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.
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
REVDATE
R017/13/18
For more detailed information on vehicle updates, refer to the applicable Model Year Update training module at:
www.mytrainingandrewards.com .
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
When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.
OWNER’S
MANUAL
9928295
9928407
9928407
9928300
9928851
REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.
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
* = 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 DESCRIPTORSVEHICLE IDENTIFIERS
1
WORLD MFG. ID
MAKE /
CHASSIS
CATEGORY
ENGINE
ENGINE SIZE
MODIFIER
CHECK DIGIT
MODEL YEAR *
MFG. LOCATION
INDIVIDUAL SERIAL NO.
1234567891011121314151617
4XASEA
570F3000000
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J= 2018; K= 2019
Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number
(VIN) and the engine model number and serial number.
The engine model and serial number can be found on a decal applied to the MAG side of the cylinder headqor
stamped into the crankcase on the PTO side of the engine
The VIN can be found stamped on a portion of the upper left frame raileabove the airbox.
w
1.20
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Polaris parts available from your Polaris dealer.
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
IMPORTANT
Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer technician perform these operations.
SPECIAL TOOLS - MAINTENANCE
2
TOOL DESCRIPTION
Oil Filter Wrench
Shock Spanner Wrench
Bosch Automotive Service Solutions: 1-800-328-6657 or https://polaris.service-solutions.com/
Inspection, adjustment and lubrication of important
components are explained in the periodic maintenance
chart.
Inspect, clean, lubricate, adjust and replace parts as
necessary. When inspection reveals the need for
replacement parts, use genuine Pure Polaris parts
available from your Polaris dealer.
NOTICE
Service and adjustments are critical. If you’re not
familiar with safe service and adjustment procedures,
have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based
upon average riding conditions and an average vehicle
speed of approximately 10 miles per hour. Vehicles
subjected to severe use must be inspected and serviced
more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
MAINTENANCE CHART KEY
The following symbols denote potential items to be
aware of during maintenance:
■ = CAUTION: Due to the nature of these
adjustments, it is recommended this service be
performed by an authorized Polaris dealer.
▶ = SEVERE USE ITEM: See information provided
above.
E = Emission Control System Service (California).
NOTICE
Inspection may reveal the need for replacement parts.
Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked ■ could
result in component failure and lead to serious injury or
death. Have an authorized Polaris dealer perform these
services.
2
Pay special attention to the oil level. A rise in oil level
during cold weather can indicate contaminants collecting
in the oil sump or crankcase. Change oil immediately if
the oil level begins to rise. Monitor the oil level, and if it
continues to rise, discontinue use and determine the
cause or see your dealer.
BREAK-IN PERIOD
The break-in period consists of the first 25 hours of
operation, or the time it takes to use 14 gallons (53 liters)
of fuel. Careful treatment of a new engine and drive
components will result in more efficient performance and
longer life for these components.
• Drive vehicle slowly at first while varying the throttle
position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas
outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or
one month.
• See “Owner’s Manual” for additional break-in
information.
There are grease fittings at each A-arm pivot point, each rear stabilizer bar bushing, and on the propshaft yoke. Apply
grease until all traces of water have been purged out at each of these areas.
ITEM
A-arm Pivot Bushings
q
Stabilizer Bar Bushings
w
Propshaft Yoke
e
METHODRECOMMENDED LUBE
Grease all fittings on
each side of the vehicle
Grease the fitting
(3 pumps maximum)
NON-CREW MODELSCREW 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
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 Inspectionpageprocedure)
• 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.
3. If adjustment is required, loosen the upper jam nut
and pull the cable out of the mountwto move the
lower jam nut
4. Adjust the shift cable so there is the same amount of
cable travel when shifting slightly past HIGH gear and
PARK.
5. Thread the upper or lower jam nut as required to
obtain proper cable adjustment.
This procedure may require a few attempts to obtain
. Replace if worn or damaged.
e
.
y
the proper adjustment.
attached to the transmission
q
NOTICE
r
, and
t
2.14
6. Once the proper adjustment is obtained, place the
shift cable and lower jam nut into the mount. Tighten
the upper jam nut against the mount.
7. Start engine and shift through all gears to ensure the
shift cable is properly adjusted. If transmission still
ratchets after cable adjustment, the transmission will
require service.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
The engine has a wet-sump design, meaning the engine
oil is contained in the bottom of the crankcase. To check
the oil level follow the procedure listed below:
Access the oil dipstick and oil fill cap by tilting the rear
cargo box.
Polaris recommends the use of PS-4 Synthetic or PS-4
Extreme Duty Synthetic 4-Cycle Engine Oil.
FLUID CAPACITY
Recommended Engine Oil:
PS-4 Synthetic (PN 2876244)
Ambient Temp Range: -35° F to 100° F
PS-4 Extreme Duty Synthetic (PN 2878920)
Ambient Temp Range: 0° F to 120° F
Capacity: 2.5 Qt (2.4 L)
1. Remove all cargo from the cargo box.
CAUTION
Always remove all cargo from the cargo box before
lifting the box to access the engine.
2. Position the vehicle on a level surface and place the
transmission in PARK.
3. Stop the engine and allow it to cool down before
removing the dipstick.
4. Pull up on the cargo box release lever to tilt the box.
5. From the right side of the vehicle, unlock the dipstick
lever
clean cloth.
. Remove the dipstick and wipe it dry with a
q
6. Reinstall the dipstick and push it into place. Do not
lock the dipstick
NOTICE
Make certain the dipstick is inserted all the way into the
dipstick tube to keep the depth of the dipstick
consistent.
7. Remove the dipstick and check the oil level.
8. Add the recommended oil as necessary to bring the
oil level within the SAFE range on dipstick. Do not
overfill (see NOTICE below).
NOTICE
A rising oil level between checks during cold weather
operation can indicate contaminants such as gas or
moisture collecting in the crankcase. If the oil level is
over the upper mark, change the oil immediately.
9. Add engine oil through the oil fill capwlocated on top
of the valve cover.
10.When finished, reinstall dipstick and lock the lever.
Always change engine oil and filter at the intervals
outlined in the Periodic Maintenance Chart. Always
change the oil filter whenever changing the engine oil.
The engine oil dipstick is located on the right front side of
the engine. The engine oil fill cap is located on top of the
valve cover. Access the oil dipstick and oil fill cap by
tilting the rear cargo box
The crankcase drain plug is located on the bottom of the
crankcase. Access the drain plug through the skid plate
access hole located directly under the crankcase.
1. Position vehicle on a level surface and place the
transmission in PARK.
2. Stop the engine and allow it to cool down.
2.15
MAINTENANCE
3. Clean the area around the crankcase drain plug.
CAUTION
Use caution when performing this procedure. Do not
allow hot engine oil to come into contact with skin, as
4. Place a drain pan under the engine crankcase and
remove the drain plug. Allow the oil to drain
completely.
5. Remove all cargo from the cargo box.
serious burns may result.
CAUTION
Always remove all cargo from the cargo box before
lifting the box to access the engine.
6. Pull up on the cargo box release lever to tilt the box.
7. Gently press the clutch outlet duct
to gain access to the oil filter
w
.
out of the way
q
8. Using the Oil Filter Wrench (PU-50105), turn the oil
filterwcounter-clockwise to remove it.
Oil Filter Wrench:
PU-50105: 2.5” (64 mm)
9. Using a clean dry cloth, clean the filter sealing
surface on the engine crankcase.
10.Lubricate the O-ring on the new oil filter with a film of
fresh engine oil. Check to make sure the O-ring is in
good condition. Install it to specification.
TORQUE
Oil Filter:Turn by hand until filter O-ring contacts
sealing surface, then turn an additional 3/4 turn.
11. Replace the sealing washer on drain plug.
NOTICE
The sealing surface on the drain plug should be clean
and free of burrs, nicks or scratches.
2.16
12.Reinstall the engine crankcase drain plug. Torque
drain plug to specification.
TORQUE
Crankcase Drain Plug:
12 lb-ft (16 Nm)
13.Remove oil fill cap (refer to Engine Oil Levelpage
2.15 procedure). Fill engine with recommended
engine oil.
FLUID CAPACITY
Recommended Engine Oil:
PS-4 Synthetic (PN 2876244)
Ambient Temp Range: -35° F to 100° F
PS-4 Extreme Duty Synthetic (PN 2878920)
Ambient Temp Range: 0° F to 120° F
Capacity: 2.5 Qt (2.4 L)
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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 OilLevelpage 2.15 procedure).
18.Reinstall the dipstick and push it into place. Do not
lock the dipstick
NOTICE
Make certain the dipstick is inserted all the way into the
dipstick tube to keep the depth of the dipstick
consistent.
19.Remove the dipstick and check the oil level.
20.Add the recommended oil as necessary to bring the
oil level within the SAFE range on dipstick. Do not
overfill.
ENGINE CRANKCASE BREATHER HOSE
INSPECTION
The engine crankcase is equipped with a breather hose.
Inspect the breather hose for possible kinks or wear. The
hose is form fitted for proper fit.
Follow the breather hoseqfrom the crankcase fitting
to the airboxe.
w
NOTICE
Make sure hoses are not kinked or pinched.
ENGINE CYLINDER LEAKDOWN TEST
A cylinder leak-down test is the best indication of engine
condition. Follow tester manufacturer’s instructions to
perform a cylinder leak-down test. Never use high
pressure leakage testers as crankshaft seals may
dislodge and leak.
2
21.When finished, reinstall the oil fill cap, oil dipstick and
lock the lever.
If leakage exceeds service limit, inspect the engine for
the cause.
2.17
MAINTENANCE
VALVE CLEARANCE INSPECTION
NOTICE
Valve clearance inspection should be performed on a
cold engine, at room temperature.
1. Tilt the rear cargo box to access the valve cover.
2. Disconnect the negative (-) battery cable.
3. Remove the eight screws that retain the outer clutch
cover and remove the cover from the vehicle in order
to rotate the engine (refer to “Belt Removal”page
5.12 procedure).
NOTICE
Replace rubber isolators (F) upon assembly.
6. The engine will need to be rotated four times to
inspect all eight valve clearances. Two valves can be
measured at each camshaft lobe position.
4. Remove the spark plug wiresqfrom the engine.
5. Remove the four T-40 boltswand rubber isolators
retaining the valve coverr. Note the location and
use of the grounding washertfor assembly.
NOTICE
Remove spark plugs to aid engine rotation.
7. Rotate the drive clutch counter-clockwise until the
cam lobes above the valves you are inspecting are
facing up.
8. Measure the valve clearance using a feeler gauge.
e
2.18
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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. Installthe plunger bolt.Torque fastener to
specification.
TORQUE
Plunger Bolt:
15 ft-lb (20 Nm)
EXHAUST - SPARK ARRESTOR
WARNING
Do not clean spark arrestor immediately after the
engine has been run, as the exhaust system becomes
very hot. Serious burns could result from contact with
the exhaust components. Allow components to cool
sufficiently before proceeding. Wear eye protection and
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas that can
cause loss of consciousnessor death in a very short
Periodically clean spark arrestor to remove accumulated
carbon.
1. Remove the retaining screw
2. Remove the spark arrestor
silencer
3. Use a non-synthetic brush to clean the arrestor
screen. A synthetic brush may melt if components
are warm. If necessary, blow debris from screen with
compressed air.
4. Inspect the screen for wear and damage. Replace if
needed.
5. Reinstall the arrestor and torque the retaining screw
to specification.
r
.
gloves.
time.
and nutw.
q
from the end of the
e
2.20
TORQUE
Spark Arrestor:
8 lb-ft (11 Nm)
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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.
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
1. Check the quick-connect fuel lineqat the fuel pump
for signs of wear, deterioration, damage or leakage.
Replace line if necessary.
2. Tilt the rear cargo box and check the quick-connect
fuel line
deterioration, damage or leakage. Replace line if
necessary.
at the fuel rail for signs of wear,
w
VENT LINE
NOTICE
If the vent line fitting is removed from the fuel tank, it
must be replaced. The fitting will not hold properly once
1. Check the fuel tank vent line
deterioration, damage or leakage. Replace every two
years.
2. Be sure vent line is routed properly and secured.
Be sure vent line is not kinked or pinched.
it is removed.
NOTICE
for signs of wear,
q
2
3. Be sure fuel lines are routed and retained properly.
NOTICE
Make sure lines are not kinked or pinched.
Throttle Pedal Inspection
Inspect the throttle pedal
sure the throttle pedal returns normally when
released. Refer to “Pedal Position Sensor (PPS)Test”page 4.30 procedure if experiencing a lack of
throttle response.
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
It is important to follow the transmission maintenance
intervals described in the Periodic Maintenance Chart.
The transmission lubricant level should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing the lubricant.
• Check vent hose to be sure it is routed properly and
unobstructed.
Transmission Lubricant Level Check
The fill plug is located on the rear portion of the
transmission gearcase. Access the fill plug at the rear of
the vehicle. Maintain lubricant level even with the bottom
of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill plug
and check the lubricant level.
q
7. Remove drain plugwand allow lubricant to drain
completely.
2
8. Clean the drain plug magnetic surface.
9. Reinstall drain plug with a new O-ring and torque to
specification.
10. Add the recommended amount of lubricant through
the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the
transmission. Do not overfill.
FLUID CAPACITY
Recommended Transmission Lubricant:
AGL Gearcase Lubricant
(PN 2878068) (Quart)
Capacity: 41 oz (1200 mL)
3. If lubricant level is not even with bottom threads, add
recommended lubricant as needed. Do not overfill.
4. Reinstall the fill plug and torque to specification.
TORQUE
Transmission Fill / Drain Plug:
10-14 lb-ft (14-19 Nm)
Transmission Lubricant Change
The drain plug is located on the bottom of the
transmission gearcase. Access the drain plug
through the drain hole in the skid plate.
5. Remove the fill plug.
6. Place a drain pan under the transmission drain plug.
11. Reinstall fill plug with a new O-ring and torque to
specification.
TORQUE
Transmission Fill / Drain Plug:
10-14 lb-ft (14-19 Nm)
12. Check for leaks. Dispose of used lubricant properly.
2.29
MAINTENANCE
FRONT GEARCASE LUBRICATION
NOTICE
It is important to follow the front gearcase maintenance
intervals described in the Periodic Maintenance Chart.
The front gearcase fluid level should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing the fluid.
• Check vent hose to be sure it is routed properly and
unobstructed.
Front Gearcase Fluid Level Check
The fill plug is located on the bottom right side of the front
gearcase. Access the fill plug through the right front
wheel well. Maintain fluid level even with the bottom of
the fill plug hole.
1. Position vehicle on a level surface.
2. Locate the gearcase fill plug
wheel well area.
through the right front
q
8. Remove the drain plug
completely.
9. Clean the drain plug magnetic surface.
10. Reinstall drain plug with a new O-ring and torque to
specification.
11. Add the recommended amount of fluid through the fill
hole. Maintain the fluid level even with the bottom
threads of the fill plug hole.
and allow fluid to drain
w
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive Fluid
(PN 2877922) (Quart)
Capacity: 8.0 oz (240 mL)
3. Remove the fill plug and check the fluid level.
4. If fluid level is not even with the bottom threads, add
the recommended fluid as needed. Do not overfill.
5. Reinstall the fill plug and torque to specification.
TORQUE
Front Gearcase Fill / Drain Plug:
8-10 lb-ft (11-14 Nm)
Front Gearcase Fluid Change:
The drain plug is located on the bottom of the front
gearcase. Access the drain plug through the access
hole in the frame underneath the front gearcase.
6. Remove the fill plug.
7. Place a drain pan under the front gearcase drain
plug.
12. Reinstall fill plug with a new O-ring and torque to
specification.
TORQUE
Front Gearcase Fill / Drain Plug:
8-10 lb-ft (11-14 Nm)
13. Check for leaks. Dispose of used fluid properly.
2.30
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
It is recommended that the PVT intake pre-filter be
inspected daily. The filter should be inspected using the
following procedure:
1. The PVT intake pre-filter is located just behind the
passenger hip bolster on the right side of the vehicle.
The pre-filter is adhered to the back of the body
panel.
2. Inspect the pre-filter. Wipe away any deposits with a
clean cloth.
3. If necessary, remove the body panel and clean the
pre-filter with soapy water and dry with low pressure
compressed air.
PVT DRYING
NOTICE
After operating in water, the vehicle’s PVT system
should be checked immediately. Use the following
instructions to dry it out before operating.
The PVT drain plug is located at the bottom of the outer
clutch cover. Access the drain plug through the left rear
wheel well.
1. Using a flat blade screwdriver, remove the PVT drain
plug
and O-ring from the outer clutch cover.
q
2. Allow the water to drain out completely.
3. Reinstall the drain plug and O-ring.
4. Place the transmission in PARK, apply the brake and
start the engine.
5. Apply varying throttle for 10-15 seconds to expel the
moisture and air-dry the belt and clutches.
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 “PVTSystem Service”page 5.7 for service and removal
procedures).
NOTICE
If the vehicle has ingested a large amount of water into
the PVT system and has not been operated for a period
of time, be sure to check the PVT system components
for water damage.
2.31
MAINTENANCE
DRIVE SHAFT BOOT INSPECTION
Inspect the front and rear drive shaft boots
damage, tears, wear or leaking grease. If the boots
exhibit any of these symptoms, they should be replaced.
Check to see the boot clamps
are properly positioned.
w
q
for
WHEEL REMOVAL
1. Position the vehicle on a level surface.
2. Place the transmission in PARK and stop the engine.
3. Loosen the wheel nuts
removal is required, remove the wheel capw, cotter
pin
and loosen the hub nutrslightly.
e
NOTICE
Limited Edition models with aluminum wheels require a
thin wall socket to loosen or tighten the wheel nuts
without damaging the finish of the rim. The wheel nut
requires a 19 mm thin wall socket with an O.D. less
than 24.7 mm to allow it to clear the rim.
slightly. If wheel hub
q
WHEEL INSTALLATION
1. Verify the transmission is still in PARK.
2. Install the wheel on the wheel hub with the valve
stem toward the outside. Be sure rotation arrow on
the tire (if applicable) point toward forward rotation.
3. Attach the wheel nuts
4. Carefully lower the vehicle to the ground.
Limited Edition models with aluminum wheels require a
thin wall socket to loosen or tighten the wheel nuts
without damaging the finish of the rim. The wheel nut
requires a 19 mm thin wall socket with an O.D. less
than 24.7 mm to allow it to clear the rim.
5. Torque wheel nuts
specification.
Wheel Nuts (Steel Wheels):
60 lb-ft (81 Nm)
Wheel Nuts (Cast Aluminum Wheels):
120 lb-ft (163 Nm)
Front Wheel Hub Castle Nuts:
80 lb-ft (108 Nm)
Rear Wheel Hub Castle Nuts:
110 lb-ft (149 Nm)
Do not lubricate the stud or the lug nut.
6. If wheel hub nut was removed, install a new cotter
pineafter the hub castle nut has been tightened. If
the holes do not line up, turn the castle nut counterclockwise until the cotter pin can be installed.
and finger tighten them.
q
NOTICE
and/or hub nutrto the proper
q
TORQUE
NOTICE
4. Elevate the appropriate side of the vehicle by placing
a suitable stand under the frame.
5. Remove the wheel nuts
and remove the wheelt.
q
2.32
CAUTION
If wheels are improperly installed it could affect vehicle
handling and tire wear. On vehicles with tapered wheel
nuts, make sure tapered end of nut goes into taper on
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
• 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)
FrontRear
Base: 12 psi (83 kPa)
CREW: 16 psi (110 kPa)
2
WARNING
Operating with worn tires will increase the possibility of
the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident. Always replace tires
Steering system components should be checked
periodically for loose fastenersq, worn tie rod endsw,
loose steering shaft U-joints
and general damage. Also check to make sure all cotter
pins
are in place. If cotter pins are removed, they must
r
be replaced.
Replace any worn or damaged steering components.
Steering should move freely through the entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
NOTICE
Check front end alignment whenever steering
components are replaced.
, worn A-arm ball joints
e
TIE ROD END / WHEEL HUB INSPECTION
• To check for play in the tie rod endq, grasp the
steering tie rod, pull in all directions feeling for
movement.
• Replace any worn steering components. Steering
should move freely through entire range of travel
without binding.
• Elevate front end of machine so front wheels are off
the ground. Check for any looseness in front wheel/
hub assembly by grasping the tire firmly at top and
bottom first, and then at front and rear. Try to move the
wheel and hub by pushing inward and pulling outward.
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD certified technician.
2.34
• If abnormal movement is detected, inspect the hub and
wheel assembly to determine the cause (loose wheel
nuts or loose front hub nut).
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
Make sure tire pressures are set the same on the right
and left tires.
1. Place machine on a smooth level surface and set
steering wheel in a straight ahead position. Secure
the steering wheel in this position.
2. Place a chalk mark on the center line of the front tires
approximately 10 in (25.4 cm) from the floor or as
close to the hub/axle center line as possible.
WHEEL TOE ADJUSTMENT
If toe alignment is incorrect, repeat steps 3-5 of “Wheel
Toe Alignment Inspection”, but instead measure the
distance between vehicle center and each wheel. This
will tell you which tie rod needs adjusting.
2
NOTICE
It is important the height of both marks be equally
positioned to get an accurate measurement.
3. Measure the distance between the marks and record
the measurement. Call this measurement “A”.
4. Rotate the tires 180° by moving the vehicle forward.
Position chalk marks facing rearward, even with the
hub/axle center line.
5. Again measure the distance between the marks and
record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The
difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/8-1/4 in (3.2-6.4 mm) toe out. This
means the front of the tire (A) is 1/8-1/4 in (3.2-6.4
Compress and release the suspension. Damping should
be smooth throughout the range of travel.
• Check all suspension components and mounting
fasteners for wear or damage.
• Inspect each shock body for leakage.
SPRING PRE-LOAD ADJUSTMENT
The front and rear shock absorber springs are
adjustable. Rotate the adjuster camqeither direction to
increase or decrease spring tension. Always adjust both
left and right sides equally.
NOTICE
Adjusting all shock cams equally will only affect ride
height as the weight transfer will not be changed.
SHOCK POSITION ADJUSTMENT
The front and rear shock position may be adjusted to
provide a stiffer suspension operation if necessary.
1. Elevate vehicle and safely support the main frame.
WARNING
Serious injury may result if machine tips or falls. Be
sure machine is secure before adjusting.
2. Remove the upper shock mounting bolts
each side of the vehicle.
3. Reposition the upper shock mounts to the outside
mounting holesw.
FRONT SHOCK
q
from
2
Vehicle loadseffectsuspension spring pre-load
requirements. Use Spanner Wrench to adjust pre-load as
necessary to avoid bottoming of the shocks.
4. Reinstall the upper shock mounting bolts and torque
to specification.
TORQUE
Shock Mounting Bolts:
40 lb-ft (54 Nm)
2.37
MAINTENANCE
BRAKE SYSTEM MAINTENANCE
BRAKE FLUID INSPECTION
Always check the brake pedal travel and inspect the
brake fluid reservoir level before each operation. If the
fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake master cylinder reservoir
through the front left wheel well.
1. Position the vehicle on a level surface.
2. Place the gear selector in Park.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches just below the MAX level
line.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
can be accessed
q
BRAKE PAD / DISC INSPECTION
1. Check the brake padsqfor wear, damage, or
looseness.
2. Inspect the brake pad surface for excessive wear.
3. Pads should be changed when the friction material is
worn below specification.
MEASUREMENT
Brake Pad Thickness (Minimum):
0.150" (3.8 mm)
4. Check surface condition of the brake discs.
5. Measure the thickness of the front and rear brake
discs.
BRAKE HOSE AND FITTING INSPECTION
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
2.38
6. The disc (s) should be replaced if thickness is less
than the specified service limit.
MEASUREMENT
Brake Disc Thickness (Minimum):
0.170" (4.32 mm)
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
Keep battery terminals and connections free of
corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm.
WASH HANDS AFTER HANDLING.
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTICE
Batteries must be fully charged before use or battery
life will be reduced by 10-30% of full potential. Charge
battery according to “Charging Procedure” provided in
Chapter 10. Do not use the vehicle’s stator/alternator to
charge a new battery.
BATTERY REMOVAL
1. Remove the passenger seat (right rear passenger
seat on the CREW models) and storage container to
access the batteryq.
2. Disconnect the black (negative) battery cablew.
3. Disconnect the red (positive) battery cablee.
CAUTION
To reduce the chance of sparks, disconnect the black
(negative) cable first. When reinstalling the battery,
connect the black (negative) cable last.
4. Remove the fastener
down strap and lift the battery out of the vehicle.
retaining the battery hold-
r
BATTERY INSTALLATION
NOTICE
Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can
also hinder vehicle performance. Follow the battery
charging procedure in Chapter 10 “Electrical” before
1. Ensure the battery is fully charged.
2. Place the battery
down strap and retaining fastener
3. Coat the terminals with dielectric grease or
petroleum jelly.
4. Install and tighten the red (positive) cable
Torque to specification.
5. Install and tighten the black (negative) cablewlast.
CAUTION
To reduce the chance of sparks, disconnect the black
(negative) cable first. When reinstalling the battery,
connect the black (negative) cable last.
6. Verify the cables are properly routed and reinstall the
storage container and passenger seat.
CHASSIS / ENGINE ELECTRICAL GROUND
Inspect the ground cable connections. Remove ground
terminals and clean if necessary.
1. Remove the passenger seat base and storage bin to
access the chassis ground terminal
below the starter solenoid
2. Inspect the chassis ground terminals. Be sure they
are clean and tight.
3. Inspect the engine ground terminal, attached to the
upper starter mounting bolt. The other end of the
engine ground cable is attached to the chassis
ground terminal).
4. Inspect the engine ground terminals. Be sure they
are clean and tight.
next to the battery.
w
, located
q
SPARK PLUG SERVICE
Inspect and replace the spark plugs at the intervals
outlined in the Periodic Maintenance Chart.
1. Tilt the rear cargo box to access the top of the engine.
CAUTION
A hot engine can cause serious burns. Allow engine to
cool or wear protective gloves when removing the spark
plugs.
2. Remove the spark plug capsq.
NOTICE
MAG and PTO reference decals on spark plug wires for
reassembly.
3. Clean out plug wells with compressed air to remove
any loose dirt or debris.
4. Rinse plug wells with water and dry with compressed
air.
NOTICE
Spark plug wells have drain holes built into the cylinder
head to allow water to drain out.
2.40
5. Remove spark plugs using a 5/8” spark plug socket
with an extension.
6. Inspect electrodes for wear and carbon buildup. Look
for a sharp outer edge with no rounding or erosion of
the electrodes.
7. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only.
CAUTION
A wire brush or coated abrasive should not be used.
8. Measure gap with a wire gauge. Adjust gap if
necessary by carefully bending the side electrode.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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.