION

LID, AIRBOX

BASE, AIRBOX

CLIP, AIRBOX

BRACKET, AIRBOX MOUNT

HOSE, ENGINE INTAKE

HOSE, ENGINE VENT

HOSE, AIRBOX INTAKE

CLAMP, HOSE

REF

DESCRIPTION

CLAMP, HOSE

CLAMP, SPRINGBAND

FILTER, MAIN AIRBOX

PLUG, DRAIN

HOSE, INTAKE BOOT

FENDER, INTAKE REAR

DUCT, AIR INTAKE

CLAMP, HOSE

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

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

Close-off Bracket

Chassis Shield

Silencer Shield, Main

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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.

7. Remove drain plugwand allow lubricant to drain completely.

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.

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

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

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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.

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.

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.

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.

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

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.

NOTICE

and/or hub nutrto the proper

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.

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

wheel.

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)

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.

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

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

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).

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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.

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)

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

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

from

Vehicle loads effect suspension spring pre-load requirements. Use Spanner Wrench to adjust pre-load as necessary to avoid bottoming of the shocks.

Shock Spanner Wrench:

2871095

REAR SHOCK

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

TORQUE

Shock Mounting Bolts:

40 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

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

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-

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-

first.

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.

, located

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

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.

2.41

MAINTENANCE

NOTES

2.42

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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

3.1

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 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

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

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

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

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)

9 lb-ft (12 Nm)

26 lb-ft (35 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

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 lb-ft (10 Nm)

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

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)

3.9

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)

.0039″ (0.1 mm)

3.10

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

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.

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)

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.

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

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

Crankcase Split-Line (Bottom)

ENGINE / COOLING / HVAC SYSTEM

Crankcase Split-Line (Top)

3.13

ENGINE / COOLING / HVAC SYSTEM

Cylinder Head

Sump Cover

3.14

9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual

Stator Cover

ENGINE / COOLING / HVAC SYSTEM

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

ENGINE / COOLING / HVAC SYSTEM

CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP

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

ENGINE / COOLING / HVAC SYSTEM

SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER

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

Polaris RANGER XP 900 (2019) Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual